Rewiring Lionel 2033 Diesel Power Unit

Check the wire coming from the pickup rollers.  If it is original it may be cracked or it may be pinched somewhere.  The entire truck assembly is ground with only the rollers and that wire being hot.

@Danr posted:

Check the wire coming from the pickup rollers.  If it is original it may be cracked or it may be pinched somewhere.

Thanks Dan for your reply.  I carefully checked the (original) red wire and it is okay.  Somehow the  current is flowing from the roller assembly to the truck, either the red wire, screws that hold the roller assembly to the truck, or the alignment pins on the roller assembly to the truck.  I placed electrical tape over the alignment pin hole on the truck and still have the short.  Next, I will unsolder the red wire from the roller assembly and see if there still is a short.

I was looking forward to seeing my first train run once again over Christmas, but this short continues to elude me.

Tom, attached is a picture of the truck assembly.  Check the insulators on the screw holding the roller assembly.  You should have an insulated shoulder washer and flat washer to isolate the screw from the roller assembly.

Dan - thanks for the diagram.  I have the insulating washers, but I believe that I  am missing the insulating spacers.  Probably, fell on the floor during disassembly  Ugh.  Tom

The part numbers are hard to read:

• insulating spacer (shoulder washer) 671-112. $0.25
• insulating washer 2333-42. $0.20

Just in case you can’t find the washer.

Unfortunately, you won’t find these in your local big box store.  These prices are from the Train Tenders website.  His minimum shipping charge is $5.75 so, it’s a good time to order a couple of other parts you might need.  

@Danr posted:

The part numbers are hard to read:

• insulating spacer (shoulder washer) 671-112. $0.25
• insulating washer 2333-42. $0.20

Just in case you can’t find the washer.

Unfortunately, you won’t find these in your local big box store.  These prices are from the Train Tenders website.  His minimum shipping charge is $5.75 so, it’s a good time to order a couple of other parts you might need.  

Dan - thanks for providing the part numbers and a place were they can be purchased.  BTW, I disassembled the truck from the dummy a-unit that provides power to the light and found that it does not have the shoulder washer, so I am wondering if Lionel stropped using them after 1950 and before 1952.  In any event, it seems prudent to purchase and install some.  Thanks again for your help.  Tom

Great but, is that the cause of the short?  If you remove the roller assembly and wire, does the short go away?

Dan - I have tried three roller assemblies and each one has a short.  Two of the assemblies don't have wires.  So, it would seem that the source of the short would either be the screws coming in contact with the metal base of he roller assembly or the alignment tabs at the base of roller assembly coming into contact with the truck frame.  I applied some electrical tape to the holes in the truck frame that accept the alignment pins, so most likely the source of the short is one or both screws.  I will order the shoulder insulating washer and hopefully that will fix the problem.

And, the short goes away when I remove the roller assembly.  I will let you know when I receive and install the shoulder washers.

Thanks for your help.  Tom

@Tom Jasper posted:

Dan - I have tried three roller assemblies and each one has a short.  Two of the assemblies don't have wires.  So, it would seem that the source of the short would either be the screws coming in contact with the metal base of he roller assembly or the alignment tabs at the base of roller assembly coming into contact with the truck frame.  I applied some electrical tape to the holes in the truck frame that accept the alignment pins, so most likely the source of the short is one or both screws.  I will order the shoulder insulating washer and hopefully that will fix the problem.

And, the short goes away when I remove the roller assembly.  I will let you know when I receive and install the shoulder washers.

Thanks for your help.  Tom

Good luck, Tom, let me know if it works out.  Happy Thanksgiving!

@Danr posted:

Good luck, Tom, let me know if it works out. 

Dan,

I don't know where the time went, but I finally got back to rewiring the 2033 and the motor, which has been disassembled, cleaned and lubricated is running perfectly.  I got the replacement insulator spacers which I believe solved the short problem.

I have not been able to solder the coupler wire to the coupler assembly.  There's probably a trick to doing this.  And, I need to figure out why the horn isn't working, but in the meantime I am very pleased with having my first Lionel train running again.

Thanks again for your help in getting me to this point.

Tom Jasper

Hi, Tom.  The coupler wire is coated, even thought it may look bare.  Use a knife to scrape the coating off.  Use some flux on the wire and tin it, then solder it.

Tom: I am not trying to insult anyone but there is a coming misty often made. Reading thru this thread I notice one thing that was not mentioned and that is a right and wrong way to install the washer. I believe the shoulder should be down so the shoulder prevents the screw from touching  the truck frame and keeps the roller assembly centered on the truck with the insulator pad between the assembly n the truck. If that shoulder is crushed to deformed in any way which is common in the older PW Stuff it will prevent the insulting factor for the screw as designed.

Tom, here's a video on how to tune up/repair Lionel horns for the 2000 FA's, which you have:  <https://www.youtube.com/watch?v=3LsDKsNBBKQ>  One thing about horns is making sure that all moving parts, including the little plate under the relay coil moves freely. I always remove the actual horn and make sure all points are sanded a bit and cleaned to make sure the electrical contact all along the way is good. Over decades, those points either get a bit loose or buildup of some kind, even rust. All avenues between roller, relay, and horn need to be clean and solid. Once you get the horn back in place, slight twisting of the little horn screw will get you the tone you want!