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Maybe a connection issue, however I 'm not sure if that's possible. Try opening him up. There might be something obviously wrong that you can't see from the outside

The only time I 've encountered a loco that doesn't always work, is when I got my plarail Bill. When his wheels wold get jammed he 's wheels wouldn't turn even if you unstuck him. After opening him up, I realized that the back half of the gear on the wheel was split, not the part with the gear the other part. I was able to swap the back wheels with a MMR Ben.I still use the Ben and sometimes I have to reposition the wheels to get him working.

I've taken him apart and dusted the thing down a few times now, he very rarely fails now