Lionel Norfolk Southern Ready-to-Run Freight Set User manual

73-0158-250
3/11
Norfolk Southern
Diesel Freight
Ready-to-Run Train Set
Owner’s Manual
Norfolk Southern
Diesel Freight
Ready-to-Run Train Set
Owner’s Manual
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

Train Set Inventory
• GP-38 diesel locomotive
• Hi-cube boxcar
• Quad hopper
• Depressed-center flatcar with generator load
• Porthole caboose
• CW-80 Transformer
• Three straight FasTrack track sections
• Eight curved FasTrack track sections
• One straight FasTrack terminal track section
• Replacement traction tire
• Owner’s Manual
Congratulations!
2
Congratulations on your purchase of the Norfolk Southern 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 con-
sist 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!
The following Lionel marks are used throughout this catalog and are protected under law. All
rights reserved.
Lionel®, LEGACY™, 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™

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
Experiencing the features of the CW-80 Transformer 11-12
Reverse unit procedure 13
Operating the TrainSound sound system 14
Adjusting the volume 15
Silencing the diesel roar 15
CW-80 Transformer operation
Powering your layout with the CW-80 Transformer 16
Setting the accessory output 17
Maintaining and servicing your set
Lubricating your locomotive 18
Replacing your locomotive’s traction tire 19
Replacing your locomotive’s lamps 20
Replacing your square window caboose lamp 21
Troubleshooting 22
FCC Statement 23
Limited Warranty/Lionel Service 24

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. 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

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.
Creating your layout
Figure 1. Track layout ideas
5
FasTrack Add-on Track Packs (available separately) 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
Additional track sections available separately in Track Packs (represented in darker shading).

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
Connecting 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, for one to four seconds. When
track power is interrupted, the locomotive advances 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
Running your train
Refer to Figure 6 on page 12 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 horn or whistle sounds. The sound
will continue 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 TrainSounds-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.
Experiencing the features of the CW-80 Transformer
Note!

12
Experiencing the features of the CW-80 Transformer
(continued)
Whistle/Horn
Activates the whistle or horn sound
effect in your Lionel locomotives.
Press WHISTLE/HORN 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 cycle
through forward, neutral, reverse, neutral,
and so on (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 6. Transformer features
Running your train

13
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 6
on page 12 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 7). To lock your locomo-
tive 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 locomo-
tive. 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.
Figure 7. Switch locations
ON
DIRECTIONAL
CON TROL
OFF ON
SOUND
OFF
Underside of GP-38 locomotive
Sound ON/OFF switch
Reverse unit control switch

Running your train
14
If you activate multiple “stand by” dialogues during the first 35 seconds, the length
of time before the “clear for departure” dialogue becomes 35 seconds, plus the
length of the diaglogue.
Press the HORN button Dialogue
Stop/Power-up to about 35 seconds “Stand by” dialogue
After 35 seconds “Clear for departure” dialogue
After 60 seconds Random, automatic crew dialogue
Note!
Note!
Operating the TrainSounds 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.
Horn
Press the 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.
Brake squeal
To activate the sound of squealing brakes, operate your locomotive at the highest RPM level
for at least ten seconds, and then slow to a lower level. The brake sounds will discontinue
automatically after a few moments.
If you are unable to activate the brake sounds, your locomotive’s speed may be too
low. Increase the speed of your locomotive, operate for at least ten seconds, and then
reduce the throttle by half.
Crew dialogue
When the locomotive is not in motion, you may activate random crew dialogue using the
HORN button on your controller.
The locomotive must be powered up on the track and not in motion for the dialogue
to play. Do not turn off track power.
Note!

Running your train
15
Adjusting the volume
Use the volume control knob on the underside of the locomotive to adjust the volume. Refer to Figure 9. Use a small screwdriver to access the volume control knob.
Silencing the diesel roar
To silence the diesel roar, slide the SOUND switch on the underside of the car to the OFF posi- tion. The user-activated horn and bell are not silenced. Refer to Figure 9 for the location of
the switch.
Figure 8. Volume control knob and switch locations
ON
DIRECTIONAL
CON TROL
OFF ON
SOUND
OFF
Underside of GP-38 locomotive
Sound ON/OFF switch
Volume control knob Reverse unit control switch

16
CW-80 Transformer operation
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 accesso-
ries require two amps of the total five-amp capacity of the Transformer, you have three amps
available 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
locomotives. To operate at this level of track power, it may be necessary to disconnect any
accessories. You may also attempt to lower the accessory voltage settings. Refer to the “Setting
the accessory output” section on page 17.
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 acces-
sories. When you reach five amps, the green light on the Transformer will begin to flash. This
indicates 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.

17
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. Accessories connected to the accessory output
terminals receive constant voltage whenever the transformer is plugged in, regardless of the throttle
position. 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 pages 7-8.
2. Bring the throttle all the way back to the OFF position.
3. Press and hold down the DIRECTION, WHISTLE, and BELL buttons on the
Transformer. Refer to Figure 6 on page 12 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 throttle again will
control track power only.
Setting the accessory output
Note!
CW-80 Transformer operation

ON
DIRECTIONAL
CON TROL
OFF ON
SOUND
OFF
18
Maintaining and servicing your set
Lubricating your locomotive
H
elp your Lionel locomotive lead a long and productive life on your railroad by maintain-
ing it properly.
We recommend that you purchase a Lionel Lubrication and Maintenance Kit (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 locomotive’s wheels, contact
rollers, or your track.
You’ll know your locomotive requires lubrication when visual inspection reveals dryness
on the parts indicated in Figure 9. Remove accumulated dirt and dust before lubricating, and
always lubricate any locomotive emerging from prolonged storage.
Figure 9. Underside details and lubrication points
Lubricate gears with
Lionel grease
sparingly
Lubricate gears with
Lionel grease
sparingly
Lubricate with Lionel oil
sparingly
Lubricate with
Lionel oil
sparingly
Location of the body
screws on the under-
side of the frame.
Location of the body
screws on the underside
of the frame.

19
Maintaining and servicing your set
Replacing your locomotive’s traction tire
Your locomotive is equipped with four traction tires. These rubber tires increase the trac- tive effort of your locomotive, allowing it to pull more cars at once. During the course
of normal operations, the traction tires may become worn out. Because you must remove the
trucks and the side frames to access the wheels, we recommend that you have the traction tires
replaced by your authorized Lionel Service Center. Should you ever need additional traction
tires (Lionel part no. 6000222108) for servicing your locomotive, you can locate your nearest
Factory Trained Authorized Service Station at www.lionel.com in the Customer Services sec-
tion.

20
Maintaining and servicing your set
Replacing your locomotive’s lamps
Your locomotive is illuminated by three 12-volt lamps. One lamp illuminates the rear lights, another illuminates the front lights, and one illuminates the cab interior. During the course of
normal operations, they may require replacement.
To replace the expired lamp, remove the four body screws (see Figure 10 on page 18`) and care-
fully lift the body away from the frame. Take care with the various wiring assemblies connected to
the shell.
Locate the assembly containing the expired lamp, which is held in position by a retaining bracket.
Refer to Figure 10. Carefully remove the lamp assembly from the bracket, then gently pull the
expired lamp from its socket. Replace the expired lamp with Lionel part no. 630-8352-311, available
from your authorized Lionel Service Center or Lionel Service. For more information, see page 24.
Reinstall the body and secure it with the four body screws.
Figure 10. Lamp replacement
Lionel part no. 6308352311
Lionel part no. 6308352311