Lionel Culvert Unloader (6-82030)

I had the same issue. The culverts were not completely clearing the door on the way in because the angle was slightly off, which resulted in the culverts going down the ramp sideways.

By slightly twisting the travel assembly in relation to the structure, the angle changed and that solved my problem. I said "slightly".

You should also review Lionel's video on the subject.

I checked Lionel's website and couldn't find the video you are referring to...is it on Youtube?

You can search google for video.  I had the same issue.  What I did as best to explain it is I pulled the support next to the track towards me.  Then the support where the culvert drops I pushed away from me.  Trying to adjust the cross member so the culverts drop straight.  
I did this slightly with a little pressure each time I pulled/pushed.  Retested until the culverts drop as they should.  You may have to inverse push /pull but it’s like you are trying to bend the cross member to align.   I hope this helps.  The video basically states the same process

Video is on YouTube, link is: https://www.youtube.com/watch?v=9uhMEBkXJhc

It's actually the product video, he makes adjustments about 8-10 minutes in.  If watch all the way through, he'll show you the adjustments.

I watched the video...it's useless. The fact that Lionel has to create a 'fix-it' video of one of their expensive accessories is shameful.

I finally analyzed the problem myself - didn't solve it, but I know why it's happening.

The magnetic 'hook' needs to pick up the culvert almost dead center, or even a smidge further out,  in order for it to be 'stopped' by BOTH of the swinging dorrs at the top of the ramp.

The fact that the contact switch at either end of the I-beam cannot be adjusted or moved WOULD provide the best solution towards making the magnet either pickup or drop the culvert at the ideal position, but that is not a viable option.

In the video it shows the operator unscrewing something at the ramp-end of th I-beam - and I tried that but it doesn't provide you with the possibility to adjust anything once the screw is loosened or even removed temporarily.

Does anyone know how the inside I-beam contacts can be moved - maybe 1/4 of an inch that would solve the problem????

• @Larry G, I did this quite a few years ago. The in-beam contact switches do in fact have to be moved. Two really tiny screws hold them to the beam.  When I sent my unloader into Lionel years ago it came back working perfectly. The contact switches were slightly moved, as you said, no more than a quarter of an inch, a really small drill bit should get you a couple of screw pilot holes to set the new location. I also made sure the beam rollers were super clean to get traction on the beam. I also put just a bit of graphite on the gate contact hinge points, not much to reduce resistance to the culverts. It finicky but once adjusted it's very consistent and reliable.
• John

OK...thanks for your reply that appears to confirm my premise. BUT what exactly has to be done and which screws have to be undone and re-driilled? I have all the necessary tools but just need some more specific guidance.

I see where the contacts appear to have two tiny screws, but I don't know where they are 'screwed into' and where should new holes be drilled to accomodate their move?

Larry G, I dug out my Unloader and I did not remember correctly about the switches. They are not held on by screws but rather looks like tiny friction fit brads. The only two screws are to hold the beam on and don't seem to affect the action.

The Loader however did have screw attachments and they were relocated on the beam by Lionel.

The Unloader looks like it had some plastic shims added under the contact switches to prevent movement when the rollers hit the switch.

The repair folks included a  sheet outlining an adjustment protocol when the unit came back to me. I've have used it to fine tune the operation. A VERY gentle touch is all that is required any more and I fear the unit will break.

I will try to answer any question you may have but remember I am not a Lionel repair tech!

John

I can easily see how the fix SHOULD BE DONE  but don't know how to go about doing it. The magnet needs to be going out towards the end of the beam by about an extra 1/4 inch to grab the culverts IN THEIR CENTER and coming back towards the ramp again, by about an extra 1/4 inch to completely clear the gates. Does anyone have an idea as to how to move the contact switches??? Lionel Customer Service is currently unavailable, probably due to virus restrictions, so I have no source of helpful information other than this forum. I see where the contact switches appear to be held in place by two small "screw-looking things" and two small, white 'glue pads', but they have no screw slots and neither do the round-head tiny objects on the flat side of the beam opposite them. I don't want to jump in and start drilling anything for fear of permanently damaging the unit.

Anyone have any suggestions.....P.S. - those printed instructions about "BENDING THE MAGNET" are silly and don't do anything constructive.