I recently set up my childhood Lionel train for the grand children. It ran but not smoothly which started an interesting learning experiment. After disassembling, cleaning, rebuilding, and lubing the engine, the train still would work at times but not at others. I thoroughly cleaned all the track and connections. Still same problem.
My next course of action was to check the transformer, a 50 watt #4150 Lionel. I discovered that it worked sometimes and would then simply quit. Upon opening it up, the coils tested fine and everything looked okay. Inside I found a glass tube auto resetting circuit breaker. I assumed that had to be the problem and began an online search. I sent out numerous emails seeking help. Jeff with Train Tender contacted me and asked for pictures of the breaker.
When I took the transformer back apart to snap some pictures, I decided to check everything again. I decided to use test jumpers and check the output of the transformer with and without the circuit breaker in the loop. The voltage was perfect. This time I decided to check the post continuity and sure enough there was none. The culprit was the black cap post. That post is spring loaded and inside it is riveted to a contact plate. The rivet had corroded to the point that the post was not getting good contact. I tried cleaning it with contact cleaner to no avail. I also tried center punching the rivet to "tighten" it. That did not work either. Finally, I drilled it out and disassembled all the pieces. After cleaning them, I drilled out the bottom of the post and tapped it with a #4nf tap. Then I used a screw to hold it back together. Voila, the train runs like brand new! I attached pictures for you.
The good news is the train runs better than it ever did in the past.
Here is everything I did:
Completely rebuilt engine:
Desoldered all connections
Re-insulated all wires
Cleaned brushes & commutator
Cleaned gearing and wheels
Re-soldered all wiring connections
Scrubbed all track pieces with a scotch brite pad
Ensured all track pins were clean and fit snugly.
Replaced all transformer wire and wire connections to track and station house. Soldered wire connectors on wires and tinned wires where connectors could not be used.
AND finally...
Refurbished transformer.
This is the connection that was formerly riveted.
Hope this helps someone else.
