Lionel U.S. ARMY SWITCHER 41 User manual

Lionel
#41 U.S. Army
Switcher
Owner’s Manual
71-8474-250
8/03

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You purchased a tough, durable locomotive—the #41 U.S. Army Switcher built by Lionel. From the crisp detail and expert decoration on the outside to the brute power under the
hood, the Lionel #41 U.S. Army Switcher is ready for duty on your model railroad. Experience
the superiority of today’s Lionel.
Congratulations!
Features of the Switcher
•Powerful Pullmor motor
•Magnetic couplers
•Directional lighting featuring front and rear headlights
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®
The name FasTrack®is used with permission from Pitsco, Inc.

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Table of contents
Transformer operations
Running your Switcher with a Lionel transformer 4
Locking your Switcher into a single operational state 5
Using your Switcher’s magnetic coupler 6
Maintaining and servicing your Switcher
Lubricating your Switcher 7
Lubricating the Pullmor motor armature 8
Replacing your Switcher’s lamps 9
Replacing your Switcher’s traction tires 10
Notes 11
Limited Warranty/Lionel Service 12

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3Move ‘em out!
•Get your Switcher moving. Press the DIRECTION button on your Lionel
transformer. This sequences the Lionel reverse unit to the next operating state.
•Adjust track voltage until your Switcher moves at your desired speed. To
increase speed, increase track voltage. To decrease speed, reduce voltage. To stop
the locomotive, turn-off track power.
•See page 5 for information on locking your Switcher in a single
operational state.
Place your Switcher on Lionel or
Lionel-compatible O gauge track.
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2Power up your Switcher with your transformer.
•Your Switcher is designed to operate on 8-18 volts alternating
current. Virtually all Lionel and Lionel-compatible alternating-current trans-
formers are suitable.
Do not power your Switcher with direct current (DC). Damage to sensi-
tive electronic components may occur.
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Running your Switcher with a Lionel transformer
Transformer operations
Caution!

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To lock your Lionel Switcher into a single operational state, you can deactivate the reverse unit’s sequencing function with the reverse unit control switch.
Get your locomotive moving in the desired direction, then stop the locomotive and slide the switch
to the OFF position without removing it from the track. Refer to Figure 1 for the location of the
switch. The Switcher is now “locked” into your chosen direction.
When you no longer want single-direction operation, just slide the reverse unit control
switch back to ON.
Your locomotive’s reverse unit will “reset” to forward after any five second or longer
power interruption, regardless of the original locked-out direction.
Locking your Switcher into single operational state
OFF
ON
Transformer operations
Figure 1. Switch location
Note!
Coupler trigger plate
Coupler trigger plate
Reverse unit
control switch
REAR
FRONT

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Using your Switcher’s magnetic coupler
Your Lionel Switcher is equipped with two operating magnetic knuckle coupler, a revolution- ary design first introduced by Lionel in 1945.
Lionel magnetic couplers react to the magnetic field generated by a Lionel Remote-Control
Track section (available separately, 6-65530 for O gauge; 6-65149 or 6-12746 for O-27 gauge;
and 6-12020 for FasTrack layouts).
Place your locomotive’s coupler trigger plate (located between the wheels of the pilot trucks)
over the central coil of a Remote-Control Track section and press UNCOUPLE on the controller.
The magnetic field pulls the plate downward, and the knuckle opens. Also, you can open the
coupler manually by pressing down the tabs by the coupler.
One operating technique favored by Lionel railroaders is the “moving uncouple.” Press the
UNCOUPLE button as the trigger plate passes over a Remote-Control Track section. The mag-
netic field will open the coupler; the consist remains behind as the Switcher moves on. Be
careful—the speed of the locomotive may increase when the load is reduced.
Transformer operations

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Lubricating your Switcher
Help your Lionel Switcher lead a long and productive life on your railroad by maintaining it properly.
We recommend that you purchase a Lionel Lubrication and Maintenance Kit (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 Switcher’s wheels or your track.
You’ll know your Switcher requires lubrication when visual inspection reveals dryness on the
parts indicated in Figure 2. Remove accumulated dirt and dust before lubricating, and always
lubricate any locomotive emerging from prolonged storage.
Maintaining and servicing your Switcher
Figure 2. Underside details and lubrication points
Lubricate with
Lionel oil sparingly
Lubricate with Lionel
oil sparingly
Lubricate with Lionel
grease sparingly
Cab mounting screw
Cab mounting screw
Reverse unit
control switch
Lubricate with Lionel
oil sparingly
REAR
FRONT

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Lubricating the Pullmor motor armature
Your Switcher will require the occasional lubrication of its Pullmor motor armature. If you hear excess noise during operation, or if the slows down intermittently, you may need to
oil the top armature bearing. Follow these steps and refer to Figure 3.
1. Remove the cab mounting screws from the bottom of the Switcher, then lift the shell away.
Refer to Figure 2 on page 7 for the location of these screws.
2. As illustrated in Figure 3, remove the set screw at the top of the motor.
3. Add a small amount (two drops) of Lionel oil (available separately in the Lubrication and
Maintenance Kit, 6-62927) to the set screw hole.
4. Replace and adjust the set screw. Roll the engine wheels back and forth by hand to be sure
that the vertical travel of the brushes or armature is about .01” (the thickness of three
pieces of paper). The up and down travel of the armature should be barely visible.
You will not be able to turn the motor armature by rolling the wheels.
5. Reinstall the body shell and replace the cab mounting screws.
Maintaining and servicing your Switcher
Note!
LIONELLIONEL
Set screw
Lionel oil
Figure 3. Armature lubrication

Maintaining and servicing your Switcher
Replacing your Switcher’s lamps
Your Switcher unit is illuminated by two small lamps. During the course of operations, these lamps may require replacement. The replacement lamps are part no. 610-8456-100,
available from your authorized Lionel Service Center or Lionel Service. Follow these steps and
refer to Figure 4 as you replace the lamps.
1. Remove the cab mounting screws from the bottom of the Switcher, then carefully lift the
shell away. Refer to Figure 2 on page 7 for the location of these screws.
2. Locate the assembly containing the expired lamp and follow the wires to the terminal on
the circuit board.
3. Separate the top portion of the terminal by pulling it out of the socket on the circuit board.
Do not pull on the wires.
4. Remove the two wires of the expired bulb from the terminal. Use a small, pointed object to
pull back the small tab on the front of the upper portion of the terminal, then pull out the
wires as illustrated in Figure 4.
5. Push the lamp and the headlight lens through the body shell toward the exterior and pull
the wires through the hole to completely remove the expired lamps.
6. Replace the lamp with Lionel part no. 610-8456-100 (available from your authorized
Lionel Service Center or Lionel Service), inserting the wires back into the shell. Connect
these wires to the terminal in the same way that the original wires were connected. Make
sure that the wires are inserted securely into the terminal. Connect the terminal to the
socket on the circuit board.
7. Press-fit the lens assembly into the shell, then tuck the wires inside and replace the cab
with the two mounting screws.
Figure 4. Lamp replacement
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Front Lamp
Front Lamp
Rear Lamp
Rear Lamp

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Replacing your Switcher’s traction tires
Your Switcher is equipped with a traction tire to enhance the tractive effort of your loco- motive. During the course of normal operations, you may find that the traction tire
requires replacement. Extra traction tires are included.
To replace the traction tire, simply remove the 1/4” nut from the traction tire-equipped drive
wheel. Slip off the old traction tire. Place the new traction tire around the wheel and reattach
the drive rod with the 1/4” nut. You’re ready to pull the long freight back to the yard!
Maintaining and servicing your Switcher