Tuneup and a new Plug for Lionel ZW Postwar Transformer

If you are handy and have a soldering gun and pliers, you can do the job yourself.

If not, try your local train hobby shop first.

Davis Lyons does transformer repairs if you need to ship it out.

Larry

Be certain that whoever does the work checks the transformer for line voltage leakage, circuit breaker operation and whistle control operation.

The last ZW brought to me for service had the whistle switch hang up midway. The transformer started overheating and smoking. The root cause was a bad centering/return spring. Fortunately for the owner, there was no permanent damage.

Don't forget roller wear too.

Davis Lyons did one for me last year.  Complete tune up, new rollers, cord and other parts to make it like new.  Very satisfied, excellent job.  If I need any transformer repairs in the future, he will be the person to do them.

Sonny

thanks for the suggestions!

Its not too hard. Unplugged, four screws on top and lift. There are four arms with graphite rollers on rivits or cotter pin (cp is not ideal, but if you check it annually and are mindful what one feels like when a wheel cracks you are fine). Look at each wheel, it must turn easily as the throttle moves, no flat spots or dragging. The arms, if without the roller wheel, will be metal edge on coil, the throttle bumps become more pronounced as it saws. Thats what else  you look for; sawing of the coil is bad , look for dark coloring from overheating on contact arms and crispy/ brown/ frays in wire covering. Time your breaker on a dead short and make sure off isn't showing voltage, wheel fully off the coil. There are some spots that benefit from lube but that is the general "quick tune" here.

 Your "mechanic" shouldn't mind if you know your machine but have them do the work anyhow. Its a compliment, and a knowledgeable customer is easiest to please. So pop the hood and take a look before hand. You dont change four tires if you get a flat, but If you sawed those coils, it may not be worth the gas and time to be told. Most would rather be working on something that will pay them more. Rollers might be fine and dandy and you just need a cord. 

 You should watch those new rollers a while to insure they keep spinning. I leave good ones alone if they aren't "too small" in my eyes. They have been "broke in".