CAUTION-ELECTRIC TOY Flyer Ready-to-Run O-27 Set Owner's Manual
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73-1935-250
2/02
Flyer
Ready-to-Run O-27 Set
Owner’s Manual
CAUTI ON—ELECTRI C 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 VACongratulations!
C ongratulations on your purchase of the
JCPenneySM Flyer! This set features a
classic 4-4-2 locomotive proudly leads a
copter, and, of course, a caboose. Complete
with a transformer, controller, and 16 sec-
tions of track, you have everything you need
9700 Boxcar, a Flatcar transporting a heli- 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 3
Suggested track layouts 4
Attaching the Lock-On to the track 5
Controller operations
Stripping the wire 6
Attaching the controller wires to the Lock-On 7
Controller functions 8
Controller and short circuits 9
Train operation
Reverse unit procedure 10
Tire-Traction 11
Coupling 11
Maintaining and servicing your set
Lubricating your 4-4-2 locomotive 12
Adding smoke fluid to your 4-4-2’s smoke generator 13
Replacing your 4-4-2 locomotive’s headlamp 14
Notes 15
Limited Warranty/Lionel Service 16
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®
JCPenneySM is a registered trademark of J. C. Penney Company, Inc.
2JCPenneySM Flyer Set Inventory
• 4-4-2 Locomotive • Lionel Lock-On
• Tender with air whistle • Eight sections of straight track
• 9700 boxcar • Eight sections of curved track
• Flatcar with helicopter • Smoke fluid
• Square window caboose • Owner’s Manual
• Controller • Service Center list
• 40-watt power pack • 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
Figure 1. “Breaking in” your track
from the Lionel maintenance kit (no. 6-62927),
available from your nearest Lionel Dealer.
3Track layout
Suggested track layouts
F igure 2 provides some examples of lay-
outs you can build with eight straight
and eight curved sections of track.
Note! We recommend that you do not set
up your track layout on carpeted
surfaces. Carpet fibers may collect on your
Remember—the more track you own, the engine’s wheels and drive gears, and prevent
more variations you can create in your train your engine from operating properly. For
layout. And that means more action and best results, place track on a hard surface.
more fun!
Figure 2. Track layout ideas
4Track 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
rail. The Lock-On should face outward when
setting up your track and make sure it is
firmly connected.
is quick and easy. First, place the Lock-On Once the Lock-On is securely attached to
under any straight section of track. Fit the the track, you are ready to insert the wires
center lip of the Lock-On onto the edge of an from the controller into the two spring clips
outside rail. Press the Lock-On upward so on the Lock-On.
that the spring contact snaps onto the center
LI
ON
LO CTC EL
CK
ON
1
2
Figure 3. Lock-On installation
5Controller 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
Caution! Only an adult should perform
this task! Always use care
when stripping wires.
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.
Figure 4. Wire stripping
6Controller 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.
troller, and plug the other end into a stan-
dard outlet.
Depress the spring clip with your finger Note! If the whistle fails to operate when
you press the whistle button on
and insert the bare end of the wire into the
your controller (see page 8),
exposed opening. Release the spring clip.
remove the wires from the Lock-
Give the wire a little tug to make sure it’s
On and reinsert each one into the
secure. Repeat these steps with the other
opposite clip to reverse polarity.
spring clip. Next, insert the small plug end
of the power pack into the back of your con-
Plug power pack
into standard
wall outlet
Plug this end into
back of controller.
Make sure that the bare end of
each wire is securely attached
to the spring clip.
R
L
FUL ED
SPE
F
OF
Figure 5. Controller connections
7Controller 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
pull, for example), the farther into the
green the knob must be turned before it will
operate the locomotive.
of the throttle control knob. When the indi- The yellow band indicates the average
cator reaches the green band, there should power range that the train will be operating
be sufficient power to operate the locomo- in. The red band represents maximum
tive. The further into the green area the power output.
knob is turned, the faster your train will go. Figure 6 illustrates the location and func-
Remember that the greater the load on the tion of the L.E.D. and the whistle and direc-
engine (adding more cars for the engine to tion buttons.
Press this button to R
The LED indicator
produce a realistic shows when your
whistle sound. controller is ON.
OFF FULL
SPEED
OFF FULL
SPEED
Press this button to go
forward or reverse, or to
place the locomotive
OFF in FULL
Green band OFF
“neutral” (no move- SPEED
OFF FULL
ment, headlight is on). SPEED
Yellow band
Turn the throttle con-
trol knob to the right
for more power.
Red band
Figure 6. Controller functions
8Controller 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
cause of short circuits, so make sure that all
wheels are properly set on the rails. Some
other causes of short circuits might be sta-
peak performance. The controller is ples, nails, paper clips, or other metallic
equipped with a built-in electronic circuit objects lying across the rails, or two bare
breaker that alternately cuts off and restores wires touching each other.
the flow of power to the track whenever a If too many cars or accessories are used,
short circuit exists—for example, when the your controller will exceed its power limit
train derails. The circuit breaker’s action and begin to cycle on and off. To correct this
continues until the cause of the short circuit problem, cars or accessories must be
is eliminated. This circuit breaker is incor- removed before normal operation can
porated into the controller to protect it from resume. For more power, see the line of
possible damage. It will not protect the loco- Lionel high-output transformers at your
motive or electrically operated accessories, Authorized Lionel Value Added Dealer.
so it’s important to eliminate short circuits The same condition can occur if the
as soon as possible. power is turned up too quickly. This also
could cause your train to move too fast and
The power pack must be
Note! unplugged from the wall socket derail.
when a short circuit is noticed, After your power pack has been operating
and the short circuit must be for a while, you will find it warm to the
corrected. touch. It is the nature of all electrical power
A short circuit is caused by a direct con- equipment to become warm when in use. If
nection between the center rail and one of your controller is loaded to capacity, it is a
the outside rails or by a direct connection good idea to let it cool down after an hour
between bare wires. The axles of a derailed or two of continuous use. Unplug the power
car or locomotive are the most frequent pack from the wall when the controller is
not in use.
9Train operation
Reverse unit procedure
T he electronic reverse unit inside your
Lionel locomotive acts like the transmis-
sion in your car. When you apply power to
will be locked in the next mode of operation
in the sequence. For instance, if the locomo-
tive is moving forward, then is stopped and
the track, the locomotive moves in the direc- the switch is thrown back, the locomotive
tion specified by the reverse unit—or it sits will be “locked” in neutral. If the switch is
in neutral, awaiting another power interrup- thrown back while the locomotive is under
tion. Power interruptions are the signal that power, the locomotive will remain in the
tells the reverse unit to mode it was in when the
sequence to the next switch was thrown. The
operational state. controller direction con-
To interrupt power trol will then have no
and sequence the loco- affect on the direction of
motive’s reverse unit, the locomotive.
press the direction con- Additionally, this
trol button or turn the reverse unit has a
throttle to the OFF posi- “power-up reset” feature.
tion and ON again. If the locomotive sit with-
Refer to Figure 8 for the Reverse unit ON/OFF switch out power for a short
location of this button. Figure 7. Switch location period of time, the
The reverse unit alter- reverse unit will auto-
nates between three states: forward, neutral, matically reset and start in the forward
and reverse. direction when the transformer is turned on
Also, the locomotive can be “locked” into or “powered up,” regardless of the locking
a certain mode of operation by throwing the switch position. If the locking switch is in
switch located on the underside of the frame the OFF position, the locomotive will start in
(see Figure 7 above). When the switch is the forward direction and be “locked” there.
thrown to the OFF position, the locomotive
R
LL
F U ED
E
SP
F
OF
Direction
control button
Figure 8. Direction control button location
10Train 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
Lionel locomotives with Tire-Traction grip
the track, enabling them to pull heavy loads
at higher speeds. Replacement traction tires
tire to enhance tractive effort so your loco- are available at your authorized Lionel Service
motive can pull many cars at once. 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.
Lock release
Figure 9. Coupler operation
11Maintaining 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 rail-
road by maintaining it properly.
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 lubrica-
We recommend that you purchase a tion when visual inspection reveals dryness
Lionel Lubrication and Maintenance Kit on the parts indicated in Figure 10. Remove
(no. 6-62927), available from your Lionel accumulated dirt and dust before lubricat-
dealer. Two basic rules to keep in mind: ing, and always lubricate any locomotive
never over-lubricate (a small amount will emerging from prolonged storage.
Lubricate axle ends
with Lionel oil Lubricate gears with Lubricate with
sparingly Lionel grease sparingly Lionel oil sparingly
Figure 10. Lubrication points
12Maintaining 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.
production commences momentarily, faster
if you run your locomotive at high speed.
When smoke production wanes, add more
The smoke generator requires the periodic fluid (4 to 8 drops). An idle locomotive will
addition of Lionel smoke fluid in order to not smoke.
function. Pierce the smoke fluid tube end Smoke production is greater at higher volt-
with a pin, then add 4 to 8 drops of fluid ages and when the locomotive is pulling a
directly into the locomotive’s stack. Smoke heavy load or a long consist.
Caution! Always keep a small amount of smoke fluid in the locomotive’s smoke genera-
tor; 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.
13Maintaining 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
Service. Be careful not to twist the lamp
or it may break.
4. Reinstall the smoke unit, making sure
require replacement. Refer to Figure 11 as that the smoke stack lines up with the
you replace the lamp. cab top opening.
1. Remove the two front truck screws and 5. Reassemble the front truck, making sure
carefully slide the front truck assembly that the linkage rods go into the holes in
off the linkage rods. the front truck. The lug wire from the
2. Lift the smoke unit out far enough from smoke unit must be reinserted through
the cab to allow lamp extraction. the slot in the front truck assembly and
3. Pull the lamp straight out and replace it secured under one of the two front
with Lionel part no. 600-0161-300, screws. Tighten the screws firmly, but do
available from your nearest Lionel not over tighten them.
Authorized Service Center or from Lionel
Smoke unit
Lionel part no.
600-0161-300
Linkage rods
Front truck Smoke unit
screws lug wire
Figure 11. Headlight replacement
14Notes
15Limited Warranty/Lionel Service
his Lionel product, including all Your nearest Lionel Service Center can be found
T mechanical and electrical components,
moving parts, motors and structural
components, except for light bulbs, is warranted
by calling 1-800-4-Lionel, or by accessing our
Website at www.lionel.com.
If you prefer to send your product back to
to the original consumer-purchaser, for one year Lionel L.L.C. for repair in Michigan, you must
against original defects in materials or first call 586-949-4100 or FAX 586-949-5429, or
workmanship when purchased through an write to Customer Service, P.O. Box 748, New
authorized Lionel merchant. Baltimore, MI 48047-0748, stating what the item
This warranty does NOT cover normal wear is, when it was purchased and what seems to be
and tear, light bulbs, defects appearing in the the problem. You will be sent a return
course of commercial use, or damage resulting authorization letter and label to ensure your
from abuse or misuse of the product by the merchandise will be properly handled upon
purchaser. Transfer of this product by the original receipt.
consumer-purchaser to another person voids this Once you have received your return
warranty. Modification of this product voids this authorization and label, make sure that the item
warranty. is packed to prevent damage during shipping and
Any warranted product which is defective in handling. We suggest that you use the product’s
original materials or workmanship and is original packaging. This shipment must be
delivered by the original consumer-purchaser to prepaid and we recommend that it be insured.
Lionel L.L.C. or an authorized Lionel L.L.C. Service Please make sure you have followed all of the
Center, together with proof of original purchase above instructions carefully before returning any
will, at the option of Lionel L.L.C., be repaired or merchandise for service. You may choose to have
replaced, without charge for parts or labor. In the your product repaired by one of our Authorized
event the defective product cannot be repaired, and Lionel Service Centers after its warranty has
a replacement is not available, a refund of the expired. A reasonable service fee will be charged.
original purchase price will be granted. Any
products on which warranty service is sought must Warranty Information
be sent freight or postage prepaid, as Please complete the information below and
transportation and shipping charges are not keep it, along with your dated sales receipt. You
covered by the warranty. must present this and your dated sales receipt
when requesting warranty service.
In no event shall Lionel L.L.C. be
liable for incidental or Name ____________________________
consequential damages.
Some states do not allow the exclusion or Address ____________________________
limitation of incidental or consequential damages,
so the above exclusion may not apply to you. Place of Purchase ____________________
This limited warranty gives you specific legal
rights, and you may have other rights which vary Date of Purchase ____________________
from state to state.
Product Number ______________________
Instructions for Obtaining Service
If service for this Lionel L.L.C. product is Product Description____________________
required, bring the item, along with your dated
sales receipt and completed warranty information
to the nearest Authorized Lionel Service Center.
©2002 LIONEL LLC, CHESTERFIELD, MI 48051-1956
UNITED STATES OF AMERICA
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