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I have a Lionel 6403B bell-ringing tender which I believe the bi-metallic thermal switch is non-functional (the solenoid coil works fine). I searched the OGR forum and someone mentioned Trainz.com but I don't see the part listed anywhere. Another poster said it's the same switch in the Lionel 455 oil derrick, and another mentioned a modern circuit board but that person did not give any specs about what board to use or where to get it. Other searches described how one could rewind, and hopefully, repair it ---- that may be my only option.
Anyway, just wondering if others have any leads to getting either a replacement switch or an appropriate substitute.
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There was an article on another source where the author suggested using a turn signal flasher from a motorcycle.  Not the newer electronic style but the older electro-mechanical type.

"Well what else uses a bi-metallic strip to run on/off.   Old style automotive blinkers.  The old mechanical, round, short, NOT heavy duty ones with just 2 connectors.   The specs on my blinker was 12v 10W 2 pin.  It was for a motorcycle, light duty.  The AC current will fry electronic ones.  Essentially the bi-metallic strip is inside the blinker.  Cheap at most auto stores.   Get housing as short as possible. Around 1” high.  I cut both connectors down at the base so just the flat base of the connectors were left.  To be short enough to fit in the front of the tender.   I had a wire from the center pickup soldered to one of the blinker connections.  The other blinker connection was soldered to a wire to the top power post of the coil.  No other wire connections needed to the coil.  Just the on/off switch on the bottom connecting the coil to ground.

Tape over the connections on the flasher so it doesn't ground out on the shell.  It is a tight fit. "

Thanks everyone for the tips. Here is an update on what I did to repairing the 6403B tender.

I followed the tip of CSXJOE who reprinted an article of another poster on a different forum who used an old-style automobile flasher --- and it worked! The ring sound was normal on the very first hit but the issue I had is that the solenoid coil plunger would not return all the way so the travel distance for the bell hammer was shortened on subsequent hits, minimizing the sound effect. I couldn't find any binding on the solenoid coil mechanism, I sprayed it with electronic electrical cleaner, but it still would not return all the way to give the hammer adequate travel. So, what I did was drill a small hole in the pawl, attached one end of a spring to this hole, and the other end to the hole where the old bi-metallic switch was attached. It took several attempts of stretching the spring just right to provide the tension needed. In case you're wondering, the spring I used came from an old mechanical typewriter that I took apart many years ago for its small screws and springs. See pic and video.

As suggested by the person who first suggested using a flasher, I cut off the two pins on the flasher so it would fit under the shell of the tender, leaving just enough of a stub to solder wires to them: one to the top post of the solenoid coil, the other to the lamp wire (which is powered by the center rail pick-up roller). Not shown on the pic and video is electrical tape I placed over the flasher's contact points so it would not touch the tenders shell.

The bell works best at 12-13v but running the 1656 engine at this voltage will most likely derail at the corners. I did notice that when the engine is in neutral and humming at less than 12v, the bell did sound. It just seems it won't sound when the engine is running.

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Images (1)
  • 6430B_Modified with Flasher: Installed spring to return solenoid pawl
Videos (1)
6403B_Modified with Flasher
@RAF posted:
... someone mentioned Trainz.com but I don't see the part listed anywhere. Another poster said it's the same switch in the Lionel 455 oil derrick, and another mentioned a modern circuit board but that person did not give any specs about what board to use or where to get it.

The bi-metallic thermal switch in the 455 derrick is part no. 455-92.  The modern replacement comes out of the modern version of the 455, which is the 6-2305 from 1981.  It uses an electronic circuit instead of a bimetal.  The part no is 2305-45.

These are available online.  A quick search turned up a couple of them posted on eBay, although they're somewhat pricey.

Follow this link here for an OGR Forum thread with a little more detail on the newer (electronic) version:

       Wiring the Lionel Substitute 2305-45 for a 455-92 oil derrick heat switch in the older 455 oil derrick (10/20/23) | Dtrainmaster

Mike

Last edited by Mellow Hudson Mike

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