What is this ZW Transformer WIRE Used For?

It's a resistor, it should actually show some conductivity, a few ohms if I remember correctly.  There are actually two of them, see arrows in attached diagram.

OOPS, I just read your description better, that one is a 60 ohm resistor for the short circuit lamp!

As John says, these are resistors. The diagram calls them out at 1.5 ohms (Ω). I suspect Lionel put them in so the full amperage does not go through the rectifier when the whistle is activated. So if you put a meter across the ends of the wire, you should see ~1.5 Ω. (Do this with the power disconnected, or else you could fry your meter!) You do not want to substitute a piece of plain wire! That will become the path of least resistance and then your whistle will never work. If you need to replace the resistor, I'd recommend a heavy wattage power type, 1.5 Ω.

OOPS, me too!  But leave the 60Ω resistor in place. It keeps the bulb from frying.

Chris

LVHR

Thanks for the wiring diagram and the info.  The wire measures 62.5Ω.

As I understand it -- I would replace with a 60ohm heavy duty resistor if necessary. Correct me if I'm wrong

I really appreciate it.

62 ohms is certainly close enough for the wire to the overload lamp.  That lamp ONLY lights on overload when the breaker is open, if the bulb is good, there's nothing wrong here.

Lionel used a crimp connection to connect the resistance wire to a copper wire so they can solder it to a terminal. My experience with these is over time the resistance of the crimp connection can go way up. Cutting off the old connector, cleaning the wires and installing a new crimp connector can resolve the problem.  

Ah... my original thinking was that the crimp was there to prevent heat damage from a soldering iron.

Your reply states the real reason -- to get the solder to make the connection.

You can't solder to the nichrome wire that makes up the resistor, so they use a crimp connection to a copper wire to give you something to solder to.

What I need to know how the ZW whistle side of it works. In particular the extra voltage circuit. On my ZW the right side doesn't maintain the voltage when uou blow the whistle. I have tried to adjust the copper contacts so they make contact but that foes nothing. What I need is direction. I want not to try to take this apart. Note that I installed a diode to replace the copper wafer about 8 years ago and has been problem until last week.

@Rich D posted:

What I need to know how the ZW whistle side of it works. In particular the extra voltage circuit. On my ZW the right side doesn't maintain the voltage when uou blow the whistle. I have tried to adjust the copper contacts so they make contact but that foes nothing. What I need is direction. I want not to try to take this apart. Note that I installed a diode to replace the copper wafer about 8 years ago and has been problem until last week.

I don't have any answer for you, but you may want to start your own separate thread, since your question has nothing to do with the topic or the previous discussion. other than involving a ZW transformer.

@Rich D posted:

What I need to know how the ZW whistle side of it works...

@Steve Tyler posted:

...question has nothing to do with the topic or the previous discussion. other than involving a ZW transformer.

close enough... the resistance wire is instrumental in the proper operation.

I mentioned this on another thread just a few moments ago.  Greenberg's Repair and Operating Manual for Lionel Trains, selling on Amazon for around $25 is a good investment to those running pre-war.  Explanation of  function from a crossing gate to a ZW is explained quite well, along with parts breakdown.  It is really a compilation of all the Lionel instruction sheets that came with various things, plus a lot more.  Many items include common problems and repair suggestions.

@CALNNC posted:

... pre-war....

Postwar mostly. The original Greenberg reprints from 1973-74 had a lot more prewar.

@ADCX Rob posted:

Postwar mostly. The original Greenberg reprints from 1973-74 had a lot more prewar.

I miss typed, meant post war, got it right on the other post, so was half right.