Lionel Pennsylvania Flyer Deluxe User manual

73-0096-250
3/08
CAUTION—ELECTRIC TOY
NOT RECOMMENDED FOR CHILDREN UNDER EIGHT 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
Pennsylvania Flyer Deluxe
Ready-to-Run Train Set
Owner’s Manual
Pennsylvania Flyer Deluxe
Ready-to-Run Train Set
Owner’s Manual

Congratulations!
2
Congratulations on your purchase of the Lionel Pennsylvania Flyer Deluxe Ready-To-Run Train Set! This set features everything you need to get started—a 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, 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 oper-
ate 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!
Pennsylvania Flyer Train Set Features
• Bright headlight
• Puffing smoke
• Mechanical whistle
• Forward-Neutral-Reverse operation
• Opening boxcar doors
• Operating couplers
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®, Wireless Tether™,
LionMaster®, FatBoy™, American Flyer®, TrainSounds™, PowerMax™, LEGACY™, PowerMax™Plus
The name FasTrack®is used with permission from Pitsco, Inc.

Pennsylvania Flyer Deluxe Train Set Inventory
• 0-8-0 Locomotive
• Tender
• Boxcar
• Searchlight car
• Square window caboose
• Billboard
• 10 telephone poles
• Construction signs
• CW-80 Transformer with accessory wire
• Three straight FasTrack track sections
• Eight curved FasTrack track sections
• One straight FasTrack terminal track section
• Smoke fluid
• Replacement traction tire
• Owner’s Manual
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
Adding smoke fluid to your locomotive’s smoke generator 10
Coupling 11
Operating your train with the CW-80 Transformer 11
Experiencing the features of the CW-80 Transformer 12-13
Reverse unit procedure 14
CW-80 Transformer operation
Powering your layout with the CW-80 Transformer 15
Setting the accessory output 16
Maintaining and servicing your set
Lubricating your locomotive 17
Replacing your locomotive’s traction tire 18
Replacing your locomotive’s headlamp 18
Operating the searchlight 19
Replacing the searchlight lamp 19
Replacing your square window caboose lamp 20
Advanced connections: powering two isolated blocks with two transformers 21
Troubleshooting 22
Notes 23
Limited Warranty/Lionel Service 24

Operating your CW-80 Transformer safely
4
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

5
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
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.

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
Creating your layout
6
Rail tab

Wiring your CW-80 Transformer
7
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 page 11 for information on coupling the cars.
3
3
2
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, 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
Connect the drawbar between the locomotive and tender.
See Figure 5.
If the smoke unit switch is in the ON position, add smoke fluid to your
locomotive’s stack to prevent damage to the smoke unit. Refer to
page 10 for additional information.
Caution!
Note!
Figure 5. Drawbar connection

Running your train
10
Adding smoke fluid to your locomotive’s smoke generator
Y
our locomotive is equipped with a smoke generator that produces safe, clean white smoke
during operation if the smoke unit switch is in the ON position. Refer to Figure 8 on
page 14 for the location of the switch.
The smoke generator requires the periodic addition of Lionel smoke fluid in order to function.
A small bottle of smoke fluid is included with this set. Press down and unscrew the cap. Pierce the
tip on the nozzle. Add about four drops of fluid directly into the locomotive’s stack. Smoke pro-
duction commences momentarily. It will start faster if you run your locomotive at higher speeds.
When smoke production decreases, add more fluid (about four drops). An idle locomotive will
not smoke.
Smoke production is greater at higher voltages and when the locomotive is pulling a heavy
load or a long consist.
Caution! When the smoke unit switch is in the ON position, always keep a small amount
of smoke fluid in the locomotive’s smoke generator; the generator’s element
can become damaged if operated without smoke fluid. This is particularly true
if your locomotive sits in neutral for an extended period of time without smoke
fluid in the generator.
If you prefer to operate the locomotive without smoke or you do not want to add
smoke fluid, slide the smoke unit switch to the OFF position.
Note!

11
Operating your trains with the CW-80 Transformer
You’re clear for departure! Move the throttle control handle forward to increase power to the track. The farther forward you push the handle, the faster your train will go.
Quickly shutting off or throwing the throttle all the way forward will not result in
an instant change in track voltage.
When operating in the conventional (non-Command) environment, remember that the great-
er the load on the engine (adding more cars for the engine to pull, for example), the farther
forward the handle must be pushed before it will operate the locomotive.
Note!
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 6. 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 6. Coupler operation
Note!

12
Refer to Figure 7 on page 13 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 an operating air whistle in the tender.
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.
Your locomotive is not equipped with bell sounds.
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!
Note!
Note!

13
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 or TrainSounds-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 forward to increase locomotive speed,
backward to slow it down.
Power-on indicator
The green light
illuminates when the
CW-80 is on.
Figure 7. Transformer features
Running your train
Experiencing the features of the CW-80 Transformer (continued)

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 9 for the loca-
tion 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 8). When the switch is thrown to the
OFF (PROG) position (towards the rear of the locomotive), the locomotive will be locked in the
next mode of operation in the sequence. To lock your locomotive 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 (RUN) 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 direction and be “locked”
there.
Figure 8. Switch location
Figure 9. Direction control button location
Direction control button
Whistle control button
Bell control button
Throttle
14
ON
OFF
RUN PROG
Reverse unit ON/
OFF switch
Smoke unit ON/OFF
switch (see page 9 )

15
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 16.
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.

16
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 7 on page 13 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

17
Maintaining and servicing your set
Figure 10. Lubrication points
Lubricating your locomotive
H
elp your steam 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 roll-
ers, or your track.
You’ll know your locomotive requires lubrication when visual inspection reveals dryness on
the parts indicated in Figure 10. Remove accumulated dirt and dust before lubricating, and
always lubricate any locomotive emerging from prolonged storage.
Lubricate axle ends
with Lionel oil
sparingly Lubricate axle ends
with Lionel oil sparingly

Maintaining and servicing your set
18
Replacing your locomotive’s traction tire
One of the locomotive’s drive wheels is fitted with a rubber traction tire to enhance tractive effort, allowing your locomotive to pull many cars at once.
To replace the traction tire, simply unscrew the drive rod screw from the wheel using a 3/16”
nut driver. Refer to Figure 11. Remove the old traction tire from under the drive rod and slip
on the replacement, Lionel part no. 600-0242-206. Replace the spacer, retighten the drive rod
screw, and you’re ready to pull that long freight back to the yard.
Replacing your locomotive’s headlamp
Your locomotive is equipped with an LED style headlight for longer life. Please contact your nearest Lionel Service Center or Lionel Service if this need replacing.
Figure 11. Traction tire replacement
Lionel part no. 600-0242-206
Spacer
Drive rod screw

19
Maintaining and servicing your set
Operating the searchlight
The searchlight is on whenever the car is powered up on the track. To prolong the life of the lamp, we recommend that you keep the track voltage at a lower range, from seven to
fifteen volts. Rotate the metal bracket and the searchlight housing (refer to Figure 12) to aim
the searchlight.
Replacing the searchlight lamp
During the course of normal operations, you may find that the lamp requires replacement. Replacement lamps, Lionel part no. 630-8352-311, are available at your authorized
Lionel Service Center or from Lionel Service.
1. Gently pull the two arms of the metal bracket away from the searchlight housing to lift the
housing away. Refer to Figure 12.
2. Pull the expired lamp straight up and out of the socket.
3. Install the new lamp and replace the searchlight housing.
Figure 12. Lamp replacement
Searchlight housing
Metal tabs
Lionel part no.
630-8352-311

20
Maintaining and servicing your set
Window
tab
Window shell
End frame tab
End frame
tab
Hinge
Part no. 630-8352-311
Replacing your Square Window Caboose lamp
Figure 13. Caboose lamp replacement
During the course of normal operations, the lamp inside your caboose may require replacement. Follow these steps and refer to Figure 13.
1. Lift off the roof from the window shell and body.
2. Pull out the end frame tab from the slot formed by the caboose body and roof. The end
frames are hinged at the platform to swing outward, away from the body.
3. Remove the window shell. To remove the window shell, carefully bend the sides of the
caboose outward while pulling up on the window shell until the tabs are released from the
windows.
4. Pull the lamp straight up and out of the socket. Replace it with Lionel part no. 630-8352-311,
available at your authorized Lionel Service Center or Lionel Service.
5. Lower the window shell back into the body, making sure that the tabs snap into the win-
dows.
6. Reposition the roof above the window shell and body, fit the tabs on the end frames into
the corresponding slots in the body, and press down the roof to secure the end frame tabs.