Fleischmann diesel switcher remotoring and dcc mod

Here’s a great little Diesel switcher loco from Fleischmann. Got it for a great deal on E-Bay. The Quarter along with the loco gives you a perspective of the size of  the loco.

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This is an old loco (probably 60’s). As is well known, older fleischmann locos came with the infamous pancake motor. This loco was no exception. This pancake motor had a continuous ring magnet around a 3-pole armature. A big issue was that this motor drew almost 500mA of stall current. Enough to cause hiccups with DZ125 (the decoder that was to be used in this loco). So i planned to replace this pancake motor with another pancake motor: The DVD/CD drive motors. You can either salvage one from a DVD player or car tape player, or buy them off Ebay. Luckily i was able to salvage some Mabuchi motors.

Unfortunately i did not take any photos during the process of the re-motoring. But here’s a shot after the motor was installed along with a wiring PCB and DZ125 decoder along with its supercap piggyback.

The 2 black bumps between the wheels and below the pinion gear are 2 of the panasonic supercaps. The 3rd one was mounted on the other side due to space constraints. A great thing about this little loco was its gearing. Lot of gears to get a smoother ride.

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The messy rear side. Here’s the Mabuchi motor. To the right of it below the duct tape is the decoder. The thing inside the heatshrink is the 3rd supercap. I also put in the obligatory directional lights (0603 LED’s). I used yellow and red to keep with the prototype. The original loco had no lights(I guess it was too small to get the lights in).  To secure the wires everywhere, i used liquid tape.

To get some of the stuff in i had to mill sections of the loco (the decoder for example). Being diecast a sharp HSS toolbit  cuts easily .

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Finished Loco on the testing track. I also put in a small cab led.

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Finally done!. I love this little loco due to its great running characteristics. I guess its gearing helps a lot. The supercaps also help a little.

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About

I am a computer engineer living in the beautiful city of Austin,TX. While my day job is designing computer chips, I love to dabble in woodworking, metalworking, r/c and electronics.

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Posted in Electronics, Model trains

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