Lionel Pennsylvania flyer User manual

73-1936-250
9/03-Rev 1.
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 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 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 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
Four
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 Pitsco, Inc.

Lionel Pennsylvania Flyer Set Inventory
•4-4-2 Locomotive
•Tender with air whistle
•Boxcar
•Gondola with four canisters
•Square window caboose
•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
•Service Center list
•Instruction video
•Catalog
•Lionel RailRoader Club flyer
3
Table of contents
Track layout
Building your Lionel layout 4
Joining the FasTrack track sections 4
Controller operations
Operating your CW-80 Transformer safely 5
Installing your CW-80 Transformer 5
Wiring your CW-80 Transformer 6-7
Advanced connections: powering two isolated blocks with two transformers 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
Train operations
Running your train set 13
Reverse unit procedure 14
Replacing your locomotive’s traction tire 15
Coupling 15
Maintaining and servicing your set
Lubricating your 4-4-2 locomotive 16
Adding smoke fluid to your 4-4-2 locomotive’s smoke generator 17
Replacing your 4-4-2 locomotive’s headlamp 18
Troubleshooting 19
Limited Warranty/Lionel Service 20

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
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!
Track layout
Figure 1. Track layout ideas
4
Rail tab

Operating your CW-80 Transformer safely
5
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.
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
6
Controller operations
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 7.
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. 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!

Controller operations
7
Wiring your CW-80 Transformer (continued)
U
120/60z
0~18VAC
AB
U
0~18VAC 
TRACK ACCESSORY
Figure 3. Controller connections
FasTrack terminal section
Notch
Spade-shaped
connector

8
Controller operations
Advanced connections: powering two isolated blocks with two
transformers
As you expand your layout, you may decide to create two isolated blocks of track. Trains in each block
are controlled by separate transformers.
Before you operate your trains on this type of layout,
be sure that your transformers are in phase. Operating
your trains on a layout with two transformers that are
out of phase may cause damage to the locomotive’s sen-
sitive electronic components.
To be certain that your transformers are in phase, use
a small 18-volt lamp with leads (available at your local
electronics supply store) to perform a quick test. Refer to
Figure 4.
1. Attach one lamp wire to the center rail in one block.
2. Attach the second lamp wire to the center rail in the other block.
3. Power up both blocks of track. Both transformers should be set to full power.
4. See if the lamp illuminates.
If the lamp illuminates brightly, your transformers are not in phase. Do not operate your
trains on the layout until you change the wiring. If the lamp does not illuminate, your trans-
formers are in phase and should not cause problems.
To bring your transformers into phase, simply swap the track wires at the A and U terminals
on one of the transformers. If you are using an older transformer that lacks a polarized plug,
you may reverse the plug at the outlet so that the prongs are inserted into the opposite
openings. Repeat the procedure described above, and you should find that the lamp does not
illuminate.
This will also reverse the operation of the BELL and WHISTLE buttons on the
transformer with the switched wires.
Figure 4. Testing for proper phasing
Note!

Refer to Figure 5 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.
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
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.
Controller operations
9
Experiencing the features of the CW-80 Transformer
Note!
Note!
Note!

Experiencing the features of the CW-80 Transformer
(continued)
10
Whistle
Activates the whistle or horn sound
effect in your Lionel locomotives.
Press WHISTLE to begin the sound;
release the button to end it.
Bell
Starts or stops the tolling bell in any
RailSounds-equipped 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 5. Transformer features
Controller operations