THE GILBERT HALL American Flyer Operating And Assembly Instructions Manual Download Page 4

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C O N T E N T S

Planning the Railroad

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Suggested Track Layouts

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Wiring Diagram for Train Layout

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Preparing the Right of Way

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Using Rubber Roadbed

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Building Grades

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Assembling the Track

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Attaching the Track Terminal

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Jumper or Feeder Lines

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Reverse Loops

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Building Scenery

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Transformers

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Locomotive Reverse Units

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Switches

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Uncoupler

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Automatic Action Cars

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Illuminated Equipment

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Operating

Equipment

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Track Trips

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Scenic Structures

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The Airchime Whistle

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Using Equipment with 3-Rail Track

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Track Maintenance

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Maintenance of Rolling Stock

Smoke and Choo-Choo Units

Testing the Locomotive

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Miscellaneous Tips

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Lamp Data

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Summary of Contents for American Flyer

Page 1: ......

Page 2: ...Instructions Suggestions and Helpful Hints for Planning and Operating your RAILROAD Developed at T H E G I L B E R T HALL O F S C I E N C E ...

Page 4: ...mper or Feeder Lines 16 Reverse Loops 16 Building Scenery Transformers 19 Locomotive Reverse Units 22 Switches 23 Uncoupler 26 Automatic Action Cars 27 Illuminated Equipment 31 Operating Equipment 32 Track Trips 33 Scenic Structures 52 The Airchime Whistle 53 Using Equipment with 3 Rail Track 54 Track Maintenance Maintenance of Rolling Stock Smoke and Choo Choo Units Testing the Locomotive 59 Misc...

Page 5: ...e an example of your skill and handiwork Such an achievement can easily become a reality for American Flyer engineers and technical experts of the Gilbert Hall of Science have created dazzling new features in scale model trains and equipment for the further perfection and realism of miniature railroading On the following pages you ll find suggestions and helpful hints for plan ning and operating y...

Page 6: ...he express become green again and the freight train proceeds to a factory siding at the out skirts of town where it picks up a car of scrap iron just loaded by a mag netic crane Thundering along it crosses a highway over a massive girder bridge and pulls into an oil depot uncoupling and leaving several tank cars of gasoline As it travels on it enters an open switch onto a passing siding The switch...

Page 7: ...ack and the size space needed for them The size and shape of the space which is available to you for your railroading will determine what type layout you can use It should be designed to provide for future addi tions The more switches track and equipment you add to your layout the more interesting your railroad becomes ...

Page 8: ...7 ...

Page 9: ...METHOD OF WIRING TRACK 8 ...

Page 10: ...CONVENIENT METHOD OF WIRING EQUIPMENT ...

Page 11: ...e not less than 44 wide Note space required for different layouts as illustrated on pages 6 and 7 Size of table is deter mined by the layout you decide to make When permanent layouts are not practical by permanent layouts we mean a complete layout on a solid table which will not be moved it is a good idea to mount track layouts permanently to plywood panels so they can be picked up in sections and...

Page 12: ...d down with small nails or brads using the holes provided in the ties Do not tighten down on the nails to the extent that the roadbed is distorted USING RUBBER ROADBED The above mentioned process of making a realistic looking roadbed is one which takes considerable time and special tools to accomplish Therefore American Flyer engineers have developed a very realistic looking rubber road bed into w...

Page 13: ...or a transfer of noise through the nails to the table top For additional realism the built in ties on the rubber roadbed can be blackened to match the ties on the track this can be done with a black ink or a marking brush Where spaces are needed to locate special track trips or operating mech anisms the rubber can be cut away In cases such as the 697 Track Trip it may be necessary to place a heavy...

Page 14: ...ts as shown in Fig 7 Tack the two pieces of wood together then mount them to the table top so that the gradual rise is accomplished then fasten a strip of plywood across the top of the uprights this will be used for the track bed Screen can then be tacked from it to the table top to build up the scenic effects as described on page 19 The steeper the grade the greater the tractive power of the loco...

Page 15: ...u fasten it down To test it electrically fasten one wire to the Base Post of the transformer and one wire to the 7 to 15 Volt Post turn the handle half way open Be sure that transformer is plugged into a regular 110 120 Volt A C 60 Cycle outlet brush the bared ends of the wires together and see that you get a small spark This indicates the transformer is alive Now hold the bared end of one of the ...

Page 16: ...marked BASE POST on the track terminal to the BASE POST on the transformer Connect the WHITE wire from the remaining terminal clip to the 7 15 VOLT POST on the transformer as shown in Fig 12 below If the terminal is used to supply track current to a piece of equipment the wires C and D are connected to the two terminals on the equipment unless equipment instruc tions read otherwise When wiring the...

Page 17: ... is used when using an airchime whistle control box and do not run jumper wires direct from the transformer REVERSE LOOPS In designing and wiring layouts some people have encountered difficulty in the attempt to incorporate a reverse loop This is a convenient method of reversing the direction of travel of the train Therefore we have packaged a No 698 Reverse Loop Kit which contains the necessary d...

Page 18: ...n thrown to receive the train from section 3 When the double pole double throw switch is thrown it does not affect the current in section 2 on which the train is operating at the time the changes in polarity are made In cases where the track forms two reverse loops as in diagram No 15 the hook up should be made as shown and while the locomotive is in the insu lated section the double pole double t...

Page 19: ... of the layout and use a long string of tank cars hauled by a No 370 General PurposeDiesel switcher and the scene cannot be beaten for realism On the highway leading out of the railroad yard where it crosses the tracks a No 592A Crossing Gate could be used blocking the path of small automobiles such as are found in any Toy Store while your train passes With the help of log and coal loaders automat...

Page 20: ...ss beneath it A small boat and a wharf or bridge will complete this interesting feature Mountains serve as a most suitable background for your rural scenery They are not too difficult to make A rough frame covered with paper or wire mesh or even heavy sheathing paper purchased from any lumber company and crumpled into a satisfactory shape supplies the foundation Over this pour a mixture of asbesto...

Page 21: ...it or overload occurs the red pilot light lights and the breaker opens the circuit to prevent damage to the transformer When the short or overload has been cleared the breaker is reset by simply pushing the Reset Button located on the top of the transformer nsformers are not equipped with the reset button but have a built in thermostatic circuit breaker which automatically resets itself when the s...

Page 22: ...1 115 25 Watts 60 Cycles 7 15 Volts 2 115 75 60 7 15 15Volts 4B 115 100 60 7 15 15 8B 115 100 60 7 15 15 12B 115 250 60 7 15 15 19B 115 300 60 7 15 15 TO CHECK THE TRANSFORMER Press Reset Button to be sure it is down Turn the lever half on Connect one end of a piece of wire to the Base Post and touch the 7 to 15 volt Post very lightly with the other end DO NOT HOLD THE WIRE ON THE 7 15 VOLT POST J...

Page 23: ...ons In other words the current must be turned off and on twice To make the control inoperative that is to make the train continue in the same direction irrespective of the number of times the current is broken shift the locking lever on the control unit On some Locomotives this protrudes from the top of the Locomotive and on others it protrudes from the bottom of the tender This locks the control ...

Page 24: ... layout the same as a piece of straight or curved track and hook up the wires from the control box as shown in Fig 19on Page 24 For Use With Transformer Hook the single YELLOW wire from the control box to the 15 VOLT POST on the transformer and the single BLACK wire to the BASE POST The two 4 wire cables go to the two switches and the various colored wires are attached to the corresponding colored...

Page 25: ...layout Use the Control Box levers to throw the switch frogs do not throw them with the manual lever unless frog should stop in a center position or hot close properly then use the manual lever to throw frog all the way over Best performance will be obtained if trains are run through switches at a moderate rate of speed lamp with a G 18 Volt lamp No 453 To change lamp bulb remove the two screws on ...

Page 26: ...f the switch on both the curved and straight sections Keep the trip about two sections of track from the switch Hook the control box to the switches as instructed Next hook wire A from clip 1 on the one track trip to the 15 VOLT POST on the transformer Connect the 2 No 1clips on track trips with wire B Connect wire C from the No 3 clip on the track trip which is on the Connect wire D from the No 3...

Page 27: ...tive to move forward you have your train assembled To uncouple cars automati cally is just as simple INSTRUCTIONS FOR OPERATING REMOTE CONTROL AUTOMATIC UNCOUPLER NO 706 The operation of the Uncoupler is very simple With it you can uncouple cars on a curve as well as on a straight track It can be attached anywhere along the track simply by placing it underneath the track between two ties so that t...

Page 28: ...You can drop a load of logs coal or scrap metal then load the cars again by means of automatic loading units operated by remote control You can unload armored cars and pick up and deliver mail bags on the fly All this can be done by using the automatic cars made by American Flyer and they are easy to hook up and operate Each car comes equipped with a special rail section which clamps on the track ...

Page 29: ...d changing the wheels to the opposite side See that the bottom portion of the outside rail rests underneath the raised part of the metal strip B then turn the locking lever A to the right as far as it will go so it clamps over the bottom part of the inside rail As shown in Fig 22 there must be at least one section of straight track in front of the special rail section so that any rolling stock com...

Page 30: ...Connect the TWO YELLOW wires from the Control Box to the 15 Connect the TWO BLACK wires from the Control Box to the Terminal Run the train around the track and stop it so that the Contact Shoe which protrudes from the truck is resting on the special contact rail Press the Control Button until the platform swings out and the auto rolls off the car Then release it and the platform will swing back in...

Page 31: ...e the button and the platform will drop back in place See Fig 26 One of the greatest play value pieces of train equipment is the No 751A Log Loader which will load logs onto the above car by remote control and the log car can also be used to dump the logs onto the log loader for reloading No 718 Mail Pick up Car Directions for Wiring to a Transformer The No 713 Special Track Section is used to ope...

Page 32: ...iety of illuminated accessories to help make your railroad more realistic You will find listed in the American Flyer Catalog Stations Signal Towers Street Lights and various other items which are lighted These all come equipped with wires and can be attached anywhere along the train layout but if connected direct to the track they will not light when the transformer is shut off So to keep them lig...

Page 33: ...the power source and to the accessory it is to operate then the weight of the passing train closes the circuit just as if you were to push a button on a con trol box so in the case of a whistle or crossing gate where you would want the entire train to keep the circuit closed the trip would be adjusted so that the lightest car would close the circuit In the case of a semaphore it would be adjusted ...

Page 34: ...they pass Do not allow the train to stand on the trip for any length of time even with the transformer handle shut off as the 15 volt current will still be sup plied to the accessory and may cause overheating or burn outs PROTECT THOSE HIGHWAY CROSSINGS At practically every point where the highways cross a railroad track the railroads have placed a safety warning device of some type One of the mos...

Page 35: ... to operate when the train crosses the portion of track to which the track trip is attached the gate arms will go down and the red lantern will light INSTRUCTIONS FOR SETTING UP AND OPERATING NO 760 HIGHWAY FLASHER To hook up the No 760 Highway Flasher first determine the approxi mate location in your layout where you wish it to operate then attach the two No 696 Track Trips to the track one on ea...

Page 36: ...eate Dead Block Systems It is now possible to create a system of dead blocks which will protect your trains from rear end collisions just as they do on all major railroads today You will find the No 761 Semaphore is not only colorful and unique in operation but a very worth while piece of equipment on your pike Connecting The No 761 Semaphore At the desired location in your layout remove a section...

Page 37: ...ntrolled section WITH THE BASE POST CLIP CONTACTING THE OUTSIDE RAIL Next attach the two 697 track trips to the track at approximately the location shown in Figure 31 Information on attaching and adjusting the No 697 Track Trip will be found on page 33 In every case when using the No 761 Semaphore it is necessary that the Base Post of the transformer be connected to the Base Post clip of the No 69...

Page 38: ...er train throws the arm up thus forming a con trolled block system to protect your trains NOTE When using a locomotive with a regular sequence reverse it will be necessary to lock the remote control unit in a forward position unless a No 709 Lockout Eliminator is used TRACK TRIP NO 709 LOCKOUT ELIMINATOR This unit is designed to supply a very low voltage to a normally dead block in the track which...

Page 39: ...n we have ever seen always on the job and popping in and out of his shanty starting and stopping trains You will get thrills galore with Sam and his semaphore First determine the approximate location in your layout where you wish the Semaphore to be stationed Remove a steel pin from the outside rail in front of the place you want the Semaphore stationed and replace with a fiber pin several section...

Page 40: ...ress the green button and Sam will go back into the house the door will close the signal arm will go to an upright position and the train will start again NOTE To change the lamp loosen the small set screw in the lamp housing which will allow the socket to be pulled out to remove the lamp Use American Flyer Lamp No 452 for replacement ATTACHING THE NO 596 WATER TANK All steam locomotives have to r...

Page 41: ...0 or 453 Lamp for replacement Over the center of the track JUST LISTEN TO THAT WHISTLE BLOW To every railroad man that deep throated tone of the locomotive whistle is real music and American Flyer engineers have made it possible for you to reproduce that very soul stirring sound in your own train layout The No 566 Whistle serves two purposes it is both billboard to add realism along the track and ...

Page 42: ...3 Standard Whistle Signals Used Throughout the Country by all Railroads Approaching public grade crossing Two long one short one long Approaching station junction or railroad crossing One long Alarm for persons or animals on track Succession of short toots Apply brakes stop One short Release brakes proceed Two long Flagman protect rear of train One long three short Flagman return from west or sout...

Page 43: ...ction Pushing either button will cause the electro magnet to be energized to pick up steel scrap When button is released the motor will stop and steel scrap will be released In operating do not allow crane to revolve more than one half revolution After you operate the crane once you can place it the proper distance distance from the rail to obtain the best position for picking the load up from the...

Page 44: ...e logs on the Log Loader platform and start operation Press the GREEN button on the Control Box and a hidden elevator lifts a log up to the jaws of the overhead conveyor Press the RED button on the Control Box and the carriage will convey the log to the end of the arms and deposit it automatically into the empty car below then return for a repeat operation A spur track can be run to the back of th...

Page 45: ...king the No 752A Seaboard Coaler untie the string which holds the chute and track in place for shipment then lift the track and truck assembly forward and insert the ends of the formed wire brace into the holes in the side of the upright See that the cord is running through the various pulleys Now place the Coal Loader in the desired position in your track layout so the chute is over the track and...

Page 46: ...NG NO 752A SEABOARD COALER If the string on the Seaboard Coaler should tear or break the following directions should be followed in restringing First procure a piece of good flexible cord or light weight fish line 5 ft long Do not use a stiff or waxed cord Tie a knot in one end Fig 37 Remove the house 1 over the motor by straighteningthe 4 nibs which protrude through the slots in the base then lif...

Page 47: ...array of real railroad sounds it again starts the train on its way INSTRUCTIONS FOR SETTING U P AND OPERATING NO 755A TALKING STATION This Talking Station is designed to operate on 60 cycle current only It will operate from a transformer running the train on alternating current or from a transformer and rectifier running the train on direct current First determine the approximate position in your ...

Page 48: ...o the horn faces away from the motor and the two pins fit into the slots on the upright brackets and the needle is resting on the record BASE POST on the transformer Now start the train and as it approaches the station and the insulated portion of the track press the control box button the train will stop at the station while the train announcer makes his announcement then with a series of train n...

Page 49: ...s are available at your dealer OILING Keep all bearings well oiled Lubricate the gears with a small amount of If the lamp should burn out replace it with either a 14 or 18 volt lamp For a maximum amount of sound open the station doors Vaseline or thin grease MECHANIZED FREIGHT HANDLING Have you ever been around a large freight or express handling station Did you notice how mechanized these places ...

Page 50: ...trol box Connect the SHORT BLACK wire from the other control box clip to the BASE POST on the transformer The unit is now ready to operate and you will find by pushing the button on the Control Box that the man on the platform will go forward When button is released the man will return to his original position and be waiting for work Next pull back the sliding Plate B in Figure 1 and place the fou...

Page 51: ...do practically everything else The No 771 Stock Yard and Car is undoubtedly the most fascinating piece of equipment ever made for model railroads The real lifelike little critters mill around and troop up the ramp into the car just like their big brothers at the stockyards all over the country This foolproof unit can run continuously and not get out of order and is very simple to install NO 771 ST...

Page 52: ...ry switch on the Control Box This will cause the floor mat to vibrate and tho steers will then mill around the corral and they can be left to mill continuously RAMP INSTRUCTIONS The ramp on which the cattle travel to go into the car is movable up and down It should always be raised into the up position when not being used If left down the cars will strike it as they pass Therefore to load or unloa...

Page 53: ...ly remove the wheel and axle assembly and reverse the position of the wheels The cattle can enter either door but must leave the car from the opposite door from which they entered When loading the cattle into the car be sure the second door is closed or the animals will travel right through the car and out the door ADD A BUMPER TO THE END OF THOSE SPURS The No 730 Bumper is designed to snap onto t...

Page 54: ...442 THE AIRCHIME WHISTLE Since the great trend toward dieselization of the railroads there has been a hue and cry set up by the public complaining about the harsh sounds of the diesel horns This caused the railroads to start looking for some type horn or whistle with a more melodious tone The result was the airchime whistle which is now being used by most railroads It is fast replacing all other t...

Page 55: ...4 prongs into the holes This can only be installed one way There are two large and two small prongs which fit into their respective holes The whistle is now ready to operate place the locomotive on the track then turn power on press the Control Box button and whistle should blow If whistle is to be blown while locomotive is standing still the power should be on and locomotive reverse control shoul...

Page 56: ... short circuit This can be remedied by loosening the clamp with a sharp screwdriver and adjusting insulation to remove the short Position of insulation is shown in Fig 41 After testing your layout as described on page 14 and you find it shorted but are unable to locate just where the trouble lies each piece of track must be tested individually following the same procedure crossovers and switches c...

Page 57: ... operating efficiency To do this we recommend that your locomotive and cars should be oiled every 4 hours of actual operation also before operating when YOU first get the train and after it has been put away for any length of time A small drop of oil is all that is necessary Apply oil with a toothpick or needle Always keep in mind the fact that too much oil can be just as harmful as no oil at all ...

Page 58: ...rod bearings and the valve rod DIESEL LOCOMOTIVES 1 Turn locomotive on its back and put about two drops of oil in each oil hole in bottom of power trucks Do not place oil in the holes on the non powered trucks 2 On bottom of truck is a steel cover plate and truck side assembly that can be removed by unfastening two screws This exposes the drive gears which should be lubricated with a small amount ...

Page 59: ...it in the American Flyer trains is a gear driven piston located in the front part of the locomotive boiler and forces the smoke directly out of the stack See Figure 44 TO REFILL THE SMOKE UNIT When the smoke in your locomotive diminishes and a refill is needed insert the small funnel which is packed with your locomotive into the tube in the smoke stack Then cut off the end of a nozzle on a smoke c...

Page 60: ...I f power is being picked up by your locomotive the headlight will light Considering that this is the case and still your locomotive will not run turn your transformer lever off then on several times to actuate the control on the locomotive Check the various piston and valve rods to see they are not bent and binding Look for loose or broken connections in the locomotive Examine the brushes to see ...

Page 61: ...n it on its back and press a piece of fine sand paper 00 or finer against the commutator Press lightly until the whole surface of the commutator is smooth and bright Then stop the motor and with a pointed tool such as a needle clean out the slots between he segments of the commutator It is essential that the copper dust from worn brushes or commutator be thor oughly cleaned from the slots between ...

Page 62: ...0 14 Round Clear 7 16 3 Used on all locomotives and on No 502 Cross 442 6 8 Round Clear 7 16 3 Used on No 774 Flood Light Tower 441 18 Round Red 9 16 3 Used on switch control boxes 443 18 Round Green 9 16 3 Used on switch control boxes 451 14 Round Frosted 5 8 1 Usedon No 579 and 580 Street Lights 452 14 Round Clear 5 16 1 Used on No 758 Sam The Semaphore Man 453 18 Round Clear 7 16 3 Used onNo 72...

Page 63: ...g the bracket to swing down and out To change lamps on the Diesel Switcher Locomotive the four body mounting screws must be removed This will allow the body to be lifted off so lamp can be replaced If the truck side assemblies are removed from the trucks first the body mounting screws will be easier to remove CARS With thumb and first finger on the two wings at the edge of the lamp bracket in the ...

Page 64: ...n the track farthest from the trans former in large layouts to prevent trains from slowing down DO Attach the track terminal in a section which will not become dead if between two Remote Control Switches DO Set the Remote Control Switches for Regular Operation unless a dead siding is desired DO Remove the transformer plug from outlet when through operating your train DO Make sure you have proper e...

Page 65: ... shorts DON T Place locomotive or cars on the track while current is turned on DON T Run trains at full speed around the curves or through switches DON T Use a transformer of less wattage than recommended in the catalog DON T Attempt to use 110 volt current without the transformer DON T Plug transformer into Direct Current or any current not specified on the item DON T Connect equipment or lamp to...

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THE GILBERT HALL American Flyer, Operating And Assembly Instructions Manual

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