Esu Class 66, Class 77 Instruction Manual
En g i n E E r i n g Ed i t i o n
Instruction manual
1. Edition, September 2014
Class 66/77
2
Content
1. Declaration of Conformity
We, ESU electronic solutions ulm GmbH & Co. KG, Edisonallee 29, D-89231 Neu-Ulm, Germany, declare in sole responsibility that the product
„ESU H0-Diesellok Class 66/77“, part number: 31050, 31051, 31052, 31053, 31054, 31055, 31056, 31057, 31058, 31059, 31070, 31071,
31072, 31073, 31074, 31075, 31076, 31077, 31078, 31079 complies with all relevant regulations of the Directive for Electromagnetic Com-
patibility (2004/108/EG). The following harmonised standards have been applied:
EN 55014-1:2006 + A1:2009: Electromagnetic Compatibility - requirements for household appliances, electric tools, and similar apparatus - Part
1: Emission - Product
EN 55014-2:1997 + A1:2001 + A2:2008: Electromagnetic Compatibility - Requirements for household appliances, electric tools, and similar
apparatus - Part 2: Immunity - Product family standard.
1. Declaration of Conformity ........................................2
2. Prototype .................................................................3
3. Model .....................................................................6
3.1. Important remarks - please read this first ......... 6
3.2. Unpacking the model ...................................... 6
3.2.2. Mounting & removing the centre pick-up ..... 6
3.3. Outward appearance and special features ........ 7
4. The technology of the ESU model ............................8
4.1. Possible operating modes of the class 66/77 .... 8
4.1.1. Analogue mode ........................................... 8
4.1.2. Digital mode ................................................. 8
4.1.2.1. Digital operation with DCC systems .......... 8
4.1.2.2. DCC with RailComPlus®............................ 9
4.1.2.3. Prerequisites for RailCom® Plus ................. 9
4.1.2.4. M4 registration .......................................... 9
4.1.2.5. Digital operation with Märklin® Digital...... 9
4.2. Your first ride................................................... 9
4.2.1. Lighting functions ......................................... 9
4.2.2. Sound functions ......................................... 10
4.2.3. Curve and turnout sensors.......................... 10
4.2.4. Synchronised smoke generator ................... 10
4.2.4.1. Filling the smoke generator holding tank . 10
4.2.4.2. Operating the smoke generator ............... 11
4.2.5. PowerPack energy storage .......................... 11
5. Decoder Settings (Programming) ............................12
5.1. Configuration Variables (CVs) ........................ 12
5.1.1. Standardisation in the NMRA ...................... 12
5.1.2. Bits and Bytes ............................................. 12
5.2. Programming the decoder ............................. 12
5.2.1. Programming with DCC systems ................. 12
5.2.2. Programming with Märklin® 6021 ............ 12
5.2.2.1. Changing to the programming mode ...... 13
5.2.2.2. Short mode ............................................. 13
5.2.2.3. Long mode .............................................. 13
5.2.3. Programming with the Märklin® Central
Station®............................................................... 13
5.2.4. Programming with ESU LokProgrammer ..... 14
5.3. Adress settings .............................................. 14
5.3.1. Short Addresses in DCC mode .................... 14
5.3.2. Long Addresses in DCC mode .................... 14
5.3.3. Motorola® address ..................................... 14
5.3.3.1 Consecutive addresses for more functions 14
5.4. Adapting the Driving Characteristics .............. 15
5.4.1. Acceleration and Deceleration .................... 15
5.4.1.1. Shunting mode ........................................ 15
5.4.2. Starting Voltage, Vmax ............................... 15
5.5. Break sectors ................................................. 15
5.5.1. DC break mode .......................................... 15
5.5.2. Märklin® brake mode ................................ 15
5.5.3. Lenz® ABC brake mode ............................. 16
5.6. Adjusting the volume .................................... 16
5.6.1. Overall sound volume ................................. 16
5.6.2. Adjust individual sounds ............................. 16
5.6.3. Motor sound .............................................. 16
5.6.4. Auxiliary sounds ......................................... 16
5.7. PowerPack ..................................................... 16
5.8. Decoder reset ................................................ 17
5.9. Adjusting the brightness of the lights ............ 17
5.10. Smoke generator ....................................... 17
5.10.1. Blower of the smoke generator ............... 17
5.10.2. Heating temperature ............................... 17
6. Maintenance..........................................................17
6.1. Removing the housing ................................... 17
6.2. Lubrication .................................................... 17
6.3. Replacing wheel sets ..................................... 17
6.4. Replacing traction tires .................................. 18
6.5. Installing a coupler ........................................ 18
7. Accessories supplied with the model ......................20
8. Technical support ...................................................20
9. Spare parts ............................................................20
10. List of all important CVs .......................................21
12. Warranty Certificate .............................................23
3
En g i n E E r i n g Ed i t i o n
Original
Prototype
2. Prototype
With the liberalisation of the international rail goods
traffic established in 2001 the newly founded rail
operators needed to procure motive power in order
to be able to handle the traffic they had fought so
hard to take away from the state owned railways.
The procurement of technically sophisticated new
vehicles was often not possible due to budgetary
restraints. A more cost effective solution was offered by the American Electro Motive Division (EMD)
with the class 666 that had already been tested and
proven in Great Britain. The locomotives known as
the JT 42 CWR are based on the American SD40
and ongoing development culminating in the SD
40-2, which were found to be most reliable due to
their simple, but proven design.
The first railway institution employing the diesel
electric class 66 on German lines was the Harbour
and Freight Services AG in Cologne the so called
Häfen und Güterverkehr Köln AG (HGK). In 1999
this company purchased two units. Almost at the
same time the class 66 was introduced to other European countries. Rail traffic corporations having
purchased or leased class 66 locomotives can be
found in France, Belgium, the Netherlands, Luxembourg and Norway. So far about 650 units have
been delivered in two different version to European
customers. The somewhat long and slim outline
Class 66‘ predecessor is named JT 26 CW-66. The picture shows Deutsche Bahn 259 003 in Sed-
din on 28.9.1997
Picture: Rolf Wiemann
meets the clearance diagram of British Rail. The
square-edged design of the body and the chassis
with its massive boogies and quite a number of seemingly confusing pipes and cables give the class 66
an unmistakable appearance.
The General Motors twelve Cylinder Two Stroke
engine 12N-710G3B-EC can not only be heard but
also recognised due to its characteristic sound and
offers a power of 3194 HP (2350 kW). The starting
tractive effort amounts to 409 kN, the continuous
tractive effort is 260 kN. With a maximum speed of
120 km/h the class 66 locomotives can easily keep
pace with other trains using electric traction even
on mainlines. Due to the independence from centenary the client can, if need be, pick up the train
from the most remote spur or siding and take it
via DB mainlines right through to his own factory.
With their livery the class 66 locomotives form a
pleasant contrast to the standardized red livery of
the DB AG.
Since 1999 the HGK mainly handles block trains
with their class 66 locomotives albeit with varying
loads. Tank cars have been a standard load for HGK
class 66 locomotives taking the train over the entire
route to Braunschweig, Ingolstadt, Marktredwitz
and Aichstetten. But one can also find the locomo-
4
Prototype
tives from Cologne in central Germany whenever
they haul a train to Leuna or Berlin, amongst others.
We have chosen the DE671 built in 2003 and with
an extended concession issued in 2011 as the prototype for our model that bears white stripes on
the front.
The livery of the class 66 locomotives is accentuated
by the sharp contrast of black or grey sides with
the light green contrast patches leading around the
cabs. In Germany, Belgium and the Netherlands the
Captrain locomotives are mainly deployed hauling
container traffic, block trains consisting of tank
wagons or coal cars. They also display their power
ahead of block trains made up of cars with sliding
sides carrying parts for the automotive industry. In
Germany these six axle locomotives regularly travel
from the Rhine Ruhr region as far as Berlin.
As from 2010 CB rail, a renter of locomotives sent
their German and Luxembourg subsidiaries under
the name of Ascendos Rail Leasing GmbH into the
game of rail freight traffic. For operations on only
partly electrified lines Ascendos has a stable of 20
class 66 locomotives and an extra three class 77.
For Modeltrain enthusiasts these locomotives with
their green livery accentuated by the turquoise and
yellow contrast stripes are highly attractive since
they are not only deployed to haul block trains with
containers, tank cars, construction materials, coal,
motor vehicles or machine parts but make themselves useful in track maintenance service of for
transfers of other vehicles. Particularly in the area
of construction site logistics these locomotives are
often seen with only a handful of cars. Well known
companies renting these six axle locomotives have
been and are the HGK, Crossrail, ITL or the Ruhrtalbahn deploying them all over Germany, Belgium
and the Netherlands.
The four units owned by the SNCF Benelux and regularly travelled through Belgium, the Netherlands
and Germany in their impressive and very elegant
blue silver livery. Initially it was quite easy to differentiate them due to their different design of the
contrast areas on the front and rear. They were
mainly hauling two axle hoppers, container trains
and tank car trains.
HKG‘s DE 62 still owns the british style headlights with outer position lamp in contrast to DE
61. Picture taken on 24.08.2011 in Ulm Hbf
Picture: Jochen Frickel
The prototype of the ESU model in Montzen
/ Belgium
Picture: Rolf Wiemann
5
En g i n E E r i n g Ed i t i o n
Original
Prototype
Section view of class 77 showing the components locationsFigure 1:
Drawing: ESU GmbH & Co. KG
DE61 of HGK is allowed to be used in ger-
many only
Picture: Jochen Frickel
Crossrail‘s class 77 DE 6311 in Neuwied train
station
Picture: Rolf Wiemann
6
Model
3. Model
3.1. Important remarks - please read this first
Congratulations to your purchase of the H0 diesel
locomotive class 66/77. Your H0 model offers various innovative functions. This manual provides a
step by step insight into the features of the class
66/77. Therefore we have one request:
Please read this manual prior to operating the model carefully. Although the model is quite robust,
inappropriate handling could lead to injury of the
operator or to damage of the locomotive. Do not
indulge in “costly” experiments.
This locomotive is not a toy and should only be •
operated under supervision.
Please make sure that the room has adequate •
ventilation when operating the smoke generator continuously!
Keep the smoke distillate away from children. It •
contains substances that may damage your health if consumed. In case of contact with your
eyes consult a doctor immediately.
Please return the pipette only into the packaging •
after you have emptied it completely. Otherwise
you may risk draining the smoke distillate.
Protect the model against wet conditions and •
humidity.
When working on the locomotive (maintenance) •
always make sure there is no power connected
to the model. Replace the housing on the chassis prior to operating the locomotive after maintenance work.
Make sure that no wires are squeezed or that no •
short circuit may occur.
Please note: All models shown here are pre-production samples. They may vary slightly from the series
production models!
3.2. Unpacking the model
Pull the model screwed to the plastic holder with
both hands out of the foam insert. At the bottom of
the plastic holder you will find a hexagon spanner.
Now place the model on its side, hold the model
and the plastic holder with one hand and release
the hexagon bolt with the other hand.
For safe keeping of the spanner there are two retaining clips at the bottom of the plastic holder.
Please keep all parts of the packaging and this
manual for later use. Only the original packaging
guarantees proper protection against transport damage. Please fix the locomotive by means of the
hexagonal bolt to the plastic holder and place it into
the foam insert and put it into the carton and the
transport box prior to shipment.
Now you must adapt your class 66/77 to the control
mode of your layout. If you are a Märklin model
train enthusiast and therefore need a locomotive
with a centre pick-up you may simply place the locomotive onto the track, enter address 3 and you
are ready to run.
The centre pick-up clipped onto the locomotive serves not only for current pick-up but also activates
the electrical connection of both rails. Thus all 12
wheels pick-up current from the tracks.
If you operate a two-rail layout you must remove
the centre pick-up. How you do this is described in
chapter 3.2.2.
3.2.2. Mounting & removing the centre pick-up
Removal: Put the locomotive on its roof. Then you
apply the tool in such a way that the ends of the
four wire brackets fit into the four holes below the
base plate of the centre pick-up. Carefully(!) squeeze the tool and then lever the centre pick-up with a
slight tug from its position.
release of hexagon boltFigure 2:
7
En g i n E E r i n g Ed i t i o n
Model
Model
Mounting: For re-converting your locomotive to a
three-rail vehicle again hold the centre pick-up between thumb and index finger and place it in the
receptacle. Please note that the centre pick-up must
be attached to bogie “1”. Finally press the centre
pick-up until there is an audible “click”. That´s it!
3.3. Outward appearance and special features of
your class 66/77
With your new class 66/77 you can operate your
model trains prototypically like never before. There
are many separately applied detail parts on the metal housing as well as on the metal chassis. Of course, such details and modifications of the housing
are correct for the respective locomotive number.
All grab irons are made off sturdy plastic and are
separately applied. Separate plastic pipes are attached to the bogies.
The large speaker powered by the LokSound V4.0
M4 decoder distributes its powerful sound through
the cut-through radiator grills. New is also the sen-
sor triggering the squealing noise in curves and on
turnouts.
The ESU 5-pole high performance motor with a virtually silent commutator and two flywheels assure
plenty of power and smooth running. All four axles
are powered.
Four traction tires assure considerable tractive effort. Model train enthusiasts who prefer to run their
locomotives without traction tires and rather enjoy
more prototypical wheels sets find a voucher for six
wheel sets (2-rail system) with RP 25 wheels (please
also refer to page 26!). In order to obtain these
wheel sets, simply send this voucher to ESU. In order to assure perfect driving dynamics and excellent
sound without interruptions due to dirty tracks the
locomotive is equipped with a “PowerPack“energy
storage module.
A coupler shaft as per NEM 362 with short coupler
kinematics provides close coupling between locomotive and train in any situation.
In terms of its lighting the class 66/77 is just as
prototypically versatile as its full scale counterpart.
Of course there is directional lighting generated by
warm white LEDs that can be turned off at one end,
wherever the train is coupled to the locomotive.
During shunting all three headlights at either end
are switched on. In addition there is directional cab
lighting as well as illuminated driver’s cab-control
panel. Since these locomotives are employed internationally one can also set the lighting according to
the Belgian, Dutch and French lighting rules.
pickup shoe removalFigure 3:
Assembly of pickup shoeFigure 4:
8
Technical functions
4. The technology of the ESU model
The new LokSound V4.0 M4 decoder is a central
part of your new class 66/77. Its circuitry is responsible for design and control of all running and sound
functions of the class 66/77:•
Driving forward and in reverse •
Lighting functions•
Sound functions•
Smoke generator•
Besides M4 the LokSound V4.0 M4 also supports
DCC with RailComPlus, Motorola® and Selectrix®
and also be operated on analogue layouts. Programming can be done either with DCC command
stations or with Märklin® central units, etc. the decoder automatically detects the mode of operation;
therefore you do not have to set anything in this
regard.
In case you wish to change any of the default settings of the locomotive (such as the address or the
sound volume) we recommend to first reading
chapter 5. This chapter lists all parameters of the
LokSound V4.0 M4 decoder and how to change
them with the various command stations available
on the market.
4.1. Possible operating modes of the class 66/77
4.1.1. Analogue mode
The class 66/77 may also be operated on conventional (=analogue) DC or AC model train layouts.
The number of available functions is, however, quite limited:
Driving forward and backwards•
Directional lighting•
Engine sounds (automatic)•
The smoke generator cannot be turned on in analogue mode. The engine sound sets in at about
6.5 V track voltage. At 8.5 V the locomotive slowly starts moving. Both DC transformers (throttles,
e.g.: ROCO®) and AC transformers (e.g.: Märklin®,
Titan) are suitable for analogue operation. Please
note, that due to the large number of different systems on the market you may not achieve troublefree operation with electronic throttles employing
PWM (pulse width modulation).
Attention: the class 66/77 must have come to a
complete standstill before you activate the changeof-direction command! Never switch to the opposite direction while the locomotive is moving.
4.1.2. Digital mode
For prototypical operation we recommend using
a digital command control system. The numerous
functions are only available in digital mode.
The default address (ex works) is “03” (DCC and
Märklin® Motorola®)
14 speed steps with Märklin® Motorola®.
In DCC mode the decoder automatically detects the
speed steps set in the command station.
4.1.2.1. Digital operation with DCC systems
The class 66/77 can be operated with any DCC
compliant system. Sounds and other functions of
the class 66/77 can be triggered with the function
buttons F0 through F21.
Function mapping (ex works):
Functionmapping:
Button
Function
F0 Directional lighting
F1 Engine sound
F2 Horn (high)
F3 Smoke generator
F4 Cab lighting
F5 Headlights off at cab 1
F6 Headlights off at cab 2
F7
Headlights as per lighting rules in BE/FR (Third headlight off)
F8 shunting lights DE/FR/BE
F9 Horn (low)
F10 Emergency stop
F11 Platform announcement
F12 Turnout sensor off
F13 Coupler sound
F14 Illuminated driver’s cab-control panel
F15 Shunting lights as per NL
F16
Air compressor / exterior lights as per CNet,TGOJ, CLF
F17 Station announcement
F18 Short horn (high)
F19 Short horn (low)
F20 Sanding
F21 Shunting mode
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