Lionel Nickel Plate Road Super Freight User manual

73-1962-250
2/04
CAUTION—ELECTRICTOY
NOT RECOMMENDED FOR CHILDREN UNDER EIGHT YEARS OF AGE. AS WITH
ALL ELECTRIC PRODUCTS, PRECAUTIONS SHOULD BE OBSERVED DURING
HANDLINGAND USETO REDUCETHE RISK OF ELECTRIC SHOCK.
TRANSFORMER RATINGS—INPUT:120VAC; 60 HZ ONLY.
AC OUTPUT:18V; 80VA
Nickel Plate Road
Super Freight
Ready-to-Run Train Set
Owner’s Manual
featuring

Congratulations!
2
Congratulations on your purchase of the ready-to-run Nickel Plate Road Super Freight Train Set with the RailSounds sound system! This set features everything you need to get started—a
mighty CW-80 Transformer, a huge loop of FasTrack track, a string of detailed cars, and a powerful
Lionel locomotive. Plus, you get the authentic locomotive sounds of the RailSounds sound system.
Have fun growing with this complete train set! Start with the set components, then follow
your imagination into your own miniature world. Expand your railroad empire with addition-
al 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 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®, PowerHouse®, TMCC®, Lionelville™, Lockon®
The name FasTrack®is used with permission from Pitsco, Inc.

3
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!
Nickel Plate Road Super Freight Train Set Features
Bright
headlight
Operating
couplers
Opening
boxcar doors
Puffing
smoke
RailSounds
sound system
Lighted
caboose
interior
Forward-Neutral-Reverse
operation
Congratulations!

Congratulations!
4
Nickel Plate Road Super Freight Train Set Inventory
• 2-8-4 Berkshire steam locomotive and tender with RailSounds
• Boxcar
• Tank car
• Flatcar with trailer
• Caboose with a replacement lamp
• CW-80 Transformer with accessory wire
• Three straight FasTrack track sections
• Eight curved FasTrack track sections
• One straight FasTrack terminal track section
• Owner’s Manual
• Service Center list
• Instruction video
• Catalog
• Lionel RailRoader Club flyer
• Smoke fluid and replacement traction tires

5
Table of contents
Creating your layout
Operating your CW-80 Transformer safely 6
Building your Lionel layout 7
Joining the FasTrack track sections 7
Wiring your CW-80 Transformer 8-9
Running your train
Running your train set 10
Adding smoke fluid to the locomotive’s smoke generator 11
Coupling 12
Experiencing the features of the CW-80 Transformer 13-14
Reverse unit procedure 15
RailSounds sound system operations
Your Locomotive’s RailSounds sound system—the basics 16
Experiencing the range of your locomotive’s RailSounds sound system 17
Notes on the RailSounds sound system 17
TowerCom announcements 18
CrewTalk communication 18
Train brakes 18
Wheel flange squeal 18
CW-80 Transformer operation
Powering your layout with the CW-80 Transformer 19
Setting the accessory output 20
Maintaining and servicing your set
Lubricating your locomotive 21
Replacing your locomotive’s traction tires 22
Replacing your locomotive’s lamp 22
Replacing the caboose’s interior lamp 23
Replacing the caboose’s rear light 24
Advanced connections: powering two isolated blocks with two transformers 25
Troubleshooting 26
Notes 27
Limited Warranty/Lionel Service 28

Operating your CW-80 Transformer safely
6
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 eight 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. A
list of authorized Service Centers is packed with this unit.
• 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

7
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!
Figure 1. Track layout ideas
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 2 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 2. Joining the track sections
Creating your layout

Wiring your CW-80 Transformer
8
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 3 on page 9.
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.
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!
Creating your layout

9
Creating your layout
Wiring your CW-80 Transformer (continued)
U120/60z
0~18VAC
AB
U
0~18VAC

TRACK ACCESSORY
Figure 3. Controller connections
FasTrack terminal section
Notch
Spade-shaped
connector

10
Running your train set
With track power off, place your train set on the track.
Refer to page 12 to couple the cars.
33
3
3
2
2
4
4
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 to forward, 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
1
Connect the drawbar between the locomotive and tender.
See Figure 4.
If the smoke unit switch on the locomotive and caboose are in the ON
position, add smoke fluid to the stacks to prevent damage to the smoke
units. Refer to page 11 for additional information.
Figure 4. Drawbar connection
Caution!
Note!
Running your train

Running your train
11
Adding smoke fluid to the smoke generator
Your locomotive and caboose are equipped with smoke generators that produce safe, clean, white smoke. The smoke units will operate only if the smoke unit switches are in the ON
position. Refer to Figure 7 on page 15 for the locomotive’s switch location.
The smoke generators require the periodic addition of smoke fluid in order to function.
Your set includes a bottle of smoke fluid. To add smoke fluid, press down and unscrew the cap.
Add four drops of smoke fluid directly to the locomotive’s stack. Lift away the caboose’s stack
and add four drops to the opening in the roof.
Smoke production will begin when the smoke unit heats up. Increasing track voltage will
cause the smoke generators to produce smoke faster. When smoke production decreases, add
four additional drops of smoke fluid. Keep in mind that the locomotive will not smoke while it
is in neutral.
If you prefer to operate the locomotive or caboose without smoke, be sure to slide
the smoke unit switches to the OFF positions.
When the smoke unit switch is in the ON position, always keep a small amount
of smoke fluid in the smoke generator. The generator’s heating element can
become damaged if it is operated without smoke fluid. This is particularly true if
the locomotive sits in neutral for an extended period of time without smoke
fluid in the generator.
Caution!
Note!

12
Running your train
Coupling
When coupling your cars, at least one of the mating couplers must be open as shown 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!

Note!
13
Experiencing the features of the CW-80 Transformer
Refer to Figure 6 on page 14 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.
Your locomotive features prototypical steam whistle sounds.
BELL
The BELL button will activate your locomotive’s bell sounds. 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
Note!

Experiencing the features of the CW-80 Transformer (continued)
14
Whistle
Activates the whistle or horn sound
effect in your Lionel locomotives.
PressWHISTLE to begin the sound;
release the button to end it.
Bell
Starts or stops the tolling bell in any
Railsounds-equipped locomotive.
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 for-
ward to increase locomotive speed,backward to slow it
down.
Power-on indicator
The green light
illuminates when the
CW-80 is on.
Figure 6. Transformer features
Running your train

15
Running your train
Reverse unit procedure
The electronic reverse unit inside your Lionel locomotive acts like the transmission in your 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 interrup-
tions 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 8
for the location of this button. The reverse unit alternates between three states: forward, neu-
tral, and reverse.
Also, the locomotive can be “locked” into a certain mode of operation by throwing the reverse
unit switch located in the cab (see Figure 7). When the switch is thrown to the OFF position, the
locomotive will be locked in that mode of operation in the sequence. To lock your locomotive
into a specific operational state, sequence your locomotive into the desired state, and reduce track
power without completely powering down the locomotive. Throw the switch to the OFF position to
lock the locomotive into this state. The DIRECTION button will then have no affect on the direc-
tion 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 “pow-
ered up,” regardless of the reverse unit
switch position. If the reverse unit switch is
in the OFF position, the locomotive will
start in the forward direction and be
“locked” there. Figure 7. Switch location
Figure 8. Direction control button location
Direction control button
Whistle control button
Bell control button
ON
SMOKE
OFF ON
REVERSE
OFF
OFF
ON
Reverse
unit
switch
Smoke
ON/OFF switch
OFF
ON
Rear of locomotive

RailSounds sound system operations
Note!
Note!
Your Locomotive’s RailSounds sound system—the basics
The Lionel RailSounds sound system is the most realistic model railroad sound system in the world. Your locomotive features digital sound samples for the ultimate in realism.
Begin by installing a nine-volt alkaline battery (not included) in the tender. This ensures
interruption-free operation of the RailSounds sound system. As illustrated in Figure 9 below,
simply remove the four body screws and lift away the body to access the battery. Connect the
nine-volt alkaline battery to the battery harness (remove the protective cover from the battery
harness), and slide the battery into the holder inside the tender.
When you first apply track power, the locomotive’s RailSounds sound system delivers an
authentic start-up sequence, followed by the sounds of the locomotive at idle. As the locomo-
tive’s speed increases, the chuff rate will increase, too.
Although the RailSounds sound system is powered by track voltage, the battery is
required for uninterrupted operation and shutdown sequences. Use only alkaline
batteries.
If the RailSounds sound system “drops out” during track power interruptions
(direction change), replace the battery.
Figure 9. Battery installation
Battery holder
Rear ofTender Battery harness
+
OFFON
RAILSOUNDS
-
Volume control knob
RailSounds ON/OFF switch Body screws
Body screws
16

17
RailSounds sound system operations
With the RailSounds sound system, you experience the sounds of real railroading like never before. Simply put, it’s the most sophisticated, authentic model railroad sound
system in the world.
• Variable chuff rate. Your locomotive’s speed determines the steam chuff rate.
• MultiWhistle/Bell. These features can be activated by pressing the WHISTLE and BELL
buttons on your Transformer (see pages 13 and 14). The bell sound will begin when you
push the button and discontinue when you push it again.
• Shutdown sequence. No other model railroad sound system shuts down like
RailSounds. Turn off track power, and after the air-release reset sound, you have two
seconds to restart your locomotive. If you’re done with operations, the RailSounds sound
system will commence with an authentic shutdown sequence about two seconds after the
air-release reset occurs.
• Braking Sounds. To activate the screeching sound of your locomotive’s brakes, simply
turn the throttle down as the locomotive is moving. Notice the sound becomes more
intense the faster your engine is moving and the greater its deceleration. This can also be
accomplished by pressing the DIRECTION button while the train is in motion.
A battery must be installed for the shutdown sequence.
Experiencing the range of your locomotive’s RailSounds sound system
Notes on the RailSounds sound system
• Use the volume control knob located on the underside of the tender. Refer to Figure 9 on
page 16. Turn the volume set screw clockwise or counter-clockwise to adjust the volume.
• Listen for incidental Locomotive sounds during the RailSounds sound system operation.
They’re automatic and, of course, authentic.
• The nine-volt alkaline battery you installed ensures continuous sounds, even during short
track-power interruptions.
• Longer track-power interruptions (including locomotive derailments) cause the
RailSounds sound system to shut down after about seven seconds.
Note!

18
RailSounds sound system operations
TowerCom announcements
TowerCom announcements are a two part message involving a “stand-by” or “clear for
departure” announcement from the dispatcher
followed by an acknowledgement from the engi-
neer. There are several messages and each time
a TowerCom announcement is triggered, a ran-
dom call/response will be played.
The TowerCom announcement, selected ran-
domly for play-back, is triggered by a short
whistle blast only when the train is stopped. A
long whistle blast will not trigger the effect, and it is disabled when the locomotive is in motion.
If the trigger (short whistle blast) occurs within 15 seconds of the train stopping, a “stand by”
message is played; if the trigger occurs more than 15 seconds after the train has stopped, a “clear
for departure” message is played. The 15-second interval is marked by the first instance of
CrewTalk communication after the engine stops.
Example
• User brings the engine to a stop and
sounds a short whistle blast.
• TowerCom announcement says, “Please
stand by.”
• User waits until the first CrewTalk mes-
sage plays. User sounds another short
whistle blast.
• TowerCom announcement message says,
“You are clear for departure.”
CrewTalk communication
There are “call” messages and “response” messages that are selected randomly for play- back. The CrewTalk messages are triggered at random intervals, from 30 seconds to 3 min-
utes, only when the train is stopped.
Train brakes
For the ultimate in realism, the sound of squealing train brakes can be played during fast stops. The engine must be moving at a medium speed then slowed quickly to trigger the sounds. With
practice, you will be able to control the sound at any time.
Wheel flange squeal
The brake sounds may also be used to simulate the sound of wheel flange squeal when traveling through tight curves. Depending on your track layout, this sound may occasionally play when
entering a curve. You may also trigger this sound by quickly moving the throttle toward the OFF posi-
tion, then quickly moving it back to its original setting. Do not move it completely to OFF or the loco-
motive will shift to neutral.

19
CW-80 Transformer operations
Powering your layout with the CW-80 Transformer
Your CW-80 Transformer provides a total output of five amps. The track outputs will deliver all of this power to the track when no accessories are connected to the Transformer. Keep
in mind that connected accessories borrow some of this power. For example, if the accessories
require two amps of the total five-amp capacity of the Transformer, you have three amps avail-
able for track power. This built-in flexibility will provide power for virtually any small- to
medium-sized railroad. Also, available voltage depends on how much load is on the two out-
puts. Generally, track voltage and accessory voltage are 0-18 volts (AC) each.
This Transformer is capable of operating trains up to and including dual-motored AC loco-
motives. To operate at this level of track power, it may be necessary to disconnect any acces-
sories. You may also want to attempt to lower the accessory voltage settings. Refer to the
“Setting the accessory output” section on page 20.
You may momentarily approach or exceed the five-amp limit of the CW-80 Transformer
when pulling illuminated cars, fighting over grades with heavy loads, or operating accessories.
When you reach five amps, the green light on the Transformer will begin to flash. This indi-
cates that the Transformer is in “fold-back mode.” In fold-back mode, the Transformer is
automatically reducing, or folding back, power. This gradual reduction in power provides
interruption-free operation while you bring the amperage back down to a safe level.

Lionel offers accessories of all shapes and sizes — from crossing signals to coal and lumber loaders — available at your authorized Lionel dealer. When you are ready to operate your
new accessory, the CW-80 Transformer allows you to choose how much power your accessory
receives with programmable accessory output. The ability to control the voltage allows you to
set the speed of your accessory motors and the intensity of your lights. Follow these steps to set
the voltage.
The accessory output voltage was set to 12 volts at the factory.
1. Connect your accessory to the CW-80 Transformer as discussed on page 8.
2. Bring the throttle all the way back to turn off the power.
3. Press and hold down the DIRECTION, WHISTLE, and BELL buttons on the
Transformer. Refer to Figure 6 on page 14 for the location of these buttons.
The green light on the Transformer will flash, and track power will turn off.
4. With all three buttons held down, raise the throttle slowly until you reach
your desired accessory voltage.
5. Release the buttons once you have reached your desired voltage.
The accessory turns off, and the solid green light indicates that you have set the accessory
voltage.
6. Bring the throttle all the way back to turn off the power.
The voltage will momentarily increase, briefly causing the lights to shine brighter or the
motors to operate faster, before returning to the set level. At this point, increasing the throt-
tle again will control track power.
Setting the accessory output
20
Note!
CW-80 Transformer operations