Repairs to Lionel ZWC transformer

if its a zw,  4/40 screw in middle of handle,,,see little hole,,

I believe it's a slip-off, but mine doesn't seem to have any threads in the hole like the old PW-ZW, so you must just have to pry them off.  I never took one off.  The shaft that it slides on appears to be a press fit one, #11 in the diagram.

John,

   Thanks, that was my line of thought, also.  I have rebuilt plenty of older PW ZW trans, but never have taken the A-D post handles off a ZWC.  Perhaps a slightly modified steering wheel puller could do the trick utilizing the small center hole and slow grip/pull on the "flange" of the handle body.  I have a used ZWC, inexpensive purchase with four 180 bricks included.  The handles are approx. 90 degrees off in position, both at a down angle, almost touching the table top when in zero voltage position.  And, though I have checked/reset the gears alignment with the pots for full rotation, only have eight volts from "D" and eleven volts from "A".  With the position limiter pins (#13), I believe I may not be getting full rotation due to misalignment of the pins within the throttle handle body.

Or.....  I could simply open the ZWC, partial disassemble the top side, rotate the pots by hand and check voltage....... OR NOT !!!!   Do not wish to subject myself to the possibilities of a poor outcome and the consequences thereof.

Thanks for the input, John.

Jesse   TCA  

Just throwing it out there that it doesn't seem like you should have to remove the handles for this fix.  It sounds like the gears skipped some teeth, so the fix may be to loosen the pot's mounting to separate the gears, then turn the handle to it's proper position, before re-securing the pot.  I'm unsure of the exact details, but I believe there is a know issue with a plastic mount on these transformers and the gear slipping issue can be solved by using a metal replacement bracket.  

JGL

There are 2 brackets that can break.  #17 is one and that is the one Lionel reproduced in metal, but so does the plastic bracket that is part of the Pot assembly item #14 or 15.  I guess it does matter if some one reassembled the handles incorrectly.  90 degrees is a significant mismatch, that seems more than just gear skip.  The handle only moves about 100 degrees.  G

     I have already opened this ZWC up to check the pot gears alignment.  Even with the pot gears loose, not meshing, the handle rotation remains the same.  This must be due to the "limiter" pins (#13?) within the handle body.  So, this is why I believe the handles must be removed to allow adequate rotation and realignment.  This transformer came with two 180 bricks, and has the milled aluminum brackets already installed.  Do not know whether it came from factory with alum brackets installed, or if previous owner did a change-out.  I have changed the plastic brackets to aluminum on an older style ZWC, with 135 bricks, and other than that, they both seem identical inside.  Now, for first time, to remove A and D throttle handles to return them to proper positioning.  BTW, the red mark for the handle position/voltage, has been painted on in new place to reflect the offset position of the handles.  And, yes, the original red position mark in there, in proper location.  Thanks to all for the input.

Jesse   TCA

OK...... finally made time today to remove the A-D handles on the ZWC.   Simple, very simple thing to do, they very easily pry off.  I did it with a simple flat screw driver that fit easily between the handle body and the aluminum spacer disk.  I first removed one handle off the ZWC I replaced the plastic brackets on.  I chose this one first because it was giving correct voltage readings and both handles were in correct positioning.  When I removed both handles off the "low voltage" ZWC, neither handle had in place the alignment pins (parts #12 in diagram) on the pot shafts.  Evidently these were left out by a previous interlude into the ZWC handles by persons unknown.  Checking with my brass and aluminum stock, I have none the correct diameter, so... I cut a finish nail of correct size and made two new pins.  They fit very well and with the handles correctly positioned, both A and D outputs read a consistent 17 volts on the attached Lionel meter bridge.  I did not check with my voltage meter/tester, but before "A" read a high of 11 volts, and "D" read a high output of 8 volts.  So.... it was a very misalignment of the handles/bodies onto the A and D pot shafts.  Hope this is useful to others and any endeavors with ZWC transformers.

Jesse    TCA

Thanks Jesse.

I love the ZWC despite the issues people have documented.  I have 4 PH180s and a meter with mine.  I replaced my U posts with Banana jacks.  There is such great info on this forum.  I am sure I can fix mine now if anything goes wrong.

George

George,

I agree, I really like my two ZWCs, even with the corrections I have had to make to them.  But, I have also made a lot of repairs to my PW ZWs, VW, KW, LW, etc. over time.  This is simply part of needed maintenance and a learning curve, IMHO.  Any time I have an opportunity to learn something new, make new friends, it is only a GOOD thing.  I have 4 180s with one ZWC and 2 180s, 2 135s with the other I did the aluminum bracket change out, and both now perform as I like, need, and provide power to track and accessories very well.  Yes, along with all the various PW transformers I have, they are a great addition and useful "modern upgrade" to my operations.

Jesse   TCA

Are the parameter brackets available yet for the ZW-C Transformers

I'm having what seems to be a common problem with my ZWC.  When I rotate the "B" handle it appears that the pot is moving and the gears are slipping.  From what I read above, it seems that Lionel made a metal bracket to replace the plastic bracket holding the pot.  I've looked at Lionel's parts site and nothing comes up for this part.  Is someone else making it?  Thanks for any help.

LionelFlyer

@lionelflyer,

I just finished doing the metal bracket change out on my 2 ZW C units. Both units exhibited severely cracked potentiometer brackets. Lionel is currently showing part # 17 as unavailable and indeed I may have gotten the last pair they had for one of the units just a week or so ago, they had no problem shipping me the parts. But I was short another set.

The good news is that the Trainz store had some. Look for "Lionel metal potentiometer bracket" in their search function. That's where I got the pair for my second unit. Both ZW C's are back in perfect order and I really like them a lot. Hopefully Lionel either is awaiting replenishment on the brackets or they will consider ordering another run to fix this annoying materials defect.

John

Hi John,

Thank you for the quick lead.  I was able to order two of them from Trainz.  I'm assuming that if one is broken, the other can't be far behind.

LionelFlyer

@lionelflyer,

Yes! I suspect those brackets are pretty much like taillights. Replace them both and be done with it. I will tell you that the top two exisiting screws to mount the potentiometers to the metal brackets are not properly threaded for the mounting plate. They weren't for the Lionel plates that I got either.

I confess that I just used a bigger screwdriver and they rethreaded themselves sufficiently for my standards....just be aware of what you might encounter. Also save the little plastic rectangular shims that you will see under the potentiometers...you may need them still to prevent wobble even after installing the metal replacement bracket. I did on one ZW C ...but not the other... go figure.

John