Lionel Santa Fe Super Freight User manual

73-1945-250
5/03
CAUTION—ELECTRICTOY
NOT RECOMMENDED FOR CHILDREN UNDER EIGHT YEARS OF AGE. AS WITH
ALL ELECTRIC PRODUCTS, PRECAUTIONS SHOULD BE OBSERVED DURING
HANDLINGAND USETO REDUCETHE RISK OF ELECTRIC SHOCK.
TRANSFORMER RATINGS—INPUT:120VAC; 60 HZ ONLY.
AC OUTPUT:18V; 80VA
Santa Fe Super Freight
Ready-to-Run Train Set
Owner’s Manual
featuring

Congratulations!
2
Congratulations on your purchase of the ready-to-run Santa Fe Super Freight Train
Set with the RailSounds sound system! This set
features everything you need to get started—a
mighty CW-80 Transformer, a huge loop of
FasTrack track, a string of detailed cars, and a
powerful Lionel locomotive. Plus, you get the
authentic locomotive sounds of the RailSounds
sound system.
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 sec-
tions, 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!
Santa Fe Super Freight Train Set Inventory
• 2-8-4 Berkshire steam locomotive
and tender with RailSounds
• Boxcar
• Tank car
• Flatcar with trailer
• Caboose with a replacement lamp
• CW-80 Transformer with accessory
wire
• Three straight FasTrack track
sections
• Eight curved FasTrack track
sections
• One straight FasTrack terminal
track section
• Owner’s Manual
• Service Center list
• Instruction video
• Catalog
• Lionel RailRoader Club flyer
• Smoke fluid and replacement
traction tires
Santa Fe Super Freight Train Set Features
Bright
headlight
Operating
couplers
Opening
boxcar doors
Puffing
smoke
RailSounds
sound system
Lighted caboose
interior
Forward-Neutral-Reverse
operation

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
Locomotive operation
Running your train set 13
Reverse unit procedure 14
RailSounds operations
Your Locomotive’s RailSounds system—the basics 15
Experiencing the range of your locomotive’s RailSounds system 16
Notes on RailSounds 16
TowerCom announcements 17
CrewTalk communication 17
Train Brakes 17
Wheel Flange Squeal 17
Maintaining and servicing your locomotive
Coupling 18
Adding smoke fluid to your locomotive’s smoke generator 19
Lubricating your locomotive 20
Replacing your locomotive’s traction tires 21
Replacing your square window caboose lamp 22
Troubleshooting 23
Limited Warranty/Lionel Service 24
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.

4
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!
Figure 1. Track layout ideas
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
Track layout

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
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
Controller operations
Wiring your CW-80 Transformer (continued)
U120/60z
0~18VAC
AB
U
0~18VAC
TRACK ACCESSORY
Figure 3. Controller connections
FasTrack terminal section
Notch
Spade-shaped
connector

8
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!
Controller operations

Note!
9
Experiencing the features of the CW-80 Transformer
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 prototypical steam whistle sounds.
BELL
The BELL button will activate your locomotive’s bell sounds. Press and hold the BELL button for
two to three seconds to begin the sounds; press and hold the button again to turn off the ringing.
Do not activate horns, whistles, or bells on 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
Note!

Experiencing the features of the CW-80 Transformer (continued)
10
Whistle
Activates the whistle or horn sound
effect in your Lionel locomotives.
PressWHISTLE 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

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. 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 page 6.
2. Bring the throttle all the way back to turn off the power.
3. Press and hold down the DIRECTION, WHISTLE, and BELL buttons on the
Transformer. Refer to Figure 5 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

12
Controller operations
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 0-18 volts (AC) each.
This Transformer is capable of operating trains up to and including dual-motored AC loco-
motives. 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 on page 11.
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 operation while you bring the amperage back down to a safe level.

13
Running your train set
With track power off, place your train set on the track.
Refer to page 18 to couple the cars.
33
3
3
2
2
4
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 to forward, 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
1
Connect the drawbar between the locomotive and tender.
See Figure 6.
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 19 for additional information.
Figure 6. Drawbar connection
Caution!
Note!
Locomotive operation

14
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 interruptions 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
control button or
briefly bring the
throttle lever all the
way back to the OFF
position. Refer to
Figure 8 for the loca-
tion of this button.
The reverse unit
alternates between
three states: forward,
neutral, and reverse.
Also, the locomo-
tive can be “locked”
into a certain mode of operation by throwing
the switch located in the cab (see Figure 7
above). When the switch is thrown to the OFF
position, the locomotive will be locked in
that mode of operation in the sequence. To
lock your locomotive into a specific opera-
tional state, sequence your locomotive into
the desired state, and reduce track power
without completely powering down the loco-
motive. Throw the switch to the OFF position
to lock the locomotive into this state. The
DIRECTION button will then have no affect
on the direction of the locomotive.
Additionally, this reverse unit has a
“power-up reset”
feature. If the loco-
motive sits without
power for a short
period of time, the
reverse unit will
automatically reset
and start in the for-
ward direction when
the transformer is
turned on or “pow-
ered up,” regardless
of the reverse unit
switch position. If
the reverse unit
switch is in the OFF position, the locomotive
will start in the forward direction and be
“locked” there.
Figure 7. Switch location
Figure 8. Direction control button location
Direction control button
Whistle control button
Bell control button
ON
SMOKE
OFF ON
REVERSE
OFF
OFF
ON
Reverse
unit
switch
Smoke
ON/OFF switch
OFF
ON
Rear of locomotive

RailSounds operation
Note!
Note!
Your Locomotive’s RailSounds system—the basics
The Lionel RailSounds sound system is the most realistic model railroad sound
system in the world. Your locomotive fea-
tures digital sound samples for the ultimate
in realism.
Begin by installing a nine-volt alkaline
battery (not included) in the tender. This
ensures interruption-free operation of
RailSounds. As illustrated in Figure 9 below,
simply remove the four body screws and lift
away the body to access the battery. Connect
the nine-volt alkaline battery to the battery
harness (remove the protective cover from
the battery harness), and slide the battery
into the holder inside the tender.
When you first apply track power, the loco-
motive’s RailSounds system delivers an
authentic start-up sequence, followed by the
sounds of the locomotive at idle. As the loco-
motive’s speed increases, the chuff rate will
increase, too.
Although RailSounds is powered by track voltage, the battery is required for unin-
terrupted operation and shutdown sequences. Use only alkaline batteries.
If RailSounds “drops out” during track power interruptions (direction change),
replace the battery.
Figure 9. Battery installation
Battery holder
Rear ofTender Battery harness
+
OFFON
RAILSOUNDS
-
Volume control
RailSounds ON/OFF switch Body screws
Body screws
15

16
RailSounds operation
With RailSounds, you experience the sounds of real railroading like never
before. Simply put, it’s the most sophisticat-
ed, authentic model railroad sound system
in the world.
• Variable chuff rate. Your locomo-
tive’s speed determines the steam chuff
rate.
• MultiWhistle/Bell. These features can
be activated by pressing the WHISTLE
and BELL buttons on your Transformer
(see pages 9 and 10). The bell sound will
begin when you push the button and dis-
continue when you push it again.
• Shutdown sequence. No other model
railroad sound system shuts down like
RailSounds. Turn off track power, and
after the air-release reset sound, you
have two seconds to restart your locomo-
tive. If you’re done with operations,
RailSounds will commence with an
authentic shutdown sequence about two
seconds after the air-release reset occurs.
• Braking Sounds. To activate the
screeching sound of your locomotive’s
brakes, simply turn the throttle down as
the locomotive is moving. Notice the
sound becomes more intense the faster
your engine is moving and the greater
its deceleration. This can also be
accomplished by pressing the
DIRECTION button while the train is in
motion.
A battery must be installed for the
shutdown sequence.
Experiencing the range of your locomotive’s RailSounds system
Notes on RailSounds
• Use the volume control knob located on
the underside of the tender. Refer to
Figure 9 on page 15. Turn the volume set
screw clockwise or counter-clockwise to
adjust the volume.
• Listen for incidental Locomotive sounds
during RailSounds operation. They’re
automatic and, of course, authentic.
• The nine-volt alkaline battery you
installed ensures continuous sounds,
even during short track-power
interruptions.
• Longer track-power interruptions
(including locomotive derailments)
cause RailSounds to shut down after
about seven seconds.
Note!

17
RailSounds operations
TowerCom announcements
TowerCom is a two part message involving a “stand-by” or “clear for departure”
announcement from the dispatcher followed
by an acknowledgement from the engineer.
There are several messages and each time
TowerCom is triggered, a random
call/response will be played.
The TowerCom message, selected random-
ly for play-back, is triggered by a short whistle
blast only when the train is stopped. A long
whistle blast will not trigger the effect, and it
is disabled when the locomotive is in motion.
If the trigger (short whistle blast) occurs
within 15 seconds of the train stopping, a
“stand by” message is played; if the trigger
occurs more than 15 seconds after the train
has stopped, a “clear for departure” message
is played. The 15-second interval is marked
by the first instance of CrewTalk after the
engine stops.
Example
• User brings the engine to a stop and
sounds a short whistle blast.
• TowerCom message says, “Please stand
by.”
• User waits until first CrewTalk plays, user
sounds another short whistle blast.
• TowerCom message says “You are clear
for departure.”
CrewTalk communication
There are “call” messages and “response” messages that are selected randomly for
playback. The CrewTalk messages are trig-
gered at random intervals, from 30 seconds
to 3 minutes, only when the train is stopped.
Train Brakes
For the ultimate in realism, the sound of squealing train brakes can be played during
heavy stops. The engine must be moving at a
medium speed then slowed quickly to trigger
the sounds. With practice, you will be able to
control the sound at any time.
Wheel Flange Squeal
The brake sounds may also be used to simu- late the sound of wheel flange squeal when
traveling through tight curves. Depending on
your track layout, this sound may occasionally
play when entering a curve. You may also trig-
ger this sound by quickly moving the throttle
toward the OFF position, then quickly moving it
back to its original setting. Do not move it com-
pletely to OFF or the locomotive will shift to
neutral.

18
Maintaining and servicing your set
Coupling
When coupling your cars, at least one of the mating couplers must be open as
shown at the left in Figure 10. Simply 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 10. Coupler operation
Note!

Maintaining and servicing your set
19
Adding smoke fluid to your locomotive’s smoke generator
Your 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 7 on page 14 for the location of the
switch.
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 about 4 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 decreases, add more
fluid (about 4 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! 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, throw the smoke unit switch to the OFF position.
Note!

20
Maintaining and servicing your set
Help your Lionel steam locomotive lead a long and productive life on your railroad
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 steam locomotive’s wheels, contact
rollers, or your track.
You’ll know your steam locomotive
requires lubrication when visual inspection
reveals dryness on the parts indicated in
Figure 11 below. Remove accumulated dirt
and dust before lubricating, and always
lubricate any locomotive emerging from
prolonged storage. Also, lightly lubricate the
steam locomotive’s side rods after every ten
hours of operation.
Lubricating your locomotive
Figure 11. Lubrication points
Body screw
Body screw
Body screw
Lubricate axle ends with
Lionel oil sparingly
Lubricate axle ends
with Lionel oil
sparingly
Lubricate both sides
with Lionel oil
sparingly
Lubricate both sides
with Lionel oil
sparingly