GM4000 Switch Machine

GRANDMASTER

™

4000

Switch Machine

Installation and Maintenance Manual

P2444

GRANDMASTER™

4000

Switch Machine

Copyright

© 2000, 2002, 2007 ALSTOM Signaling Inc.

Installation and Maintenance Manual

ALSTOM SIGNALING INC.

P2444, Rev. January 2007 Printed in U.S.A.

LIST OF EFFECTIVE PAGES

P2444, GrandMaster

™ 4000 Switch Machine

ORIGINAL ISSUE DATE: Sep/00

CURRENT REVISION AND DATE: Jan/07

CURRENT CHANGE AND DATE: NONE i thru vi

1-1 thru 1-12

2-1 thru 2-10

3-1 thru 3-34

4-1 thru 4-12

5-1 thru 5-6

6-1 thru 6-22

7-1 thru 7-10

A-1 thru A-32

NONE

NONE

NONE

NONE

NONE

NONE

NONE

Page 7-7, item 44 updated from -01 to -02 (-01 is obsolete)

NONE

P2444, Rev. Jan/07 ALSTOM Signaling Inc.

THIS PAGE INTENTIONALLY LEFT BLANK


TABLE OF CONTENTS

SECTION 1 - GENERAL DESCRIPTION

SCOPE OF MANUAL ................................................................................................................ 1-1

SWITCH MACHINE OVERVIEW ............................................................................................ 1-1

FEATURES ................................................................................................................................. 1-2

Modular Design ..................................................................................................................... 1-2

Configurable Latchout ........................................................................................................... 1-2

Operating Power Configurations ........................................................................................... 1-2

Manual Operation Switch ...................................................................................................... 1-2

Electronic Clutch ................................................................................................................... 1-3

Slip Link Cam Bar ................................................................................................................. 1-3

Configuration Plug................................................................................................................. 1-3

MAJOR COMPONENTS ............................................................................................................ 1-4

Covers .................................................................................................................................... 1-4

Guards .................................................................................................................................... 1-4

Latch Stand Module............................................................................................................... 1-4

Hand Throw Module.............................................................................................................. 1-4

Amplifier................................................................................................................................ 1-6

Electrical Harness .................................................................................................................. 1-6

Motor ..................................................................................................................................... 1-6

5:1 Gearbox............................................................................................................................ 1-6

30:1 Gearbox.......................................................................................................................... 1-7

Main Drive ............................................................................................................................. 1-7

Point Detector Switch Module............................................................................................... 1-7

Point Detector System Module .............................................................................................. 1-7

Lock Rod ............................................................................................................................... 1-8

Point Detector Rod ................................................................................................................ 1-8

Cam Bar ................................................................................................................................. 1-8

Throw Bar .............................................................................................................................. 1-8

Cross Brace ............................................................................................................................ 1-8

SAFETY PRECAUTIONS FOR MAINTAINERS................................................................... 1-10

General Requirements.......................................................................................................... 1-10

Proper Attire ........................................................................................................................ 1-10

General Safety on Transit Property ..................................................................................... 1-10

Safety at Trackside............................................................................................................... 1-11

Safety at Switch Machines................................................................................................... 1-11

P2444, Rev. Jan/07 i ALSTOM Signaling Inc.

TABLE OF CONTENTS (Cont.)

SECTION 2 - THEORY OF OPERATION

INTRODUCTION ....................................................................................................................... 2-1

DRIVE TRAIN ............................................................................................................................ 2-1

SEQUENCE OF OPERATION ................................................................................................... 2-1

SWITCH MACHINE CONTROL............................................................................................... 2-2

Fail Safe Features................................................................................................................... 2-2

Universal Features ................................................................................................................. 2-3

NORMAL AND REVERSE LOCKING..................................................................................... 2-4

POINT DETECTION .................................................................................................................. 2-5

LATCHOUT ................................................................................................................................ 2-7

SECTION 3 - INSTALLATION

GENERAL ................................................................................................................................... 3-1

PROPERTY'S REQUIREMENTS .............................................................................................. 3-2

INSTALLATION PROCEDURES.............................................................................................. 3-2

Switch Machine Inspection.................................................................................................... 3-2

Switch Layout ........................................................................................................................ 3-3

Switch Machine Mounting..................................................................................................... 3-4

Electrical Wiring.................................................................................................................... 3-5

Field Wiring ..................................................................................................................... 3-5

Motor Wiring ................................................................................................................... 3-6

Wiring Configuration....................................................................................................... 3-8

Switch Machine Connecting and Adjusting .......................................................................... 3-9

Throw Rod ....................................................................................................................... 3-9

Lock Rod........................................................................................................................ 3-10

Connect and Initially Adjust Point-Detector Rod.......................................................... 3-12

Motor Limit Adjustment ................................................................................................ 3-14

Switch Machine Operation .................................................................................................. 3-15

Hand Crank .................................................................................................................... 3-15

Hand Throw ................................................................................................................... 3-17

Manual Operating Switch .............................................................................................. 3-18

LEFT-HAND OR RIGHT-HAND CONFIGURATION........................................................... 3-19

Throw Bar ............................................................................................................................ 3-19

Lock and Detector Rods ...................................................................................................... 3-20

Hand Throw Lever and Latch Stands .................................................................................. 3-21

BEFORE PLACING MACHINE IN SERVICE ....................................................................... 3-23

P2444, Rev. Jan/07 ii ALSTOM Signaling Inc.


SECTION 4 - SCHEDULED MAINTENANCE

INTRODUCTION ....................................................................................................................... 4-1

SPECIAL TOOLS AND TEST EQUIPMENT ........................................................................... 4-1

Hand Crank ............................................................................................................................ 4-1

AFTER FLOODING ................................................................................................................... 4-2

LUBRICATION GUIDELINES ................................................................................................. 4-2

PREVENTIVE MAINTENANCE INDEX ................................................................................. 4-2

SITE INSPECTION..................................................................................................................... 4-3

PREVENTIVE MAINTENANCE CHECKS.............................................................................. 4-3

Point Pressure Test................................................................................................................. 4-4

Switch Obstruction Test # 17................................................................................................. 4-4

Point Detector Check ............................................................................................................. 4-5

External PM Checks .............................................................................................................. 4-5

Internal PM Checks ............................................................................................................... 4-6

LOCK ROD AND POINT DETECTOR ADJUSTMENTS........................................................ 4-9

Lock Rod Adjustment (Narrow Notch) ................................................................................. 4-9

Lock Rod Adjustment (Wide Notch) ..................................................................................... 4-9

Point-Detector Rod Adjustment........................................................................................... 4-10

WEAR PLATE REPLACEMENT ............................................................................................ 4-12

SECTION 5 - TROUBLESHOOTING

PHILOSOPHY............................................................................................................................. 5-1

TROUBLESHOOTING............................................................................................................... 5-1

Amplifier LED Display.......................................................................................................... 5-4

Amplifier Fuse ....................................................................................................................... 5-6

SECTION 6 - CORRECTIVE MAINTENANCE

PURPOSE .................................................................................................................................... 6-1

REMOVAL AND REPLACEMENT PROCEDURES ............................................................... 6-1

Covers .................................................................................................................................... 6-2

Cross Brace ............................................................................................................................ 6-3

Amplifier................................................................................................................................ 6-4

Switches ................................................................................................................................. 6-5

Brushless DC Motor and 5:1 Gearbox................................................................................... 6-6

30:1 Gearbox.......................................................................................................................... 6-8

Hand Throw Lever............................................................................................................... 6-10

P2444, Rev. Jan/07 iii ALSTOM Signaling Inc.


Latch Stand .......................................................................................................................... 6-12

Main Drive ........................................................................................................................... 6-13

Lock Rod.............................................................................................................................. 6-15

Point Detector Module......................................................................................................... 6-15

Point Detector Switch Module............................................................................................. 6-17

Point Detector Rod............................................................................................................... 6-18

Housing ................................................................................................................................ 6-19

Throw Bar ............................................................................................................................ 6-20

Cam Bar ............................................................................................................................... 6-21

Throw Bar and Lock Rod Wear Plate Assembly................................................................. 6-22

SECTION 7 - PARTS CATALOG

GENERAL ................................................................................................................................... 7-1

PARTS LIST................................................................................................................................ 7-1

APPENDIX A - DRAWINGS

OVERVIEW ............................................................................................................................... A-1

WIRING AND CIRCUIT APPLICATIONS.............................................................................. A-2

INSTALLATION AND SPACE REQUIREMENTS............................................................... A-12

P2444, Rev. Jan/07 iv ALSTOM Signaling Inc.

LIST OF FIGURES

Figure No. Description Page

1-1

1-2

Model GM4000 Switch Machine - Exterior View .............................................. 1-5

Model GM4000 Switch Machine - Interior View ............................................... 1-9

Throw Bar Locking Position................................................................................ 2-4

Latch Out Components ........................................................................................ 2-8

6-3

6-4

6-5

6-6

6-7

6-8

6-9

6-10

3-16

3-17

4-1

4-2

6-1

6-2

3-8

3-9

3-10

3-11

3-12

3-13

3-14

3-15

2-1

2-2

3-1

3-2

3-3

3-4

3-5

3-6

3-7

Typical GM4000 Switch Layout ......................................................................... 3-1

Throw Rod Clearance .......................................................................................... 3-3

Typical Mounting of GM4000............................................................................. 3-4

Typical GM4000 Internal Wiring Components................................................... 3-6

Typical GM4000 Internal Wiring Connections (TB1) ........................................ 3-7

Terminal Wiring and Configuration Plug Location............................................. 3-8

Throw Rod Connection Hardware ..................................................................... 3-10

Lock Rod Connection Hardware ....................................................................... 3-10

Lock Rod Features and Components ................................................................. 3-11

Point-Detector Rod Connection Hardware ........................................................ 3-12

Point-Detector Rod Adjustment Hardware........................................................ 3-14

GM4000 Hand Crank Operation........................................................................ 3-16

Hand Throw Hardware ...................................................................................... 3-17

Manual Operation Hardware ............................................................................. 3-18

Throw Bar (Right and Left-Hand Configuration).............................................. 3-19

Lock and Detector Rod (Right and Left-Hand Configuration).......................... 3-20

Hand Throw Lever and Latch Stand Components............................................. 3-22

Internal GM4000 Components ............................................................................ 4-7

Point-Detector Rod Adjustment Components ................................................... 4-11

Cover Removal and Replacement Components .................................................. 6-2

Cross Brace Removal and Replacement Components......................................... 6-3

Amplifier Removal and Replacement Components ............................................ 6-5

Switch Removal and Replacement Components ................................................. 6-6

Motor and Gearbox Removal and Replacement Components............................. 6-8

Gearbox Removal and Replacement Components .............................................. 6-9

Hand Throw Lever Removal and Replacement Components............................ 6-11

Latch Stand Removal and Replacement Components ....................................... 6-12

Main Drive Removal and Replacement Components........................................ 6-14

Point Detector Module Removal and Replacement Components...................... 6-16

P2444, Rev. Jan/07 v ALSTOM Signaling Inc.

LIST OF FIGURES (Cont.)

Figure No. Description Page

6-11

6-12

7-1

Point Detector Switch Module Removal and Replacement Components ......... 6-18

Wear Plate Assembly Removal and Replacement ............................................ 6-22

Typical GM4000 Switch Machine....................................................................... 7-3

P2444, Rev. Jan/07 vi ALSTOM Signaling Inc.

LIST OF TABLES

Table No. Description Page

Switch Movement ............................................................................................... 2-5 2-1

5-1

5-2

Troubles Noticed from the Control Locations ..................................................... 5-2

Trackside Noted Symptoms ................................................................................. 5-3

P2444, Rev. Jan/07 vii ALSTOM Signaling Inc.


P2444, Rev. Jan/07 viii ALSTOM Signaling Inc.

PREFACE

ABOUT THE MANUAL

This manual is intended to provide the necessary information to maintain and ensure proper operation of an ALSTOM GrandMaster 4000 (GM4000) Switch Machine. The information provided is not limited to the components of the switch machine. Most of the drawings within this manual are final or approved. Some of the drawings that contain hardware not subject to change have been finalized and call-outs added. The balance of the drawings with call-outs will be added to this manual upon finalization.

The information in this manual is arranged into sections. The title and a brief description of each section follow:

Section 1 - General DESCRIPTION: This section gives general information on the components of the GM4000 Switch Machine. Safety precautions are also provided in this section.

Section 2 - THEORY OF OPERATION: This section gives general information on the operation of the GM4000 Switch Machine. Safety precautions are also provided in this section.

SECTION 3 - INSTALLATION: This section describes the field installation and setup of the

GM4000 Switch Machine.

Section 4 - PREVENTIVE MAINTENANCE: This section describes the tools, preventive maintenance procedures, and functional tests used on the GM4000 Switch Machine. The frequency and interval, for the performance of the given information, are also included.

Section 5 - TROUBLESHOOTING: This section describes possible failures/symptoms along with the corrective action for the GM4000 Switch Machine.

Section 6 - CORRECTIVE MAINTENANCE: This section describes the adjustment and replacement procedures associated with corrective maintenance of the GM4000 Switch Machine.

Section 7 - PARTS CATALOG: This section identifies and lists the spare parts associated with operations of the GM4000 Switch Machine.

APPENDIX A - DRAWINGS: this section has representative circuit drawings along with an installation and space requirement drawing of the GM4000 Switch Machine.




SECTION 1

GENERAL DESCRIPTION

SCOPE OF MANUAL

The purpose of this manual is to describe features of the ALSTOM GrandMaster 4000

™

(GM4000) electric switch machine and describe how to properly inspect, service, test, remove, and replace the recommended spare parts.

SWITCH MACHINE OVERVIEW

The universal design concept of the ALSTOM model GM4000 electric switch machine allows utilization at interlockings and derails regardless of the variations with existing switch machines, available power, and weights of rail. It is especially suitable for use in subways or on rapid transit properties.

The GM4000 weighs approximately 1000 pounds, measures 67.25 inches long, 40.83 inches wide, and 8.13 inches high and has a 6.5 inch stroke. The switch machine produces 4000 pounds of thrust utilizing 110V (AC or DC) operating energy.

The GM4000 switch machine incorporates all of the features required to meet interlocking practices. Some additional features include configurable latchout, operating power configurations, manual operation switch, an electronic clutch, and a slip link cam bar.

WARNING

Switch Calls, for a duration of 150 milliseconds or greater, will begin the switch machine unlocking process. If this condition exists, due to the control system used, a timing relay is required in the circuit connected to the switch machine.

P2444, Rev. Jan/07 1-1 ALSTOM Signaling Inc.

FEATURES

The GM4000 is designed for long life and low maintenance, and helps reduce inventory due to its field configurable change-out design. Its long life and low maintenance are attributable to a low stressed mechanical system, dry film lubrication (DFL), brushless motor, solid state amplifier, and significantly fewer parts than existing switch machines. The ease of field configurable change out is the result of a modular design concept with fewer and simplified adjustments.

The switch machine can be manually operated, utilizing supplied power, through a manual operation switch located near the motor. The switch machine can be manually operated, without utilizing supplied power, through the use of the hand-throw lever or hand crank. The hand crank operation is provided for making or checking setup adjustments when power is not available.

When power is available, manual operation through the use of the manual operation switch is recommended. These machine operating procedures are described in Section 2 of this manual.

Modular Design

The modular design of the GM4000 allows for ease of assembly and corrective maintenance.

Module locating pins in the switch machine base and a modular weight limit of 85 pounds, with most module weight less than 50 pounds, make it possible to remove and replace switch machine modules at trackside. Module removal and replacement procedures are described in Section 6 of this manual.

Configurable Latchout

The latchout capabilities of the GM4000 are configurable for location requirements and can be implemented or removed from the GM4000. Implemented latchout can be set for a restorable or non-restorable configuration. This feature is described in Section 2 of this manual.

Operating Power Configurations

The GM4000 functions without additional hardware in a number of supplied power conditions

(24 VDC, 110 VDC, or 110 VAC). This feature is described in the following sections of this manual.

Manual Operation Switch

The GM4000 can be field operated under power as long as a switch call is present and the switch machine amplifier is set in the “Local” operation mode. This operation is described in the following sections of this manual.


Electronic Clutch

The amplifier, utilized as an electronic clutch, uses current limit to determine the overload trip point of the motor. When the current limit is reached, a 5-second timer starts. After 5 seconds, the overload trip point is reached and the overload circuit shuts down power to the motor. To resume operation, either reverse the switch call or remove and restore supplied operational power.

Slip Link Cam Bar

When the lock rod is out of position relative to the cam bar locking dog, a fouled condition occurs. The slip link allows the cam bar to separate so the throw bar can complete stroke without locking the lock rod or indicating position (normal or reverse). This occurrence allows switch points to be moved by the hand throw device. With the lock rod out of position, the splitlink feature permits the hand throw lever to be positioned in the latch stand.

Configuration Plug

The configuration plug sets the switch machine for a 3-wire, 4-wire, or 5-wire application

(typical ALSTOM and US&S wiring applications). Two configuration plugs are labeled and shipped with the machine. The 3-wire plug is utilized for both 3-wire and 5-wire applications.


MAJOR COMPONENTS

The components of a mainline GM4000 switch machine are described in the following paragraphs and shown in Figures 1-1 and 1-2.

Covers

The GM4000 has three light-weight aluminum covers, as shown in Figure 1-1, that protect internal switch machine components from unwanted debris, water, or other material. These covers are attached to the switch machine by a hold-down on the housing and a removable strap that can be locked. An AAR wrench is required to remove or secure the straps that hold down the center and end covers. The covers are removable and can be utilized as a tray to hold hardware or tools during maintenance.

To remove a cover, a pivoting and upward pulling motion is required. The end covers attach to the housing by slipping the thick cover lip underneath the 3/8-inch diameter rods on either end of the housing and pivoting cover down to allow housing wall to be captured by the gasket groove of the cover.

Guards

Guards of the GM4000, as shown in Figure 1-1, protect the space for lateral movement of the throw bar, lock rod, and point detector rod by keeping away unwanted trackside debris, ballast, or other material.

Latch Stand Module

The latch stand module, as shown in Figure 1-1, is a support fixture and most importantly, a locking fixture for the hand throw lever and selector lever. The module bolts directly to the switch machine housing. The latch stand accommodates right or left hand switch machine configurations.

Hand Throw Module

The hand throw module, as shown in Figure 1-1, is a manual means of switching tracks without electrical power. While in a hand throw mode, the switch machine can complete stroke, lock switch points, and indicate normal or reverse position.


REAR COVER

(GM050-006-00)

CENTER COVER

(GM050-007-00)

THROW BAR GUARD

TRACK SIDE

(GM050-029-00)

HAND THROW

MODULE

(GM050-200-01)

THROW BAR GUARD

FIELD SIDE

(GM050-030-00)

LATCH STAND MODULE

(GM050-400-01)

LOCK ROD GUARD

TRACK SIDE

(GM050-031-00)

FRONT COVER

(GM050-008-00)

LOCK ROD GUARD

FIELD SIDE

(GM050-032-00)

Figure 1-1. Model GM4000 Switch Machine - Exterior View


Amplifier

The amplifier, as shown in Figure 1-2, controls the brushless DC motor by reading the switch call and configuring the motor power. The configured power causes the motor to turn in the proper direction. The amplifier monitors the condition of the GM4000 and checks for obstructions, motor faults, and amplifier faults. LEDs mounted on the amplifier housing display the switch machine operational status. The amplifier features an electronic clutch, three motor speeds, two current limits, inhibit circuits to disable the motor in a hand throw or hand crank mode, and non-restorable latchout.

The amplifier can be set for 4-wire (model 5G/5H), 3-wire (model 5E/5F and M23), or 5-wire

(model M23) switch machine configuration through the use of a configuration plug connected to the amplifier. The amplifier is mounted to the switch machine housing. All electrical connections to it are made by removable connectors. The amplifier and electrical connections are watertight and keyed to prevent damage to the amplifier. The amplifier is 2-1/4 inches wide,

13-1/4 inches long, 5-1/4 inches high, and field replaceable, and weighs approximately 6 pounds.

Electrical Harness

The electrical harness, as shown in Figure 1-2, connects the amplifier to field electrical connections at a terminal strip located at the point detector end of the switch machine. The electrical harness also connects limit switches located within some of the GM4000 modules to the amplifier. These limit switches provide feedback to the amplifier, stopping the motor at completion of a stroke. The switches and electrical connectors are watertight. The harness is also connected to configuration jumpers (switch machine speed, current limit, and latch-out) and the manual operation switch located within the motor end of the switch machine.

Motor

The brushless DC motor, as shown in Figure 1-2, works with the amplifier to drive the switch machine. The motor connects to the amplifier by a pigtail harness. The two-horsepower motor produces 110 inch-pounds of torque at 2500 rpm and bolts to the 5:1 gearbox. The motor is 4-

1/2 inches wide, 4-1/2 inches high, and 9 inches long. The motor weighs 12 pounds and is field replaceable.

5:1 Gearbox

The 5:1 gearbox, as shown in Figure 1-2, reduces motor output speed while increasing motor torque. This gearbox is basically maintenance-free with spring loaded lip seals, grease packed sealed bearings, and a synthetic lubricant for the helical gearing.


30:1 Gearbox

The 30:1 gearbox, flex coupled to the 5:1 gearbox as shown in Figure 1-2, reduces motor speed while increasing drive torque. It uses spring loaded lip seals, synthetic lubricant, and low stressed worm gearing.

The gearbox has dual input, either the hand crank or the motor. Gearbox output of the spur gear drives the main gear with up to a possible 10,000 inch-pounds of torque.

Main Drive

The main drive module’s patented low profile design, as shown in Figure 1-2, is the driving force and mechanical control of the switch machine. The main drive converts the rotating motion of the motor and gearboxes to linear motion of the cam bar and throw bar, both of which have cam surfaces designed to achieve proper stroke and timing with the lock rod and point detector rod.

The hand crank function of the main drive module cuts out operational power to the motor

(indicated by the “Remote/Local” LED of amplifier going off). The non-electrical operation of the switch machine is performed through the use of a hand crank.

When a faster non-electrical operation of the main drive is desired, the hand throw system is used. The manual select lever of the hand throw shuts off electrical power prior to permitting hand throw operation, thus allowing fast manual operation of throw bar, cam bar, lock rod, and point detection system.

Point Detector Switch Module

The point detector switch module, as shown in Figure 1-2, consists of two rotary cam switches

(right and left) used to indicate the switch point position and switch machine correspondence.

Each switch has six contacts. Two are used in the indication relay circuit for a correspondence condition; two are used to shunt the relay circuit in mid-stroke; one is used in the latch out circuit; and one is used in the point detector switch module LED circuit.

Point Detector System Module

The point detector module, as shown in Figure 1-2, bolts to the switch machine base and is the mechanical link between the point detector switches, lock rod, point detector rod, and cam bar.

The point detector module, along with other modules of the point detector system, indicate to the train control room if a switch point position has moved off point and can be utilized to indicate normal and reverse switch positioning.


Lock Rod

The lock rod, as shown in Figure 1-2, locks the front rod in position (normal or reverse) and consists of two rods (curved and straight) that can be adjusted for varying stroke of 6.5 to 3.5 inches. The lock rod accommodates right- or left-hand switch machine configurations.

The lock rod can be either a wide or narrow notch configuration. A narrow notch will not allow the machine to lock with a 1/4 inch obstruction, but a wide notch will. The lock rod can also be ordered with a threaded or spade end connection.

Point Detector Rod

The point detector rod, as shown in Figure 1-2, is used to detect the position or movement of the switch points and consists of three pieces that provide adjustment for varying (3.5 to 6.5 inches) switch machine stroke. The point detector rod can be ordered with a solid (threaded), spade, or threaded swivel end connection.

Cam Bar

The split link cam bar, not visible in Figure 1-2, is located under the main drive module and point detection modules. The cam bar moves in a machined channel within the switch machine base plate and is key to the operation of the point detector system. It is the mechanism that, in conjunction with the lock rod, locks the switch points in position. The cam bar also prevents indication while the switch machine is unlocked.

The slip link feature allows the cam bar to separate when the cam bar dog interferes with the lock rod, during completion of stroke. When the lock rod is in adjustment, the cam bar will automatically reset itself.

Throw Bar

The high strength throw bar, as shown in Figure 1-2, moves the switch points into position. The linear movement of the throw bar is generated by the integral cam and the rotary movement of the main drive crank. The high wear-resistant nickel plating eliminates the need of lubrication.

Cross Brace

The cross brace, as shown in Figure 1-2, is connected to the switch machine housing and supports the covers. Two cross braces are utilized in the switch machine and can be removed when required to give additional access to switch machine components.


MOTOR

(GM050-020-00)

5:1 GEARBOX

(GM050-026-00)

30:1 GEARBOX

(GM050-025-00)

THROW BAR

(GM050-002-00)

MAIN DRIVE

(GM050-100-01)

LOCK ROD

(GM050-300-0_ )

AMPLIFIER

(GM050-024-00)

CROSS BRACE

(GM050-005-00)

ELECTRICAL HARNESS

(GM050-900-01)

POINT DETECTOR

SWITCH MODULE

(GM050-800-01)

POINT DETECTOR ROD

(GMO5O-500-0_ )

POINT DETECTOR

SYSTEM MODULE

(GM050-700-01)

Figure 1-2. Model GM4000 Switch Machine - Interior View


SAFETY PRECAUTIONS FOR MAINTAINERS

Safe practices and common sense should always be used when working around any equipment.

Remember that good common sense and an understanding of the equipment is essential to any safety policy. The following describes health and safety standards for testing, alterations, repairs, improvements, or maintenance and applies to all maintenance personnel.

Note: Only authorized personnel who have reviewed and understand the information contained in this manual should be working on or around the switch machine.

General Requirements

Maintenance personnel shall comply with all local laws, rules, statutes, and regulations of governing or regulatory bodies within the geographical area of operation of the property (or

Authority). The requirements of these bodies or the user’s safety manual, whichever is more stringent, shall apply. When specific standards and details are not set forth in the manual, job specifications, or in the local laws and regulations referenced, standards published by the

Occupational Safety and Health Administration (OSHA) shall apply.

Proper Attire

1. Wear hard hats at all times.

2. Wear work shoes that are in good repair. Sneakers or tennis shoes are unsafe.

3. Wear clothing of proper fit. Loose fitting clothing is a hazard.

4. Avoid wearing belt-type key rings, and never carry tools in hip pockets.

General Safety on Transit Property

1. Never go out on a track of an operating railroad alone. Flagmen familiar with operating procedures and safety regulations must accompany all field maintenance personnel for maximum safety.

2. Always be alert and watchful as if each man were by himself. Be aware of the area you and others are in at all times. Yell or signal a warning if a dangerous situation develops.


Safety at Trackside

1. Check for a safe place to go before starting a job and be sure that enough safe places are available for all personnel on the track. Avoid sudden unplanned moves.

2. Never attempt to complete a job when a train is approaching.

3. Stand along the track in a clear area, stand where the train operator can see you, and take precautionary measures.

4. When crossing the tracks in front of or behind a stopped train, cross at a great enough distance from the train to be prepared for the train to proceed in either direction.

5. If boarding or dismounting a train, wait until the train comes to a full stop and the operator gives his or her permission. When carrying equipment or plans, always hand them up or down to allow free use of your hands.

6. Never step or walk on rails. Slipping off may result in serious injury.

7. Never lay tools or equipment on the rails. Objects left on a rail may derail or damage a train and flying debris could endanger personnel along the track.

8. When taking shelter from an approaching train, always watch for a train on the adjacent track.

9. Exercise special caution in tunnels, curves, and turnouts and on grades, as it is very difficult to determine the direction from which a train is approaching and its distance away.

Safety at Switch Machines

1. Keep fingers, feet, tools, and equipment out of switch points. Closing points can trap and crush hands and feet or damage tools and equipment. A wedge properly inserted between points will prevent an inadvertently energized switch machine from causing personal injury or equipment damage.

2. Never step on switch rods. Rod movement can cause serious foot injury or loss of balance.

3. Because the switch machine is often operated from a remote station (a local control room), be sure to notify this station that maintainers are working on or around a given switch machine. This notification may prevent the equipment from being activated during the reported service.

Note: For safety when working on machine and power is not required: 1) place

"LOCAL/REMOTE" switch on amplifier, in the local position; 2) rotate the hand crank cover to the open position to inhibit power to the motor.

4. When covers are removed from switch machine and gearing is exposed, keep fingers away from gearing.




SECTION 2

THEORY OF OPERATION

INTRODUCTION

The following is a functional overview of the GM4000 Switch Machine. The operation of a functional area is described along with associated modules and components.

DRIVE TRAIN

The GM4000 switch machine drive train consists of a motor, two gearboxes, and a main drive module. The motor is bolted to and drives a 5:1 gearbox. The 5:1 gearbox is coupled to and drives a 30:1 gearbox. The 30:1 gearbox drives 1.58:1 open spur gears. The splined main drive crank converts the rotational movement of gears into a linear movement of the throw bar and cam bar. This drive train, along with the throw bar, provides the thrust required to throw a switch in 4, 9, or 15 seconds in 110V (AC or DC) applications and 17 seconds in 24 VDC applications. Note that the speed of machine switching is dependent on supplied voltage.

SEQUENCE OF OPERATION

The correct order of operation for the GM4000 switch machine is as follows:

1. Break indication

2. Unlock

3. Throw

4. Lock

5. Indicate if switch points are in correct position

P2444, Rev. Sep/00 2-1 ALSTOM Signaling Inc.

SWITCH MACHINE CONTROL

The GM4000 uses a brushless DC motor and amplifier to drive the gear train. A brushless DC motor contains a permanent magnet armature that rotates and drives the 5:1 gearbox. The motor contains three field coils that surround the armature. The amplifier energizes and de-energizes the three field coils in a circular fashion. This creates a rotating magnetic field that pulls the armature around.

There are three hall sensors that monitor the armature and provide position information to the amplifier. This information is used to control the circuitry that powers the three field coils.

Together, the hall sensors and the amplifier regulate the motor’s RPM. The motor’s RPM is independent of the switch machine’s load. This implies that as the switch machine’s load varies, the switch machine’s throw time remains constant (the switch machine doesn’t slow down as the load increases).

The amplifier also monitors the motor’s current. Motor current is directly proportional to motor torque. As the switch machine sees an increased load such as point pressure or an obstruction, the motor sees an increased load. The amplifier senses the increased load on the motor and supplies more current to the motor thus increasing the motor torque. This additional motor torque increases the switch machine’s output force up to 4000 pounds.

Fail Safe Features

The universal switch machine amplifier is fail safe. Fail Safe, as used in the signaling context means that no failure will cause the system to be less safe than it would be if the failure had not occurred. That is, a failure will leave the system at least as safe as it was before the occurrence of the failure. One of the fail safe properties is that the motor cannot turn on at the wrong time.

For example, if the motor uses a transistor as a power switch and the transistor shorts out due to a surge, the motor cannot be allowed to turn on. The same holds true for the control lines on the motor controller. If there are transistors or transistor junctions used as switches on the control lines and one of them shorts out, the motor again cannot be allowed to run. Any failure mode of any part of the circuitry cannot cause the motor to operate. This includes transistor junctions shorting, opening or shorting to ground. A failure, or combination of failures, cannot cause or permit the motor to operate without the presence of a proper control signal (i.e. switch call).

The amplifier consists of two functional blocks. The first is the MOTOR DRIVER. There is one driver that switches power to each motor coil. If any or all of the drivers short out, the field coil associated with the damaged driver could be energized but it would not be de-energized at the appropriate time. The result: the motor would stop running.


The second is the AMPLIFIER, the device controlling the timing signals that control the motor driver. The amplifier controls the direction and the speed of the motor. The amplifier receives its power only from the switch machine control lines (i.e. switch call). The amplifier can only generate the proper sequence of signals when the control lines are energized therefore the motor can only run when the control lines are energized. Isolation will prevent the motor power from energizing the amplifier.

When the hand throw cut out limit switch or the hand crank cut out limit switch opens, the power to the amplifier is removed. This vitally disables the motor. The hand throw switch and the hand crank switch are both positive break limit switches. A positive break switch contains a mechanism that breaks open frozen or welded contacts.

Universal Features

The amplifier has a universal power supply. The GM4000 motor will operate at a power voltage range of 13 to 140 VDC or 88 to 140 VAC. There are no jumpers or special configurations needed for the amplifier to work over this wide voltage range.

The system has three speed settings available if the supply voltage is above 85 volts (DC or AC).

By installing the proper speed configuration jumper, the amplifier sets the motor RPM to allow the switch machine to throw in 4, 9, or 15 seconds. Below 85 volts, speeds will decrease proportionally with voltage.

The system has two current settings. High-current mode allows the machine to push up to 4000 pounds. The peak current is 35 amps. The external fuses must be rated at 17 amps. Lowcurrent mode allows the machine to push up to 2800 pounds. External fuses must be rated at 12 amps.

The optimal installation is the high-voltage, high-current mode since this provides the system with the most output force and allows for speed configuration. The universal power supply allows the system to run at high-voltage with the maximum force out and have a low-voltage battery backup. A low-voltage battery backup could supply a minimum of 2500 pound load requirement.

The amplifier will run off all input configurations. It can be installed in a 3-wire mode (Model

5E/5F or M23), 4-wire mode (Model 5G/5H), or 5-wire mode (Model M23).


NORMAL AND REVERSE LOCKING

Both the throw bar and lock rod must be locked at end of stroke in the “normal” and “reverse” switch point positions.

The throw bar is locked when the crank has traveled over the center of the throw bar, as shown in Figure 2-1. When the crank is in the over-center position any load on the throw bar (point pressure) drives the crank roller into the locking pocket of the throw bar. The cogging action of the motor and the gear train hold the crank in the over-center position if there is no load on the throw bar (point pressure).

The lock rod is locked when the cam bar dog is centered in the notch of the lock rod. If the crank isn’t over center of the throw bar or the cam bar dog isn’t centered in the lock rod notch then the motor limit cams must be adjusted per the Motor Limit Switch Adjustment Procedure.

CRANK

POSITION MARKS

(LOCKED POSITION)

THROW

BAR

MID-STROKE

(UN-LOCKED)

P2444, Rev. Jan/07

POSITION

MARKS

Figure 2-1. Throw Bar Locking Position

2-4 ALSTOM Signaling Inc.

POINT DETECTION

There are five modules that interact to perform point detection. They are the point detector system module, the point detector switch module, the point detector rod, the lock rod, and the cam bar. See the module descriptions for a detailed explanation.

The point detector switch module contains two “positive break” rotary cam switches. One switch rotates clockwise and one rotates counter-clockwise. A positive break switch contains a mechanism that breaks open frozen or welded contacts. Each rotary cam switch consists of six switches for indication, shunting, latchout, and continuity checking. Switches 1 and 2 are used to shunt the NWP and WP coils in the indication relays when the switch machine is unlocked.

Switches 3 and 4 are used to indicate that the switch points, switch machine, lock rod, and point detector rod are either in, or out of, correspondence. Switch number 5 is used for latchout.

Switch 6 is used for the continuity checking LED.

The range of motion for the rotary cam switch is 60 degrees. There is an external spring return mechanism that returns the switch to the 0 degree position. As the switch rotates, the six contacts actuate. See Table 2-1 for detailed switch movement.

Table 2-1. Switch Movement

Switch

Type 0

°

8

° 20°

21

°

60

°

3 indicate X-------------------------X

4 indicate X----------------X

5 latch out X----------------------------------X

6 LED X------------------------------(LED on)----------X (LED off)

NOTE: X-----X = closed switch

Switch 6 is used to check the mechanical interface (continuity) between the point detector switch actuating lever and rotary cam switch. When the switch machine is indicating a closed point, the

LED is on and at mid-stroke the LED is off.

If contacts 3, 4, and 5 are closed, the switch machine is in correspondence and the switch machine is indicating. Switches 3, 4, and 5 begin to open at 8 degrees. Switches 3, 4, and 5 are open at 20 degrees. The variance in switch closure is due to tolerances in the manufacturing process. Switches 3, 4, and 5 all must be closed before the point detector system indicates.

There is a range where the LED is on and the point detector is not indicating. This range occurs between 8 degrees and 21 degrees, when one of the indicating switches (3, 4, or 5) is open and the LED switch is closed.


There are two methods to verify that the point detector is indicating.

Method 1

1. The roller on the pivot arm is not touching the trigger on the point detector switch module.

2. The LED is on.

Method 2

1. Use a meter on TB-1, TB-2, and TB-3 to verify contact closure. Refer to schematic in

Appendix A.

Note: DO NOT use the LED when making point detector adjustments.

The point detector module interfaces between the point detector rod, the lock rod, the cam bar, and the point detector switch module. The point detector module actuates the rotary cam switches. As the point detector rod is displaced, the pivot arm rotates and actuates the rotary cam switch. If it moves the correct amount (1/4 inch or 3/8 inch), the indication switches open and the indication is broken.

The point detector system interfaces with the lock rod. There is one pin on each point detector pivot arm that senses the position of the lock rod. If the lock rod is out of correspondence, the pin on the pivot arm does not fall into the notch on the top of the lock rod and the point detector system will not indicate.

The cam bar interfaces with the point detector module. The cam bar locks the Lock rod. As the machine is operated, the first thing that happens is the cam bar separates the Latchout dogs and the pivot arms. This action rotates both rotary cam switches and thus breaks indication. The indication is broken before the cam bar dog unlocks the lock rod. In mid-stroke, the cam bar holds latchout dogs separated on the point detector module. This keeps both rotary cam switches rotated 25 degrees. Switches 1 and 2 stay closed and the NWP and the WP short out. As the switch machine reaches end-of-stroke and the machine is locked, the cam bar leaves the latchout dogs and the pivot arms rotate allowing the point detector switch module to indicate.


LATCHOUT

Latchout is an indication option and a mechanical memory system that stores position information of points that have moved at least 1/4 inch. Latchout can be configured for 1/4 inch or 3/8 inch. This section highlights the 1/4 inch latchout. The same principles apply for 3/8 inch latchout. Refer to the installation section of this manual for 1/4 inch versus 3/4 inch installations.

If there is a 1/4 inch movement of the switch points in a system without latchout, the point detector system will not indicate. If the points close back up, the system will re-indicate.

If latchout is used and there is a ¼-inch movement of the points, the point detector system will not indicate. If the points close back up, the system will not indicate regardless of the point position. The system is “latched out”.

There are two ways to reset the system once the system is latched out.

1. Restorable latchout - The system can be reset remotely or locally. To reset the system remotely in restorable latchout mode issue a switch call. To reset the machine locally; hand throw the machine, move the latchout dog as described in the scheduled maintenance section, or use the manual control switch. The motor will run in restorable latchout mode.

2. Non-Restorable latchout - The system can only be reset locally. To reset the machine hand throw the machine or move the latchout dog as described in the scheduled maintenance section. The motor will not run if the system is latched out in non-restorable latchout mode.

As the switch points open up the point detector rod moves, as shown in Figure 2-2. This movement causes the pivot arms to rotate. When the switch points are open 1/4 inch, the switch machine will not indicate. When the point detector rod moves an additional 0.045 inch, the latchout dog drops behind the retaining ring. The retaining ring and the latchout dog keeps the pivot arm from rotating even if the points close up. Since the pivot arm cannot rotate once the system is latched out, the rotary cam switch contact numbers 3, 4, and 5 of the point detector switch module are held open. If the three rotary cam switch contacts are open, the switch machine will not indicate.

The motor is disabled if the system is latched out in non-restorable latch out mode. There are three switches in parallel that are used to disable the amplifier. There is one switch located on each rotary cam switch (switch number 5) and there is one switch located on the top of the point detector switch module (latch out switch). If the amplifier is disabled, the motor will not run. If one of the three switches is closed, the motor will run. If all of the switches are open, the motor will not run.

In non-restorable latchout, the motor is dependent on the position of the latchout system and the position of the three latchout switches. The following sequence of events describes the latchout system under normal operation. Refer to Figure 2-2.


LATCH

OUT DOG

RETAINING

RING

PIVOT

ARM

ROTARY

CAM

SWITCH

POINT

DETECTOR

ROD

Figure 2-2. Latch Out Components

1. The machine is at end-of-stroke (Reverse) - Latch out switch number 5 on the “reverse” rotary cam switch is closed. The motor can run.

2. The machine moves to mid-stroke - The Latch out switch closes. Switch number 5 on the

“reverse” and “normal” rotary cam switches open. The motor can run.

3. The machine is at end-of-stroke (Normal) - Latch out switch number 5 on the “normal” rotary cam switch is closed. The motor can run.

4. The points move 1/4” + 0.045” - The mechanical system latches out. Switch number 5 on the “normal” rotary cam switch opens. (Now all three latchout switches are open.) The motor cannot run.

5. The latch out is reset - Latchout switch number 5 on the “normal” rotary cam switch closes.

The motor can run.

6. The machine moves to mid-stroke - The Latchout switch closes. Switch number 5 on the

“normal” rotary cam switch opens. The motor can run.

7. The machine is at end-of-stroke (Reverse) - Latchout switch number 5 on the “reverse” rotary cam switch is closed. The motor can run.

8. The points move 1/4” + 0.045” - The mechanical system latches out. Switch number 5 on the “reverse” rotary cam switch opens. (Now all three latchout switches are open.) The motor cannot run.


9. The latchout is reset - Latchout switch number 5 on the “reverse” rotary cam switch closes.

The motor can run.

In restorable latchout mode, the three parallel switches are shorted out via the latchout jumper located on TB1. The motor operates independently of the latch out system.




SECTION 3

INSTALLATION

GENERAL

There are two types of GM4000 switch machine installations:

• A new installation

• Replacement of an existing switch machine

Either type of installation may be performed with or without electrical energy available for operation of the switch machine. This Section describes both kinds of installations and the required switch machine adjustments.

Satisfactory operation of a switch layout depends on correct switch machine installation, proper switch layout adjustments, and periodic maintenance done at prescribed intervals. The Model

GM4000 switch machine should be installed in accordance with the property’s approved switch layout. Figure 3-1 shows a typical GM4000 switch machine layout with the associated mounting hardware identified.

THROW BAR

CONNECTION

HARDWARE

SWITCH

MACHINE

EXTENDED

TIES

P2444, Rev. Jan/07

SWITCH

POINTS

STOCK

RAIL

LOCK ROD &

POINT DETECTION

CONNECTION

HARDWARE

Figure 3-1. Typical GM4000 Switch Layout


PROPERTY’S REQUIREMENTS

Although this publication provides set-up information for a typical machine installation, the maintainer should always ensure the switch layout is installed in accordance with the property's own requirements.

INSTALLATION PROCEDURES

Installation of a new switch machine or the replacement of an existing machine consists of the following elements:

• Switch Machine Inspection

• Switch Layout (Requirements and Inspection)

• Switch Machine Mounting

• Electrical Wiring

• Switch Machine Connecting and Adjusting

• Switch Machine Operation

Specific drawings for switch machine wiring are given in Appendix A.

Switch Machine Inspection

The following steps describe visual inspection of external switch machine areas. This procedure should be performed before proceeding with the installation.

1. Check the configuration of the machine being installed. If the switch machine requires changing from left-hand to right-hand or vice versa, perform the procedure described in

"Left-Hand or Right-Hand Configuration” in this Section.

2. Check external surfaces for any damage (bent, cracked, or broken housings, hinges, or brackets).

3. Insure covers are installed properly and fit tightly.

4. Insure wear plates are in place (in the four positions).

5. Check the switch machine control requirements (either single or dual).

6. Check the switch machine for proper lock rod configuration (either narrow- or widenotch).

7. Check the switch machine for proper connection configuration (either spade end or thread end).

8. Check the switch machine for proper connection hardware.

9. Check for the required wiring harness and hardware.


Switch Layout

The following describes the installation requirements for a typical switch layout. All requirements should be met and checked before proceeding with the installation.

A maximum clearance of 1/4 inch (less is desirable) between the throw rod and the base of the stock rail, as shown in Figure 3-2, is essential. During operation, if proper clearance is not maintained, the points may move up relative to the stock rail (particularly if the stock rail is beveled for AREA detail 6100 Sampson points) and pry themselves away from the stock rail.

This motion may cause the point-detector rod in a switch machine to move enough to cause the indication contacts to be pushed open. The tendency of points to move up can be reduced by keeping ballast under the ties of the switch layout firmly tamped, and maintaining proper clearance.

THROW

ROD

1/4" (MAX)

Figure 3-2. Throw Rod Clearance

Inspection Points - The following describes the visual inspection points of a typical switch layout. All points should be checked before proceeding with the installation.

1. Inspect the heel blocks and bolts. Ensure that the thimble bolts in the heel blocks are in place and secure.

2. Check the heel block surface in relation to the switch by sighting down the rail from the heel block to switch point.

3. Check that rail braces are tight and tie straps are in place and secure.

4. Check all gauge plates, extension gauge plates, rail braces, and ties.

5. Check that the gauge distance of 56-1/2 inches is correct at the throw-bar and lock-rod locations.


Switch Machine Mounting

The two extended ties that directly support the switch machine must be reasonably straight and, where required, properly framed. All ties that support the switch machine must be well tamped for their entire length to minimize vibration from passing trains. Also, it is important to check the switch layout plans to verify the installation.

The stock rail and switch machine must be secured to well tamped ties, as shown in Figure 3-3, to prevent movement of the switch machine and stock rail when connected and operated. More than 4000 pounds of force can be exerted on the number one rod by the switch machine during operation.

New Installations - Either the ALSTOM standard mounting hole pattern (3/4-inch diameter bolts on 15-1/2 inch centers) or the US&S standard mounting hole pattern (7/8-inch diameter bolts on

16 inch centers) can be used. Do not locate the mounting hole pattern on the ties until the switch machine is positioned in accordance with an approved switch layout drawing.

Replacement Installations - The universal mounting hole pattern interfaces with the 3/4 inch diameter, 15-1/2 inch on center studs or bolts and 7/8 inch diameter, 16 inch on center studs or bolts.

STOCK

RAIL

MOUNTING

HOLES

EXTENDED

TIES (2)

P2444, Rev. Jan/07

SWITCH

MACHINE

Figure 3-3. Typical Mounting of GM4000


Electrical Wiring

The switch machine has internal electrical wiring that integrates the switch machine components

(switches, amplifier, LEDs, and motor) and field wiring requirements that are performed based upon location specific conditions (supplied motor power, indication circuits, and control circuits). The switch machine’s internal wiring is completed in the factory with a wiring harness and watertight connectors. Figure 3-4 identifies the internal wiring components of the GM4000 switch machine. The internal wiring schematic is in Appendix A.

Field Wiring

Field wiring associated with motor power, control, and indications enter the switch machine through a wire entrance fitting located at either end of the switch machine (motor or detector compartment).

Motor Power - Field wiring for motor power is connected to posts at terminal TB1 in accordance with the detail wiring plans that apply to the location. Typical power circuits are in Appendix A.

Control - Field wiring for switch machine control is connected to posts at terminal TB1 in accordance with the detail wiring plans that apply to the location. Typical power circuits are in

Appendix A.

Indications - Field wiring for point-detector provided indications are connected to posts on terminals TB1, TB2, and TB3 in accordance with the detail wiring plans that apply to the location. Typical indication circuits are in Appendix A.


TB1

TB2

TB4

WIRE

ENTRANCE

WIRE

ENTRANCE

TB3

Figure 3-4. Typical GM4000 Internal Wiring Components

Motor Wiring

There are three motor wiring configurations:

• 5-wire (three power lines and two auxiliary lines connected to a single AAR post)

• 4-wire (two power lines and two control lines)

• 3-wire (three power lines)

5-wire configuration - has three power lines that are energized only when the machine is requested to operate. The power lines are always 24 VDC, 110 VDC, or 120 VAC. These wires are connected to TB1-1, TB1-2, and TB1-3. The throw bar travels in one direction when power is applied to TB1-1 and TB1-2 and in the other direction when power is applied to the TB1-2 and

TB1-3. The two auxiliary wires, connected to TB1-8, are common feed.

4-wire configuration - has two energized power lines that can be 24 VDC, 110 VDC, or 120

VAC. These wires connect to TB1-1 and TB1-3. The control lines connect to TB1-4 and TB1-

5. The control lines are only energized when the machine is requested to operate.

3-wire configuration - has three power lines that are energized only when the machine is requested to operate. Power lines are always 24 VDC, 110 VDC, or 120 VAC. These wires are connected to TB1-1, TB1-2, and TB1-3. The throw bar travels in one direction when power is applied to TB1-1 and TB1-2 and in the other direction when power is applied to TB1-2 and

TB1-3.

5-wire 4-wire 3-wire


TB1

TB1-8 TB1-5 TB1-4 TB1-3 TB1-2 TB1-1

Figure 3-5. Typical GM4000 Internal Wiring Connections (TB1)

To operate the switch machine using the manual switch, in the 3-, 4-, or 5-wire configuration, set the “REMOTE/LOCAL” switch located on the amplifier to “LOCAL”. Send a request to throw the switch machine in either direction from the control house. Operate the machine with the manual switch. After completing manual switch operation, set the “REMOTE/LOCAL” switch to “REMOTE”.


Wiring Configuration

The machine must be configured for 3-wire (ALSTOM model 5E/5F, US&S model M23/M3),

4-wire (ALSTOM model 5G/5H), or 5-wire (US&S model M23A/M23B/M3) operation via a configuration plug. The GM4000 will not operate if the configuration plug is not installed.

Speed Configuration - The default speed of the GM4000 is four seconds. To configure the machine for slower speeds, install the appropriate speed select jumper located on terminal TB4, as shown in Figure 3-6.

Current Configuration - The default current configuration of the GM4000 is the high-current operation. The GM4000 produces up to 4000 pounds of force at the end of stroke at this current setting. If external fuses are used to limit the current to the GM4000, they must be rated above

17 amps.

The GM4000 can be configured for low-current operation by installing the low-current jumper on TB4. The GM4000 produces up to 2800 pounds of force at the end of stroke. If external fuses are used to limit the current to the GM4000, they must be rated above 12 amps.

CONFIGURATION

PLUG

LOW

CURRENT

JUMPER

TB4-1

TB4-2

TB4-3

TB4-4

TB4-5

SPEED

JUMPER

OPTION

Low Current

JUMPER

TB4-1 to TB4-2

P2444, Rev. Jan/07

Figure 3-6. Terminal Wiring and Configuration Plug Location


Switch Machine Connecting and Adjusting

The following describes connecting and adjusting specific switch layout hardware to the switch machine and assumes that proper mounting of the switch machine per switch layout plan has been completed together with all electrical wiring.

Note: When working on machine:

1. Place "LOCAL/REMOTE" switch in the “LOCAL” position.

2. Rotate the hand crank cover to the open position to inhibit power to the motor.

Throw Rod

The following describes the throw rod connection and adjustment within a typical switch layout.

Refer to Figure 3-7.

Crank machine to mid-stroke position. Refer to “Switch Machine Operating - Hand Crank” in this Section.

6. If this is a dual-control machine, move the selector lever to hand-throw mode.

7. Connect the throw rod clevis end to the throw bar coupler using the provided bolt, lock washer, and nut.

8. Slide the threaded end of throw rod through the “Lost Motion” basket and the connect rod to the basket using the double nuts provided.

9. Place and lock the switch machine into the “Normal” position. For a dual-control switch machine, use the hand throw; refer to “Switch Machine Operating - Hand Throw” in this

Section. For a single-control switch machine, use the hand crank or the manual operating switch; refer to the hand crank procedure of the manual operating switch procedure in this Section.

Note: Adjust the double nuts at the switch basket if switch points close, preventing the switch machine from completing stroke.

10. Adjust the double nuts at the switch basket to obtain a slight pressure condition at the closed switch point with no visible hardware deformation.

11. Secure this position using the switch basket double nuts.

12. Place switch machine into “Reverse” position, using the switch machine hand throw and repeat steps 6 and 7.

13. Hand throw, hand crank, or manually operate the switch machine back and forth a few times as a final check.

Note: Points should fit snugly and uniformly against the stock rails without being stressed by force from the throw bar. Excessive layout stress causes excessive wear to the switch machine.


LOST MOTION

BASKET

THROW

ROD

THROW

BAR

DOUBLE

NUTS

DOUBLE

NUTS

Figure 3-7. Throw Rod Connection Hardware

Lock Rod

The following describes lock rod connection and adjustment within a typical switch layout and assumes that proper throw bar connection and adjustment has been completed. Refer to Figures

3-8 and 3-9.

1. Move inner jam nut to end of lock rod thread (inner position).

2. Position the lock rod drop lug in center of threaded Section and install outer jam nut.

P2444, Rev. Jan/07

Figure 3-8. Lock Rod Connection Hardware


4. Hand throw, crank, or manually operate the switch machine to mid-stroke position.

5. Position the lock rod so that the locating marks, above notch, on the straight section, are centered over the cam bar.

6. Complete the stroke of switch machine so that the track side of the throw bar is drawn into the switch machine. Verify that the slip link of the cam bar did not separate. If it did separate, hand throw, crank, or manually operate the switch machine to mid-stroke.

This engages slip-link. Verify that locking dog on cam bar is centered through notch of lock rod.

7. Assemble lock connecting rod to the front rod and the lock rod drop lug.

8. Adjust drop lug height until the lock connecting rod is aligned parallel to the lock rod.

9. Tighten and lock nuts at lug to keep this adjustment.

10. Crank, hand throw, or manually operate machine to opposite end of stroke, but do not lock far switch point. a. Adjust the curved lock rod using double nuts so that locating marks on curved lock rod are centered over the cam bar. Complete the locking portion of the switch machine stroke. b. Check that the cam bar locking dog is centered in the lock rod notch. c. Tighten and lock field side lock rod nuts to keep this adjustment.

11. Hand throw, crank, or manually operate the switch machine back and forth a few times and verify that cam bar does not separate.

12. Refer to the adjustments Section of this manual for the proper positioning of wide notches relative to the cam bar locking dog.

CURVED

LOCK ROD

ADJUSTING

NUTS

CURVED

LOCK ROD

SECTION

LOCK ROD

LOCATING

MARKS

LOCK ROD

NOTCHES

STRAIGHT

LOCK ROD

SECTION

Figure 3-9. Lock Rod Features and Components


Connect and Initially Adjust Point-Detector Rod

When working on the machine:

1. Place the "LOCAL/REMOTE" switch in the “LOCAL” position.


The following describes point-detector connection and adjustment associated with wide- and narrow-notch lock rods. These procedures assume that connection of the throw bar and lock rod to the track switch has been completed together with all electrical wiring.

1. Fasten the point-detector connecting rod to the switch point lug and to the lug on the point-detector rod. Refer to Figure 3-10.

2. Manually operate the switch machine so that the point-detector rod is drawn out from the track side of the switch machine to close and lock the far switch point.

PO IN T-D ET EC TO R

RO D N EC K

P OINT-DE TE C TO R

R OD

PO IN T-D ETEC TO R

R O D LU G

PO IN T-D ETEC TO R

CO NN EC TING

RO D

SW ITC H

PO INT

LU G

Figure 3-10. Point-Detector Rod Connection Hardware


1. Position the spoon gauge into the necked down portion of the point-detector rod (track side). Use either the ¼-inch end of gauge or the 3/8-inch end (whichever is required by the railroad). Refer to Figure 3-11.

Note: For narrow-notch lock rods, if a ¼-inch obstruction test is done for point detection, the lock rod must be disconnected (floated). For wide-notch lock rods, if the lock rod is adjusted properly, the rod does not have to be disconnected.

2. Adjust position of point-detector rod at the lug end by adjusting the inner jam nut.

Adjust nut until pressure of the spoon gauge against the point-detector pivot arm on the point-detector system module engages the track-side point-detector switch lever.

Continue adjustment until the indication contacts of the rotary cam switch open

(outward position). If configured with latchout, continue adjusting until the latchout dog of the point detector system engages (approximately 3/4 more of a turn), as shown in

Figure 3-11.

Note: Check the indication contact status of the cam switch (open or closed circuit condition) using a meter on TB-2 or TB-3 in accordance with the field wiring.

3. Tighten and lock the jam nuts that hold this adjustment. Remove the spoon gauge. If configured with latchout, verify that the cam switch indication contacts are still open.

Release the latchout condition by applying a light force to the spring end of the latchout dog.

4. Crank the machine to the draw the point-detector rod into the machine.

5. Position the spoon gauge in the necked down portion of the point-detector rod (field side). Use either the ¼-inch end of gauge or the 3/8-inch end (as required by the railroad).

6. Adjust by loosening the nut and slave (1-1/8-inch open wrenches required) of the pointdetector bar and then by screwing in or out the free end of the rod (slave). Adjust the nut until the pressure of the spoon gauge against the point-detector pivot arm on the point-detector system module engages the field side point-detector switch lever.

Continue the adjustment until the cam switch indication contacts open (outward position). If configured with latchout, continue adjusting until the latchout dog of the point-detector system engages (approximately a additional 3/4 turn).

Note: Check cam switch indication contact status (open or closed circuit condition) using a meter on TB-2 or TB-3 in accordance with the field wiring for location.

7. Hold this position by screwing in the free end of point-detector rod. Remove the spoon gauge and release the latched out condition by applying a light force to the spring end of the latchout dog.

8. After making adjustments in both directions, manually the operate machine back and forth a few times. Check that the point-detector pivot arm engages the associated track


or the field side point-detector switch lever at the end of each throw-bar stroke with the spoon gauge installed and the associated indication contacts open.

9. Remove the spoon gauge and manually operate the machine back and forth a few times.

Check that the point-detector pivot arm engages the associated track or field side pointdetector switch lever at the end of each throw-bar stroke and the cam switch indication contacts DO NOT OPEN.

POINT-DETECTOR

SWITCH LEVER

ROTARY CAM

SWITCH

LATCHOUT

DOG

PIVOT

ARM

SPRING

SPOON

GAUGE

POINT-DETECTOR

ROD

Figure 3-11. Point-Detector Rod Adjustment Hardware

Motor Limit Adjustment

Cams mounted on the main drive gear are attached by slotted holes and provide motor limit adjustment. The following describes the motor limit adjustment procedure. This procedure assumes that connection of the throw bar and lock rod to the track switch has been completed, connection and adjustment of the point-detector rod has been completed, and all electrical wiring including speed configuration.

Note: This procedure requires switch machine operation, under electrical power, utilizing the manual operating switch as described in the following Switch

Machine Operation procedures.

1. Operate the switch machine to end of stroke, utilizing the manual operating switch described in the Switch Machine Operation procedures. Ensure the machine is properly locked as described in “Normal and Reverse Locking” in Section 2.


2. Insert the hand crank and check for an additional movement (over-travel) of 1/2 to

1/4 turn before binding.

• If Less than 1/4 turn of over-travel: Move the cam, actuating the motor limit switch, toward the switch as described in Step 3. This will cause the cam to actuate the motor limit switch earlier allowing more over-travel.

• If Greater than 1/2 turn of over-travel: Move the cam, actuating the motor limit switch, away from the switch as described in Step 3, and toward the drive gear timing mark. This will cause the cam to actuate the motor limit switch later allowing less over-travel.

3. Loosen the two socket head cap screws attaching the cam to the drive gear, move cam as described in Step 2, and tighten the two socket head cap screws.

4. Repeat Steps 1, 2 & 3 until 1/2 to 1/4 turn of over-travel is met.

Switch Machine Operation

The following describes three manual operating modes of the GM4000 Switch Machine. Two of these modes (Hand Crank and Hand-Throw Lever) can be performed before or after the supply power has been connected to the machine. The third operating mode (the Manual Operation

Switch) can only be used after proper electrical connections to the machine have been made and a switch call is present.

Note: When working on the machine, place the "LOCAL/REMOTE" switch on the amplifier to “LOCAL”.

Hand Crank

This procedure can be used on a switch machine that has been properly installed:

1. Remove the rear and center machine covers to expose the modules.

2. Check that the “LOCAL/REMOTE” switch position on amplifier is in “LOCAL”.

3. Insert the hand crank into the main drive by aligning the crank hole cover.

4. Manually operate the machine by turning the crank, making sure the lock rod notch is centered on the cam bar such that interference does not occur.

5. After hand cranking, remove hand crank, re-position crank hole cover to release cut-out switch, and position the “LOCAL/REMOTE” switch on amplifier to “REMOTE”.


LOCAL/REMOTE

SWITCH

CRANK

HOLE

COVER

LOCK

ROD

LOCK ROD

NOTCH

MARKS

LOCK

ROD

CAM

BAR

Figure 3-12. GM4000 Hand Crank Operation


Hand-Throw

This procedure is used to set up and perform a hand-throw operation on a switch machine that has been properly installed. Refer to Figure 3-13 for components described in the following.

1. Check that the location of the letters N and R on the hand-throw lever correspond to the position of the switch points. If the letters are out of correspondence, remove the mounting hardware holding the N and R letters to the hand-throw lever and properly position them. Replace mounting hardware to secure letters to lever.

2. Pivot the selector lever of hand throw from “POWER” to “HAND” position. This will prevent power from energizing the switch machine motor, eliminating the possibility of a remote switch machine operation and unlocking the hand-throw lever.

3. Pivot the hand-throw lever and lock in the latch stand. The pivot action causes the eccentric pin and gear of the hand-throw module to move internal mating components of the main drive module and associated switch machine components.

4. After hand throwing, pivot the selector lever from “HAND” to “POWER” and lock in the latch stand.

ECCENTRIC

PIN

HAND

THROW

GEAR

GRS

HAND

THROW

LEVER

P2444, Rev. Jan/07

SELECTOR

LEVER

Figure 3-13. Hand Throw Hardware


Manual Operating Switch

This procedure is used to set up and perform a manual switch machine operation using the manual operating switch of a properly installed switch machine. Refer to Figure 3-14 for the location of associated manual operating switch components described in the following procedure. Refer to the drawing in Appendix A for electrical connections.

1. Remove all covers to expose the modules.

2. Position the “LOCAL/REMOTE” switch on the amplifier to “LOCAL”.

3. Loosen the gold AAR nut of the test link (if used), or remove the DC+ wire from terminal block to cause an absence of normal or reverse position indication; this absence of indication will cause a switch call to be automatically issued. Alternatively, request a switch call from the dispatch office.

4. Place and hold the Manual Operating Switch in the position of the intended move.

5. Release the switch to stop the operation short of stroke completion. The motor will automatically stop when the stroke is completed if the switch is not released.

6. When finished using the manual operation switch, position the “LOCAL/REMOTE” switch on the amplifier to “REMOTE”.

LOCAL/REMOTE

SWITCH

TERMINAL

BLOCK

(TB4)

AMPLIFIER

MOTOR

MANUAL

OPERATING

SWITCH

TERMINAL

BLOCK

(TB3)

TERMINAL

BLOCK

(TB1)

Figure 3-14. Manual Operation Hardware


LEFT-HAND OR RIGHT-HAND CONFIGURATION

The following describes the switch machine hardware and procedures required to change switch machine configurations (right-hand or left-hand). This procedure assumes that all three switch machine covers and guards are removed.

Throw Bar

This procedure is used to set the throw bar of a properly installed switch machine for left-hand or right-hand operation. Refer to Figure 3-15 for the location of the associated switch components described in the following procedure.

1. Place "LOCAL/REMOTE" switch on amplifier in the “LOCAL” position.


3. Change the throw bar coupling from one end of the throw bar to the other.

LOCAL/REMOTE

SWITCH

HAND

CRANK

COVER

THROW

BAR

Figure 3-15. Throw Bar (Right and Left-Hand Configuration)


Lock and Detector Rods

This procedure is used to set the lock and detector rods of a properly installed switch machine, for left-hand or right-hand operation. Refer to Figure 3-16 for the location of associated switch components described in the following procedure.

1. Insert hand crank and rotate until a mid-stroke position is obtained.

2. Separate lock rod from lock-rod connecting rod if so connected. Remove lock rod from switch machine, rotate rod 180 degrees and insert from other end. The lock rod will now be in the opposite position.

3. Separate point-detector connecting rod and point-detector rod if so connected. Pull the point-detector rod out of switch machine, rotate the rod 180 degrees, and reinsert.

LOCK

ROD

POINT

DETECTOR

ROD

Figure 3-16. Lock and Detector Rod (Right and Left-Hand Configuration)


Hand-throw Lever and Latch Stands

This procedure is used to set the hand-throw lever and latch stands of a properly installed switch machine for left-hand or right-hand operation. Refer to Figure 3-17 for the location of the associated switch components described in the following procedure.

1. Place the selector lever into "HAND" position.

2. Rotate the hand-throw lever 90 degrees (to the vertical position) and remove the two bolts connecting the hand-throw lever to the hand-throw lever support. This makes it much easier to accomplish the remaining change-over steps.

3. Remove the eight bolts attaching latch stands to the switch machine housing.

4. Remove hand-throw cover plate from the opposite side of the switch machine housing.

5. Remove the two mount bolts attaching the hand-throw module to the housing.

6. While holding the hand-throw module with the hand-throw lever support in the vertical position and the select lever in hand position, disengage the bevel gears by pulling the module away from the housing by approximately 1/2 inch. Continue to remove the hand-throw module by pulling up and away to allow the hand-throw bevel gear to clear the motor-limit cam on the gear of the main drive module. Do not use a hammer or pry bar to separate the module.

7. Move the hand-throw module to the opposite side and reverse the last step. Clear the motor-limit cam but do not engage the bevel gears.

8. Through the housing opening where the hand-throw module was removed, visually check that the upper hand-throw dog of the main drive module is engaged in the lower hand-throw dog gear.

9. Look through the housing opening where the hand-throw module was removed to visually check that the timing mark on top of the lower hand-throw dog gear is centered in the housing opening.

10. Note: If the timing mark is not in the proper position, rotate the lower hand-throw dog gear until it reaches the proper position.

11. With the hand-throw lever support in the vertical position and s the elect lever in the hand position, engage the bevel gears. The module should slip in and the mounting flange should be flush with the switch machine housing.

12. Note: Very little pressure is required for this operation. Do not hammer or beat on the module.

13. Verify proper timing of the hand-throw module by rotating the hand-throw lever support until the top gears of the main-drive module move. Rotate the hand-throw lever support to the other side until the top gears of the main drive module move; this motion of the hand-throw level support should be equal on either side of the vertical position. If not, disengage the bevel gears and repeat steps 14 - 16.

14. Re-install the mounting flange hardware.

15. Re-install the two latch stands on side of the machine with the hand-throw module, using existing mounting hardware.

16. Re-install the hand-throw lever.


17. Insert the hand-throw lever into the latch stand and check that the cam-bar dog is engaged with lock rod.

18. Throw the switch to opposite position and check that the cam-bar dog is engaged with the lock rod.

19. Re-install the cover plate on the opposite side of the housing.

20. Re-install the connecting rods and lugs and readjust the lock rod and point detector rod.

21. Re-install the guards on the opposite sides.

22. Remove the hand crank and close the hand crank cover.

23. Return the “LOCAL” (remote switch on amplifier) to “REMOTE”.

24. Place the covers back on the machine.

25. Return the selector level on the hand throw to the power position and lock in the latch stand.

HAND

THROW

LEVER

SELECTOR

LEVER

LATCH

STAND (2)

SASIB

SASIB

GRS

RAILWAY

HAND THROW

COVER PLATE

P2444, Rev. Jan/07

Figure 3-17. Hand-throw Lever and Latch Stand Components


BEFORE PLACING MACHINE IN SERVICE

Perform the following in the sequence given:

1. Check inside the machine and remove any tools, rags, etc..

2. Insure the electrical harness is properly attached.

3. Clean and lubricate the switch as instructed by the railroad.

4. Check the hand-throw module to ensure that the power lever is in the power mode and not in the hand-mode position.

5. Check the electrical power to the motor.

6. Place the machine in “LOCAL” mode.

7. Using the Manual Operation Switch, located by the motor, cycle the machine back and forth to insure proper operation.

8. Return the amplifier switch to the “REMOTE” position.

9. Verify that all terminal jumpers are properly configured.

10. Connect the signal and indication wires to AAR terminals TB1, TB2, and TB3. The connections are given in Appendix A.

11. Replace the covers on the machine.

12. Insure all external locking features are in place.

13. Verify that the motor limit cams are adjusted correctly.




SECTION 4

SCHEDULED MAINTENANCE

INTRODUCTION

Preventive maintenance (PM) checks by maintainers, as well as periodic inspection of the switch machine, are required to ensure continued proper operation. This Section identifies the periodic inspection points of the switch machine and switch layout and describes the functional tests and related adjustments that should be made; a preventive maintenance index that summarizes the various checks and proposed intervals is also included.

SPECIAL TOOLS AND TEST EQUIPMENT

Following is a list of special tools and test equipment that will be required to perform scheduled maintenance as described in this Section. All special tools required to facilitate maintenance are shown in Section 7.

• ¼- and 3/8-inch Spoon Gauge

• Hand Crank

• Multimeter

• Switch Wrench 1-1/16 inch through 2 inch

• Terminal Nut Wrench, AAR or ALSTOM

• Switch Point Obstruction Gauge (1/8, 3/16, 1/4, 3/8)

Hand Crank

A hand crank is used to manually operate the machine to the full normal and reverse positions.

Hand crank operation can be used in either the presence or the absence of switch machine operational power. To use a hand crank, remove the cover over the amplifier module and turn the “LOCAL/REMOTE” switch to “LOCAL”. This switches control of the machine from the control room to the site. Next, remove the cover over the main drive module and rotate the hand crank cover on the main drive module to allow insertion of the hand crank. Remove the crank when the operation is complete and restore the hand-crank cover to the position blocking crank insertion .

Note: The manual operation switch can also be used to operate the machine. This switch can only be used when switch-machine operational power is present and a


switch call is placed on the machine. Refer to the operational description in

Section 3.

AFTER FLOODING

If the switch machine was flooded, clean and ensure all drain holes are clear. Cleaning consists of washing down with a water jet of low velocity. Dry out all water -- in cold weather, trapped water will freeze and prevent the switch from operating.

The amplifier should be removed from a flooded machine, washed out with distilled or deionized water, and replaced as described in Section 6. De-ionized or distilled water (most commonly used to clean steam irons) can usually be purchased at a grocery store. If flood water reached the main drive module bearings, replace the drive module as described in Section 6.

LUBRICATION GUIDELINES

The GM4000 is designed with dry-film lubricants and corrosion-resistant coatings on the external surfaces of high-wear components. These components do not require the use of greases or lubricating oils. However, the 5:1 and 30:1 gearboxes contain an oil lubricant, and these gearboxes are sealed so oil-level checks are not required. If gearbox seals appear to be leaking oil, refer to Section 6 for gearbox replacement.

PREVENTIVE MAINTENANCE INDEX

Table 4-1 lists the recommended intervals, preventive maintenance actions, and references to the associated maintenance procedures in this Section. If the switch machine is operated with morethan-usual frequency each day, these inspections should be done more often.

Table 4-1. Preventive Maintenance Index

Monthly

Quarterly

As Required

As Required

External Switch Machine Inspection

Wear Plate and Bushing Inspection

Internal Switch Machine Inspection

Site Inspection and PM checks

PM Checks

Point Detector Module Adjustment Obstruction Adjustments


SITE INSPECTION

A site inspection consists of making a visual check of the entire switch layout and recording any problems found. To fix recorded problems, use the corrective maintenance instructions in

Section 6.

WARNING

The switch machine can be remotely activated instantly, possibly causing personnel injury and equipment damage.

A checklist of primary inspection areas follows:

1. Inspect the switch machine housing, covers, and guards for physical damage or distortion.

2. Inspect around the complete switch layout, including between the points and stock rail for foreign material, ballast or excessive dirt, which might block motion of rods or points.

3. During winter months, check for snow and ice under the cut-away area of a switch point which meshes with stock rail. Ensure that snowmelters, if installed, are melting snow and ice.

4. Check that connecting hardware is secure and condition of connecting rods.

PREVENTIVE MAINTENANCE CHECKS

Preventive maintenance checks should be done on each switch machine, whether it operates independently or in conjunction with another switch machine. Preventive maintenance checks are intended to serve as a reference for fault isolation procedures. If a problem is found, take the necessary action to correct it.

WARNING

Keep clear of gears and switch points when machine is under remote operational control. Power to switch machine can be cut off at the control room. With covers removed, switch machine control can be changed from control room to machine. While in machine control, use caution as the machine can operate in a power mode by the manual operation switch located near the motor (see Figure 1-2). Either condition could cause equipment damage or personnel injury.


Point Pressure Test

Check switch points monthly and adjust the point pressure, if required, by performing the following procedure in the sequence given. Point pressure is the amount of pressure exerted by a switch point against a stock rail. Proper point pressure is determined by observing and listening to a point closing operation. Another method is measured by a maintainer through the resistance felt in the hand throw during point closure. Some resistance is acceptable but excessive resistance must be avoided.

1. Begin by using the hand crank or manual operation switch to operate machine to the end of the throw bar stroke (6.5 inches). The switch point should fit snugly against the stock rail.

2. Use a pry bar to pry the switch point away from the stock rail. The point should move slightly but not more than 1/8 inch.

3. If the switch point does not fit properly against the stock rail, adjust the nuts at the switch adjustment basket until the proper position and pressure is achieved.

4. Crank the switch machine to move the points to opposite position and test for proper pressure.

5. After the adjustments have been made for the normal and reverse positions, crank the machine back and forth a few times to double-check these adjustments.

Switch Obstruction Test # 17

The switch machine can be configured with a narrow- or wide-notched lock rod. Determine the type of lock rod and each month perform the following associated procedure in the sequence given. These tests are performed in accordance with FRA Rule 236.382.

Narrow-Notch Lock Rod:

1. Insert an obstruction gauge (1/4 inch for machines without latchout feature or 3/8 inch for machines with latchout feature) between the switch point and stock rail, 6 inches back of the point on the reverse side.

2. Operate the switch point against the obstruction gauge. The switch machine should not lock and the indication circuit contacts should not close.

3. Operate the switch point open and remove the obstruction gauge.

4. Insert the obstruction gauge between the switch point and stock rail at 6 inches back of the point on the normal side.

5. Operate the switch machine to move the points to close against the obstruction gauge.

6. The switch machine should not lock and the indication circuit contacts should not close.

7. Operate the machine to open the switch point and remove the obstruction gauge.

8. Operate the switch machine to close and lock points in the normal and reverse positions without obstruction. Check that point position and point pressure have not been changed.

9. If the machine fails the obstruction test by locking with the obstruction gauge between the switch point and stock rail, the lock rod must be adjusted as described in this

Section.


Wide-Notch Lock Rod:

1. Insert an obstruction gauge (1/4 inch for machines without latchout feature or 3/8 inch for machines with latchout feature) between the switch point and stock rail, 6 inches back of the point on the reverse side.

2. Operate the switch point against the obstruction gauge. The switch machine should lock and the indication circuit contacts should close.

3. Operate the switch point open and remove the obstruction gauge.

4. Insert the obstruction gauge between the switch point and stock rail, 6 inches back of the point on the normal side.

5. Operate the switch machine to move the points to close against the obstruction gauge.

The switch machine should lock and the indication circuit contacts should close.

6. Operate the machine to open the switch point and remove the obstruction gauge.

7. Operate switch machine to close and lock points in the normal and reverse positions without obstruction. Check that the point position and point pressure have not been changed.

8. If the switch machine fails the obstruction test by not locking with the obstruction gauge between the switch point and stock rail, the lock rod must be adjusted as described in this

Section.

Point Detector Check

Check monthly unless otherwise recommended.

1. A Normal (N) or Reverse (R) indication should not be observed when switch points are operated in either position against a ¼-inch or 3/8-inch obstruction gauge inserted between the switch point and stock rail.

2. If an indication (N or R) is observed, the point detector rod must be checked and adjusted using the procedure described in this Section.

External PM Checks

Check monthly unless otherwise recommended:

• All machine tie-downs must be tight and securely fastened. Replace all damaged or missing parts per installation instructions.

• View external surfaces of the switch machine for any damage -- bent, cracked, or broken housings, hinges, or brackets. Check that all covers fit tightly.

• Record any out-of-normal conditions of looseness or any broken tie-downs.

• Put the machine in the hand-throw position. Operate the machine by using the hand throw while checking the rods extending from the machine for any obstruction and loss of motion from worn bushings.


Internal PM Checks

Check the following quarterly unless otherwise recommended (refer to Figure 4-1 for location of internal components):

• Remove the three covers and inspect for worn or damaged gaskets.

• Visually check the wear limits of:

1. Point detector flanged bushing

2. Lock rod wear plates

3. Throw bar wear plates

• Switch the amplifier toggle switch "LOCAL/REMOTE" to 'LOCAL" position. This places full control of the machine at the machine.

• Check the two motor-limit switches - Using the manual operation switch, hand throw, or hand crank, traverse through a complete cycle noting operation of both switches. The condition of each switch can be determined by using a multimeter at specific terminal block connections and checking continuity. Refer to the electrical schematic of the switch machine internal wiring (in Appendix A) for the proper connections.

1. Operate to end-of-stroke and check that the Motor Limit Cam of the main drive actuates the Latchout and proper Motor Limit Switch.

2. While at end-of-stroke, check the position of timing marks on the main drive gears.

3. While at end-of-stroke, check that the cam bar locking dog is centered in the lock rod notch.

4. Repeat procedure for opposite position.

• Check the latch-out, hand-throw, and hand-crank switches. The condition of each switch can be determined by using a multimeter at specific terminal block connections and checking continuity. Refer to the electrical schematic of switch machine internal wiring, located in

Appendix A, for proper connections.

1. Latch out switch is located on point detector switch module. Operate machine to midstroke position (main drive gear timing marks align in window of main drive upper support). Check that the amplifier “Remote/Local” LED is lit. Depress latch out switch.

The "Remote/Local" LED on amplifier module will go out if switch is working.

2. Hand throw switch, located in main drive module, will open (REMOTE/LOCAL LED on the amplifier module will go out) after the hand throw selector lever is moved out of the “POWER” position but before the hand throw selector lever is moved into the

"HAND" position. Preferably, mid-way between either position.

3. Hand crank switch is tested by opening hand crank cover to the position that allows insertion of a hand crank. The “Remote/Local” LED on the amplifier module should go out when hand crank is inserted.

Note: If the Remote/Local LED is lit, this indicates power is available at the motor.


MOTOR

(GM050-020-00)

5:1 GEARBOX

(GM050-026-00)

30:1 GEARBOX

(GM050-025-00)

THROW BAR

(GM050-002-00)

MAIN DRIVE

(GM050-100-01)

LOCK ROD

(GM050-300-0_ )

AMPLIFIER

(GM050-024-00)

CROSS BRACE

(GM050-005-00)

ELECTRICAL HARNESS

(GM050-900-01)

POINT DETECTOR

SWITCH MODULE

(GM050-800-01)

POINT DETECTOR ROD

(GMO5O-500-0_ )

POINT DETECTOR

SYSTEM MODULE

(GM050-700-01)

Figure 4-1. Internal GM4000 Components


• View modules for signs of wear or damaged parts. The following can be replaced in the field:

Main Drive

Point Detector Rod

Point Detector Switch

Point Detector

Note: Method of removal and replacement of modules is covered in Section 6,

“Corrective Maintenance".

• Causes for replacement of modules:

− Amplifier - Refer to Section 5.

− Motor - Replace if the RED light on the amplifier module is lit and reset functions do not clear fault indication.

− Point Detector - Replace if parts are damaged such that point indication will not occur, if parts are worn or broken causing false indications due to wear or broken parts, or parts are out of calibration.

− Lock Rod - Replace if rod is bent, fractured or has wear on rubbing surfaces, which would preclude smooth sliding.

− Point Detector Rod - Replace if the rod is bent, will not slide smoothly in bushings, or lock nuts will not stay locked.

− Hand Throw Lever - Replace if gear teeth are broken or show excessive wear or the assembly does not move freely.


LOCK ROD AND POINT DETECTOR ADJUSTMENTS

For safety when working on machine and power is not required:

1. Place the "LOCAL/REMOTE" switch in the local position.

2. Rotate the hand crank cover to the open position to inhibit power to the motor. When using the manual operation switch while working on machine, place the

"LOCAL/REMOTE" switch in the local position. Use the manual operation switch to change machine position (normal or reverse).

Lock Rod Adjustment (Narrow Notch)

1. Remove the guards over lock and point-detector rods.

2. Operate the machine to close but not lock near the switch point. Ensure that the cam bar is centered in the lock rod slot and continue operating the machine until locking is complete.

3. When properly locked, the cam bar locking dog will be protruding an equal amount on either side of the lock rod.

4. Center the straight lock rod slot to locking dog using the inner and outer jam nuts associated with the lock rod drop lug. Tighten and lock nuts at drop lug to keep this adjustment.

5. Operate the machine to close, but do not lock far switch point. Ensure that the cam bar is centered in lock rod notch and continue cranking the machine until locking is complete.

6. Center the curved lock rod notch to the locking dog using the inner and outer nuts on the field side of the lock rod. Tighten and lock the field side lock rod nuts to retain this adjustment.

Lock Rod Adjustment (Wide Notch)

1. Remove the guards over the lock and point-detector rods.

2. Operate the machine to close near the switch point against a 1/4 inch obstruction. Make sure cam bar is in the lock rod notch.

3. Note: Spaces between the sides of the notch and the cam bar dog are not equal.

4. When locked, the cam bar locking dog will protrude an equal amount on either side of the lock rod.

5. Offset the straight lock rod slot to the locking dog using the inner and outer jam nuts associated with the lock rod drop lug. Tighten and lock nuts at drop lug to retain this adjustment.

6. Operate the machine to close the far switch point against a 1/4 inch obstruction. Ensure the cam bar is in the lock rod notch and continue operating the machine until locking is complete.

7. Offset the curved lock rod notch to the locking dog using the inner and outer nuts on the field side of the lock rod. Tighten and lock the field side lock rod nuts to retain this adjustment.


Point-Detector Rod Adjustment

Refer to Figure 4-2 while performing the following.

1. Operate machine to mid-stroke and position a point-detector-rod spoon gauge into the necked down portion on the track-side end of the point-detector rod. Use either the ¼inch or the 3/8-inch end of the spoon gauge, whichever is required by railroad.

2. Operate machine to close and lock the far switch point. Position the lever against the spoon gauge. If the track-side indication contacts of the point detector switch module are on, use the adjusting nut to adjust the position of the point-detector rod at the lug end.

3. Adjust the nut until the LED on the point detector switch module turns off. Continue adjusting until latch-out occurs. Tighten and lock the lug nuts to hold this adjustment and remove the spoon gauge. Release the latch-out condition by applying a light force to the end of the latch out dog.

4. Operate the machine to mid-stroke and position the point-detector rod spoon gauge into necked down portion on the field side of the point-detector rod. Use either the 1/4 inch or 3/8 inch end of the spoon gauge, whichever is required by the railroad.

5. Operate the machine to close and lock near the switch point. Position the lever against the spoon gauge; if the field side indicating contacts of the point detector switch module are on, adjustment is required. Adjust by first loosening the nuts on the point-detector bar and then by either screwing in or out on the free end of the bar. Adjust nut pressure on the gauge until the light on the field-side switch turns off, immediately followed by latch-out.

6. Lock the nut in this position by screwing in the free end of point-detector rod. Remove the spoon gauge. Release the latched-out condition by applying a light force to the end of the latch-out dog.

7. If point detection requirements cannot be achieved, examine all associated components for wear or fault before replacing the point detector system module.

8. After making adjustments in both directions, operate the machine back and forth a few times to check that (1) the light still comes on, at the end of each throw-bar stroke with the spoon gauge installed, and (2) no light comes on with the spoon gauge removed.

9. Remove the hand crank (if it was used) from the main drive module. Place the machine in operation.


POINT-DETECTOR

SWITCH LEVER

ROTARY CAM

SWITCH

LATCHOUT

DOG

PIVOT

ARM

SPRING

SPOON

GAUGE

POINT-DETECTOR

ROD

Figure 4-2. Point-Detector Rod Adjustment Components

WEAR PLATE REPLACEMENT

To replace the wear plates on the throw bar and the lock rod module, refer to the Throw Bar and

Lock Rod Wear Plate Assembly procedure described in Section 6.




SECTION 5

TROUBLESHOOTING

PHILOSOPHY

Troubleshooting the GM4000 switch machine can be performed in a control location or at the wayside. In the control location, an understanding of relay operation and knowledge of circuit plans is essential. At wayside, an understanding of the switch machine operation along with knowledge of switch machine setup and layout is essential.

TROUBLESHOOTING

The following troubleshooting information helps determine if a switch machine and its associated circuit equipment are faulty. Table 5-1 lists troubles/symptoms of abnormal switch machine circuit and trackside equipment operation as observed from the control location. This table also describes the corrective action(s) required.

Table 5-2 lists troubles/symptoms of abnormal switch machine circuit and trackside equipment operation as observed from the wayside location. This table also describes the corrective action required.

Troubleshooting performed at a wayside location, using the amplifier LED display of a switch machine, is given in this section together with the required corrective action. The corrective action repair procedures associated with given switch machine and wayside equipment can be found in this manual.

P2444, Rev. Feb/02 5-1 ALSTOM Signaling Inc.

Table 5-1. Troubles Noticed from the Control Locations

Trouble/ Symptom

1. Switch out of correspondence, Reverse or

Normal position relay down (per switch position request).

Corrective Action

1. Check for power at Normal and Reverse relay coil.

2. Check for bad relay.

2. Switch out of correspondence, switch machine(s) failed to move (per switch position request).

1. Check that Reverse or Normal relay is up.

2. Check for switch operational power at entrance rack. If none, check for blown fuse or switch machine amplifier.

3. Check for switch operational power at switch machine. If none, possible bad cable, loose hardware and/or connections.

4. Check for obstruction in rail points.

5. Check rail conditions in area.

6. Check that proper configuration plug is present.

7. Check switch machine amplifier LEDs for display. Refer to “Amplifier LED

Display” in this section.

8. Check fuse on underside of amplifier.


Table 5-2. Trackside Noted Symptoms

Trouble/ Symptom

1. Motor runs but points do not move.

Corrective Action

1. Linkage disconnected - reconnect throw rod to switch points.

2. Throw bar drive train disconnected check from main crank shaft back to motor.

3. Check Coupler.

2. Motor cuts out and “OVERLOAD” LED on amplifier lights. Refer to “Amplifier LED

Display” in this section.

1. Obstruction in points - remove obstructions.

2. Excessive resistance in track point system - determine cause and correct.

3. Excessive resistance in switch machine drive train - determine cause and correct.

3. Motor will not run with a proper switch call and “MOTOR” LED located on amplifier is not lit, but amplifier “RUN” LED is lit.

4. Motor will not run and “MOTOR” LED located on amplifier is lit.

5. Points move but switch machine does not lock and indicate.

Confirm power to motor - “MOTOR” LED malfunction in conjunction with faulty motor; replace motor and amplifier module.

1. Reset Amplifier.

2. Check internal switch machine wiring.

3. Replace motor module

Cam bar has separated - determine cause: friction drag or blockage in cam bar track or out of adjustment of lock rod.

6. Bent or cracked rods, couplings or lugs switch caused by a train running through closed points of layout. (Note: Any train speed will bend or break fittings.)

Inspect for damage to layout and components - confirm switch machine operation.


Table 5-2. Trackside Noted Symptoms (Continued)

Trouble/ Symptom Corrective Action

7. With selector lever in “HAND” position and hand throw lever operated in both directions, the switch machine does not throw.

1. Check switch machine layout for obstruction.

2. Operate hand throw lever while checking movement of internal switch machine components.

3. Remove hand throw module and check for damaged hand throw eccentric pin.

4. If pin is damaged, replace hand throw module.

8. “AMPLIFIER” LED on amplifier module is lit but switch machine operates.

1. Reset Amplifier.

2. Check internal switch machine wiring.

3. Replace motor module.

9. A switch call issued (normal or reverse), no

LEDs lit, motor not operating.

1. Check configuration plug is installed.

2. Check hand throw selector lever is latched in “POWER” position.

3. Check hand crank cutout switch is not activated.

4. Check latchout and reset.

5. Check fuse on underside of amplifier.

Amplifier LED Display

The following LED displays help determine faulty switch machine equipment. The LED displays for Normal operation as well as Abnormal operation are given in Table 5-3.

Note: LED displays occur only while the operation (Normal or Abnormal) is being performed and operating power is being supplied to the amplifier of the switch machine. Without operational power, the LEDs of the amplifier remain off.


Amplifier LED

Normal Operation

Automatic operation

Table 5-3. Amplifier LED Displays

Run Motor Amplifier

on

Overload off off off

Hand off off off off

Abnormal Operation

Motor fault

Amplifier Fault

Overload Fault off off

on off off off on off

The Overload function is an electronic clutch. The motor current is directly proportional to the motor torque. If there is an obstruction, the motor will deliver more torque, thus drawing more current. When the current reaches the current limit threshold, a 5-second timer starts. After 5 seconds, the overload circuit will shut down the motor.

An overload will occur if there is an obstruction in the rails or if the switch machine mechanically seizes (flooding, mechanical failure, etc.). If there is an overload, the amplifier will shut down power to the motor and control system. To run the machine, check the rails for obstructions and the switch machine for mechanical failures. If an obstruction is found and cleared, the machine can be run by issuing another switch call. The machine will operate properly and the overload LED will remain lit until the amplifier is reset.

Motor Fault

The Motor Fault function monitors the condition of the brushless DC motor. A Motor Fault can indicate several problems and can only be reset by the amplifier reset switch.

1. Short in the motor or bad Hall sensors. Hall sensors feed back position information to the Amplifier. This information helps the Amplifier to control the motor’s rotation. The motor will not run if the Hall sensors fail. Reset the switch machine. If that does not resolve the problem, replace the motor.

2. Damaged motor harness. If the motor harness is shorted or open the Motor fault will go on. Reset the switch machine. If that does not resolve the problem, replace the motor.


Amplifier Fault

The Amplifier fault function monitors the condition of the Amplifier. An amplifier fault can indicate several problems:

1. Shorted power leads: Check the field terminations. Reset the Amplifier.

2. Amplifier overheated: Turn off the switch machine for several minutes, then reset the

Amplifier.

3. Motor Overheated: Turn off the switch machine for several minutes, then reset the

Amplifier.

4. Under-voltage Condition: Check switch machine supplied voltage and verify it is within specification.

5. Short in internal wiring harness.

6. Faulty Amplifier: Reset the Amplifier. If that doesn’t work, replace the Amplifier.

There are three methods to reset the amplifier for an overload or amplifier fault.

Note: The amplifier fault LED will remain lit until the amplifier is reset.

1. There is a reset switch on the side of the amplifier. This switch can be used if power is supplied to the amplifier.

2. The amplifier is reset by removing power from the system and a switch call is issued.

3. The amplifier is reset by calling the machine to move in the opposite direction, (i.e. if the machine reaches the current limit in the normal direction, the amplifier is reset by calling the machine to the reverse direction).

A motor fault can only be cleared by depressing the amplifier reset switch while supply power is applied to the amplifier.

Amplifier Fuse

There is a 1-amp, 3AG fuse located on the bottom of the amplifier. This fuse is in series with the low-voltage control input on the amplifier. The fuse protects the amplifier from hooking up the high-voltage motor power to the low-voltage control in the 4-wire configuration.


SECTION 6

CORRECTIVE MAINTENANCE

PURPOSE

This section describes removal and replacement procedures of major components found to be faulty through inspection and test procedures described in Section 4, Scheduled Maintenance and

Section 5, Troubleshooting. The removal and replacement procedure, for a given component, describes any adjustment or test along with special tools that may be required to complete the procedure. Recommended spare parts are identified and shown in "SECTION 7 - PARTS

CATALOG".

REMOVAL AND REPLACEMENT PROCEDURES

The following are removal and replacement procedures for specific switch machine components.

These procedures should be followed in the sequence given. Tools and adjustments, if required, are described in the procedure.

WARNING

Keep clear of gears and switch points when machine is under operational control. Power to switch machine must be cut off at control room before any removal or replacement procedure is performed.


Covers

All three covers are attached and held to the switch machine housing by cover straps and clamps, as shown in Figure 6-1. The following procedure can be used to remove and replace any one of the three switch machine covers. No special tools are required.

Removal Procedure

1. Remove lock from cover strap, if utilized, and release cover clamp.

2. Pivot cover strap on hinge pin of housing to expose covers.

3. Pivot cover to a vertical position on hinge pin of housing. Remove cover when pivot receptacle in cover clears pivot pin in housing.

Replacement Procedure

1. With cover in vertical position, insert pivot receptacle in cover into hinge pin of housing.

2. Pivot cover about the hinge pin of housing until cover is horizontal and resting on the machine housing.

3. Replace cover strap and lock if utilized.

SASIB

SASIB

GRS

RAILWAY

COVER

STRAP

Figure 6-1. Cover Removal and Replacement Components


Cross Brace

Both cross braces are attached and held to the switch machine housing. The following procedure can be used to remove and replace either one of the switch machine cross braces. Refer to

Figure 6-2 while performing this procedure. No adjustments or special tools are required.


1. Remove motor end and center covers.

2. Remove two socket head cap screws on each side attaching cross brace to switch machine housing.

3. Remove by pulling upward while separating cross brace from machined cavity in switch machine housing.

4. Check cross brace for cracks or fractures that may allow water to enter switch machine or compromise the strength of cross brace.


1. Insert cross brace into machined cavity of switch machine housing.

2. Install two socket head cap screws on each side attaching cross brace to switch machine housing.

SCREWS (2)

P2444, Rev. Jan/07

SCREWS (2) CROSS

BRACE

Figure 6-2. Cross Brace Removal and Replacement Components


Amplifier

Perform the following procedure, in sequence given, to remove and replace the switch machine amplifier. Refer to Figure 6-3 while performing this procedure. No adjustment procedures or special tools are required.

WARNING

Power to switch machine must be cut off at control room before performing this removal or replacement procedure.


1. Remove motor end cover, center cover, and cross brace between covers.

2. Remove four pan head screws attaching amplifier to switch machine housing.

3. Remove amplifier by pulling upward while checking wire harness clearance.

4. Disconnect two wiring harness 23-way amp connectors, and motor wiring three-pin connector from amplifier. Remove configuration plug.


1. Connect two wiring harness 23-way amp connectors, and motor wiring three-pin connector to amplifier. Replace configuration plug.

2. Carefully lower amplifier into switch machine while checking wire harness clearance.

3. Visually align amplifier mounting holes with mounting holes in switch housing.

4. Install four pan head screws into amplifier mounting holes.

5. Replace motor end and center cover along with cross brace between covers.

6. Operate switch machine to verify proper operation.


MOTOR

WIRING

CONNECTOR

PAN HEAD

SCREWS (4)

AMPLIFIER

WIRING

HARNESS

CONECTORS (2)

CONFIGURATION

PLUG

Figure 6-3. Amplifier Removal and Replacement Components

Switches

Perform the following procedure, in sequence given, to remove and replace switches. Refer to


WARNING



1. Remove associated switch machine covers.

2. Remove socket head cap screws attaching access cover to water tight switch housing.

3. Disconnect wiring harness from the switch and hardware attaching switch to case.

4. Lift switch out of switch machine and water tight case while checking wire harness clearance.



1. Connect wiring harness to replacement switch.

2. Carefully lower switch into switch machine while checking wire harness clearance.

3. Visually align mounting holes of switch to mounting holes in the switch machine water tight case.

4. Install socket head cap screws through mounting holes attaching switch to case.

5. Install socket head cap screws attaching access cover to water tight switch housing.

6. Replace the switch machine cover.


SCREWS (4)

SWITCH

HOUSING

Figure 6-4. Switch Removal and Replacement Components

Brushless DC Motor and 5:1 Gearbox

The motor and gearbox must be removed as an assembly. After the assembly is removed from the switch machine, the motor can be separated from the gearbox. Perform the following procedure, in sequence given, to remove and replace the motor and gearbox assembly. Refer to


WARNING




1. Remove motor end and center cover along with cross brace between covers.

2. Remove motor wiring connector from amplifier.

3. Remove socket head cap screws and attached manual operation switch.

4. Remove four socket head cap screws attaching 5:1 gearbox to base plate.

5. Remove two jig pins from gearbox mounting flange and slide motor with 5:1 gearbox away from the 30:1 gearbox as far as space will allow or until the drive coupling between the 5:1 and 30:1 gearbox has separated.

6. Lift motor and gearbox out of switch machine while checking wire harness and drive coupling clearance. Remove drive coupler and keys (2).

7. If required, separate motor from 5:1 gearbox by removing four socket head cap screws attaching motor to gearbox.


1. Connect motor to 5:1 gearbox, if separated.

2. Attach motor wiring to amplifier and install drive coupler to 5:1 gearbox.

3. Lower motor and 5:1 gearbox assembly into switch machine while checking drive coupling and wire harness clearance.

4. Slide motor and 5:1 gearbox toward 30:1 gearbox and drive gear assembly while aligning the drive coupler located between 5:1 and 30:1 gearboxes. Visually align mounting holes of 5:1 gearbox to mounting holes in machine base plate.

5. Install jig pins (2) and manual operation switch.

6. Install remaining socket head cap screws (4) attaching 5:1 gearbox to base plate.

7. Replace manual operation switch and attaching socket head cap screws.




MOTOR SCREWS (4)

MOTOR

WIRING

CONNECTOR

SCREWS (2)

MANUAL

OPERATION

SWITCH

JIG

PIN (2)

DRIVE

COUPLER

30:1

GEARBOX

Figure 6-5. Motor and Gearbox Removal and Replacement Components

30:1 Gearbox

Perform the following procedure, in sequence given, to remove and replace the 30:1 gearbox.

Refer to Figure 6-6 while performing this procedure. No adjustments or special tools are required.

WARNING





2. Remove manual operation switch and motor with 5:1 gearbox.

3. Remove four socket head cap screws attaching 30:1 gearbox to machine base plate.

4. Lift 30:1 gearbox off locating pins in base plate and out of switch machine by pulling upward while checking wire harness clearance.


1. Carefully lower 30:1 gearbox into machine while checking wire harness clearance.

2. Align locating holes of 30:1 gearbox to locating pins in the machine base plate.

3. Install four socket head cap screws through mounting holes attaching 30:1 gearbox to machine base plate. Note: Use proper length mounting screws.

4. Replace manual operation switch and motor with 5:1 gearbox.



30:1

GEARBOX

SCREWS (4)

Figure 6-6. Gearbox Removal and Replacement Components


Hand Throw Lever

Perform the following procedure to remove and replace the hand throw lever. No adjustments are required; however, a hand crank is required. Set-up instructions, when required, are given in the removal and replacement procedure. Follow procedure in the sequence given to avoid equipment damage. Refer to Figure 6-7 while performing the following procedure.

WARNING



1. Remove motor end and center cover.

2. Note position of switch machine (normal, mid-stroke, reverse). If in normal or reverse position, insert hand crank and rotate until switch machine is in mid-stroke.

3. Disengage hand throw from latch stand and position hand throw in mid-position while removing the two socket head cap screws attaching hand throw to machine housing.

4. Separate and remove hand throw assembly from switch machine housing.


1. With replacement hand throw module and switch machine in the mid-position, insert hand throw into switch machine making sure that the hand throw spur gear meshes properly with switch machine drive gears and mounting flange on hand throw is positioned flush to switch housing.

2. Align mounting holes of hand throw to switch housing and attach to machine housing using two socket head cap screws.

3. Secure the hand throw into latch stand, in position noted in step 3 of removal procedure.

4. Using hand crank, position switch machine as noted in step 2 of removal procedure.

5. Replace motor end and center cover.



HAND

CRANK

LATCH

HAND

THROW

LATCH

STAND

SCREWS (2)

MID-STROKE

(UN-LOCKED)

POSITION

MARKS

Figure 6-7. Hand Throw Lever Removal and Replacement Components


Latch Stand

Perform the following procedure, in sequence given, to remove and replace the latch stand.

Refer to Figure 6-8 while performing the following procedure. No adjustments or special tools are required.

WARNING



1. Remove four socket head cap screws attaching latch stand to side of switch machine housing. Move hand throw if required.


1. Align replacement latch stand and attach to machine housing using four socket head cap screws. Move hand throw if required.

2. Replace hand throw into latch stand.

SCREWS (4)

LATCH

STAND

P2444, Rev. Jan/07

Figure 6-8. Latch Stand Removal and Replacement Components


Main Drive

Perform the following procedure, in sequence given, to remove and replace the main drive.

Refer to Figure 6-9 while performing the following procedure. No adjustments or special tools are required.

WARNING




2. Using hand crank, move switch to mid-stroke position and align timing marks on gears of main drive.

3. Remove manual operation switch and motor with 5:1 gearbox.

4. Remove 30:1 gearbox and hand throw.

5. Remove hand crank and two socket head cap screws attaching hand crank cutout switch to main drive module.

6. Remove two socket head cap screws attaching hand throw switch to main drive module.

7. Remove six socket head cap screws attaching main drive to switch machine base plate.

8. Lift main drive off locating pins in base plate and out of switch machine by pulling upward while checking wire harness and switch clearance.


1. Align timing marks, on gears of replacement main drive.

2. Check that throw bar and cam bar are at mid-stroke.

3. Align locating holes of replacement main drive with locating pins in base plate.

4. Carefully lower main drive into switch machine while checking wire harness and switch clearance.

5. Install six large socket head cap screws attaching main drive to machine main drive module.


6. Replace two socket head cap screws attaching hand crank cutout switch to main drive module.

7. Replace two socket head cap screws attaching hand throw switch to base plate.

8. Replace 30:1 gearbox, hand throw, manual operation switch, and motor with 5:1 gearbox.



MOTOR MANUAL

OPERATION

SWITCH

5:1

GEARBOX

30:1

GEARBOX

HAND

CRANK

CUTOUT

SWITCH

HAND

THROW

MAIN

DRIVE

SCREWS

(6)

MAIN

DRIVE

MID-STROKE

(UN-LOCKED)

HAND

THROW

SCREWS

(2)

HAND

THROW

SWITCH

P2444, Rev. Jan/07

POSITION

MARKS

Figure 6-9. Main Drive Removal and Replacement Components


Lock Rod

Perform the following procedure, in sequence given, to remove and replace the lock rod. No special tools are required.

WARNING



1. Remove center cover.

2. Note position of switch machine (normal, mid-stroke, reverse). If in normal or reverse position, insert hand crank and rotate until switch machine is in mid-stroke.

3. Remove all connection hardware attaching lock rod to switch points.

4. Slide lock rod out of switch machine.


1. With switch machine in the mid-position, slide replacement lock rod into switch machine and install all connection hardware attaching lock rod to switch points.

2. Crank switch machine, using hand crank, to position noted in step 2 of removal procedure.

3. Perform Lock Rod Adjustment procedure, as described in Section 3.

4. Replace center cover.


Point Detector Module

Perform the following procedure, in sequence given, to remove and replace the point detector module. Refer to Figure 6-10 while performing the following procedure. No special tools are required.

WARNING




1. Remove point detector end cover.

2. Remove four socket head cap screws attaching point detector module to switch machine base plate.

3. Lift point detector module off locating pins in base plate and out of switch machine by pulling upward while checking wire harness clearance.


1. Align locating holes of replacement point detector module with locating pins in switch machine base plate.

2. Carefully lower point detector module into switch machine while checking wire harness clearance.

3. Install four socket head cap screws attaching point detector module to switch machine base plate.

4. Replace point detector end cover.


POINT

DETECTOR

MODULE

POINT

DETECTOR

MODULE

SCREW

(4)

Figure 6-10. Point Detector Module Removal and Replacement Components


Point Detector Switch Module

Perform the following procedure, in sequence given, to remove and replace the point detector switch module. Refer to Figure 6-11 while performing the following procedure. No special tools are required.

WARNING



1. Remove point detector end and center cover along with cross brace between covers.

2. Remove point detector module.

3. Remove 12 socket head cap screws attaching the two motor limit and one latch out switch.

4. Disconnect wiring harness.

5. Remove two socket head cap screws attaching point detector switch module to switch machine base plate.

6. Lift point detector switch module out of switch machine by pulling upward while checking wire harness clearance.


1. Carefully lower point detector switch module into switch machine while checking wire harness clearance.

2. Align mounting holes of replacement point detector switch module and mounting holes in switch machine base plate.

3. Install two socket head cap screws attaching point detector switch module to switch machine base plate.

5. Replace point detector module.

6. Replace point detector end and center cover along with cross brace between covers.



POINT

DETECTOR

SWITCH

MODULE

MOTOR LIMIT AND

LATCHOUT SWITCH (3) WIRE

HARNESS

CONNECTION

POINT

DETECTOR

SWITCH MODULE

SCREW (2)

Figure 6-11. Point Detector Switch Module Removal and Replacement Components

Point Detector Rod

Perform the following procedure, in sequence given, to remove and replace the point detector rod. No special tools are required.

WARNING




1. Remove all connection hardware attaching point detection rod to switch points.

2. Slide point detection rod out of switch machine.


1. Slide replacement point detection rod into switch machine.

2. Install all connection hardware attaching rod to switch points.


4. Adjust point detector rod, as described in Section 3, if required.

Housing

Perform the following procedure, in sequence given, to remove and replace the switch machine housing. Adjustments or special tools, if required, are described in the procedure.

WARNING



1. Remove motor end center and point detector end covers.

2. Remove hand throw and wiring harness attached to switch machine housing.

3. Remove amplifier, hand throw, point detector rod, field wiring and wire conduit.

4. Remove the seven large socket head cap screws attaching switch machine housing to switch machine base plate.

5. Lift housing by pulling upward while checking wire harness and switch clearance.


1. Align replacement housing mounting holes and cavities for throw bar and lock rod wear plates with corresponding mounting holes and cavities in base plate.

2. Carefully lower housing onto switch machine base plate while checking wire harness and component clearance.

3. Install the seven large socket head cap screws attaching housing to switch machine base plate.

4. Replace amplifier, hand throw, point detector rod, field wiring, and wire conduit.

5. Replace motor end, center, and point detector end covers.



Throw Bar

Perform the following procedure, in sequence given, to remove and replace the throw bar.

Adjustments or special tools, if required, are described in the procedure.

WARNING



1. Remove motor end, center, and point detector end covers along with cross braces between covers.

2. Remove all connecting hardware attaching throw bar to switch points.

3. Remove amplifier, manual operation switch, motor with 5:1 gearbox, 30:1 gearbox, hand throw, and main drive.

4. Remove the seven large socket head cap screws attaching switch machine housing to switch machine base plate.

5. Raise housing by pulling upward while removing throw bar.


1. Raise housing by pulling upward while installing replacement throw bar.


3. Replace the seven large socket head cap screws attaching switch machine housing to switch machine base plate.

4. Replace manual operation switch, motor with 5:1 gearbox, 30:1 gearbox, hand throw, and main drive.

5. Replace motor end, center, and point detector end covers along with cross braces between covers.



Cam Bar

Perform the following procedure, in sequence given, to remove and replace the cam bar.

Adjustments or special tools, if required, are described in the procedure.

WARNING



1. Remove motor end, center, and point detector end covers along with cross braces between covers.


3. Remove amplifier, manual operation switch, motor with 5:1 gearbox, 30:1 gearbox, hand throw, and main drive.

4. Remove throw bar, lock rod, point detection rod, point detection system, point detection switch module.

5. Remove switch machine housing.

6. Raise cam bar from machined cavity in switch machine base plate.


1. Insert replacement cam bar into machined cavity of switch machine base plate.

2. Replace throw bar, lock rod, point detection rod, point detection system, and point detection switch module.

3. Replace amplifier, manual operation switch, motor with 5:1 gearbox, 30:1 gearbox, hand throw, and main drive.

4. Replace motor end, center, and point detector end covers along with cross braces between covers.



Throw Bar and Lock Rod Wear Plate Assembly

Perform the following procedure, in sequence given, to remove and replace the cam bar. Refer to Figure 6-12 while performing the following procedure. No adjustments or special tools are required.

WARNING



1. Remove two socket head cap screws attaching wear plate assembly to side of switch machine housing.

2. Slide wear plate assembly out of cavity in switch machine housing and disassemble the four plates that configure the assembly.


1. Slide the replacement wear plate assembly into the cavity of the switch machine housing.

2. Install the two socket head cap screws attaching wear plate assembly to switch machine housing.

WEAR PLATE

MOUNTING

SCREWS (2)

THROW

BAR

LOCK

ROD

WEAR PLATE

MOUNTING

SCREWS (2)

Figure 6-12. Wear Plate Assembly Removal and Replacement


SECTION 7

PARTS CATALOG

GENERAL

This section identifies and lists the replaceable parts of the GM4000 switch machine along with kits, associated connecting hardware, and tools. These items and replaceable components are identified by a 10-digit drawing number. When ordering, always refer to the 10-digit drawing number.

A sub-assembly is provided as a field replaceable unit. A kit is provided as multiple components. The kit components are listed and can be ordered singularly. Removal and replacement instructions for the kit and kit components are provided when ordering.

PARTS LISTS

The illustration of the switch machine is followed by Tables 7-1 through 7-4; these tables are parts lists giving part descriptions and numbers of the field replaceable parts and kits, connecting hardware, and tools. Reference numbers are listed to precisely locate referenced parts in the illustration. This section of the manual covers currently available manufactured spare parts for field level replacement.




Signaling Inc.

3

28

73

75

4

23

62

89

53

36

47

77

"A"

76-85-86 24 73-74

55 5

Run

Motor Amplifier Overload

GM050-024-00

6

52

1

TB4

6

10-11 66-69

40

45 92-93

76-78 66-70 26

66-71

9

25 66-67

66-68

94

54

34-72

29

19-20 51 18 50

30 34-72

38

64-91 44-76-78

79-81

32

53

43

34-72

62

63

1

TB3

TB2 TB1

1

10

12

90

79-83

37

96

62-89

35-80-84

27-65-91

82

7

36-46-77

34-72

31

41

39

8 33-49 22 58-79-87

"A"

36

77

88

B

A

C

GRS

21

1

SECTION "A-A"

2 42 76-78 GM050-000-00

Figure 7-1. Typical GM4000 Switch Machine

Table 7-1. ALSTOM Model GM4000 Switch Machine Replaceable Components

14

15

16

11

12

13

17

REF. DESCRIPTION DRAWING

- Switch Machine GM4000 GM050-000-01

GM050-002-00

3 Housing GM050-003-00

GM050-005-00

GM050-006-00

GM050-007-00

GM050-008-00

GM050-009-00

GM050-010-00

Screw, .313-18 x .875 Lg Hex Hd Modified

Wear Plate, Side Lock Rod

Wear Plate, Top Lock Rod

Wear Plate, Bottom Lock Rod

Wear Plate, Bottom Throw Bar

Wear Plate, Side Throw Bar

Wear Plate, Top Throw Bar

GM050-011-00

GM050-012-00

GM050-013-00

GM050-014-00

GM050-015-00

GM050-016-00

GM050-017-00

GM050-018-00

GM050-019-00

GM050-020-00

GM050-021-00

25

26

27

20 Motor

21 Bracket, Plate Double Term Strip AAR 12 Post

22

23

24

Bracket, Angle Term Strip AAR 10 Post

Screw, .138 x .25 Lg Drive

Amplifier, w/Config Plugs and Stand-Offs

Worm Drive Module, 30:1

Gearbox Module, 5:1

Cover, Hand Throw

29

30

Guard, Throwbar Track Side

Guard, Throwbar Field Side

GM050-022-00

52681-010-00

GM050-024-00

GM050-025-00

GM050-026-00

GM050-027-00

GM050-028-00

GM050-029-00

GM050-030-00


Table 7-1. ALSTOM Model GM4000 Switch Machine Replaceable Components (Cont.)


39

40

41

41

41

38

39

39

39

31

32

33

34

35

43

44

48

49

50

51

52

Guard, Lock Rod Track Side

Guard, Lock Rod Field Side

Ring, Backing Brg Pd Rod

Washer, Conical .375 Nom x .630 OD x .039 Thk Serrated

Washer, .164 ID, .293 OD, .05 Thk Lock

Hand Throw Lever Comp

Lock Rod Comp (Threaded End Narrow Notch)

Lock Rod Comp (Threaded End Wide Notch)

Lock Rod Comp (Spade End Narrow Notch)

Lock Rod Comp (Spade End Wide Notch)

Latch Stand Comp

Rod Comp, Point Detector (Swivel)

Rod Comp, Point Detector (Solid)

Rod Comp, Point Detector (Spade End)

Point Detector System Comp

Point Detector Switch Comp

45 Harness

46 Strip, Terminal (10 Way)

47 Strip, Terminal (6 Way)

Nut, .242-24, .125 Thk, Jam

Bearing, Flanged Garlock 20FDU24

Jaw, Coupling Lovejoy L-095 1.00 Bore (Vibratite Screw)

Spider, Coupling Lovejoy L-095

Gasket, .625 x .625 x 203 Lg Adh Bk

GM050-031-00

GM050-032-00

GM050-033-00

00590-115-00

01273-003-ON

GM050-100-01

GM050-200-01

GM050-300-01

GM050-300-02

GM050-300-03

GM050-300-04

GM050-400-01

GM050-500-01

GM050-500-02

GM050-500-03

GM050-600-01

GM050-700-01

GM050-800-02

GM050-900-01

56140-019-00

56140-022-00

42839-008-00

08942-144-00

52592-009-00

52592-010-00

43460-038-00




73

74

75

70

71

72

76

77

78

79

65

66

67

62

63

64

68

69

59

60

61

62

53

54

55

56

Pin, Dowel .250 OD x .50 Lg

Pin, Dowel .375 OD x .75 Lg

Pin, Jig

Washer, .250 ID, .478 OD, .03 Thk Shk’prf

Washer, .242 ID, .563 OD, .040 Thk Flat

Nut, .242-24 x .188 Thk, Jam

Nut, .242-24, Binding

Screw, .625-11 x .75 Lg Soc Hd

Washer, .625 ID, 1.072 OD, .16 Thk Lock

Screw, .625-11 x 3.50 Lg Soc Hd












Screw, .313-18 x .75 Lg Hex Hd


Screw, .250-20 x 1.00 Lg Soc Hd Self Lock



00500-057-00

00500-058-00

42737-020-00

53029-075-00

43587-006-00

29855-014-00

01225-002-00

42839-005-00

42843-001-00

17708-147-00

01273-011-ON

17708-148-00

17708-128-00

17708-147-00

01273-008-ON

17708-146-00

17708-145-00

17708-124-00

17708-122-00

17708-121-00

17708-143-00

01273-007-ON

17708-142-00

00441-006-ON

01273-006-ON

17708-076-00

17708-119-00

01273-004-ON




85

86

87

88

89

80

81

82

83

84

93

94

95

90

91

92

Washer, .164 ID, .375 OD, .03 Thk Flat


Screw, .190-32 x 1.75 Lg But Hd (Vibratite)



Screw, .250-20 x .88 Lg But Hd



Strip, Terminal (12 Way)


Screw, Shoulder .313-18 Soc Hd .375 OD x 2.0 Lg

Washer, .625 ID, 1.072 OD, .16 Thk Lock



Plug Cap

Screw, .313-18 x 2.25 Lg Nylok

01250-006-ON

17708-130-00

17708-141-00

17708-129-00

17708-158-00

17708-139-00

17708-140-00

17708-138-00

56140-021-00

17708-112-00

17708-156-00

01273-011-ON

01273-008-ON

17708-122-00

20132-015-00

17708-157-00


4

Table 7-2. ALSTOM Model GM4000 Switch Machine Field Replaceable Kits

REF. QTY

1 -

2

DESCRIPTION

Kit, Lock Rod Wear Plate

Wear Plate, Side Lock Rod

2

3

1

1

-

1

2

1

-

Wear Plate, Top Lock Rod

Wear Plate, Bottom Lock Rod

Kit, Throw Bar Wear Plate

Wear Plate, Bottom Throw Bar

Wear Plate, Side Throw Bar

Wear Plate, Top Throw Bar

Kit, Point Detector Rod Bushing

5

6

7

8

1

1

2

-

-

-

-

-

Screw, .190-32 x 1.75 Lg. Soc Hd

Kit, Point Detector Pivot Arm Bushing

Bearing, Roller .625 Dia.

Pin, Pivot Arm

Kit, Latch-Out Dog Bearing

Kit, Latch-Out Dog Spring

Kit, Maintenance Tool

Kit, M23 Wiring Harness

GM050-012-00

GM050-013-00

GM050-014-00

GM050-015-00

GM050-016-00

GM050-017-00

08942-144-00

17708-130-00

49536-134-00

GM050-713-00

05713-090-00

12267-008-00

01273-004-0N

01272-007-0N

01581-052-00

GMK50-000-01

GMK50-010-01


Table 7-3. ALSTOM Model GM4000 Switch Machine Connecting Hardware


1

2

Point Detector Rod Drop Lug

Adjustable Lock Rod Drop Lug (Treaded Lock Rod)

GMA50-003-00

GMA50-008-01

3

4

5

Adjustable Lock Rod Drop Lug (Spade-End Lock Rod)

Throw Bar Coupler (Straight)

Throw Bar Coupler (Downset, 3.4-inches)

GMA50-008-02

GMA50-006-00

GMA50-007-00

Table 7-4. ALSTOM Model GM4000 Switch Machine Tools


1 Handcrank GMA50-001-00

GMA50-002-00


APPENDIX A

DRAWINGS

OVERVIEW

The following drawings are given to assist maintainers with installation, wiring, and troubleshooting a GM4000 switch machine.

P2444, Rev. Jan/07 A-1 ALSTOM Signaling Inc.

WIRING AND CIRCUIT APPLICATIONS

3-Wire Configuration

(For Replacement of ALSTOM Model 5E & 5F Switch Machines)

NWR LR

3E

OR

S

RWR

3E

RW

(NW)

TB1-1

TO CONTROL RELAYS

FOR SECOND SWITCH

OF CROSSOVER

WZR

DC(+)

DC(–)

NW

(RW)

TB1-3

–

+

24 - 32 OR

110 VOLTS DC

CW

TB1-2

O

Note:

Connect CW to TB1-2.

Connect RW to TB1-1 and NW to TB1-3.

If the machine travels in the wrong direction, interchange RW and NW.


3-Wire Configuration (Continued)

(For Replacement of ALSTOM Model 5E & 5F Switch Machines)

RWR

LR

3E

OR

S

NWR

3E

RW

(NW)

TB1-1

TO CONTROL RELAYS

FOR SECOND SWITCH

OF CROSSOVER

WZR

DC(+)

DC(–)

NW

(RW)

TB1-3

–

+

24 - 32 OR

110 VOLTS DC

CW

TB1-2

O

Note:

Connect CW to TB1-2.

Connect RW to TB1-1 and NW to TB1-3.

If the machine travels in the wrong direction, interchange RW and NW.



(For Replacement of US&S Model M23A or M3 Switch Machine)

External connections are shown to the main terminal board for a switch having the right-hand point normal closed. For a switch having the left-hand point normally closed, interchange the external leads to terminals 35 and D.

Typical circuit control of standard GM4000 brushless DC motor switch machine for connection to US&S high and low voltage, series-parallel field motor application using DP-25 and OR-11 shelf type of PNP-69 and ORP-60 plug in type relays.

N-WR

TO

CONTROL

CIRCUITS

-WR1

+ –

-WR

NW

WR

+

P

–

DP-25 or

PNP-69

RELAY

OR-11 or

ORP-60

RELAY

O

S

OR

BW

+

+

C

TB1-2

D

35

TB1-1

TB1-3

Note: If the machine travels in the wrong direction, interchange D and 35 connection.



(For Replacement of ALSTOM Model 5G & 5H Switch Machines)

Typical GM4000 wiring diagram for ALSTOM Model 5G/5H switch machine control circuit applications with left-hand point normally closed.

1 1

1

16 TO 140 VDC

OR

85 TO 140 VAC

TB1-1 TB1-3

NWR

WR

10

TB3

12

TB2 TB1

12

Note: If the machine travels in the wrong direction, interchange NWR and WR.



(For Replacement of ALSTOM Model 5G & 5H Switch Machines)

Typical GM4000 wiring diagram for ALSTOM Model 5G/5H switch machine control circuit applications with right-hand point normally closed.

1 1

1

16 TO 140 VDC

OR

85 TO 140 VAC

TB1-1 TB1-3

WR

NWR

10

TB3

12

TB2 TB1

12

Note: If the machine travels in the wrong direction, interchange NWR and WR.



(For Replacement of US&S Model M23A, M23B, or M3 Switch Machines)

External connections are shown to the main terminal board for a switch having the right-hand point normal closed. For a switch having the left-hand point normally closed, interchange the external leads to terminals 5 and 10.

Typical circuit control of standard GM4000 brushless DC motor switch machine for connection to US&S high and low voltage, series-parallel field motor application using DP-25 and OR-11 shelf type or PNP-69 and ORP-60 plug in type relays.

N-WR

TO

CONTROL

CIRCUITS

-WR1

-WR

+

–

WR

+

P

–

DP-25 OR

PNP-69

RELAY

OR-11 OR

ORP-60

RELAY

O

S

OR

NW

BW

+

D

TB1-2

+

B

TB1-8/TB4-6*

5

10

TB1-1

TB1-3

C

TB1-8/TB4-6*

Note: If the machine travels in the wrong direction, interchange wires 5 and 10.



(For Replacement of US&S Model M23A, M23B, or M3 Switch Machines)

External connections are shown to the main terminal board for a switch having the right-hand point normal closed. For a switch having the left-hand point normally closed, interchange the external leads to terminals 5 and 10.

Typical circuit control of standard GM4000 brushless DC motor switch machine for connection to US&S high and low voltage, series-parallel field motor application using PP-151, PN150BM and N-150SO relays.

N-WR

TO

CONTROL

CIRCUITS

-WR1

-WR

+ –

PN-151

RELAY

+ –

PN-15050

RELAY

O

S

OR

N110

-WRPR

+

B110

+

–

PN-1508M

RELAY

+

D

TB1-2

B

TB1-8/TB4-6*

5

TB1-1

10

TB1-3

C

TB1-8/TB4-6*

Note: If the machine travels in the wrong direction, interchange wires 5 and 10.


Terminal Block Pin Outs

1

1

1

10

TB3

12

TB2 TB1

12

* MOTOR LIMIT

P2444, Rev. Jan/07 A-9

AUX

LO

LO

POWER

POWER

POWER

12V CONTROL

12V CONTROL

HAND THROW

HAND THROW

ALSTOM Signaling Inc.

Restorable Latch Out Circuit

AMPLIFIER

NORMAL POINT

DETECTOR

ROTARY CAM

SWITCH 5

LATCH OUT

SWITCH

REVERSE POINT

DETECTOR

ROTARY CAM

SWITCH 5

MOTOR

DRIVER

MACHINE AT REVERSE

NOT LATCHED OUT

AAR TERMINAL POST

LATCH OUT JUMPER

MOTOR

DRIVER

MACHINE AT MID-STROKE

NOT LATCHED OUT

MOTOR

DRIVER

MACHINE AT NORMAL

NOT LATCHED OUT

MOTOR

DRIVER

MACHINE LATCHED OUT


Non-Restorable Latch Out Circuit

AMPLIFIER

NORMAL POINT

DETECTOR

ROTARY CAM

SWITCH 5

LATCH OUT

SWITCH

REVERSE POINT

DETECTOR

ROTARY CAM

SWITCH 5

MOTOR

DRIVER

MACHINE AT REVERSE

NOT LATCHED OUT

AAR TERMINAL POST

NO LATCH OUT

JUMPER

MOTOR

DRIVER

MACHINE AT MID-STROKE

NOT LATCHED OUT

MOTOR

DRIVER

MACHINE AT NORMAL

NOT LATCHED OUT

MOTOR

DRIVER

P2444, Rev. Jan/07

MACHINE LATCHED OUT

A-11 ALSTOM Signaling Inc.

INSTALLATION AND SPACE REQUIREMENTS

19.88

15.50 WITH

.781 DIA HOLES

OR

16.00 WITH

.906 DIA HOLES

33.90

2.00

8.50

6.50

THROW

11.50

2.00

20.00

17.00

2.80

2.00

24.42

1.65

11.00

2.75

4.74

8.13

67.25

P2444, Rev. Jan/07

22.25

18.43

***

A-12 ALSTOM Signaling Inc.

P2444, Rev. Jan/07

TB-3

1 shunt

2

3 shunt

4

5 indicate

6

7 indicate

8

9 motor limit

10 right

TB-2

1 shunt

2

TB-1

1 power

2 power

3 3 shunt

4 4 control

5 5 indicate

6

7 indicate

8

6 hand thr

7

8 aux

9 motor limit

10

9 latch out

10

11 hand crk

12 left

11 aux

12

Typical Polarized Switch Repeater Circuit, Single Switch

Point detector contacts are shown in position for right hand point normally closed.

INDICATION IN HAND THROW

RH point normally closed

LH point normally closed

To verify indication for left hand point normally closed, connect a meter to TB2 and or TB3 as follows:

NWP / WP (TB2-7 / TB2-5)

NWP WP

To verify indication for right hand point normally closed, connect a meter to TB2 and or TB3 as follows:

WP / NWP (TB2-7 / TB2-5)

Note 1

DC+

WP

DC+

NWP

DCDC-

When using shunt contacts connect the bold wires as shown

Note 1: A fuse is required for short circuit protection on the positive energy used for indication. Fuse: 10 amp, type SC, Form 1, class J or equivalent.

A-13 / A-14 Blank ALSTOM Signaling Inc.

energy end

TB-3

1 shunt

2

3 shunt

4

5 indicate

6

7 indicate

8

9 motor limit

10 right

P2444, Rev. Jan/07

Typical Polarized Switch Repeater Relay Circuit Crossover


INDICATION IN HAND THROW point detector end

TB-2 TB-1

1 shunt

2

1 power

2 power

3 3 shunt

4 4 control

5 5 indicate

6 6 hand thr

7 7 indicate

8 8 aux

9 motor limit

10

9 latch out

10

11 hand crk

12 left

11 aux

12

Note 1

DC+

WP

WP1

DC-


WP1A

NWP1

NWP


WP1

NWP1

WP

DC+

NWP

WP1A

DC-

3 shunt

4

5 indicate

6

7 indicate

8 relay end

TB-3

1 shunt

2

9 motor limit

10 right point detector end

TB-2 TB-1

1 shunt

2

1 power

2 power

3 3 shunt

4 4 control

5 5 indicate

6 6 hand thr

7 7 indicate

8 8 aux

9 motor limit

10

9 latch out

10

11 hand crk

12 left

11 aux

12


WP / NWP (TB2-6 / TB2-8)

NWP1 / WP1 (TB2-7 / TB2-5)

NWP1 / WP1A (TB3-7 / TB3-5)


NWP / WP (TB2-6 / TB2-8)

NWP1 / WP1A (TB2-7 / TB2-5)

NWP1 / WP1 (TB3-7 / TB3-5)




energy end

TB-3

1 shunt

2

3 shunt

4

5 indicate

6

7 indicate

8

9 motor limit

10 right

P2444, Rev. Jan/07

Typical Polarized Switch Repeater Relay Circuit Crossover


NO INDICATION IN HAND THROW point detector end

TB-2 TB-1

1 shunt

2

1 power

2 power

3 3 shunt

4 4 control

5 5 indicate

6 6 hand thr

7 7 indicate

8 8 aux

Note 1

9 motor limit

10

9 latch out

10

11 hand crk

12 left

11 aux

12


WP1A

NWP1

NWP


WP1

NWP1

WP

DC+

WP

WP1

DC-

DC+

NWP

WP1A

DC-

3 shunt

4

5 indicate

6

7 indicate

8 relay end

TB-3

1 shunt

2

9 motor limit


TB-2 TB-1

1 shunt

2

1 power

2 power

3 3 shunt

4 4 control

5 5 indicate

6 6 hand thr

7 7 indicate

8 8 aux

9 motor limit

10

11 hand crk

12 left

9 latch out

10

11 aux

12



WP / NWP

NWP1 / WP1

(TB2-6 / TB2-8)

(TB2-7 / TB2-5)

NWP1 / WP1A (TB3-7 / TB3-5)


NWP / WP (TB2-6 / TB2-8)

NWP1 / WP1A (TB2-7 / TB2-5)

NWP1 / WP1 (TB3-7 / TB3-5)



P2444, Rev. Jan/07

TB-3

1 shunt

2

3 shunt

4

5 indicate

6

7 indicate

8

9 motor limit

10 right

TB-2

1 shunt

2

TB-1

1 power

2 power

3 3 shunt

4 4 control

5 5 indicate

6

7 indicate

8

6 hand thr

7

8 aux

9 motor limit

10

9 latch out

10

11 hand crk

12 left

11 aux

12

Typical Polarized Switch Repeater Circuit, Single Switch






NWP / WP (TB2-7 / TB2-5)

NWP WP


WP / NWP (TB2-7 / TB2-5)

Note 1

DC+

WP

DC+

NWP


DCDC-



energy end

TB-3

1 shunt

2

3 shunt

4

5 indicate

6

7 indicate

8

9 motor limit

10 right

P2444, Rev. Jan/07

Typical 6 Wire Polarized Switch Repeater Relay Circuit Crossover



TB-2 TB-1

1 shunt

2

1 power

2 power

3 3 shunt

4 4 control

5 5 indicate

6 6 hand thr

7 7 indicate

8 8 aux

9 motor limit

10

9 latch out

10

11 hand crk

12 left

11 aux

12

Note 1

DC+

WP

WP1

DC-


WP1A

NWP1

NRWP1

NWP


WP1

NWP1

NRWP1

WP

DC+

NWP

WP1A

DC-

3 shunt

4

5 indicate

6

7 indicate

8 relay end

TB-3

1 shunt

2

9 motor limit


TB-2 TB-1

1 shunt

2

1 power

2 power

3 3 shunt

4 4 control

5 5 indicate

6 6 hand thr

7 7 indicate

8 8 aux


WP / NWP (TB2-6 / TB2-8)

NRWP1 / WP1 (TB2-7 / TB2-5)

NWP1 / WP1A (TB3-7 / TB3-5)


NWP / WP (TB2-6 / TB2-8)

NRWP1 / RWP1 (TB2-7 / TB2-5)

NWP1 / WP1 (TB3-7 / TB3-5)

9 motor limit

10

9 latch out

10

11 hand crk

12 left

11 aux

12




P2444, Rev. Jan/07

TB-3

1 shunt

2

3 shunt

4

5 indicate

6

7 indicate

8

9 motor limit

10 right

TB-2

1 shunt

2

TB-1

1 power

2 power

3 3 shunt

4 4 control

5 5 indicate

6

7 indicate

8

6 hand thr

7

8 aux

9 motor limit

10

9 latch out

10

11 hand crk

12 left

11 aux

12

Typical Neutral Switch Repeater Circuit, Single Switch


NO INDICATION IN HAND THROW



CRWP CNWP

NWP WP


CNWP / NWP

RWP / CRWP

(TB2-7 / TB2-5)

(TB3-6 / TB3-8)


CRWP / RWP

NWP / CNWP

(TB2-7 / TB2-5)

(TB3-6 / TB3-8)

Note 1

DC+

NWP

CNWP

DC-

DC+

RWP

CRWP

DC-




P2444, Rev. Jan/07

TB-3

1 shunt

2

3 shunt

4

5 indicate

6

7 indicate

8

9 motor limit

10 right

TB-2

1 shunt

2

TB-1

1 power

2 power

3 3 shunt

4 4 control

5 5 indicate

6

7 indicate

8

6 hand thr

7

8 aux

9 motor limit

10

9 latch out

10

11 hand crk

12 left

11 aux

12

Typical Neutral Switch Repeater Circuit, Single Switch





CRWP CNWP


CNWP / NWP

RWP / CRWP

(TB2-7 / TB2-5)

(TB3-6 / TB3-8)

RWP NWP


CRWP / RWP (TB2-7 / TB2-5)

NWP / CNWP (TB3-6 / TB3-8)

Note 1

DC+

NWP

CNWP

DC-

DC+

RWP

CRWP

DC-




5 indicate

6

7 indicate

8

9 motor limit

10 right energy end

TB-3

1 shunt

2

3 shunt

4

P2444, Rev. Jan/07

Typical Neutral Switch Repeater Relay Circuit Crossover


NO INDICATION IN HAND THROW point detector end

TB-2 TB-1

1 shunt

2

1 power

2 power

3 3 shunt

4 4 control

5 5 indicate

6 6 hand thr

7 7 indicate

8 8 aux

Note 1

9 motor limit

10

9 latch out

10

11 hand crk

12 left

11 aux

12


CRWP1

RWP1

RWP

CRWP

CNWP

NWP


CNWP1

NWP1

NWP

CNWP

CRWP

RWP

DC+

NWP1

CNWP1

CWP1

DC-

DC+

RWP1

CRWP1

CWP1

DC-

5 indicate

6

7 indicate

8

9 motor limit

10 right relay end

TB-3

1 shunt

2

3 shunt

4 point detector end

TB-2 TB-1

1 shunt

2

1 power

2 power

3 3 shunt

4 4 control

5 5 indicate

6 6 hand thr

7 7 indicate

8 8 aux

9 motor limit

10

9 latch out

10

11 hand crk

12 left

11 aux

12


NWP / CNWP

RWP / CRWP

(TB2-5 / TB2-7)

(TB3-6 / TB3-8)

CNWP1 / NWP1 (TB2-7 / TB2-5)

RWP1 / CRWP1 (TB3-6 / TB3-8)


RWP / CRWP

NWP / CNWP

(TB2-5 / TB2-7)

(TB3-6 / TB3-8)

CRWP1 / RWP1 (TB2-7 / TB2-5)

NWP1 / CNWP1 (TB3-6 / TB3-8)




energy end

TB-3

1 shunt

2

3 shunt

4

5 indicate

6

7 indicate

8

9 motor limit

10 right

P2444, Rev. Jan/07

Typical Neutral Switch Repeater Relay Circuit Crossover



TB-2 TB-1

1 shunt

2

1 power

2 power

3 3 shunt

4 4 control

5 5 indicate

6 6 hand thr

7 7 indicate

8 8 aux

Note 1

9 motor limit

10

9 latch out

10

11 hand crk

12 left

11 aux

12


CRWP1

RWP1

RWP

CRWP

CNWP

NWP


CNWP1

NWP1

NWP

CNWP

CRWP

RWP

DC+

NWP1

CNWP1

DC-

DC+

RWP1

CRWP1

DCrelay end

TB-3

1 shunt

2

3 shunt

4

5 indicate

6

7 indicate

8

9 motor limit


TB-2 TB-1

1 shunt

2

1 power

2 power

3 3 shunt

4 4 control

5 5 indicate

6 6 hand thr

7 7 indicate

8 8 aux

9 motor limit

10

9 latch out

10

11 hand crk

12 left

11 aux

12


NWP / CNWP

RWP / CRWP

(TB2-5 / TB2-7)

(TB3-6 / TB3-8)

CNWP1 / NWP1 (TB2-7 / TB2-5)

RWP1 / CRWP1 (TB3-6 / TB3-8)


RWP / CRWP

NWP / CNWP

(TB2-5 / TB2-7)

(TB3-6 / TB3-8)

CRWP1 / RWP1 (TB2-7 / TB2-5)

NWP1 / CNWP1 (TB3-6 / TB3-8)


Note 1: A fuse is required for short circuit protection on the positive energy used for indication.

Fuse: 10 amp, type SC, Form 1, class J or equivalent.


P2444, Rev. Jan/07

TB1-

5

6

7

8

9

10

3

4

1

2

11

12

POWER

POWER

CONTROL

HAND THROW

LATCH OUT

AUX

8

7

TB3-

6

12

11

10

9

3

2

1

5

4

HAND CRANK

MOTOR LIMIT

INDICATE

INDICATE

SHUNT

SHUNT

PDR CONNECTOR

8 8

7

6

5

4

3

2

1

7

6

5

4

3

2

1

12

12

11 10 9

11 10 9

PDR

CONNECTOR

BUTT

SPLICE

LED

22 21

HAND THROW

SWITCH

12 11

1 2 3 4 5 6 7 8 9 10 11 12

RIGHT POINT DETECTOR ROTORY CAM SWITCH

LEFT POINT DETECTOR ROTORY CAM SWITCH

7

8

9

10

5

6

3

4

2

1

TB2-

SHUNT

SHUNT

INDICATE

INDICATE

MOTOR

LIMIT

4

5

6

7

8

1

2

3

PDL

CONNECTION

4

5

6

7

8

1

2

3

1 2 3 4 5 6 7 8 9 10 11 12

LED

BUTT

SPLICE

PDL

CONNECTION

12

11

10

9

12

11

10

9

1 2

LATCH OUT

SWITCH

HAND CRANK

SWITCH

11 12

21 22

POWER

P1-1

P1-16

12 VOLT

CONTROL

MANUAL

SWITCH

2-3

2-4

1-4

1-3

P1-2

P1-18

P1-10

MANUAL CONTROL

P1-21

P1-4

INHIBIT

MOTOR AMPLIFIER

P1-9

GND

CONFIGURATION

MODULE

MOTOR

HARNESS

BRUSHLESS

DC MOTOR

12

MOTOR LIMIT (L)

11 21 22

LIMIT -

P1-11

12 VOLT

OUT

P1-20

INHIBIT

P1-23

INHIBIT

GND

P1-7

LIMIT +

P1-3

12 VOLT

OUT

P1-19

CURRENT

SELECT

P1-5

P1-12

12V

SPEED

SELECT

SPEED 1

12V

P1-13

P1-17

P1-6

SPEED 2

AUX

TB4-

1

4

5

6

2

3

12

MOTOR LIMIT (R)

11 21 22

DIAGNOSTIC

OUTPUTS

WIRING DIAGRAM

GM050-040-00


GM4000 Switch Machine

4000

Switch Machine

GRANDMASTER™

4000

Switch Machine

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