73-1931-2504/02

Rev. 1

CAUTION—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: 20 V; 54 VA

Ballyhoo Brothers Circus TrainReady-to-Run O-27 Set

Owner’s Manual

Congratulations!

2

Congratulations on your purchase of theBallyhoo Brothers Circus Train Set! This

whimsical set features a powerful Hudsonlocomotive, a chase gondola, an elephantsweeper car, a bobbing head clown car, and

a caboose. With a transformer/controllerand 16 sections of track, you haveeverything you need to start on youradventure!

Table of contentsTrack layoutJoining the track sections 3Suggested track layouts 4Attaching the Lock-On to the track 4

Controller operationsStripping the wire 5Attaching the controller wires to the Lock-On 6Connecting the Uncoupling Track section 7Controller functions 8Controller and short circuits 9

Locomotive operationRunning your locomotive with a Lionel transformer 10Locking your locomotive into a single operational state 11Lubricating your steam locomotive 12-13Replacing your locomotive’s Traction Tires 13Adding smoke fluid to your locomotive’s smoke generator 14Replacing your locomotive’s lamp 14

Train operationCoupling 15Operating your Elephant Sweeper Car 16Replacing the lamps in your Elephant Sweeper Car 16Installing the clown head 17Lubricating the gear on your Chase Gondola 18Replacing your square window caboose lamp 19Limited Warranty/Lionel Service 20

The transformer included with this set should be periodicallyexamined for conditions that may result in the risk of fire, electricshock, or injury to persons (such as damage to the output cord,blades, housing, or other parts). In the event that such conditionsexist, the transformer should not be used until properly repaired.

Parents!

The following Lionel marks may be used throughout this instruction manual and are protected underlaw. 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™

Joining the track sections

Join the track sections together by insertingthe pins of one track section into the open

ends of another. For good electrical contact, thepins must be carefully inserted and the trackjoints tightly fitted.

If the track is difficult to connect, try thisinstallation tip. You can “break in” O gaugetrack sections by inserting and withdrawing atrack pin into one rail at a time before joiningthe entire track section as illustrated in Figure 1.

If the openings become too large (causingthe track to fit loosely), pinch the rail togetheraround a track pin with a pair of pliers. If anypins fall out of the track and are missing, replacethem with extras available from your Lioneldealer.

Maintenance tip: The rails should be keptclean, dry, and free from oil and grease. Cleanrust and dirt spots with a track eraser. Wipe thetrack using a cloth dampened with track cleanerfrom the Lionel Maintenance Kit (6-62927),available from your nearest Lionel Dealer.

Track layout

3

Ballyhoo Brothers Circus Set Inventory

• 4-6-4 Hudson locomotive andtender

• Chase gondola• Elephant sweeper car• Bobbing head clown car• Caboose• Controller• 40-watt power pack

• Lionel Lock-On• Seven sections of straight track• Uncoupling track section• Eight sections of curved track• Smoke fluid• Owner’s Manual• Service Center list• Warranty card

Figure 1. “Breaking in” your track

Attaching the Lock-On to the track

The Lock-On connects power from yourcontroller to the track. As illustrated in

Figure 3, attaching the Lock-On to the trackis quick and easy. First, place the Lock-Onunder any straight section of track. Fit thecenter lip of the Lock-On onto the edge of anoutside rail. Press the Lock-On upward sothat the spring contact snaps onto the center

rail. The Lock-On should face outward whensetting up your track. Make sure it is firmlyconnected.

Once the Lock-On is securely attached tothe track, you are ready to insert the wiresfrom the controller into the two spring clipson the Lock-On.

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LIONEL CTCLOCKON

Track layout

4

Suggested track layouts

Figure 2 provides some examples oflayouts you can build with eight straight

and eight curved sections of track.Remember—the more track you own, themore variations you can create in your trainlayout. And that means more action andmore fun!

We recommend that you do not setup your track layout on carpeted

surfaces. Carpet fibers may collect on yourengine’s wheels and drive gears, preventingyour engine from operating properly. Forbest results, place the track on a hard surface.

Figure 2. Track layout ideas

Figure 3. Lock-On installation

Note!

Controller operations

5

Stripping the wire

Once your track is assembled and theLock-On is securely attached, you can

connect the wires from the controller to theLock-On.

First you’ll want to check the ends of thewires to make sure that the insulation isstripped back about 1⁄4˝ to 3⁄8˝. To strip thewires, use a pair of wire strippers or a sharpknife as illustrated in Figure 4.

Only an adult should performthis task! Always use care whenstripping wires.

Figure 4. Wire stripping

Caution!

Controller operations

6

OFF

FULL

SPEED

R

Attaching the controller wires to the Lock-On

Now you’ll need to insert a controllerwire 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 theexposed opening. Release the spring clip.Give the wire a little tug to make sure it’ssecure. Repeat these steps with the otherspring clip. Next, insert the small plug endof the power pack into the back of your

controller, and plug the other end into astandard outlet.

If the circus sounds fails to operatewhen you press the sound button onyour controller (see page 8), removethe wires from the Lock-On andreinsert each one into the oppositeclip to reverse polarity.

Plug this end intoback of controller.

Plug power packinto standardwall outlet

Make sure that the bare end ofeach wire is securely attachedto the spring clip.

Figure 5. Controller connections

Note!

Controller operations

7

Connecting the Uncoupling Track section

The Uncoupling Track section is used touncouple the cars and to activate the

Elephant Sweeper Car. To hook it up, justfollow these instructions and refer to Figure 6.

1. Attach one wire to the underside of theelectromagnet and connect it to one of

the terminals on the Lock-On controllerbutton.

2. Attach the second wire to the otherterminal on the controller button andattach it to Lock-On terminal No. 1.

Uncoupling button

To transformerElectromagnet

Figure 6. Uncoupling Track connections

Controller operations

8

Controller functions

As you turn the throttle control knob tothe right, power to the track is

increased. Refer to Figure 7 for the locationof the throttle control knob. When theindicator reaches the green band, thereshould be sufficient power to operate thelocomotive. The farther into the green areathe knob is turned, the faster your train willgo. Remember that the greater the load onthe engine (adding more cars for the engine

to pull, for example), the farther into thegreen the knob must be turned before it willoperate the locomotive.

The yellow band indicates the averagepower range that the train will be operatingin. The red band represents maximumpower output.

Figure 7 illustrates the location andfunction of the LED and the whistle anddirection buttons.

FULLFULLSPEEDSPEED

OFFOFF

R

FULLSPEED

OFF

Press this button to goforward or reverse, or toplace the locomotive in“neutral” (no movement,headlight is on).

Turn the throttle controlknob to the right formore power.

The LED indicatorshows when yourcontroller is ON.

Green band

Yellow band

Red band

FULLSPEED

OFF

FULLSPEED

OFF

Figure 7. Controller functions

FULLSPEED

OFF

Press the soundbutton to activate thecircus sounds in thetender.

Controller operations

9

Your Lionel power pack is listed byUnderwriters Laboratories Inc. and has

been carefully designed and tested to ensurepeak performance. The controller isequipped with a built-in electronic circuitbreaker that alternately cuts off and restoresthe flow of power to the track whenever ashort circuit exists—for example, when thetrain derails. The circuit breaker’s actioncontinues until the cause of the short circuitis eliminated. This circuit breaker isincorporated into the controller to protect itfrom possible damage. It will not protect thelocomotive or electrically operatedaccessories, so it’s important to eliminateshort circuits as soon as possible.

The power pack must beunplugged from the wall socketwhen a short circuit is noticed,and the short circuit must be corrected.

A short circuit is caused by a directconnection between the center rail and oneof the outside rails or by a direct connectionbetween bare wires. The axles of a derailedcar or locomotive are the most frequent

cause of short circuits, so make sure that allwheels are properly set on the rails. Someother causes of short circuits might bestaples, nails, paper clips, or other metallicobjects lying across the rails, or two barewires touching each other.

If too many cars or accessories are used,your controller will exceed its power limitand begin to cycle on and off. To correct thisproblem, cars or accessories must beremoved before normal operation canresume. For more power, see the line ofLionel high-output transformers at yourAuthorized Lionel Value Added Dealer.

The same condition can occur if thepower is turned up too quickly. This alsocould cause your train to move too fast andderail.

After your power pack has beenoperating for a while, you will find it warmto the touch. It is the nature of all electricalpower equipment to become warm when inuse. If your controller is loaded to capacity,it is a good idea to let it cool down after anhour or two of continuous use. Unplug thepower pack from the wall when thecontroller is not in use.

Controller and short circuits

Note!

Locomotive operation

Move ‘em out!

Place your locomotive on Lionel or Lionel-compatible O gauge track.• With track power OFF, connect the drawbar between the locomotive and tender as

illustrated in Figure 8.

11

Running your locomotive with a Lionel transformer

Power up your steam locomotive with your transformer.

• Your locomotive is designed to operate on 8-16 volts alternatingcurrent. Virtually all Lionel and Lionel-compatible alternating-currenttransformers are suitable.

Do not power your locomotive with direct current (DC). Damage tosensitive electronic components may occur.• When you first power up your track, your locomotive’s headlight

will illuminate. At this point, the locomotive is in neutral. When the power isremoved and again applied (by pressing the Direction button on yourcontroller), the train will move forward. This condition holds true if the engineis being powered up for the first time or if the engine has been powered down forlonger than five seconds.

• Get your locomotive moving. Press the DIRECTION button on your Lioneltransformer. This advances the Lionel reverse unit to the next operating state inthe repeating sequence: forward, neutral, reverse, and neutral.

• Adjust track voltage until your locomotive moves at your desired speed. Toincrease speed, increase track voltage. To decrease speed, reduce voltage. To stopthe locomotive, turn off track power.

• See page 11 for information on locking your locomotive into asingle operating state.

33

44

Add smoke fluid to the locomotive or switch the smokegenerator off.• See page 14 for more information.

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10

Figure 8. Drawbar connection

Caution!

11

Locomotive operationLocking your locomotive into a single operational state

The reverse unit inside your Lionellocomotive is an electronic device that

acts like the transmission in your car. Whenyou apply power to the track, the locomotivemoves in the direction specified by thereverse unit—or it sits in neutral, awaitinganother power interruption. Powerinterruptions are the signal that tells thereverse unit to sequence to the nextoperational state.

To interrupt power and sequence thelocomotive’s reverse unit, press the directioncontrol button or turn the throttle to theOFF position and then ON again. Thereverse unit alternates between these states:forward, neutral, reverse, and neutral.

Also, the locomotive can be “locked” intoa particular mode of operation by throwingthe reverse unit switch located on theunderside of the frame (see Figure 9). When

the switch is thrown to the OFF position, thelocomotive will be locked in the next modeof operation in the sequence. For instance, ifthe locomotive is moving forward, then isstopped and the switch is thrown back, thelocomotive will be “locked” in neutral. Ifthe switch is thrown to the OFF positionwhile the locomotive is under power, thelocomotive will remain in the mode it wasin when the switch was thrown. Thecontroller direction button will then have noaffect on the direction of the locomotive.

Should the locomotive sit without powerfor a short period of time, the reverse unitwill automatically reset and start in theforward direction when the transformer isturned on, regardless of the reverse unitswitch position. If the switch is in the OFFposition, the locomotive will start in theforward direction and be “locked” there.

Figure 9. Switch locations

OFF ON

Reverseunit switch

SmokeON/OFF switch

OFF ON

Rear

of

loco

mot

ive

Locomotive operation

12

Help your Lionel steam locomotive lead along and productive life on your railroad

by maintaining it properly. We recommendthat you purchase a Lionel Lubrication andMaintenance Kit (no. 6-62927), availablefrom your Lionel dealer. Two basic rules tokeep in mind: never over-lubricate (a smallamount will do), and avoid getting grease oroil on the steam locomotive’s wheels, contactrollers, or your track.

You’ll know your steam locomotiverequires lubrication when visual inspectionreveals dryness on the parts indicated in theFigure 10 below. Remove accumulated dirtand dust before lubricating, and alwayslubricate any locomotive emerging fromprolonged storage. Also, lightly lubricate thesteam locomotive’s side rods after every 10hours of operation.

Lubricating your steam locomotive

Lubricate axle endswith Lionel oil sparingly

Lubricate axle endswith Lionel oil sparingly

Cab screws Lubricate with Lioneloil sparingly

Lubricate rod ends, both sideswith Lionel oil sparingly

Cab screw

Lubricate with Lionel grease sparingly

Figure 10. Lubrication points

Locomotive operation

13

Lubricating your steam locomotive (continued)

Do not lubricate your locomotive’s electricmotor. It has been pretested and all thenecessary moving parts have beensufficiently lubricated for life at the factory.

If you have any difficulty in the operation ofyour engine, see the Lionel Service sectionfor more information.

Replacing your locomotive’s Traction Tires

Two of the drive wheels are fitted withrubber Traction Tires to enhance tractive

effort, allowing your locomotive to pullmany cars at once.

To replace the Traction Tires, simplyunscrew the drive rod nut from the wheel

and slip off the old Traction Tire. Remove itfrom under the drive rod. Place the new oneon the wheel and retighten the drive rodnut. You’re ready to pull that long freightback to the yard.

Your locomotive’s headlight isilluminated by one lamp. During the

course of normal operation, the lamp mayrequire replacement.

Carefully remove the three cab screws (seepage 12 for their locations). Set the engine onits side and carefully pull the front of theframe away from the cab. Refer to Figure 11below. Be careful you do not bend the drawbarthat connects the engine to the tender. The

replacement lamp (600-2314-300) isavailable from your Authorized Lionel ServiceCenter or Lionel Service. See the Lionel Servicesection on page 20 for more information.Remove the expired lamp by unscrewing itand install the replacement lamp. Reinstallthe cab and the three screws taking care to notpinch any wires during reassembly.

Check to be sure the smoke stack isaligned with the smoke generator.

Replacing your locomotive’s lamp

LampPart No. 600-2314-300

Locomotive operation

14

Adding fluid to your locomotive’s smoke generator

Y our locomotive is equipped with asmoke generator that produces safe,

clean, white smoke during operation.The smoke generator requires the periodic

addition of Lionel smoke fluid in order tofunction. Pierce the tube end with a pin,then add four to eight drops of fluid directlyinto the locomotive’s stack. Smokeproduction will commence momentarily,faster if you run your locomotive at speed.When smoke production wanes, add morefluid (four to eight drops).

If you prefer smoke-free locomotive

operation, there is a switch located on thebottom of the engine under the cab (seepage 11 for its location). Move the switch tothe OFF position and your locomotive willstop smoking.

When the smoke unit is on always keep asmall amount of smoke fluid in thelocomotive’s smoke generator; thegenerator’s element can become damaged ifoperated without fluid. Smoke production isgreater at higher voltages and when thelocomotive is pulling a heavy load or longconsist.

Figure 11. Lamp replacement

Train operation

15

Coupling

When coupling your cars, at least one ofthe mating couplers must be open as

shown below at the left. Simply press down on

the lock release to open the coupler, then pushthe cars toward each other until they locktogether as illustrated in Figure 12.

Keep in mind that it’s easier to couple cars on a straight stretch of track.

Lock release

Figure 12. Coupler operation

Note!

You may also uncouple your cars byremote controlling using the UncouplingTraction section. Simply position thecoupler “trigger disc” over the central coil

and press UNCOUPLE on the controller. Thedisc is pulled downward, and the coupleropens. Refer to Figure 13.

Figure 13. Magnetic coupler operation

Operating your Elephant Sweeper Car

Use the Uncoupling Track section to trigger the Elephant Sweeper Car.

1. Close the door to set the trigger mechanism.

2. Position the trigger disc at the bottom of the car over the magneticuncoupling disk on the Uncoupling Track.

3. Press UNCOUPLE on the Uncoupling Track controller.

4. The door slides open, and the figure appears to sweep out the car.

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Replacing the lamps in your Elephant Sweeper Car

Your Elephant Sweeper Car is illuminated by two lamps. During the course of normaloperation, these lamps may require replacement. Replace the lamps with Lionel part

no. 600-8352-311, available from your authorized Lionel dealer.

1. Remove the screw at the brake wheel end of the car.

2. Separate the body from the frame. Lift the brake wheel end of the body off of the frame, then slide the body forward. The twotabs at the other end of the car will slide back through the slots in the body.

3. Locate and remove the expired lamp. Pull the lamp straight up and out of the socket. Refer to Figure 14.

4. Replace the lamp with Lionel part no. 600-8352-311.

5. Replace the body.Slide the stamped metal tabs into the slots in the body. Press the opposite end of the frameinto position, then replace the screw.

Be sure the door is closed and the trigger is set when you replace the body.

Figure 14. Elephant Sweeper Car lamp replacement

Note!

Train operation

17

Train operationInstalling the clown head

To install the clown head to the bobbinglever inside the car, remove the boxcar

body from its frame. The body isn’t screwedtogether to the frame, so a gentle prying atthe bottom of the boxcar body will unsnap itfrom its frame. After the figure head issnapped onto the peg of the bobbing lever,

carefully snap body back into place so thatthe clown head will rise through hole in roofof the boxcar. Refer to Figure 15.

Once the clown head is in place, you areready to operate the car. The faster the traingoes, the quicker the clown will bob up anddown.

Bobbing lever

Figure 15. Figure attachment

18

Train operation

Your animated gondola is equipped witha gear drive mechanism that propels the

two figures around the crates in the centerof the gondola when the car is moving.

Occasionally, the worm gear may needlubrication. You can determine this bysimply inspecting it periodically. If you see

little or no lubrication on the worm gear, it’stime to add a small amount lubricant. SeeFigure 16. We recommend that you purchasethe Lubrication/Maintenance Set (6-62927),available at your Authorized Lionel Dealer.

Lubricating the gear on your Chase Gondola

Figure 16. Chase Gondola worm gear lubrication

lubricate the wormgear sparingly

If the crate load retainers become detached, make sure that they are pushed back downcompletely.

Note!

Train operation

19

During the course of normal operation,the lamp inside your caboose may

require replacement. Follow these steps andrefer to Figure 17.

1. Pull out the end frame tab fromthe slot formed by the caboosebody and roof. The end frames arehinged to the platform. This allows theend frame to bend downward, away fromthe body.

2. Lift off the roof from the windowshell and body.

3. Remove the window shell. Thewindow shell is held in place by fourtabs on the sides of the shell (two oneither side) that lock into the windowson the caboose. To remove the window

shell, carefully separate the sides of thecaboose while pulling up on the windowshell until the tabs are released from thewindow.

4. Remove the lamp, pull it straightup. Replace it with Lionel bulbno. 600-8352-311, available at yourlocal Lionel Authorized Service Center orLionel Service.

5. Insert the window shell back intothe body, making sure that thetabs snap into the windows.

6. Insert the roof into the windowshell.

7. Fit the tabs on the end framesinto the corresponding slotsformed by the roof and body.

Windowtab

Window shell

End frame tab

End frametab

Hinge

Lamp no. 600-8352-311

Replacing your square window caboose lamp

Figure 17. Caboose lamp replacement

Limited Warranty/Lionel Service

This Lionel product, including allmechanical and electrical components,moving parts, motors and structural

components, except for light bulbs, is warrantedto the original consumer-purchaser, for one yearagainst original defects in materials orworkmanship when purchased through anauthorized Lionel merchant.

This warranty does NOT cover normal wearand tear, light bulbs, defects appearing in thecourse of commercial use, or damage resultingfrom abuse or misuse of the product by thepurchaser. Transfer of this product by the originalconsumer-purchaser to another person voids thiswarranty. Modification of this product voids thiswarranty.

Any warranted product which is defective inoriginal materials or workmanship and isdelivered by the original consumer-purchaser toLionel L.L.C. or an authorized Lionel L.L.C. ServiceCenter, together with proof of original purchasewill, at the option of Lionel L.L.C., be repaired orreplaced, without charge for parts or labor. In theevent the defective product cannot be repaired, anda replacement is not available, a refund of theoriginal purchase price will be granted. Anyproducts on which warranty service is sought mustbe sent freight or postage prepaid, astransportation and shipping charges are notcovered by the warranty.

In no event shall Lionel L.L.C. beliable for incidental orconsequential damages.

Some states do not allow the exclusion orlimitation of incidental or consequential damages,so the above exclusion may not apply to you.

This limited warranty gives you specific legalrights, and you may have other rights which varyfrom state to state.

Instructions for Obtaining ServiceIf service for this Lionel L.L.C. product is

required, bring the item, along with your datedsales receipt and completed warranty informationto the nearest Authorized Lionel Service Center.

Your nearest Lionel Service Center can be foundby calling 1-800-4-Lionel, or by accessing ourWebsite at www.lionel.com.

If you prefer to send your product back toLionel L.L.C. for repair in Michigan, you mustfirst call 586-949-4100 or FAX 586-949-5429, orwrite to Customer Service, P.O. Box 748, NewBaltimore, MI 48047-0748, stating what the itemis, when it was purchased and what seems to bethe problem. You will be sent a returnauthorization letter and label to ensure yourmerchandise will be properly handled uponreceipt.

Once you have received your returnauthorization and label, make sure that the itemis packed to prevent damage during shipping andhandling. We suggest that you use the product’soriginal packaging. This shipment must beprepaid and we recommend that it be insured.

Please make sure you have followed all of theabove instructions carefully before returning anymerchandise for service. You may choose to haveyour product repaired by one of our AuthorizedLionel Service Centers after its warranty hasexpired. A reasonable service fee will be charged.

Warranty InformationPlease complete the information below and

keep it, along with your dated sales receipt. Youmust present this and your dated sales receiptwhen requesting warranty service.

Name ____________________________

Address ____________________________

Place of Purchase ____________________

Date of Purchase ____________________

Product Number ______________________

Product Description____________________

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