American Flyer Defender Set

Owner’s Manual

74-9624-2503/13

CAUTION: Use only the projectiles included with this product. Do not aim the projectile and launching mechanism at any person. Adult supervision is recommended.

CAUTION: The coil on the flatcar deck may reach high temperatures. Do not touch the coil until cool.

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C ongratulations on your purchase of the American Flyer Defender Set. The set you have always wanted, beautifully recreated. From the sleek little bell ringer C&O GP-7 to the

Rocket Launcher and Searchlight Cars, this set has all the makings of childhood memories with the features you’ve come to expect. Roll down the rails with this set and keep your railroad empire safe from intruders with ‘The Defender’.

First cataloged in 1959, this American Flyer favorite has been brought back for everyone to enjoy today! Similar to the original, the set includes GP-7 diesel with ringing bell, Navy flatcar with vehicles, searchlight car, Marines boxcar, rocket launcher, and caboose

Congratulations!

Features of this locomotive

Rolling stock features:

• Transformer controlled forward, neutral, and reverse operation• Powerful maintenance-free motor• Ringing bell• Directional lighting, including operating headlight and back-up light• Interior cab light• Front and rear operating couplers• Traction tires• Metal frame• Die-cast metal trucks

• Die-cast metal trucks with operating couplers• Illuminated searchlight on searchlight car• Removable vehicles on Navy flatcar• Removable rocket on rocket launcher car• Metal frame and opening doors with latches on boxcar• Interior illumination in caboose

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Table of contents

Transformer operationsRunning your locomotive with a Lionel transformer 4Locking your locomotive into a single operational state 5Turning off the bell sounds. 5

Operating your train setUsing your locomotive's couplers 6Installing the control rail 6Unloading the boxcar 7Placing the automobiles on the flatcar 7Launching the missile 8

Maintaining and servicing your locomotiveLubricating your locomotive 9-10Replacing your locomotive’s lamps 10Replacing the searchlight car lamps 11Replacing the caboose lamp 11Limited Warranty/Lionel Service 12

The following Lionel marks are used throughout this Owner’s Manual and are protected under law. All rights reserved.

Lionel®, LEGACY™, FasTrack™, TrainMaster®, Odyssey®, RailSounds®, CrewTalk™, TowerCom™, DynaChuff™, StationSounds™, Pullmor®, ElectroCoupler™, Magne-Traction®, CAB-1® Remote Controller, American Flyer®, Lionel ZW®, ZW®, MagniVision®, TMCC®, Lionelville®, Wireless Tether™, Powerhouse™, LionMaster®, Conventional Classics™, Postwar Celebration Series™, TruRail™, PH-1 Powerhouse®, Powermaster®, Powerstation-Powerhouse®, Accessory Motor Controller™, AMC™, Accessory Switch Controller™, ASC™, Action Recorder Controller™, ARC™, Track Power Controller 300™, TPC 300™, Track Power Controller 400™, TPC 400™, Block Power Controller™, BPC™, Operating Track Controller™, OTC™, FatBoy™, Lionel Lines®, Joshua Lionel Cowen Series™, Lockon®, TrainSounds™, MultiHorn™, MultiWhistle™, Choo-Choo™

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3Move ‘em out!

Get your trainset moving. Press the DIRECTION button on your transformer. This sequences the reverse unit to the next operating state.

Adjust track voltage until your locomotive 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 locomotive into a single operational state.

Place your train set on American Flyer or S gauge two-rail track.

The curves must have a radius of at least 20”.

2Power up your locomotive with your transformer.

Your locomotive is designed to operate on 9-15 volts alternating current. Virtually all American Flyer or Lionel alternating-current transformers are suitable.

Do not power your locomotive with direct current (DC). Damage to sensitive electronic components may occur.

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Running your locomotive with a Lionel transformer

Transformer operations

Caution!

Note!

It is imperative that you keep the powered truck liberally lubricated for reliable operation. See page 9-10 for more information.

Important!

To select a single operational state for your locomotive (example: forward only), you can deactivate the reverse unit’s sequencing function with the directional control switch.

Get your locomotive moving in the desired direction, then slow it down without stopping. Set the directional control switch to OFF. Refer to Figure 1 for the location of the switch. The locomotive is now “locked” into your chosen direction.

When you no longer want single-direction operation, just slide the 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.

Slide the sound switch to the OFF position to turn off the bell sounds.

Locking your locomotive into a single operational state

Turning off the bell sounds

Transformer operations

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Note!

Figure 1. Switch location

Reverse unit locking switch

Sound switch

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Operating your train set

Push up on the uncoupling weight located directly under the coupler to open the coupler. To couple two cars together, place them on the track with at least one of the couplers open,

then slide them together. The couplers will close automatically.

Using your locomotive’s couplers

POWERSUPPLY

UA

1. As illustrated in Figure 2, snap the control rail onto the track. The two arms snap onto the underside of the ties.

2. Attach a wire to the terminal on the control rail and connect it to a terminal on the other separate switch. Refer to Figure 3.

3. Attach a wire to the remaining switch terminal and connect it to the Common/Ground U terminal on the power supply.

Installing the control rail

Control rail

Control rail arm

Control rail spring clip

Switch terminals

Sliding contact

Figure 2. Control rail attachment

Figure 3. Control rail power connections

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Operating your train set

To unload the car, be sure that the power contact is in position on the power rail. Press the button on the controller, and the door will open and package will be pushed out of the car. Press the

button repeatedly until all packages are unloaded. Reload the packages on the ramp inside the car.

Unloading the boxcar

Control rail

Place packages on ramp

Control rail arm

Figure 4. Unloading the boxcar

Placing the automobiles on the flatcar

Place the automobiles on the flatcar as shown in Figure 5. Place the axles into the slots on the holder.

Slot

Figure 5. Place the autombiles on the flatcar

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Launching the missile

To launch the missile, press the rocket down into the base until the mechanism clicks. Position the power contact on the power rail (see Figure 6), and then press the button on the controller

momentarily to fire. To avoid damage to the car, do not hold the button down for more than 10 seconds with the car in place on the control rail.

Keep clear of the missle and launch mechanism.

The coil on the flatcar deck may reach high temperatures. Do not touch the coil until cool.

Caution!

Caution!

Control rail

Control rail arm

Power contract

Hot surface!Do not touch!

Coil

Figure 6. Launching the missile

Operating your train set

Do NOT press the button on the controller for more than 10 seconds at a time.

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Maintaining and servicing your train setLubricating your locomotive

H elp your American Flyer locomotive lead a long and productive life on your railroad by maintaining it properly.

It is imperative that you keep the powered truck liberally lubricated for reliable operation.

We recommend that you purchase a Lionel Lubrication and Maintenance Kit (no. 6-62927), available from your Lionel dealer. Avoid getting grease or oil on the locomotive’s wheels or your track. You’ll know your locomotive requires lubrication when visual inspection reveals dryness on the parts indicated in Figure 7 and 8. Remove accumulated dirt and dust before lubricating, and always lubricate any locomotive emerging from prolonged storage.

Figure 7. Underside details and lubrication points

ON

OF

F

Body screw(under truck)

Body screw(under truck)

Lubricate axles with Lionel oil

sparingly on both sides

Lubricate gears with Lionel

grease sparingly

Lubricate axles with Lionel oil

sparingly on both sides

Body screw(under truck)

Important!

Lubricating your locomotive (continued)

Replacing your locomotive’s lamps

In addition to oiling all axles and the idler gears on the sides of the powered truck (as shown on in Figure 7 page 9), it is imperative that you lubricate the worm gear with a liberal

amount of Lionel oil (not grease) for optimal performance. To access the square slot on the underside of the powered truck, remove the two screws from the underside of the bottom plate, and lift it away, along with the side frame. Refer to Figure 8. Lubricate the gear through the rectangular slot using Lionel oil, then replace the bottom plate, ensuring that the rubber gasket is in place.

The headlamps are secured in the number board/headlight lens inside the cab. To replace a lamp, remove the four chassis screws from the underside of the frame (see Figure 7 on page 9) and

gently lift off the cab. Locate the expired lamp and gently pull it out of the socket. Replace it with Lionel part no. 6008352311. To reassemble, reverse the procedure.

Maintaining and servicing your train set

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Figure 8. Truck lubrication

Screws

Worm gear in rectangular slot

Rubber gasket

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Maintaining and servicing your train set

Replacing the searchlight car lamp

The searchlight is on whenever the car is powered up on the track. This car was designed to operate at

12-18 volts (AC). To prolong the life of your lamps, we recommend that you operate this car at lower voltages.

Each searchlight is illuminated by one lamp, Lionel part no. 6000057300. During the course of normal operations, the lamps may require replacement. Replacement lamps are available at your authorized Lionel Service Center or from Lionel Service.

1. Carefully pry out the searchlight lens. Refer to Figure 9.

2. Unscrew the expired lamp and remove it from the socket.

3. Install the replacement lamp.4. Press the searchlight lens back into position.

Replacing the caboose lamp

Your Square Window Caboose is illuminated by one lamp, Lionel part no. 6000057300. During

the course of normal operations, the lamp may require replacement. Follow these steps and refer to Figure 10 as you replace the lamp.

1. Turn over the car and locate the lamp socket attached to the frame.

2. Grasp the lamp socket by the two tabs and rotate it clockwise 90 degrees. Lift the socket straight out of the frame to expose the lamp.

3. Gently rotate the lamp counter-clockwise, then pull it straight up and out of the socket.

4. Install the replacement lamp and reassemble the car, following these steps in reverse order.

Lionel part no. 6000057300

Tabs

Lamp socket

Bottom of the caboose

Figure 10. Caboose lamp replacement

Figure 9. Searchlight lamp replacement

Lens

Screwdriver

Lionel part no. 6000057300

©2013 LIONEL L.L.C., CONCORD, NC 28027UNITED STATES OF AMERICAPRINTED IN CHINA

Lionel Limited Warranty Policy & Service

This Lionel product, including all mechanical and electrical components, moving parts, motors and structural components, with the exception of LIGHT BULBS, LED’s & TRACTION TIRES are warranted to the original owner-purchaser for a period of one

year from the original date of purchase against original defects in materials or workmanship when purchased through a Lionel Authorized Retailer*.

This warranty does NOT cover the following:• Normal wear and tear• Light bulbs or LED’s• Defects appearing in the course of commercial use• Damage resulting from abuse/misuse of the product

Transfer of this product by the original owner-purchaser to another person voids this warranty in its entirety. Modification of this product in any way; visually mechanically or electronically, voids the warranty in its entirety.

Any warranted product which is defective in original materials or workmanship and is delivered by the original owner-purchaser (this warranty is non-transferrable) to Lionel LLC or any Lionel Authorized Service Station MUST be accompanied by the original receipt for purchase (or copy) from an Authorized Lionel Retailer*, will at the discretion of Lionel LLC, be repaired or replaced, without charge for parts or labor. In the event the defective product cannot be repaired, and a suitable replacement is not available, Lionel will offer to replace the product with a comparable model (determined by Lionel LLC), if available. In the event a comparable model is not available the customer will be refunded the original purchase price (requires proof of purchase from the Authorized Lionel Retailer* it was originally purchased). Any products on which warranty service is sought must be sent freight or postage prepaid (Lionel will refuse any package when postage is due). Transportation and shipping charges are not covered as part of this warranty.

NOTE: Products that require service that do not have a receipt from an LIONEL AUTHORIZED RETAILER* will be required to pay for all parts required to repair the product (labor will not incur a charge) providing the product is not older than 3 years from date of manufacture and is within 1 year from date of purchase. A copy of the original sales receipt is required.In no event shall Lionel LLC be held 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 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 LLC product is required; bring the item, along with your DATED sales receipt and completed warranty information (at the bottom of this page) to the nearest Lionel Authorized Service Station. Your nearest Lionel Service Station can be found by calling 1-800-4-LIONEL or by accessing the website at www.lionel.com.

If you prefer to send your Lionel product directly to Lionel, for repair you must FIRST call 586-949-4100 extension 9105 or FAX Lionel at 586-949-5429 or write to Customer Service, 26750 Twenty Three Mile Road, Chesterfield, MI 48051-2493. Please have the 6-digit Lionel product number, the date of original purchase, the dealer where the item was purchased and what seems to be the problem. You will receive a return authorization (RA) number to ensure your merchandise will be properly tracked and handled upon receipt at Lionel LLC.

Once you have your Return Authorization (RA) number, make sure the item is packed in its original Styrofoam inner container which is placed inside the original outer display box (this will help prevent damage during shipping and handling). This shipment MUST be prepaid and we recommend that it be insured with the carrier of your choice.

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 Lionel LLC’s Authorized Service Stations after its warranty has expired. A reasonable service fee should be expected once the product warranty has expired.Warranty Information Please complete the information below and keep it, along with your DATED ORIGINAL SALES RECEIPT. You MUST present this form AND your DATED SALES RECEIPT when requesting warranty service.

*A complete listing of Lionel Authorized retailers can be found by calling 1-800-4-LIONEL or by visiting our website at www.lionel.com.

Products that are more than 3 years old, from date of manufacture, are not applicable for warranty coverage, even if they have never been sold prior to this date. (Under no circumstance shall any components or labor be provided free of charge.)

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