Rewiring a Lionel 250 Watt ZW Transformer - Question

I've repaired a few ZW's, the one I'm working on right now has been stored in a really damp environment, but appears to have had little use in its life. Repair what's needed, don't mess with what's not. I've never come across a ZW, even with all original wiring, that needed any wiring replacement besides a new line cord. If the cloth covered wiring is still intact and in decent shape, leave it.

Dennis, you're a Digital Subscriber, so you can see the OGR Videos we have here. You should watch this one, a Backshop video with the late Jim Barrett:

Refurbish Your Lionel ZW Transformer

Thanks Rich!  The video only covers the power cord and rollers.  It does mention a 16 gauge power cord.  Should  the wiring in the transformer be 16 gauge?

My original question was:  Can I use the typical, coated, solid #12 AWG wiring to replace the old cloth-coated wiring in the transformer?

Three ZW repair tech tips by Jim Weatherford attached (in a single pdf). I don't remember where I downloaded from, but was several years ago.

Dennis,

Check out this link.

https://www.youtube.com/watch?...Ola5lqp4&index=2

If you are replacing the breaker and diodes, you most likely will need to extend

some wire.

When I completely did mine I replaced almost all of the wire with a high temp 14 awg.

There are other videos out there, but this one I thought was the most inclusive.

Good luck,

Robert

@dennish posted:

Thanks Rich!  The video only covers the power cord and rollers.  It does mention a 16 gauge power cord.  Should  the wiring in the transformer be 16 gauge?

My original question was:  Can I use the typical, coated, solid #12 AWG wiring to replace the old cloth-coated wiring in the transformer?

The short answer is yes. 12 gauge is overkill but no issue. Thermoplastic insulation like thhn, thwn and similar is rated at around 170F and higher. Can't imagine temperature rating being an issue.