Lionel Southern Diesel Freight User manual

73-1938-250
2/03
Southern Diesel Freight
Ready-To-Run Train 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 Southern Diesel Freight 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 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!
Southern Diesel Freight Train Set Features
Southern Diesel Freight Train Set Inventory
•GP-38 diesel locomotive
•Boxcar
•Hopper
•Searchlight Car
•Caboose
•CW-80 Transformer
•Three straight FasTrack track
sections
•Eight curved FasTrack track
sections
•One straight FasTrack terminal
track section
•Owner’s Manual
•Service Center list
•Instruction video
Bright
headlights
Operating
couplers
Opening
boxcar
doors
Operating
searchlight
Lighted
caboose
interior
Diesel
horn
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
Operating your trains with the CW-80 Transformer 7
Experiencing the features of the CW-80 Transformer 8-9
Setting the accessory output 10
Powering your layout with the CW-80 Transformer 11
Troubleshooting 12
Locomotive operation
Running your locomotive with a Lionel transformer 13
Reverse unit procedure 14
Maintaining and servicing your locomotive
Lubricating your locomotive 15
Replacing your GP-38’s lamps 16
Tire-Traction 16
Train operations
Coupling 17
Operating the searchlight 18
Replacing the lamp 18
Replacing your square window caboose lamp 19
Limited Warranty/Lionel Service 20
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.

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
4
Figure 1. Track layout ideas
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
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 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
6
Caution!
U
120/60z
0~18VAC
AB
U
0~18VAC 
TRACK ACCESSORY
Figure 3. Transformer 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
7
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

Note!
Note!
Controller operations
8
Experiencing the features of the CW-80 Transformer
Refer to Figure 4 on page 9 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 horn. The sound will continue
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.

Experiencing the features of the CW-80 Transformer (continued)
9
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 6.
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 9 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
10
Note!
Controller operations