Lionel ZW Transformer Complete Disassembly and Rebuild Video (Upgrades and Replacememts)
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- Опубликовано: 21 окт 2024
- This is my first ZW transformer and my first ZW transformer repair. I bought this 275 Watt unit on eBay in hope to have a large train table someday. Upon receiving this item it was matted up on the outside but the inside yeilded some repairs.
Before I touched anything inside the transformer, I purchased the Greenberg’s Repair & Operating Manual for Lionel Trains. After reading about the parts, wiring diagram (physical and schematic) and how the ZW comes apart, I felt more confident on repairing the transformer.
First thing I did was LABEL and DOCUMENT ALL WIRES that have to be unsoldered so reassembly can be easy. The coil pack has 6 wires going to the control boards and circuit breaker of the ZW. Once I understood the physical wiring of the transformer, I was ready to work on it. I hope this video can help remove the intimidation on disassembling and repairing a ZW transformer.
Please enjoy the copyright free 1950’s music for a 1950’s model train powerhouse.
Music credited to RUclips users TUBE MUSIC, Freesound Music, AndrewVovchynaMusic and Adam Vitovsky. I do not own any of the music provided.
Credit to RUclips music creator: Freesound Music: freesoundmusic.eu
Credit to RUclips music creator: TUBE MUSIC: / tubemusic
Credit to RUclips music creator: Andrew Vovchyna: AndrewVovchynaMusic
Credit to RUclips music creator: Adam Vitovsky: Adam Vitovský - Free Music For Videos
Instrumental songs in order of appearance:
Artists respectively ask to copy and paste sections for credit to their work. In certain videos they did not contain sections to copy and paste for credit. I did my best to give artist name, song title and link to video.
At introduction:
TUBE MUSIC
Title: Wild Race
Link to video: • Wild Race - [Tube Musi...
At 11:22
Rock Around The Block by Freesound Music
royalty free Music by Giorgio Di Campo for FreeSound Music
freesoundmusic.eu
/ freemusicfor...
/ freesoundmusic
original video: • Rock Around The Block ...
download mp3: link-to.net/49...
At 14:39
Free 50s Rock N Roll Background Music by Adam Vitovsky
Channel: Adam Vitovský - Free Music For Videos
Video: • Video
Video Link: • Video
Download Link: www.adamvitovsk...
At 16:46
Rock The Roll by Freesound Music
royalty free Music by Giorgio Di Campo for FreeSound Music
freesoundmusic.eu
/ freemusicfor...
/ freesoundmusic
original video: • Rock The Roll - no cop...
At 19:24
Driving - Rock N Roll Background Music by AndrewVovchynaMusic
Music: Driving - Andrew Vovchyna.
Music Link: • Driving - Rock n Roll ...
At 21:30
Rocking Roller by Freesound Music
royalty free Music by Giorgio Di Campo for @FreeSound Music
freesoundmusic.eu
/ freemusicfor...
/ freesoundmusic
original video: • Rocking Roller - no ...
At 24:44
Bye Bye Baby by Freesound Music
royalty free Music by Giorgio Di Campo for FreeSound Music
freesoundmusic.eu
/ freemusicfor...
/ freesoundmusic
original video: • Bye Bye Baby no copy...
download mp3: direct-link.ne...
At 27:27
Free Soft Rock Background Music by Adam Vitovsky
Channel: Adam Vitovský - Free Music For Videos
Video Link: • Video
DOWNLOAD LINK: www.adamvitovsk...
Video time segments:
Intro at 0:10
Opening and Identifying X-FMR parts at 2:18
Issues to correct at 2:57
Testing the coil pack at 4:05
Lets begin the teardown / rebuild at 11:22
--All parts for the ZW transformer and literature were purchased from eBay.
---Novus Plastic polish - at Amazon OR www.professionalplastics.com
--Harbor Freight 6 inch Buffer by Central Machinery
--MG Chemicals 8481-1 Premium Carbon Conductive Grease - Amazon
--Drill bit kit
--Pop rivet kit
--Fish Paper Roll CG100320FT
--4-40 drill and tap
--4-40 screw assorment kit 3/16” to 1” from Amazon
--Soldering gun and Solder
--Any parts or items missed, please take note on stock in video
Hello everyone, I hope you're all enjoying the video. If anybody is curious on which Greenberg book I'm using it's ISBN# 0442213638. If there's a better book please let me know here. Also replace the WD-40 electric contact cleaner with INOX MX3, it has a protectant that makes the copper look last and it's a great track cleaner.
Outstanding work. Beautifully done. Your motivated me to refurbish my ZW (": Keep up the great work. Thanks
Thank you.
Beautiful and fun to watch. I have two ZWs on my layout. Paid full retail for the first but picked up a sketchy one two years ago from a guy who knew little about trains. He used the voltage meter and some terminals worked others did not. I paid $35 and then took it to my hobby shop. They charged $90 for a full rebuild. So I got my second ZW for a low $125 with full peace of mind. My most adventurous repair is right now on a Lionel Erie Alco and I'm building up my courage to do an E-unit rebuild. Wish me luck.
Thank you, even with the rebuild price sounds like you did well. I need to find more ZWs for that price. I think you'll do fine on the e-unit rebuild. I took one apart with with an e-unit jig and reassembled it to try it out.
When that emblem feel off and the look on your face. I laughed so hard. Buffing out that case, that made it better then anyone elses. Perfect!
I was just as surprised as the next person and didn't expect it. The bakelite deserved a good cleaning, it was more dirty than what my old analog camera picked up.
Just starting this video. When the Emblem falls off (at 1:31mark ) it is just awesome.
I am going to study your process - as I have one to overhaul as well.
Thank you for sharing.
Didn't expect that to come, thought it was funny so I left it in. Its really simple once you start taking it all apart. Just be sure to label all your wires, you will do just fine
Excellent video and I must say you take the definition of the word " complete " to a whole different level ! Your efforts on putting this video together I'm sure has helped many people contemplating buying a fantastic Lionel ZW and were concerned about possibly having to do repair work.The Lionel ZW is American design,engineering and build quality at its best and still relevant at 70 plus years ! Amazing given the technical advancements in electronics. Appreciate your efforts...WILLIAM
Thank you William. This project was a labor of love from the start from dissassembly to editing. I hoped the video has shown the ways to completely take apart the transformer with ease. I guess i did something right. Hopefully I will get a lot more years out of the ZW. Thanks for watching.
Hi Ed, The video is fantastic! I wouldn't have tried restoring a ZW if I didn't watch this. All terminals register over 20v and the whistle over 25v. Adding the ZW to the table now. two trains running on one 18 awg lockon. Thanks again, looking forward to your other videos!
Thank you Alfredo, I'm glad to hear everything went well and your readings are spot on. Enjoy running your trains with your new rebuild. Please correct me if I'm wrong, I may have seen your comment earlier with having some trouble with the whistle output on one of the terminals. Is everything good now?
@@TheCreativeMind I was incorrectly testing the whistle/reversing assembly and the circuit breaker. I needed to move the switch lever slower for precise contact. To test the circuit breaker, I grounded the B&U, C&U, terminals before I started increasing voltage which tripped the breaker without any sparking. My old hands/mind took a little bit longer to realize what I was doing. 😉
Honestly, this is one brilliant video! You did a fantastic job of capturing your 'tear down'.
I just got myself a ZW.... and it's become clear very quickly that a total tear down is going to be required to rehab it. I don't have all the equipment you do but as much as I've been finding myself gasping in horror at all the work that needs doing, I also am relieved to see such a clear video of exactly how everything came apart and what work was performed. Time to ready the soldering iron, begin ordering parts, and wait for the Greenberg repair manual to show up at my doorstep!
Hey Leverett, thanks for the comment. I found myself in the same boat you are in knowing how much work had to be done, it can be overwhelming. First I can say is label all the wires from the coil pack going to the whistle/directional board. Even sketch it out on paper where the wires go to, makes it so much easier for reassembly. All my tools I acquired over time but that angle bit will be a huge help in drilling out the terminals. If you go drilling in straight, you could damage the bakelite case. The Greenburg book will help a lot with line assembly and if needed parts. And if you get stuck, come back to the video. Best of luck on your rebuild, when you get it finished you can do 10 in your sleep
Nicely done Ed, great work and video!!👍
@@TwistedMacGyversTrains thanks Frank, this one was a labor of love
@@TheCreativeMindHow’s it working today? Is there a place for making an 18v tap? I’ve been think about adding one to mine. I’ve seen in added on other postwar ZW’s.
@TwistedMacGyversTrains the ZW works great today. I've put it under some heavy loads and still running. I have to research the 18 volt tap on the ZW. This is the first I'm hearing about it. Thanks Frank.
@@TheCreativeMindI purchased mine fully upgraded with a power switch added to the front. They are also adding a button for the bell now.
Excellent video for anyone wanting to completely refurbish your Lionel ZW transformer
Thank you
It’s beginning to look a lot like Trainmaster! I’m rebuilding a prewar set as well as a ZW-275. If you hadn’t made this video, it wouldn’t be possible and I’d be at the mercy of our local store. Fingers crossed we’ll be using our Standard gauge and O gauge with the same rebuilt transformer. Many thanks for generations to come brother! 🚂🙏🎄
Thank you. I think you'll do fine on the rebuild.
The video is good. Shows LOTS of detail that is lacking in many ZW videos.
A great reference, thank you. My unit buzzed. The core laminations had been inserted in an irregular pattern by a rushed Lionel worker. You could even see how the die they were stamped from had dulled on one side. This kept the laminations from laying flat together. I hammered out the burred edges and 3D printed a spacer to keep them squeezed tight.
FINALLY! A ZW repair video! I bought one off ebay and got a good deal but one of the rollers is worn. I was looking for a video to see how to repair it and found one where a guy did a replacement on a KW. Basically the same thing but still liking yours a lot. Thank You for posting it. Merry Christmas and Happy New Year.
Superb. Your electronic knowledge and patience to disassemble and assemble such a complicated device is awesome. Keep up the great work. 👍
Geez, that's a kind of rebuilt that i never seen before . You are a real maniac of things well made . i'm a bit maniac too when
it's time to re-done my trains and transformers like this ZW but you beat me at 100% here on this vidéo .Great work of art
dear friend and it is cool to see your good work on your ZW , congratulation to you .
Thanks for the comment chanous. I wasn't intending to go this far with the ZW but the oiled papers and thick grease made me pursue an entire breakdown. This project was a labor of love lol.
Yes ,your restoration is a real labor of love ,i'm with you on that point . Have a nice end of day dear friend .
You did a fantastic job the ZW !!!!!!!!Thank you for sharing!!!!
Very informative video ! The rebuild was exceptional , I’m sending you mine .
I bought a used ZW for $100 about 8 years ago. I’ve never used it but I should get my new layout setup again and try it.
Awesome video! I am about to take my trains out of the attic for the first time in 25 years and might need to do this to my ZW. The _only_ complaint I have is that it's only in 480p resolution. I wish it was in at least 720p or 1080p. Keep up the good work!
Thank you Michael. For some reason my camera was going bad on me and I didn't realize it until I did the editing. Everything is now done by my phone.
Outstanding video !
Extremely nice work...
A little tip for you as an avid Lionel collector I have come across some tricks of the trade I work in the bowling business as well .. in the bowling ball repair world when they use a pentagraph to add your name into a bowling ball or your refurbishing a bowling ball for someone, you can get the wax crayons for terms of a better word, that you can refill in the lettering on your Lionel transformers you can get the white wax crayon, you take a paper clip or a jeweler's screwdriver and you can clean out the old paint or white lettering for your gauges or your whistle lettering, clean them out and then you can take this wax pencil and fill them in and wipe off the excess and voila all of your stamped lettering is brand new just a little tip... Although yours turned out well I like to redo mine so they're nice and bright... I have subscribed and look forward to more videos keep up the good work
WOW! Thank you Izzynutz. Iwas wondering how to redo those. I thought paint and wipe away but the wax crayon sounds better. I'm on my 3rd ZW now and the terminal lettering is gone. The wax crayon method won't work there but I'm thinking of rubber stencils to paint them on.
@@TheCreativeMind you could do that too but I have sometimes taken a Dremel with a very fine tip and cleaned up lettering... You could go through ACE Mitchell which is a bowling supplier to get the wax crayons you can either get the whole set which is just about every color under the rainbow including neon colors or I think you can buy it's been a while since I have individual colors yeah you just rub it in until it fills it and then when you wipe off the excess your lettering is clean and crisp good luck looking forward to some more videos
Awesome rebuild that zw looks better then when new ,,,thanks for sharing,,,.Ken,,,,just subscribed
Best quality rebuild I have seen EVER!
I am about to attempt rebuilds on 2 of mine, and not sure I can do as great of a job.
Do you stock things like high temperature wire? And that insulating paper?
Why don’t I just send you my ZW’s and the rebuild kits and you can charge me for labor!
I actually have a Megohmeter in my shopping cart at $100…
Do you take on rebuilds?
Thanks D W. I don't stock any of the items shown in the video. Much of it comes from ebay or other websites. I do try to post all information on my sources and model numbers where you can purchase them from. At the current time, I'm not taking on any rebuilds. However it's something I may consider upon retirement.
A great under taking in a complete restoration I'm amazed Good Show!
Thank you
This is an insane rebuild. To me you went above and beyond what others won't do. I'm not sure about that megger putting out that kind of power you sure it won't damage anything. Other than that awesome work
Hey Jeremy, much thanks for the comment. Meggers only put out high voltage/minimal current for insulation testing. Curiosity made me try it on one of the bulbs for the ZW and it didn't blow the element. Meggers are only good for inductor testing but will have devastating consequences for testing electronics.
Great vid- thanks for sharing 👍
Great Video
Thank you
Thank You for uploading, i hawe for a long time concidering buying one of those but because the shipping and import taxes probably are going to be alot more then the transformer where i live i wanted to know more about them and this is exactly the type of in depth information i was looking for.
Hi Vampi, I try and give as much info as I can in my videos so everyone can understand the process. I wasn't planning to go as far as this but the hardened grease and oiled papers made me do a complete teardown which I think everybody can benefit from. Thanks for watching.
@@TheCreativeMind
Thank You, i hawe a few 1950-60s Lionel steamers in my collection with the original track and some period acessories for it, so this came in handy. Im not an enemy of modern tecnology, but for the display it looks much better with the original setup for the wisible parts in my personal opinion. I hawe a pair of the single steel case transformers, and the original 220V converter transformer (it's made in The United States, but i am not sure if it mainly was for the European export market in order to make the original Lionel transformers to work with 220V, it has a 110V socket built in to the steel case so it is just to plug in any traintransformer of Your choise the output can handle).
I used them as display before, but decided to restore the whole setup back to working condition for historical reasons a few month ago and i realy like it.
But, despite the total weight, it is only designed for one ot two locomotives.
Hi, I loved the video. Is there any chance you would do this as a business and repair other ZW's?
Thanks for sharing🚂🚃🚃🚃
Bravo!!!! Great job!!!
Thanks for positing! Can you rebuild mine?
Thank you, this was quite a project. I get asked this a lot but unfortunately I'm not able to do orders right now. I am considering rebuilding ZWs when I retire.
I remember seeing them in operation in the mid '50s. It seems to me that the original retail price for them was about equal to a weeks average middle class salary back then ....over about $900 to $1,000 in today's money..
What spec diode did you replace the old one with? Thanks
I used a Ruttonsha 16 amp stud diode. It has a perfect washer size that fits in the old disc location. There is a 40 amp available but it doesn't fit so well because it has a larger washer. I got mine from ebay.
@@TheCreativeMind I got some 70 amp stud diodes. Hopefully those work. If not I’ll get some 16s
IF WE HAD MOORE SMART PEOPLE AS YOU WE WOULD BRING BACK AMERICA
And Europe!
Do you do these rebuilds for paying followers ? My dad and I just purchased one and it has all sorts of issues.
Excellent video! Not sure I could put it back together after all the parts are removed. I am going to purchase one of these. If I bring my voltmeter can I just test it to
Make sure it puts out 19v? Is that a good indicator that it’s good? Thks
19 VAC is good to read but I've seen some ZWs go as high as 21.5 VAC. It's all about the natural tolerances of the components. If your purchasing from an actual store, most likely they serviced it with new rollers, diodes, breakers etc if needed and hopefully a warranty. If you're purchasing from a train show, you may read your AC output voltage but pay for what you get without them overcharging you.
I had to subscribe to your channel because your videos are just that good! Now I've got to acquire a ZW transformer to go with my American Flyer 16B.
Thank you
مدهش amazing 🤩 🇰🇼👍
How much would you charge to do this overhaul on my ZW???
That is amazing attention to detail and great work. I added the whistle Diodes to mine but did not change the circuit breaker. does the coil need to be removed? Can you tell me exactly what breaker I should install? Thanks
Thank you OneMore, the coil pack from what I know doesn't have to be removed. I got my circuit breaker off eBay. Just type in "ZW circuit breaker" and you'll get the one I have in the video. I had to extend my wires (soldering additional wire) to the new circuit breaker location. If the coil pack had to get removed to gain access to a wire and extend it, just unscrew the 4 bolts on the bottom and the coil pack will slide forward a little. Just make sure the wires are not pinched during reassembly.
Creative Mind, I watched your video as well. Very thorough, very knowledgeable. Made me real comfortable in tackling my repair work!
I’m coming to you to ask about the Bakelite circuit breaker being replaced by the newer 15 amp breaker. Tandem says Bakelite is more reliable than the upgrade Lionel did back in the day. Am I correct that this new 15 amp breaker on EBay is better than the one Lionel converted to?
Have you experienced any issues converting to the new 15 amp breaker?
Thank you
Carmine
Creative mind, the ground wire going to the Bakelite circuit breaker looked like it was snipped . Does it get attached to anything when the conversion to the new circuit breaker is used?
I'm so happy for stumbling on to this video, so someone like me better buy from a good train shop ,not ebay ,could buy a pig in a polk as they say
Nice rhyme lol. I'm thankful I got it at a low price and mostly knew what I was getting into before purchasing it.
@@TheCreativeMind wish I had knowledge on repair of these I would not hesitate to purchase off of ebay,being said I'm a retired RV mechanic know exactly now not to buy electronics off ebay unless know seller
Do you have the brand and part numbers for the new circuit breaker and diodes along with that L. E. D. Bulb? Or do you sell them? I really need to upgrade the circuit breaker in my zw275r because I am sick of burning out electronics.
Everything I got is on ebay. Just search under ZW transformer LED bulb, Circuit Breaker, and diodes. 16 amp diodes is plenty enough and they fit nicely where the rectifier sits.
@@TheCreativeMind is there any way to tell which circuit breaker I need without popping the top to look? I am pretty sure mine is a zw275R because it doesn't him at all, and I think the core is riveted. Again I can't remember, it's been years since I've be inside it.
@@inscoredbz According to my Greenberg book for the ZW model R, your Circuit Breaker is model number ZW-232. From what I heard, these breakers start to fail as time goes on and tend to trip more often. If you look up this number you will find the updated quick blow breaker and the majority is sold on ebay. You did mention you are burning out electronics, is the transformer creating a surge or circuit breaker issues?
@@TheCreativeMind my guess would be circuit breaker issues. I haven't tested it for surges, but with the circuit breaker being old and pretty slow, that's my guess. Those old transformers just wasn't made for electronics. I've had several whistle boards pop and one true blast from a Williams.
I do have tvs diodes across all the rear C-U abcd. It probably is spikes now that you mention it, during a detailed wheel or what ever. It will drag the derailed car forever before the breaker finally shuts it down, and as soon as the short is removed, the light goes off. I may need to replace the TVS diodes. I'm sure they can go bad as well, and I have no way to test them. I'll probably just do both. New breaker and TVS. Probably need to add more of them around the layout.
Just think how many train show units have overhauled like this.
LOL
Hi fantastic job would you ever do ZW repairs for hire ?
It's something I may consider when I retire in the future.
What is the part number for the led bulb?
I didnt see a part number when I ordered these bulbs from ebay a few years ago. I just searched Lionel ZW LED bulb and they came up. I recently checked Ebay and the LED is sold by seller "autolumination" in 6 volt and 7.5 volt clear, red and green variations. No 18 volt yet for the overload. My 8 star LED bub may be outdated. S U P E R L U M I N A T I O N . C O M has model number 51-Ba9s-7V-4Star-Led and 53-Ba9s-14V-4Star-Led. Hope this helps.
@@TheCreativeMind Thanks! I appreciate the information.
What lube are you using and where do you find the 14 guage high temperature wire
The dark grease I'm using is MG Chemicals 8481-1 Premium Carbon Conductive Grease. It has a very low resistance rating and won't break down. I got it on Amazon. The grease I used before I put the throttle dial back in is Labelle 106 grease with PTFE. But any silicone grease with PTFE will do plus you can use it on your trains. You don't have to lube it that item, I did so I thought it would roll smoother. The high temperature wire I got from Ebay.
@@TheCreativeMind thanks do they have a chapter on the zw in the greenburgs operation book that's in your video and the proper wiring diagram for it as the zw I bought from ebay it looks like someone tried to rewire it with the wrong wires.
@@edwardheyrich8601 In my book pages 591 to 596 covers type VW / ZW transformers. It's the same transformer except the VW is 150 watts. In case you come across a ZW Model R transformer, pages 597 to 601 will help you too.
@@TheCreativeMind ok everything is making sense now one more question on the switch rivet what oil did you use when drilling and tapping to a 4-40 screw and when you were reassembling the switch what did you put on the 4-40 screw thread's.
Thanks for all your help
@@edwardheyrich8601 Glad to have helped. I used 3 in 1 oil to tap the switch rivet. The liquid I used on the screw is Loc Tite super glue. This holds it very well in place, however the blue Loc Tite liquid is what I hoped to use in case I made a mistake. This way it won't be so hard to unscrew the assembly
Good job, do mine? Haha what’s the name of that template?
Hey Scott, the template is a 1:12 Tinplate Track Template made by CTT Inc. I don't think they are made anymore since track programs came out. I printed one out and cut the needed tracks sections by razor.
Can you do that to mine !!
I do speak to people about rebuilding ZWs and been asked to rebuild them. I have to respectfully decline because of family life, work deadlines and currently working on the Crescent 8702 complete teardown and Rebuild. I couldn't guarantee a quick turnaround. However I may consider rebuilding transformers when I retire.
did you ever find someone to rebuild yours?
I'm sorry, that opening had me ROLF, the timing couldn't of been better.
That emblem was hanging on a thread LOL
Nice but the only real test for a ZW is under load. A Megger really? This sounds a bit too doomsday for me and shows nothing useful in this regard. Maybe a carbon pile on the output along with a good A.C. voltmeter would at least give you something useful to show a customer," your transformer was able to produce X amperes at it's rated max output on all terminals" would be something better.
Yes the true test would be to put the transformer under a load, that I had no problem with. The megger only measures the enamel resistance to ground only and tells me if there's any faults. Best example is when I found a short in the Crescent Ltd armature. Certain volt/ohm meters won't pick up the short to ground but the megger did.
Those rectifier wires have asbestos lining. You should be more careful with them. Good video otherwise
I have read also that the wires has asbestos on them. I was required to take an OSHA course and asbestos was one of the topics. The instructor said a tiny amount is not harmful like on this wire. But i do agree on approaching this with caution.
Dude he is like using a 2007 potato quality camera in 2021😜🤪😝😄😆😅😂🤣
Edit: it is 2022 when this is being written