Postwar ZW Help

Will,

depending on your level of comfort and knowledge,

Inside, the outer handle connects to the contact arm via a metal pin.  If the pin is missing, that might cause the issue.  Or the metal shaft that connects to the handle may be loosening.  I recently repaired a ZW where this same issue happened with the inner control.  The knurling on the metal shaft wore out and caused the inner handle to slip.  There are alot of guys on here with vast experience...I am sure with the combined experience you'll be in good shape.

Bill

As I recall, if the pin is out the handle shaft can slide off, but there is a spring{?} inboard of that pin that keeps the play out...probably that has or is failing. It's been a few months since I've had mine apart for new A&D lever rollers.

The handle can be pushed off by using a long 4/40 bolt in the little hole in the middle of each outer handle...possibly your handle knurling has gotten sloppy...see if you can pull the handle off without the lil bolt. New/reman handles are out there if needed.

The outer zw transformer handles are pressed on.
The shaft has a couple of flat spots stamped into the handle that engages slots in the round hub of the plastic handle. The hub should have a metal band around it to hold it tightly to the shaft.

The handle is removed by running a small screw into the small hole in the center of the round portion of the handle.

If the handle is loose, the band may be missing, or the hub may be damaged. See page 3 from the service manual below.

There is a pin holding the contact wiper arm to the shaft. It should be inserted so it is nestld between the folded edges of the wiper arm. The pin should stick out past the wiper arm on both sides.

 If the pin was missing, the control would fall apart. If a smaller diameter pin was used, there might be play. If the pin was not put in the proper position, there also might be play, and more importantly, the sharp edges of the contact arm could come in contact with the transformer coils.

page 3

Thanks guys. I have to get my hand on one of those screws, then I will try it.

If I cannot handle this (for some reason this has me nervous, although I work on my engines all the time), does anyone have any experience with Harry Lutz? I picked up his card at a train show yesterday, saying he does transformer repair locally.

The outer ZW handles have been reproduced, and should be readily available.

I understand being uncomfortable working on a transformer.

If you are comfortable, I suggest looking inside (remove four cover screws in the top) to check the location of the pins (one on each side). The service manual page shows how the assembly should look. You can check your rollers for wear at the same time. (are they turning when you move the handles, and are the holders touching the coil)

Mike - It's like everything else, take your time and go slow. I felt the same way when I took my ZW apart to replace the rectifier disks with diodes!

Good Luck!!

Micheal, you can do this! Just take it slow and easy.

1st, off go get "1" long 4-40 bolt....longest you can find. Stash it somewhere where you can find it again should you ever need to remove a handle.

2nd, remove the 4 cover bolts and take a look inside the transformer to get familiar with it...no harm in that. Take the lil bolt and slowly screw that in to remove the handle...all you have to do is push it back on...real easy to do. Look for the tiny side hole in the end of the handle....that's what that is for-for removal.

3rd, when you've got the cover off, look for the cause of the handle slop..take a pic for us and we'll guide you thru the fix...no problem.

Speaking of removal, I need to remove myself and my son to the trainshow today...I'll check back on this one if you need any help or pop the cover off of mine for any reference shots you might want.

Michael,

You can do this. If you get stumped don't force anything but take some detailed photos and post here with your questions. Someone will have the answer.

I have emailed you a document that I use when I work on a ZW. Let me know if it helps.

Regarding any parts you might need I purchase most of if not all of mine from "The Train Tender" Jeff will have whatever part you will need to fix your transformer and he is a great guy to deal with.

Good luck

Dave

Thanks everyone. I plan to get the screw Tuesday night to try it.

So it took me a lot longer than I though to get time to do this. I bought the bolt, stuck it in the hole, and it would not grab! I tried it on the other side, and had no problem feeling it screw in. I tried it on both sides of another ZW, and had no problems on that one either. I ended up having to pry it off with a few screwdrivers. I then moved the control by the shaft, and everything was tight. I put on the old handle (when I got this, they replaced that handle, though neither dad nor I remember why), and had the same problem, play in the handle for about 2.5 or 3 volts.

So, if both handles are giving me this problem, does that mean the problem is in the arm? Should I try the handle from the other transformer? Is their anything I can do to make the handle tight on this shaft again?

Swap the handles out to isolate the problem to the handle or transformer.

Larry

Well, with your words of encouragement, I did just that. I took the one off the working ZW, and put it on the one which was giving me the trouble, and it works fine. So, I put the handle which was on the troublesome one on the good ZW, and it worked there too! So now, I have two working ZW's with only 45 cents spent (I bought two bolts, in case I would have dropped and lost the first one).

Thanks a lot to everyone!