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I have a Lionel SD80MAC (6-38582) and have had a significant amount of trouble with it derailing on my Atlas O switches, even with the little plastic inserts in place.  What happens is the pickup roller manages to slide down between the rails and then get hung up on the center rail when it crosses over for the other path of the switch.

I only have two locomotives and the other, a Mallet, doesn't suffer from the same problem, but my guess is that this problem is caused by there being too much play in the outer truck axles.  As you can see in the attached photo, the outermost axles on each truck can shift quite a bit from side to side, which allows the truck (and therefore the roller) to get pointed well off the center rail as it enters the turnout, enough that it drops down and hits the side of the crossing center rail, rather than rolling over the top of it.

On O-54 and O-72 switches what usually happens is that the locomotive stops dead, mechanically jammed in the switch.  On the curved O-54/O-72 turnouts, however, it actually causes the truck to climb out of the rails.  If I use my hand to guide the rear truck as it goes over the turnout this avoids the derailment.

Any ideas on how to resolve this?  Is there a way to add washers to the axle to limit the travel?  This locomotive is rated at a minimum O-36 curve; my layout has a minimum O-54.

Thanks!

Adam

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You could check to see that the rollers are centered on the frame between the drivers  and that the rollers do not excess lateral movement.  There have been a number of methods described here in the past about reducing wheel set lateral movement by inserting  various spacers around the axle between the driver and the frame. A snap rings (e rings) seem to have been favored. 

Hot Water, I searched around quite a bit on the web but couldn't find much of anything about how the Sunset/3rd Rail rollers are acquired.  Call and order directly from them?

 

David, good to hear that adding some spacers is legitimate. I cut up a cocktail straw and used it as a temporary spacer; the results were not perfect but pretty good, maybe better after experimenting with the amount of spacing.  I'll have to get some E-rings.

 

Thanks for the replies!

Personally, I'd be reluctant to change the roller direction/position, as if it is OK running on other track types (Down to O36 diameter.) then it should be fine on larger diameter curves. In addition, reversing the roller direction will shorten the distance between the rollers, and could cause other problems such as stalling when both rollers are on dead sections in crossovers or suchlike.

My choice would be to address the problems with the switches, as suggested above.

Yea had a similar problem with a Lionel GP 9 and a K-line 072 switch track. The roller would drop down get stuck in the switch  derail and take half the train with it. Was a thread on this a while back. Someone on line here had said putting a tie from a piece of gar graves track in the space would stop the pickup from dropping down and getting stuck. Tried it on 2 K-line 072 turnouts and no more problem. Engine goes through like butter.

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