Lionel 73-0211-250 BNSF GP38 User manual

BNSF Maxi-Stack
Ready-to-Run Set
Owner’s Manual
73-0211-250
8/13
CAUTION—ELECTRIC TOY
NOT RECOMMENDED FOR CHILDREN UNDER FOURTEEN YEARS OF AGE. AS
WITH ALL ELECTRIC PRODUCTS, PRECAUTIONS SHOULD BE OBSERVED DURING
HANDLING AND USE TO PREVENT ELECTRIC SHOCK.
TRANSFORMER RATINGS—INPUT: 120 VAC; 60 HZ ONLY.
AC OUTPUT: 18 V; 80 VA
BNSF Maxi-Stack
Ready-to-Run Set
Owner’s Manual

Set includes
• GP38 Diesel
• Maxi-Stack Pair
• Maxi-Stack Pair
• Extended Vision Caboose
• Eight curved O-36 FasTrack sections, three 10” straight FasTrack sections, one FasTrack
• Terminal straight track section
• CW-80 Transformer
• Replacement traction tire
• Lionel DVD
• Owner’s Manual
Congratulations!
2
Congratulations on your purchase of the BNSF GP38 Maxi-Stack Ready-to-Run Freight Set! This set features everything you need to get started—a mighty CW-80 Transformer, a huge loop of
easy-to-assemble FasTrack track, a string of detailed cars, and a powerful Lionel locomotive.
Have fun growing with this complete train set! Start with the set components, and then follow your
imagination into your own miniature world. Expand your railroad empire with additional FasTrack
track sections, enhance your layout with accessories, lengthen your consist with extra cars, or operate
a new locomotive at the head end of your train! Explore the possibilities at your authorized Lionel
dealer.
Use this Owner’s Manual to learn how to set up, operate, and maintain your train set for years of
reliable operation.
The transformer included with this set should be periodically
examined for conditions that may result in the risk of fire, electric
shock, or injury to persons (such as damage to the output cord,
blades, housing, or other parts). In the event that such conditions
exist, the transformer should not be used until properly repaired.
Parents!

3
Table of contents
Creating your layout
Operating your CW-80 Transformer safely 4
Building your Lionel layout 5
Joining the FasTrack track sections 6
Wiring your CW-80 Transformer 7-8
Running your train
Running your train set 9
Coupling 10
Stacking the containers 11
Expanding the Maxi-Stack into a unit train 12-14
Experiencing the features of the CW-80 Transformer 15-16
Reverse unit procedure 17-18
Operating the RailSounds RTR sound system 19
Adjusting the volume 20
CW-80 Transformer operation
Powering your layout with the CW-80 Transformer 21
Setting the accessory output 22
Maintaining and servicing your set
Lubricating your locomotive 23
Replacing your locomotive’s traction tire 24
Replacing your locomotive’s lamps 24
Replacing the lamp in your extended vision caboose 25
Troubleshooting 26
FCC Statement 27
Limited Warranty/Lionel Service 28
The following Lionel marks are used throughout this Owner’s Manual and are protected under
law. All rights reserved.
Lionel®, LEGACY™, FasTrack®,TrainMaster®, Odyssey®, RailSounds®, CrewTalk™, TowerCom™,
DynaChuff™, StationSounds™, Pullmor®, ElectroCoupler™, Magne-Traction®, CAB-1®Remote
Controller, American Flyer®, Lionel ZW®, ZW®, MagniVision®, TMCC®, Lionelville®, Wireless
Tether™, Powerhouse™, LionMaster®, Conventional Classics™, Postwar Celebration Series™,
TruRail™, PH-1 Powerhouse®, Powermaster®, Powerstation-Powerhouse®, Accessory Motor
Controller™, AMC™, Accessory Switch Controller™, ASC™, Action Recorder Controller™, ARC™, Track
Power Controller 300™, TPC 300™, Track Power Controller 400™, TPC 400™, Block Power
Controller™, BPC™, Operating Track Controller™, OTC™, FatBoy™, Lionel Lines®, Joshua Lionel
Cowen Series™, Lockon®, TrainSounds™, MultiHorn™, MultiWhistle™, Choo-Choo™

4
Operating your CW-80 Transformer safely
Your Lionel CW-80 Transformer is listed by Underwriter’s Laboratory Inc. and has been carefully designed to ensure peak performance. When using electrical products, basic
safety precautions should be maintained.
Be sure to observe the following guidelines:
• Read the manual thoroughly before using this device.
• This device is not recommended for children under fourteen years of age.
• Parents should periodically inspect this product for potential hazards and, if necessary,
have them repaired by an authorized Lionel Service Center. In the event that such a condi-
tion exists, the transformer should not be used until it has been properly repaired.
• The CW-80 Transformer is intended to be used indoors. Do not use this device if water is
present. Serious or fatal injuries may result.
• Use the CW-80 Transformer only for its intended purpose.
• The CW-80 Transformer was meant to operate on 120-volt, 60-Hertz power. Do not connect
this product to any other power supply.
• Do not operate the CW-80 Transformer with a damaged cord, plug, or case.
• To avoid the risk of electrical shock, do not disassemble the unit. There are no user service-
able parts inside. If damaged, take this product to an authorized Lionel Service Center. Visit
www.lionel.com for a list of authorized Service Centers.
• Do not operate the CW-80 Transformer on your layout unattended. Obstructed accessories
or stalled trains may overheat, resulting in damage to your layout.
• Always unplug the CW-80 Transformer from the power source when not in use.
• Never insert objects into the ventilation slots on this product. Damage to sensitive
electronic components can result.
Creating your layout

Building your Lionel layout
Your set comes with eight curved, three straight, and one terminal section of track. Figure 1 provides some examples of layouts that you can build with these track sections.
By adding more FasTrack track sections, you can create an endless number of exciting
track arrangements for more fun, action, and variety. The railroad empire of your dreams can
quickly become a reality!
Creating your layout
Figure 1. Track layout ideas
5
FasTrack Add-on Track Packs make it easy to expand your railroad. Each Track Pack
includes all the track sections you need to create a more advanced layout using the sections
included with this set. Refer to Figure 2 to explore the possibilities.
Figure 2. Add-on Track Pack layouts
Inner Passing Loop Add-on Track Pack
6-12028
Figure 8 Add-on Track Pack
6-12030
Outer Passing Loop Add-on Track Pack
6-12031
Siding Track Add-on Track Pack
6-12044
Track Packs available separately.

Creating your layout
6
Joining the FasTrack track sections
FasTrack track sections join together easily. With interlocking roadbed sections and large rail tabs, the track fits together securely so you always get good electrical contact. Take a
look at Figure 3 to see how to join the track sections.
1. Line up your two sections of track.
2. Insert the rail tabs into the openings at the ends of the corresponding
rails.
3. Press the sections together until the interlocking roadbed snaps into
place.
Figure 3. Joining the track sections
Rail tab

7
Wiring your CW-80 Transformer
Creating your layout
Connect your FasTrack terminal section to the CW-80 Transformer. Use the wires that are already attached to the terminal section. Make sure that all connections are secure.
Loose connections can produce extremely high temperatures. For this reason, do not touch
the terminals or track connections during use. Also, do not locate scenery materials such as
lichen or ground foam near the terminals.
1. Feed the wires through the notch in the FasTrack terminal section. Refer to
Figure 4 on page 8.
2. Loosen the red TRACK thumbscrew terminal, then slide the red
spade-shaped connector into position. The thumbscrew post should be positioned
between the “blades” of the spade connector. Be sure that the blades are touching the
metal post. Tighten the thumbscrew to secure the connection.
3. Loosen the black TRACK thumbscrew terminal, then slide the black
spade-shaped connector into position. Tighten the thumbscrew to secure the
connection. Be sure that the blades are touching the metal post. Tighten the thumbscrew
to secure the connection.
4. If you need to power an accessory (available separately at your
authorized Lionel dealer), connect the accessory to the ACCESSORY
thumbscrew terminals. Use the accessory wire included with the CW-80 Transformer.
5. Plug the CW-80 Transformer into your wall outlet (120 volts).
As your layout expands, you may also make power connections with the stripped ends
of wires, placing no more than two wires on each terminal. For best performance on large
layouts, it is recommended that you use 16-gauge wire to connect your CW-80 Transformer to
the track. On larger layouts where several track connections are required, the use of separate
junctions/terminal strips (available at your local electronics store) is recommended to
prevent voltage drops.
To prevent the excessive build up of heat, be sure to select the proper wire gauge
for your layout. Follow these guidelines:
• Track connections must be made with 18-gauge wire or heavier. Larger
layouts require a minimum of 16-gauge wire.
• Use 24-gauge wire only when connecting single accessories that require lower
current.
• When wiring multiple accessories (two or more) or accessories that require
higher current, be sure to use 18- to 16-gauge wire.
Caution!

8
Creating your layout
Wiring your CW-80 Transformer (continued)
U
120/60z
0~18VAC
AB
U
0~18VAC
TRACK ACCESSORY
Figure 4. Controller connections
FasTrack terminal section
Notch
Spade-shaped
connector

9
Running your train
Running your train set
With track power off, place your train set on the track.
Refer to the following section for information on coupling the cars.
3
2
3
Power up your locomotive with your transformer.
Your locomotive is designed to operate on 7-15 volts alternating cur-
rent. Virtually all Lionel and Lionel-compatible alternating-current transformers
are suitable.
Do not power your locomotive with direct-current (DC) transformers.
The locomotive was designed for use with alternating-current (AC)
transformers only.
Move ‘em out!
Get your locomotive moving. Your locomotive goes through a repeating pattern
of operations: forward, neutral, reverse, neutral, and so on. To sequence the reverse
unit, press the DIRECTION button on your transformer, or briefly bring the throttle
all the way back to the OFF position and then forward. Each press of the DIRECTION
button or interruption in track power causes the locomotive to advance to the next
operational state.
Adjust track voltage until your locomotive moves at your desired speed.
1
Note!

10
Running your train
Coupling
When coupling your cars, at least one of the mating couplers must be open as shown at the left in Figure 5. Press down on the lock release to open the coupler, then push the cars toward
each other until they lock together.
Keep in mind that it’s easier to couple cars on a straight stretch of track.
Lock release
Figure 5. Coupler operation
Note!

11
Stacking the containers
When stacking the containers, the pegs on the underside of the upper container should be inserted into the holes on the bottom container. This will keep the upper container from
sliding around.
In order to lift each container separately with a Lionel Intermodal Crane, the ribbed con-
tainer must be on the bottom as shown in Figure 6.
Do not stack more than two containers as the car may hit obstructions and be too
top heavy.
Figure 6. Maxi-Stack Containers
Opening
doors
Running your train
Caution!

12
Expanding the Maxi-Stack into a unit train
If you wish to articulate your Maxi-Stack with additional sets, you will need to add on to the ends of each set. Refer to Figure 9 on page 14 to help identify the parts.
Do not over-tighten the screws or damage could be caused to the cars and connectors.
1. Remove the truck from the non-brakewheel end of the Maxi-Stack Set using a 3/16” nut driver to
remove the hex-head screw (labeled “B” in Figure 9) from the bottom of the truck.
2. Remove the Phillips head screw (labeled “C” in Figure 9) from the bottom of the platform.
12
Figure 7. Platform removal and connector attachment
Female articu-
lating
connector
Platform
Caution!
Running your train

13
Expanding the Maxi-Stack into a unit train (continued)
3. Install the female articulating connector using the screw removed in step 2.
4. On the second Maxi-Stack Set, remove the truck from the brakewheel end. Again, use a
3/16” nut driver to remove the hex-head screw (labeled “B” in Figure 4) from the bottom
of the truck.
5. Remove the Phillips head screw (labeled “C” in Figure 9) from the bottom of the brake-
wheel platform on the second Maxi-Stack.
6. Install the male articulating connector using the screw removed in step 5.
7. Pass the plain truck shoulder screw (labeled “A” in Figure 9) through the plain truck and
into the male and female connectors as illustrated in Figure 8.
13
Figure 8. Installing the plain truck
Shoulder Screw A
Plain truck
Running your train

1414
MALE ARTICULATING
CONNECTORS
FEMALE
ARTICULATING
CONNECTORS
TWO UPPER INTERMODAL CONTAINERS WITH PEGS
TWO PLAIN TRUCKS
TWO COUPLER TRUCKS
TWO LOWER INTERMODAL CONTAINERS WITH PEG
HOLES
SCREW A Joins the two articulating connectors that connect the two cars in
the center and mounts the plain truck to the pair of connectors.
TWO INTERMODAL
FLATCARS (NOT
SHOWN)
SCREW C Joins the end platforms to the body and the male/female articu-
lating connectors to the body.
SCREW B Mounts the two operating coupler trucks to the end platforms.
Figure 9. Parts list
Expanding the Maxi-Stack into a unit train (continued)
Running your train

15
Refer to Figure 10 on page 16 for the location of the Transformer features listed in this section.
THROTTLE
Push the throttle forward to increase track power. The markings on the throttle approxi-
mate the percentage of full power. For more realism, push the throttle slowly to gradually
increase or decrease the speed of the locomotive. Slowing or stopping the locomotive with the
throttle instead of the DIRECTION button will allow you to continue in the same direction
when you increase the throttle again. To achieve this effect, reduce the throttle to the point
that the locomotive stops moving, but don’t completely turn off the throttle. That way, your
train won’t sequence into neutral.
DIRECTION
The DIRECTION control button interrupts track power to activate the reverse unit in your
locomotive. Your locomotive will not respond to this button when the reverse unit switch is in
the OFF position.
WHISTLE
The WHISTLE button will activate your locomotive’s whistle or horn. The sound will con-
tinue until the button is released. No external sound activation buttons are needed.
BELL
The BELL button will activate the bell sounds on locomotives equipped with this feature. Press
and hold the BELL button for two to three seconds to begin the sounds; press and hold the button
again to turn off the ringing.
Do not activate horns, whistles, or bells on RailSounds-equipped locomotives
until track power has been turned on for a few moments, or a continuous horn/
whistle or bell sound may occur. To correct this problem, simply turn off the CW-80
Transformer, then turn it back on.
POWER-ON INDICATOR
The green light will remain on during normal operation. The green light will begin to
flash if you exceed the power limit of the Transformer. The unit will allow you to momentarily
exceed the power limit, but power will be gradually reduced until the problem is corrected.
The benefit is that the Transformer will not instantly turn off.
Running your train
Experiencing the features of the CW-80 Transformer
Note!

16
Experiencing the features of the CW-80 Transformer
(continued)
Whistle
Activates the whistle or horn sound
effect in your Lionel locomotives.
Press WHISTLE to begin the sound;
release the button to end it.
Bell
Starts or stops the tolling bell in
any RailSounds-equipped locomo-
tive. Press BELL to begin the sound,
again to stop it.
Direction
Press the DIRECTION button to go forward
or reverse, or to place the locomotive in
neutral (no movement, headlight is on).
Throttle
Controls your locomotive’s speed. Throw the throttle
forward to increase locomotive speed, backward to slow
it down.
Power-on indicator
The green light
illuminates when the
CW-80 is on.
Figure 10. Transformer features
Running your train

Running your train
Reverse unit procedure
The electronic reverse unit inside your Lionel locomotive acts like the transmission in a car. When you apply power to the track, the locomotive moves in the direction specified by the
reverse unit—or it sits in neutral, awaiting another power interruption. Power interruptions
are the signal that tells the reverse unit to sequence to the next operational state.
To interrupt power and sequence the locomotive’s reverse unit, press the direction control
button or briefly bring the throttle lever all the way back to the OFF position. Refer to Figure
12 on page 18 for the location of these controls. The reverse unit alternates between three
states: forward, neutral, and reverse.
Also, the locomotive can be “locked” into a certain mode of operation by throwing the
reverse unit switch located on the underside of the frame (see Figure 11). To lock your loco-
motive into a specific operational state, sequence the locomotive into the desired state and
reduce track power without completely powering down the locomotive, then throw the switch
to the OFF position. The DIRECTION button will then have no affect on the direction of the
locomotive. If you would like to resume forward-neutral-reverse operation, simply throw the
reverse unit switch back to the ON position.
Additionally, this reverse unit has a “power-up reset” feature. If the locomotive sits without
power for a short period of time, the reverse unit will automatically reset and start in the forward
direction when the transformer is turned on or “powered up,” regardless of the reverse unit
switch position. If the switch is in the OFF position, the locomotive will start in the forward direc-
tion and be “locked” there.
17
ON
OFF
ON
OFF
SMOKE
DIR
Figure 11. Switch locations
Front of the locomotive
Rear of the locomotive
Reverse Unit Switch

Running your train
18
Reverse unit procedure (continued)
Figure 12. Direction control button location
Direction control button
Whistle control button
Bell control button
Throttle

19
Running your train
Note!
Operating the RailSounds RTR sound system
When you power up the locomotive on the track, you will hear the sounds of the idling diesel motor. As you increase speed, the RPM sounds will ramp up through two levels.
Refer to Figure 10 on page 16 for the location of the controls.
Horn
Press the WHISTLE/HORN button on your transformer to sound the horn. The sound will play
for as long as you hold the button.
Bell
Press the BELL button on your transformer to activate the bell sound. Press BELL again to dis-
continue the sound.
Crew dialog
Press the WHISTLE/HORN button on your transformer briefly (for less than a second) to trig-
ger the train dialog. The dialog varies with the state of the locomotive.
Power must be applied to the track for the dialog to play.
• If the locomotive set has been stopped for longer than 15 seconds, a short horn blast trig-
gers a “cleared outbound” dialog.
• If the locomotive set has started moving within the last seven seconds, a short horn blast
will trigger a “train is underway” dialog.
• If the locomotive set has been moving for more than seven seconds, a short horn blast will
trigger a “are we clear?” dialog.
• If the locomotive set has been moving and the bell is ringing, a short horn blast will trig-
ger a “go to restricted speed” dialog.

Running your train
20
Adjusting the volume
Use the volume control knob on the underside of the locomotive to adjust the volume. Refer to Figure 13. Use a small screwdriver to access the volume control knob.
ON
OFF
ON
OFF
SMOKE
DIR
Figure 13. Volume control knob
Front of the locomotive
Rear of the locomotive
Volume control knob (located
on the frame). Rotate the truck
to access this control.