Lionel 59 Minuteman User manual

Lionel
#59 Minuteman
Motorized Unit
Owner’s Manual
71-8456-250
7/02
®
featuring

2
You purchased a tough, durable loco- motive—the #59 Minuteman Unit built
by Lionel. From the crisp detail and expert
decoration on the outside to the brute power
under the hood, the mighty Minuteman is
ready for duty on your model railroad.
Experience the superiority of today’s Lionel.
Congratulations!
The following Lionel marks may be used throughout this instruction manual and are protected under law. All rights
reserved.
Lionel®, TrainMaster®, Odyssey®, RailSounds™, CrewTalk™, TowerCom™, DynaChuff™, StationSounds™,
Pullmor®, ElectroCoupler™, Magne-Traction®, CAB-1 Remote Controller®, Powermaster®, Lionel ZW®, ZW®
Features of the #59 Minuteman Unit
• Pullmor motor
• Digital TrainMaster Command Control system
• Tire-Traction
• Illuminated headlight/rear light
• Directional lighting

3
Table of contents
Transformer operations
Running your #59 Minuteman Unit with a Lionel transformer 4
Locking your #59 Minuteman Unit into a single operational state 5
Using your #59 Minuteman Unit’s ElectroCouplers in the non-Command environment 6
TrainMaster Command operations
The Command Control environment 7
Running your #59 Minuteman Unit in the TrainMaster Command environment 8
CAB-1 numeric keypad commands for your #59 Minuteman Unit 8
Tuning your #59 Minuteman Unit’s performance 9
Assigning your #59 Minuteman Unit a new ID# 10
Reprogramming the Command reverse unit to restore features 11
Maintaining and servicing your #59 Minuteman Unit
Lubricating your #59 Minuteman Unit 12
Lubricating your #59 Minuteman Unit Pullmor motor armature 13
Replacing your #59 Minuteman Unit’s lamps 14
Replacing your #59 Minuteman Unit’s traction tires 15
Lionel Service 16

4
3
3Move ‘em out!
•Get your #59 Minuteman Unit moving. Press the DIR button on your
Lionel transformer. This sequences the Lionel reverse unit to the next operating
state.
•Adjust track voltage until your #59 Minuteman Unit moves at your desired
speed. To increase speed, increase track voltage. To decrease speed, reduce voltage.
To stop the locomotive, turn-off track power.
•See page 5 for information on locking your #59 Minuteman Unit in
a single operating state.
Place your #59 Minuteman Unit locomotive on Lionel or
Lionel-compatible O gauge track.
2
2Power up your #59 Minuteman Unit with your transformer.
•Your #59 Minuteman Unit is designed to operate on 8-18 volts
alternating current (AC). Virtually all Lionel and Lionel-compatible alter-
nating-current transformers are suitable.
•Do not power your #59 Minuteman Unit with direct current (DC).
Damage to sensitive electronic components may occur.
•When you first power up your track, the #59 Minuteman Unit will
wait between 3 and 8 seconds as it “listens” for digital language from the
TrainMaster Command Base (available separately). When it’s determined that
it’s on a conventional (non-Command) railroad, the #59 Minuteman Unit’s
headlight will illuminate and RailSounds will fire up. At this point, the #59
Minuteman Unit is in neutral. (This occurs when placing the #59 Minuteman
Unit on your railroad for the first time. Thereafter, it will start in forward after
every three-second power interrupt.)
Note!
1
1
Running your Lionel #59 Minuteman Unit with a Lionel transformer
Transformer operations
Caution!
Note! Your locomotive is designed to operate on track with a minimum radius of O-27.

5
To lock your Lionel #59 Minuteman Unit into forward only, you can deactivate the
reverse unit’s sequencing function with the
reverse unit control switch.
Get your locomotive into neutral, then
remove it from the track. Set the reverse unit
control switch to PROG. Refer to Figure 1 for
the location of the switch. The #59 Minuteman
Unit is now “locked” into forward.
When you no longer want single-direction
operation, just slide the reverse unit control
switch back to RUN.
Your locomotive’s reverse unit will
“reset” to forward after any five
second or longer power interrup-
tion, regardless of the original
locked-out direction.
Locking your #59 Minuteman Unit into forward
Transformer operations
Figure 1. Switch location
Note!

6
Using your #59 Minuteman Unit’s ElectroCouplers in the
non-Command environment
To use your #59 Minuteman Unit’s ElectroCouplers in the non-Command
environment, you must first couple a piece
of rolling stock equipped with Lionel mag-
netic couplers directly to your #59
Minuteman Unit’s ElectroCouplers. The
magnetic coupler on the rolling stock will
then react to the magnetic field generated
by a Lionel remote-control track section
(available separately). Place your rolling
stock’s coupler “trigger disc” over the cen-
tral coil of a remote-control track section
and press UNCOUPLE on the controller.
The magnetic field pulls the disc down-
ward, and the coupler opens.
Your #59 Minuteman Unit’s
ElectroCouplers will NOT open
manually or by using a remote-
control track section.
Magnetic coupler on the rolling stock coupled
to your #59 Minuteman Unit
Note!
Remote-control
track section
Transformer operations
Figure 2. Trigger disc operation

7
TrainMaster Command operations
The Command Control environment
Lionel TrainMaster Command is the advanced model railroad control system
from Lionel. TrainMaster Command gives
you the power to operate multiple Command-
equipped locomotives on the same track, at
the same time.
To operate in Command mode, you
need a Command Base and a CAB-1
remote. Find them both at your authorized
Lionel retailer.
Place your #59 Minuteman Unit on Lionel or
Lionel-compatible O gauge track.
2
2Address your #59 Minuteman Unit using CAB-1.
• Press ENG and 1 on the numeric keypad of your CAB-1 remote. This
command is sent by CAB-1 to the Command Base, which then translates
your command into digital code. That code is sent around your railroad’s
outside rails in the form of a digital “halo.” All Command-equipped Lionel
engines listen to this digital communication, but they do not respond until
they hear their individual ID number—in this case, “1.”
• The digital language of TrainMaster Command—and not track
power—controls the actions of Command-equipped Lionel
engines. Track power is simply like gasoline in the tank of your car—it
gives you the power to go places, but it doesn’t tell you where to go or how
fast to get there.
• All Command locomotives come factory-programmed with an
ID# of “1.” To change the ID# of your #59 Minuteman Unit, see page 10.
3
3Move ‘em out!
• Throttle up or press any command button on CAB-1. Your #59 Minuteman
Unit will respond to your every command. Read on.
1
1• Make sure track power is OFF before placing on the track.
• Make sure your Lionel Command Base is plugged in and its
communications wire is connected to the COMMON post on your Lionel
transformer or the U terminal on any of your installed PowerMasters.
• Once positioned on the track, increase track voltage to FULL (no
more than 20 volts). On PowerMasters, slide the CMD/CONV switch to
CMD.

Running your #59 Minuteman Unit in the TrainMaster Command
environment
Press AUX2 to turn
your #59 Minuteman
Unit’s headlights on
and off.
Activates keypad.
Press HALT to shut
down all PowerMaster
electrical output on
your railroad. Stops all
Command-equipped
Lionels in operation.
Turn the THROTTLE
to the right to
accelerate, left to
decelerate.
Your Command-equipped #59 Minuteman Unit comes factory-
programmed with an ID# of “1.” To
get your #59 Minuteman Unit in
action, set PowerMasters to CMD or
set all power supplies on full (no
more than 20 volts). Press ENG and
“1” on CAB-1. Turn the throttle or
press any command button; your
#59 Minuteman Unit is ready for
Command operations.
Address Locomotive #1
PowerMasters set to CMD or
traditional power supplies ON FULL
(no more than 20 volts)
Press ENG
Press 1 (the ID#)
Throttle up/press any command
button
Example
CAB-1 commands for your #59 Minuteman Unit
Press DIR—the locomotive
decelerates to a complete
stop; turn the throttle up, and the
locomotive will accelerate in the
new, opposite direction. There is no
neutral state.
Press and hold BOOST for
extra power. Release
BOOST and return to the #59
Minuteman Unit’s previous speed.
Press and hold BRAKE to
slow down or stop. Release
BRAKE and return to the previous
speed.
Front coupler releases.
Rear coupler releases.
AUX 2
AUX 1
TrainMaster Command operations
SET L M H
Beneath this panel
Use “Halt” only in “emergency” situations.
Note!
8

9
Tuning your #59 Minuteman Unit’s performance
MOMENTUM
TrainMaster Command’s momentum fea-
ture simulates the labored performance of a
locomotive pulling a heavy load. Press L,
M, or H(located under CAB-1’s removable
panel) for light, medium, or heavy momen-
tum. The #59 Minuteman Unit’s Command
reverse unit remembers this setting until
you change it. For quick locomotive
response, choose L.
BRAKING AND BOOSTING
There’s more to starting and stopping
than just turning the CAB-1 throttle. Use the
BOOST and BRAKE command buttons for
incremental control of speed—they are the
superior way to handle grades, gradual
stops-and-starts, and more.
HIGH VOLTAGE SETTING
Press SET, and the headlight will flash.
Get your locomotive moving to the maxi-
mum speed you want it to run, then press
BOOST. Use this to keep your locomotive
from derailing at excessive speeds. Turn off
the high voltage setting by pressing SET,
then BOOST, holding each for one second.
STALL
Make your #59 Minuteman Unit feel more
responsive by setting a “stall” voltage. Get
your locomotive moving, then press SET;
the #59 Minuteman Unit will stop. Turn the
throttle clockwise to get the locomotive
moving, then decrease speed until the loco-
motive just barely stops. Press SET again;
the Command reverse unit remembers the
stall setting until you change it. To clear the
stall setting, press SET twice, holding it for
one second each time.
These settings will be lost when you assign a new engine ID number.
Note!
TrainMaster Command operations

10
TrainMaster Command operations
Assign a new ID# to your
Command-equipped #59
Minuteman Unit
Set the #59 Minuteman Unit reverse unit control
switch to PROGRAM
Command Base plugged in
Place the #59 Minuteman Unit on track
PowerMasters set to CMD or traditional power
supplies ON FULL (no more than 20 volts)
Turn track power on (PowerMasters):
Press BOOST
Program the #59 Minuteman Unit with a
new ID#:
Press ENG
Press a number you choose
(the ID#)
Press SET
Set the reverse unit control switch to
FORWARD/RUN
Your #59 Minuteman Unit remembers its ID#
forever; change it any time with these steps
Example
We recommend that you choose an easy to
remember ID# for your engine. Some possi-
bilities are part of the engine road number,
your age, or any two digit number that is not
used by another engine. Write the number on
a small piece of tape and put this on the bot-
tom of the fuel tank to aid in remembering.
As your fleet of Command-equipped Lionels grows, you’ll want to give your
#59 Minuteman Unit a more individualized
number. Choose from any between 1 and
99. To make things easy, use a portion of
your #59 Minuteman Unit’s cab number.
Set the #59 Minuteman Unit’s reverse
unit control switch to PROG (see the illus-
tration on page 5). Plug in the Command
Base and place the #59 Minuteman Unit on
track. Then, power up. Using CAB-1, press
ENG, the locomotive ID# that you select,
then press the SET button located under
CAB-1’s removable panel. See the headlight
flash; that’s the Command reverse unit con-
firming the new ID#. Set the reverse unit
control switch to RUN. Your #59
Minuteman Unit is ready for operations
with its all-new ID#.
Assigning your #59 Minuteman Unit a new ID#

11
TrainMaster Command operations
Reprogramming Command reverse unit circuit board
to restore features
Due to the inevitable derailments and static, it is possible that your Command
reverse unit could someday lose its setup
program.The symptoms of this condition
would be unresponsiveness in Command
mode. This can be easily remedied by
“reprogramming” your Command reverse
unit using the following steps.
STEP 1: Move the switch on your locomo-
tive from RUN to PROG.
STEP 2: Plug in your Command Base.
STEP 3: Place the locomotive on track,
then turn on power to your track.
STEP 4: Press “ENG,” then input the loco-
motive’s ID#. Press “SET.”
STEP 5: Press “ENG,” then the ID#,
“AUX1,” then press 6 for your locomotive.
STEP 6: Turn off power to your track and
wait ten seconds.
STEP 7: Remove the locomotive from your
track, and move the switch from PROG to
RUN.
STEP 8: Place the locomotive back on
track, then turn power on to the track.
STEP 9: Press “ENG” and the ID#, then
operate as normal.

12
Cab mounting screw
Cab mounting screw
Lubricate with
Lionel oil sparingly
Lubricate with Lionel oil
sparingly To remove shell,unscrew
cab mounting screws,and
slip shell off. Be careful
with the wires attached to
the shell.
Lubricate with Lionel
grease sparingly
Front
Rear
Lubricate with Lionel
oil sparingly
Lubricating your #59 Minuteman Unit
Help your Lionel #59 Minuteman Unit lead a long and productive life on your
railroad by maintaining it properly.
We recommend that you purchase a
Lionel Lubrication and Maintenance Kit
(no. 6-62927), available from your Lionel
dealer. Two basic rules to keep in mind:
never over-lubricate (a small amount will
do), and avoid getting grease or oil on the
#59 Minuteman Unit’s wheels or your track.
You’ll know your #59 Minuteman Unit
requires lubrication when visual inspection
reveals dryness on the parts indicated in
Figure 3. Remove accumulated dirt and dust
before lubricating, and always lubricate any
locomotive emerging from prolonged
storage.
Maintaining and servicing your
#59 Minuteman Unit
Figure 3. Underside details and lubrication points

13
Lubricating the Pullmor motor armature
Your Minuteman Motorized Unit will require the occasional lubrication of its Pullmor motor armature. If you hear excess noise during operation, or if the slows down intermit-
tently, you may need to oil the top armature bearing. Follow these steps and refer to Figure 4.
1. Remove the cab mounting screws from the bottom of the Minuteman, then lift the shell
away. Refer to Figure 3 on page 12 for the location of these screws.
2. As illustrated in Figure 4, remove the set screw at the top of the motor.
3. Add a small amount (two drops) of Lionel oil (available separately in the
Lubrication/Maintenance Set, no. 6-62927) to the set screw hole.
4. Replace and adjust the set screw. Roll the engine wheels back and forth by hand to be sure
that the travel of the brushes or armature is about .01” (the thickness of three pieces of
paper). The up and down travel of the armature should be barely visible.
You will not be able to turn the motor armature by rolling the wheels.
5. Reinstall the body shell and replace the cab mounting screws.
Maintaining and servicing your
#59 Minuteman Unit
Note!
LIONELLIONEL
Set screw
Lionel oil
Figure 4. Armature lubrication

Maintaining and servicing your
#59 Minuteman Unit
Replacing your #59 Minuteman Unit’s lamps
Your Minuteman unit is illuminated by two small lamps. During the course of operation, these lamps may require replacement. The replacement lamps are part no. 610-8515-100,
available from your authorized Lionel Service Center or Lionel Service. Follow these steps and
refer to Figure 5 as you replace the lamps.
1. Remove the cab mounting screws from the bottom of the Minuteman, then carefully lift
the shell away. Refer to Figure 3 on page 12 for the location of these screws.
2. Locate the assembly containing the expired lamp and follow the wires to the terminal on
the circuit board.
3. Separate the top portion of the terminal by pulling it out.
4. Remove the wire that connects the terminal to the expired bulb. Use a small, pointed object
to pull back the small tab on the front of the upper portion of the terminal, then pull out
the wire as illustrated in Figure 5.
5. Follow the other wire from the expired lamp to the wire nut, and free this wire by unscrew-
ing the nut from the wire ends and removing the tape.
6. Push the lamp through the body shell toward the exterior and pull the wires through the
hole to completely remove the expired lamps.
7. Replace the lamp with Lionel part no. 610-8456-100 (available from your authorized
Lionel Service Center or Lionel Service), inserting the wires back into the shell. Connect
these wires in the same way that the original was connected.
8. Press-fit the lens assembly into the shell, then tuck the wires inside and replace the cab
with the two mounting screws.
Figure 5. Lamp replacement 14
Front Lamp
Front Lamp
Rear Lamp
Rear Lamp
Antenna
Antenna

Replacing your #59 Minuteman Unit’s traction tires
15
Maintaining and servicing your
#59 Minuteman Unit
Your Minuteman Unit is equipped with a traction tire to enhance the tractive effort of your locomotive. During the course of normal operation, you may find that the traction tires
require replacement. Extra traction tires are included.
To replace the traction tires, simply remove the 1/4” nut from the traction tire-equipped
drive wheel. Slip off the old traction tire. Place the new traction tire around the wheel and
reattach the drive rod with the 1/4” nut. You’re ready to pull the long freight back to the yard!

Limited Warranty/Lionel Service
This Lionel product, including all
mechanical and electrical components,
moving parts, motors and structural
components, except for light bulbs, is warranted to
the original consumer-purchaser, for one year
against original defects in materials or
workmanship when purchased through an
authorized Lionel merchant.
This warranty does NOT cover normal wear
and tear, light bulbs, defects appearing in the
course of commercial use, or damage resulting
from abuse or misuse of the product by the
purchaser. Transfer of this product by the original
consumer-purchaser to another person voids this
warranty. Modification of this product voids this
warranty.
Any warranted product which is defective in
original materials or workmanship and is delivered
by the original consumer-purchaser to Lionel
L.L.C. or an authorized Lionel L.L.C. Service
Center, together with proof of original purchase
will, at the option of Lionel L.L.C., be repaired or
replaced, without charge for parts or labor. In the
event the defective product cannot be repaired, and
a replacement is not available, a refund of the
original purchase price will be granted. Any
products on which warranty service is sought must
be sent freight or postage prepaid, as
transportation and shipping charges are not
covered by the warranty.
In no event shall Lionel L.L.C. be
liable for incidental or
consequential damages.
Some states do not allow the exclusion or
limitation of incidental or consequential damages,
so the above exclusion may not apply to you.
This limited warranty gives you specific legal
rights, and you may have other rights which vary
from state to state.
Instructions for Obtaining Service
If service for this Lionel L.L.C. product is
required, bring the item, along with your dated
sales receipt and completed warranty information
to the nearest Authorized Lionel Service Center.
Your nearest Lionel Service Center can be found by
calling 1-800-4-Lionel, or by accessing our
Website at www.lionel.com.
If you prefer to send your product back to
Lionel L.L.C. for repair in Michigan, you must first
call 586-949-4100 or FAX [phone], or write
to Customer Service, P.O. Box 748, New Baltimore,
MI 48047-0748, stating what the item is, when it
was purchased and what seems to be the problem.
You will be sent a return authorization letter and
label to ensure your merchandise will be properly
handled upon receipt.
Once you have received your return
authorization and label, make sure that the item
is packed to prevent damage during shipping and
handling. We suggest that you use the product’s
original packaging. This shipment must be
prepaid and we recommend that it be insured.
Please make sure you have followed all of the
above instructions carefully before returning any
merchandise for service. You may choose to have
your product repaired by one of our Authorized
Lionel Service Centers after its warranty has
expired. A reasonable service fee will be charged.
Warranty Information
Please complete the information below and
keep it, along with your dated sales receipt. You
must present this and your dated sales receipt
when requesting warranty service.
Name ____________________________
Address____________________________
Place of Purchase ____________________
Date of Purchase ____________________
Product Number______________________
Product Description____________________
©2002 LIONEL LLC, CHESTERFIELD, MI 48051-1956
UNITED STATES OF AMERICA
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