Lionel The Polar Express Train Set - Answered Questions & Fixed issues

I have used 18ga lamp wire but you can use wire as thin as telephone wire. My rule of thumb is to use thicker wire (lower gauge number) the more motors on the train you are running. 20 or 22ga is generally used by most.

indicates a dead short to ground in the smoke unit that is overloading the transformer replace/repair the smoke unit

You've done the right thing by talking with Lionel. Their techs should be able to guide you trough trouble shooting as it seems that you have some knowledge of electronics.

electric trains that sit for a few years require cleaning (yeah I know how'd it get dirty in the box ) but its not the same kind of dirt u/I see its a type of oxidation called corrosion , and it affects the metal parts of set , IE: tracks , wire connectors, engine power pick-ups on bottom of engine they ALL get this light powdery stuff on them this "stuff" will not pass power over to engine and it will not run , this powder can be easy removed with a light rub of 3M scotchbright pad , I don't recommend using steel wool , but I have in a pinch before and 4 sure don't use brillo as this has soap in it (worse than powder)

Lionel uses insulated wheels on there power pickup trucks , one side will have insulation bands and one will not , insulated bands need to be all same side on same truck , lead end is different than tail end this is how it picks up power from tracks , sometimes trucks axles get popped out in playing and maybe don't get popped back in the same way , also its possible for insulating bands to get holes in them from use , a dot or two of black latex paint fixes these up (don't paint entire wheel)

I am assuming you are using the Lionel CW80 power source. If so, the blinking light might indicate a partial short or a problem with the motor. The reason I believe that is that the CW80 has an internal fuse, which will blow for near shorts/shorts. A stalled motor i.e stuck drive gear, can cause excessive power drain although not enough to blow the internal fuse and also cause the engine not to move. Also, If the engine has the neoprene belt on one of the drive wheels it might have come off and is jamming the running gear or wheel. I believe the Polar Express only has one neoprene belt.

I am assuming that the throttle is off when you put the train on the track. If off, then you are correct that there is an internal short in the engine. You might try disassembling the unit and looking for a pinched wire specifically from a roller(s) (center rail pickup). You might also check for a short between a pickup roller and a wheel with a VOM. Make sure the wheel is not the one with the neoprene belt.

Have you let the loco charge first? The instructions are a bit vague but the loco needs to charge before it runs. Not easily understood from the instructions and many have spent some frustrating hours wondering why their train wouldn't move.

You will have to solder them using a pencil soldering iron.

see attached pdf, page 7: http://www.lionel.com/media/servicedocuments/6596730220250FTPsgrStreamlinerSet.pdf

CLEAN wheels, roller pickups & track.

There are more than just one Polar Express set. What's the set number?

You could try contacting the Lionel Service Department on their website contact service. Contact Lionel Trains

Have you let the loco charge first? The instructions are a bit vague but the loco needs to charge before it runs. Not easily understood from the instructions and many have spent some frustrating minutes wondering why their train wouldn't move.

Strange indeed? Is there more that power to track connector going to the track. If so one may have been incorrectly orientated? The only other thing I think of that would cause a short between the two rails on the track is perhaps a set of dodgy points. sorry couldn't be more helpful.

It sounds like the gears have worn out or come adrift somehow. You will be able to get replacement gears from any of the Lionel authorised dealers Lionel Authorized Dealers or their replacement parts service Replacement Parts

The instructions are sometimes a bit vague: for example, once switched on the train needs to sit and charge before it runs, but that is not very evident from the instructions and many folks spent some frustrating minutes wondering why the train wouldn't move.

Check with the store you purchased it from. If they don't repair trains they should be able to direct to one that does. You're not the first person to need repairs so they will know.

Power wire to the center track and ground to the other terminal. You can turn over the track to see which terminal goes where.

Remove the shell. Soak up as much as you can. Leave out to dry or use a hair dryer on low until controls are dry.