73-1935-250
2/02
Flyer
Ready-to-Run O-27 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: 20 V; 54 VA
Congratulations!
C ongratulations on your purchase of the
JCPenney SM Flyer! This set features a classic 4-4-2 locomotive proudly leads a
9700 Boxcar, a Flatcar transporting a helicopter, and, of course, a caboose. Complete with a transformer, controller, and 16 sections of track, you have everything you need to build your layout!
Parents!
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.
Table of contents
Track layout
Joining the track sections
Suggested track layouts
Attaching the Lock-On to the track
Controller operations
Stripping the wire
Attaching the controller wires to the Lock-On
Controller functions
Controller and short circuits
Train operation
Reverse unit procedure
Tire-Traction
Coupling
Maintaining and servicing your set
Lubricating your 4-4-2 locomotive
Adding smoke fluid to your 4-4-2’s smoke generator
Replacing your 4-4-2 locomotive’s headlamp
Notes
Limited Warranty/Lionel Service
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 ®
JCPenney SM is a registered trademark of J. C. Penney Company, Inc.
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JCPenney
SM
Flyer Set Inventory
• 4-4-2 Locomotive
• Tender with air whistle
• 9700 boxcar
• Flatcar with helicopter
• Square window caboose
• Controller
• 40-watt power pack
• Lionel Lock-On
• Eight sections of straight track
• Eight sections of curved track
• Smoke fluid
• Owner’s Manual
• Service Center list
• Warranty card
Track layout
Joining the track sections
J oin the track sections together by inserting the pins of one track section into the open ends of another. For good electrical contact, the pins must be carefully inserted and the track joints tightly fitted.
If the track is difficult to connect, try this installation tip. You can “break in” O gauge track sections by inserting and withdrawing a track pin into one rail at a time before joining the entire track section as illustrated in Figure 1.
If the openings become too loose (causing the track to fit loosely), pinch the rail together around a track pin with a pair of pliers. If any pins fall out of the track and are missing, replace them with extras available from your Lionel dealer.
Maintenance tip: The rails should be kept clean, dry, and free from oil and grease. Clean rust and dirt spots with a track eraser. Wipe the track using a cloth dampened with track cleaner from the Lionel maintenance kit (no. 6-62927), available from your nearest Lionel Dealer.
Figure 1. “Breaking in” your track
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Track layout
Suggested track layouts
F igure 2 provides some examples of layouts you can build with eight straight and eight curved sections of track.
Remember—the more track you own, the more variations you can create in your train layout. And that means more action and more fun!
Note!
We recommend that you do not set up your track layout on carpeted surfaces. Carpet fibers may collect on your engine’s wheels and drive gears, and prevent your engine from operating properly. For best results, place track on a hard surface.
Figure 2. Track layout ideas
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Track layout
Attaching the Lock-On to the track
T he Lock-On connects power from your controller to the track. As illustrated in
Figure 3, attaching the Lock-On to the track is quick and easy. First, place the Lock-On under any straight section of track. Fit the center lip of the Lock-On onto the edge of an outside rail. Press the Lock-On upward so that the spring contact snaps onto the center rail. The Lock-On should face outward when setting up your track and make sure it is firmly connected.
Once the Lock-On is securely attached to the track, you are ready to insert the wires from the controller into the two spring clips on the Lock-On.
1
2
LIONEL
CTC
LOCKON
Figure 3. Lock-On installation
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Controller operations
Stripping the wire
O nce your track is assembled and the
Lock-On is securely attached, you can connect the wires from the controller to the
Lock-On.
First you’ll want to check the ends of the wires to make sure that the insulation is stripped back about 1⁄4˝ to 3⁄8˝. To strip the wires, use a pair of wire strippers or a sharp knife as illustrated in Figure 4.
Caution!
Only an adult should perform this task! Always use care when stripping wires.
Figure 4. Wire stripping
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Controller operations
Attaching the controller wires to the Lock-On
N ow you’ll need to insert a controller wire into each of the two spring clips on the Lock-On as illustrated in Figure 5.
Depress the spring clip with your finger and insert the bare end of the wire into the exposed opening. Release the spring clip.
Give the wire a little tug to make sure it’s secure. Repeat these steps with the other spring clip. Next, insert the small plug end of the power pack into the back of your controller, and plug the other end into a standard outlet.
Note!
If the whistle fails to operate when you press the whistle button on your controller (see page 8), remove the wires from the Lock-
On and reinsert each one into the opposite clip to reverse polarity.
Plug power pack into standard wall outlet
Make sure that the bare end of each wire is securely attached to the spring clip.
R
OFF
FULL
SPEED
Plug this end into back of controller.
Figure 5. Controller connections
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Controller operations
Controller functions
A s you turn the throttle control knob to the right, power to the track is increased. Refer to Figure 6 for the location of the throttle control knob. When the indicator reaches the green band, there should be sufficient power to operate the locomotive. The further into the green area the knob is turned, the faster your train will go.
Remember that the greater the load on the engine (adding more cars for the engine to pull, for example), the farther into the green the knob must be turned before it will operate the locomotive.
The yellow band indicates the average power range that the train will be operating in. The red band represents maximum power output.
Figure 6 illustrates the location and function of the L.E.D. and the whistle and direction buttons.
Press this button to produce a realistic whistle sound.
OFF
Press this button to go forward or reverse, or to
“neutral” (no movement, headlight is on).
Turn the throttle control knob to the right for more power.
FULL
SPEED
FULL
SPEED
OFF
R
The LED indicator shows when your controller is ON.
Green band
FULL
SPEED
Yellow band
Red band
OFF
Figure 6. Controller functions
FULL
SPEED
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Controller operations
Controller and short circuits
Y our Lionel power pack is listed by
Underwriters Laboratories Inc. and has been carefully designed and tested to ensure peak performance. The controller is equipped with a built-in electronic circuit breaker that alternately cuts off and restores the flow of power to the track whenever a short circuit exists—for example, when the train derails. The circuit breaker’s action continues until the cause of the short circuit is eliminated. This circuit breaker is incorporated into the controller to protect it from possible damage. It will not protect the locomotive or electrically operated accessories, so it’s important to eliminate short circuits as soon as possible.
Note!
The power pack must be unplugged from the wall socket when a short circuit is noticed, and the short circuit must be corrected.
A short circuit is caused by a direct connection between the center rail and one of the outside rails or by a direct connection between bare wires. The axles of a derailed car or locomotive are the most frequent cause of short circuits, so make sure that all wheels are properly set on the rails. Some other causes of short circuits might be staples, nails, paper clips, or other metallic objects lying across the rails, or two bare wires touching each other.
If too many cars or accessories are used, your controller will exceed its power limit and begin to cycle on and off. To correct this problem, cars or accessories must be removed before normal operation can resume. For more power, see the line of
Lionel high-output transformers at your
Authorized Lionel Value Added Dealer.
The same condition can occur if the power is turned up too quickly. This also could cause your train to move too fast and derail.
After your power pack has been operating for a while, you will find it warm to the touch. It is the nature of all electrical power equipment to become warm when in use. If your controller is loaded to capacity, it is a good idea to let it cool down after an hour or two of continuous use. Unplug the power pack from the wall when the controller is not in use.
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Train operation
Reverse unit procedure
T he electronic reverse unit inside your
Lionel locomotive acts like the transmission in your car. When you apply power to will be locked in the next mode of operation in the sequence. For instance, if the locomothe track, the locomotive moves in the direction specified by the reverse unit—or it sits in neutral, awaiting another power interruption. Power interruptions are the signal that tive is moving forward, then is stopped and the switch is thrown back, the locomotive will be “locked” in neutral. If the switch is thrown back while the locomotive is under tells the reverse unit to sequence to the next operational state.
To interrupt power power, the locomotive will remain in the mode it was in when the switch was thrown. The controller direction conand sequence the locomotive’s reverse unit, press the direction control button or turn the trol will then have no affect on the direction of the locomotive.
Additionally, this throttle to the OFF position and ON again.
reverse unit has a
“power-up reset” feature.
If the locomotive sit with-
Refer to Figure 8 for the location of this button.
Reverse unit ON/OFF switch
Figure 7. Switch location
The reverse unit alternates between three states: forward, neutral, out power for a short period of time, the reverse unit will automatically reset and start in the forward and reverse.
Also, the locomotive can be “locked” into a certain mode of operation by throwing the switch located on the underside of the frame
(see Figure 7 above). When the switch is thrown to the OFF position, the locomotive direction when the transformer is turned on or “powered up,” regardless of the locking switch position. If the locking switch is in the OFF position, the locomotive will start in the forward direction and be “locked” there.
R
Direction control button
Figure 8. Direction control button location
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OF
F
FU
LL
SP
EE
D
Train operation
Tire-Traction
Y our locomotive is equipped with Tire-
Traction. This means that one of the drive wheels is fitted with a rubber traction tire to enhance tractive effort so your locomotive can pull many cars at once.
Lionel locomotives with Tire-Traction grip the track, enabling them to pull heavy loads at higher speeds. Replacement traction tires are available at your authorized Lionel Service
Center.
Coupling
W hen coupling your cars, at least one of the mating couplers must be open as shown below at the left. Simply press down on the lock release to open the coupler, then push the cars toward each other until they lock together as illustrated in Figure 9.
Note!
Keep in mind that it’s easier to couple cars on a straight stretch of track.
Figure 9. Coupler operation
Lock release
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Maintaining and servicing your set
Lubricating your 4-4-2 locomotive
H elp your 4-4-2 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
4-4-2’s wheels, contact rollers, or your track.
You’ll know your 4-4-2 requires lubrication when visual inspection reveals dryness on the parts indicated in Figure 10. Remove accumulated dirt and dust before lubricating, and always lubricate any locomotive emerging from prolonged storage.
Lubricate axle ends with Lionel oil sparingly
Figure 10. Lubrication points
Lubricate gears with
Lionel grease sparingly
Lubricate with
Lionel oil sparingly
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Maintaining and servicing your set
Adding smoke fluid to your 4-4-2’s smoke generator
Y our 4-4-2 locomotive is equipped with a smoke generator that produces safe, clean white smoke during operation.
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 4 to 8 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 wanes, add more fluid (4 to 8 drops). An idle locomotive will not smoke.
Smoke production is greater at higher voltages and when the locomotive is pulling a heavy load or a long consist.
Caution!
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.
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Maintaining and servicing your set
Replacing your 4-4-2 locomotive’s headlamp
Y our 4-4-2 locomotive lights the way with its operating headlight. During the course of normal operation, the lamp may require replacement. Refer to Figure 11 as you replace the lamp.
1. Remove the two front truck screws and carefully slide the front truck assembly off the linkage rods.
2. Lift the smoke unit out far enough from the cab to allow lamp extraction.
3. Pull the lamp straight out and replace it with Lionel part no. 600-0161-300, available from your nearest Lionel
Authorized Service Center or from Lionel
Service. Be careful not to twist the lamp or it may break.
4. Reinstall the smoke unit, making sure that the smoke stack lines up with the cab top opening.
5. Reassemble the front truck, making sure that the linkage rods go into the holes in the front truck. The lug wire from the smoke unit must be reinserted through the slot in the front truck assembly and secured under one of the two front screws. Tighten the screws firmly, but do not over tighten them.
Smoke unit
Linkage rods
Front truck screws
Figure 11. Headlight replacement
Lionel part no.
600-0161-300
Smoke unit lug wire
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Notes
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Limited Warranty/Lionel Service
T his Lionel product, including all mechanical and electrical components, moving parts, motors and structural components, except for light bulbs, is warranted to the original consumer-purchaser, for one year against original defects in materials or workmanship when purchased through an authorized Lionel merchant.
This warranty does NOT cover normal wear and tear, light bulbs, defects appearing in the course of commercial use, or damage resulting from abuse or misuse of the product by the purchaser. Transfer of this product by the original consumer-purchaser to another person voids this warranty. Modification of this product voids this warranty.
Any warranted product which is defective in original materials or workmanship and is delivered by the original consumer-purchaser to
Lionel L.L.C. or an authorized Lionel L.L.C. Service
Center, together with proof of original purchase will, at the option of Lionel L.L.C., be repaired or replaced, without charge for parts or labor. In the event the defective product cannot be repaired, and a replacement is not available, a refund of the original purchase price will be granted. Any products on which warranty service is sought must be sent freight or postage prepaid, as transportation and shipping charges are not covered by the warranty.
In no event shall Lionel L.L.C. be liable for incidental or consequential damages.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above exclusion may not apply to you.
This limited warranty gives you specific legal rights, and you may have other rights which vary from state to state.
Instructions for Obtaining Service
If service for this Lionel L.L.C. product is required, bring the item, along with your dated sales receipt and completed warranty information to the nearest Authorized Lionel Service Center.
Your nearest Lionel Service Center can be found by calling 1-800-4-Lionel, or by accessing our
Website at www.lionel.com.
If you prefer to send your product back to
Lionel L.L.C. for repair in Michigan, you must first call 586-949-4100 or FAX 586-949-5429, or write to Customer Service, P.O. Box 748, New
Baltimore, MI 48047-0748, stating what the item is, when it was purchased and what seems to be the problem. You will be sent a return authorization letter and label to ensure your merchandise will be properly handled upon receipt.
Once you have received your return authorization and label, make sure that the item is packed to prevent damage during shipping and handling. We suggest that you use the product’s original packaging. This shipment must be prepaid and we recommend that it be insured.
Please make sure you have followed all of the above instructions carefully before returning any merchandise for service. You may choose to have your product repaired by one of our Authorized
Lionel Service Centers after its warranty has expired. A reasonable service fee will be charged.
Warranty Information
Please complete the information below and keep it, along with your dated sales receipt. You must present this and your dated sales receipt when requesting warranty service.
Name ____________________________
Address ____________________________
Place of Purchase ____________________
Date of Purchase ____________________
Product Number ______________________
Product Description____________________
©2002 L
IONEL
LLC, C
HESTERFIELD
, MI 48051-1956
U NITED S TATES OF A MERICA
P
RINTED IN
C
HINA
