Glad you got it working Bob, one last post on this before this thread drops off into oblivion.Keep in mind, I don't want to put as scare in anyone with this as there are too many varibles involved with poor smoke output.
My legacy k4 has always had a noisier fan than every other loco I own I lubed the fan bushing shortly after I got it a year ago and it seemed to help. The fan quit altogether over the Thanks giving holiday, so I opened it up again to see if I could get it going again. I did, though it seemed it was vibrating a bit excessively, reassembled and the smoke unit worked. Noisier than normal I ran it to see if it would get better or worse, seemed to steadily get worse, and as it did smoke output dropped, not fan, smoke altogether. I'm no tech but my guess is that the poorly operating fan was robbing power from the resistor.
I just replaced the fan, WOW, huge difference, of course, but it almost seems as though the new fan while whisper quite blows a bit less forceful than the defective original, almost like the original was over revving if thats possible. I also noticed the smoke volume has noticably increased as if the resistor is getting the proper (all of) its voltage.
Last bit of info. I was getting the "3 cab light blinks" when the fan quit. This resets automatically when the loco is "reprogrammed" or power has been removed for a bit. Testing the fan with the shell off showed the fan briefly turn then stop as the smoke unit was tested and shut down the fan due to too much draw. Repairing the problem i.e. the smoke unit fan resets the diagnostic and everything works as normal.
There has been a bit of "unknown" regarding the "blinking light diagnostics" that had previously given (me at least) the impression that the loco would need resetting from a Lionel tech. This does not seem to be the case.
I'm not posting this to deter anyone from Lionels service, arguably the best in the hobby, and a good way to go if your still under warranty. I figure the best way for me to be able to do some repairs on my own is to try, especially with something like a smoke unit that will at the very least need new wicking at some point. All thats required is a good #1 and #0 magnetic philips screwdriver and alot of patience. I've still got work some to do on the patience which I've been trying to aquire from other members.