73-1960-250 Polar Exp - Lionel Trains Customer Services

1 Ready-to-Run Train SetOwner s Manual73- 1960 -2505/05 Ready-to-Run Train SetOwner s ManualCAUTION ELECTRIC TOYNOT RECOMMENDED FOR CHILDREN UNDER EIGHT YEARS OF AGE. AS WITHALL ELECTRIC PRODUCTS, PRECAUTIONS SHOULD BE OBSERVED DURINGHANDLING AND USE TO REDUCE THE RISK OF ELECTRIC SHOCK. TRANSFORMER RATINGS INPUT: 120 VAC; 60 HZ ONLY. AC OUTPUT: 18 V; 80 VA & Warner ! 2 Congratulations on your purchase of The Polar ExpressTrain Set! This set features every-thing you need to get started a mighty CW-80 Transformer, a huge loop of easy-to-assem-ble 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 followyour imagination into your own miniature world. Expand your railroad empire with addition-al FasTrack track sections, enhance your layout with accessories, lengthen your consist withextra cars, or operate a new locomotive at the head end of your train!

2 Explore the possibilitiesat your authorized Lionel this Owner s Manual to learn how to set up, operate, and maintain your train set foryears of reliable operation. The transformer included with this set should be periodicallyexamined for conditions that may result in the risk of fire,electric shock, or injury to persons (such as damage to theoutput cord, blades, housing, or other parts). In the event thatsuch conditions exist, the transformer should not be used untilproperly !The Polar ExpressTrain Set FeaturesThe following Lionel marks may be used throughout this instruction manual and are protected underlaw. All rights , TrainMaster , Odyssey , RailSounds , CrewTalk , TowerCom , DynaChuff ,StationSounds , Pullmor , ElectroCoupler , Magne-Traction , CAB-1 Remote Controller,PowerMaster , Lionel ZW , ZW , PowerHouse , TMCC , Lionelville , Lockon , Wireless Tether The name FasTrack is used with permission from Pitsco.

3 InteriorsAir whistleForward-Neutral-ReverseoperationT HE Polar express and all related characters and elements are trademarksof and Warner Bros Entertainment Polar ExpressTrain Set Inventory 2-8-4 Berkshire steam locomotive Tender with air whistle Two passenger coaches Observation car Four articulated figures Christmas bell CW-80 Transformer with accessory wire Three straight FasTrack track sections Eight curved FasTrack track sections One straight FasTrack terminal track section Smoke fluid Replacement traction tire Owner s Manual Service Center list Instruction video Lionel RailRoader Club flyer3 Table of contentsCreating your layoutOperating your CW-80 Transformer safely4 Building your Lionel layout5 Joining the FasTrack track sections5 Wiring your CW-80 Transformer6 Running your trainRunning your train set7 Adding smoke fluid to your locomotive s smoke generator8 Coupling8 Installing the observation car platform9 Attaching the figures10 Experiencing the features of the CW-80 Transformer11-12 Reverse unit procedure13CW-80 Transformer operationPowering your layout with the CW-80 Transformer14 Setting the accessory output15 Maintaining and servicing your setLubricating your locomotive16 Replacing your locomotive s traction tire17 Replacing your locomotive s headlamp17 Replacing the passenger car lamps18 Advanced connections: powering two isolated blocks with two transformers19 Limited Warranty/ Lionel Service20 Operating your CW-80 Transformer safely4 Your Lionel CW-80 Transformer is listed by Underwriter s Laboratory Inc.

4 And has beencarefully designed to ensure peak performance. When using electrical products, basicsafety 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 ispresent. 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 connectthis product to any other power supply. Do not operate the CW-80 Transformer with a damaged cord, plug, or case.

5 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. Alist of authorized Service Centers is packed with this unit. Do not operate the CW-80 Transformer on your layout unattended. Obstructed accessoriesor 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 your layoutJoining the FasTrack track sectionsFasTrack track sections join together easily. With interlocking roadbed sections and largerail tabs, the track fits together securely so you always get good electrical contact. Take alook at Figure 2 to see how to join the track Line up your two sections of Insert the rail tabs into the openings at the ends of the Press the sections together until the interlocking roadbed snaps 2.

6 Joining the track sectionsBuilding your Lionel layoutYour set comes with eight curved, three straight, and one terminal section of track. Figure 1provides some examples of layouts that you can build with these track adding more FasTrack track sections, you can create an endless number of excitingtrack arrangements for more fun, action, and variety. The railroad empire of your dreams canquickly become a reality!Creating your layoutFigure 1. Track layout ideas5 Rail tabWiring your CW-80 Transformer6U120/60z0~18 VACABU0~18 VACTRACKACCESSORYF igure 3. Controller connectionsCreating your layoutFasTrack terminal sectionNotchSpade-shapedconnectorConnect your FasTrack terminal section to the CW-80 Transformer. Use the wires that are alreadyattached to the terminal section. Make sure that all connections are secure. Loose connectionscan produce extremely high temperatures. For this reason, do not touch the terminals or trackconnections during use.

7 Also, do not locate scenery materials such as lichen or ground foam nearthe Feed the wires through the notch in the FasTrack terminal section. Refer toFigure Loosen the red TRACK thumbscrew terminal, then slide the red spade-shaped connector into position. The thumbscrew post should be positionedbetween the blades of the spade connector. Be sure that the blades are touching the metal the thumbscrew to secure the Loosen the black TRACK thumbscrew terminal, then slide the black spade-shaped connector into position. Tighten the thumbscrew to secure theconnection. The thumbscrew post should be positioned between the blades of the spadeconnector. Be sure that the blades are touching the metal If you need to power an accessory (available separately at your authorizedLionel dealer), connect the accessory to the ACCESSORY thumbscrewterminals. Use the accessory wire included with the CW-80 Plug the CW-80 Transformer into your wall outlet (120 volts).

8 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 isrecommended that you use 16-gauge wire to connect your CW-80 Transformer to the track. On largerlayouts 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 foryour layout. Follow these guidelines: Track connections must be made with 18-gauge wire or heavier. Larger layoutsrequire a minimum of 16-gauge wire. Use 24-gauge wire only when connecting single accessories that require lowercurrent. When wiring multiple accessories (two or more) or accessories that require highercurrent, be sure to use 18- to 16-gauge !

9 7 Running your trainsRunning your train setWith track power off, place your train set on the to page 8 for information on coupling the up your locomotive with your locomotive is designed to operate on 7-15 volts alternating all Lionel and Lionel -compatible alternating-current transformersare not power your locomotive with direct-current (DC) transformers. The locomotive was designed for use with alternating-current (AC) transformers em out!Get your locomotive locomotive goes through a repeating patternof operations: forward, neutral, reverse, neutral, and so on. To sequence the reverseunit, press the DIRECTION button on your transformer, or briefly bring the throttleall 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 nextoperational state. Adjust track voltageuntil your locomotive moves at your desired speed.

10 11 Connect the drawbar between the locomotive and Figure the smoke unit switch is in the ON position, add smoke fluid to yourlocomotive s stack to prevent damage to the smoke unit. Refer to page 9 for additional !Note!Figure 4. Drawbar connectionCouplingWhen coupling your cars, at least one of the mating couplers must be open as shown at the leftin Figure 5. Press down on the lock release to open the coupler, then push the cars towardeach other until they lock in mind that it s easier to couple cars on a straight stretch of releaseFigure 5. Coupler operationNote!Running your train8 Adding smoke fluid to your locomotive s smoke generatorYour locomotive is equipped with a smoke generator that produces safe, clean white smokeduring operation if the smoke unit switch is in the ON position. Refer to Figure 9 on page 13 for the location of the smoke generator requires the periodic addition of Lionel smoke fluid in order to small bottle of smoke fluid is included with this set.