Lionel Pennsylvania Flyer Ready-to-Run Set User manual

73-1936-251
2/03
Pennsylvania Flyer
Ready-to-Run Set
Owner’s Manual
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 REDUCE THE RISK OF ELECTRIC SHOCK.
TRANSFORMER RATINGS—INPUT: 120 VAC; 60 HZ ONLY.
AC OUTPUT: 18 V; 80 VA

Congratulations!
2
Congratulations on your purchase of the ready-to-run Pennsylvania Flyer Train
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 power-
ful Lionel locomotive.
Have fun growing with this complete train
set! Start with the set components, then fol-
low your imagination into your own minia-
ture 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!
Pennsylvania Flyer Train Set Features
Bright
headlight
Puffing
smoke
Operating
couplers
Opening
boxcar
doors
Removable
canisters
Air whistle
Forward-Neutral-Reverse
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™
The name FasTrack®is used with permission from Pitso, Inc.

Lionel Pennsylvania Flyer Set Inventory
•4-4-2 Locomotive
•Tender with air whistle
•Boxcar
•Gondola with canisters
•Square window caboose
•CW-80 Transformer
•Three straight FasTrack track
sections
•Eight curved FasTrack track
sections
•One straight FasTrack terminal
track section
•Smoke fluid
•Owner’s Manual
•Service Center list
•Instruction video
3
Table of contents
Track layout
Building your Lionel layout 4
Joining the FasTrack track sections 5
Controller operations
Operating your CW-80 Transformer safely 6
Installing your CW-80 Transformer 6
Wiring your CW-80 Transformer 7
Operating your trains with the CW-80 Transformer 8
Experiencing the features of the CW-80 Transformer 9-10
Setting the accessory output 11
Powering your layout with the CW-80 Transformer 12
Troubleshooting 13
Train operations
Running your locomotive with a Lionel transformer 14
Reverse unit procedure 15
Tire-Traction 16
Coupling 16
Maintaining and servicing your set
Lubricating your 4-4-2 locomotive 17
Adding smoke fluid to your 4-4-2 locomotive’s smoke generator 18
Replacing your 4-4-2 locomotive’s headlamp 19
Limited Warranty/Lionel Service 20

Building your Lionel layout
Your set comes with eight curved, three straight, and one power 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!
Track layout
Figure 1. Track layout ideas
4

Track layout
5
Joining the FasTrack track sections
FasTrack track sections join together easily. With interlocking roadbed sections and large rail, the track fits together securely so you always get good electrical contact. Take a look
at Figure 2 to show you 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

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 electron-
ic components can result.
Installing your CW-80 Transformer
To mount your CW-80 Transformer to your layout or control panel, drive a screw through each of the four mounting holes located at the corners of the base.
Controller operations

Wiring your CW-80 Transformer
7
Caution!
U
120/60z
0~18VAC
AB
U
0~18VAC 
TRACK ACCESSORY
Figure 3. Controller connections
Controller operations
FasTrack terminal section
Notch
Spade-shaped
connector
For best performance on large layouts, it is recommended that you use 16-gauge wire to con- nect your CW-80 Transformer to the track. Connect the spade connectors on the wires from the
FasTrack terminal section. 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. As your layout expands, you may also make power connections with the
stripped ends of the wires or banana plugs, placing no more than two wires on each terminal.
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.
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.
1. Feed the wires through the notch in the FasTrack terminal section. Refer to
Figure 3.
2. Loosen the red TRACK thumbscrew terminal, then slide the spade-shaped
connector at the end of the RED wire into position. The thumbscrew post
should be positioned between the “blades” of the spade connector. Tighten the thumbscrew
to secure the connection.
3. Loosen the black TRACK thumbscrew terminal, then slide the spade-
shaped connector at the end of the BLACK wire into position. Tighten the
thumbscrew to secure the connection.
4. If you need to power an accessory, connect the accessory to the
ACCESSORY thumbscrew terminals.
5. Plug the CW-80 Transformer into your wall outlet (120 volts).

Operating your trains with the CW-80 Transformer
8
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.
You will notice that the power increases and decreases at a set rate. For example,
quickly throwing the throttle all the way forward will not result in an instant
increase to full power.
When operating in the conventional (non-Command) environment, remember that the
greater the load on the engine (adding more cars for the engine to pull, for example), the far-
ther forward the handle must be pushed before it will operate the locomotive.
Note!
Controller operations

Refer to Figure 4 on page 10 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.
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.
This safety feature replaces the circuit breaker. The benefit is that the Transformer will not
instantly turn off.
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/HORN
The WHISTLE/HORN button will activate your locomotive’s whistle. The sound will contin-
ue until the button is released. No external sound activation buttons are needed. This button
will also activate the horn and whistle sounds on locomotives equipped with the digital
RailSounds sound system.
BELL
When you purchase an advanced locomotive equipped with the RailSounds sound system,
the BELL button will activate the bell sound. 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.
One thing to keep in mind when you purchase a RailSounds-equipped locomotive:
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.
The CW-80 Transformer may cause random whistles in the Lionel Mighty Sounds of
SteamTM tenders with a three-pin connector. We recommend that you a purchase a
RailSounds-equipped tender to solve this problem.
Note!
Note!
Controller operations
9
Experiencing the features of the CW-80 Transformer

Experiencing the features of the CW-80 Transformer
(continued)
10
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 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 4. Transformer features
Controller operations

Take control of your Lionel empire with your CW-80 Transformer! You choose how much power your accessories need. Your CW-80 Transformer features a 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 voltage was set to 12 volts at the factory.
1. Connect your accessory to the CW-80 Transformer as discussed on page 7.
2. Bring the throttle all the way back to turn off the power.
3. Press and hold down the DIRECTION, WHISTLE/HORN, and BELL buttons
on the Controller. Refer to Figure 4 on page 10 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
11
Note!
Controller operations

Controller operations
12
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 0-16 volts (AC) each.
This Transformer is capable of operating trains up to and including dual-motored AC
engines. 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.
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 Controller will begin to flash. This indicates
that the Transformer is in “fold-back mode.” In fold-back mode, the Transformer is automati-
cally reducing, or folding back, power. This gradual reduction in power provides interruption-
free power while bringing the amperage back down to a safe level.

Troubleshooting
13
No lights or operation
Be sure CW-80 Transformer is plugged in.
Train runs, but WHISTLE/HORN, BELL, and DIRECTION buttons do not work
Check track connections. The track must be connected to the “A” and “U” terminals on the
Transformer.
No change when DIRECTION button is pressed
Be sure that your locomotive reverse unit switch is ON.
Accessory operation is intermittent or absent
Check for loose, shorted, or improper connections. The accessory voltage may have been set
too low for the accessory. Refer to page 11 and reset the voltage to a higher level.
Locomotive runs slowly or lights dim at the far end of the track
On larger layouts, additional track resistance may cause a voltage drop. Install additional
FasTrack terminal sections around your layout and connect them to your Transformer to dis-
tribute power.
Green light begins to flash
The power limit of the Transformer has been exceeded. The unit will gradually reduce power
until the problem is corrected.
Bell button blows whistle
Switch the wire connections at the Transformer terminals. The U terminal should be connect-
ed to the outside (common) rail.
Controller operations

14
Running your locomotive with a Lionel transformer
Place your locomotive on Lionel or Lionel-compatible track.
(O-27 minimum radius)
2
2
3
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. To sequence the reversing unit, press the
Direction button on your transformer, or turn the throttle OFF and back ON again
until you are moving in the desired direction.
Adjust track voltage until your locomotive moves at your desired speed.
1
1
With track power OFF, 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 20 for additional information.
Figure 5. Drawbar connection
Caution!
Note!
Locomotive operation

Locomotive operation
Reverse unit procedure
The electronic reverse unit inside your Lionel locomotive acts like the transmis-
sion in your car. When you apply power to
the track, the locomotive moves in the direc-
tion specified by the reverse unit—or it sits
in neutral, awaiting another power interrup-
tion. Power interrup-
tions are the signal that
tells the reverse unit to
sequence to the next
operational state.
To interrupt power
and sequence the loco-
motive’s reverse unit,
press the direction con-
trol button or briefly
bring the throttle lever
all the way forward to
the OFF position. Refer
to Figure 7 for the loca-
tion of these controls.
The reverse unit alter-
nates between three states: forward, neutral,
and reverse.
Also, the locomotive can be “locked” into
a certain mode of operation by throwing the
switch located on the underside of the frame
(see Figure 6 above). When the switch is
thrown to the OFF position (towards the rear
of the locomotive), the locomotive will be
locked in the next mode of operation in the
sequence. For instance, if the locomotive is
moving forward, then is stopped and the
switch is thrown back, the locomotive will
be “locked” in neutral. If the switch is
thrown back while the locomotive is under
power, the loco-
motive will
remain in the
mode it was in
when the switch
was thrown. The
controller direc-
tion control will
then have no
affect on the
direction of the
locomotive.
Additionally,
this reverse unit
has a “power-up
reset” feature. If
the locomotive sit without power for a short
period of time, the reverse unit will auto-
matically reset and start in the forward
direction when the transformer is turned on
or “powered up,” regardless of the locking
switch position. If the locking switch is in
the OFF position, the locomotive will start in
the forward direction and be “locked” there.
Reverse unit
ON/OFF switch
Figure 6. Switch location
Figure 7. Direction control button location
Direction control button
Whistle/horn control button
Bell control button
OFF ON
15
Throttle

Train operation
16
Tire-Traction
Coupling
Your locomotive is equipped with Tire- Traction. This means that one of the
drive wheels is fitted with a rubber Traction
Tire to enhance tractive effort so your loco-
motive can pull many cars at once.
Lionel locomotives with Tire-Traction grip
the track, enabling them to pull heavy loads
at higher speeds. Replacement Traction Tires
are available at your authorized Lionel Service
Center.
When coupling your cars, at least one of the mating couplers must be open as
shown below at the left. Simply press down on
the lock release to open the coupler, then push
the cars toward each other until they lock
together as illustrated in Figure 8.
Keep in mind that it’s easier to couple cars on a straight stretch of track.
Lock release
Figure 8. Coupler operation
Note!

17
Maintaining and servicing your set
Figure 9. Lubrication points
Lubricating your 4-4-2 locomotive
Help your 4-4-2 steam locomotive lead a long and productive life on your rail-
road by maintaining it properly.
We recommend that you purchase a Lionel
Lubrication and Maintenance Kit
(no. 6-62927), available from your Lionel
dealer. Two basic rules to keep in mind: never
over-lubricate (a small amount will do) and
avoid getting grease or oil on the locomo-
tive’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 loco-
motive emerging from prolonged storage.
Lubricate axle ends
with Lionel oil
sparingly
Lubricate gears with
Lionel grease sparingly
Lubricate axle ends
with Lionel oil
sparingly

Maintaining and servicing your set
18
Adding smoke fluid to your 4-4-2 locomotive’s smoke generator
Your 4-4-2 locomotive is equipped with a smoke generator that produces safe ,
clean white smoke during operation.
The smoke generator requires the periodic
addition of Lionel smoke fluid in order to
function. Pierce the smoke fluid tube end
with a pin, then add 4 to 8 drops of fluid
directly into the locomotive’s stack. Smoke
production commences momentarily, faster
if you run your locomotive at high speed.
When smoke production wanes, add more
fluid (4 to 8 drops). An idle locomotive will
not smoke.
Smoke production is greater at higher volt-
ages and when the locomotive is pulling a
heavy load or a long consist.
Caution! Always keep a small amount of smoke fluid in the locomotive’s smoke genera-
tor; 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.

Maintaining and servicing your set
19
Linkage rods
Front truck
screws
Smoke unit
lug wire
Smoke unit
Lionel part no.
600-0161-300
Your 4-4-2 locomotive lights the way with its operating headlight. During the
course of normal operation, the lamp may
require replacement. Refer to Figure 10 as
you replace the lamp.
1. Remove the two front truck screws and
carefully slide the front truck assembly
off the linkage rods.
2. Lift the smoke unit out far enough from
the cab to allow lamp extraction.
3. Pull the lamp straight out and replace it
with Lionel part no. 600-0161-300,
available from your nearest Lionel
Authorized Service Center or from Lionel
Service. Be careful not to twist the lamp
or it may break.
4. Reinstall the smoke unit, making sure
that the smoke stack lines up with the
cab top opening.
5. Reassemble the front truck, making sure
that the linkage rods go into the holes in
the front truck. The lug wire from the
smoke unit must be reinserted through
the slot in the front truck assembly and
secured under one of the two front
screws. Tighten the screws firmly, but do
not over tighten them.
Replacing your 4-4-2 locomotive’s headlamp
Figure 10. Headlight replacement

Limited Warranty/Lionel Service
This Lionel product, including all
mechanical and electrical components,
moving parts, motors and structural
components, except for light bulbs, is warranted
to the original consumer-purchaser, for one year
against original defects in materials or
workmanship when purchased through an
authorized Lionel merchant.
This warranty does NOT cover normal wear
and tear, light bulbs, defects appearing in the
course of commercial use, or damage resulting
from abuse or misuse of the product by the
purchaser. Transfer of this product by the original
consumer-purchaser to another person voids this
warranty. Modification of this product voids this
warranty.
Any warranted product which is defective in
original materials or workmanship and is
delivered by the original consumer-purchaser to
Lionel L.L.C. or an authorized Lionel L.L.C. Service
Center, together with proof of original purchase
will, at the option of Lionel L.L.C., be repaired or
replaced, without charge for parts or labor. In the
event the defective product cannot be repaired, and
a replacement is not available, a refund of the
original purchase price will be granted. Any
products on which warranty service is sought must
be sent freight or postage prepaid, as
transportation and shipping charges are not
covered by the warranty.
In no event shall Lionel L.L.C. be
liable for incidental or
consequential damages.
Some states do not allow the exclusion or
limitation of incidental or consequential damages,
so the above exclusion may not apply to you.
This limited warranty gives you specific legal
rights, and you may have other rights which vary
from state to state.
Instructions for Obtaining Service
If service for this Lionel L.L.C. product is
required, bring the item, along with your dated
sales receipt and completed warranty information
to the nearest Authorized Lionel Service Center.
Your nearest Lionel Service Center can be found
by calling 1-800-4-Lionel, or by accessing our
Website at www.lionel.com.
If you prefer to send your product back to
Lionel L.L.C. for repair in Michigan, you must
first call 586-949-4100 or FAX [phone], or
write to Customer Service, P.O. Box 748, New
Baltimore, MI 48047-0748, stating what the item
is, when it was purchased and what seems to be
the problem. You will be sent a return
authorization letter and label to ensure your
merchandise will be properly handled upon
receipt.
Once you have received your return
authorization and label, make sure that the item
is packed to prevent damage during shipping and
handling. We suggest that you use the product’s
original packaging. This shipment must be
prepaid and we recommend that it be insured.
Please make sure you have followed all of the
above instructions carefully before returning any
merchandise for service. You may choose to have
your product repaired by one of our Authorized
Lionel Service Centers after its warranty has
expired. A reasonable service fee will be charged.
Warranty Information
Please complete the information below and
keep it, along with your dated sales receipt. You
must present this and your dated sales receipt
when requesting warranty service.
Name ____________________________
Address____________________________
Place of Purchase ____________________
Date of Purchase ____________________
Product Number______________________
Product Description____________________
©2003 LIONEL LLC, CHESTERFIELD, MI 48051-1956
UNITED STATES OF AMERICA
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