Lionel Pioneer Zephyr User manual

Lionel
Pioneer Zephyr
Owner’s Manual
75-1008-250
9/04
®
SYSTEM
featuring
and

Congratulations!
Congratulations on your purchase of the Lionel Pioneer Zephyr! The famous streamlined locomotive is equipped with TrainMaster Command Control and the Odyssey System for
speed control. Riding on shared trucks, two articulated passenger cars follow the locomotive.
Features of the set
• TrainMaster Command Control equipped—able to run in the TrainMaster
Command Control environment or in the conventional environment with
only a standard transformer
• RailSounds sound system with CrewTalk communication and TowerCom
announcements
• Odyssey System for speed control with ON/OFF switch
• Operating headlight and cab light
• Illuminated marker lights and classification lights
• Dual powerful maintenance-free motors with momentum flywheels
• Four traction tires
• Fan-driven smoke unit
• Lighted interiors
• Articulated trucks and vestibules
• Minimum curve: O-72
2
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®
The name FasTrack®is used with permission from Pitsco, Inc.

Table of contents
Quick Start
Transformer operations 4
TrainMaster Command Control operations 4
Conventional transformer operations
Conventional operations 5
Operating your locomotive in the conventional environment 6
Locking your locomotive into a single direction 7
Coupling the cars 8
RailSounds sound system operations
RailSounds sound system operations 9
Installing the battery 10
Using the RailSounds sound system in the conventional environment 11
Installing a Lionel Sound Activation Button for conventional operation 12
Using the RailSounds sound system in the TrainMaster Command Control environment 13
Odyssey System operations
Odyssey System operations 14
Activating the Odyssey System in the conventional environment 14
Turning off the Odyssey System in the conventional environment 15
Odyssey System Command Control operation 16
TrainMaster Command Control operations
TrainMaster Command Control operations 17
Operating your locomotive in the Command Control environment 17
CAB-1 Remote Controller commands 18
CAB-1 Remote Controller numeric keypad commands 19
Tuning your locomotive’s performance 20-21
Assigning your locomotive a new ID# 22
Reprogramming your locomotive to restore features 23
Maintaining and servicing your locomotive
Adding fluid to your locomotive’s smoke generator 24
Lubricating your locomotive 25
Replacing the locomotive’s lamps 26
Replacing the coach and observation car lamps 26
Replacing the traction tires 27
Limited Warranty/Lionel Service 28
3

4
Quick Start
Transformer operations
1. Place your train set on Lionel or Lionel-compatible O-72 or larger track.
2. Power your locomotives at 8-18 volts with your alternating current (AC)
transformer.
Do not power your locomotives with a direct-current (DC) transformer. Damage to
sensitive electronic components may occur.
3. Wait three to eight seconds as your locomotives determine whether they
are in a conventional environment or a TrainMaster Command Control
environment.
4. Move ‘em out! Press the DIRECTION button on your controller, then
throttle up.
TrainMaster Command Control operations
To operate your train set in the Command Control environment, you need a Command Base (available separately, 6-12911) and a CAB-1 Remote Controller (available separately, 6-12868).
These products are also available together in the TrainMaster Command Set (6-12969).
1. Turn off track power and plug-in the Command Base.
2. Place your train set on Lionel or Lionel-compatible O-72 or larger track.
3. Increase track voltage to full power (no more than 19 volts AC).
Do not power your locomotives with a direct-current (DC) transformer. Damage to
sensitive electronic components may occur.
4. Press ENG and 1 to address your locomotive with your CAB-1 Remote
Controller.
5. Throttle up and move ‘em out.
Note!
Note!

Conventional transformer operations
Conventional operations
Your locomotive is capable of operating in the conventional environment with nothing more
than a standard Lionel alternating-current (AC) transformer.
In the conventional environment, your locomotive cycles through a repeating pattern of
operations: forward, neutral, reverse, neutral, and so on. To advance to the next operation, press
the DIRECTION button on your transformer. Alternately, you could use the throttle to briefly
turn off track power so that the locomotive advances to the next operation when power is
restored.
Once you cycle the locomotive into forward or reverse, you control your locomotive’s speed
by varying track voltage with the transformer’s throttle. To increase the speed of the locomotive,
you increase track voltage. To decrease the speed, you decrease track voltage. To stop the
locomotive and to change directions (or to enter neutral), track voltage is turned off or
interrupted.
Use the HORN and BELL buttons on your transformer (or separate buttons if your
transformer is not equipped with these controls) to activate these features.
To experience all of your locomotive’s features, we recommend operating in the TrainMaster
Command Control environment. With a simple one-wire connection, you can use the CAB-1
Remote Controller to access all of the functions of your locomotive. Refer to page 17 to see how
to operate your locomotive in the TrainMaster Command Control environment.
5

Conventional transformer operations
Operating your locomotive in the conventional environment
1. Place your train set on Lionel or Lionel-compatible O-72 or larger track.
Refer to page 8 to couple the cars.
2. Power your locomotive at 8-18 volts with your alternating current (AC)
transformer.
Power your locomotive with an alternating-current (AC) transformer only.
Powering your locomotive with a direct-current (DC) transformer may result in
damage to sensitive electronic components.
3. Wait three to eight seconds as your locomotive determines whether it is in
a conventional environment or a TrainMaster Command Control
environment.
When the locomotive has determined that a TrainMaster Command Base is not connected to
the track, the locomotive’s headlight will illuminate and the RailSounds sound system will
start. You are ready for operation in the conventional environment.
4. Move ‘em out!
Press the DIRECTION button on your transformer to sequence your locomotive through
the repeating pattern of operations: forward, neutral, reverse, neutral, and so on. You may
also briefly turn off track power to advance the locomotive to the next operating state. Adjust
the throttle until your locomotive moves at your desired speed.
When placing your locomotive on your layout for the first time, it will start out in
neutral. Thereafter, it will start in forward after every power interruption lasting five
seconds or longer.
Use the HORN and BELL buttons on your transformer to activate those features. Refer to
page 12 if your transformer is not equipped with those buttons. Adjust the volume using the
volume control knob located on the bottom of the frame. Refer to Figure 5 on page 25.
6
Note!
Caution!

Conventional transformer operations
Locking your locomotive into a single direction
When the Command reverse unit switch is in the RUN position, your locomotive sequences
through a repeating pattern of operations: forward, neutral, reverse, neutral, and so on.
To “lock” your locomotive into a single direction (for example, to operate in forward only),
you can deactivate the Command reverse unit’s sequencing function. Refer to Figure 1 for the
location of the Command reverse unit (PROG/RUN) switch.
1. Use your transformer’s DIRECTION button or interruptions in track power to get your
locomotive moving in the desired direction or into neutral.
2. Slow the locomotive down without stopping (reduce the throttle without turning off track
power).
3. Lift off the roof-top hatch and slide the Command reverse unit switch to the PROG position.
At this point, the locomotive is “locked” into your chosen direction.
To restore the forward-neutral-reverse sequence, just slide the Command reverse unit switch
back to the RUN position.
Your locomotive will “reset” to forward after any power interruption lasting five
seconds or longer, regardless of the direction you set.
7
Note!
Figure 1. Switch locations
ON
ODYSSEY
SMOKE
OFF
ONOFF
RAILSIGNAL
RUNPROG
Command reverse
unit switch
RailSounds sound
system switch
Lift off the
roof-top hatch

8
True to the prototype, your train set features cars that are connected at shared trucks. As illustrated in Figure 2, arrange the cars on the track and, holding them horizontally, slide
the vestibule into the end of the car. The clasp will catch the metal ring and the contacts will
lock around the post.
To uncouple the cars, press down on the vestibule to release the clasp and slide the cars
apart.
Be sure track power is off before coupling the cars to prevent accidental short
circuits.
Coupling the cars
Transformer operations
FRONT
Figure 2. Coupling the cars
Metal ring
Clasp
Vestibule
Contact
post
Contact
Caution!

9
RailSounds sound system operations
RailSounds sound system operations
Your locomotive is equipped with the Lionel RailSounds sound system, the most realistic
model railroad sound system in the world. The RailSounds sound system brings the sounds
of the railroad to your layout through high quality digital samples of real locomotives.
When you operate your locomotive in the conventional environment, you get the realistic
sounds of the diesel engine, which automatically rev up as the speed of the locomotive
increases. You can sound the locomotive’s horn or activate the ringing of the mechanical bell.
When you are through with operations and power down the track, your locomotive’s RailSounds
sound system starts a realistic diesel shutdown sequence. A nine-volt alkaline battery is required
for the shutdown sequence.
When you operate your locomotive in the TrainMaster Command Control environment, you
get full control of the RailSounds sound system. You still get the horn and bell sounds. The
locomotive’s RPM sounds automatically rev up, but you can also set a particular RPM sound
using your CAB-1 Remote Controller. Use the BRAKE button, and listen for the sound of
squealing metal. You can also trigger CrewTalk communication and TowerCom
announcements, which simulate the interaction between the locomotive crew and the
yardmaster. Whenever you choose to shutdown your locomotive, the realistic shutdown sequence
commences. A nine-volt alkaline battery is required if track power is turnd off.

RailSounds sound system operations
Installing the battery
While the RailSounds sound system is powered through the track, we recommend that you
install a nine-volt alkaline battery to prevent the sound system from shutting down
during track power interruptions (for example, at a switch or a dirty section of track). Follow
these steps and refer to Figure 3 as you install the battery.
If the RailSounds sound system turns off during interruptions in track power, you
may need to replace the battery.
1. Remove the body screws on the locomotive as shown in Figure 5 on page 25.
2. Lift the body away being careful of the attached wires.
3. Remove the protective cover from the battery harness.
4. Snap the battery harness onto the nine-volt alkaline battery’s terminals.
5. Slide the battery into the battery clip.
6. Replace the body, being careful not to pinch any wires between the frame and the body.
Secure the body in place with the eight screws.
10
Note!
Battery
harness
Battery
holder
Figure 3. Battery installation

RailSounds sound system operations
Using the RailSounds sound system in the conventional environment
When you first power up your locomotive, you will hear the sounds of the locomotive at
rest. As the locomotive moves, the RPM sounds automatically increase with the
locomotive’s speed. In the conventional environment, the horn and bell sounds are activated by
your transformer controls.
To silence the diesel roar, slide the RailSounds sound system switch located under the roof-
top access panel to the SIGNAL position before you power up the locomotive or after the
locomotive has been powered down for a minimum of ten seconds. The horn and bell sounds
will still be active. To adjust the volume, use the volume control knob located on the bottom of
the locomtive.
For proper operation of the RailSounds sound system during track power
interruptions and for the locomotive shutdown sequence, you must install a nine-volt
alkaline battery. See page 10.
In the conventional environment, you will experience several features of the RailSounds
sound system.
•Four levels of diesel roar. Your locomotive's speed automatically determines the level
of diesel RPM roar.
•MultiHorn. A different horn sound at different speeds—a RailSounds sound system
exclusive.
•Mechanical bell. Press BELL on your transformer to begin the effect, then press BELL a
second time to discontinue the effect.
•Reverse unit reset sound. Power down your track, wait three seconds, and listen for
the air-release sound—that’s the locomotive telling you that its Lionel Command reverse
unit has reset to forward.
•Shutdown sequence. When you turn off track power, you have two seconds to power up
again after you hear the reverse unit reset sound. If you do not restore power, you will hear
the realistic diesel shutdown sequence. Because track power is off, a battery is required for
this sequence to function.
11
Note!

RailSounds sound system operations
Installing a Lionel Sound Activation Button for conventional operation
If your transformer lacks HORN and BELL buttons, you will need to install Lionel
no. 610-5906-001 Sound Activation Buttons (available separately) to activate the locomotive’s
horn and bell sounds.
Connect the buttons as shown below. Be sure that all track power passes through the Sound
Activation Button(s). Do not bypass the buttons.
12
12
POWER
SUPPLY
POWER
SUPPLY
For AC transformers lacking a bell button
For AC transformers lacking bell and horn/whistle buttons
Existing wire
Black wire
Red wire
Lionel no. 610-5906-001
SoundActivation Button for
activating the bell
Lionel no. 610-5906-001
SoundActivation Button
for activating the
horn Lionel no. 610-5906-001
SoundActivation Button for
activating the bell
Black wire
Black wire
Wire
nut
Red wire
Red wire Existing wire
Common/Ground/U
Power/A
Common/Ground/U
Power/A

13
RailSounds sound system operations
Using the RailSounds sound system in the TrainMaster Command
Control environment
To access all of the features of the RailSounds sound system, you must operate your locomotive in the TrainMaster Command Control environment. The CAB-1 Remote
Controller is required to activate features such as TowerCom announcements, CrewTalk
communication, and coupler release sounds. Refer to pages 17 to 21 to learn how the
RailSounds sound system is integrated into TrainMaster Command Control operations.
For proper operation of the RailSounds sound system during track power
interruptions and for the locomotive shutdown sequence, you must install a nine-volt
alkaline battery. See page 10.
In the TrainMaster Command Control environment, you will experience all of the features of
the RailSounds sound system.
•Four levels of diesel roar. Your locomotive’s speed automatically determines the level
of diesel RPM roar. You may also set the RPM sounds to a particular level using your CAB-1
Remote Controller.
•MultiHorn. A different horn sound at different speeds—a RailSounds sound system
exclusive.
•Mechanical bell. Press BELL on your CAB-1 Remote Controller to begin the effect, then
press BELL a second time to discontinue the effect.
•Squealing brakes. Press the BRAKE button and listen for the squealing of the
locomotive’s brakes as the locomotive slows down.
•TowerCom announcements. These messages simulate the communication from the
yardmaster. You get “clear for departure” and “hold for clearance” messages.
•CrewTalk communication. Listen for the crackling, unintelligible radio
communication inside your locomotive.
•Reverse unit reset sound. Power down your track, wait three seconds, and listen for
the air-release sound—that’s the locomotive telling you that its Lionel Command reverse
unit has reset to forward.
•Shutdown sequence. When you turn off track power, you have two seconds to power up
again after you hear the reverse unit reset sound. If you do not restore power, you will hear
the realistic diesel shutdown sequence. Because track power is off, a battery is required for
this sequence to function.
Note!

Odyssey System operations
Odyssey System operations
The Odyssey System is “cruise control” for your locomotive. Once the speed control is set,
your locomotive will maintain a constant speed, no matter what load is placed on the
locomotive or grades you have on your layout. The Odyssey System also allows for extremely
slow movement that will amaze any scale enthusiasts.
In the conventional environment, you activate the Odyssey System and set your locomotive
to operate at one particular speed. Your locomotive maintains this speed until you turn off speed
control or set a new speed.
In the Command Control environment, the Odyssey System is always active, unless the
Odyssey System switch is in the OFF position or turned off using your CAB-1 Remote Controller.
When the Odyssey System is active, your locomotive will maintain its speed until you adjust the
CAB-1 Remote Controller’s throttle.
Activating the Odyssey System in the conventional environment
Follow these steps to activate your locomotive’s speed control in the conventional environment.
1. Slide the Odyssey switch to the ON position. Refer to Figure 1 on page 7 for the location of
the switch.
2. Run the locomotive at the desired speed for approximately five seconds.
3. Press and hold the HORN button on the transformer.
4. While holding the HORN button, increase the track voltage by at least three volts (at least a
quarter turn).
The locomotive’s speed will increase before returning to the initial speed. At this point, speed
control is set. Increasing the throttle will not increase the speed of the locomotive; however,
decreasing the throttle will decrease the speed of the locomotive.
In the conventional environment, the lights in the locomotive are connected
directly to track power. To prolong the life of your lamps, do not exceed 14 to 16
volts for extended periods.
14
Caution!

15
Odyssey System operations
Turning off the Odyssey System in the conventional environment
Follow these steps to turn off the Odyssey System in the conventional environment.
1. While the locomotive is in neutral, turn your controller up to the maximum power (no more
than 19 volts), wait one second, then press and hold the horn button.
2. While holding the HORN button, slowly reduce the track voltage to approximately one-third
or one-half of the full power.
3. Release the HORN button.
4. Move the locomotive in forward OR reverse. The locomotive is now out of speed control mode.
Sliding the Odyssey System switch to the OFF position will disable the Odyssey System.
We recommend that you keep the Odyssey System switch in the OFF position unless
you want to activate the locomotive’s speed control.
Note!

Odyssey System operations
Odyssey System Command Control operation
When the Odyssey System switch is in the ON position, changes in the speed of the
locomotive will correspond to each signal from the Command Base. For example, when
you address the locomotive and slowly turn the throttle knob, the first flash of the light on the
Command Base corresponds to the first speed step, which is the slowest speed of the locomotive.
The locomotive will maintain that speed until you increase or decrease the throttle. To turn off
the Odyssey System, slide the Odyssey System switch to the OFF position.
In the TrainMaster Command Control environment, you can use your CAB-1 Remote
Controller to turn the Odyssey System on or off. The position of the Odyssey System switch (see
Figure 1 on page 7) is the Odyssey System default setting when you power up the locomotive.
You can override the default setting with the following commands. The override settings will be
cleared and the default setting will be restored when you power down the locomotive.
Do not wait longer than two or three seconds between pushing the buttons in each sequence.
If the command is not accepted, repeat the sequence.
The locomotive must be in “neutral” when you enable or disable the Odyssey System.
Turn off the Odyssey System.
When you press 7, you will trigger a TowerCom announcement. This has no impact
on the Odyssey System function.
Turn on the Odyssey System.
When you press 9, you will activate the Air release sound and turn on the smoke unit
(if it was off). This has no impact on the Odyssey System.
16
Note!
Note!
Note!

TrainMaster Command Control operations
TrainMaster Command Control operations
TrainMaster Command Control is the advanced model railroad control system from Lionel.
To operate your locomotive in the Command Control environment, you need a Command
Base (available separately, 6-12911) and a CAB-1 Remote Controller (available separately,
6-12868). These products are available together in the TrainMaster Command Set (available
separately, 6-12969).
Your commands are sent by the CAB-1 Remote Controller to the Command Base, which then
translates the command into digital code. That code is sent through the outside rails to your
locomotive, which will not respond until it recognizes its unique ID#. TrainMaster Command
Control gives you the power to operate multiple Command-equipped locomotives on the same
track at the same time.
Keep in mind that track power is like gasoline in the tank of a car—it gives you the power
to go places, but it doesn’t tell you where to go or how fast to get there.
Operating your locomotive in the Command Control environment
1. Turn off track power and plug-in the Command Base. Be sure that the
Command Base is connected to the outside rail or to the Common/Ground/U terminal on
your track power supply.
2. Place your locomotive on Lionel or Lionel-compatible O-72 or larger
track.
3. Increase track voltage to full power (19 volts AC). On PowerMasters, slide the
CMD/CONV switch to CMD. Program Track Power Controllers to Command Control
operation.
4. Press ENG and enter the ID# to address your locomotive with your CAB-1
Remote Controller. All Lionel locomotives come factory-programmed as ID# 1. To
change the ID#, see page 22.
5. Throttle up and move ‘em out! Your locomotive will respond to every command from
your CAB-1 Remote Controller.
17

TrainMaster Command Control operations
CAB-1 Remote Controller commands
The CAB-1 Remote Controller commands are detailed below. The corresponding
RailSounds sound system effects are in bold italic type.
Activates the numeric keypad.
Air release sound.
Toggles the headlight on and off.
Accelerates the locomotive with a clockwise
rotation. Decelerates the locomotive with a
counter-clockwise rotation.
Shuts down all PowerMasters on your railroad.
Stops all TrainMaster Command Control-
equipped locomotives in operation. Use HALT only in
emergency situations.
Activates the locomotive’s horn. Release the
button to discontinue the sound. Multihorn
diesel horn sound.
Toggles the bell sound on and off. Mechanical
bell sound.
Changes the locomotive’s direction. The
locomotive decelerates to a stop and continues in
the opposite direction when you increase the throttle.
Air release sound.
Increases the locomotive’s speed while the button is
pressed. Release the button to return to the initial speed.
Decreases the locomotive’s speed while the button is
pressed. Squealing brake sounds.
18
SET L M H
See page 20 for the
momentum settings.

TrainMaster Command Control operations
CAB-1 Remote Controller numeric keypad commands
When you press the AUX1 button on your CAB-1 Remote Controller,
you turn the numeric keypad into ten command buttons. These
commands are specific to your locomotive, and an overlay is included to
help you learn these functions. After you press the AUX1 button, you will
be able to press any numbered button until you address a different
Command Control equipped product. The corresponding
RailSounds sound system effects are in bold italic type.
Stops and resets the locomotive. Resets the locomotive’s direction to forward. Resets the
RailSounds sound system to automatic RPM operation. Horn blows. RPM sounds
return to automatic.
Raises the volume of the RailSounds sound system. Sound volume increases.
Activates CrewTalk communication, unintelligible radio dialogue. CrewTalk
communication.
Increases the RailSounds sound system RPM level. Starts the RailSounds sound system.
RPM level increases. Start-up sequence commences.
Lowers the volume of the RailSounds sound system. Sound volume decreases.
Activates the shutdown sequence. Like prototypical locomotives, the RPM level must be at
idle for shutdown to occur. Press 6repeatedly to lower the RPM level until the RPM sounds
reach idle. Press 5to initiate the shutdown sequence and listen for the CrewTalk
communication. Keep in mind that the horn, bell, and RPM sounds are inactive until you
restart the RailSounds sound system by pressing 3. CrewTalk communication.
Diesel shutdown sequence.
Lowers the RailSounds sound system RPM level. RPM level decreases.
Activates a TowerCom announcement, which includes a call-out specific to your
locomotive. Pressing AUX1,7the first time triggers a “hold for clearance” message. Press
7again, and a “clear for departure” message plays. There is a four-second delay in this
function. TowerCom announcement.
Turns off the smoke unit. Air release sound.
Turns on the smoke unit if the smoke unit switch is in the ON position. Be sure to add
smoke fluid before turning on the smoke unit to prevent damage to your locomotive. Air
release sound.
AUX1,8 and 9function only if the locomotive’s smoke unit switch is in the ON
position. 19
Note!
➠
➠
➠
➠
AUX1

TrainMaster Command Control operations
Tuning your locomotive’s performance
TrainMaster Command Control allows you to fine-tune the performance of your locomotive.
Use your CAB-1 Remote Controller to make these adjustments.
These settings will be lost if you assign a new ID#.
Momentum
The TrainMaster Command Control momentum feature simulates the labored performance
of a locomotive pulling a light, moderate, or heavy load. Press L, M, or H(located under the
removable panel on the CAB-1 Remote Controller) to adjust the momentum setting. For quicker
response to your commands, press L, which is the factory default setting. Your locomotive will
keep this setting until it is changed.
Adjusting the speed
The BRAKE and BOOST buttons give you incremental control of your locomotive’s speed
while you press and hold these buttons, allowing you to make small, gradual adjustments
around curves and over grades. The locomotive will resume its initial speed when the buttons
are released. Listen for the squeal of your locomotive’s brakes when you use the BRAKE button.
Sound quality
Press AUX1,1or 4on your CAB-1 Remote Controller to raise and lower the overall volume
of the RailSounds sound system. To limit your locomotive’s volume, we recommend that you
adjust your locomotive’s volume control knob (see Figure 5 on page 25 for the location).
Setting the maximum speed
You may use your CAB-1 Remote Controller to set your locomotive’s maximum speed. This
will prevent locomotives from derailing as a result of excessive speed.
1. With the Command reverse unit switch in the RUN position, address your locomotive by
pressing ENG and entering the ID#.
2. Press SET on the CAB-1 Remote Controller. The headlight will flash.
3. Get your locomotive moving at your desired maximum speed.
4. Press BOOST.
The maximum voltage has been set. To clear this setting, press SET and then BOOST,
holding each button for one second.
20
Note!