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I recently bought a 6403B sloped back tender and have a question.  The lever on the side switches off the bell solenoid, but does not switch off the bi-metal thermo-switch.  So, the bi-metal thermo-switch constantly cycles.  Is this normal?  Wouldn’t it be better (last longer) to wire it such that the bi-metal thermo-switch is switched off with the bell solenoid?  TIA, Rick

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You are correct. The switch only turns off the bell, not the bimetallic strip heater. That design goes back to the late 1930s. Considering how many of those tenders are out there with the bimetallic  heaters on continuously, it does not look like the as built design was a problem.   One thing to watch is that, as best as I can tell, Lionel intended those switchers to run on 12 to 14 volts. A higher voltage would shorten the life to the heating wire on the bimetallic strip. 

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OGR Publishing, Inc., 1310 Eastside Centre Ct, Ste 6, Mountain Home, AR 72653
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