Alstom 5 Series 5E, 5F, 5G, 5H Switch Machine Installation, Operation and Maintenance Manual

The 5 Series 5E, 5 Series 5F, 5 Series 5G & 5 Series 5H Electric Switch Machines are designed for single and dual control operations. They are used to switch railroad tracks and are compatible with various control systems. These machines are robust and reliable, offering features like hand-crank and hand-throw operation for manual control. The manual provides detailed instructions for installation, operation, and maintenance.

PDF

Document

Models 5E, 5F, 5G &

5H Electric Switch

Machines: Single and

Dual Control

Signaling Inc.

Installation, Operation and Maintenance Manual

P1293

Models 5E, 5F, 5G &

5H Electric Switch

Machines: Single and

Dual Control

Signaling Inc.

Installation, Operation and Maintenance Manual

Alstom Signaling Inc.

P1293, Rev. October 2012, Printed in U.S.A.

LIST OF EFFECTIVE PAGES

P1293, Models 5E, 5F, 5G & 5H Electric Switch Machines Installation, Operation and Maintenance Manual

ORIGINAL ISSUE DATE: June 1988

CURRENT REVISION AND DATE: October 2012, Figure A-8 correction.

PAGE CHANGE OR REVISION LEVEL

Cover

Title page

Preface

Oct/12

Oct/12 i thru xii

1–1 thru 1–14

2–1 thru 2–40

3–1 thru 3–40

Oct/12

4–1 thru 4–52

5–1 thru 5–4

6–1 thru 6–100

7–1 thru 7–62

A–1 thru A–12

Oct/12

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P1293, Rev. Oct/12 Alstom Signaling Inc.

PREFACE

NOTICE OF CONFIDENTIAL INFORMATION

Information contained herein is confidential and is the property of Alstom

Signaling Incorporated. Where furnished with a proposal, the recipient shall use it solely to evaluate the proposal. Where furnished to customer, it shall be used solely for the purposes of inspection, installation or maintenance. Where furnished to a supplier, it shall be used solely in the performance of the contract. The information shall not be used or disclosed by the recipient for any other purposes whatsoever.

FOR QUESTIONS AND INQUIRIES, CONTACT CUSTOMER SERVICE AT

1-800-717-4477

WWW.ALSTOMSIGNALINGSOLUTIONS.COM

ALSTOM SIGNALING INC.

1025 JOHN STREET

WEST HENRIETTA, NY 14586

P1293, Rev. Oct/12 Alstom Signaling Inc.

REVISION LOG

Revision

Date Description By

June 1988 Original issue

December 1994 Update

November 2001 Update

May 2004 Update

September 2004 Update point detector illustration text

MAS

December 2005 Updated maintenance procedures & drawings

April 2006 Updated catalog & drawing numbers of item

17 on page 7–4

May 2006

June 2007

January 2008

MAS

Updated circuit drawings MAS

Updated parts list & wiring diagrams

MAS

Updated detail parts and drawings, installation and maintenance procedures

MAS

August 2008

October 2012

Added location of switch machine serial number

Corrected Figure A-8

MAS

Checked Approved

P1293, Rev. Oct/12 Alstom Signaling Inc.

ABOUT THE MANUAL

This manual is intended to provide the necessary information to maintain and ensure proper operation of Models 5E, 5F, 5G & 5H Electric Switch Machines (5 Series Switch

Machines). The information provided is not limited to the components of the switch machine.

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 5 Series Switch Machines. Safety precautions are also provided in this section.

Section 2 – THEORY OF OPERATION: This section gives general information on the operation of the 5 Series Switch Machines. Safety precautions are also provided in this section.

Section 3 – INSTALLATION: This section describes the field installation and setup of the 5 Series Switch Machines.

Section 4 – SCHEDULED MAINTENANCE: This section describes the tools, preventive maintenance procedures, and functional tests used on the 5 Series Switch

Machines. 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 5 Series Switch Machines.

Section 6 – CORRECTIVE MAINTENANCE: This section describes the adjustment and replacement procedures associated with corrective maintenance of 5 Series Switch

Machines.

Section 7 – PARTS CATALOG: This section identifies and lists the spare parts associated with operations of the 5 Series Switch Machines.

Appendix A – DRAWINGS: This section has representative circuit drawings and wiring diagrams for the 5 Series Switch Machines.

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MANUAL SPECIAL NOTATIONS

In the Alstom manuals, there are three methods used to convey special informational notations to the reader. These notations are warnings, cautions, and notes. Both warnings and cautions are readily noticeable by boldface type two lines beneath the caption.

Warning

A warning is the most important notation to heed. A warning is used to tell the reader that special attention needs to be paid to the message because if the instructions or advice is not followed when working on the equipment then the result could be either serious harm or death. The sudden, unexpected operation of a switch machine, for example, or the technician contacting the third rail could lead to personal injury or death. An example of a typical warning notice follows:

WARNING

DISCONNECT MOTOR ENERGY WHENEVER WORKING ON SWITCH

LAYOUT OR SWITCH MACHINE. UNEXPECTED OPERATION OF

MACHINE COULD CAUSE INJURY FROM OPEN GEARS, ELECTRICAL

SHOCK, OR MOVING SWITCH POINTS.

Caution

A caution statement is used when an operating or maintenance procedure, practice, condition, or statement, which if not strictly adhered to, could result in damage to or destruction of equipment. A typical caution found in a manual is as follows:

CAUTION

Turn power off before attempting to remove or insert circuit boards into a module. Boards can be damaged if power is not turned off.

Note

A note is normally used to provide minor additional information to the reader to explain the reason for a given step in a test procedure or to just provide a background detail.

An example of the use of a note follows:

NOTE

A capacitor may be mounted on the circuit board with a RTV adhesive.

Use the same color RTV.

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TABLE OF CONTENTS

Topic Page

1. SECTION 1 – GENERAL DESCRIPTION ............................................................. 1–1

1.1. SCOPE OF MANUAL ....................................................................................... 1–1

1.2. SWITCH MACHINE FEATURES...................................................................... 1–1

1.2.1. Single Control Versus Dual Control .................................................................. 1–1

1.2.2. Controllers ........................................................................................................ 1–2

1.3. MODEL 5E, 5F, 5G AND 5H DESIGN ............................................................. 1–3

1.3.1. Model 5E Switch Machine ................................................................................ 1–4

1.3.2. Model 5F Switch Machine ................................................................................ 1–4

1.3.3. Model 5G Switch Machine ................................................................................ 1–4

1.3.4. Model 5H Switch Machine ................................................................................ 1–4

1.4. MODEL 5 SERIES SWITCH MACHINE COMPONENTS ................................ 1–5

1.4.1. Switch Machine Serial Numbers ....................................................................... 1–7

1.5. SAFETY PRECAUTIONS FOR MAINTAINERS ............................................. 1–10

1.5.1. General Recommendations ............................................................................ 1–10

1.5.2. Proper Attire ................................................................................................... 1–11

1.5.3. Train Control Room (TCR) Work .................................................................... 1–11

1.5.4. General Safety on Property ............................................................................ 1–11

1.5.5. Safety at Wayside .......................................................................................... 1–12

1.5.6. Safety at Station Platforms ............................................................................. 1–12

1.5.7. Safety at Switch Machines ............................................................................. 1–13

2. SECTION 2 – THEORY OF OPERATION ............................................................. 2–1

2.1. GENERAL ........................................................................................................ 2–1

2.2. POWER OPERATION ...................................................................................... 2–1

2.3. HAND CRANK OPERATION ............................................................................ 2–4

2.4. HAND THROW OPERATION (5F AND 5H SWITCH MACHINES) .................. 2–6

2.5. COMPONENT FUNCTIONS ............................................................................ 2–8

2.5.1. Motor ................................................................................................................ 2–9

2.5.1.1. Commutator and Brushes ............................................................................ 2–11

2.5.1.2. Magnetic Detent ........................................................................................... 2–12

2.5.2. Hand Crank Cutout Switches ......................................................................... 2–14

2.5.3. Friction Clutch................................................................................................. 2–16

2.5.3.1. Friction Clutch Gear Mechanism .................................................................. 2–17

2.5.3.2. Main Gear Bracket ....................................................................................... 2–18

2.5.4. Cam Bar, Throw Bar, Point Detector Mechanism ........................................... 2–19

2.5.5. Lock Rod ........................................................................................................ 2–22

2.5.6. Point Detector Rods ....................................................................................... 2–24

2.5.7. Box Style Bearings and Wear Plates.............................................................. 2–26

2.5.8. Point Detector Circuit Controller ..................................................................... 2–27

2.5.8.1. Normal/Reverse Contacts ............................................................................ 2–28

2.5.8.2. Motor Control Contacts ................................................................................ 2–29

2.5.8.3. Shunt Contact .............................................................................................. 2–30

P1293, Rev. Oct/12 i Alstom Signaling Inc.

TABLE OF CONTENTS (CONT.)

Topic Page

2.5.9. Switch Machine Wiring ................................................................................... 2–31

2.5.9.1. Switch Operating Relay ............................................................................... 2–36

2.5.9.2. Overload Relay ............................................................................................ 2–37

2.5.9.3. Example Relay Circuits Provided In Appendix A ......................................... 2–38

2.5.10. Switch and Pipeline Fittings ......................................................................... 2–39

2.5.11. Covers ......................................................................................................... 2–39

3. SECTION – INSTALLATION ................................................................................. 3–1

3.1. GENERAL ........................................................................................................ 3–1

3.2. PROPERTY’S REQUIREMENTS ..................................................................... 3–1

3.3. INSTALLATION ................................................................................................ 3–1

3.3.1. Left-Hand or Right-Hand Layout ....................................................................... 3–3

3.3.2. Mounting to Ties ............................................................................................... 3–5

3.3.3. Wiring of Machine ............................................................................................. 3–5

3.3.4. Motor Field Connections ................................................................................... 3–6

3.3.5. Hand-Throw Lever (Models 5F and 5H Only) ................................................... 3–7

3.3.6. Hand Cranking Before Applying Power ............................................................ 3–7

3.3.7. Connect and Adjust Throw Rod ........................................................................ 3–8

3.3.8. Connect and Initially Adjust Point Detector Connector Rod ............................. 3–9

3.3.9. Connect and Initially Adjust Lock Rod Connector Rod ................................... 3–11

3.3.10. Machine With Two Lock Rods and Two Point-Detector Rods ..................... 3–11

3.4. LOCK AND POINT-DETECTOR RODS ADJUSTMENT ................................ 3–12

3.4.1. Point Detector Rod Adjustment Without Releasing (“Floating”) Narrow-Notched

Lock Rod ........................................................................................................ 3–13

3.4.2. Point Detector Rod and Lock Rod Adjustment Without Releasing (“Floating”)

Wide-Notched Lock Rod ................................................................................ 3–15

3.4.3. Point Detector Rod Adjustment With Lock Rod Released (“Floating”) ........... 3–18

3.4.4. Narrow Notched Lock Rod Adjustment .......................................................... 3–19

3.5. BEFORE REPLACING MACHINE IN SERVICE ............................................ 3–20

3.5.1. Final Layout Check ......................................................................................... 3–20

3.5.2. Friction Clutch Operational Check .................................................................. 3–21

3.5.3. Temperature Considerations and Commutator Cover .................................... 3–22

3.5.4. Commutator Shield Use ................................................................................. 3–22

3.6. CHANGING FROM LEFT-HAND TO RIGHT-HAND OPERATION AND VICE

VERSA ........................................................................................................... 3–22

3.6.1. Throw Bar ....................................................................................................... 3–22

3.6.2. Lock and Detector Rods ................................................................................. 3–22

3.6.2.1. Changing Over the One Lock and One Point-Detector Rod, Right- Or Left-Hand

(RH Or LH) Single Switch Configuration ......................................................... 3–24

3.6.2.2. Changing Over the Two Locks and Two Point-Detector Rods With Movable-

Point Frog Configuration ................................................................................. 3–28

3.6.3. Changing Over the Dual-Control Mechanism (Models 5F and 5H) ................ 3–32

3.7. OPTIONAL SWITCH MACHINE AND LAYOUT SENSING KIT ..................... 3–37

P1293, Rev. Oct/12 ii Alstom Signaling Inc.

TABLE OF CONTENTS (CONT.)

Topic Page

4. SECTION 4 – SCHEDULED MAINTENANCE ...................................................... 4–1

4.1. GENERAL ........................................................................................................ 4–1

4.2. INTRODUCTION .............................................................................................. 4–1

4.3. FIELD OR WAYSIDE SERVICE....................................................................... 4–1

4.4. SPECIAL TOOLS AND TEST EQUIPMENT .................................................... 4–2

4.5. PREVENTIVE MAINTENANCE INDEX ............................................................ 4–3

4.6. PREVENTIVE MAINTENANCE CHECKS ........................................................ 4–4

4.6.1. After Flooding ................................................................................................... 4–4

4.7. WEEKLY MAINTENANCE ............................................................................... 4–5

4.7.1. Site and Switch Machine Inspection ................................................................. 4–5

4.8. MONTHLY MAINTENANCE ............................................................................. 4–7

4.8.1. Lubrication ........................................................................................................ 4–7

4.8.1.1. Lubrication Procedures .................................................................................. 4–7

4.9. QUARTERLY MAINTENANCE ...................................................................... 4–14

4.9.1. Recycling Time Test Procedure ..................................................................... 4–14

4.9.2. Obstruction and Overload Relay Test and Adjustment .................................. 4–15

4.9.3. Motor Brush Inspection Procedure ................................................................. 4–18

4.9.4. Box-Style Bearing and Wear Plate Inspection ................................................ 4–20

4.9.5. Throw Rod Check and Adjustment Procedure ............................................... 4–23

4.9.6. Lock Rod Check and Adjustment Procedure .................................................. 4–25

4.9.7. Point Detector Rod Check and Adjustment Procedure .................................. 4–27

4.9.8. Point-Detector Contact Check and Adjustments ............................................ 4–29

4.9.9. Shunt Contact Check and Adjustment............................................................ 4–32

4.9.9.1. Models 5E and 5F Shunt Contacts C6, C7, D2 and D3 ............................... 4–32

4.9.9.2. Models 5G and 5H Shunt Contacts C7, C8, D1 and D2 .............................. 4–34

4.9.10. Motor-Control Contacts (All Models) ............................................................ 4–35

4.9.11. Controller Contact Adjustments ................................................................... 4–37

4.9.12. Friction Clutch Inspection ............................................................................ 4–40

4.9.13. Friction Clutch Test ...................................................................................... 4–42

4.9.14. Friction Clutch Adjustment ........................................................................... 4–44

4.9.15. Crank Cut-Out Switch Adjustment ............................................................... 4–46

4.9.16. Hand-Power Lever Test ............................................................................... 4–47

4.10. SEMI-ANNUAL MAINTENANCE .................................................................... 4–48

4.10.1. Commutator Inspection ................................................................................ 4–48

4.11. ANNUAL MAINTENANCE .............................................................................. 4–49

4.11.1. Magnetic Detent Inspection ......................................................................... 4–49

4.11.2. Blocking Rectifier Test ................................................................................. 4–51

5. SECTION 5 – TROUBLESHOOTING.................................................................... 4–1

5.1. GENERAL PHILOSOPHY ................................................................................ 5–1

5.2. POSSIBLE SYMPTOMS AND CORRECTIVE ACTIONS ................................ 5–1

P1293, Rev. Oct/12 iii Alstom Signaling Inc.

TABLE OF CONTENTS (CONT.)

Topic Page

6. SECTION 6 – CORRECTIVE MAINTENANCE ..................................................... 6–1

6.1. GENERAL ........................................................................................................ 6–1

6.2. SUMMARY ....................................................................................................... 6–2

6.3. TEST EQUIPMENT AND TOOLS .................................................................... 6–3

6.4. REPAIR AND REBUILD ................................................................................... 6–4

6.5. DISASSEMBLY AND ASSEMBLY ................................................................... 6–9

6.5.1. Switch Machine .............................................................................................. 6–10

6.5.2. Motor .............................................................................................................. 6–37

6.5.3. Clutch ............................................................................................................. 6–53

6.5.4. Point Detector Contact ................................................................................... 6–55

6.5.5. Biased-Neutral Controller ............................................................................... 6–57

6.6. COMPLETE CLEANING AND LUBRICATION ............................................... 6–58

6.6.1. Detent Cleaning .............................................................................................. 6–60

6.6.2. Brush Holder .................................................................................................. 6–61

6.6.3. Armature ......................................................................................................... 6–62

6.6.4. Motor Hasp ..................................................................................................... 6–63

6.6.5. Motor Stator .................................................................................................... 6–64

6.6.6. Motor Heater .................................................................................................. 6–65

6.6.7. Throw Bar Bearing .......................................................................................... 6–66

6.6.8. Throw Bar Guard ............................................................................................ 6–67

6.6.9. Contact and Gear Compartment Cover .......................................................... 6–67

6.6.10. Cover Hasp .................................................................................................. 6–68

6.6.11. Lock and Point Detector Rod Guards .......................................................... 6–68

6.6.12. Lock Rod Wear Plate ................................................................................... 6–69

6.6.13. Point Detector Rod Wear Plate.................................................................... 6–70

6.6.14. Cutout Switch ............................................................................................... 6–71

6.6.15. Main Gear Bracket ....................................................................................... 6–71

6.6.16. Clutch ........................................................................................................... 6–72

6.6.17. Intermediate Gear ........................................................................................ 6–73

6.6.18. Main Gear .................................................................................................... 6–74

6.6.19. Rectifier ........................................................................................................ 6–75

6.6.20. Heater .......................................................................................................... 6–76

6.6.21. Point Detector Contact Group ...................................................................... 6–77

6.6.22. Contact Movement ....................................................................................... 6–78

6.6.23. Insulation Block ............................................................................................ 6–79

6.6.24. Arm (Clips) ................................................................................................... 6–80

6.6.25. Lock Rod ...................................................................................................... 6–80

6.6.26. Point Detector Rod ...................................................................................... 6–81

6.6.27. Throw Bar .................................................................................................... 6–82

6.6.28. Contact Frame ............................................................................................. 6–82

6.6.29. Gear Frame ................................................................................................. 6–83

6.6.30. Main Bed Frame .......................................................................................... 6–83

P1293, Rev. Oct/12 iv Alstom Signaling Inc.

TABLE OF CONTENTS (CONT.)

Topic Page

6.6.31. Cam Bar ....................................................................................................... 6–84

6.6.32. Cable Harness ............................................................................................. 6–85

6.6.33. Conduit Coupling ......................................................................................... 6–85

6.7. SWITCH MACHINE TESTING ....................................................................... 6–86

6.7.1. Mechanical Test Procedure ............................................................................ 6–87

6.7.2. Electrical Test Procedure ............................................................................... 6–99

7. SECTION 7 – PARTS CATALOG ......................................................................... 7–1

7.1. GENERAL ........................................................................................................ 7–1

7.1.1. PARTS LIST ..................................................................................................... 7–1

A. APPENDIX A – DRAWINGS ................................................................................. A–1

A.1. OVERVIEW ...................................................................................................... A–1

P1293, Rev. Oct/12 v Alstom Signaling Inc.

LIST OF FIGURES

Description Page

Figure 1–1. Model 5G Switch Machine Components ................................................. 1–5

Figure 1–1. Name Plate and Serial Number Locations .............................................. 1–7

Figure 2–1. Lock Rod, Point Detector Rod, and Point Detector ................................. 2–2

Figure 2–2. Movement of the Lock Rod, Point Detector Rod, and Point

Detector ................................................................................................................. 2–2

Figure 2–3. Hand Throw Selector Lever Positions ..................................................... 2–3

Figure 2–4. Hand Crank Cover Position ..................................................................... 2–4

Figure 2–5. Inserting the Hand Crank ........................................................................ 2–5

Figure 2–6. Hand Throw Lever and Correspondence Indication ................................ 2–6

Figure 2–7. 5 Series Switch Machine Components (Model 5G) ................................. 2–8

Figure 2–8. DC Motor ................................................................................................. 2–9

Figure 2–9. Motor Connection (Series Split Field) Diagram ..................................... 2–10

Figure 2–10. Commutator and Brushes ................................................................... 2–11

Figure 2–11. Schematic Diagram of Holding Device, Showing Magnetic

Detent

Effect ................................................................................................................... 2–12

Figure 2–12. Cutout Switch in Open Position (Models 5F and 5H) .......................... 2–14

Figure 2–13. Cutout Switch in Open Position (Models 5E and 5G).......................... 2–15

Figure 2–14. Friction Clutch ..................................................................................... 2–17

Figure 2–15. Main Gear Bracket (Models 5F and 5H) ............................................. 2–18

Figure 2–16. Cam Bar Centering Point Detector ...................................................... 2–19

Figure 2–17. Lock Rod in Locked and Unlocked Positions ...................................... 2–19

Figure 2–18. Throw Bar Dog Unlocking Throw Bar .................................................. 2–20

Figure 2–19. Cam Roller Moving Throw Bar ............................................................ 2–20

Figure 2–20. New Style Lock Rod Arm (Two Required Per Machine)...................... 2–22

Figure 2–21. Old Style Lock Rod Arm (Two Required Per Machine) ....................... 2–22

Figure 2–22. Point-Detector Contact Yoke With Left, Center and Right

Positioning of Lock and Detector Rods .................................................................................. 2–23

Figure 2–23. Point Detector Rod Normal and Reverse Positions ............................ 2–24

Figure 2–24. Point Detector Connecting Rod Location ............................................ 2–25

Figure 2–25. Wear Plates ........................................................................................ 2–26

Figure 2–26. Box Style Bearings .............................................................................. 2–27

Figure 2–27. Point Detector Contacts, Top View of Models 5G and 5H .................. 2–28

Figure 2–28. Normal/Reverse Contacts In Open Position ....................................... 2–28

Figure 2–29. Motor Control Contacts In Open Position ............................................ 2–29

Figure 2–30. Shunt Contacts Used in Polarized Repeater Relay Circuit,

Models 5E and 5F ............................................................................................... 2–30

Figure 2–31. Shunt Contacts Used in Neutral Repeater Relay Circuit,

Models 5E and 5F ............................................................................................... 2–30

Figure 2–32. Simplified Wiring Diagram With Snubbing Circuit and 24V

Control ................................................................................................................. 2–31

Figure 2–33. Biased-Neutral Controller .................................................................... 2–32

P1293, Rev. Oct/12 vi Alstom Signaling Inc.

LIST OF FIGURES (CONT.)

Description Page

Figure 2–34. Typical Model 5G Wiring Diagram and Control Circuit,

Right-Hand Point Normally Closed ...................................................................... 2–33

Figure 2–35. Typical Model 5H Wiring Diagram and Control Circuit,

Right-Hand Point Normally Closed ...................................................................... 2–34

Figure 2–36. Overload Relay ................................................................................... 2–37

Figure 2–37. Cover Hasp-Type Latching Device ...................................................... 2–39

Figure 3–1. Typical Right-Hand Single-Switch Layout With Hinged Front

Rod ........................................................................................................................ 3–4

Figure 3–2. Motor Connection Diagram ..................................................................... 3–6

Figure 3–3. Inserting the Hand Crank ........................................................................ 3–7

Figure 3–4. Lock Rod and Point Detector Rod Locations ........................................ 3–23

Figure 3–5. 5H Switch Machine With Dual Operation Detail .................................... 3–35

Figure 4–1. Lubrication Locations For Models 5E and 5G ....................................... 4–10

Figure 4–2. Lubrication Locations For Models 5F and 5H ....................................... 4–12

Figure 4–3. Shunt Contacts Used in Polarized Repeater Relay Circuit ................... 4–32

Figure 4–4. Shunt Contacts Used in Neutral Repeater Relay Circuit ....................... 4–33

Figure 7–1. Model 5E Switch Machine ....................................................................... 7–2

Figure 7–2. Model 5G Switch Machine ...................................................................... 7–3

Figure 7–3. Model 5F Switch Machine ....................................................................... 7–6

Figure 7–4. Model 5H Switch Machine ....................................................................... 7–7

Figure 7–5. Detail Parts for Switch Machines ......................................................... 7–10

Figure 7–6. Bars, Couplings, and Hasp For Switch Machines ................................. 7–17

Figure 7–7. Brackets, Plates, and Lock Stand For Switch Machines ....................... 7–19

Figure 7–8. Selector-Lever and Hand-Throw Parts .................................................. 7–22

Figure 7–9. Frames .................................................................................................. 7–27

Figure 7–10. Point-Detector Contacts and Movements ........................................... 7–32

Figure 7–11. Lock Rods and Point-Detector Rods ................................................... 7–37

Figure 7–12. Link Motion .......................................................................................... 7–39

Figure 7–13. Biased-Neutral Controller .................................................................... 7–41

Figure 7–14. Contactor and Overload Relay ............................................................ 7–45

Figure 7–15. Switch Machine Motors ....................................................................... 7–50

Figure 7–16. Terminal Board ................................................................................... 7–55

Figure 7–17. Wire Entrance Couplings, Conduit Lock Rod and Detector

Rod Lugs ............................................................................................................ 7–57

Figure 7–18. Tools ................................................................................................... 7–60

Figure A–1. Typical Right-Hand Point Normally Closed Wiring Diagram and

Control Circuit, Model 5E Switch Machine ............................................................ A–2

Figure A–2. Typical Left-Hand Point Normally Closed Wiring Diagram and

Control Circuit, Model 5E Switch Machine ............................................................ A–2

P1293, Rev. Oct/12 vii Alstom Signaling Inc.

LIST OF FIGURES (CONT.)

Description Page

Figure A–3. Typical Polarized Switch Repeater Relay Circuit Using Shunt

Strips A, Single Switch, Model 5E Switch Machine ............................................... A–3

Figure A–4. Typical Polarized Switch Repeater Relay Circuit Using Shunt

Strips A, Crossover, Two Model 5E Switch Machines ........................................... A–3

Figure A–5. Typical Neutral Switch Repeater Relay Circuit, Single Switch,

Model 5E Switch Machine ..................................................................................... A–4

Figure A–6. Typical Neutral Switch Repeater Relay Circuit, Crossover, Two

Model 5E Switch Machines ................................................................................... A–4

Figure A–7. Typical Model 5F Wiring Diagram and Control Circuit, Right-

Hand Point Normally Closed ................................................................................. A–5

Figure A–8. Typical Model 5F Wiring Diagram and Control Circuit, Left-

Hand Point Normally Closed ................................................................................. A–5

Figure A–9. Typical Polarized Switch Repeater Relay Circuit Using Shunt

Strips A, Single Switch, Model 5F Switch Machine ............................................... A–6

Figure A–10. Typical Polarized Switch Repeater Relay Circuit Using Shunt

Strips A, Crossover, Model 5F Switch Machine .................................................... A–6

Figure A–11. Typical Neutral Switch Repeater Relay Circuit, Single Switch,

Model 5F Switch Machine ..................................................................................... A–7

Figure A–12. Typical Neutral Switch Repeater Relay Circuit, Crossover,

Two Model 5F Switch Machines ............................................................................ A–7

Figure A–13. Typical Polarized Switch Repeater Relay Circuit, Single

Switch, Model 5G Switch Machine ........................................................................ A–8

Figure A–14. Typical Polarized Switch Repeater Relay Circuit, Crossover,

Two Model 5G Switch Machines ........................................................................... A–8

Figure A–15. Typical Neutral Switch Repeater Relay Circuit, Single Switch,

Model 5G Switch Machine ..................................................................................... A–9

Figure A–16. Typical Neutral Switch Repeater Relay Circuit, Crossover,

Two Model 5G Switch Machines ........................................................................... A–9

Figure A–17. Typical Polarized Switch Repeater Relay Circuit, Single

Switch, Model 5H Switch Machine ...................................................................... A–10

Figure A–18. Typical Polarized Switch Repeater Relay Circuit, Crossover,

Model 5H Switch Machine ................................................................................... A–10

Figure A–19. Typical Neutral Switch Repeater Relay Circuit, Single Switch,

Model 5H Switch Machine ................................................................................... A–11

Figure A–20. Typical Neutral Switch Repeater Relay Circuit, Crossover,

Two Model 5H Switch Machines ......................................................................... A–11

P1293, Rev. Oct/12 viii Alstom Signaling Inc.

LIST OF TABLES

Description Page

Table 1–1. Principal Feature Comparison .................................................................. 1–3

Table 1–2. Model 5 Series Switch Machine Components .......................................... 1–8

Table 1–3. Model 5 Series Switch Machine Model Specific Components ................. 1–9

Table 2–1. Typical Switch Request and Affected Relays, Position of Relay

Per Request ........................................................................................................ 2–36

Table 2–2. Relay Position Abbreviation Definitions .................................................. 2–36

Table 3–1. Connect and Adjust Throw Rod Procedure .............................................. 3–8

Table 3–2. Connect and Initially Adjust Point Detector Connector Rod

Procedure .............................................................................................................. 3–9

Table 3–3. Connect and Initially Adjust Lock Rod Connector Rod

Procedure ............................................................................................................ 3–11

Table 3–4. Lock Rod and Point Detector Rod Adjustment Methods ........................ 3–12

Table 3–5. Point Detector Rod Adjustment Procedure Without Releasing

(“Floating”) Narrow-Notched Lock Rod ................................................................ 3–13

Table 3–6. Point Detector Rod and Lock Rod Adjustment Procedure

Without Releasing (“Floating”) Wide-Notched Lock Rod .................................... 3–15

Table 3–7. Point Detector Rod Adjustment Procedure With Lock Rod

Released (“Floating”) ........................................................................................... 3–18

Table 3–8. Narrow Notched Lock Rod Adjustment Procedure ................................. 3–19

Table 3–9. Final Layout Check Procedure ............................................................... 3–20

Table 3–10. Friction Clutch Operational Check Procedure ...................................... 3–21

Table 3–11. Changing Over Procedure For One Lock and One Point-

Detector Rod, Right- Or Left-Hand (RH Or LH) Single Switch ............................ 3–24

Table 3–12. Changing Over Procedure For Two Locks and Two Point-

Detector Rods, Right- and Left-Hand (RH and LH) Double Slip Switch .............. 3–26

Table 3–13. Changing Over Procedure For Two Locks and Two Point-

Detector Rods With Movable-Point Frog ............................................................. 3–28

Table 3–14. Changing Over Procedure For Dual Control Mechanism ..................... 3–32

Table 3–15. Throw Rod Point Pressure Verification Procedure ............................... 3–37

Table 4–1. Preventive Maintenance Index ................................................................. 4–3

Table 4–2. Site and Switch Machine Inspection Procedure ....................................... 4–5

Table 4–3. Lubrication Procedure .............................................................................. 4–8

Table 4–4. Lubrication Instructions for Models 5E and 5G ........................................ 4–9

Table 4–5. Lubrication Instructions For Models 5F and 5H ...................................... 4–11

Table 4–6. Switch Machine Tube Lubrication Procedure (Models 5F and

5H) ...................................................................................................................... 4–13

Table 4–7. Recycling Time Test Procedure ............................................................. 4–14

Table 4–8. Obstruction and Overload Relay Test Procedure ................................... 4–15

Table 4–9. Overload Relay Adjustment Procedure .................................................. 4–17

Table 4–10. Motor Brush Inspection Procedure ....................................................... 4–18

Table 4–11. Box-Style Bearing and Wear Plate Inspection Procedure .................... 4–20

P1293, Rev. Oct/12 ix Alstom Signaling Inc.

LIST OF TABLES

Description Page

Table 4–12. Throw Rod Check and Adjustment Procedure ..................................... 4–23

Table 4–13. Lock Rod Check and Adjustment Procedure for Switch

Machines with Wide Notch Lock Rods ................................................................ 4–25

Table 4–14. Point Detector Rod Check and Adjustment Procedure ........................ 4–27

Table 4–15. Point Detector Contact Check and Adjustment Procedure .................. 4–29

Table 4–16. Point Detector Contact Check and Adjustment Procedure For

Models 5E and 5F Normal and Reverse Contacts C5, C8, D1 and D4, and Snub Contacts C3, C4, D5 and D6; Models 5G and 5H Normal and

Reverse Contacts C3, C6, D3, and D6 ............................................................... 4–31

Table 4–17. Point Detector Contact Adjustment Procedure For Models 5G and 5H Shunt Contacts C7, C8, D1 and D2 ........................................................ 4–34

Table 4–18. Motor Control Contact Adjustment Procedure ...................................... 4–35

Table 4–19. Controller Contact Adjustment Procedure ............................................ 4–38

Table 4–20. Friction Clutch Inspection ..................................................................... 4–40

Table 4–21. Friction Clutch Test Procedure ............................................................. 4–42

Table 4–22. Friction Clutch Adjustment Procedure .................................................. 4–44

Table 4–23. Crank Cut-Out Switch Adjustment Procedure (Models 5E and

5F) ....................................................................................................................... 4–46

Table 4–24. Hand-Power Lever Test ....................................................................... 4–47

Table 4–25. Commutator Inspection Procedure ...................................................... 4–48

Table 4–26. Magnetic Detent Inspection Procedure ................................................ 4–49

Table 4–27. Blocking Rectifier Test Procedure ........................................................ 4–51

Table 5–1. Symptoms Noticed From the Control Locations ....................................... 5–1

Table 5–2. Trackside Noted Symptoms ..................................................................... 5–4

Table 6–1. Tools and Test Equipment Index ............................................................. 6–3

Table 6–2. Switch Machine Component Removal and Replacement ........................ 6–5

Table 6–3. Switch Machine Motor Disassembly and Assembly ................................. 6–6

Table 6–4. Friction Clutch Disassembly and Assembly ............................................. 6–7

Table 6–5. Point Detector Contact Disassembly and Assembly ................................ 6–7

Table 6–6. Cleaning, Lubrication, and Testing Procedures For Use After

Repair or Rebuild .................................................................................................. 6–8

Table 6–7. Switch Machine Disassembly and Assembly Procedure ........................ 6–10

Table 6–8. Motor Disassembly and Assembly Procedure ........................................ 6–37

Table 6–9. Clutch Disassembly and Assembly Procedure ....................................... 6–53

Table 6–10. Point Detector Contact Disassembly and Assembly Procedure ........... 6–55

Table 6–11. Biased-Neutral Controller Replacement Procedure ............................. 6–57

Table 6–12. Cleaning and Lubrication Index ............................................................ 6–58

Table 6–13. Detent Cleaning Procedures ................................................................ 6–60

Table 6–14. Brush Holder Maintenance Procedure ................................................. 6–61

Table 6–15. Armature Maintenance Procedure ....................................................... 6–62

Table 6–16. Motor Hasp Maintenance Procedures .................................................. 6–63

Table 6–17. Motor Stator Maintenance Procedure .................................................. 6–64

P1293, Rev. Oct/12 x Alstom Signaling Inc.

LIST OF TABLES

Description Page

Table 6–18. Motor Heater Maintenance Procedure ................................................. 6–65

Table 6–19. Throw Bar Bearing Maintenance Procedure ........................................ 6–66

Table 6–20. Throw Bar Guard Maintenance Procedure ........................................... 6–67

Table 6–21. Contact and Gear Compartment Cover Maintenance

Procedure ............................................................................................................ 6–67

Table 6–22. Cover Hasp Maintenance Procedure ................................................... 6–68

Table 6–23. Lock and Point Detector Rod Guards Maintenance Procedure ........... 6–68

Table 6–24. Lock Rod Wear Plate Maintenance Procedure .................................... 6–69

Table 6–25. Point Detector Rod Wear Plate Maintenance Procedure ..................... 6–70

Table 6–26. Cutout Switch Maintenance Procedure ................................................ 6–71

Table 6–27. Main Gear Bracket Maintenance Procedure ........................................ 6–71

Table 6–28. Clutch Maintenance Procedure ............................................................ 6–72

Table 6–29. Intermediate Gear Maintenance Procedure ......................................... 6–73

Table 6–30. Main Gear Maintenance Procedure ..................................................... 6–74

Table 6–31. Rectifier Maintenance Procedure ......................................................... 6–75

Table 6–32. Heater Maintenance Procedure ........................................................... 6–76

Table 6–33. Point Detector Contact Group Maintenance Procedure ....................... 6–77

Table 6–34. Contact Movement Maintenance Procedure ........................................ 6–78

Table 6–35. Insulator Block Maintenance Procedure............................................... 6–79

Table 6–36. Arm Maintenance Procedure ............................................................... 6–80

Table 6–37. Lock Rod Maintenance Procedure ....................................................... 6–80

Table 6–38. Point Detector Rod Maintenance Procedure ........................................ 6–81

Table 6–39. Throw Bar Maintenance Procedure...................................................... 6–82

Table 6–40. Contact Frame Maintenance Procedure .............................................. 6–82

Table 6–41. Gear Frame Maintenance Procedure ................................................... 6–83

Table 6–42. Main Bed Frame Maintenance Procedure............................................ 6–83

Table 6–43. Cam Bar Maintenance Procedure ........................................................ 6–84

Table 6–44. Cable Harness Maintenance Procedure .............................................. 6–85

Table 6–45. Conduit Coupling Maintenance Procedure ........................................... 6–85

Table 6–46. Special Switch Machine Testing Equipment ........................................ 6–86

Table 6–47. Mechanical Test Procedure ................................................................. 6–87

Table 6–48. Electrical Test Procedure ..................................................................... 6–99

Table 7–1. Main Parts For Models 5E and 5G Switch Machines ............................... 7–4

Table 7–2. Main Parts For Models 5F and 5H Switch Machines................................ 7–8

Table 7–3. Detail Parts For Switch Machines Table ................................................ 7–12

Table 7–4. Bars, Couplings, and Hasp For Switch Machines .................................. 7–18

Table 7–5. Brackets, Plates, and Lock Stand For Switch Machines ........................ 7–20

Table 7–6. Selector-Lever and Hand-Throw Parts ................................................... 7–23

Table 7–7. Frames ................................................................................................... 7–28

Table 7–9. Lock Rods and Point-Detector Rods ...................................................... 7–38

Table 7–10. Link Motion ........................................................................................... 7–40

Table 7–11. Biased-Neutral Controller ..................................................................... 7–42

Table 7–12. Contactor and Overload Relay ............................................................. 7–46

P1293, Rev. Oct/12 xi Alstom Signaling Inc.

LIST OF TABLES

Description Page

Table 7–13. Switch Machine Motors ........................................................................ 7–51

Table 7–14. Terminal Board ..................................................................................... 7–56

Table 7–15. Wire Entrance Couplings and Conduit Lock Rod and Detector

Rod Lugs ............................................................................................................. 7–59

Table 7–16. Tools .................................................................................................... 7–61

P1293, Rev. Oct/12 xii Alstom Signaling Inc.

General Description

1. SECTION 1 – GENERAL DESCRIPTION

1.1. SCOPE OF MANUAL

The purpose of this manual is to describe the principal features of the Alstom Model 5E,

5F, 5G and 5H Electric Switch Machines and tell how to properly inspect, service and test the switch machine, and identify both recommended spare parts and replacement parts. Spare parts are identified in this manual.

To order a switch machine complete refer to the Alstom Signaling Inc. Product and

Parts Catalog. The illustrated catalog also includes all the parts necessary to complete the total layout.

1.2. SWITCH MACHINE FEATURES

The Alstom Model 5E-5H Electric Switch Machines incorporate all of the features required to meet interlocking practices. They can be used at single switches, doubleslip switches, movable-point frogs, and derails, regardless of variations in switch fitting standards and weights of rail. They are notably suitable for use in subways or on rapid transit properties.

5E, 5F, 5G, and 5H switch machines weigh between 900 and 1100 pounds. Models 5E and 5F are about five feet eight inches long by eight inches high by 38 inches wide.

Models 5G and 5H are one foot longer.

1.2.1. Single Control Versus Dual Control

The 5E and 5G Switch Machines operate by the internal electric motor only; they are single-control machines.

The 5F and 5H Switch Machines are operated by a motor or by a mechanical hand throw lever; they are dual control machines.

P1293, Rev. Oct/12 1–1 Alstom Signaling Inc.

General Description

1.2.2. Controllers

Some applications require that a low voltage (10-24 VDC) control from the relay house switch a biased-neutral controller mounted in the switch machine. A biased-neutral controller is actually a device with heavy-duty contacts that control the high current feed wires to the motor.

The 5G and 5H Switch Machines contain biased-neutral controllers. Machines are available that work on low or high voltage DC (24 VDC or 110VDC). The higher operating voltage allows faster movement and less line loss in the cables. Control circuits to the machine operate on 10 or 24 VDC.

Other applications use heavy-duty control relays in the relay house instead of a biasedneutral controller. The 5E and 5F Switch Machines do not contain biased-neutral controllers; control relays for these switch machines are housed externally. The control circuit uses two biased-neutral control relays.

P1293, Rev. Oct/12 1–2 Alstom Signaling Inc.

General Description

1.3. MODEL 5E, 5F, 5G AND 5H DESIGN

Table 1–1 compares the principle features of the Model 5E, 5F, 5G, and 5H Switch

Machines. Discussion of the four switch machines follows.

Table 1–1. Principal Feature Comparison

Length of Throw

Hand Throw

Hand Crank (maintenance and emergency use)

Operating Speed at 110V

(approx.)

Operating Speed at 20V

(approx.)

Operating Voltage

Control Voltage

Controller

Model

“Over/locked” Contacts

Point-Detector (separate)

Magnetic Detent

Dynamic Snubbing

Friction Clutch

Frost Protection

Yes

3 Sec.

11-14 Sec.

110/24

Yes

Optional

Yes

3 Sec.

11-14 Sec.

110/24

Yes

Optional

Yes

3 Sec.

11-14 Sec.

110/24

10 or 24

Yes

Optional

Yes

3 Sec.

11-14 Sec.

CAUTION

To preserve the dynamic snubbing feature, limit the number of consecutive throws to ten (10), followed by a 60 second wait to allow cool down of the snub resistor wire before actuating an additional series of throws.

110/24

10 or 24

Yes

Optional

P1293, Rev. Oct/12 1–3 Alstom Signaling Inc.

General Description

1.3.1. Model 5E Switch Machine

The Model 5E Switch Machine is designed for power operation only. A hand crank is provided for making and checking adjustments and for emergency use. The hand crank mechanism has an automatic motor cutout device to prevent power operation with the crank in use.

Control and overload relays are housed externally. The two-wire control circuit uses two biased-neutral control relays and a neutral overload relay. Three wires for motor control are required between the relay housing and the switch machine. The number of indication wires required depends on the type of circuit used.

1.3.2. Model 5F Switch Machine

The Model 5F Switch Machine is the same as the Model 5E machine except that it contains a dual-control mechanism. The Model 5F machine, therefore, is designed for both power and hand-throw operation. A hand crank is provided for making and checking adjustments. The hand crank mechanism has an automatic motor cutout device to prevent power operation with the crank in use.

The gear train is designed in the Model 5F machine to permit removal and replacement of the friction clutch and intermediate gears without disassembling the dual-control mechanism.

1.3.3. Model 5G Switch Machine

The Model 5G Switch Machine is designed for power operation only. A hand crank is provided for making and checking adjustments and for emergency use. The hand crank mechanism has an automatic motor cutout device to prevent power operation with the crank in use.

This switch machine contains a biased-neutral controller. Control energy (10 to 12 or 24 to 32 volts DC) is applied to the controller either through relays located near the switch machine, or directly through the switch control lever. The controller also provides overload protection and dynamic snubbing of the switch machine motor.

1.3.4. Model 5H Switch Machine

The Model 5H Switch Machine is the same as the Model 5G machine except that it has a dual-control mechanism added. This machine is designed for both power and handthrow operation. A hand crank is provided for making and checking adjustments. The hand crank mechanism has an automatic motor cutout device to prevent power operation with the crank in use.

The Model 5H Switch Machine gear train is designed to permit removal and replacement of the friction clutch and intermediate gears without disassembling the dual-control mechanism.

P1293, Rev. Oct/12 1–4 Alstom Signaling Inc.

General Description

1.4. MODEL 5 SERIES SWITCH MACHINE COMPONENTS

The switch machine has a DC motor at one end to drive the gear train, which moves the throw bar and the lock rod. To ensure the throw bar and lock rod continue to move easily, preventive maintenance includes inspection; always replace any worn parts.

Figure 1–1 shows the components of a Model 5G switch machine.

P1293, Rev. Oct/12

Figure 1–1. Model 5G Switch Machine Components

1–5 Alstom Signaling Inc.

General Description

Operating energy is derived from a central source, fed through external control relays, and applied to the field windings and armature of the motor. After the machine has operated to the called position and locked the switch, a dynamic snub arrangement stops the motor. A ceramic permanent magnetic detent restrains the motor armature after the dynamic snub stops armature rotation at the completion of a stroke or whenever energy is removed from the motor.

Underneath the outer cover is an inner cover over the gear train.

For maintenance purposes or emergency use, a hand crank is inserted through the top cover. Table 1–2 summarizes the major common components provided on all 5 Series

Switch Machines.

P1293, Rev. Oct/12 1–6 Alstom Signaling Inc.

General Description

1.4.1. Switch Machine Serial Numbers

The underside (inside) of the Gear Compartment Cover has a name plate that includes the switch machine part number and serial number. The switch machine serial number is also stamped on the frame, typically near the mounting holes closest to the motor end.

The name plate attached to the top of the motor case specifies the motor part number and motor serial number.

See Figure 1–2 for the locations of the motor and switch machine name plates and the stamped serial numbers.

P1293, Rev. Oct/12

Figure 1–2. Name Plate and Serial Number Locations

1–7 Alstom Signaling Inc.

General Description

Table 1–2. Model 5 Series Switch Machine Components

Component Function

Box Style Bearings and

Wear Plates

Cam Bar

Protects the frame from wear.

Cutout Switches

DC Motor

Motor Commutator and

Brushes

Motor Magnetic Holding

Device

Motor Magnetic Detent and

Dynamic Snubbing

Friction Clutch

Gears

Hand Crank

Lock Rod

Moves along the machine frame, unlocking the lock rod and throw bar, so that the throw bar and switch points can move to the opposite direction.

Removes all power to the switch machine motor.

Converts 110 VDC (or 24 VDC) electrical energy to mechanical energy, providing a rotating motion for driving the gear train.

Work together to provide current to the correct armature winding(s) in the motor and provide torque.

Prevents unwanted armature rotation after energy is removed from the motor.

Quickly slows and stops armature rotation.

Absorbs the shock encountered in switch operation.

Provides the force needed to move the switch points.

Operates the switch machine any time operation by power is not desired or not possible.

Mechanically locks the points; ensures that false point detection is not obtained when the switch machine is locked and the lock and detector rods have not moved together.

Point Detector Mechanism Indicates position of the points; detects when the switch points are within the proper distance from the stock rail and are locked.

Throw Bar Moves the points; works with the cam bar and point detector mechanism to provide the movement of the switch points.

P1293, Rev. Oct/12 1–8 Alstom Signaling Inc.

General Description

The components in Table 1–3 are provided on the models indicated.

Table 1–3. Model 5 Series Switch Machine Model Specific Components

Component

Biased-Neutral Controller

(5G and 5H only)

Hand Throw Lever

(5F and 5H only)

Function

Provides overload protection. Controls high current feed to the motor.

Allows the operator to manually throw the switch machine.

P1293, Rev. Oct/12 1–9 Alstom Signaling Inc.

General Description

1.5. SAFETY PRECAUTIONS FOR MAINTAINERS

WARNING

WHEN USING THE HAND CRANK ON THIS SWITCH MACHINE, KEEP

A FIRM HOLD ONTO THE HAND CRANK. IF THERE IS SPRING IN THE

SWITCH POINTS WHEN THE MACHINE BECOMES UNLOCKED, THE

HAND CRANK WILL ACCELERATE RAPIDLY IN THE DIRECTION IT IS

BEING TURNED. IF NOT CAUTIOUS, INJURY BY THE CRANK’S

SUDDEN MOVEMENT COULD RESULT.

Safe practices and common sense should always be followed when working around any equipment. Remember that good common sense and an understanding of the equipment is essential to any safety policy. The information following describes the health and safety standards for testing, alterations, repairs, improvements or maintenance for 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. Maintainers should work in pairs at the switch site.

1.5.1. General Recommendations

Maintenance personnel shall comply with all local laws, rules, statues and regulations of governing or regulatory bodies within the geographical area of operations of the property (or Authority). The requirements of these bodies or the user’s safety manual, whichever are 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 be applied.

P1293, Rev. Oct/12 1–10 Alstom Signaling Inc.

General Description

1.5.2. Proper Attire

1. Wear hard hats at all times.

2. Wear only leather work shoes that are not worn-out and 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.

1.5.3. Train Control Room (TCR) Work

All personnel working in the TCR areas shall observe the following outlined safety precautions.

1. Assume busses are energized.

2. Use proper size fuse pullers for inserting and replacing cartridge type fuses. Do not substitute hand tools for fuse pullers.

3. Do not use frayed or worn extension cords. All extension lights must have a protective cover over the bulb.

4. Use extension cords of the three-wire type. If a two-pronged adapter is used, it must have a ground wire attached to a known ground.

5. Use proper socket wrenches (AAR type) when working on entrance racks or racks with AAR terminals. Do not use open end or adjustable wrenches.

1.5.4. General Safety on Property

1. Never go out on a track of an operating railroad alone. Flagmen familiar with operating procedures and safety regulations should 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 at all times. Yell or shout a warning if a dangerous situation develops.

P1293, Rev. Oct/12 1–11 Alstom Signaling Inc.

General Description

1.5.5. Safety at Wayside

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. When standing along the track in clearance, 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 operator gives 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, turnouts and on grades, as it is very difficult to determine the direction from which a train is approaching and how close is it.

1.5.6. Safety at Station Platforms

1. Jumping up or down between the station platform and track level is dangerous.

When working on tracks or equipment in platform areas, always move into and out of the area at track level.

2. Before stepping out into the track area from a track level TCR, ensure that no train is passing. If a train is standing at the platform, wait until it has passed before exiting.

3. Before ascending steps from track level area to a station platform, ensure that no train is entering or standing at the platform.

4. Before stepping off a platform onto a stairway to the track level, be sure no train is entering or is at a platform behind you.

P1293, Rev. Oct/12 1–12 Alstom Signaling Inc.

General Description

1.5.7. 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.

WARNING

ALWAYS BE PREPARED FOR IMMEDIATE SWITCH MOVEMENT.

FAILURE TO DO SO COULD CAUSE YOU TO BE INJURED BY

UNEXPECTED OPERATION.

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

4. Because the switch machine is often activated from a remote station (a train 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.

When the hand crank is inserted, the motor is electrically cut off and the machine can not be activated. Insert a hardwood wedge into an open switch point (the gap that is formed between the through and alternate track) to prevent the point from closing. Use these features as protection, but never leave a hand crank inserted in a switch machine or wedge in the switch points when a train is approaching and the switch must be thrown.

P1293, Rev. Oct/12 1–13 Alstom Signaling Inc.

General Description

THIS PAGE INTENTIONALLY LEFT BLANK.

P1293, Rev. Oct/12 1–14 Alstom Signaling Inc.

Theory of Operation

2. SECTION 2 – THEORY OF OPERATION

2.1. GENERAL

This section discusses the basic operation of the 5E, 5F, 5G, and 5H Switch Machines and highlights the main differences between the four versions. Table 1–1 compares and summarizes the principle features of each switch machine.

2.2. POWER OPERATION

A switch machine is an electro-mechanical device consisting of a motor and gear train which moves the rails (points) into position for a rail vehicle to change route.

The motor uses a clutch and gear mechanism to move the throw bar. The throw rod connected to the throw bar moves the switch points. Depending on the direction of rotation of the switch machine motor, either the near or far switch points close.

The lock rod is connected to the switch points by the lock connecting rod. The lock rod mechanically locks the switch points against any movement away from the position of correspondence, which is defined as the point where the position indicated by the switch call circuitry “corresponds” with the indications provided by the point detector circuits. The switch machine remains in the locked position until the machine receives a signal to reverse the action.

The point detector rod is connected to movable switch points by the point detector connecting rod. The point detector rod operates the detector as the switch points move, providing the associated circuits of the display panel and signal control relays with the switch point position indications. Figure 2–1 shows the cam bar and point detector rod along with the detector yoke. Figure 2–2 shows each of the four operating positions.

The point detector motor control contacts remove energy from the motor after each stroke.

P1293, Rev. Oct/12 2–1 Alstom Signaling Inc.

Theory of Operation

Figure 2–1. Lock Rod, Point Detector Rod, and Point Detector

Figure 2–2. Movement of the Lock Rod, Point Detector Rod, and Point Detector

For 5F and 5H Switch Machines, the Hand Throw Selector Lever must be in the

POWER position for energy to be supplied to the motor, enabling power operation of the switch machine. The lever position is labeled and visible from above the switch machine, as in Figure 2–3.

P1293, Rev. Oct/12 2–2 Alstom Signaling Inc.

Theory of Operation

Figure 2–3. Hand Throw Selector Lever Positions

The Hand Crank must NOT be inserted into the cover near the motor end for power to be supplied to the switch machine motor. See Figures 2–4 and 2–5.

P1293, Rev. Oct/12 2–3 Alstom Signaling Inc.

Theory of Operation

2.3. HAND CRANK OPERATION

The Hand Crank is provided for performing and verifying adjustments, and for emergency operation. It is used by the maintainer to operate the switch machine when operation by power is not desired or is not possible.

The hand crank is inserted under the Hand Crank Cover near the motor end of the switch machine to operate the switch machine without power.

d

Motor

Hand

Crank

Cover

Figure 2–4. Hand Crank Cover Position

WARNING

REMAIN CLEAR OF GEARS AND SWITCH POINTS WHEN INSERTING

OR REMOVING HAND CRANK. THE SWITCH MACHINE CAN BE

REMOTELY ACTIVATED INSTANTLY, POSSIBLY CAUSING

PERSONNEL INJURY OR EQUIPMENT DAMAGE.

WARNING

WHEN USING THE HAND CRANK ON THIS SWITCH MACHINE, KEEP

A FIRM HOLD ONTO THE HAND CRANK. IF THERE IS SPRING IN THE

SWITCH POINTS WHEN THE MACHINE BECOMES UNLOCKED, THE

HAND CRANK WILL ACCELERATE RAPIDLY IN THE DIRECTION IT IS

BEING TURNED. IF NOT CAUTIOUS, INJURY BY THE CRANK’S

SUDDEN MOVEMENT COULD RESULT.

Place the end of the hand crank (1) against the inside lip of the blocking plate (2) then move the blocking plate to the detent position, centering the hole in the blocking plate to the clutch crank hole as shown in Figure 2–5.

P1293, Rev. Oct/12 2–4 Alstom Signaling Inc.

Theory of Operation

Figure 2–5. Inserting the Hand Crank

When the Hand Crank is installed the cutout arm contact opens the motor power circuit.

Keeping the switch machine hand crank in place during maintenance provides a primary safety precaution, assuring that the switch machine will not operate electrically.

Keep in mind that electrical power is present at inside components and contacts unless electrical power is removed externally.

To return the machine to power operation, it is necessary to remove the hand crank and restore the position of the blocking plate.

WARNING

DISCONNECT MOTOR ENERGY WHENEVER WORKING ON SWITCH

LAYOUT OR SWITCH MACHINE. UNEXPECTED OPERATION OF

MACHINE COULD CAUSE INJURY FROM OPEN GEARS, ELECTRICAL

SHOCK, OR MOVING SWITCH POINTS

P1293, Rev. Oct/12 2–5 Alstom Signaling Inc.

Theory of Operation

2.4. HAND THROW OPERATION (5F AND 5H SWITCH MACHINES)

The Hand Throw Selector Lever must be in the POWER position for energy to be supplied to the motor as shown in Figure 2–3. This enables power operation of the switch machine.

WARNING

ALWAYS MOVE THE HAND THROW SELECTOR TO THE HAND

POSITION BEFORE MOVING THE HAND THROW LEVER.

ATTEMPTING TO MOVE THE HAND THROW LEVER WHILE THE

LEVER IS IN THE POWER POSITION COULD RESULT IN INJURY.

WARNING

STORED MECHANICAL ENERGY, CAUSED BY IMPROPER

ADJUSTMENT, SHIFTS IN RAILS OR OTHER SWITCH COMPONENTS,

OR OBSTRUCTIONS, CAN BE TRANSFERRED TO THE HAND-

THROW LEVER DURING HAND OPERATION CAUSING IT TO MOVE

RAPIDLY AND FORCEFULLY. DIFFICULTY IN HAND OPERATING THE

SWITCH COULD INDICATE A POTENTIAL HAZARD. IF ANY OF

THESE CONDITIONS ARE OBSERVED, CHECK THAT THE SWITCH IS

ADJUSTED PROPERLY.

To hand operate the 5H Switch Machine rotate the Hand Throw Selector Lever to the

HAND position to remove energy to the motor. Then, rotate the HAND THROW lever

180 degrees to move the switch points.

Figure 2–6. Hand Throw Lever and Correspondence Indication

P1293, Rev. Oct/12 2–6 Alstom Signaling Inc.

Theory of Operation

The locations of the letters N and R on the hand-throw lever must correspond to the positions of the switch after the machine (Models 5F and 5H only) has been operated by hand. Figure 2–6 shows the hand throw bar in the N position of normal correspondence.

If the HAND THROW moves freely (no resistance) the switch machine and the points are out of correspondence with the lever.

To reset correspondence- once the lever clicks into place, move it back 180 degrees to move the switch points.

To return the switch to power operation, move the Hand Throw Selector Lever to the

POWER position to supply energy to the motor.

P1293, Rev. Oct/12 2–7 Alstom Signaling Inc.

Theory of Operation

2.5. COMPONENT FUNCTIONS

The operation and function of the primary switch machine components follows. Figure

2–7 highlights the component locations.

Figure 2–7. 5 Series Switch Machine Components (Model 5G)

P1293, Rev. Oct/12 2–8 Alstom Signaling Inc.

Theory of Operation

2.5.1. Motor

The 24- or 110-volt motor is fastened to the end of the machine frame with four fasteners that can be easily removed.

The magnetic detent is a permanent magnet holding device mounted on the outer motor frame. It includes a front bearing for the motor armature, thus making the motor a complete unit. Figure 2–8 shows the motor and its detent.

Figure 2–8. DC Motor

In Models 5E and 5F, the circuit includes the snub-resistor lead, one-half of the snub rectifier, point-detector contacts, and the opposite field coils of the motor. In the Models

5G and 5H, the circuit includes the snub-resistor lead, one-half of the snub rectifier, the snub contact in the controller, and the opposite field coils of the motor.

WARNING

DISCONNECT MOTOR ENERGY WHENEVER WORKING ON SWITCH

LAYOUT OR SWITCH MACHINE. UNEXPECTED OPERATION OF

MACHINE COULD CAUSE INJURY FROM OPEN GEARS, ELECTRICAL

SHOCK, OR MOVING SWITCH POINTS.

P1293, Rev. Oct/12 2–9 Alstom Signaling Inc.

Theory of Operation

The switch machine motor converts 110 VDC (or 24 VDC) electrical energy to mechanical energy, providing a rotating motion for driving the gear train. Reversing current flow to the motor and energizing different field coils changes direction of rotation. Figure 2–9 shows the motor connection diagram as viewed from the commutator end of the motor.

Figure 2–9. Motor Connection (Series Split Field) Diagram

Electrical motors are furnished with series split-connected field coils. The internal arrangement of the field coils does not permit changes in the field coil connections.

Each field coil is stamped with Alstom drawing number and resistance value.

Resistance of 110-volt coil is 0.354-ohm; resistance of 24-volt coil is 0.105-ohm.

When viewing the motor from the commutator end, the armature rotates to the right when positive energy is supplied to Terminal 6 and negative energy to Terminal 4.

Positive flow is through the armature to Terminal 1, through field coils F3 to F4 and then to Terminal 4. Viewed from the commutator end, the armature rotates to the left when positive energy is supplied to Terminal 3 and negative energy to Terminal 6. Positive flow is through field coils F1 and F2 to Terminal 1, through the armature and then to

Terminal 6.

NOTE

Field coils F1 and F2 are energized for rotation to the left and coils F3 and

F4 are energized for rotation to the right.

P1293, Rev. Oct/12 2–10 Alstom Signaling Inc.

Theory of Operation

2.5.1.1. Commutator and Brushes

The commutator is part of the armature to which the windings are connected. The commutator consists of an insulated steel hub with wedge shaped insulated copper segments arranged around the hub.

Brushes made from current conducting material ride on the commutator, making an electrical connection between the commutator and the power supply. Brushes ride on the outer edges of commutator bars that are connected to armature windings, and are seated to match the shape of the commutator. To insure proper electrical contact, brush pressure to the commutator is set to 1-1/4 to 1-3/4 pounds.

The commutator and brushes work together to provide current to the correct armature winding(s) to generate torque as shown in Figure 2–10.

Figure 2–10. Commutator and Brushes

A heater is located over the commutator and brushes to eliminate moisture in the motor area. The heater is energized by a 110 VAC source.

P1293, Rev. Oct/12 2–11 Alstom Signaling Inc.

Theory of Operation

2.5.1.2. Magnetic Detent

At the completion of each stroke, the overrun of the motor generates a current. This current flows through a low-resistance circuit. Flux generated in this circuit quickly slows and stops armature rotation.

• In Models 5E and 5F, the circuit includes the snub-resistor lead, one-half of the snub rectifier, point-detector contacts, and the opposite field coils of the motor.

• In the Models 5G and 5H, the circuit includes the snub-resistor lead, one-half of the snub rectifier, the snub contact in the controller, and the opposite field coils of the motor.

The holding device magnetically locks the motor armature when it is not rotating. A permanent ring magnet is fixed to the housing cover while a similar magnet is attached to the armature shaft. These magnets, shown in Figure 2–11, slow the motor to prevent unwanted armature rotation after energy is removed from the motor.

With the motor de- energized, the poles of the armature magnet line up with the poles of opposite polarity in the fixed magnet. A magnetic detent effect, produced by a magnetic-flux linkage between the magnetic poles, prevents armature rotation.

P1293, Rev. Oct/12

Figure 2–11. Schematic Diagram of Holding Device,

Showing Magnetic Detent Effect

2–12 Alstom Signaling Inc.

Theory of Operation

When the motor is energized, the motor torque overcomes the magnetic restraining force, and the armature magnet rotates parallel to the fixed magnet. At the completion of the switch stroke, the dynamic snub on the motor again stops the armature rotation, and the holding device securely prevents any more armature rotation.

It is necessary to overcome the initial holding force of the holding device when hand cranking the machine, but once started, cranking is easy to do. The full restraining effect returns any time cranking slows down enough or stops permitting the magneticflux linkage to overcome the cranking torque.

P1293, Rev. Oct/12 2–13 Alstom Signaling Inc.

Theory of Operation

2.5.2. Hand Crank Cutout Switches

The cutout switch, shown in the open position in Figures 2–12 and 2–13, removes all power to the switch machine motor. The cutout switch is engaged via the mechanical interaction of the hand crank being inserted into the blocking plate. To insert the hand crank, the hole in the blocking plate must align with the hole in the clutch pinion. When the blocking plate moves, the contact plunger also moves and opens the control line to the motor armature.

Figure 2–12. Cutout Switch in Open Position (Models 5F and 5H)

WARNING

CUTOUT SWITCH CONTACTS CARRY 110-VDC WHEN POWER IS

APPLIED. USE CAUTION WHEN WORKING AROUND EXPOSED

CONTACTS. FAILURE TO DO SO COULD RESULT IN SERIOUS

INJURY OR DEATH.

NOTE

The crank cutout switch opens the neutral (return) line in the motor circuit.

If external power is connected with the cutout switch open, all motor windings, the “hot” side of the cutout switch, and the motor control circuits are energized to 110 VDC.

P1293, Rev. Oct/12 2–14 Alstom Signaling Inc.

Theory of Operation

THROW

BAR

HAND CRANK

ENTRANCE HOLE

HAND CRANK

CUTOUT CONTACTS

LOCKING

BAR

Figure 2–13. Cutout Switch in Open Position (Models 5E and 5G)

P1293, Rev. Oct/12 2–15 Alstom Signaling Inc.

Theory of Operation

2.5.3. Friction Clutch

The friction clutch shown in Figure 2–14 reduces gear mechanism shock and motor burnout. The friction clutch is typically adjusted to slip when motor operating current exceeds 12 to14 amps for 110V switch machines or 17 to 20 amps for 24V switch machines. The overload relay, located in the control circuit, opens the switch motor control circuit approximately 3 seconds after the clutch begins slipping. To reset an overload condition, the switch must be called to the opposite position.

The pinion gear of the motor meshing with the bevel gear drives the clutch body. Inside are friction disks compressed against the clutch body. Some disks are engaged with the pinion shaft. Other disks (metal) are engaged with the clutch body. The pinion is driven until torque to drive the remainder of the gear train increases enough to cause the friction disks to slip. When the friction disks slip, the clutch body continues to rotate though the pinion stops.

WARNING

FRICTION DISCS IN OLDER CLUTCHES MAY CONTAIN ASBESTOS.

FOLLOW PROPER ASBESTOS HANDING PROCEDURES

ACCORDING TO LOCAL REGULATIONS.

THE ASBESTOS CONTAMINATION MAY EXTEND TO NEARBY

SURFACES AND GREASE.

An adjusting nut is provided to increase or decrease the amount of pressure on the friction disks to the clutch body. The maximum amount of torque that the friction clutch pinion must provide for the switch machine to move the switch points and provide for switch point pressure is closely related to current draw of the motor.

P1293, Rev. Oct/12 2–16 Alstom Signaling Inc.

HOLE FOR PIN

PINION

LOCK NUT

Theory of Operation

NOTCH FOR LOCKING

ADJUSTING SCREW

SETSCREW

BEVEL GEAR

CASE

DRAIN HOLE

(KEEP CLEAR)

Figure 2–14. Friction Clutch

2.5.3.1. Friction Clutch Gear Mechanism

The friction clutch drives an intermediate gear, which in turn drives the main gear. The gear ratio obtained by these gears is sufficient to provide the force needed to move the switch points.

The friction clutch pinion gear drives the large gear of the intermediate gear assembly.

Attached to the intermediate gear shaft is the intermediate pinion gear, which drives the main gear.

P1293, Rev. Oct/12 2–17 Alstom Signaling Inc.

Theory of Operation

2.5.3.2. Main Gear Bracket

The main gear bracket provides stability for the switch machine gear compartment.

Figure 2–15 shows the main gear bracket for the 5F and 5H switch machines. The rugged bracket prevents the gears and clutch assembly from moving out of alignment.

The bracket also provides suitable access for lubrication of the main and intermediate gears and friction clutch assemblies. The blocking plate for the crank cutout switch is also mounted on the bracket.

Figure 2–15. Main Gear Bracket (Models 5F and 5H)

P1293, Rev. Oct/12 2–18 Alstom Signaling Inc.

Theory of Operation

2.5.4. Cam Bar, Throw Bar, Point Detector Mechanism

The cam bar, throw bar and point detector mechanism work together to provide the actual movement of the switch points. The locking of the switch points in the near and far positions, and indication of switch point positioning is obtained by the mechanical operation of the point detector.

A roller drives the cam bar. Movement is along the length of the machine frame. First movement of the cam bar causes the point detector to swing to the center position by the point detector dog on the cam bar, intercepting lower rollers on point detector yoke.

See Figure 2–16.

Figure 2–16. Cam Bar Centering Point Detector

With continuing motion of the cam bar, the lock rod dog on the cam bar, unlocks the lock rod by withdrawing from the notch in the lock rod, as shown in Figure 2–17.

Figure 2–17. Lock Rod in Locked and Unlocked Positions

P1293, Rev. Oct/12 2–19 Alstom Signaling Inc.

Theory of Operation

Final cam bar motion towards the point detector unlocks the throw bar. The throw bar dog on the cam bar withdraws from the throw bar locking surface, as in Figure 2–18.

Figure 2–18. Throw Bar Dog Unlocking Throw Bar

After the cam bar moves completely to the unlocked position, the cam roller drives the throw bar and switch points to the opposite position, as in Figure 2–19.

P1293, Rev. Oct/12

Figure 2–19. Cam Roller Moving Throw Bar

2–20 Alstom Signaling Inc.

Theory of Operation

Following movement of the throw bar to the opposite position, the cam roller continues moving and pulls the cam bar back toward the motor end of the machine. The throw bar dog on the cam bar slides against the locking surface of the throw bar, thus locking the throw bar in the opposite direction. The lock rod dog positions itself into the slot in the lock rod, locking the lock rod in place.

Final movement of the cam roller and cam bar releases the point detector yoke by the point detector dog moving away from the lower rollers on the point detector yoke. The point detector yoke is then allowed to swing into a new position depending on the positioning of the point detector rod and the lock rod.

P1293, Rev. Oct/12 2–21 Alstom Signaling Inc.

Theory of Operation

2.5.5. Lock Rod

The Lock Rod, when released by the cam bar lock dog, follows the movement of the switch points and locks the switch points in the near of far positions. Two lock rod arms

(clips) are used on the Model 5E - 5H switch machines (Figures 2–20 and 2–21).

LOCK ROD ARM

(CLIP). ONE BOLTED

TO EACH LOCK ROD.

LOCK RODS

POINT DETECTOR

END OF MACHINE

Figure 2–20. New Style Lock Rod Arm (Two Required Per Machine)

OLD STYLE LOCK ROD

ARM (CLIP). ONE BOLTED

TO EACH LOCK ROD.

LOCK RODS

POINT DETECTOR

END OF MACHINE

Figure 2–21. Old Style Lock Rod Arm (Two Required Per Machine)

WARNING

TO PROVIDE PROTECTION AGAINST FALSE POINT-DETECTOR

INDICATIONS BECAUSE OF BROKEN DETECTOR ROD OR BROKEN

LOCK ROD CONNECTIONS, INSTALL THE ARMS ON THE LOCK

RODS. IT IS ALSO IMPERATIVE THAT THOSE ARMS FURNISHED

BEFORE 1967 BE INSTALLED ON THE LOCK RODS SO THE HIGH

SIDE OF THE ARM IS UNDER THE CONTACT YOKE, AWAY FROM

THE MOTOR END OF THE SWITCH MACHINE.

P1293, Rev. Oct/12 2–22 Alstom Signaling Inc.

Theory of Operation

The two lock rod arms ensure that false point detection is not obtained when the switch machine is locked if the lock and detector rods have not moved together. This provides protection against a broken or loose point-detector connection or a broken or loose lock rod. This protection is obtained by the interference between the end of the contact yoke and a blocking arm as shown in Figure 2–22. This view shows the point-detector contact yoke from the motor end of the switch machine.

Figure 2–22. Point-Detector Contact Yoke With Left,

Center and Right Positioning of Lock and Detector Rods

P1293, Rev. Oct/12 2–23 Alstom Signaling Inc.

Theory of Operation

2.5.6. Point Detector Rods

The point detector rod follows the position of the switch points. When released, the point detector yoke drops into the grooves cut in the top of the rod, showing the point position. Figure 2–23 illustrates the point detector rod in extreme positions and the point detector yoke engaged to the rod grooves.

If the point detector rod moves far enough from the extreme positions, the point detector yoke swings to a center position, such as when a switch is improperly trailed.

Locating notches are provided on the rods to allow initial adjustment of the rods to the switch layout.

Figure 2–23. Point Detector Rod Normal and Reverse Positions

The point detector rod is connected to movable switch points by the point detector connecting rod as shown in Figure 2–24. The point detector rod operates the detector as the switch points move. The point detector contacts remove energy from the motor after each stroke and provide the associated circuits of the display panel and signal control relays with the switch point position indications.

P1293, Rev. Oct/12 2–24 Alstom Signaling Inc.

Theory of Operation

P1293, Rev. Oct/12

Figure 2–24. Point Detector Connecting Rod Location

2–25 Alstom Signaling Inc.

Theory of Operation

2.5.7. Box Style Bearings and Wear Plates

Bearings and plates protect the machine frame from wear.

Wear plates, as shown in Figure 2–25 are used on the lock rod and point detector rod to allow wear to occur without damage to the frame.

SWITCH MACHINE HOUSING

LOCK ROD

WEAR PLATE

POINT DETECTOR

ROD WEAR PLATE

LONG ROD

SHORT ROD

LONG ROD

LOCK ROD

CONNECTING ROD

SHORT ROD

POINT DETECTOR

CONNECTING ROD

Figure 2–25. Wear Plates

P1293, Rev. Oct/12 2–26 Alstom Signaling Inc.

Theory of Operation

Box style bearings, as shown in Figure 2–26, provide a renewable wear surface for the throw bar, but must be replaced before the bearing is worn through. Holes are provided in the bearing for lubrication.

Figure 2–26. Box Style Bearings

2.5.8. Point Detector Circuit Controller

The switch machine includes a point detector circuit using point detector contacts and point detector rods.

The point detector circuit controller is an over-and-lock type of circuit controller. Some point detector contacts indicate and verify that switch points are within the proper distance of the stock rail. These contacts then verify that the points are locked at the end of the point movement. Other contacts control the motor operating circuit. When the point detector is not in a closed position, contacts shunt the indication circuit to prevent false indications due to grounding or induced currents. Figure 2–27 shows a top view of circuit controller contacts. See Figure 2–22 for examples of engaged contacts.

WARNING

DISCONNECT MOTOR ENERGY WHENEVER WORKING ON THE

SWITCH LAYOUT OR SWITCH MACHINE. UNEXPECTED OPERATION

OF THE MACHINE COULD CAUSE INJURY FROM OPEN GEARS,

ELECTRICAL SHOCK, OR MOVING SWITCH POINTS.

P1293, Rev. Oct/12 2–27 Alstom Signaling Inc.

Theory of Operation

Figure 2–27. Point Detector Contacts, Top View of Models 5G and 5H

2.5.8.1. Normal/Reverse Contacts

The first unlocking movement of the cam bar opens either the normal or reverse contacts, depending on the direction of operation, as shown in Figure 2–28.

Figure 2–28. Normal/Reverse Contacts In Open Position

P1293, Rev. Oct/12 2–28 Alstom Signaling Inc.

Theory of Operation

2.5.8.2. Motor Control Contacts

During motor operation, both motor control contacts are closed due to detector yoke pivoting to center position. Only one of the two motor control contacts provides energy to the electrical circuit for the motor winding. At completion of movement, the detector yoke pivots, as shown in Figure 2–29, opening only that motor control contact providing energy to the electrical circuit, thereby de-energizing motor. The other motor control contact, still closed, is part of motor snub circuit and is in position to apply energy to switch the motor for next switch movement.

Figure 2–29. Motor Control Contacts In Open Position

P1293, Rev. Oct/12 2–29 Alstom Signaling Inc.

Theory of Operation

2.5.8.3. Shunt Contact

Immediately after the snub and normal/reverse contacts are opened, shunt contacts, shown in Figure 2–30 and 2–31, are closed. If the machine is unlocked, or if the point detector rod is out of adjustment, a shunt is placed on the repeater relay circuit. The shunt prevents the energizing of the repeater relays so that any outside energy present does not give a false indication when the machine is not over and locked.

Figure 2–30. Shunt Contacts Used in Polarized Repeater Relay Circuit,

Models 5E and 5F

Figure 2–31. Shunt Contacts Used in Neutral Repeater Relay Circuit,

Models 5E and 5F

P1293, Rev. Oct/12 2–30 Alstom Signaling Inc.

Theory of Operation

2.5.9. Switch Machine Wiring

A built-in biased-neutral controller with dynamic snubbing is furnished in Model 5G and

5H switch machines. This controller provides for two-wire polarized control, either normally energized or de-energized. Overload protection is self-contained. The snub arrangement provides for dynamically snubbing the switch machine motor after it has operated and locked the switch.

CAUTION

A simplified diagram of the switch machine circuit with 24-volt control and snubbing arrangement is shown in Figure 2–32.

MOTOR

CRANK

CONTACT

8 7

CONTROL WIRE #1

CONTROL WIRE #2

CONNECTOR

SHUNT STRIPS "A"

6 5 4 3 2 1

BLACK

SNUB

RECTIFIER

RESISTIVE

LEAD

1 2 3 4 5 6 7 8

GND.

LUG

POINT DETECTOR

RED

YELLOW

CONTROL

WIRE #3

Figure 2–32. Simplified Wiring Diagram With Snubbing Circuit and 24V Control

The controller consists of two biased-neutral contactors (C1 and C2), an overload relay, a snubbing contact operated by the contactors, a snubbing rectifier, and a snub-resistor lead. All components are housed in an aluminum case provided with a terminal board.

See Figure 2–33.

Extra-heavy-duty snub and contactor contacts have permanent magnets that help to blow out the arc that occurs when the motor contacts open. Figure 2–34 shows the front and back contacts C1 and C2 of the biased-neutral controllers in Model 5G and

5H switch machines.

P1293, Rev. Oct/12 2–31 Alstom Signaling Inc.

Theory of Operation

WARNING

ADHERE TO ALL APPLICABLE WARNINGS WHEN WORKING ON

SWITCH MACHINES AND SWITCH LAYOUTS. DISCONNECT

ELECTRICAL ENERGY WHENEVER POSSIBLE AND WHEN

INSTRUCTED, WHILE WORKING ON THE SWITCH MACHINE OR

SWITCH LAYOUT. INJURY COULD RESULT FROM ELECTRICAL

SHOCK DUE TO EXPOSED WIRES AND ELECTRICAL DEVICES, AS

WELL AS INJURY FROM OPEN GEARS OR MOVING SWITCH POINTS

DUE TO UNEXPECTED OPERATION OF THE SWITCH MACHINE.

Figure 2–33. Biased-Neutral Controller

Typical wiring diagrams for the Model 5G and 5H switch machines with biased-neutral controllers are shown in Figures 2–34 and 2–35.

P1293, Rev. Oct/12 2–32 Alstom Signaling Inc.

Theory of Operation

Figure 2–34. Typical Model 5G Wiring Diagram and Control Circuit,

Right-Hand Point Normally Closed

P1293, Rev. Oct/12 2–33 Alstom Signaling Inc.

Theory of Operation

Figure 2–35. Typical Model 5H Wiring Diagram and Control Circuit,

Right-Hand Point Normally Closed

P1293, Rev. Oct/12 2–34 Alstom Signaling Inc.

Theory of Operation

When the switch machine is to operate to the left, positive control energy is applied to the NWR wire and negative control energy to the WR wire. This causes contactor C2 to be energized. When contactor C2 picks up, the snub contact opens. Contactor C2 closes its front contact and, through the centering device, closes the back contact of contactor C1. This completes the motor circuit, and operating energy flows from terminal 5, through the front contact of C2, the reverse field of the motor, the armature, the crank contact, the operating coil of the overload relay, and the back contact of contactor C1 to negative.

As the switch machine unlocks, point-detector contacts 7D-2C close. The machine continues to operate to the left. When the machine completes its stroke, point-detector contacts 1C-8D open, de-energizing contactor C2 and opening the motor circuit. The contactor armatures return to their normally centered position and the snub contact closes. The motor armature continues to rotate, generating a dynamic current that flows from field coil through terminals 4 and 9, one-half of the snub rectifier, the snub resistor lead, the snub contact, terminals 12 and 7, the crank contact, terminal 6, the armature, terminal 1, and back to coil N.

When the switch machine is to operate to the right, positive control energy is applied to the WR wire and negative control energy to the NWR wire. This causes contactor C1 to be energized. When contactor C1 picks up, the snub contact opens. Contactor C1 closes its front contact and through the centering device closes the back contact of contactor C2 (point-detector contacts 7D-2C were closed and contacts 1C-8D were opened during the operation of the machine to the left). This completes the motor circuit, and operating energy flows through the motor in a direction to operate the machine to the right.

As the machine completes its stroke, contacts 7D-2C open, de-energizing contactor C1 and opening the motor circuit. The contactor armatures return to their normally centered position and the snub contact closes. Any overrun of the motor armature generates a dynamic current that now flows from field coil through terminal 1, the armature, the crank contact, terminals 7 and 12, the snub contact, the snub resistor lead, the other half of the snub rectifier, terminals 8 and 3, and back to coil R.

P1293, Rev. Oct/12 2–35 Alstom Signaling Inc.

Theory of Operation

2.5.9.1. Switch Operating Relay

Table 2–1 shows the correlation between a switch call and the typical pick or drop of the named relay, with the switch machine moving its throw bar to the requested position. Certain relays (with an asterisk in the table below) picks only if manually levered from either an emergency or central control panel. An upward arrow signifies the relay is picked; a downward arrow signifies the relay has dropped. Table 2–2 provides the relay abbreviation definitions.

Table 2–1. Typical Switch Request and Affected Relays, Position of Relay Per Request

Switch Action Relay Position Switch

Request

NORMAL

*RP

↓

*NP

↑

REVERSE *RP

↑

*NP

↓

Relay Position

RWZ

NWZ

RWZ

NWZ

↓ RW↓

↑ NW↑

↑ RW↑

↓ NW↓

SWITCH MACHINE

THROWS TO

REQUESTED

POSITION

RWP

↓

RWC

↓

NWP

↑

NWC

↑

RWP

↑

RWC

↑

NWP

↓

NWC

↓

Table 2–2. Relay Position Abbreviation Definitions

Abbreviation

RWZ

NWZ

RWP

NWP

RWC

NWC

Definition

Reverse Repeater Relay

Normal Repeater Relay

Reverse Switch Call Relay

Normal Switch Call Relay

Reverse Switch Relay

Normal Switch Relay

Reverse Switch Repeater Relay

Normal Switch Repeater Relay

Reverse Switch Correspondence Relay

Normal Switch Correspondence Relay

P1293, Rev. Oct/12 2–36 Alstom Signaling Inc.

Theory of Operation

2.5.9.2. Overload Relay

The Overload Relay, Figure 2–36, operates to release the energized contactor, which in turn opens the motor circuit whenever an overload is encountered. The operating coil is connected in multiple with external resistance wire RT. Normally, most of the operating current flows through the resistance wire and therefore, there is not sufficient current flowing in the operating coil to operate the relay.

High current, such as the motor would draw if there were an overload, heats resistance wire RT and increases its resistance. This effect causes sufficient current to flow through operating coil 0 to operate the relay. Once operated, the armature is held up by a stick coil until the control circuit is either interrupted or reversed.

A metal slug and washers slow operation of the relay so that it does not operate in response to the momentary surges of current that occur when starting or reversing the motor. When the overload relay operates, it removes energy from contactors C1 and C2.

P1293, Rev. Oct/12

Figure 2–36. Overload Relay

2–37 Alstom Signaling Inc.

Theory of Operation

2.5.9.3. Example Relay Circuits Provided In Appendix A

Appendix A contains these example circuits from Model 5E- 5H Switch Machines.

Figure No. Description Page

Figure A–1. Typical Right-Hand Point Normally Closed Wiring Diagram and

Control Circuit, Model 5E Switch Machine ............................................................ A–2

Figure A–2. Typical Left-Hand Point Normally Closed Wiring Diagram and

Control Circuit, Model 5E Switch Machine ............................................................ A–2

Figure A–3. Typical Polarized Switch Repeater Relay Circuit Using Shunt

Strips A, Single Switch, Model 5E Switch Machine ............................................... A–3

Figure A–4. Typical Polarized Switch Repeater Relay Circuit Using Shunt

Strips A, Crossover, Two Model 5E Switch Machines ........................................... A–3

Figure A–5. Typical Neutral Switch Repeater Relay Circuit, Single Switch,

Model 5E Switch Machine ..................................................................................... A–4

Figure A–6. Typical Neutral Switch Repeater Relay Circuit, Crossover, Two

Model 5E Switch Machines ................................................................................... A–4

Figure A–7. Typical Model 5F Wiring Diagram and Control Circuit, Right-

Hand Point Normally Closed ................................................................................. A–5

Figure A–8. Typical Model 5F Wiring Diagram and Control Circuit, Left-

Hand Point Normally Closed ................................................................................. A–5

Figure A–9. Typical Polarized Switch Repeater Relay Circuit Using Shunt

Strips A, Single Switch, Model 5F Switch Machine ............................................... A–6

Figure A–10. Typical Polarized Switch Repeater Relay Circuit Using Shunt

Strips A, Crossover, Model 5F Switch Machine .................................................... A–6

Figure A–11. Typical Neutral Switch Repeater Relay Circuit, Single Switch,

Model 5F Switch Machine ..................................................................................... A–7

Figure A–12. Typical Neutral Switch Repeater Relay Circuit, Crossover,

Two Model 5F Switch Machines ............................................................................ A–7

Figure A–13. Typical Polarized Switch Repeater Relay Circuit, Single

Switch, Model 5G Switch Machine ........................................................................ A–8

Figure A–14. Typical Polarized Switch Repeater Relay Circuit, Crossover,

Two Model 5G Switch Machines ........................................................................... A–8

Figure A–15. Typical Neutral Switch Repeater Relay Circuit, Single Switch,

Model 5G Switch Machine ..................................................................................... A–9

Figure A–16. Typical Neutral Switch Repeater Relay Circuit, Crossover,

Two Model 5G Switch Machines ........................................................................... A–9

Figure A–17. Typical Polarized Switch Repeater Relay Circuit, Single

Switch, Model 5H Switch Machine ...................................................................... A–10

Figure A–18. Typical Polarized Switch Repeater Relay Circuit, Crossover,

Model 5H Switch Machine ................................................................................... A–10

Figure A–19. Typical Neutral Switch Repeater Relay Circuit, Single Switch,

Model 5H Switch Machine ................................................................................... A–11

Figure A–20. Typical Neutral Switch Repeater Relay Circuit, Crossover,

Two Model 5H Switch Machines ......................................................................... A–11

P1293, Rev. Oct/12 2–38 Alstom Signaling Inc.

Theory of Operation

2.5.10. Switch and Pipeline Fittings

For a general description of the various fittings and ordering information, refer to

Section 7, Parts Catalog and to the Alstom Signaling Inc. Product and Parts Catalog.

2.5.11. Covers

Covers over each half of the frame protect internal mechanisms. Each cover can be removed independently. The covers are held in place by a hasp-type latching device shown in Figure 2–37.

Figure 2–37. Cover Hasp-Type Latching Device

P1293, Rev. Oct/12 2–39 Alstom Signaling Inc.

Theory of Operation

THIS PAGE INTENTIONALLY LEFT BLANK.

P1293, Rev. Oct/12 2–40 Alstom Signaling Inc.

Installation

3. SECTION – INSTALLATION

3.1. GENERAL

Model 5E-5H Switch Machines should be installed in accordance with the property’s approved switch layout. A newly installed machine should be adjusted and lubricated according to the criteria in this manual.

Satisfactory operation of the switch machine depends on it being installed properly, adjustments made correctly, all identified parts lubricated according to the lubrication chart, and maintenance performed at regular intervals. Maintain good drainage around a switch machine so it does not flood.

NOTE

After the installation is completed or after making any adjustments to the machine or switch layout, hand crank the machine first before applying

DC power to check for responses to the adjustments.

3.2. PROPERTY’S REQUIREMENTS

Although this publication gives set-up information on a typical machine installation, the maintainer should always be sure the switch layout is done in accordance with the requirements of the rail property.

3.3. INSTALLATION

The installation process consists of three elements: physical mounting of the equipment by the tracks, making necessary adjustments and electrical connections, and testing for proper mechanical movement. Details of this process are described next.

When following the procedures in this manual, the following warnings must be heeded:

WARNING

WHEN USING THE HAND CRANK ON THIS SWITCH MACHINE, KEEP

A FIRM HOLD ONTO THE HAND CRANK. IF THERE IS SPRING IN THE

SWITCH POINTS WHEN THE MACHINE BECOMES UNLOCKED, THE

HAND CRANK WILL ACCELERATE RAPIDLY IN THE DIRECTION IT IS

BEING TURNED. IF NOT CAUTIOUS, INJURY BY THE CRANK’S

SUDDEN MOVEMENT COULD RESULT.

P1293, Rev. Oct/12 3–1 Alstom Signaling Inc.

Installation

WARNING

DISCONNECT MOTOR ENERGY WHENEVER WORKING ON THE

SWITCH LAYOUT OR SWITCH MACHINE. UNEXPECTED OPERATION

OF THE MACHINE COULD CAUSE INJURY FROM OPEN GEAR,

ELECTRICAL SHOCK, OR MOVING SWITCH POINTS.

Keep the clearance between the number one rod and the base of the stock rail 1/4 inch maximum (less is desirable) to prevent the switch points from moving up relative to the stock rail. It is essential if the stock rail is beveled for AREA detail 6100 (Samson) points. During use these points pry themselves away from the stock rail when moving up. This motion may cause the point-detector rod in the switch machine to move enough to open the indication contacts. The tendency of the points to move up and in can also be reduced by keeping the ballast firmly tamped under the ties of the switch layout.

The stock rail and the switch machine must be secured to ties that are well tamped to prevent movement when the switch machine is operated against an obstruction. More than 3800 pounds can be exerted on the number one rod by the switch machine if the clutch is adjusted too tightly.

Gauge plates, extension gauge plates, rail braces, and ties must be correct. Points must fit snugly and uniformly against the stock rails without being bent by force from the throw bar. Excessive throw bar force disturbs the layout and causes excessive wear to the switch machine.

P1293, Rev. Oct/12 3–2 Alstom Signaling Inc.

Installation

3.3.1. Left-Hand or Right-Hand Layout

Different arrangements of single and dual control machines exist, depending on whether left-hand or right-hand switch machine operation is required. A typical layout of the switch machine is shown in Figure 3–1.

Models 5E and 5G Switch Machines with one lock rod and one point-detector rod are supplied for right-hand operation only. They are easily changed to left-hand operation.

Also Models 5E and 5G Switch Machines with two lock rods and two point-detector rods can be ordered for either right-hand or left-hand operation. Machines used for double slip switches can be changed in the field; however, machines for movable point frog applications require different point-detector rods from those used in the existing location, if changing from right-hand to left-hand, or vice versa.

Dual-control Models 5F and 5H Switch Machines can be ordered for either right-hand or left-hand operation. Changing from right-hand to left-hand, or vice versa is not recommended only because much more time is required to convert a dual-control machine than to convert a single-control machine.

Instructions to change switch machine models from left-hand to right-hand layout, or vice versa, are found under heading 3.6. CHANGING FROM LEFT-HAND TO RIGHT-

HAND OPERATION AND VICE VERSA.

An optional Switch Machine and Layout Sensing Kit is available from Alstom (P/N

59649-218-00) that can be used to detect point pressure at each point. For a procedure on use of this kit, see Table 3–15 for the Throw Rod Point Pressure Verification

Procedure.

P1293, Rev. Oct/12 3–3 Alstom Signaling Inc.

Installation

Figure 3–1. Typical Right-Hand Single-Switch Layout With Hinged Front Rod

P1293, Rev. Oct/12 3–4 Alstom Signaling Inc.

Installation

3.3.2. Mounting to Ties

All ties that support the switch machine and switch points must be well tamped for their entire length to minimize vibration from passing trains. The two extended ties which directly support the switch machine must be reasonably straight and, where required, properly framed. It is necessary to securely fasten the machine to the ties to ensure little chance of movement with respect to the rails. Also, it is important to check the switch layout plans to verify the installation is correctly made.

3.3.3. Wiring of Machine

In Models 5E and 5F Switch Machines operating circuits are completely wired at the factory. To wire the point-detector, connect the external wires to the machine through a wire entrance fitting to the terminal posts in the machine in accordance with the detail wiring plan that applies to the location.

In Models 5G and 5H Switch Machines, the biased-neutral controller, motor, and pointdetector are completely wired at the factory. In the field, the external wires for switch control, motor energy, heaters (if included), and repeater relay circuits are brought into the machine through a suitable wire entrance fitting and connected to the terminal board posts. To connect these external wires, follow the detail wiring plan for the location.

Typical switch machine wiring diagrams and repeater relay circuits are included in the appendix, and are grouped by model. Repeater relay circuits show metal connectors between some adjacent posts on the terminal board. Connectors are supplied with each new machine and must be arranged as required in the field.

P1293, Rev. Oct/12 3–5 Alstom Signaling Inc.

Installation

3.3.4. Motor Field Connections

Figure 3–2 shows the motor connection diagram as the motor is viewed from the commutator end of the machine. Each motor has two poles with series-split field coils.

Note: For block type derails, transpose leads to motor terminals 3 and 4

Figure 3–2. Motor Connection Diagram

P1293, Rev. Oct/12 3–6 Alstom Signaling Inc.

Installation

3.3.5. Hand-Throw Lever (Models 5F and 5H Only)

Check that the locations of the letters N and R on the hand-throw lever correspond to the positions of the switch after the machine has been operated by hand.

3.3.6. Hand Cranking Before Applying Power

Once the installation is completed, the hand crank should be used to move the machine to the extremes of the normal and reverse throw positions. Doing this enables the maintainer or installer to check that the adjustments were made correctly and that no undue strain is placed on the layout or parts of the machine. Storage of the hand crank is normally in the toolbox compartment by the motor.

Figure 3–3. Inserting the Hand Crank

WARNING

WHEN USING THE HAND CRANK ON THIS SWITCH MACHINE, KEEP

A FIRM HOLD ONTO THE HAND CRANK. IF THERE IS SPRING IN THE

SWITCH POINTS WHEN THE MACHINE BECOMES UNLOCKED, THE

HAND CRANK WILL ACCELERATE RAPIDLY IN THE DIRECTION IT IS

BEING TURNED. IF NOT CAUTIOUS, INJURY BY THE CRANK’S

SUDDEN MOVEMENT COULD RESULT.

P1293, Rev. Oct/12 3–7 Alstom Signaling Inc.

Installation

3.3.7. Connect and Adjust Throw Rod

Table 3–1. Connect and Adjust Throw Rod Procedure

Step

Action

Connect throw rod (1) to coupling (4) on throw bar using the lock nuts (2) and adjustment nuts (3).

Crank machine to end of throw-bar stroke, a distance of six inches.

Adjust nuts (3) at switch basket to obtain proper pressure at switch points.

Lock the outer set of nuts (2) in this position. Avoid excessive pressure, which wears the switch machine and switch layout.

Crank machine to opposite position and repeat step 3.

Crank machine back and forth a few times as a final check.

P1293, Rev. Oct/12 3–8 Alstom Signaling Inc.

Installation

3.3.8. Connect and Initially Adjust Point Detector Connector Rod

NOTE

It is not necessary to install point detector rods in new switch machines since they are part of the switch machine assembly. To remove and insert the rods to change the machine from right to left hand or left to right hand operation use the procedure provided in Table 3–11, 3–12, or 3–13

(depending on the switch machine configuration).

Table 3–2. Connect and Initially Adjust Point Detector Connector Rod Procedure

Step

Action

Fasten point detector connector rod to point-detector rod lug and point lug.

Point Detector Connector Rod

NOTE

It is assumed the lock rod is not yet connected to anything.

Crank machine to close and lock far switch point.

Adjust track side nuts on machine until locating notch on top of pointdetector rod, on field side, is flush with the outside finished surface of contact frame. Tighten and lock nuts.

Crank machine to close and lock near switch point.

Move adjusting plate of point detector rod until locating notch on top of this plate, on track side, is flush with outside finished surface of frame. Tighten and lock nuts that hold this adjustment.

P1293, Rev. Oct/12 3–9 Alstom Signaling Inc.

Installation

Table 3–2. Connect and Initially Adjust Point Detector Connector Rod Procedure

(Cont.)

Step

Action

After adjustments in both directions, crank machine back and forth a few times to check that locating notches return to proper position at end of each throw-bar stroke.

NOTE

Locating notches on point detector rod indicate rollers of the point detector yoke are centered in the semicircular notches of the point detector rod. Final adjustments must be made in accordance with AREMA or railroad instructions.

P1293, Rev. Oct/12 3–10 Alstom Signaling Inc.

Installation

3.3.9. Connect and Initially Adjust Lock Rod Connector Rod

Table 3–3. Connect and Initially Adjust Lock Rod Connector Rod Procedure

Step Action

Remove guards over lock and point-detector rods.

Position lug on lock rod in center of threaded section. Run nuts finger-tight against each side.

Lock Rod Connector Rod

Assemble lock rod connecting rod to lug on front rod and lug on lock rod. 3

Crank machine to close, but do not lock far switch point. Move lock rod toward track until outside edge of locating notch on top of rod, on field side, is flush with outside finished surface on contact frame.

Crank machine to close, but do not lock near switch point. Move adjusting plate on lock rod until edge of locating notch on top of this plate, on track end, is flush with outside finished surface on contact frame. Tighten and lock nuts to keep this adjustment.

6 After completing adjustments for both directions, crank machine back and forth a few times to verify locating notches return to proper position at end of each throw-bar stroke.

3.3.10. Machine With Two Lock Rods and Two Point-Detector Rods

If a switch machine has two lock rods and two point detector rods, connect and adjust one point detector rod, then the second point detector rod. After the two point detector rods are installed and adjusted, install and adjust one lock rod, then the second lock rod.

P1293, Rev. Oct/12 3–11 Alstom Signaling Inc.

Installation

3.4. LOCK AND POINT-DETECTOR RODS ADJUSTMENT

After the initial switch machine installation is complete, several methods of making adjustments to the lock rod and point-detector rod can be followed. The particular method to be followed depends on the type of lock rod used with a given machine, condition of switch layout and customer standards and requirements. Lock rods are referred to here as narrow or wide-notched. A narrow-notched rod has 2-1/8 inch wide slots; a wide-notched lock rod has 2-5/16 inch slots.

Table 3–4. Lock Rod and Point Detector Rod Adjustment Methods

Method

Action

Point-Detector Rod Adjustment without Releasing (“Floating”) Lock Rod.

This method is only for narrow-notched lock rods. The switch layout must be in good condition, with switch solidly secured near stock rail, and stock rail well braced and switch points fitted properly.

Point-Detector Rod and Lock Rod Adjustment without Releasing (“Floating”)

Lock Rod. This method applies to switch layout where only a wide-notched lock rod is used and customer requires the switch machine to lock with a ¼” obstruction and not lock with a 3/8” obstruction..

Point-Detector Adjustment with Lock Rod Released (“Floating”). This method can be used with any switch layout and with either narrow or widenotched lock rods. Generally this method is used when customers require that the switch machine does not lock with a ¼” obstruction.

Narrow-Notched Lock Rod Adjustment. This method applies to only a narrow-notched lock rod.

Each method contains step-by-step instructions to follow to insure that any rod is adjusted properly.

P1293, Rev. Oct/12 3–12 Alstom Signaling Inc.

Installation

3.4.1. Point Detector Rod Adjustment Without Releasing (“Floating”) Narrow-

Notched Lock Rod

Table 3–5. Point Detector Rod Adjustment Procedure

Without Releasing (“Floating”) Narrow-Notched Lock Rod

Step

Action

Check machine for lock rod with V-shaped notches on top surface.

Hand-crank switch to full reverse position and remove guards.

Loosen trackside nuts on detector rod more than 1/4 inch at detector rod lug.

Push detector rod toward switch.

Place 1/4-inch point-detector rod gauge between lug and machine side nuts. A gauge that can be used is shown in Figure 7–18. A regular switch point obstruction gauge is equally effective.

Tighten track-side nuts against rod lug.

Verify that the point-detector contacts have a 0.060 to 0.070 inch opening. If so, go to step 8; otherwise, proceed as follows:

If opening is larger than 0.070 inch, loosen machine-side nuts and tighten track-side nuts until proper adjustment is obtained. Then tighten machineside nuts.

If opening is less than 0.060 inch or closed, loosen track-side nuts and tighten machine-side nuts until proper adjustment is obtained.

Slightly loosen track-side nuts, remove gauge, and retighten track-side nuts.

Hand-crank machine to full normal position.

Loosen detector rod nuts on machine side of detector-rod lug more than

1/4- inch. Do not disturb track-side nuts.

P1293, Rev. Oct/12 3–13 Alstom Signaling Inc.

Installation

Table 3–5. Point Detector Rod Adjustment Procedure

Without Releasing (“Floating”) Narrow-Notched Lock Rod (Cont.)

Step

Action

Push detector rod toward track.

Place gauge over rod between rod lug and track-side nuts.

Retighten machine-side nuts against rod lug with gauge in place.

Verify that the point-detector contacts have a 0.060 to 0.070 inch opening. If so, go to step 15; otherwise, proceed as follows:

If contacts open more that 0.070 inch, go to field (opposite) end of detector rod, loosen field-side nuts and tighten machine-side nuts until proper adjustment is obtained. Retighten field-side nuts, then snug machine-side nuts securely. Return to track end of detector rod.

If opening is less than 0.060 inch or closed, go to field (opposite) end of detector rod, loosen machine-side nuts and tighten field-side nuts until proper adjustment is obtained. Retighten machine-side nuts, then snug field-side nuts securely. Return to track end of detector rod.

At track-side of the detector rod, slightly loosen the machine-side nuts, remove gauge and retighten machine-side nuts, again taking care not to disturb track side nuts.

P1293, Rev. Oct/12 3–14 Alstom Signaling Inc.

Installation

3.4.2. Point Detector Rod and Lock Rod Adjustment Without Releasing (“Floating”)

Wide-Notched Lock Rod

Table 3–6. Point Detector Rod and Lock Rod Adjustment Procedure

Without Releasing (“Floating”) Wide-Notched Lock Rod

Step

Action

Check machine for its lock rod with wide notches.

Adjust throw rod so that points have proper pressure against stock rail -- in both normal and reverse positions.

Adjust long lock rod as follows: a. Crank open switch point associated with long lock rod. b. Insert 1/4-inch obstruction gauge in switch point opened in step a. c. Crank switch machine, and adjust long lock rod so that machine is locked with 1/4-inch obstruction gauge in point. d. With machine locked, adjust long lock rod so that side of notch is snug against lock dog. Be careful when tightening lock rod so excessive pressure is not applied to lock dog. To ensure lock rod is adjusted in the proper direction, verify long rod mark extends as far as possible outside switch machine. e. Crank switch point open, and remove 1/4 inch obstruction gauge. f. Crank switch points closed, and ensure that machine locks. g. Crank switch point open, and install 3/8-inch switch point obstruction gauge (3/8-gauge). h. Crank switch point closed, and ensure that lock dog fouls long lock rod. i. Open switch point, and remove 3/8-inch obstruction gauge. This completes long lock rod adjustment.

P1293, Rev. Oct/12 3–15 Alstom Signaling Inc.

Installation

Table 3–6. Point Detector Rod and Lock Rod Adjustment Procedure

Without Releasing (“Floating”) Wide-Notched Lock Rod (Cont.)

Step

Action

Adjust short lock rod as follows: a. Crank open switch point associated with short lock rod. b. Insert 1/4-inch obstruction gauge in switch point. c. Crank the switch machine, and adjust short lock rod so machine is locked with 1/4-inch obstruction gauge in point. d. With machine locked, adjust short lock rod so that side of notch is snug against lock dog. Be careful when tightening lock rod that excessive pressure is not applied by lock plate to lock dog. To ensure that rod is adjusted in proper direction, verify short lock rod mark extends as far as possible outside switch machine. e. Crank switch point open, and remove 1/4 inch obstruction gauge. f. Crank switch points closed, and ensure that machine locks. g. Crank switch point open, and install 3/8-inch switch point obstruction gauge (3/8-gauge). h. Crank switch point closed, and ensure that lock dog fouls short lock rod. i. Open switch point, and remove 3/8-inch obstruction gauge. This completes short lock rod adjustment.

Adjust long point detector rod as follows: a. Crank open switch point associated with long point detector rod. b. Insert 1/4-inch obstruction gauge in switch point. c. Crank switch point closed and verify that the switch machine lock rods are locked. d. Adjust long point-detector rod so point detector contacts are just broken.

After rod nuts are tightened, ensure that contacts are still broken. e. Crank switch points open, and remove 1/4-inch obstruction gauge. f. Crank switch point closed, and ensure machine locks and point-detector contacts are properly made. This completes long point-detector rod adjustment.

P1293, Rev. Oct/12 3–16 Alstom Signaling Inc.

Installation

Table 3–6. Point Detector Rod and Lock Rod Adjustment Procedure

Without Releasing (“Floating”) Wide-Notched Lock Rod (Cont.)

Step

Action

Adjust short point-detector rod as follows: a. Crank open switch point associated with short point-detector rod. b. Install 1/4-inch obstruction gauge in point. c. Crank switch machine so machine locks with 1/4-inch obstruction gauge in point. d. Adjust short point-detector rod so point contacts are just broken. e. Crank switch points open, and remove 1/4-inch obstruction gauge. f. Crank switch point closed, and ensure point-detector contacts are properly made. This completes short point-detector rod adjustment.

P1293, Rev. Oct/12 3–17 Alstom Signaling Inc.

Installation

3.4.3. Point Detector Rod Adjustment With Lock Rod Released (“Floating”)

Table 3–7. Point Detector Rod Adjustment Procedure

With Lock Rod Released (“Floating”)

Step

Action

Adjust lock rods per customer requirements.

NOTE

Generally this procedure is used when narrow notch lock rods are used or when wide notch lock rods are adjusted so that machine does not lock the lock rods with a ¼” obstruction.

Release lock rod. A switch machine can have either a narrow-notched or wide-notched lock rod in this procedure.

Crank open switch point associated with long point-detector rod.

Place 1/4-inch obstruction gauge in switch point. Place lock rod so machine can lock.

Crank switch to close switch point against obstruction and complete stroke.

Adjust long-point-detector rod until point-detector contacts just break (open).

Tighten rod nuts and verify contacts are still open.

Crank switch point open and remove 1/4-inch obstruction gauge.

Crank switch points closed and confirm point-detector contacts have made

(closed). This completes long point-detector rod adjustment.

Adjust short point-detector rod as follows: a. Crank open switch point associated with short point-detector rod. b. Place 1/4-inch obstruction gauge in switch point. Place lock rod so machine can lock. c. Crank switch machine to close switch points against obstruction in point and complete stroke. d. Adjust short point-detector rod until point-detector contacts just break

(open). e. Crank switch points open and remove 1/4-inch obstruction gauge. f. Crank switch points closed and confirm point-detector contacts have made (closed). g. Reconnect and adjust lock rod per customer requirements and standards. h. This completes short point-detector rod adjustment.

P1293, Rev. Oct/12 3–18 Alstom Signaling Inc.

Installation

3.4.4. Narrow Notched Lock Rod Adjustment

Table 3–8. Narrow Notched Lock Rod Adjustment Procedure

Step

Action

Crank switch to close, but do not lock switch point.

Move lock rod toward track until outside edge of locating notch on top of rod, on field side, is even with outside finished surface of contact frame.

Crank machine to close, but do not lock near switch point.

Move adjusting plate on lock rod until edge of locating notch on top of plate, on the track end, is even with outside finished surface of contact frame.

Test each adjustment by obstructing switch point and cranking switch machine to close point against obstruction. Verify switch machine does not lock.

P1293, Rev. Oct/12 3–19 Alstom Signaling Inc.

Installation

3.5. BEFORE REPLACING MACHINE IN SERVICE

3.5.1. Final Layout Check

Table 3–9. Final Layout Check Procedure

Step

Action

Lubricate machine thoroughly as indicated in Section 4, Scheduled

Maintenance.

Clean and lubricate switch as instructed by the railroad.

Check all external wiring for proper connections, polarity, fusing, etc.

Check clutch slipping current using the friction clutch operational check procedure (next procedure in this section).

Check operation of overload relay, if used, as indicated in Section 4,

Scheduled Maintenance.

If machine has optional commutator cover and if frost conditions do not exist at switch location, then remove cover.

P1293, Rev. Oct/12 3–20 Alstom Signaling Inc.

Installation

3.5.2. Friction Clutch Operational Check

The clutch should be tested when placing the machine in service and at scheduled intervals thereafter. The clutch is factory-adjusted to slip at a motor current of about 12 to 14 amperes for the 110 volt motor and 17 to 20 amperes for the 24-volt motor.

Slipping current may be varied to meet the property’s specifications. To test the clutch setting, follow the procedure in Table 3–10.

Table 3–10. Friction Clutch Operational Check Procedure

Step

Action

Place a ¼” obstruction, such as an obstruction gauge, between the switch point and rail.

2 Shunt out operating winding of overload relay in controller for Models 5G and 5H.

Shunt out the overload relay in the instrument house for Models 5E and 5F.

Connect an ammeter in series with motor energy.

Operate switch point against obstruction.

Read motor current as clutch slips. If current value too high or too low, see adjustment procedure in Section 4, Scheduled Maintenance.

Disconnect the ammeter, remove shunt on overload relay, and remove the obstruction from switch point.

P1293, Rev. Oct/12 3–21 Alstom Signaling Inc.

Installation

3.5.3. Temperature Considerations and Commutator Cover

The silicone-treated, moisture-repellent commutator cover keeps moisture off the commutator. At switch locations where no frost occurs, no cover is needed.

At locations where frost occurs, the cover is used only during the frost season and removed when all danger of frost is past. Replace cover at start of next frost season.

If the used cover is still in good condition, clean it thoroughly with a suitable brush or air blast after removal. The frost shield is then clean and ready for reuse at the start of the next frost season. If the used frost shield is not in good condition, discard it. Put a new one around the commutator at start of the next frost season.

3.5.4. Commutator Shield Use

The transparent commutator shield is furnished only in machines without a 15-watt heater in the motor compartment. It is best to keep shield in place all year and keep nuts tight that hold shield in place. To remove shield, loosen nuts and slide shield toward armature.

3.6. CHANGING FROM LEFT-HAND TO RIGHT-HAND OPERATION AND VICE

VERSA

WARNING

DISCONNECT MOTOR ENERGY WHENEVER WORKING ON THE

SWITCH LAYOUT OR SWITCH MACHINE. UNEXPECTED OPERATION

OF THE MACHINE COULD CAUSE INJURY FROM OPEN GEAR,

ELECTRICAL SHOCK, OR MOVING SWITCH POINTS.

3.6.1. Throw Bar

Simply change throw rod coupling from one end of the throw bar to the other.

3.6.2. Lock and Detector Rods

Tables 3–11 through 3–13 provide procedures for changing over from left-hand to righthand or right-hand to left-hand operation for the following configurations:

• One lock and one point-detector rod for right- or left-hand (RH or LH) single switch

• Two locks and two point-detector rods -- for right- and left-hand (RH and LH) double slip switch

• Two locks and two point-detector rods -- movable-point frog

P1293, Rev. Oct/12 3–22 Alstom Signaling Inc.

Installation

SWITCH MACHINE HOUSING

LOCK ROD

WEAR PLATE

POINT DETECTOR

ROD WEAR PLATE

LONG ROD

SHORT ROD

LONG ROD

LOCK ROD

CONNECTING ROD

SHORT ROD

POINT DETECTOR

CONNECTING ROD

Figure 3–4. Lock Rod and Point Detector Rod Locations

P1293, Rev. Oct/12 3–23 Alstom Signaling Inc.

Installation

3.6.2.1. Changing Over the One Lock and One Point-Detector Rod, Right- Or

Left-Hand (RH Or LH) Single Switch Configuration

Table 3–11. Changing Over Procedure For One Lock and One Point-Detector Rod,

Right- Or Left-Hand (RH Or LH) Single Switch

Step

Action

Remove lug with adjacent lock and adjusting nuts from solid-through lock rod.

Remove two arms (clips) from top of lock rod.

Crank machine to unlocked position.

Pull lock rod as a unit out of one side of machine and insert it into machine from opposite side.

Replace lug and lock and adjust nuts on solid-through lock rod.

Replace arms (clips) on top of lock rod.

Remove lug with adjacent lock and adjusting nuts from solid-through pointdetector rod.

P1293, Rev. Oct/12 3–24 Alstom Signaling Inc.

Installation

Table 3–11. Changing Over Procedure For One Lock and One Point-Detector Rod,

Right- Or Left-Hand (RH Or LH) Single Switch (Cont.)

Step

Action

CAUTION

When removing or installing detector rods it is important to first lift the point detector movement yoke and rollers up.

Use a small pry bar (Stanley Proto #2130 16” Rolling Head Bar is recommended) to lift the point detector movement yoke up. Using the switch machine lock rod to support the bottom of the pry bar, lift the extension of the center yoke that extends over the lock rod as illustrated.

Pull the point-detector rod as a unit out of one side of machine and insert it into opposite side.

When installing the detector rod verify that the rod is aligned below the rollers and does not catch the edge of the spacer adjacent to the rollers.

CAUTION

Slide the rod by hand. Never tap the end of the rod with a hammer to force it to slide. Failure to lift the center yoke and rollers before sliding the rod or application of unnecessary force with a hammer can cause damage to the roller support pins or yoke casting.

Replace lug and lock and adjust nuts on the solid-through point-detector rod.

P1293, Rev. Oct/12 3–25 Alstom Signaling Inc.

Installation

Table 3–12. Changing Over Procedure For Two Locks and Two Point-Detector Rods,

Right- and Left-Hand (RH and LH) Double Slip Switch

Step

Action

Remove lugs with adjacent lock and adjusting nuts from solid-through lock and point detector rods. Notice which rods are closest to motor end of machine.

Remove two arms (clips) from top of each set of lock rods. The figure below shows the type of clip used on No. 2 set of lock rods (these are nearer point-detector end of machine).

NO. 2

LOCK

ROD

CLIP

Crank machine to unlocked position.

CAUTION

When removing or installing detector rods it is important to first lift the point detector movement yoke and rollers up.

P1293, Rev. Oct/12 3–26 Alstom Signaling Inc.

Installation

Table 3–12. Changing Over Procedure For Two Locks and Two Point-Detector Rods,

Right- and Left-Hand (RH and LH) Double Slip Switch (Cont.)

Step

Action

Pull both lock and point detector rods as a unit out of one side of machine and insert into machine from opposite side.

When installing the detector rods be sure that the rods are aligned below the rollers and do not catch the edge of the spacer adjacent to the rollers.

CAUTION

Slide the rods by hand. Never tap the end of a rod with a hammer to force it to slide. Failure to lift the center yoke and rollers before sliding the rods, or applying unnecessary force with a hammer can cause damage to the roller support pins or yoke casting.

Verify set of rods previously nearer motor end of machine is now nearer wire-entrance end.

Replace lugs and lock and adjusting nuts on solid-through lock and pointdetector rods.

Replace two clips on top of each set of lock rods.

P1293, Rev. Oct/12 3–27 Alstom Signaling Inc.

Installation

3.6.2.2. Changing Over the Two Locks and Two Point-Detector Rods With

Movable-Point Frog Configuration

Table 3–13. Changing Over Procedure For Two Locks and Two Point-Detector Rods

With Movable-Point Frog

Step Action

NOTE

Point-detector rods for a machine used on a movable-point frog are not L-

H to R-H interchangeable. When the hand throw configuration of the machine is changed, different sets of point-detector rods must be used.

1 Remove lugs, lock and adjusting nuts, and clips (arms) from rods. The figure below shows one pair of clips mounted on No. 2 lock rod.

There are two lock rod arm styles.

P1293, Rev. Oct/12 3–28 Alstom Signaling Inc.

Installation

Table 3–13. Changing Over Procedure For Two Locks and Two Point-Detector Rods

With Movable-Point Frog (Cont.)

Step Action

WARNING

THE TWO ARMS ON THE NO. 1 SET OF LOCK RODS AS SHOWN

BELOW ARE TO ENSURE THAT BOTH THE LOCK RODS AND

DETECTOR RODS MOVE CONCURRENTLY, THUS PROTECTING

AGAINST A BROKEN CONNECTION BETWEEN ONE OF THESE

RODS AND THE SWITCH. THEY MUST BE REINSTALLED.

SWITCH MACHINES FURNISHED BEFORE 1967 HAD ARMS AS

SHOWN IN THE BOTTOM FIGURE. IT WAS POSSIBLE TO INSTALL

THESE ARMS REVERSED, SO THEY COULDN’T OPERATE. THESE

ARE PROPERLY INSTALLED WHEN THE EXTENDED, RAISED

PORTION OF THE ARM, POSITIONED ON THE NO. 1 SET OF LOCK

RODS FACES THE POINT-DETECTOR END OF THE SWITCH

MACHINE (RAISED PORTION OF THE ARM UP). ARMS FURNISHED

AFTER 1967 ARE REVERSIBLE AND CANNOT BE INSTALLED

INCORRECTLY.

The current style:

LOCK ROD ARM

(CLIP). ONE BOLTED

TO EACH LOCK ROD.

LOCK RODS

POINT DETECTOR

END OF MACHINE

The old style:

OLD STYLE LOCK ROD

ARM (CLIP). ONE BOLTED

TO EACH LOCK ROD.

LOCK RODS

POINT DETECTOR

END OF MACHINE

P1293, Rev. Oct/12 3–29 Alstom Signaling Inc.

Installation

Table 3–13. Changing Over Procedure For Two Locks and Two Point-Detector Rods

With Movable-Point Frog (Cont.)

Step

Action

Crank machine to unlocked position.

CAUTION

When removing or installing detector rods it is important to first lift the point detector movement yoke and rollers up.

Pull the lock point-detector rods as a unit out of one side of machine.

Insert two sets of lock rods as a group into machine from opposite side.

Insert two replacement sets of point-detector rods, designed for desired direction of operation, into machine. Note that previously used rods cannot be reused in a machine of opposite hand operation.

When installing the detector rods be sure that the rods are aligned below the rollers and do not catch the edge of the spacer adjacent to the rollers.

CAUTION

P1293, Rev. Oct/12 3–30 Alstom Signaling Inc.

Installation

Table 3–13. Changing Over Procedure For Two Locks and Two Point-Detector Rods

With Movable-Point Frog (Cont.)

Step

Action

Replace lugs and lock and adjusting nuts on solid-through lock and pointdetector rods.

Check that link motion is in proper position. Replace two clips (arms) on top of each set of lock rods.

P1293, Rev. Oct/12 3–31 Alstom Signaling Inc.

Installation

3.6.3. Changing Over the Dual-Control Mechanism (Models 5F and 5H)

Figure 3–5 on page 3–35 is the Model 5H drawing including dual control mechanism.

Table 3–14. Changing Over Procedure For Dual Control Mechanism

Step Action

CAUTION

Only trained and qualified personnel should perform this change to the mechanism.

1 Remove nut and washers from top of operating crank’s splined shaft (16).

2 Loosen, but do not remove, nut from idler gear stud.

3 Remove five dowel screws that hold gear plate in place. Pry plate up and off.

Since the crankshaft’s top bearing and idler gear with stud comes off with plate as a unit, remove these from gear plate.

P1293, Rev. Oct/12 3–32 Alstom Signaling Inc.

Installation

Table 3–14. Changing Over Dual Control Mechanism (Cont.)

Step Action

Remove selector shaft bearing, which is on opposite side of machine from hand-throw lever. Leave snowguard in place.

Remove hand-throw lever extension handle from end of hand-throw lever and set aside.

Remove two screws that hold selector and hand-throw lever assembly to machine. Pull assembly as a unit from side of machine. Leave snowguard in place.

Remove throw-bar guards and coupling. Reverse throw bar guards and install coupling on opposite side of throw bar. Flip the gear and contact compartment cover hasp around 180 degrees (end for end).

8 Replace selector and hand-throw lever assembly as a unit on opposite side of machine.

Replace hand-throw lever extension handle in opposite tapped hole. 9

10 Replace selector shaft bearing on track side of machine. Keep grease fitting toward contact compartment end of machine. Leave the snowguard in place.

11 To start timing operation of dual-control mechanism, place selector lever in

POWER position.

12 Crank machine in direction that brings throw-bar coupling nearest machine.

13 After full stroke in this direction, make a mark across throw-bar against edge of wear bearing.

14 Crank machine until full throw-bar stroke is completed in opposite direction.

15 Measure midway between mark on throw-bar and edge of wear bearing and mark throw-bar at this point.

16 Crank machine back until throw-bar mark is just at edge of wear bearing to get throw-bar and crank exactly in midstroke position.

17 Place selector lever in HAND position.

18 Rotate hand-throw clutch gear by hand counterclockwise until it stops.

19 With a pointer resting on edge of gear frame, slowly rotate hand-throw clutch gear clockwise counting number of teeth it rotates.

20 Now, rotate it back just half as many teeth and mark tooth nearest centerline of gear frame, place corresponding mark on gear frame.

P1293, Rev. Oct/12 3–33 Alstom Signaling Inc.

Installation

Table 3–14. Changing Over Dual Control Mechanism (Cont.)

Step Action

21 Place and hold hand-throw lever in a vertical position (90 degrees to base of the machine).

22 Hold hand-throw clutch gear firmly in alignment with marks just put on it and adjacent frame. Hold idler gear suspended by its stud, and mesh it with handthrow clutch gear so that letters R are in line for right-hand assembly or letters

L are in line for left-hand assembly.

23 Let idler gear down until it meshes freely with hand-throw pinion and the outside of its spur gear teeth closely follow the contour of adjacent gear frame.

24 Set gear plate in position on machine. Be sure small pin on side of idler gear stud lines up with groove in hole in gear plate.

25 Insert five dowel screws in gear plate, finger-tight.

26 Assemble nut and lock washer on idler gear stud and roller bearing, washers, and nut on top of crankshaft. Tighten five dowel screws that hold gear plate in place.

27 Tighten all screws and nuts. Bend washer up (preferably at a new place) to lock the nut on top of operating crankshaft.

28 Perform the Timing Test provided in the Switch Machine Disassembly and

Assembly Procedure (Table 6–7, Step 56k) to verify accurate timing.

Then perform the Mechanical Test (Table 6–47) and Electrical Test (Table

6–48) to verify system performance.

NOTE

If operating crank or clutch sleeve has been removed from the operating crank’s splined shaft, be sure that after reassembly the prick-punch mark on the clutch sleeve’s uppermost raised cam surface is aligned with the center-line of the operating crank.

If the gear frame is assembled on the base, and the crank is therefore not visible, align the prick-punch mark with the one located on the top of the crank’s splined shaft. This ensures that the splines on the shaft and inside the sleeve are in proper engagement.

Lubricate thoroughly after assembly in accordance with instructions in Section 4,

Scheduled Maintenance.

P1293, Rev. Oct/12 3–34 Alstom Signaling Inc.

Installation

P1293, Rev. Oct/12

Figure 3–5. 5H Switch Machine With Dual Operation Detail

3–35 Alstom Signaling Inc.

P1293, Rev. Oct/12

Installation

3–36 Alstom Signaling Inc.

Installation

3.7. OPTIONAL SWITCH MACHINE AND LAYOUT SENSING KIT

A Switch Machine and Layout Sensing Kit is available from Alstom (P/N 59649-218-00) that can be used to detect point pressure at each point. It can be used during switch machine installation, maintenance, or troubleshooting to verify the force generated against the points when the switch machine is thrown. The kit includes a Clevis Pin,

Portable Load Indicator, and a cable. For a procedure on the use of this kit, see

Table 3–15.

Table 3–15. Throw Rod Point Pressure Verification Procedure

Step

Action

Remove the bolt connecting the Jaw Rod to the Throw Bar Connector.

Jaw Rod Throw Bar Connector Throw Bar

P1293, Rev. Oct/12 3–37 Alstom Signaling Inc.

Installation

Table 3–15. Throw Rod Point Pressure Verification Procedure (Cont.)

Step

Action

Replace the bolt removed in Step 1 with the Clevis Pin from the Switch

Machine and Layout Load Sensing Kit.

Align the arrows on the sides of the Clevis Pin in the direction of force

(towards the point).

Connect the Switch Machine and Layout Sensing Kit Cable to the Clevis Pin and Portable Load Indicator.

P1293, Rev. Oct/12 3–38 Alstom Signaling Inc.

Installation

Table 3–15. Throw Rod Point Pressure Verification Procedure (Cont.)

Step

Action

Turn on the Portable Load Indicator from the Switch Machine and Layout

Load Sensing Kit.

On/Off Knob

PORTABLE

LOAD INDICATOR

MODEL PLN- D2

S/N 0746

OFF BAL CAL-CHK

STRAIN

WEST CONSHOHOCKEN PA., USA.

Observe the indicator while actuating the switch machine to determine the point pressure generated when the switch is thrown.

Perform any adjustments and repeat Step 5 to obtain desired force.

Turn off Portable Load Indicator and disconnect the Switch Machine and

Layout Sensing Kit Cable from the Clevis Pin and Portable Load Indicator.

Remove the Clevis Pin from the Jaw Rod.

Reinstall the bolt connecting the Jaw Rod to the Throw Bar Connector.

10 Return switch machine back to service if no further testing or verification is required.

P1293, Rev. Oct/12 3–39 Alstom Signaling Inc.

Installation

THIS PAGE INTENTIONALLY LEFT BLANK.

P1293, Rev. Oct/12 3–40 Alstom Signaling Inc.

Scheduled Maintenance

4. SECTION 4 – SCHEDULED MAINTENANCE

4.1. GENERAL

This Section provides the required preventive maintenance procedures performed by maintainers to keep the Model 5E, 5F, 5G, and 5H switch machines in good working order, including recommended interval of each procedure.

4.2. INTRODUCTION

Preventive maintenance (PM) checks include the periodic inspection points of the switch machine and switch layout, functional tests, and related adjustments that should be made. These checks are intended to serve as a reference for fault isolation procedures. If a problem is found, take the necessary corrective action.

PM checks should be done on each switch machine, whether it operates independently or in conjunction with another switch machine.

4.3. FIELD OR WAYSIDE SERVICE

To service the switch machine and be sure the switch machine is continuing to operate properly requires periodic inspection and lubrication as well as a few preventive maintenance checks to be made by the maintainers. This section describes key inspection points including the switch layout, what lubricants to use and how to apply them and the functional tests and related adjustments that can be made. A preventive maintenance index summarizes various check intervals.

P1293, Rev. Oct/12 4–1 Alstom Signaling Inc.

Scheduled Maintenance

4.4. SPECIAL TOOLS AND TEST EQUIPMENT

A list of the special tools and test equipment used in preventive maintenance procedures follows:

• 1 Ammeter, 15A Min. DC • 1 Oil Can with Mobil Aero HFA or equivalent

• 1 Ammeter, 30-0-30 Amps DC

• 1 Multimeter

• 1 Hand Crank

• 1/4" Point-Detector Gauge

• .010 Feeler Gauge

• Wire Gauge for measuring 0.030 to

0.045 inches

• 1 Terminal Nut Wrench, AAR or Alstom

• 1 Switch Wrench 1 1/4"

• 1 Switch Wrench 1 1/16"

• 1 Switch Wrench 2"

• 1 Switch Wrench 1 5/8"

• 1 Wrench 3/8"

• 1 Rule/Tape Measure

• 1 Force Gauge (pounds)

• 1 Force Gauge (grams)

• 1 Grease Gun with Spare Cartridge

• All-Temperature, Lithium-Based,

Extreme-Pressure Grease, such as

Fiske Bros. Lubriplate MAG 1 per

Alstom 91A0012

• 1 Wrench 3/4" and 7/8"

• 1 Wrench 9/16"

• Cotter Pins

• Rags

• 1 No. 00 Sandpaper

All special tools required to facilitate maintenance are shown in Figure 7–18 located in

Section 7, Parts Catalog

P1293, Rev. Oct/12 4–2 Alstom Signaling Inc.

Scheduled Maintenance

4.5. PREVENTIVE MAINTENANCE INDEX

Table 4–1 lists the recommended intervals for preventive maintenance (PM) actions and references the particular procedure in this section. A high number of daily switch operations may require these inspections be performed more often.

Interval

Weekly

Monthly

Quarterly

Semi-annually

Annually

As Required

Table 4–1. Preventive Maintenance Index

Maintenance Action

Site and Switch Machine Inspection

Switch Machine Lubrication

(Quarterly if less than 20 moves per day)

Recycling Time Test

Obstruction and Overload Relay Test and

Adjustment

Motor Brush Inspection

Box-style Bearing and Wear Plate Inspection

Throw Rod Check and Adjustment

Lock Rod and Adjustment

Point Detector Rod and Adjustment

Point Detector Contact and Adjustment

Motor Control Contact and Adjustment

Controller Contact Adjustment (Model 5G and 5H)

Friction Clutch Inspection

Friction Clutch Test

Friction Clutch Adjustment

Crank Cut-Out Switch Adjustment

Hand-Power Lever Test (Model 5F and 5H)

Commutator inspection

Magnetic Detent Inspection

Blocking Rectifier Test

Component Replacement

Table

4–2

4–3 through 4–6

4–7

4–8 and 4–9

4–10

4–11

4–12

4–13

4–14

4–15 through

4–17

4–18

4–19

4–20

4–21

4–22

4–23

4–24

4–25

4–26

4–27

See

Section 6 Table 6–2

P1293, Rev. Oct/12 4–3 Alstom Signaling Inc.

Scheduled Maintenance

4.6. PREVENTIVE MAINTENANCE CHECKS

Preventive maintenance checks should be done to each switch machine, regardless of whether a switch machine operates independently or in series 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.

When performing the procedures provided in this section, the following warnings must be heeded:

WARNING

KEEP CLEAR OF GEARS AND SWITCH POINTS WHEN INSERTING

OR REMOVING A HAND CRANK. ACTIVATION OF THE SWITCH

MACHINE WHILE INSERTING OR REMOVING THE HAND CRANK MAY

CAUSE EQUIPMENT DAMAGE OR PERSONNEL INJURY. THE

SWITCH MACHINE MAY NOT BE IN ITS FULLY LOCKED POSITION.

THE SWITCH MACHINE CAN BE REMOTELY ACTIVATED WHEN THE

HAND CRANK IS NOT INSERTED. IT CAN BE ACTIVATED ONCE THE

HAND CRANK IS REMOVED AND THE HAND CRANK MECHANISM

CUTOUT SWITCH IS RESET BY MOVING THE BLOCKING PLATE TO

THE NORMAL POSITION.

WARNING

WHEN USING THE HAND CRANK ON THIS SWITCH MACHINE, KEEP

A FIRM HOLD ONTO THE HAND CRANK. IF THERE IS SPRING IN THE

SWITCH POINTS WHEN THE MACHINE BECOMES UNLOCKED, THE

HAND CRANK WILL ACCELERATE RAPIDLY IN THE DIRECTION IT IS

BEING TURNED. IF NOT CAUTIOUS, INJURY BY THE CRANK’S

SUDDEN MOVEMENT COULD RESULT.

Whenever a switch machine is repaired or rebuilt, complete cleaning and lubrication should be performed. These procedures are found in Section 6, Corrective

Maintenance.

4.6.1. After Flooding

If the switch machine is or was flooded, clean, dry and regrease it and make sure that magnetic detent is free of water. In cold weather, trapped water freezes and prevents the switch machine from operating. In this case the sealed motor bearings may require replacement.

After flooding, water-resistant grease in motor bearings may have become contaminated or washed away. If so, the motor should be disassembled and the bearings removed, then cleaned and greased or replaced. This is also true for the main-gear bearings in Models 5F and 5H switch machines. Replace lubricant between the main crankshaft and the clutch sleeve and the clutch gear area.

P1293, Rev. Oct/12 4–4 Alstom Signaling Inc.

Scheduled Maintenance

4.7. WEEKLY MAINTENANCE

4.7.1. Site and Switch Machine Inspection

A site inspection consists of making a visual check of the entire switch layout.

Table 4–2. Site and Switch Machine Inspection Procedure

Step Action

WARNING

WHEN USING THE HAND CRANK ON THIS SWITCH MACHINE, KEEP

A FIRM HOLD ONTO THE HAND CRANK. IF THERE IS SPRING IN THE

SWITCH POINTS WHEN THE MACHINE BECOMES UNLOCKED, THE

HAND CRANK WILL ACCELERATE RAPIDLY IN THE DIRECTION IT IS

BEING TURNED. IF NOT CAUTIOUS, INJURY BY THE CRANK’S

SUDDEN MOVEMENT COULD RESULT.

Inspect the switch machine case and guards for physical damage or distortion. Guards should be clear to allow moving parts to move freely.

Inspect around complete switch layout, including between points (1) and stock rail (2) for foreign material, ballast or excessive dirt, which might block the motion of the rods or points. During winter conditions, check for snow and ice under the cut-away area of a switch point that meshes with the stock rail. Check to ensure that, where required, snowmelters are melting snow and ice.

P1293, Rev. Oct/12 4–5

Alstom Signaling Inc.

Scheduled Maintenance

Table 4–2. Site and Switch Machine Inspection Procedure (Cont.)

Step

Action

4 Inspect the switch machine case (1) and guards (2) for physical damage or distortion.

Check for loose or broken hardware or loose connections. Tighten if necessary.

Remove the hand crank from the clutch shaft and reset the cutout contact by moving the blocking plate to the normal position.

Re-install all covers and padlocks.

P1293, Rev. Oct/12 4–6 Alstom Signaling Inc.

Scheduled Maintenance

4.8. MONTHLY MAINTENANCE

4.8.1. Lubrication

Switch machines, located in a clean environment and making an average of less than

20 moves each day, should be lubricated at least once every three months, or when a machine has been flooded. If a switch machine makes more than 20 moves a day or is located in a dusty environment, lubricate machine monthly. An established lubrication routine is recommended for each switch machine based on its use and operating conditions.

CAUTION

Oil or grease in the friction clutch render s the clutch and switch machine inoperable.

Use an all-temperature, lithium-based, extreme-pressure grease, such as Fiske Bros.

Lubriplate MAG 1 per Alstom 91A0012, in all pressure grease fittings, on all gear teeth, on all sliding surfaces, on all surfaces not plated, painted, made of corrosion-resistant material, or coated with anti-rust film, and other parts specified in the tables.

Avoid the use of too much grease and oil; any excess should be removed. By not permitting grease and oil to drop or collect on wires, coils, commutator shield, commutator cover, or friction faces of clutch, a minimum amount of unscheduled maintenance can be expected.

4.8.1.1. Lubrication Procedures

Table 4–3 provides the lubrication procedure. Since the actual lubrication points are slightly different for the single versus dual control machines, Table 4–4 contains the lubrication details for Models 5E and 5G, while Table 4–5 contains the lubrication details for Models 5F and 5H. In addition, Table 4–6 provides the procedure for lubrication through an additional three tubes located on Models 5F and 5H.

P1293, Rev. Oct/12 4–7 Alstom Signaling Inc.

Scheduled Maintenance

Table 4–3. Lubrication Procedure

Step

Action

Disconnect the switch machine power by removing the 110 VDC fuses and heater fuse. Locate the fuses by using the Book of Plans.

Remove the padlock from the switch machine hasp that holds down both the gear and contact compartment covers.

Release the tension on the hasp strap and pull the strap up and off the covers.

Verify that the cover is free of the motor side and point detector side eyebolts before lifting the cover off from the machine.

Remove the gear and contact compartment covers by lifting the covers straight up and off.

Place the end of the hand crank against the inside lip of the blocking plate and move the plate to the detent position, centering hole in plate to clutch crank hole. This action separates the contact plunger from the cutout switch contact block

Insert the hand crank through the blocking plate hole into the clutch.

Observe that the motor cutout contacts are open. Leave the hand crank inserted throughout the procedure.

For Model 5E and 5G Switch Machines, Figure 4–1 is an illustration showing the lubrication points and the lubricants to be used. Table 4–4 lists the lubrication points with detailed instructions.

For Model 5F and 5H Switch Machines, Figure 4–2 is an illustration showing the lubrication points and the lubricants to be used. Table 4–5 lists the lubrication points with detailed instructions. Table 4–6 includes the procedure for lubricating three additional tubes.

Remove the hand crank from the clutch shaft and reset the cutout contact by moving the blocking plate to the normal position.

Re-install all covers and padlocks.

Reset the hand crank mechanism cutout switch by moving the blocking plate to the normal position.

Re-install the fuses removed in Step 1 and restore the machine to service.

P1293, Rev. Oct/12 4–8 Alstom Signaling Inc.

Scheduled Maintenance

Table 4–4. Lubrication Instructions for Models 5E and 5G

Item No. Part(s) To Be Lubricated Instructions

Pivot pins for brush-holder arms Oil sparingly.

Upper clutch bearing

Lower clutch bearing

Oil. Do not spill on clutch.

See Note 1.

Force grease through tube to bearing.

Lower intermediate-gear bearing Force grease through pinion shaft.

Upper intermediate-gear bearing Force grease through pinion shaft.

Main gear bearing Force grease through pinion shaft.

Throw-bar and locking-bar roller Lubrication location is on main gear.

Crank machine to align fitting with hole in gear frame.

10 Point-detector

11 Point-detector rollers and shaft, and rollers on centering arms

Grease.

Oil sparingly. Keep notches on rods open.

12 Gear faces and all internal sliding parts

Includes cam faces and locking-bar slots in point-detector compartment.

See Note 2.

13 Throw bar

14 External sliding surfaces

Grease.

Includes lock and detector rod.

15 Nuts of lock rod and detector rod Oil occasionally to prevent corrosion.

16 Padlock hasp hinge pins Oil occasionally to prevent corrosion.

NOTE 1

Do not fill oil cup up to top of tube inside cup. Too much oil floods the bearing and may result in fouling the clutch. Add only three drops of oil once a month.

NOTE 2

Apply only a thin coat of grease to gear teeth and sides of gear, especially to clutch output pinion and mating intermediate gear.

P1293, Rev. Oct/12 4–9 Alstom Signaling Inc.

Scheduled Maintenance

Figure 4–1. Lubrication Locations For Models 5E and 5G

P1293, Rev. Oct/12 4–10 Alstom Signaling Inc.

Scheduled Maintenance

Table 4–5. Lubrication Instructions For Models 5F and 5H

Item No. Part(s) To Be Lubricated Instructions

Pivot pins for brush-holder arms Oil sparingly.

Upper clutch bearing Oil. Do not spill on clutch. See Note 1.

Lower clutch bearing Force grease through tube to bearing.

Lower intermediate-gear bearing Force grease through pinion shaft.

Upper intermediate-gear bearing Force grease through pinion shaft.

Upper crank bearing On top of washer.

9 Throw-bar and locking-bar roller See Table 4–6.

10 Clutch gear and clutch sleeve See Table 4–6.

11 Crank and main gear

12 Clutch-shifter mechanism

See Table 4–6.

Grease at selector lever. Put oil in oil holes and around nut.

13 Point-detector

14 Point-detector rollers and shaft, and rollers on centering arms

15 Gear faces and all internal sliding parts

Grease.

Oil sparingly. Keep notches on rods open.

Includes cam faces and locking-bar slots in point-detector compartment. See Table

Note 2.

Outside of machine. 16 Selector-lever and hand-throw lever assemblies

17 Hand-throw and selector-lever shafts

18 Throw bar

19 External sliding surfaces

20 Nuts and threaded ends of lock rod and detector rod

21 Padlock hasp hinge pins

On top of assembly housing.

Grease.

Includes lock and detector rod.

Oil occasionally to prevent corrosion.

NOTE 1

Do not fill oil cup up to top of tube inside cup. Too much oil floods the bearing and may result in fouling the clutch. Add only three drops of oil once a month.

NOTE 2

Apply only a thin coat of grease to gear teeth and sides of gear, especially to clutch output pinion and mating intermediate gear.

P1293, Rev. Oct/12 4–11 Alstom Signaling Inc.

Scheduled Maintenance

Figure 4–2. Lubrication Locations For Models 5F and 5H

P1293, Rev. Oct/12 4–12 Alstom Signaling Inc.

Scheduled Maintenance

Table 4–6. Switch Machine Tube Lubrication Procedure (Models 5F and 5H)

Step Action

NOTE

In the 5F and 5H, the throw-bar and locking-bar roller (9), hand-throw clutch sleeve (10), and surface between the crankshaft and main gear

(11) are lubricated through three tubes. See Figure 4–2. One open tube with a grease fitting is used to lubricate the roller. The long closed tube with the grease fitting is used to lubricate the surface between the crankshaft and the main gear. The short closed tube is used to lubricate the hand-throw clutch gear and the clutch sleeve.

Remove short closed tube from crankshaft.

Insert open tube into crankshaft. Force grease through tube to lubricate roller. Remove tube and clip it inside of the gear compartment cover.

Insert long closed tube into crankshaft. Force grease through tube to lubricate crankshaft and main gear surfaces. Remove tube and clip it inside of the gear compartment cover.

Insert short closed tube into crankshaft. Before forcing grease into tube, put selector lever in HAND position and operate hand-throw lever to move switch points. This action ensures that the sliding clutch sleeve is fully engaged in the HAND position and lubrication occurs as intended. Force grease into tube to lubricate parts. Leave tube in crankshaft to seal out dirt.

P1293, Rev. Oct/12 4–13 Alstom Signaling Inc.

Scheduled Maintenance

4.9. QUARTERLY MAINTENANCE

4.9.1. Recycling Time Test Procedure

This procedure must be performed in the sequence given.

NOTE

Refer to your site Local Control Panel manual for information on the operation of the control panel and to gain an understanding of how to determine which auxiliary switches to use and what the various indicator lights designate.

WARNING

BE SURE TO NOTIFY THE TRAIN CONTROL ROOM BEFORE

ACTIVATING THE SWITCH MACHINE. THIS NOTIFICATION MAY

PREVENT THE EQUIPMENT FROM BEING ACTIVATED DURING THE

PROCEDURE.

Table 4–7. Recycling Time Test Procedure

Step Action

Cycle the switch machines several times from the Local Control Panel (LCP) before testing, leaving the machines to be tested in reverse position. Refer to your Local Control Panel manual for information on the procedures for changing the switch positions.

Call each switch machine, one at a time, to the normal position. Within 5 seconds of indicating the switch is moving, the Indicators on the local control panel should be:

N (Normal) – Positive

R (Reverse) - Negative

Call each switch machine, one at a time, to the reverse (R) position and begin timing. Within 5 seconds of indicating the switch is moving, the indicators for positions should be:

N (Normal) - Negative

R (Reverse) - Positive

Again, call each switch machine, one at a time, to the normal (N) position and begin timing. Indicators for the positions should be:

N (Normal) – Positive

R (Reverse) - Negative

Repeat cycling action at least two more times if the cycling period is too long.

If specifications are not met during the cycling period, refer to Section 5,

Troubleshooting.

P1293, Rev. Oct/12 4–14 Alstom Signaling Inc.

Scheduled Maintenance

4.9.2. Obstruction and Overload Relay Test and Adjustment

Overload relays are factory adjusted to pick up in about three seconds after the clutch begins to slip. There must be at least 0.010 inch clearance between spring 3 and stop 4 when the relay is de-energized. De-energized contact pressure should be 90 to 100 grams.

Table 4–8. Obstruction and Overload Relay Test Procedure

Step

Action

Place the obstruction gauge (1) between the switch point and the stock rail for the reverse position.

Operate the switch machine, noting the length of time from when the machine encounters the obstruction and until the overload relay picks up. It should pick up within 1 to 10 seconds.

To increase the pickup time of the overload relay turn slotted-head nut clockwise. To decrease the pickup time turn nut counterclockwise.

N U T

4 If an adjustment was made in step 3, repeat step 2 to verify position.

P1293, Rev. Oct/12 4–15 Alstom Signaling Inc.

Scheduled Maintenance

Table 4–8. Obstruction and Overload Relay Test Procedure (Cont.)

Step

Action

Place a second obstruction (2) gauge between the switch point and the stock rail for normal position.

Change switch position to alternate correlation (Normal to Reverse), noting the length of time from when the machine encounters the obstruction and until the overload relay picks up. It should pick up within 1 to 10 seconds.

(Some variation in time for pickup may be expected between tests in two directions.)

It is important to let the resistance wire cool between tests or a wrong setting results. Wire should be cool to the touch, use caution when verifying wire is cool.

To increase the pickup time of the overload relay, turn slotted-head nut shown in step 3 clockwise; to decrease the pickup time turn nut counterclockwise.

If an adjustment was made in step 8, repeat steps 5 through 8 to verify original position again.

Remove the two obstruction gauges.

Call the switch machine to reverse and verify that the overload relay does not pick up and that the Local Control Panel indicates reverse position within 5 seconds.

Call the switch machine to normal, and verify that the overload relay does not pick up and that the Local Control Panel indicates reverse position within 5 seconds.

Perform the Overload Relay Adjustment Procedure.

P1293, Rev. Oct/12 4–16 Alstom Signaling Inc.

Scheduled Maintenance

Table 4–9. Overload Relay Adjustment Procedure

Step

Action

Place a 0.010 inch feeler gauge between spring (3) and stop (4) to verify that a minimum .010” gap exists when the relay is not picked.

Remove 0.010 feeler gauge.

Apply pressure to the contact on spring (5) until the contact opens. When the relay is fully picked up, spring (3) must rest against stop (4).

The contact opening with the armature picked up should be 0.030 to 0.045 inch. Measure the gap with an appropriate wire gauge.

Adjustment of the contact opening is made by carefully bending arm (2) and repeating steps 1-4 to verify performance.

NOTE

To increase Overload Relay pickup time, turn nut (1) clockwise; to decrease pickup time, turn nut (1) counter-clockwise.

P1293, Rev. Oct/12 4–17 Alstom Signaling Inc.

Scheduled Maintenance

4.9.3. Motor Brush Inspection Procedure

Table 4–10. Motor Brush Inspection Procedure

Step

Action

Disconnect the switch machine power by removing the 110 VDC fuses and heater fuse. Locate the fuses by using the Book of Plans.

3 Unlock the motor cover padlock and lift the cover up and away from motor.

P1293, Rev. Oct/12 4–18 Alstom Signaling Inc.

Scheduled Maintenance

Table 4–10. Motor Brush Inspection Procedure (Cont.)

Step

Action

Verify that the commutator (6) is smooth and free of grease and oil. The commutator should be brown in color and highly polished.

Remove any carbon dust from the commutator end of the armature, inside the undercuts (3), the brush holders, (4) and the sides of the brushes (5).

NOTE

Always use lint-free cloth. Never use emery cloth on the commutator or brushes.

Verify that the brushes (5) slide freely in the holders (4) and seat fully on the commutator (6). Brush pressure is 1.25 to 1.75 pounds. Brushes are to be replaced when the brush pusher lever becomes flush with the top of the brush holder (4). Replace the brushes with the same grade brushes. (Refer to Table 6–8 for replacement procedure.)

Remove the hand crank from the clutch shaft and reset the cutout contact by moving the blocking plate to the normal position.

Reinstall all covers and padlocks.

Reinstall the fuses and return the machine to service.

P1293, Rev. Oct/12 4–19 Alstom Signaling Inc.

Scheduled Maintenance

4.9.4. Box-Style Bearing and Wear Plate Inspection

The box-style bearings and wear plates eventually wear out and should be replaced before wearing through. To maintain proper operation and safety, lock rod wear plates must be replaced before the distance between the clip on the lock rod and the blocking extension on the yoke of the point detector reaches 3/16 inch. Other wear plates must be replaced before wearing through. Failure to replace wear plates results in frame damage, and wear of internal components may occur.

Perform the following procedure in the sequence given.

Table 4–11. Box-Style Bearing and Wear Plate Inspection Procedure

Step

Action

Disconnect the switch machine power by removing the 110 VDC fuses and heater fuse. Locate the fuses by using the Book of Plans.

Remove the padlock from the switch machine hasp that holds down both the gear and contact compartment covers.

Release the tension on the hasp strap and remove the strap up and off from the covers.

Verify that the cover is free of the motor side and point detector side eyebolts before lifting the cover off from the machine.

Remove the gear and contact compartment covers by lifting the covers straight up and off.

Place the end of the hand crank against the inside lip of the blocking plate then move the plate to the detent position, centering the hole in the plate with the crank entrance hole. This action separates the contact plunger from the cutout switch contact block.

Insert the hand crank through the blocking plate hole into the clutch.

Observe that the motor cutout contacts are open. Leave the hand crank inserted throughout the procedure.

P1293, Rev. Oct/12 4–20 Alstom Signaling Inc.

Scheduled Maintenance

Table 4–11. Box-Style Bearing and Wear Plate Inspection Procedure (Cont.)

Step

Action

Inspect the box-style bearings (1) on both ends of the throw bar for excessive wear.

THROW

BAR

LOCKING

BAR

P1293, Rev. Oct/12 4–21 Alstom Signaling Inc.

Scheduled Maintenance

Table 4–11. Box-Style Bearing and Wear Plate Inspection Procedure (Cont.)

Step

Action

Inspect the wear plates (4) on both sides of the machine for excessive wear.

Replace before the plates are worn through. Refer to Table 6–7 for the replacement procedure.

WARNING

REPLACE THE LOCK ROD WEAR PLATES BEFORE 3/16

INCH IS OBTAINED BETWEEN THE TOP OF THE LOCK

ROD CLIPS AND THE BLOCKING EXTENSION ON THE

YOKE, OR FAILSAFE OPERATION WILL BE

JEOPARDIZED.

Crank the machine to place the lock rod clips under the yoke extension and measure the distance between points A and B. Replace the lock rod wear plates if the distance is 3/16 inch or greater. Refer to Table

6–7 for the replacement procedure.

11 Remove the hand crank from the clutch shaft and reset the cutout contact by moving the blocking plate to the normal position.

Re-install all covers and padlocks.

Reset the crank mechanism cutout switch by moving the blocking plate to the normal position.

Re-install the fuses removed in Step 1 and restore the machine to service.

P1293, Rev. Oct/12 4–22 Alstom Signaling Inc.

Scheduled Maintenance

4.9.5. Throw Rod Check and Adjustment Procedure

The following procedure describes the switch machine throw rod adjustment.

Table 4–12. Throw Rod Check and Adjustment Procedure

Step

Action

Disconnect the switch machine power by removing the power fuses and heater fuse. Locate the fuses by using the Book of Plans.

Place the end of the hand crank against the inside lip of the blocking plate then move the blocking plate to the detent position, centering the hole in the blocking plate to the clutch crank hole.

Hand crank the switch machine to the end of its six-inch throw bar stroke.

Once started, hand cranking continues easily. Place a piece of heavy paper

(e.g.: paper currency, front cover of a pamphlet, etc.) between the switch point and the stock rail. Make sure that the paper is located above the front switch rod. Observe that when the points close, they exert a light pressure on the paper, but the paper can still be pulled out from between the switch point and the stock rail. The closed switch point should tuck in tight to the stock rail with no gaps at the tip of the point.

Continuing the rotation of the hand crank should cause the locking dog in the machine to enter through the wide notch in the lock rod causing the switch points to lock in place.

NOTE

If the locking dog does not enter through the wide notch in the lock rod, the locking dog bolts need to be adjusted so that the side of the notch on the lock rod is snug against the locking dog.

P1293, Rev. Oct/12 4–23 Alstom Signaling Inc.

Scheduled Maintenance

Table 4–12. Throw Rod Check and Adjustment Procedure (Cont.)

Step

Action

If the points do not fully close, then readjust the nuts at the switch basket by backing off the lock-nut (38) of the nuts on the side of the basket applying pressure to the point.

Then loosen or tighten the adjustment nut (37) to obtain the proper closed pressure of the points. Retighten the lock-nut (38).

Repeat steps 2 through 5 for the opposite direction.

Remove the hand crank from the clutch shaft and reset the cutout contact by moving the blocking plate to the normal position.

Re-install all covers and padlocks.

Restore the switch machine power by installing the power fuses and heater fuse.

Restore the machine to service.

P1293, Rev. Oct/12 4–24 Alstom Signaling Inc.

Scheduled Maintenance

4.9.6. Lock Rod Check and Adjustment Procedure

The following describes the switch machine lock rod adjustment procedure. Switch adjusting tools, a 1/8” obstruction gauge, and a 1/4" obstruction gauge are required to perform this procedure.

NOTE

This procedure is used when customers require that the wide notch lock rods do not lock with a ¼” obstruction. For other procedures including wide notch lock rods that lock with a ¼” obstruction and not lock with a

3/8” obstruction, or narrow notch lock rods, see Tables 3–5 through 3–8.

Table 4–13. Lock Rod Check and Adjustment Procedure for Switch Machines with

Wide Notch Lock Rods

Step

Action

Disconnect the switch machine power by removing the power fuses and heater fuse. Locate the fuses by using the Book of Plans.

Place the end of the hand crank against the inside lip of the blocking plate then move the blocking plate to the detent position, centering the hole in the blocking plate to the clutch crank hole.

Insert a 1/8” obstruction gauge in the far point.

Hand crank the switch machine to close the far switch point, and adjust the lock rod so that the switch machine is locked (locking dog entered through the smaller “locking” notch of lock rod) with the 1/8” obstruction gauge in the far switch point.

With the switch machine locked, adjust the lock rod so that the side of the notch on the lock rod is snug against the locking dog. Be careful when adjusting the lock rod ensuring that excessive pressure is not being applied to the lock dog.

NOTE

Be sure to adjust the locking dog against the proper side of the locking notch in the lock rod.

Hand crank the far switch point open enough to remove the 1/8” obstruction gauge.

Hand crank the far switch point closed and verify that the switch machine locks.

Hand crank the far switch point open enough to insert a 1/4” obstruction gauge.

P1293, Rev. Oct/12 4–25 Alstom Signaling Inc.

Scheduled Maintenance

Table 4–13. Lock Rod Check and Adjustment Procedure for Switch Machines with

Wide Notch Lock Rods (Cont.)

Step

Action

Hand crank the switch machine to close the far switch point against the 1/4” obstruction gauge and observe that the locking dog does not enter the locking notch in the lock rod (switch machine is not locked).

Hand crank the far switch point open enough to remove the 1/4” obstruction gauge. Adjust the lock plate per steps 11 through 18. If no adjustment is required, go to step 19.

Insert a 1/8” obstruction gauge in the near switch point

Hand crank the switch machine to close the near switch point, and adjust the lock plate so that the switch machine is locked with the 1/8” obstruction gauge in the near switch point.

With the switch machine locked, adjust the lock plate so that the side of the locking notch on the lock plate is snug against the locking dog. Be careful when adjusting the lock rod ensuring that excessive pressure is not being applied to the lock dog.

NOTE

Be sure to adjust the locking dog against the proper side of the locking notch in the lock rod.

Hand crank the near switch point open enough to remove the 1/8” obstruction gauge.

Hand crank the near switch point closed and observe that the switch machine locks.

Hand crank the near switch point open enough to insert a 1/4” obstruction gauge.

Hand crank the switch machine to close the near switch point against the

1/4” obstruction gauge and observe that the locking dog does not enter the locking notch in the lock plate (switch machine is not locked).

Hand crank the near switch point open enough to remove the 1/4” obstruction gauge.

Remove the hand crank from the clutch shaft and reset the cutout contact by moving the blocking plate to the normal position.

Re-install all covers and padlocks.

Restore the switch machine power by installing the power fuses and heater fuse.

Restore the machine to service.

P1293, Rev. Oct/12 4–26 Alstom Signaling Inc.

Scheduled Maintenance

4.9.7. Point Detector Rod Check and Adjustment Procedure

The following describes the switch machine point detector rod adjustment procedure.

The following equipment is required to perform this procedure: switch adjusting tool,

1/8” obstruction gauge, 1/4” obstruction gauge, and a feeler gauge.

NOTE

This procedure is used when customers require that the wide notch lock rods to lock with a ¼” obstruction and not lock with a 3/8” obstruction. See

Table 3–7 for point detector rod adjustment procedure when lock rods are adjusted to not lock with a ¼” obstruction and “floating” lock rod is required.

Table 4–14. Point Detector Rod Check and Adjustment Procedure

Step Action

Disconnect the switch machine power by removing the power fuses and heater fuse. Locate the fuses by using the Book of Plans.

Place the end of the hand crank against the inside lip of the blocking plate then move the blocking plate to the detent position, centering the hole in the blocking plate to the clutch crank hole.

Insert a 1/8” obstruction gauge in the far switch point.

Hand crank the switch machine to close the far switch point against the 1/8” obstruction gauge, and adjust the point detector rod so that the point detector contacts are broken off their stops (closed) by less than 1/32”. After the point detector rod adjustment nuts are tightened, observe that the point detector contacts are still broken off their stops (closed) by less than 1/32”.

Hand crank the far switch point open enough to remove the 1/8” obstruction gauge.

Hand crank the far switch point closed and verify that the switch machine locks with the point detector contacts broken off their stops (closed) by 1/32”

-1/16”.

Hand crank the far switch point open enough to insert a 1/4” obstruction gauge.

8 Hand crank the switch machine to close the far switch point against the 1/4” obstruction and verify that the switch machine point detector contacts do not break off their stops (open).

9 Hand crank the far switch point open enough to remove the 1/4” obstruction gauge.

10 Insert a 1/8” obstruction gauge in the near switch point.

P1293, Rev. Oct/12 4–27 Alstom Signaling Inc.

Scheduled Maintenance

Table 4–14. Point Detector Rod Check and Adjustment Procedure (Cont.)

Step

Action

Hand crank the switch machine to close the near switch point against the

1/8” obstruction gauge, and adjust the point detector plate so that the point detector contacts are broken off their stops (closed) less than 1/32”. After the point detector plate adjustment bolts are tightened, observe that the point detector contacts are still broken off their stops (closed) less than

1/32”.

Hand crank the near switch point open enough to remove the 1/8” obstruction gauge.

Hand crank the near switch point closed and observe that the switch machine locks with the point detector contacts broken off their stops (open)

1/32” - 1/16”.

Hand crank the near switch point open enough to insert a 1/4” obstruction gauge.

Hand crank the switch machine to close the near switch point against the

1/4” obstruction gauge observing that the switch machine point detector contacts do not break off their stops (open).

Hand crank the near switch point open enough to remove the 1/4” obstruction gauge.

Remove the hand crank from the clutch shaft and reset the cutout contact by moving the blocking plate to the normal position.

Re-install all covers and padlocks.

Restore the switch machine power by installing the power fuses and heater fuse.

Restore the machine to service.

P1293, Rev. Oct/12 4–28 Alstom Signaling Inc.

Scheduled Maintenance

4.9.8. Point-Detector Contact Check and Adjustments

Table 4–15. Point Detector Contact Check and Adjustment Procedure

Step

Action

Before replacing or adjusting contacts, verify that yoke to which contact (5) is attached moves freely, as forced by the springs pushing the horizontal yoke downward.

When point-detector is properly adjusted, rollers in the point-detector movement must rest on bottom of slots in point-detector rods in both normal and reverse positions.

The proper fully-made position for normal and reverse contacts is below.

The figures above and below also show this position for the shunt contacts.

1/32" TO 1/16"

C3, C6

D3, D6

Contact pressure for normal and reverse contacts, measured very near the point of contact, should be 2-1/2 to 3 pounds, preferably nearer 2-1/2 pounds, and is adjustable. See figure in step 2.

P1293, Rev. Oct/12 4–29 Alstom Signaling Inc.

Scheduled Maintenance

Table 4–15. Point Detector Contact Check and Adjustment Procedure (Cont.)

Step

Action

A method of checking contact force is to make a loop of unwaxed twine and hook it around spring contact (1) or (4) just above H-shaped contact (5).

Hook the loop around contact 3, close to the point of contact.

Using a force gauge, for example, made by John Chatillon and Sons, pull outward on the twine as nearly horizontally as possible to open the contact.

Contact pressure for shunt contacts in Models 5E and 5F, measured very near point of contact, should be 2-1/2 to 3 pounds, and is adjustable.

Pressure of these adjustable contacts against it stop may be reduced to 3/4 to 1-1/4 pounds when heaters are used in machines.

Coil spring and contact openings determine contact pressure of motorcontrol and shunt contacts of Models 5G and 5H. Pressure is not adjustable for these contacts.

To decrease pressure of a normal, reverse, snub, or Models 5E and 5F shunt contact, bend U-shaped spring in until it has taken a set that gives the desired pressure. To increase pressure, release U-shaped spring from its stop and bend spring outward.

P1293, Rev. Oct/12 4–30 Alstom Signaling Inc.

Scheduled Maintenance

Table 4–16. Point Detector Contact Check and Adjustment Procedure For Models 5E and 5F Normal and Reverse Contacts C5, C8, D1 and D4, and Snub Contacts C3, C4,

D5 and D6; Models 5G and 5H Normal and Reverse Contacts C3, C6, D3, and D6

Step

Action

Adjust contacts on each side of point-detector to make and break at same time.

With the contacts made, verify gap between U-shaped spring (3) and front stop (2) is not more than 1/16 inch or less than 1/32 inch.

To adjust gap for all contacts, loosen screws in contact block assembly and move it in or out as required. Tighten screws after gap is proper.

To adjust individual contact opening, bend finger (1) at point X, making sure that finger (1) does not hit stop (2).

P1293, Rev. Oct/12 4–31 Alstom Signaling Inc.

Scheduled Maintenance

4.9.9. Shunt Contact Check and Adjustment

4.9.9.1. Models 5E and 5F Shunt Contacts C6, C7, D2 and D3

The switch machine shipped from Alstom has shunt strips A, Figure 4–3 connected across contacts C6-D3 and C7-D2. Shunt strips A are used only in a polarized repeater relay circuit. To use a neutral repeater relay circuit, shunt strip A must be removed and shunt strip B must be added between contacts C6-C7 and D2-D3, Figure 4–4 Shunt strips B, supplied with each new machine, are in a bag which also contains the motor ventilators.

When the switch machine operates, the first or unlocking movement of the locking bar simultaneously opens the snub contacts and either the normal or reverse contacts, depending on the direction of operation.

Immediately after these contacts are opened, the shunt contacts are closed. With the machine unlocked, or if the point-detector rod is out of adjustment, there is a shunt on the repeater relay circuit. The shunt prevents pickup of the repeater relays so that any extraneous energy, which may be present, cannot cause a false indication.

In a polarized repeater relay circuit using shunt strips A, Figure 4–3 the shunt is closed through terminal post C6, U-shaped spring (1), front stop (2), shunt strip (A), front stop

(3), U-shaped spring (4), and opposite terminal post D3. A similar shunt arrangement exists between posts C7 and D2.

Figure 4–3. Shunt Contacts Used in Polarized Repeater Relay Circuit

In a neutral repeater relay circuit using shunt strips B, Figure 4–4 the shunt is closed through terminal post C6, U-shaped spring (1), front stop (2), shunt strip (B), front stop

(3), U-shaped spring (4), and adjacent terminal post C7. A similar shunt arrangement exists between posts D2 and D3.

P1293, Rev. Oct/12 4–32 Alstom Signaling Inc.

Scheduled Maintenance

After the switch points have been properly positioned, the locking movement of the locking bar permits the point-detector to complete its movement. Shunt contact finger

(5), Figure 4–3, which is attached to the movable block, moves U- shaped spring (1) about 1/16 inch before the other section of this contact finger closes the normal or reverse contact. Thus, the shunt on the repeater relay circuit is removed before the normal or reverse contacts and the snub contacts are closed.

In summary, the normal or reverse and snub contacts must be open before the shunt contacts close. Shunt contacts must be open about 1/16 inch before normal or reverse and snub contacts close.

Figure 4–4. Shunt Contacts Used in Neutral Repeater Relay Circuit

P1293, Rev. Oct/12 4–33 Alstom Signaling Inc.

Scheduled Maintenance

4.9.9.2. Models 5G and 5H Shunt Contacts C7, C8, D1 and D2

Normal and reverse contacts should be completely adjusted before attempting to adjust the shunt contacts.

Table 4–17. Point Detector Contact Adjustment Procedure For Models 5G and 5H

Shunt Contacts C7, C8, D1 and D2

Step

Action

Shunt contacts should make only after normal and reverse contacts are open, and normal and reverse contacts should make after appropriate shunt contact is open.

2 Verify that opening of shunt contact is about 7/32 inch. Adjust opening by loosening screw (2), lifting adjuster tip out of hole, and moving contact (1) in or out as required. Retain adjustment by setting adjuster tip in new hole and tightening screw.

Align contact tip (1) with contact tip (3). These should make at least 75 percent of their full width when contact is closed.

Adjust tip of movable contact so there is about 1/64 to 1/32 inch contact wipe. Bend tip down to increase contact wipe.

P1293, Rev. Oct/12 4–34 Alstom Signaling Inc.

Scheduled Maintenance

4.9.10. Motor-Control Contacts (All Models)

Table 4–18. Motor Control Contact Adjustment Procedure

Step

Action

Adjust all other contacts completely before adjusting motor-control contact.

Models 5E and 5F motor-control contacts shown positioned as indication contacts make:

Models 5G and 5H Motor-Control and Shunt Contacts

P1293, Rev. Oct/12 4–35 Alstom Signaling Inc.

Scheduled Maintenance

Table 4–18. Motor Control Contact Adjustment Procedure (Cont.)

Step

Action

Motor-control contacts of a 24-32V machine should be open from 0.045 to

0.060 inch when the related normal or reverse contact just makes.

In a 110V machine, this opening may vary from 0.170 to 0.200 inch.

Adjust the opening by loosening screw (2), lifting the adjuster tip out of its hole, and moving the contact (1) in or out, as required. Retain this adjustment by setting the adjuster tip in a new hole and tightening the screw.

Adjust the tip of the moveable contact so that there is 1/64 to 1/32” of contact wipe. If necessary, bend the tip down slightly to increase the contact wipe.

NOTE

Since pressure of motor-control contacts is governed by contact opening and coil spring design, there is no adjustment.

Adjust tip of movable contact to get a 1/64 to 1/32 inch contact wipe. Bend tip down to increase contact wipe.

P1293, Rev. Oct/12 4–36 Alstom Signaling Inc.

Scheduled Maintenance

4.9.11. Controller Contact Adjustments

Controllers are components of the Model 5G and 5H Switch Machines only.

Shims are provided behind the upper bearing support of the contactor centering shaft.

These shims permit the centering device to be properly positioned so that the back contact of one contactor makes at the same time, or slightly before, the front contact of the other contactor.

Permanent magnets blowout the arc which occurs during switch operation. These magnets are located behind the snub and contactor contacts. One pole of each magnet is stamped N to indicate which is the north pole of each magnet. If these magnets should be removed, be sure to reassemble them in their original positions with respect to magnet polarity.

When periodic inspection shows there is not enough contact wipe because of wear on the contacts, the contacts should be replaced and adjusted. New contact fingers are not adjusted.

P1293, Rev. Oct/12 4–37 Alstom Signaling Inc.

Scheduled Maintenance

Table 4–19. Controller Contact Adjustment Procedure

Step

Action

The controller contacts are adjusted by using shims.

Place shims behind the head of the contact screw so that the front contact just makes when the armature is 0.030 to 0.040 inch away from the upper residual pin in the top pole piece.

Contact pressure should not be less than 256 grams (9 ounces) and contact resistance should not exceed 0.1-ohm.

Verify current by operating the contactors.

• To operate contactor C1 electrically when the controller is not in the machine, connect positive energy to post B, negative energy to post 10.

• To operate contactor C2, connect positive energy to post 6, negative energy to post B.

(On single switches, contactor C1 operates the switch to the right when energized; contactor C2, to the left.)

Compare current to the electrical values of the contactors at 70°F provided below

At Nominal Voltage 10 -12 24 – 32

Working Current Not To Exceed 0.145A 0.145A

Dropaway Current Not Less Than 0.026A 0.026A

P1293, Rev. Oct/12 4–38 Alstom Signaling Inc.

Scheduled Maintenance

Table 4–19. Controller Contact Adjustment Procedure (Cont.)

Step

Action

If working current is too high, the horizontal spring below the snub contact is too tight, and should be adjusted as required by changing the position of the nut holding it in compression.

CONTROL WIRE #1

MOTOR

CONTROL WIRE #2

CONNECTOR

F2 F3

BLACK

8 7

SHUNT STRIPS "A"

6 5 4 3 2 1

SNUB

RECTIFIER

RESISTIVE

LEAD

1 2 3 4 5 6 7 8

C 3

RED

YELLOW

GND.

LUG

CRANK

CONTACT POINT DETECTOR

CONTROL

WIRE #3

P1293, Rev. Oct/12 4–39 Alstom Signaling Inc.

Scheduled Maintenance

4.9.12. Friction Clutch Inspection

The following describes how to disassemble, inspect and reassemble the friction clutch once it has been, determined to be functioning outside the requirements in “FRICTION

CLUTCH TEST.”

Table 4–20. Friction Clutch Inspection

Step

Action

Release setscrew on clutch housing and back off adjusting nut while keeping control of it. Notice spring inside clutch goes to zero force before nut is free of clutch.

Remove shaft and nut.

Unscrew screws on bevel gear to open clutch. Remove gear.

WARNING

FRICTION DISCS IN OLDER CLUTCHES MAY CONTAIN

ASBESTOS. FOLLOW PROPER ASBESTOS HANDING

PROCEDURES ACCORDING TO LOCAL REGULATIONS.

THE ASBESTOS CONTAMINATION MAY EXTEND TO

NEARBY SURFACES AND GREASE.

Notice sequence of discs in clutch while removing discs.

Examine friction discs for cracks, roughness or uneven wear.

Examine metal discs for corrosion, roughness or excessive wear. Replace any defective discs. New discs do not contain asbestos.

NOTE

Corrosion is a potential problem because metal discs are hard chrome plated to increase resistance to wear; however, they are susceptible to corrosion. Chrome may peel in a clutch disc, increasing resistance to slippage.

Inspect all friction surfaces of clutch body. If roughness of surfaces noted, repair or replace clutch body.

To reassemble clutch, clean pieces of clutch with soft cloth or bristle brush.

Make sure no grease is present which does not belong.

Apply Rust-Veto™ to unpainted surfaces that do not slide or rotate against anything else.

P1293, Rev. Oct/12 4–40 Alstom Signaling Inc.

Scheduled Maintenance

Table 4–20. Friction Clutch Inspection (Cont.)

Step

Action

Add a little grease to sides of bottom hole of clutch housing. Make sure no grease touches flat surface against which friction disc rides.

Reassemble discs in clutch as follows:

− First, a friction disc

− Second, an inside steel disc

− Third, a friction disc

− Last, an outside disc

Repeat this sequence twice.

Add discs on top same as were in clutch.

Center discs by hand to allow shaft to be installed.

Bolt bevel gear to the clutch body.

Apply a thin film of grease on only upper part of shaft, extending no more than 3/4-inch below bottom of gear on shaft.

Insert shaft into adjusting nut, rotating shaft to align inside discs. Be sure shaft hits bottom of clutch body.

After assembly, follow instructions for clutch test and adjustment.

P1293, Rev. Oct/12 4–41 Alstom Signaling Inc.

Scheduled Maintenance

4.9.13. Friction Clutch Test

The clutch should be tested when placing the machine in service and at scheduled intervals thereafter. The clutch is factory-adjusted to throw a load in accordance with

AREMA Signal Manual Part 12.2.5. Slipping current may be varied to meet your property’s specifications. To test the clutch setting, proceed as follows:

Table 4–21. Friction Clutch Test Procedure

Step

Action

Shunt out operating winding of overload relay (housed internally in Models

5G and 5H, housed externally in wayside case for Models 5E and 5F).

Place an obstruction (1/2 inch to 4 inch) between the switch point and the stock rail, no closer than six (6) inches from the tip of the switch point.

WARNING

DO NOT USE THE 1/4 INCH OBSTRUCTION GAUGE AS AN

OBSTRUCTION WHILE OPERATING THE SWITCH

MACHINE UNDER POWER. DAMAGE TO THE LOCK

ASSEMBLY MAY OCCUR IF THE SWITCH MACHINE

MOVES THE HEAD OF THE STOCK RAIL ENOUGH TO

LOCK.

Open the gear compartment cover to gain access to the cutout switch terminal connections.

Connect a 30-0-30 DC ammeter in series with the motor by opening the crank contact and inserting the ammeter between the connections.

Operate the switch against the obstruction. The motor should run and slip the friction clutch (do not allow the clutch to slip for more than 10 seconds).

The clutch is factory set to slip at the correct current.

Read motor current as clutch slips. If current value too high or too low, perform the adjustment procedure in Table 4–22.

Voltage

DC Clutch

24 to 32

110

Ampere Range to

Operate AREMA Load

17 – 20

12 - 14

NOTE

The throw current, at or near mid-stroke, should read between

6-8 amperes. The throw current is dependent upon the load placed upon the motor, improper adjustment and/or lubrication increases the load.

P1293, Rev. Oct/12 4–42 Alstom Signaling Inc.

Scheduled Maintenance

Table 4–21. Friction Clutch Test Procedure (Cont.)

Step

Action

Remove shunt on overload relay and obstruction from switch point and if the switch machine under test is one of a pair, then perform steps 1 through 6 for the other switch machine prior to operating the pair under power.

Perform the Friction Clutch Adjustment Procedure in Table 4–22 only if the current was out of range in Step 6.

P1293, Rev. Oct/12 4–43 Alstom Signaling Inc.

Scheduled Maintenance

4.9.14. Friction Clutch Adjustment

Table 4–22. Friction Clutch Adjustment Procedure

Step

Action

Insert the hand crank and crank the machine to the unlocked position.

Leave the hand crank inserted.

Back off setscrew that holds clutch adjusting nut.

WARNING

FRICTION DISCS IN OLDER CLUTCHES MAY CONTAIN

ASBESTOS. FOLLOW PROPER ASBESTOS HANDING

PROCEDURES ACCORDING TO LOCAL REGULATIONS.

THE ASBESTOS CONTAMINATION MAY EXTEND TO

NEARBY SURFACES AND GREASE.

Insert a 5/16 inch diameter pin through hole in gear bracket and into hole in the clutch adjusting nut. The pin holds adjusting nut when hand crank is rotated.

To increase slipping current, rotate hand crank counterclockwise.

NOTE

If clutch is so loose that friction is insufficient to tighten adjustment nut, rotate clutch housing until friction increases enough to permit adjustment with the hand crank.

To decrease slipping current, rotate hand crank clockwise.

To retain the setting position, position the notch in the adjusting nut opposite the set screw and tighten the set screw. Tighten setscrew.

P1293, Rev. Oct/12 4–44 Alstom Signaling Inc.

Scheduled Maintenance

Table 4–22. Friction Clutch Adjustment Procedure (Cont.)

Step

Action

When the adjustment is complete, remove the pin and hand crank, then restore the hand crank cutout latch by moving the blocking plate.

Shunt out operating winding of overload relay. Test clutch again to determine slipping current per Table 4–21. Remove shunt on overload relay.

To confirm that the snubbing (dynamic braking) is operating satisfactorily, observe that the switch gear train does not reverse direction after reaching its mechanical stop. Also observe that the switch points close firmly against the stock rail (with no movement of the stock rail) and the point detector assembly is in the over and locked position.

P1293, Rev. Oct/12 4–45 Alstom Signaling Inc.

Scheduled Maintenance

4.9.15. Crank Cut-Out Switch Adjustment

Table 4–23. Crank Cut-Out Switch Adjustment Procedure (Models 5E and 5F)

Step

Action

On a single control machine, insert an 11/16-inch diameter rod into crank entrance hole and gently push interlock plunger (1) toward contacts (2).

THROW

BAR

CRANK

ENTRANCE

HOLE

CRANK CUTOUT

CONTACTS

LOCKING

BAR

2 1

Check for a 1/8-inch minimum clearance between any part of the

• plunger and contacts

• arm and contacts

If clearance is too little, adjust screw end of plunger or arm and contacts.

If still not sufficient clearance, bend push rod (3) slightly.

If push rod is over straightened, it is difficult to insert hand crank into machine.

P1293, Rev. Oct/12 4–46 Alstom Signaling Inc.

Scheduled Maintenance

4.9.16. Hand-Power Lever Test

Hand-power levers are components of the Model 5F and 5H Switch Machines only.

Check mode-selector lever contact in dual-control machines as follows:

Table 4–24. Hand-Power Lever Test

Step

Action

Place mode-selector lever in HAND position. Hand-throw switch machine using hand-throw lever.

Place mode-selector lever in vertical position.

Hand-crank switch machine until hand-throw lever starts to rise out of latch stand. At this point, notice clutch sleeve is nearly engaged in clutch gear as well as main gear.

Oscillate hand crank back and forth while moving mode-selector lever toward POWER position.

When hand-throw lever stops rising in latch stand, stop hand-cranking and hold mode-selector lever in that position. At this point, notice clutch sleeve just disengages from clutch gear.

Measure selector-lever contact opening - it should be at least 1/16-inch. If not, bend contact to produce desired opening.

Place mode-selector lever in POWER position.

Check mode-selector lever contact makes at least 3/16-inch contact. If not, bend contact to produce desired contact. Repeat Steps 1 - 7 if it was necessary to bend contact.

P1293, Rev. Oct/12 4–47 Alstom Signaling Inc.

Scheduled Maintenance

4.10. SEMI-ANNUAL MAINTENANCE

4.10.1. Commutator Inspection

Table 4–25. Commutator Inspection Procedure

Step

Action

Disconnect the switch machine power by removing the 110 VDC fuses and heater fuse. Locate the fuses by using the Book of Plans.

Inspect commutator area that contacts the brushes.

If area is not black or dark brown-colored and highly polished, check for proper grade of brush and possible external contaminants.

If external contamination is causing commutator to roughen and gall, try removing the motor's two ventilators and refinishing the commutator.

Replace wrong brush with proper grade of brush. See Figure 7–15 item 2 for the ventilator location (one is called out, but there are two ventilators, one on each side of the motor).

Keep commutator smooth and free of grease or oil.

Remove any carbon dust around commutator end of armature in undercuts.

Reconnect energy to motor.

P1293, Rev. Oct/12 4–48 Alstom Signaling Inc.

Scheduled Maintenance

4.11. ANNUAL MAINTENANCE

4.11.1. Magnetic Detent Inspection

Table 4–26. Magnetic Detent Inspection Procedure

Step

Action

Disconnect the switch machine power by removing the 110 VDC fuses and heater fuse. Locate the fuses by using the Book of Plans.

Insert the hand crank (1) and manually crank the machine to the far switch point and near switch point positions. Listen for any unusual noises coming from the motor holding device area. If the magnets are loose, there is a clapping sound.

Remove magnetic detent cover and check for water trapped in holding device housing. Drain and wipe dry.

Confirm armature and attached magnets rotate freely.

Verify armature shaft has no end play.

Apply Permagum or similar sealant to cover the surface that mates with holding device. Omit sealant along bottom inch of cover to permit condensation or flooding water to drain away.

P1293, Rev. Oct/12 4–49 Alstom Signaling Inc.

Scheduled Maintenance

Table 4–26. Magnetic Detent Inspection Procedure (Cont.)

Step

Action

Replace magnetic detent cover.

Check that all screws and nuts are tight.

9 Check the locked torque on the armature by measuring the amount of pull needed to move the hand crank to the next detent position. The locked torque measured from the end of the hand crank must be in excess of 10 pounds. If the detent torque is less than 10 pounds, refer to Table 6–47

Mechanical Test Procedure Steps 33 and 34.

Check operation of magnetic holding device by hand-cranking switch machine. It should require at least 3 foot pounds for a high-speed machine

(110V) or 6.25 foot pounds for a low-speed machine (24V) to initiate handcranking. (Six or 12-1/2 pounds, respectively, of force at hand-crank handle.)

Remove the hand crank from the clutch shaft and reset the cutout contact by moving the blocking plate to the normal position.

Re-install all covers and padlocks.

Reset the crank mechanism cutout switch by moving the blocking plate to the normal position.

Re-install the fuses removed in Step 1 and restore the machine to service.

P1293, Rev. Oct/12 4–50 Alstom Signaling Inc.

Scheduled Maintenance

4.11.2. Blocking Rectifier Test

Table 4–27. Blocking Rectifier Test Procedure

Step

Action

Locate the blocking rectifiers connected between the coils of each biasedneutral contactor to protect it against the effects of lightning.

Place a DC milli-ammeter in the control circuit.

Check current. It should not exceed 0.025-ampere when the machine is fully over and locked.

Change switch position to alternate correlation (Normal to Reverse)

Check current. It should not exceed 0.025-ampere when the machine is fully over and locked.

If the current is too high replace the rectifier.

P1293, Rev. Oct/12 4–51 Alstom Signaling Inc.

Scheduled Maintenance

THIS PAGE INTENTIONALLY LEFT BLANK.

P1293, Rev. Oct/12 4–52 Alstom Signaling Inc.

Troubleshooting

5. SECTION 5 – TROUBLESHOOTING

5.1. GENERAL PHILOSOPHY

Troubleshooting Model 5E through 5H Switch Machines is usually done in the control location before going out to the field for inspection. In order to understand troubleshooting procedures, knowledge of how to read circuit plans is essential. Relays in the control location are checked using a volt-ohm-meter (multimeter). Also, in troubleshooting techniques, a multimeter is used to check continuity of fuses and the resistance of resistors and continuity of circuits.

5.2. POSSIBLE SYMPTOMS AND CORRECTIVE ACTIONS

Tables 5–1 and 5–2 give examples of symptoms of abnormal operation of the switch machine circuit and trackside equipment and how to begin to determine the faulty component or circuit.

A optional Switch Machine and Layout Sensing Kit is available from Alstom (P/N 59649-

218-00) that can be used during troubleshooting, installation, or maintenance to detect point pressure at each point. For a procedure on use of this kit, see Table 3–15 for the

Throw Rod Point Pressure Verification Procedure.

Table 5–1. Symptoms Noticed From the Control Locations

Symptom Corrective Action

1) Switch flashing out of correspondence, RP or NP relay down

(per switch position request).

2) Switch flashing out or correspondence, RWZ or NWZ relay down (per switch position request).

3) Switch flashing out of correspondence, RW or NW relay down

(per switch position request).

1) Check for 24V DC power at RP or NP coil.

2) Check for bad relay.

1) Check that RP or NP relay is up.

2) Check for 24V DC power at RWZ or NWC coil.

3) Check for bad relay.

1) Check that RWZ or NWZ relay is up.

2) Check for 24V DC power at RW or NW coil.

3) Check for bad relay.

P1293, Rev. Oct/12 5–1 Alstom Signaling Inc.

Troubleshooting

Table 5–1. Symptoms Noticed from the Control Locations (Cont.)

Symptom

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

5) Switch flashing out of correspondence,

display on panel flashing.

6) All switches flashing out of correspondence, display on panel flashing.

7) Switch flashing out of correspondence, RWP or NWP relay down (per switch position request).

Corrective Action

1) Check that RW or NW relay is up.

2) Check for BX 120 power at entrance rack.

If none, possible blown fuse or bad switch rectifier.

3) Check for BX120 power at switch machine motor. If none, possible bad cable, bad finger in contactor, loose hardware and/or connections.

4) Check for obstruction in rail points.

5) Check rail conditions in area.

6) Check that crank cut-out switch place is closed

1) Check that RWC or NWC relay is up.

2) Check for faulty contact in circuit.

3) Check for loose hardware and connections.

1) Check for AC power at switch machine rectifier.

2) Check for DC output at switch machine rectifier.

3) Check for WPB power at NWP and RWP.

4) Check for blown fuse(s).

1) Check that switch machine has thrown to a requested position.

2) Check for LB12V DC power at RWP or

NWP relay coil.

3) Check for faulty relay.

4) Check for LB12V DC power at entrance rack.

5) Check for LB12V DC power at switch machine contactor finger.

6) Check switch machine contactor fingers.

7) Check for loose hardware connections.

8) Check for obstruction in rail points.

P1293, Rev. Oct/12 5–2 Alstom Signaling Inc.

Troubleshooting

Table 5–1. Symptoms Noticed from the Control Locations (Cont.)

Symptom

8) Switch flashing out of correspondence, RWC or NWC relay down (per switch position request).

Corrective Action

1) Check that RWP or NWP relay is up.

2) Check for 12V DC at relay.

3) Check for loose hardware and connections.

4) Check for faulty relay.

P1293, Rev. Oct/12 5–3 Alstom Signaling Inc.

Troubleshooting

Table 5–2. Trackside Noted Symptoms

Symptom Corrective Action

1) Motor runs but points do not move. 1) Clutch slips - see friction clutch and adjustment.

2) Object in points - remove object.

3) Linkage disconnected - reconnect throw rod to switch points.

2) Points move but switch machine does not lock and indicate.

1) Reconnect and/or readjust lock rod.

3) Motor does not run.

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

1) Verify hand crank cut-out contact is closed.

2) Check motor control contacts in pointdetector.

3) Check for power to switch, NW to A5, RW to B4, CW to B8.

4) Check power to motor. Find cause of open circuit.

5) Check condition of motor brushes.

1) Inspect for damage to layout and components.

2) Inspect point-detector movement for damage. Replace as necessary.

5) Switch circuit controller does not indicate.

1) Obstruction in points or under flange of point - remove.

2) Linkage disconnected, reconnect as necessary.

3) If no signal energy present, check wiring from control location.

4) If signal return is interrupted, check wiring back to control location.

P1293, Rev. Oct/12 5–4 Alstom Signaling Inc.

Corrective Maintenance

6. SECTION 6 – CORRECTIVE MAINTENANCE

6.1. GENERAL

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.

P1293, Rev. Oct/12 6–1 Alstom Signaling Inc.

Corrective Maintenance

6.2. SUMMARY

Table 6–1 summarizes the tools and test equipment required for corrective maintenance and Table 6–46 summarizes the special equipment required for testing.

The complete overhaul procedure of the Alstom Model 5 Switch Machine is provided in

Table 6–7. Procedures for complete disassembly and assembly are listed in the proper sequence. If a part is found to be malfunctioning, the part must be replaced. For replacement, the disassembly process is followed down to the individual part. The assembly process begins at the specific part and proceeds back to a completed switch machine. Tables 6–2 through 6–5 reference where to find the steps for complete disassembly and assembly of listed parts.

Perform all lubrication procedures found in Section 4, and perform complete switch machine testing from the end of this section, following the replacement of a part.

WARNING

THESE PROCEDURES ARE PERFORMED WITH THE POWER

REMOVED FROM THE SWITCH MACHINE UNLESS OTHERWISE

INDICATED.

WARNING

KEEP CLEAR OF GEARS AND SWITCH POINTS WHEN MACHINE IS

UNDER OPERATIONAL CONTROL. OTHER THAN WHEN REMOVING

COVER (S) OR CROSS BRACE, POWER TO SWITCH MACHINE MUST

BE CUT OFF AT CONTROL ROOM BEFORE ANY REMOVAL OR

REPLACEMENT PROCEDURE IS PERFORMED.

WARNING

BE AWARE THAT WHEN POWER HAS NOT BEEN REMOVED FROM

THE SWITCH MACHINE, IT CAN BE REMOTELY ACTIVATED

INSTANTLY, POSSIBLY CAUSING PERSONAL INJURY AND

EQUIPMENT DAMAGE.

CAUTION

Always replace any covers and guards removed during maintenance before placing the switch machine back into service. Covers and guards are used to protect the lateral movement space for the throw bar, lock rod and detector rod by keeping away unwanted trackside debris, ballast or other material.

P1293, Rev. Oct/12 6–2 Alstom Signaling Inc.

Corrective Maintenance

6.3. TEST EQUIPMENT AND TOOLS

Following is a listing of tools required for switch machine disassembly and assembly.

Part numbers for tools and test equipment are listed here. Part numbers and drawings for tools and test equipment can be found in Section 7. Common toolbox tools such a screw drivers, pliers, and allen wrenches are not specifically listed but may be required.

Table 6–1. Tools and Test Equipment Index

Equipment Name Specific Use Manufacturer/Model

Crow Bar General use

Wrench, 1/2” Open End General use

Wrench, 3/8” and 7/16”

Double Open End

General use

Commercially available

Alstom P/N 36593-022-00

Commercially available

Wrench, 9/16” Open End General use

Wrench, 5/8” Open End Switch Adjusting, Detector

Rods

Wrench, 7/8” and 3/4”

Double Open End

Wrench, 1” Open End

Wrench, 1 1/16” Single

End

For removing Motor and

Gear Bracket, Lock and

Detector Rods

Commercially available

Alstom P/N 43576-005-00

Switch Adjusting, Lock Rod Commercially available

Switch Adjusting Alstom P/N 36593-008-00

Alstom P/N 36593-007-00 Wrench, 1 1/4” Single End Throw Rod and Switch

Adjusting

Wrench, 1 5/8” Single End Switch Adjusting

Wrench, 2” Single End Switch Adjusting

Wrench, Insulated socket For No. 14 AAR terminal post nuts

Wrench, for No. 10 Nuts No. 10 Terminal Nuts

Coupling Throw Bar

Test Bar

Oil Alstom 91A0007

3M Scotch-Grip Rubber

And Gasket Adhesive 847

Cover gasket adhesive

Alstom P/N 36593-006-00

Alstom P/N 36593-005-00

Alstom P/N 15194-010-02

Commercially available

Alstom P/N 51153-001-00

Alstom P/N 59515-001-00

Alstom P/N 51347-006-03

Commercially available

P1293, Rev. Oct/12 6–3 Alstom Signaling Inc.

Corrective Maintenance

6.4. REPAIR AND REBUILD

The replacement procedures provided in this section are summarized in Tables 6–2 through 6–5. The tables indicate where to find the disassembly and assembly steps for each listed component, which steps are specific to the component and where to find the associated adjustment procedure, if required.

The biased-neutral controller is a component of the Model 5G and 5H Switch Machines only. A replacement procedure for the controller is provided in Table 6–11.

The cleaning, lubrication and testing procedures that should follow any switch machine repair or rebuild are listed in Table 6–6.

P1293, Rev. Oct/12 6–4 Alstom Signaling Inc.

Corrective Maintenance

Table 6–2. Switch Machine Component Removal and Replacement

Piece Part/Unit

Arm (Clips)

Bearing, Throw Bar

Bracket, Main Gear

Cable, Harness

Cam Bar

Clutch

Contact Group

Cover, Contact

Compartment

Cover, Gear Compartment

Frame, Contact

Frame, Gear

Gasket(s) & Cover(s)

Gear, Intermediate

Gear, Main

Guard (s) (Lock & Detector

Rod

Guard, Throw Bar

Hand Throw Cutout Switch

Block

Hasp, Complete

Heater, Complete

Motor, 110 VDC

Movement, Complete

Rod(s), Lock

Rod(s), Point Detector

Shaft, Pinion

Switch, Cutout

Disassembly

Step(s) from

Table 6–7

35-36

13-15

16-18

Assembly

Step (s) from

Table 6–7

57-58

55-56

63-66

Mechanical Test

Procedure Location (if required)

Table 4–18

22-23

5-6

22-23

11-12

1-2

19-21

27-33

29-33

11-14

55-56

68-69

53-54

59-62

Table 6–3

Table 4–13

Table 4–14

Table 4–23

P1293, Rev. Oct/12 6–5 Alstom Signaling Inc.

Corrective Maintenance

Table 6–2. Switch Machine Component Removal and Replacement (Cont.)

Piece Part/Unit Disassembly

Step(s) from

Table 6–7

27-28

29-30

Assembly

Step (s) from

Table 6–7

49-50

51-52

Adjustment or

Inspection Procedure

Location (if required)

Throw Bar

Wear Plate, Lock Rod

Wear Plate, Point Detector

Rod

Table 6–3. Switch Machine Motor Disassembly and Assembly

Table 4–11

Piece Part/Unit

Armature, Complete

Bearing, Ball(Armature)

Brush, Complete

Brush Holder, Complete

Case, Armature

Case, Motor

Coil, Complete

Cone

Cover, Complete

Detent, Complete

Hasp, Complete

Magnet, Complete

Pinion, Bevel

Pole Piece, Complete

Heater, Complete

Spacer (s)

Washer, Wave

Disassembly

Step(s) from

Table 6–8

13 - 16

9-12

17 & 18

1 - 19

1-5

2-4

5 & 6

3, 4, 14

19 & 20

7 & 8

Assembly

Step (s) from

Table 6–8

30 & 31

21 - 27

37 & 38

28, 29, 37

33 & 34

Adjustment or

Inspection Procedure

Location (if required)

Table 4–10

Table 4–26

P1293, Rev. Oct/12 6–6 Alstom Signaling Inc.

Corrective Maintenance

Piece Part/Unit Disassembly

Step(s) from

Table 6–9

2 & 3

1-2

Assembly

Step (s) from

Table 6–9

Adjustment or

Inspection Procedure

Location (if required)

Body, Clutch

Disk(s)

Gear

Nut

Spring

Washer

Table 6–5. Point Detector Contact Disassembly and Assembly

Piece Part/Unit

Adjusting Screw

Arm, Complete

Finger, H-shaped

Block (Insulator)

Contact, Movable

Spring, U-shaped

Stop, Contact

Terminal Post, Comp

Washer, (Retaining

Bracket)

Table 6–4. Friction Clutch Disassembly and Assembly

Finger, Adjusting

Finger, Contact Comp.

Disassembly

Step(s) from

Table 6–10

Assembly

Step (s) from

Table 6–10

Adjustment or

Inspection Procedure

Location (if required)

Tables 4–15 through

4–18, by contact type

Tables 4–15 through

4–18, by contact type

Tables 4–15 through

4–18, by contact type

Tables 4–15 through

4–18, by contact type

P1293, Rev. Oct/12 6–7 Alstom Signaling Inc.

Corrective Maintenance

Table 6–6. Cleaning, Lubrication, and Testing Procedures For Use After

Repair or Rebuild

Component Component

Detent Cleaning

Brush Holder

Armature

Motor Hasp

Motor Stator

Motor Heater

Throw Bar Bearing

Throw Bar Guard

Contact and Gear

Compartment Cover

Cover Hasp

Lock and Point Detector

Rod Guards

Lock Rod Wear Plate

Point Detector Rod Wear

Plate

Cutout Switch

Main Gear Bracket

Clutch

Table 6–24

Table 6–25

Table 6–26

Table 6–27

Table 6–28

Procedure

Location

Table 6–13

Table 6–14

Table 6–15

Table 6–16

Table 6–17

Table 6–18

Table 6–19

Table 6–20

Table 6–21

Table 6–22

Table 6–23

Intermediate Gear

Main Gear

Table 6–29

Table 6–30

Rectifier

Heater

Point Detector Contact

Group

Contact Movement

Insulation Block

Arm (Clips)

Lock Rod

Point Detector Rod

Throw Bar

Contact Frame

Gear Frame

Main Bed Frame

Cam Bar

Cable Harness

Conduit Coupling

Overall Mechanical Test

Procedure

Overall Electrical Test

Procedure

Procedure

Location

Table 6–31

Table 6–32

Table 6–33

Table 6–34

Table 6–35

Table 6–36

Table 6–37

Table 6–38

Table 6–39

Table 6–40

Table 6–41

Table 6–42

Table 6–43

Table 6–44

Table 6–45

Table 6–47

Table 6–48

P1293, Rev. Oct/12 6–8 Alstom Signaling Inc.

Corrective Maintenance

6.5. DISASSEMBLY AND ASSEMBLY

The following disassembly/assembly procedures are provided in an efficient process that ensures proper operation. Keep all hardware separated for facilitated assembly of the switch machine and switch machine components.

The following warnings should be adhered to whenever working on or around switch machines and their layouts.

WARNING

TWO-WAY COMMUNICATION SHOULD BE MAINTAINED BETWEEN

FIELD PERSONNEL AT THE SWITCH MACHINE AND SWITCH

LAYOUT AND THE LOCAL CONTROL PANEL PERSONNEL TO

ENSURE THEY REMAIN IN SYNCHRONIZATION ON TASKS BEING

PERFORMED. FAILURE TO KEEP EACH OTHER INFORMED COULD

RESULT IN SERIOUS INJURY TO FIELD PERSONNEL.

WARNING

DO NOT ATTEMPT TO DISASSEMBLE THE SWITCH MACHINE WITH

ELECTRICAL POWER CONNECTED TO THE MACHINE. THE CRANK

CUTOUT SWITCH DOES NOT DISCONNECT POWER FROM

MACHINE.

WARNING

MANY OF THE SWITCH MACHINE PARTS AND ASSEMBLIES ARE

HEAVY. ENSURE PARTS AND ASSEMBLIES ARE APPROPRIATELY

SUPPORTED WHILE PERFORMING ANY MAINTENANCE

PROCEDURES REQUIRING THEM TO BE LOOSENED OR REMOVED.

FAILURE TO DO SO COULD RESULT IN PERSONNEL INJURY OR

DAMAGE TO PARTS.

P1293, Rev. Oct/12 6–9 Alstom Signaling Inc.

Corrective Maintenance

6.5.1. Switch Machine

To disassemble and assemble the switch machine, perform the following procedure in the sequence provided. Table 6–2 provides references for the disassembly and assembly of specific components.

Table 6–7. Switch Machine Disassembly and Assembly Procedure

Step

Action

Disassembly is covered in steps 1 through 39.

Release the tension on the hasp strap (1).

Remove the strap from the covers.

2 Loosen and remove the dowel screw and washer holding the hasp bracket to the frame.

Remove the bracket.

Remove the gear compartment cover by lifting the cover straight up and off.

Remove the contact compartment cover by lifting the cover straight up and off.

Remove the gasket from the inside cover, using needle nose pliers, if the gasket is deteriorated

Scrape the gasket residue from the groove and apply 3M Scotch-Grip

Rubber And Gasket Adhesive 847 to the groove.

Seat the new gasket properly in the groove. (Make a new gasket by cutting

7-foot lengths from closed cell sponge material.)

P1293, Rev. Oct/12 6–10 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

Remove the two nuts holding the throw bar guard (6).

Remove the guard by pulling the guard straight away from the machine.

Repeat this step for the opposite throw bar guard.

9 Remove the lock and detector rod guard (7) by tapping the guard slightly to the left, unlocking the guard from the two flat head pins.

Lift the guard straight up and off.

Crank the machine to center (midstroke) position. For Models 5F and 5H be sure arrow on washer on end of operating crankshaft is aligned with the centerline of the machine. Remove the cotter pin holding the rod to the crank on the bracket.

Remove the two screws, securing the hand throw cutout switch block to the frame. Remove the cutout switch block and carefully lay over side of switch machine housing.

P1293, Rev. Oct/12 6–11 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

Move the hand throw cutout switch contact arm shorting link to allow the main gear bracket to clear it. If sufficient clearance cannot be attained, remove the locknut and bolt holding the shorting link to the contact arm.

This picture shows the shorting link of Models 5F and 5H.

Remove the screw securing the cable tie to the main gear bracket and remove the cable tie, still retaining the wires.

Remove the two screws, securing the cutout switch block to the frame.

Remove the cutout switch block and carefully lay over same side of switch machine housing as other switch.

This picture shows the cutout switch block of Models 5F and 5H.

15 Loosen and remove the four hex head screws securing the main gear bracket.

Remove the main gear bracket, using caution not to damage the hand throw cutout switch arm.

P1293, Rev. Oct/12 6–12 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

Remove the clutch pinion shaft (15) straight up and out of the clutch body

(16). The pinion shaft is Woodruff-keyed and must be removed to further disassemble. The pinion can be removed axially from shaft.

WARNING

FRICTION DISCS IN OLDER CLUTCHES MAY CONTAIN

ASBESTOS. FOLLOW PROPER ASBESTOS HANDING

PROCEDURES ACCORDING TO LOCAL REGULATIONS.

THE ASBESTOS CONTAMINATION MAY EXTEND TO

NEARBY SURFACES AND GREASE.

P1293, Rev. Oct/12 6–13 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

Remove the intermediate gear shaft and pinion straight up. Slide the intermediate gear (17), in the direction of the motor, off the pinion gear. The gear is keyed to the pinion and can be slid horizontally. The direction of the slot on the pinion side (bottom) of the gear matches the slot of the shaft cross dowel pin (top). Once the gear is clear of the back of the housing, it can be lifted straight up.

18 Lift the clutch body (16) straight up and out of the machine.

P1293, Rev. Oct/12 6–14 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

Remove the two nuts on the locating studs securing the bottom of the motor to the switch machine base.

CAUTION

Before motor removal, disconnect and label all wires from external power terminals or damage to equipment may occur when wires are reconnected.

Remove the two hex head cap screws securing the top of the motor to the gear frame.

P1293, Rev. Oct/12 6–15 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

CAUTION

Switch machine motor is heavy. When removing or replacing motor, be sure to use two people to lift the motor.

Lift the motor complete (18) away from the switch machine frame.

Continue to Step 22 for Models 5E and 5G; skip to Step 23 for Models 5F and 5H.

For Models 5E and 5G

Loosen and remove the two remaining hex head nuts that secure the frame to the base.

Remove the gear frame straight up.

CAUTION

The main gear may drop free when the hex HEAD nut is removed from the bearing stud. To avoid damage, support the main gear while removing the hex head nut.

Remove the hex head nut from the bearing stud. A bent lock washer accompanies the hex head nut. Straighten the locking tab and remove the washer with the nut.

Tap out and remove the main gear assembly from the frame.

Proceed to Step 24.

P1293, Rev. Oct/12 6–16 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

For Models 5F and 5H.

Remove the six dowels that hold gear frame to base.

Remove gear frame with dual control mechanism attached.

Remove main gear and operating crank from gear frame. If dual-control mechanism is to be retimed when the machine is reassembled, simply remove nut and washers from top end of operating crank and pull crank down and out.

To remove gear and crank without having to retime the dual control mechanism when reassembling, proceed as follows: a. Remove hand-throw lever extension. b. Stand gear frame unit on its motor end. c. Place selector lever in the HAND position. Verify hand-throw lever is in a downward position. d. If necessary, rotate main gear and crank until clutch sleeve engages clutch gear. e. Remove nut and washer from top of crankshaft. f. Carefully notice alignment of crank with respect to gear frame. It must be replaced in the same alignment, according to where it meets the main gear. g. Force crank out. Follow it part way through with a tool that just goes through the top bearing. Hold tool in position to prevent clutch gear from unmeshing with idler gear. h. With crank removed, remove main gear.

Remove the nuts (23) holding the two wires (24) to the heater (25), making sure wires are labeled.

Remove the wires and heater complete.

P1293, Rev. Oct/12 6–17 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

Remove the four screws (33) securing the contact group (32) to the frame.

Remove the contact group.

32 33

Loosen and remove the four screws holding the movement complete to the frame.

Remove the movement complete (34).

3 4

T O

FRAME

Remove the two retaining screws holding the top wear plate to the frame.

P1293, Rev. Oct/12 6–18 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

Pull the four-piece wear plate (35) assembly from the frame over the lock rod.

29 Remove the two retaining bolts (36) that secure the top wear plate to frame.

Remove the filler block retaining bolt (37) from the wear plate assembly and machine frame.

30 Pull the four-piece wear plate assembly (38) and filler block from the frame and out over the point detector rod.

P1293, Rev. Oct/12 6–19 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

Remove the four socket head cap screws (39) on the two arms (clips).

Remove the arms (40).

32 Remove the nuts and lugs (41), if present, from the lock rod and point detector rod.

Remove the lock and point detector rods from the switch machine.

Remove the four dowel screws from the base of the frame.

Remove the frame.

P1293, Rev. Oct/12 6–20 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

Bend out the lock tabs on the washers (43) under the mounting screws (44) on the box style throw bar bearing.

Remove the screws and washers.

Repeat for the other bearing.

36 Pull the box-style bearing (45) out of the frame and over the throw bar until removed.

P1293, Rev. Oct/12 6–21 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

Remove the throw bar (46) from the machine by lifting the bar up and out.

38 Slide the cam bar (47) to the left and remove the cam bar complete.

39 Remove the cable harness from the machine.

NOTE

If necessary, remove the conduit coupler from the machine.

P1293, Rev. Oct/12 6–22 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step Action

Assembly is covered in steps 40 through 74.

40 Install the cam bar (47) complete into the machine and slide the bar to the right.

41 Install the throw bar (46) into the machine.

Place the contact frame into position.

Insert and tighten the four dowel screws and nuts on the base of the frame.

Replace the cable harness back onto machine.

Replace the conduit coupler if removed.

P1293, Rev. Oct/12 6–23 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

Place the movement complete (34) into position and tighten the four screws holding the movement complete to the frame.

45 Install the contact group (32) and tighten the four screws (33) holding the contact group to the machine.

Install the lock rods to the machine.

P1293, Rev. Oct/12 6–24 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

Install the point detector rod to machine.

48 Install and tighten the four socket head cap screws (39) on the two arms

(40). Replace screws if the screws lack prevailing torque due to warn out locking patches.

P1293, Rev. Oct/12 6–25 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

Assemble the wear plates (35) around the lock rod, making certain all plates are interlocked.

50 Slide the bearing assembly along the lock rod and into the frame.

Tighten the bearing with the two retaining screws.

51 Assemble the wear plates (38) around the detector rod, making certain all plates are interlocked.

P1293, Rev. Oct/12 6–26 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

Slide the bearing assembly (35) along the detector rod and into the frame.

Tighten the bearing with the two retaining bolts (36).

Secure the filler block the filler block retaining bolt (37) from the wear plate assembly and machine frame.

53 Install the heater complete (25) and wires (24), making sure that the wires are correctly connected.

Tighten the nuts (23) that hold the heater complete.

CAUTION

If wires were not labeled during disassembly, refer to wiring diagram. Incorrect wiring could cause damage to the equipment.

Connect all wires to the point detector.

For Models 5E and 5G continue to Step 55; for Models 5F and 5H skip to

Step 56.

P1293, Rev. Oct/12 6–27 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

Main Gear Assembly For Models 5E and 5G

Install the main gear assembly by driving the bearing stud into the frame.

Install the lock washer and tighten the hex head nut.

Bend the lock washer over one flat side of the hex bend nut.

Apply Permagum or Volcatex to the mating surfaces of the main frame.

Install the gear frame.

Install the six hex head nuts that secure the frame to the base.

Tighten the nuts.

P1293, Rev. Oct/12 6–28 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

Main Gear Assembly For Models 5F and 5H

If the main gear and operating crank are removed and replaced according by following actions a through h listed in Step 23, it should not be necessary to retime the dual control mechanism. Proceed as follows: a. Replace main gear and crank in frame. Be sure to insert crank in same alignment with respect to gear frame as it was before removal. This ensures that the same splines of crank and clutch sleeve are engaged with one another. b. With crank in place, and washers and nut replaced on the end of the crank, place the selector lever to the POWER position and rotate the gears until the crank points straight up. c. See that prick-punch mark on uppermost raised cam surface of clutch sleeve is on centerline of machine. This means that splines are properly engaged. d. Replace gear frame assembly. e. Check alignment of parts. Check that operating crank is in the proper position for throw bar and locking bar. f. Replace and tighten screws finger tight.

If the main gear and crank were removed by simply removing the nut and washers from the top end of the operating crank and pulling the crank out, retiming of the dual control mechanism is required. If retiming is required for any reason, proceed as follows: a. Get the main gear, grease its teeth and bearing surfaces, and place the gear over crank. Insert crank and main gear through bearing on the gear frame. Position gear frame over the base frame and secure. b. Grease sleeve and crank. Position and slide sleeve over crank so that pin marks on both the sleeve and crank are in alignment. c. Position hand throw so that it is perpendicular to the floor (mid-stroke position). Clamp into place with a C-clamp. d. Get the clutch gear, grease teeth and bearing surfaces, and place gear over sleeve such that dog on gear engages the dog on sleeve. (continued on next page)

P1293, Rev. Oct/12 6–29 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

(Cont.)

Action

e. Get the hand throw gear (27 tooth spur gear and 24 tooth bevel gear pinned and keyed together and stud, grease both, and place stud into gear. f. Position the hand throw gear and stud in gear frame so that the “L” or “R” on gear is in alignment with the “L” or “R” on gear comp (P/N 54549-001-

02). “L” is for left hand machine and “R” is for right hand machine. g. Grease bottom of plate and place it on top of gear frame making sure the pin on the side of the stud lines up with groove on plate. Secure with screws and washers. h. Place lock washer and nut over stud and tighten. i. Grease bearing and place over bore in plate. Gently tap it into the bore with hammer. j. Remove C-clamp. k. Check that timing is correct:

NOTE 1

Key slot on top of crank should be in line with throw bar.

Middle of stroke positional accuracy only has to be such that machine is in region when cam bar has stopped moving.

NOTE 2

To ensure accurate final roller position, machine should be hand thrown slowly in order to prevent cam bar / roller separation from impact or momentum. Verify no separation has occurred by pushing cam bar against roller.

1. Hand throw switch machine to approximately middle stroke (see notes 1

& 2).

2. Mark the cam bar at this position relative to the base.

3. Hand throw switch machine to normal: hand throw lever fully resting in latch stand (note 2).

4. Measure the displacement of cam bar. The displacement must be 9/16” or greater.

5. Hand throw switch machine back to approximately middle stroke (notes 1

& 2).

6. Verify the cam bar return to original marked position.

(Continued next page)

P1293, Rev. Oct/12 6–30 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

(Cont.)

Action

7. Hand throw switch machine to reverse: hand throw lever fully resting in latch stand (note 2).

8. Measure the displacement of cam bar. The displacement must be 9/16” or greater.

9. If cam bar displacement from mid-stroke is less than 9/16” in either direction (normal or reverse), the throw bar can possibly be back driven by the force from the point. The point should be immediately clamped closed and the switch machine should be inspected for wear, damage, or improper timing.

Install the box-style bearing (45) over the throw bar and into the frame.

Tighten the bearing with the two screws and washers.

58 Bend the lock tabs (one tab down, one tab up) on the washers (43) over one flat side of the mounting screws (44).

P1293, Rev. Oct/12 6–31 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

Align motor complete (18) with the switch machine frame.

60 Tighten the two hex head cap screws securing the top of the motor to the gear frame.

61 Tighten the two nuts on the locating studs securing the bottom of the motor to the switch machine base.

P1293, Rev. Oct/12 6–32 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

CAUTION

If wires were not labeled during disassembly, refer to wiring diagram. Incorrect wiring could cause damage to the equipment.

Connect all wires to the motor and heater power terminals, if used

63 Install the clutch (16), without the pinion and shaft, straight down into the switch machine.

P1293, Rev. Oct/12 6–33 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

Install the intermediate gear (17) into the switch machine in the reverse steps used to remove it. Insert the pinion shaft into the intermediate gear and align the dowel pin in the gear slot.

65 Install the clutch pinion shaft (15) straight down into the clutch body (16).

Install the gear bracket and tighten the four hex head screws and washers.

Install the cutout switch block.

Tighten the two screws that hold the block to the frame.

Install the hand throw cutout switch block and secure with the two screws.

Reassemble the hand throw cutout switch arm contacts, if they were removed and tighten the locknut on the bolt.

P1293, Rev. Oct/12 6–34 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

Install the lock and detector rod guards (7) by tapping the guard slightly to the right, locking the guard in place.

71 Install the throw bar guards (6), by placing the guards into position and tightening the two nuts for each guard.

72 Install both the gear and contact compartment covers onto the switch machine.

P1293, Rev. Oct/12 6–35 Alstom Signaling Inc.

Corrective Maintenance

Table 6–7. Switch Machine Disassembly and Assembly Procedure (Cont.)

Step

Action

Install the dowel screw (2) and apply tension to the hasp strap (1) securing the hasp to the switch machine.

74 Reapply power to the switch machine and perform the Mechanical Test in

Table 6–47 and the Electrical Test in Table 6–48.

P1293, Rev. Oct/12 6–36 Alstom Signaling Inc.

Corrective Maintenance

6.5.2. Motor

Table 6–8. Motor Disassembly and Assembly Procedure

Step

Action

Remove the roll pin, bevel pinion gear, and the Woodruff key from the motor armature shaft.

2 Remove the four bolts securing the motor detent cover (1) to the motor frame.

3 Remove the cover (1) and magnet assembly (2) from the motor frame.

P1293, Rev. Oct/12 6–37 Alstom Signaling Inc.

Corrective Maintenance

Table 6–8. Motor Disassembly and Assembly Procedure (Cont.)

Step

Action

Only if the magnet must be replaced, remove the three nuts holding the magnet to the cover. Remove the fixed magnet.

5 Release the tension on the motor cover strap (3). Remove the motor cover

(4).

6 Remove the hasp (5), if damaged, by drilling out the roll pin (6).

P1293, Rev. Oct/12 6–38 Alstom Signaling Inc.

Corrective Maintenance

Table 6–8. Motor Disassembly and Assembly Procedure (Cont.)

Step

Action

If present, remove and label the two wires (7) on the heater complete (8).

8 Remove the two nuts (9) securing the heater to the motor housing. Remove heater (8).

P1293, Rev. Oct/12 6–39 Alstom Signaling Inc.

Corrective Maintenance

Table 6–8. Motor Disassembly and Assembly Procedure (Cont.)

Step

Action

Remove wires on terminal posts 1 though 6 with a terminal wrench. Be sure to label wires.

10 Pull back on the pusher arm (10) to obtain access to the brush.

11 Gently pull the brush (11) out of the brush holder (12), using the attached wire (13).

12 Remove the brush from the other side of the brush holder.

P1293, Rev. Oct/12 6–40 Alstom Signaling Inc.

Corrective Maintenance

Table 6–8. Motor Disassembly and Assembly Procedure (Cont.)

Step

Action

Remove the hex head screw (14) securing the armature to the motor housing.

Hold the armature from rotating.

Avoid side load on the armature, which might bend the shaft.

14 Remove the cone (15), spacer (16), magnet (17), spacer (18), and wave washer.

P1293, Rev. Oct/12 6–41 Alstom Signaling Inc.

Corrective Maintenance

Table 6–8. Motor Disassembly and Assembly Procedure (Cont.)

Step

Action

Remove the four hex head screws (19) holding the armature case (20) to the motor case (21).

Remove the armature case.

Remove the ball bearing assembly and wavy washer.

16 Remove the armature complete from the case.

Remove the bearing from shaft.

P1293, Rev. Oct/12 6–42 Alstom Signaling Inc.

Corrective Maintenance

Table 6–8. Motor Disassembly and Assembly Procedure (Cont.)

Step

Action

Remove the two nuts and washers holding the brush holder complete to the frame.

Remove the brush holder complete (22).

NUTS AND

WASHERS

Remove the four screws (23) and washers (24) holding the block complete

(25) to the brush holder (22).

Remove the holder from the block. There are four spacers between the holder and the block.

P1293, Rev. Oct/12 6–43 Alstom Signaling Inc.

Corrective Maintenance

Table 6–8. Motor Disassembly and Assembly Procedure (Cont.)

Step

Action

Remove the eight hex head screws (26) and washers holding the pole pieces to the case.

20 Remove the four coils and pole pieces (27) as a unit. The coils and pole pieces are joined by solid (very stiff) wires.

P1293, Rev. Oct/12 6–44 Alstom Signaling Inc.

Corrective Maintenance

Table 6–8. Motor Disassembly and Assembly Procedure (Cont.)

Step

Action

Install the four coils and pole pieces (27) as a unit. Tighten the eight hex head screws and washers that secure the coils and pole pieces.

22 Install and tighten the four screws (23) and washers (24) which hold the block complete (25) to the brush holder (22). Remember to place the four spacers into position between the holder and block.

P1293, Rev. Oct/12 6–45 Alstom Signaling Inc.

Corrective Maintenance

Table 6–8. Motor Disassembly and Assembly Procedure (Cont.)

Step

Action

Position and tighten the two nuts with washers that hold the brush holder

(22) to the frame.

NUTS AND

WASHERS

Install the bearing and armature complete into the motor case.

25 Install the ball bearing assembly (29) and wave washer (30) to the armature shaft.

P1293, Rev. Oct/12 6–46 Alstom Signaling Inc.

Corrective Maintenance

Table 6–8. Motor Disassembly and Assembly Procedure (Cont.)

Step

Action

Apply Permagum or Volcatex to the radial surfaces between the motor case

(21) and the armature housing (20), leaving one inch untreated at the bottom of the case for drainage.

Assemble the motor case (21) with the bearing and wave washer to the armature housing (20). Secure with four hex head screws (19).

Install the spacer (18), magnet (17), spacer (16), and cone (15) to armature the shaft.

P1293, Rev. Oct/12 6–47 Alstom Signaling Inc.

Corrective Maintenance

Table 6–8. Motor Disassembly and Assembly Procedure (Cont.)

Step

Action

Secure the magnet and associated hardware to the armature with a hex head screw (14) and lock washer.

30 Pull back on the pusher arm (10). Place the brush (11) into position inside the brush holder (12) by using the attached wire (13). Insert the brushes so that beveled surfaces ride flat on the commutator.

P1293, Rev. Oct/12 6–48 Alstom Signaling Inc.

Corrective Maintenance

Table 6–8. Motor Disassembly and Assembly Procedure (Cont.)

Step

Action

CAUTION

Make sure the correct wires are connected to each terminal post or damage to equipment may occur. IF wires were not

LABELED during disassembly, refer to wiring diagram.

Connect the brush wire to the correct terminal on terminal block.

Connect all wires to the correct terminal posts 1 through 6.

If used, install the heater (8) by tightening the two nuts (9) which hold the heater to the motor housing.

P1293, Rev. Oct/12 6–49 Alstom Signaling Inc.

Corrective Maintenance

Table 6–8. Motor Disassembly and Assembly Procedure (Cont.)

Step

Action

Connect the two wires (7) to heater (8).

35 Install the motor hasp (5), if removed, by tapping the roll pin (6) into position.

36 Install the motor cover (4) by applying tension to the motor cover strap (3).

P1293, Rev. Oct/12 6–50 Alstom Signaling Inc.

Corrective Maintenance

Table 6–8. Motor Disassembly and Assembly Procedure (Cont.)

Step

Action

If previously removed, install the magnet to the detent cover. Tighten the three nuts that hold the magnet in place.

38 Apply Permagum or Volcatex to the radial surfaces between the cover (1) and the housing, leaving one inch untreated at the bottom for drainage.

Place the motor detent cover (1) into position. Secure the cover to the motor frame by tightening the four bolts, tighten the two diagonal bolts first, and then tighten the remaining two bolts.

P1293, Rev. Oct/12 6–51 Alstom Signaling Inc.

Corrective Maintenance

Table 6–8. Motor Disassembly and Assembly Procedure (Cont.)

Step

Action

Install the beveled pinion gear with the Woodruff key and secure with the roll pin.

40 Reapply power to the switch machine.

P1293, Rev. Oct/12 6–52 Alstom Signaling Inc.

Corrective Maintenance

6.5.3. Clutch

Table 6–9. Clutch Disassembly and Assembly Procedure

Step

Action

Loosen and remove the jam nut (1) and screw (2). Loosen and remove the nut (3) securing the spring (4) and washer (5) in the clutch case. Remove the spring and washer.

Verify that the free spring length is 2 1/6 to 2 3/16 inches.

Verify that the spring pressure is 238 to 242 pounds at the minimum working length of 1 1/2 inches. Coils are not to touch at the minimum working length.

WARNING

FRICTION DISCS IN OLDER CLUTCHES MAY CONTAIN

ASBESTOS. FOLLOW PROPER ASBESTOS HANDING

PROCEDURES ACCORDING TO LOCAL REGULATIONS.

THE ASBESTOS CONTAMINATION MAY EXTEND TO

NEARBY SURFACES AND GREASE.

Loosen and remove the six hex head cap screws (6) and washers that hold the gear (7).

Remove the gear.

P1293, Rev. Oct/12 6–53 Alstom Signaling Inc.

Corrective Maintenance

Table 6–9. Clutch Disassembly and Assembly Procedure (Cont.)

Step

Action

Remove the 12 disks (8) from the clutch body (9). Notice sequence of discs in clutch while removing discs.

Install the12 replacement disks (8) in the clutch body (9).

Refer to the parts list for the correct order of disk insertion.

Install and tighten the six hex head cap screws (6) and washers that secure the gear (7) onto the clutch.

6 Referring to the figure in step 1, install the washer (5), spring (4), and nut

(3).

Install the screw (2) with the jam nut (1).

Tighten the jam nut (1).

P1293, Rev. Oct/12 6–54 Alstom Signaling Inc.

Corrective Maintenance

6.5.4. Point Detector Contact

Table 6–10. Point Detector Contact Disassembly and Assembly Procedure

Step

Action

Remove the two retaining screws (22 and 23) and their washers holding the contact stop (18) and U-spring (20) to the contact block on the normal and reverse contacts. Remove the U-spring.

MOTOR

CONTROL

CONTACTS

NORMAL AND

REVERSE

CONTACTS

SHUNT

CONTACTS

NORMAL AND

REVERSE

CONTACTS

1 2 3 4 5 6 7 8

A-FOR MODELS 5E AND 5F SWITCH

MACHINES

MOTOR

CONTROL

CONTACTS

NORMAL AND

REVERSE

CONTACTS

SHUNT

CONTACTS

1 2

4 5 6

B-FOR MODELS 5G AND 5H SWITCH

MACHINES

P1293, Rev. Oct/12 6–55 Alstom Signaling Inc.

Corrective Maintenance

Table 6–10. Point Detector Contact Disassembly and Assembly Procedure (Cont.)

Step

Action

Remove the adjusting screw (31) with its washer, and adjuster (32), retaining washer (30) on the motor control and shunt contacts.

Remove the contact finger complete (28) from the motor control and shunt contacts.

Remove screw (16) and washer (17). Remove terminal post complete (33).

Remove the three H-shaped contact fingers (19) by removing the two screws (21) and their washers holding each contact finger to the rocker block.

Remove the two retaining screws (22 and 23) and their washers holding the finger complete (27) assembly to the contact block on the motor control and shunt contacts. Remove the movable contact.

Remove the two screws (21) and their washers holding the arm complete

(29) to rocker block. Remove the arm.

Remove the screws (3) and washers (2) holding the block (1) (insulator) to frame and remove the block.

Install the block (1) (insulator) to frame and secure with screws (2) and washers (3).

Install the arm complete (29) to rocker block securing with screws (21) and their washers.

Install the moveable contact on the motor control and shunt contact and then install the finger complete (27) assembly to the contact block by tightening the screws (22 and 23) and their washers.

Install the three H-shaped contact fingers (19). Tighten the two screws (21) and their washers to the rocker block for each finger.

Install the terminal post complete (33) onto terminal block (1). Tighten the screw (16) and washer (17).

Install the contact finger complete (28) to motor control and shunt contacts, securing the finger with the retaining washer (30), adjuster (32), and adjusting screw (31) and its washer.

Perform the contact gap and pressure adjustments after installing the contact. See tables 4–15, 4–17 and 4–18.

Install the contact stop (18) and U-spring (20) on the contact block for the normal and reverse contacts. Tighten the two screws (22 and 23) and their washer that holds the stop and spring. Perform contact gap and pressure adjustments after installing the contact. See Table 4–16.

P1293, Rev. Oct/12 6–56 Alstom Signaling Inc.

Corrective Maintenance

6.5.5. Biased-Neutral Controller

Table 6–11. Biased-Neutral Controller Replacement Procedure

Step

Action

Open disconnect switch on terminal board.

Remove elastic stop nuts from studs.

Lift out controller case with wiring attached.

Disconnect wiring. Wires are made up in a cable and can be removed from one controller and replaced on the other in a group, without error.

To position the new controller in the switch machine, place the switch machine in its unlocked position. The bottom of the controller should just clear the lock dog.

The controller should be free to move in any direction to allow for vibration, but it must not touch other parts of the machine, except through the resilient mounting springs. After the controller is installed, and periodically thereafter, check it as follows:

Make sure wires are arranged to allow free movement of controller.

Make sure stop nuts are tight.

Operate machine to its fully unlocked position and check that controller case does not touch dog on locking bar.

P1293, Rev. Oct/12 6–57 Alstom Signaling Inc.

Corrective Maintenance

6.6. COMPLETE CLEANING AND LUBRICATION

Complete cleaning and lubrication of the switch machine is advised when the machine is placed into line service or is repaired or rebuilt. This section describes the cleaning and lubrication procedures associated with proper operation of the switch machine.

Table 6–12 indicates the recommended parts to be cleaned and lubricated and provides associated procedural page numbers.

1. Motor, Complete a. Detent b. Brush Holder c. Armature d. Motor Hasp e. Motor Stator f. Motor Heater

2. Throw Bar Bearing

3. Throw Bar Guard

4. Contact and Gear Compartment Covers

5. Cover Hasp

6. Lock and Point Detector Rod Guards

7. Lock Rod Wear Plate

8. Point Detector Rod Wear Plate

9. Cutout Switch

10. Main Gear Bracket

11. Clutch

12. Intermediate Gear

13. Main Gear

14. Rectifier

15. Heater

Table 6–12. Cleaning and Lubrication Index

Switch Machine Part Maintenance Action

Clean

YES

Lubricate

YES

Table

6–23

6–24

6–25

6–26

6–27

6–28

6–29

6–30

6–31

6–32

6–13

6–14

6–15

6–16

6–17

6–18

6–19

6–20

6–21

6–22

P1293, Rev. Oct/12 6–58 Alstom Signaling Inc.

Corrective Maintenance

Table 6–12. Cleaning and Lubrication Index (Cont.)

Switch Machine Part Maintenance Action Table

16. Point Detector a. Contact Group b. Contact Movement c. Insulation Block

17. Arm (Clips)

18. Lock Rod

19. Point Detector Rod

20. Throw Bar

21. Contact Frame

22. Gear Frame

23. Main Bed Frame

24. Cam Bar

25. Cable Harness

26. Conduit Coupling

Clean

YES

Lubricate

YES

6–33

6–34

6–35

6–36

6–37

6–38

6–39

6–40

6–41

6–42

6–43

6–44

6–45

The following procedures are separated according to individual parts of switch machine.

NOTE

When lubricating switch machine parts, always wipe off excess grease and oil. Keep grease and oil away from all electrical contacts and wire.

WARNING

DO NOT CLEAN OR LUBRICATE MACHINE WHILE ELECTRICAL

POWER IS CONNECTED TO PREVENT POTENTIAL PERSONAL

INJURY OR EQUIPMENT DAMAGE

P1293, Rev. Oct/12 6–59 Alstom Signaling Inc.

Corrective Maintenance

6.6.1. Detent Cleaning

Table 6–13. Detent Cleaning Procedures

Step

Action

NOTE

For detent disassembly and reassembly, see Table 6–8.

Clean detent (1) completely by using a lint free cloth dampened with an approved cleaning solvent.

Wipe detent dry.

P1293, Rev. Oct/12 6–60 Alstom Signaling Inc.

Corrective Maintenance

6.6.2. Brush Holder

Table 6–14. Brush Holder Maintenance Procedure

Step

Action

NOTE

For brush holder disassembly and reassembly, see Table 6–8.

Clean brush holder (1) of any dirt or grease by using a lint free cloth with an approved cleaning solvent applied.

Dry completely after cleaning.

Blow out any dust that has accumulated on brush holder.

Use one to three drops of light oil to lubricate the brush holder arm pivot pins (2).

Do not allow any oil to drip onto the commutator.

P1293, Rev. Oct/12 6–61 Alstom Signaling Inc.

Corrective Maintenance

6.6.3. Armature

Table 6–15. Armature Maintenance Procedure

Step

Action

NOTE

For armature disassembly and reassembly, see Table 6–8.

Use a lint-free cloth dampened with approved cleaning solvent to clean armature complete (1). Armature Complete includes armature rotor and commutator.

Wipe dry.

CAUTION

USE ONLY A NON-CONDUCTIVE POLISHING MATERIAL

ON COMMUTATOR TO PREVENT COMMUTATOR FROM

BECOMING SHORTED.

Wipe commutator with a damp cloth to obtain a shiny surface. If unable to produce shiny surface with a damp cloth, polish commutator (2) with 7-0

Garnet paper (3) until surface becomes shiny and coffee colored.

P1293, Rev. Oct/12 6–62 Alstom Signaling Inc.

Corrective Maintenance

6.6.4. Motor Hasp

Table 6–16. Motor Hasp Maintenance Procedures

Step

Action

NOTE

For motor hasp disassembly and reassembly, see

Table 6–8.

Clean hasp (1) of all grease, oil or dirt by using a lint-free cloth dampened with an approved cleaning solvent.

2 Apply a film of light oil on hasp link pins (2) to prevent rusting.

P1293, Rev. Oct/12 6–63 Alstom Signaling Inc.

Corrective Maintenance

6.6.5. Motor Stator

Table 6–17. Motor Stator Maintenance Procedure

Step

Action

NOTE

For motor stator disassembly and reassembly, see

Table 6–8.

Clean stator (1) of all grease, dirt, or oil by using a lint free cloth dampened with an approved cleaning solvent. Make sure all surfaces are dry after cleaning stator.

2 Blow out any dust present in stator.

P1293, Rev. Oct/12 6–64 Alstom Signaling Inc.

Corrective Maintenance

6.6.6. Motor Heater

Table 6–18. Motor Heater Maintenance Procedure

Step

Action

NOTE

For motor heater disassembly and reassembly, see

Table 6–7.

Clean heater assembly (1) using a clean cloth.

Wipe off dust and dirt. If necessary, a damp cloth may be used to clean the heater.

P1293, Rev. Oct/12 6–65 Alstom Signaling Inc.

Corrective Maintenance

6.6.7. Throw Bar Bearing

Table 6–19. Throw Bar Bearing Maintenance Procedure

Step

Action

NOTE

For throw bar bearing disassembly and reassembly, see Table

6–7.

Clean throw bar bearing (1) of any dirt, grease, or oil by using an approved cleaning solvent. Replace if excessive wear is evident.

2 Install throw bar bearing. Use grease to lubricate all surfaces affected by throw bar sliding action.

P1293, Rev. Oct/12 6–66 Alstom Signaling Inc.

Corrective Maintenance

6.6.8. Throw Bar Guard

Table 6–20. Throw Bar Guard Maintenance Procedure

Step

Action

NOTE

For throw bar guard disassembly and reassembly, see

Table 6–7.

Clean throw bar guard of all grease, oil, dirt, etc., by using an approved cleaning solvent.

6.6.9. Contact and Gear Compartment Cover

Table 6–21. Contact and Gear Compartment Cover Maintenance Procedure

Step

Action

NOTE

For contact and gear compartment cover disassembly and reassembly, see Table 6–7.

Clean cover of dust, grease, or oil by using an approved cleaning solvent.

P1293, Rev. Oct/12 6–67 Alstom Signaling Inc.

Corrective Maintenance

6.6.10. Cover Hasp

Table 6–22. Cover Hasp Maintenance Procedure

Step

Action

NOTE

For cover hasp disassembly and reassembly, see Table

6–7.

Clean hasp of all grease, dirt, and oil with an approved cleaning solvent and cloth.

Use oil to lubricate all link pins on hasp complete. Do not use an excessive amount of oil.

6.6.11. Lock and Point Detector Rod Guards

Table 6–23. Lock and Point Detector Rod Guards Maintenance Procedure

Step

Action

NOTE

For lock and point detector rod guard disassembly and reassembly, see Table 6–7.

Clean guards of all grease, dirt, oil, etc., by using an approved cleaning solvent.

P1293, Rev. Oct/12 6–68 Alstom Signaling Inc.

Corrective Maintenance

6.6.12. Lock Rod Wear Plate

Table 6–24. Lock Rod Wear Plate Maintenance Procedure

Step

Action

NOTE

For lock rod wear plate disassembly and reassembly, see

Table 6–7.

Clean lock rod wear plates of any dirt, grease, or oil by using an approved cleaning solvent.

Replace if excessive wear is evident.

2 Install lock rod wear plates using grease to lubricate all surfaces affected by lock rod sliding action.

P1293, Rev. Oct/12 6–69 Alstom Signaling Inc.

Corrective Maintenance

6.6.13. Point Detector Rod Wear Plate

Table 6–25. Point Detector Rod Wear Plate Maintenance Procedure

Step

Action

NOTE

For point detector rod wear plate disassembly and reassembly, see Table 6–7.

Clean point detector rod wear plates of any dirt, grease, or oil by using approved cleaning solvent.

Replace if excessive wear is evident.

2 Install point detector rod wear plates, using grease to lubricate all surfaces affected by point detector rod sliding action.

P1293, Rev. Oct/12 6–70 Alstom Signaling Inc.

Corrective Maintenance

6.6.14. Cutout Switch

Table 6–26. Cutout Switch Maintenance Procedure

Step

Action

NOTE

For cutout switch disassembly and reassembly, see

Table 6–7.

Wipe all contacts of cutout switch with a clean cloth.

6.6.15. Main Gear Bracket

Table 6–27. Main Gear Bracket Maintenance Procedure

Step

Action

NOTE

For main gear bracket disassembly and reassembly, see

Table 6–7 (Model 5F and 5H detail).

Remove and clean main gear bracket of any grease, dirt, oil, etc., by using an approved cleaning solvent.

2 Re-install main gear bracket and tighten four retaining bolts.

P1293, Rev. Oct/12 6–71 Alstom Signaling Inc.

Corrective Maintenance

6.6.16. Clutch

Table 6–28. Clutch Maintenance Procedure

Step

Action

NOTE

For clutch disassembly and reassembly, see Table 6–7.

Clean all parts of the clutch, with the exception of the clutch friction disks, by using an approved cleaning solvent. The clutch pads are to be clean using a dry cloth only.

WARNING

FRICTION DISCS IN OLDER CLUTCHES MAY CONTAIN

ASBESTOS. FOLLOW PROPER ASBESTOS HANDING

PROCEDURES ACCORDING TO LOCAL REGULATIONS.

THE ASBESTOS CONTAMINATION MAY EXTEND TO

NEARBY SURFACES AND GREASE.

Replace bearing (1) and pinion shaft (2) and lubricate with grease. Do not use an excessive amount of grease. Do not allow grease to contact the clutch pad surfaces, as this causes unwanted slippage.

P1293, Rev. Oct/12 6–72 Alstom Signaling Inc.

Corrective Maintenance

6.6.17. Intermediate Gear

Table 6–29. Intermediate Gear Maintenance Procedure

Step

Action

NOTE

For intermediate gear disassembly and reassembly, see Table

6–7.

Clean intermediate gear and pinion of any dirt, grease, or oil by using an approved cleaning solvent. Do not soak intermediate gear or pinion in solvent.

2 Force grease through intermediate gear grease fitting. See Table 4–5. Do not use excessive amount of grease.

P1293, Rev. Oct/12 6–73 Alstom Signaling Inc.

Corrective Maintenance

6.6.18. Main Gear

Table 6–30. Main Gear Maintenance Procedure

Step

Action

NOTE

For main gear disassembly and reassembly, see

Table 6–7.

Clean the main gear of grease, oil, and dirt by using a cloth dampened with an approved cleaning solvent. Do not soak the main gear bearing in cleaning solvent.

For Models 5E and 5G, apply grease to roller through fitting on main gear and this procedure is complete.

For Models 5F and 5H, which are equipped with three tubes that require lubrication, complete Step 2.

The Model 5F and 5H throw-bar and locking-bar roller (9), hand-throw clutch sleeve (10), and surface between the crankshaft and main gear (22) are lubricated through three tubes, see Figure 4–2. One open tube with a grease fitting is used to lubricate the roller. The long closed tube with the grease fitting is used to lubricate the surface between the crankshaft and the main gear. The short closed tube is used to lubricate the hand-throw clutch gear and the clutch sleeve.

Do not use an excessive amount of grease.

To use these tubes, proceed as follows: a. Remove short closed tube from crankshaft. b. Insert open tube into crankshaft. Force grease through tube to lubricate roller. Remove tube and clip it inside of the gear compartment cover. c. Insert long closed tube into crankshaft. Force grease through tube to lubricate crankshaft and main gear surfaces. Remove tube and clip it to the inside of gear compartment cover. d. Insert short closed tube into crankshaft. Before forcing grease into tube, put selector lever in HAND position and operate hand-throw lever to move switch points. This action ensures that the sliding clutch sleeve is fully engaged in the HAND position and lubrication occurs as intended. Force grease into tube to lubricate parts. Leave tube in crankshaft to seal out dirt.

P1293, Rev. Oct/12 6–74 Alstom Signaling Inc.

Corrective Maintenance

6.6.19. Rectifier

Table 6–31. Rectifier Maintenance Procedure

Step

Action

Remove the rectifier from the switch machine:

For Model 5E and 5F Switch Machines the rectifier is located in the contact compartment. See Figure 7–1 reference 5 and Figure 7–3 reference 29.

For Model 5G and 5H Switch Machines the rectifier is located on the biasedneutral controller. See Figure 7–13 reference 19

Clean the rectifier with a clean cloth, wiping off dust and dirt. If necessary, a damp cloth can be used to clean the rectifier.

Reinstall the biased-neutral controller.

P1293, Rev. Oct/12 6–75 Alstom Signaling Inc.

Corrective Maintenance

6.6.20. Heater

Table 6–32. Heater Maintenance Procedure

Step

Action

NOTE

For heater disassembly and reassembly, see Table 6–7.

Clean the heater (1) with a clean cloth, wiping off dust and dirt. If necessary, a damp cloth may be used to clean the heater.

2 Reinstall the heater.

P1293, Rev. Oct/12 6–76 Alstom Signaling Inc.

Corrective Maintenance

6.6.21. Point Detector Contact Group

Table 6–33. Point Detector Contact Group Maintenance Procedure

Step

Action

NOTE

For removal of contact group, see Table 6–10.

Wipe dust from all contacts by using a clean cloth. Cleaning solvent should not be needed for the removal of dust from individual contacts.

2 Use light oil to lubricate the motor and shunt contact pivot pins (1). Do not lubricate any other part of the point detector contacts.

P1293, Rev. Oct/12 6–77 Alstom Signaling Inc.

Corrective Maintenance

6.6.22. Contact Movement

Table 6–34. Contact Movement Maintenance Procedure

Step

Action

NOTE

For contact movement disassembly and reassembly, see

Table 6–10.

Clean contact movement of dirt, oil, grease, etc., with an approved cleaning solvent.

Use light oil to lubricate shaft movement (1).

3 Reinstall contact movement and lubricate with grease through the grease fittings on the movement. See Figure 4–2, reference number 14. Do not use excessive grease.

P1293, Rev. Oct/12 6–78 Alstom Signaling Inc.

Corrective Maintenance

6.6.23. Insulation Block

Table 6–35. Insulator Block Maintenance Procedure

Step

Action

NOTE

For insulation block disassembly and reassembly, see

Table 6–10.

Clean contact insulation block (1) of all dirt and oil by using a damp cloth.

P1293, Rev. Oct/12 6–79 Alstom Signaling Inc.

Corrective Maintenance

6.6.24. Arm (Clips)

Table 6–36. Arm Maintenance Procedure

Step

Action

NOTE

For arm disassembly and reassembly, see Table 6–7.

Clean the two arms (clips), removing dirt, grease, and oil by using approved cleaning solvent.

6.6.25. Lock Rod

Table 6–37. Lock Rod Maintenance Procedure

Step

Action

NOTE

For lock rod disassembly and reassembly, see Table 6–7.

Clean the lock rod of all grease, oil, dirt, etc., using an approved cleaning solvent.

2 Use grease to lubricate all sliding surfaces and threads on the lock rod. Do not use excessive grease.

P1293, Rev. Oct/12 6–80 Alstom Signaling Inc.

Corrective Maintenance

6.6.26. Point Detector Rod

Table 6–38. Point Detector Rod Maintenance Procedure

Step

Action

NOTE

For point detector rod disassembly and reassembly, see Table

6–7.

Clean the point detector rod of all grease, oil, dirt, etc., by using an approved cleaning solvent. Observe the condition of the grooves (1) for wear.

2 Use grease to lubricate all sliding surfaces and threads on the point detector rod. Do not use excessive grease.

P1293, Rev. Oct/12 6–81 Alstom Signaling Inc.

Corrective Maintenance

6.6.27. Throw Bar

Table 6–39. Throw Bar Maintenance Procedure

Step

Action

NOTE

For throw bar disassembly and reassembly, see Table 6–7.

Clean the throw bar of all grease, dirt, oil, etc., by using approved cleaning solvent.

2 Use grease to lubricate all sliding and machined surfaces to prevent rusting.

Do not use excessive amounts of grease. Excessive grease is scraped off by the wear plates and deposited in the bottom of the machine.

6.6.28. Contact Frame

Table 6–40. Contact Frame Maintenance Procedure

Step

Action

NOTE

For contact frame disassembly and reassembly, see

Table 6–7.

Remove and clean contact frame off all grease, oil, dirt, etc., with approved cleaning solvent.

Reinstall the frame.

Protect all unfinished machine surfaces with Rust Veto (Alstom spec.

91A0004, Class A).

P1293, Rev. Oct/12 6–82 Alstom Signaling Inc.

Corrective Maintenance

6.6.29. Gear Frame

Table 6–41. Gear Frame Maintenance Procedure

Step

Action

NOTE

For gear frame disassembly and reassembly, see

Table 6–7.

Remove and clean the gear frame of grease, oil, dirt, etc., using an approved cleaning solvent.

2 Lubricate all sliding machined surfaces with all temperature EP grease,

Alstom spec. 91A0012. Do not use excessive grease.

6.6.30. Main Bed Frame

Table 6–42. Main Bed Frame Maintenance Procedure

Step

Action

NOTE

For main bed frame disassembly and reassembly, see Table

6–7.

Remove and clean the main bed frame of grease, oil, and dirt using an approved cleaning solvent.

2 Use all temperature EP grease, Alstom spec. 91A0012, to lubricate all sliding machined frame surfaces. Do not use excessive grease.

P1293, Rev. Oct/12 6–83 Alstom Signaling Inc.

Corrective Maintenance

6.6.31. Cam Bar

Table 6–43. Cam Bar Maintenance Procedure

Step

Action

NOTE

For cam bar disassembly and reassembly, see Table 6–7.

Remove and clean the cam bar of grease, oil, or dirt by using an approved cleaning solvent.

2 Reinstall the cam bar.

Use grease to lubricate all sliding surfaces and threads. Do not use excessive grease.

P1293, Rev. Oct/12 6–84 Alstom Signaling Inc.

Corrective Maintenance

6.6.32. Cable Harness

Table 6–44. Cable Harness Maintenance Procedure

Step

Action

NOTE

For cable harness disassembly and reassembly, see

Table 6–7.

Clean all dust, dirt, and debris from the cable harness (1) by using a damp cloth.

6.6.33. Conduit Coupling

Table 6–45. Conduit Coupling Maintenance Procedure

Step

Action

NOTE

For conduit coupling disassembly and reassembly, see Table

6–7.

Remove any grease, oil, dirt, etc., from the conduit coupling (1) by using an approved cleaning solvent.

Replace the coupling and tighten the two retraining bolts.

P1293, Rev. Oct/12 6–85 Alstom Signaling Inc.

Corrective Maintenance

6.7. SWITCH MACHINE TESTING

Following describes the Mechanical and Electrical Test Procedures associated with the

Alstom Model 5 Series Switch Machine and the Special Equipment required.

Table 6–46. Special Switch Machine Testing Equipment

Special Equipment Required

- AAR socket wrench

- Feeler gauge set

- Push-pull force gauge

- Test bar, Alstom P/N 59571-000-01

- Coupling, Alstom P/N 51153-001-00

- Switch machine power supply, Alstom rectifier P/N 29804-057-00 or equivalent

P1293, Rev. Oct/12 6–86 Alstom Signaling Inc.

Corrective Maintenance

6.7.1. Mechanical Test Procedure

WARNING

VERIFY THAT ELECTRICAL POWER IS COMPLETELY

DISCONNECTED FROM THE SWITCH MACHINE BEFORE

PERFORMING STEPS 1 THROUGH 34 OF THIS TEST PROCEDURE.

Table 6–47. Mechanical Test Procedure

Step

Action

NOTE

It is recommended to test switch machines with the same lock and point detector rods intended to be used while the machine is in service.

Verify that the sides of the cam portion (1) of the throw bar (2) do not strike the side of the main frame (3), at full six inch stroke.

P1293, Rev. Oct/12 6–87 Alstom Signaling Inc.

Corrective Maintenance

Table 6–47. Mechanical Test Procedure (Cont.)

Step

Action

Verify the clearance between the box style wear plates (4) and the throw bar

(2).

Insure that clearance does not exceed 0.030 inch and is not less that 0.003 inch.

Verify that there is less than 0.005 inch clearance between the roller on the main gear and the shaft on which the roller turns.

Verify the clutch shaft (6), intermediate gear (7), and pinion (8) have the correct amount of endplay (less than 3/32 inch).

P1293, Rev. Oct/12 6–88 Alstom Signaling Inc.

Corrective Maintenance

Table 6–47. Mechanical Test Procedure (Cont.)

Step

Action

Verify there is a minimum of 1/32 inch clearance between the moveable arm of the point detector (9) and the cam slot of the cam bar (1). Measure the clearance when the arm is in the vertical position.

6 Verify that there is no unnecessary friction in the movable arm (9) of the point detector by observing the point detector operation.

The movable arm should move without hesitation at the end of each direction of stroke.

P1293, Rev. Oct/12 6–89 Alstom Signaling Inc.

Corrective Maintenance

Table 6–47. Mechanical Test Procedure (Cont.)

Step

Action

Verify that the rollers (10) in the point detector movement rest firmly on the bottom of the point detector rod slots in both near and far positions. If point detector movement does not rest firmly, excessive friction may be present or contact block contact forces may be too great.

8 Verify that the normal and reverse contacts, are fully closed. The distance between the stationary contact (11) and the front stop (12) should be no more than 1/16 inch and no less that 1/32 inch.

9 Verify that the normal and reverse contact pressure force is 2 1/2 to 3 pounds measured at the near point of contact.

P1293, Rev. Oct/12 6–90 Alstom Signaling Inc.

Corrective Maintenance

Table 6–47. Mechanical Test Procedure (Cont.)

Step

Action

Adjust the motor control adjuster (16) on the finger so that the opening is

0.170 inch to 0.200 inch between contact (15) and contact (17) when normal or reverse contacts just make. The finger must rest firmly on the stop.

Crank the machine back toward midstroke until the movable finger just touches the stationary finger.

Verify that the screw (18) is not touching the underside of the finger (17). If the screw does touch, bend the stop up until 0.020 inch clearance exists between the screw and the underside of the finger.

13 Verify that both motor control contacts open between 0.170 inch and 0.200 inch when normal or reverse contacts just make. If not within tolerance, loosen the screw (19) and lift adjuster (16) tip out of the hole.

P1293, Rev. Oct/12 6–91 Alstom Signaling Inc.

Corrective Maintenance

Table 6–47. Mechanical Test Procedure (Cont.)

Step

Action

Move the contact in or out as needed to obtain the correct specification.

Place the adjuster (16) tip in the hole which best corresponds with the specified contact opening and tighten the screw (19). The motor control contact pressure is set by contact opening and coil spring design is not adjustable.

16 Adjust the tip of the movable contact (20) to obtain 1/64 inch to 1/32 inch of contact wipe. Bending the contact tip down increases contact wipe.

17 Verify that the wiring is in a neat and orderly wire harness, arranged so that any moving parts or covers do not damage the wires.

P1293, Rev. Oct/12 6–92 Alstom Signaling Inc.

Corrective Maintenance

Table 6–47. Mechanical Test Procedure (Cont.)

Step

Action

Verify that the wiring (22) is arranged so the wiring does not come into contact with the armature and is clear of the cover. Verify that the wiring is correct by using the appropriate wiring diagram.

19 Verify that the lock (23) and point detector (24) rods move freely in their associated slots.

P1293, Rev. Oct/12 6–93 Alstom Signaling Inc.

Corrective Maintenance

Table 6–47. Mechanical Test Procedure (Cont.)

Step

Action

With the machine locked up, verify that the point detector rod marks (25) line up within 1/64 inch of the frame.

21 Move the point detector rod out until the incline of the rod stops against the roller (10).

22 Verify that the distance between the frame and the machined mark (25 in step 20) on the rod is no more than 1/4 inch.

P1293, Rev. Oct/12 6–94 Alstom Signaling Inc.

Corrective Maintenance

Table 6–47. Mechanical Test Procedure (Cont.)

Step

Action

Operate the machine and move the rod in the opposite direction until the rod incline stops against the roller (10).

24 Verify that the distance between the frame and the machined mark (26) on the rod is no more than 1/4 inch.

25 Lock the machine in one direction and pull the lock rod out of the machine as far as possible. Scribe a mark next to the machined location mark.

P1293, Rev. Oct/12 6–95 Alstom Signaling Inc.

Corrective Maintenance

Table 6–47. Mechanical Test Procedure (Cont.)

Step

Action

Push the rod in as far as it goes and scribe another mark next to the first mark.

Verify that the machined locating notch is at least 1/32 inch from either one of scribed marks.

Check all gears in the gear compartment for any imperfections that could affect performance of the switch machine.

P1293, Rev. Oct/12 6–96 Alstom Signaling Inc.

Corrective Maintenance

Table 6–47. Mechanical Test Procedure (Cont.)

Step

Action

Hand crank the machine, checking for variations in crank force. Verify that all gears run smoothly and that no binding is encountered.

When fitting new brushes, insert No. 00 sandpaper or equivalent (33) between the brush and the commutator. Press the brush against the sandpaper. Move the sandpaper over the brush surface until the curve of the commutator is obtained. The brush must be fitted properly to the commutator before power is applied to the motor. This procedure must be followed whenever a motor brush is replaced.

31 Remove all carbon dust from the assembly by using a lint free cloth (34).

32 Verify that all covers fit tightly to prevent rain and dirt from entering the machine.

P1293, Rev. Oct/12 6–97 Alstom Signaling Inc.

Corrective Maintenance

Table 6–47. Mechanical Test Procedure (Cont.)

Step

Action

Check detent holding torque for pull of 10 pounds on the end of the hand crank.

34 If holding torque needs to be increased, a washer (36) may be added to each of the three mounting screws between the magnets and the cover.

P1293, Rev. Oct/12 6–98 Alstom Signaling Inc.

Corrective Maintenance

6.7.2. Electrical Test Procedure

Perform the following test procedure in the sequence given.

Table 6–48. Electrical Test Procedure

Step

Action

Remove the guards and connect the test bar and coupling to the switch machine throw bar, lock rod and point detector rod.

Adjust the nuts on the lock rod and point detector rod to provide proper operation of the point detector when the throw bar is moved to the extreme positions.

CAUTION

Equipment damage may result from unexpected motor overrun if the friction clutch is not adjusted for minimum operating torque.

WARNING

USE CAUTION WHEN WORKING WITH THE ELECTRICAL

ENERGY DESCRIBED IN THESE PROCEDURES. FAILURE

TO DO SO CAN RESULT IN SERIOUS INJURY OR DEATH.

Electrically operate the switch machine by applying electrical energy to the switch machine terminals, to provide throw bar movement left and right as observed from the motor end of the machine. Refer to wiring diagram Figure

2–32 for wiring information.

Verify that the throw bar movement and the point detector turns off the motor at the end of each throw bar stroke.

Remove the test bar coupling unit and secure the covers and guards to the switch machine.

P1293, Rev. Oct/12 6–99 Alstom Signaling Inc.

Corrective Maintenance

THIS PAGE INTENTIONALLY LEFT BLANK.

P1293, Rev. Oct/12 6–100 Alstom Signaling Inc.

Parts Catalog

7. SECTION 7 – PARTS CATALOG

7.1. GENERAL

This section identifies and lists the replaceable parts of the Model 5E, 5F, 5G and 5H

Switch Machines and the available kits, associated connecting hardware, and tools. A

10-digit drawing number identifies each item. When ordering, always refer to the 10digit drawing number.

7.1.1. PARTS LIST

Illustrations of the switch machine are followed by a parts list, including reference (ref.) numbers, part descriptions and 10 digit drawing numbers.

Each part has been given a reference number. This reference number is repeated in the parts list and illustration. The illustration, parts list and reference number aids the maintainer in the identification of component parts. The parts list illustrations are a valuable tool for disassembly and assembly of the unit.

P1293, Rev. Oct/12 7–1 Alstom Signaling Inc.

Parts Catalog

P1293, Rev. Oct/12

Figure 7–1. Model 5E Switch Machine

7–2 Alstom Signaling Inc.

Parts Catalog

P1293, Rev. Oct/12

Figure 7–2. Model 5G Switch Machine

7–3 Alstom Signaling Inc.

Parts Catalog

Table 7–1. Main Parts For Models 5E and 5G Switch Machines

Ref

No.

Description Catalog

No.

Drawing No.

2 CONNECTOR, 9.95 - 1.05 ohms, for 110-volt

5E machine only

FRAME, back 3

TERMINAL BLOCK

RECTIFIER, for 110-volt switch machine

5A RECTIFIER, for 24-volt switch machine

MOTOR COMPLETE

CAM BAR COMPLETE

CONTROLLER COMPLETE, biased-neutral

POINT-DETECTOR MOVEMENT and

CONTACT GROUP

See

Table 7–13

P85-977 42760-224-03

P85-548

A53-321

A53-322

COVER COMPLETE, for contact compartment P85-473

P85-467

See Table 7–7

46048-009-01

29174-011-00

29174-010-00

45520-002-01

45510-007-01

See

Table 7–11

See

Table 7–8

10 COVER COMPLETE, for contact compartment P85-475 45520-009-02

11 SCREW, stainless steel 1/4"-20 x 1-1/4" long slotted pan head

11A FLAT WASHER, stainless steel, for a 1/4" dia. screw

12 TERMINAL BOARD COMPLETE See

Table 7–14

13 GASKET, black sponge rubber 9/16" dia.

14 CLUTCH COMPLETE

15 CUT-OUT SWITCH

16 GEAR COMPLETE, intermediate

17 GEAR COMPLETE, MAIN, 53 teeth

18 BRACKET

19 GUARD, for throw bar

20 THROW BAR

21 HASP COMPLETE

P85-598

See Table 7–3

51140-001-01

See Table 7–5

P85-595 51114-004-00

P85-513 45538-008-00

See Table 7–4

P1293, Rev. Oct/12 7–4 Alstom Signaling Inc.

Parts Catalog

Table 7–1. Main Parts For Models 5E and 5G Switch Machines (Cont.)

Ref

No.

Description Catalog

No.

Drawing No.

22 GUARD, RIGHT-HAND, for lock and pointdetector rods

23 FRAME, main bed

24 HAND CRANK

25 COVER COMPLETE, for crank opening, includes hinge pin

P85-738

P85-826

P85-788

51190-000-02

See Table 7–7

54477-002-01

52318-016-01

26 COVER COMPLETE, for gear compartment P85-472 45520-001-01

27 GASKET, 3/8" thick x 1/2" wide gray felt

28 LOCK ROD and POINT-DETECTOR ROD

GROUPS

See Table 7–9

P85-737 51190-000-01 29 GUARD, left-hand, for lock and point-detector rods

30 FILLER BLOCK, for cam bar opening

31 CAP SCREW, steel 5/16" - 18 x 1" long hex. head

P85-725 51173-004-00

31A LOCK WASHER, steel spring for a 5/16" dia. screw

32 COUPLING, wire inlet to motor P85-562 48795-001-00

P1293, Rev. Oct/12 7–5 Alstom Signaling Inc.

Parts Catalog

Figure 7–3. Model 5F Switch Machine

P1293, Rev. Oct/12 7–6 Alstom Signaling Inc.

Parts Catalog

P1293, Rev. Oct/12

Figure 7–4. Model 5H Switch Machine

7–7 Alstom Signaling Inc.

Parts Catalog

Table 7–2. Main Parts For Models 5F and 5H Switch Machines

Ref

No.

Description Catalog

No.

Drawing No.

MOTOR COMPLETE

FRAME, main bed

FRAME COMPLETE, gear

BRACKET, for clutch and gear

CUT-OUT SWITCH

GEAR, intermediate

PLATE, top, for bearing bracket

GUARD, for throw bar, for use in position shown

9 THROW BAR

10 HASP COMPLETE

11 FRAME, contact

12 CONNECTOR, 0.95-1.05 ohms, for 110-volt machine only

13 GUARD, right-hand, for lock and point-detector rods

14 COUPLING, for motor

15 PLATE, for lock stand

16 LOCK STAND COMPLETE

17 GUARD, for throw bar, for use on lever side of machine

See

Table 7–13

See Table 7–7

See Table 7–5

See Table 7–3

See Table 7–5

P85-595 51114-004-00

P85-513

P85-977 42760-224-03

P85-738

P85-562

45538-008-00

See Table 7–4

See Table 7–7

51190-000-02

48795-001-00

See Table 7–5

P85-596 51114-013-00

18 SELECT LEVER COMPLETE

19 HAND-THROW LEVER COMPLETE

20 LOCK- and POINT-DETECTOR RODS

21 GUARD, left-hand, for lock and point-detector rods

HAND CRANK

GASKET, black sponge rubber 9/16" dia.

P85-737

See Table 7–6

See Table 7–9

51190-000-01

P85-826 54477-002-01

25 COVER COMPLETE, for crank opening, includes hinge pin

P85-788 52318-016-01

26 COVER COMPLETE, for gear compartment P85-476 45520-011-01

P1293, Rev. Oct/12 7–8 Alstom Signaling Inc.

Parts Catalog

Table 7–2. Main Parts For Models 5F and 5H Switch Machines (Cont.)

Ref

No.

Description Catalog

No.

Drawing No.

27 SELECTOR LEVER SWITCH

28 CLUTCH SHIFTER COMPLETE

29 RECTIFIER, for 110-volt machines

29A RECTIFIER, for 24-volt machines

See Table 7–6

A53-321 29174-011-00

A53-322 29174-010-00

30 COVER COMPLETE, for contact compartment P85-473 45520-002-01

31 CAP SCREW, steel 5/16" - 18 x 1" long hex. head

31A LOCK WASHER, steel spring, for a 5/16" dia. screw

32 CLUTCH COMPLETE

33 GEAR COMPLETE, main

See Table 7–3

34 CAM BAR COMPLETE

35 CONTROLLER COMPLETE, biased-neutral

P85-467 45510-007-01

See

Table 7–11

36 COVER COMPLETE, for contact compartment P85-475 45520-009-02

37 POINT-DETECTOR MOVEMENT AND

CONTACT GROUPS

See Table 7–8

38 TERMINAL BOARD COMPLETE See

Table 7–14

39 MACHINE SCREW, stainless steel 1/4"-20 x

1-1/4" long slotted pan head

39A FLAT WASHER, stainless steel, for a 1/4" dia. screw

40 GASKET, black sponge rubber 9/16" dia.

P1293, Rev. Oct/12 7–9 Alstom Signaling Inc.

Parts Catalog

3/16

1/8

Figure 7–5. Detail Parts for Switch Machines (Sheet 1 of 2)

P1293, Rev. Oct/12 7–10 Alstom Signaling Inc.

Parts Catalog

MODEL 5F AND 5H SELECTOR LEVER CONTACT PARTS

MODEL 5F AND 5H CUTOUT SWITCH PARTS

MODEL 5E AND 5G SINGLE CUTOUT SWITCH PARTS

MODEL 5E AND 5G DOUBLE CUTOUT SWITCH PARTS

Figure 7–5. Detail Parts for Switch Machines (Sheet 2 of 2)

P1293, Rev. Oct/12 7–11 Alstom Signaling Inc.

Parts Catalog

Table 7–3. Detail Parts For Switch Machines Table

Ref

No.

Description Catalog

No.

Drawing No.

A CLUTCH COMPLETE, for 110-volt Models 5E and 5G switch machines, has 16 tooth pinion and 60 tooth gear

A1 CLUTCH COMPLETE, for 110-volt Models 5F and 5H switch machines, has 19 tooth pinion and 60 tooth gear

A2 CLUTCH COMPLETE, for 24-volt Models 5E and 5G switch machines, has 12 tooth pinion and 75 tooth gear

A3 CLUTCH COMPLETE, for 24-volt Models 5F and 5H switch machines, has 14 tooth pinion and 75 tooth gear

B GEAR COMPLETE, intermediate, for 110-volt

Models 5E and 5G switch machines, has 10 tooth pinion and 80 tooth gear

B1 GEAR COMPLETE, intermediate, for 24-volt

Models 5E and 5G switch machines, has 10 tooth pinion and 84 tooth gear

C GEAR COMPLETE, intermediate, includes

Refs. 19, 20, 21, and 22, for 110-volt Models

5F and 5H switch machines, has 11 tooth pinion and 74 tooth gear

P85-478

P85-479

P85-480

P85-481

P85-599

P85-600

45522-001-03

45522-001-13

45522-001-14

45522-001-16

51140-006-01

51140-006-02

C1 GEAR COMPLETE, intermediate, includes

Refs. 19, 20, 21, and 22, for 24-volt Models 5F and 5H switch machines, has 11 tooth pinion and 79 tooth gear

D BEARING, for main gear

D1 BEARING, for main gear, for replacement orders only

E GEAR COMPLETE, main, 53 teeth, for Models

5E and 5G switch machines

F BLOCK COMPLETE, includes contact springs, terminal posts, base nuts and washers

P85-501 45532-047-00,

45560-005-00,

45533-014-00,

00500-010-00

P85-500 45532-046-00

P85-512

P85-1380

45560-005-00,

45533-014-00,

00500-010-00

45536-008-00

50638-003-01

P85-598 51140-001-01

P85-912 51352-001-01

P1293, Rev. Oct/12 7–12 Alstom Signaling Inc.

Parts Catalog

Table 7–3. Detail Parts For Switch Machines Table (Cont.)

Ref

No.

Description Catalog

No.

Drawing No.

SWITCH LEVER COMPLETE, includes link

Ref. 29, bushing Ref. 73 and contacts

BLOCK COMPLETE, for motor cut-out switch, includes contact springs

SWITCH LEVER COMPLETE, for motor cutout switch, includes contact button

K TERMINAL BLOCK COMPLETE, with one set of contact fingers

M TERMINAL BLOCK COMPLETE, with two sets of contact fingers

P85-855

P85-775

P85-857

P85-774

P85-549

54594-003-01

51352-002-01

54594-002-01

51352-000-02

46048-073-01

1 GEAR, 60 teeth, for 110-volt switch machines P85-510 45535-001-00

1A GEAR, 75 teeth, for 24-volt switch machines P85-511 45535-002-00

2 CAP SCREW, steel 5/16" - 18 x 1-1/8" long hex. head

2A LOCK WASHER, steel spring, for a 5/16" dia. screw

3 PINION, 16 teeth, for clutch Ref. A

3A PINION, 19 teeth, for clutch Ref. A1

3B PINION, 12 teeth, for clutch Ref. A2

3C PINION, 14 teeth, for clutch Ref. A3

P85-606

P85-609

P85-607

P85-608

51144-000-01

51144-000-04

51144-000-02

51144-000-03

NUT, for spring

SCREW, for locking nut Ref. 4

5A HEX. NUT, steel, 5/16" - 18

6 DISC, metal, for clutch

6A WASHER, for clutch

DISC, metal, for clutch

9 DISC, friction material, for clutch

10 WOODRUFF KEY, steel 3/16" x 3/4"

11 SPRING, for clutch

P85-521 45559-003-00

P85-359 30049-020-00

P85-520 45557-028-00

P85-913 07670-003-00

P85-519 45557-027-00

P85-518 45557-026-00

P85-517 45557-019-00

P85-192 00786-005-00

P1293, Rev. Oct/12 7–13 Alstom Signaling Inc.

Parts Catalog

Table 7–3. Detail Parts For Switch Machines Table (Cont.)

Ref

No.

Description Catalog

No.

Drawing No.

12 PIN

13 CASE

14 SHAFT

15 LUBRICATION FITTING, 1/4" drive type straight

16 GEAR, 80 teeth, for gear Ref. B

16A GEAR, 84 teeth, for gear Ref. B1

17 WOODRUFF KEY, steel 5/16" x 1-1/8"

18 SHAFT, with 10 tooth pinion, for gears Refs. B and B1

19 PIN, for fastening gear to shaft

20 GEAR, 74 teeth, for gear Ref. C

P85-336

P85-516

P85-522

P85-380

P85-495

P85-496

P85-506

21517-001-00

45556-002-00

45560-003-00

34232-021-00

45532-011-00

45532-012-00

45533-006-00

20A GEAR, 79 teeth, for gear Ref. C1

21 PINION, 11 teeth, for gears Refs. C and C1

22 SHAFT, only, for gears Refs. C and C1

23 LOCK WASHER, for nut Ref. 24

24 HEX. NUT, steel 1-1/4" - 7

25 PIN, for bearing Ref. D

26 ROLLER, for main bearing

P85-162 00500-010-00

P85-499 45532-047-00

P85-498 45532-046-00

P85-508 45533-014-00

P85-523 45560-005-00

P85-239 03053-001-00

P85-332 17188-060-00

P85-514 45541-011-00

27 MACHINE SCREW, stainless steel #10-32 x

1/2" long slotted flat head

28 PLATE, for roller Ref. 26

29 LINK, for lever

30 STUD, for link

30A FLAT WASHER, stainless steel, for studs Ref.

30 and 32A

P85-727

P85-402

P85-152

51175-000-00

36024-010-00

00441-124-00

31 PIN, for switch lever

32 LEVER COMPLETE, with stud

P85-306 15350-027-00

P85-859 54596-000-01

32A STUD, for above P85-153 00441-266-00

33 BLOCK, for use under blocks Refs. F and 34 P85-779 51359-003-00

P1293, Rev. Oct/12 7–14 Alstom Signaling Inc.

Parts Catalog

Table 7–3. Detail Parts For Switch Machines Table (Cont.)

Ref

No.

Description Catalog

No.

Drawing No.

34 BLOCK, for mounting contact springs

35 SCREW, terminal post for block Ref. F

35A LOCK WASHER, stainless steel internal tooth, for a 1/4" dia. screw

36 SCREW, 1/4"-201-1/4" long for fastening blocks Refs. 33, 34, 52 and 53 to bracket

36A MACHINE SCREW, steel #14-24 x 1-1/4" long slotted round head

36B LOCK WASHER, stainless steel internal tooth, for a 1/4" dia. screw

37 SPRING, contact, 2-7/8" long

38 BUTTON, contact, for lever

39 SPRING, contact, 1-7/8" long

40 NUT, for stud lever Ref. 43

41 STUD, for contact button

42 PLATE WASHER, for contact springs

43 LEVER, with bushing Ref. 73, for selectorlever switch Ref. G

44 CRANK COMPLETE, includes stud for rod

45 FLAT WASHER, stainless steel, for a 3/8" dia. screw

P85-780

P65-102

P85-579

N/A

P85-705

51359-004-00

00350-005-00

49589-095-00

46553-004-00

P85-580 49589-096-00

P85-278 07628-003-00

P85-202 00980-032-00

P85-219 01601-088-00

P85-914 53936-016-00

51147-000-01

46 BOLT, .313-24 x 2.00 Lg

47 NUT, lock, for button Ref. 38

49 LEVER, only

50 SCREW, terminal post for block Ref. H

N/A

P85-550

P85-817

P65-101

03440-082-00

46548-001-00

53936-004-00

00350-004-00

51 MACHINE SCREW HEX. NUT, brass #14-24

52 BLOCK, for mounting contact springs P85-782 51359-008-00

53 BLOCK, for use under block Ref. 52 P85-781 51359-007-00

P1293, Rev. Oct/12 7–15 Alstom Signaling Inc.

Parts Catalog

Table 7–3. Detail Parts For Switch Machines Table (Cont.)

Ref

No.

Description Catalog

No.

Drawing No.

54 MACHINE SCREW, stainless steel 1/4" - 20 x

3/4" long slotted pan head

54A MACHINE SCREW, stainless steel #14-24 slotted pan head

54B LOCK WASHER, stainless steel internal tooth, for a 1/4" dia. screw

55 BRACKET, for mounting block Ref. H to frame P85-373 32168-008-00

56 PLUNGER, for control switch P85-354 29960-001-00

57 SPRING, for plunger

58 SPRING, contact, upper, 2-3/16" long

P85-193

P85-578

00786-007-00

49589-056-00

59 SPRING, contact, lower, 2-1/16" long

60 ROD, for cut-out switch

61 STUD, for lever

P85-746 51194-000-01

P85-249 04196-003-00

P85-771 51333-000-00

LEVER, only

PIN, for lever

FINGER, contact

JAM NUT, steel #14-24 hex.

66 MACHINE SCREW, stainless steel #8-32 x

1/2" long slotted pan head

66A LOCK WASHER, steel spring, for 1/4" dia. screw

67 CONTACT, for cut-out switch

68 FINGER, contact

69 FINGER, contact

72 MACHINE SCREW, nickel plated brass 1/4"-

20 x 2-1/4" long slotted fillister head

72A LOCK WASHER, steel spring, for a 1/4" dia. screw

73 BUSHING, for levers Refs. G or 43

P85-777 51354-000-00

P85-778 51358-000-00

P85-770 51332-000-00

P85-776

P85-388

P85-389

P85-940

51353-000-00

34425-068-00

34425-069-00

06714-335-00

P1293, Rev. Oct/12 7–16 Alstom Signaling Inc.

Parts Catalog

Figure 7–6. Bars, Couplings, and Hasp For Switch Machines

P1293, Rev. Oct/12 7–17 Alstom Signaling Inc.

Parts Catalog

Table 7–4. Bars, Couplings, and Hasp For Switch Machines

Ref

No.

Description Catalog

No.

Drawing No.

THROW BAR, for all switch machines

HASP COMPLETE, for covers

CAM BAR COMPLETE

STRAP, for hasp

RIVET, steel 1/4" dia. x 9/16" long rnd head

PIN, for link

LINK, for hasp

PIN, for bracket

BRACKET, for hasp

HASP, only

DISC, for strap

9 BRACKET, for hasp

10 LOCK WASHER, steel spring, for an 11/16" dia. screw

P85-513

P85-758

P85-467

P85-361

P85-444 42737-001-00

P85-189

P85-342 22949-000-00

P85-710 51154-000-00

P85-711

P85-724

P85-759

45538-008-00

51323-000-01

45510-007-01

30804-004-00

00734-001-00

51155-000-00

51172-000-00

51324-000-01

11 SCREW, dowel, for fastening throw bar end of contact frame and hasp bracket to main bed frame

12 BOLT, for fastening coupling to throw bar

12 BOLT item 12 , AND items 13, 14, and 14A

13 LOCK WASHER, steel spring, for a 7/8" dia. screw

14 HEX. NUT, steel 7/8" -9 heavy slotted

14A COTTER PIN, steel 3/16" x 2" long

15 COUPLING, for throw bar

16 COUPLING, offset, for throw bar

P85-254 04811-004-00

P85-424

N/A

P85-552

P81-102

P85-709

P85-925

38186-004-00

01273-014-00

47191-009-00

00046-001-ON

51153-001-00

51153-003-00

P1293, Rev. Oct/12 7–18 Alstom Signaling Inc.

MODEL 5E AND 5G BRACKET

Parts Catalog

MODEL 5F AND 5H BRACKET

3 4

25”

6”

½”

Figure 7–7. Brackets, Plates, and Lock Stand For Switch Machines

P1293, Rev. Oct/12 7–19 Alstom Signaling Inc.

Parts Catalog

Table 7–5. Brackets, Plates, and Lock Stand For Switch Machines

Ref

No.

Description Catalog

No.

Drawing No.

BRACKET COMPLETE, upper bearing for clutch and gear with main pinion, includes grease fittings, oil cup, bushing for clutch shaft and stud for cut-out switch

GEAR BRACKET COMPLETE, for intermediate gear and clutch, includes studs for cut-out switch, bushing for clutch, oil cup, grease fitting and wire clip

BEARING BRACKET COMPLETE, for main gear, selector clutch and clutch operating mechanism, includes stud for motor cut-out switch

PLATE, top, for use on bracket Ref. C

LOCK STAND, for selector and hand-throw levers

P85-701

P85-702

P85-858

P85-823

P85-794

51145-000-01

51145-001-02

54595-000-01

54314-000-00

52589-005-03

OILER FITTING, 1/8" - 27 N.P.T. 90º elbow

OILER FITTING, for machines with frequent operations

P85-074 34232-003-02

OILER FITTING, 1/8" N.P.T. 7/16" dia., 90º elbow

LOCK WASHER, steel spring, for a 5/8" dia. screw

CAP SCREW, steel 5/8" - 11 x 1-1/2" long hex. head

BUSHING, for brackets Ref. A and B

STUD, for brackets Refs. A and B

STUD, for gear bracket

LUBRICATION FITTING, 1/8" x 2-5/8" long

N.P.T. straight

P85-279

P85-147

P85-151

08942-052-00

00441-008-00

00441-036-00

9 CABLE TIE, white nylon self locking, with mount

10 MACHINE SCREW, stainless steel #10-32 x

7/16" long slotted pan head

11 STUD, for bearing bracket P85-154 00441-276-00

P1293, Rev. Oct/12 7–20 Alstom Signaling Inc.

Parts Catalog

Table 7–5. Brackets, Plates, and Lock Stand For Switch Machines (Cont.)

Ref

No.

Description Catalog

No.

Drawing No.

12 LOCK WASHER, steel spring, for an 11/16" dia. screw

13 SCREW, for fastening top plate to bearing bracket

14 PLATE, for lock stands

15 CAP SCREW, steel 1/2" - 13 x 1" long hex. head

15A LOCK WASHER, stainless steel internal tooth, for a 1/2" dia. screw

P85-255 04811-052-00

P85-719 51168-015-00

P1293, Rev. Oct/12 7–21 Alstom Signaling Inc.

Parts Catalog

P1293, Rev. Oct/12

Figure 7–8. Selector-Lever and Hand-Throw Parts

7–22 Alstom Signaling Inc.

Parts Catalog

Table 7–6. Selector-Lever and Hand-Throw Parts

Ref

No.

Description Catalog

No.

Drawing No.

CLUTCH SHIFTER COMPLETE, for shifting from power to hand-throw, comprises parts

Refs. 1, 2, 4, 5, 6, 7, 12, 13, 14, 21 through 26

CRANK COMPLETE, with roller, for operating throw bar, does not include fittings, Refs. 17 or

HAND-THROW LEVER COMPLETE, includes

Refs. 36, 44, 46, 47, 48, 49, 53, 54, 55, 56 61,

61A, 62, and 63 - only, if extension (Ref. 64) is needed you must order it separately

STUD, for connecting selector lever contacts to yoke

YOKE, for operating selector lever contacts

PIN, for pin Ref. 5

PIN, for fastening yokes Refs. 2 and 3 to bracket Ref. 7

PIN, for fastening eyebolt to yoke

BRACKET, with pins Refs. 4 and 5 for clutch shifter unit

8 CAP SCREW, steel 1/2" – 13 x 1-1/4" long hex. Head

8A LOCK WASHER, steel spring, for a 1/2" dia. screw

9 GEAR, main, 67 teeth

10 GEAR COMPLETE, clutch, 25 teeth

11 TRUNNION, for yoke

12 YOKE, for operating clutch sleeve Ref. 30

13 CAP SCREW, for fastening Ref. 21 to bracket

Ref. 7

14 LOCK WASHER, steel spring, for a 3/8" dia. screw

15 LUBRICATION FITTING, 1/4" drive type straight

P85-852 54591-000-02

P85-853 54592-000-06

P85-851 54590-003-01

P85-917 00441-268-00

P85-848 54584-001-00

P85-169 00504-247-00

P85-167 00504-202-00

P85-168 00504-208-00

P85-1177 54319-000-00

P85-497 45532-015-00

P85-840 54549-001-02

P85-351 29545-015-00

P85-849 54584-002-00

P85-227 02472-035-00

P1293, Rev. Oct/12 7–23 Alstom Signaling Inc.

Parts Catalog

Table 7–6. Selector-Lever and Hand-Throw Parts (Cont.)

Ref

No.

Description Catalog

No.

Drawing No.

16 CRANK, splined

17 FITTING, oiler, top

17A FITTING, oiler, top

18 FITTING, oiler, bottom

19 JAM NUT steel 3/4" - 10 heavy hex.

20 WASHER, for nut Ref. 19

21 CAP, for top of bracket Ref. 7

22 EYEBOLT, for clutch shifter

23 NUT, for eyebolt

P85-918 54592-000-03

P85-383 34232-067-01

N/A 34232-084-01

P85-382 34232-064-02

P85-181 00590-041-00

P85-824 54318-000-00

P85-436 39319-015-00

P85-431 38931-004-00

24 ROLLPIN, stainless steel 1/8" dia. x 3/4" long

24A COTTER PIN, steel 1/8" x 3/4" long

25 SPRING, for clutch shifter

26 COLLAR, for spring Ref. 25

P85-196 00786-139-00

P85-412 37522-003-00

27 WASHER, for bearing Ref. 28

28 ROLLER BEARING, for 63/64" dia. shaft

29 BALL BEARING, light duty single row radial, for 2-3/4" shaft

P85-180 00590-040-00

30 SLEEVE, clutch, splined, for crank

31 ROLLER, for main crank

32 PLATE, for roller

33 MACHINE SCREW, stainless steel #10-32 x

1/2" long slotted flat head

34 PIN, for plugging oil holes in crank

35 PLATE, for use between selector lever and hand-throw lever

P85-175

P85-514

P85-727

P85-166

P85-846

00585-013-00

45541-011-00

51175-000-00

00504-122-00

31084-000-01

36 PIN, for fastening gear Ref. 56 to shaft, also for fastening hand-throw lever to shaft

40 CAP SCREW, steel 5/8" - 11 x 2-3/4" long hex. head

P85-164 00504-109-00

38 ROLL PIN, stainless steel 1/4" x 1-3/4" long

39 COLLAR, for shaft Ref. 45 P85-143 00420-027-00

P1293, Rev. Oct/12 7–24 Alstom Signaling Inc.

Parts Catalog

Table 7–6. Selector-Lever and Hand-Throw Parts (Cont.)

Ref

No.

Description

40A LOCK WASHER, steel spring, for a 5/8" dia. screw

41 ROLLPIN, stainless steel 1/4" x 2" long

42 WOODRUFF KEY, steel 3/16" x 3/4"

43 BALL BEARING, chrome steel 5/8"

44 WOODRUFF KEY, steel 1/4" x 7/8"

45 SHAFT COMPLETE, concentric, includes collar and pin

46 SHAFT, for hand-throw lever

47 BEARING, bracket, for hand-throw and selector levers

48 THRUST BEARING for 1-3/4" dia. shaft

49 BALL BEARING, single row radial, for 1-5/8" dia. shaft

50 BUSHING, oil impregnated, for gear Ref. D

51 STUD COMPLETE, includes pin, for mounting gear Ref. D to top plate

52 LOCK WASHER, steel spring, for a 3/4" dia. screw

53 LUBRICATION FITTING, 1/8" x 2-5/8" long

N.P.T. straight

54 PIPE PLUG, steel 1/8" -27 x 3/8" dia. square head

55 PIN, for fastening bevel gear Ref. 56 to shaft

Ref. 46

56 GEAR, bevel, 30 tooth

57 BOLT, steel, 5/8" -11 x 1-3/4" long hex. head, with hex nut

57A LOCK WASHER, steel spring, for a 5/8" dia. screw

58 LUBRICATION FITTING, 3/16" drive type straight

59 BEARING, for shaft Ref. 45

Catalog

No.

Drawing No.

P85-704 51146-002-03

P85-815 53908-002-00

P85-844 54578-000-00

P85-267 06714-336-00

P85-799 52923-001-01

P85-165 00504-121-00

P85-334 20263-001-00

P85-845 54578-002-00

P1293, Rev. Oct/12 7–25 Alstom Signaling Inc.

Parts Catalog

Table 7–6. Selector-Lever and Hand-Throw Parts (Cont.)

Ref

No.

Description Catalog

No.

Drawing No.

60 SELECTOR LEVER COMPLETE

61 PLATE, letter "R"

61A PLATE, letter "N"

62 BOLT, steel 3/8" -16 x 1-3/4" long square head, with square nut

62A LOCK WASHER, steel spring, for a 3/8" dia. screw

63 LEVER, hand-throw

64 EXTENSION, for lever Ref. 63

65 GEAR COMPLETE, for hand-throw operation, includes 27 tooth spur gear and 24 tooth bevel gear pinned and keyed together

P85-854 52557-017-00

P85-370 31760-090-00

P85-371 31760-091-00

P85-793 52557-011-00

P85-792 52557-009-00

P85-839 54549-000-02

P1293, Rev. Oct/12 7–26 Alstom Signaling Inc.

Parts Catalog

P1293, Rev. Oct/12

Figure 7–9. Frames

7–27 Alstom Signaling Inc.

Parts Catalog

Table 7–7. Frames

Ref

No.

Description Catalog

No.

Drawing No.

A1 FRAME COMPLETE, main bed, includes oil tube and grease fitting, bushings for clutch and intermediate gear shafts, wear plates, nipple for wire inlet, plate and mounting screws for wire duct; for Models 5F and 5H switch machines using box-style bearing and wear plates Refs. F, G and H

B FRAME COMPLETE, gear, includes screws and washers for mounting motor, eyebolts with nuts for cover, grease fittings for throw bar and dowel screws for mounting to main bed frame; for Models 5E and 5G switch machines, using box-style bearing Ref. F

FRAME COMPLETE, main bed, includes oil tube and grease fitting, bushings for clutch and intermediate gear shafts, wear plates, nipple for wire inlet, plate and mounting screws for wire duct; for Models 5E and 5G switch machines using box-style bearing and wear plates, Refs. F, G and H

FRAME COMPLETE, gear, includes screws and washers for mounting motor, eyebolts with nuts for cover, grease fittings for throw bar and dowel screws for mounting to main bed frame; for Models 5F and 5H switch machines using box-style bearing Ref. F

FRAME COMPLETE, contact, includes studs for lock and point-detector rod guards, eyebolts with nuts for cover, and dowel; for

Models 5E and 5F switch machines, using box-style wear plates Refs. G and H

E FRAME COMPLETE, contact, includes studs for lock and point-detector guards, eyebolts with nuts for cover, and dowel screws for mounting to main bed frame; for Models 5G and 5H switch machines using box-style wear plate Refs. G and H

P85-901 58847-005-01

P85-903 58847-004-01

P85-893 57028-001-03

P85-894 57028-001-04

P85-886 57028-000-09

P85-889 57028-000-08

P1293, Rev. Oct/12 7–28 Alstom Signaling Inc.

Parts Catalog

Table 7–7. Frames (Cont.)

Ref

No.

Description Catalog

No.

Drawing No.

BEARING COMPLETE, with screws and washers, for throw bar, one required for each side of machine

PLATE, wear, for each lock rod, one required for each side of machine

H PLATE, wear, for all detector rod combinations, one required for each side of machine

BUSHING, for intermediate gear shaft 1

2 TUBE COMPLETE, with bushing for clutch shaft

2A LUBRICATION FITTING, 1/8" x 3/4" long

N.P.T. straight

PIPE PLUG, steel 1/2" dia. square head

MACHINE SCREW, steel 1/4" -20 x 5/8" long slotted fillister head

4A LOCK WASHER, steel spring, for a 1/4" dia. screw

5 PLATE, for covering wire duct

5A MACHINE SCREW, steel 1/4" -20 x 3/8" long slotted flat head

P85-344

P85-864

P85-865

P85-268

P85-302

P85-720

23434-000-01

06714-271-00

14937-001-01

51168-033-00

NIPPLE, 1" N.P.T.

STUD, for mounting motor, for use at bottom P85-566 49476-046-00

HEX. NUT, steel 1/2" - 13

7B LOCK WASHER, steel spring, for a 1/2" dia. screw

8 GIB, for throw bar P85-286 11072-002-00

P85-810 53721-022-00 9 CLIP, for gib, Ref. 8

10 PLATE, wear, for use under lock rod, Dim. "Y"

= 1-1/2"

P85-862 54920-001-01

10A PLATE, wear, for use under lock rod, Dim. "Y"

= 1-1/4"

P85-863 54920-001-02

P1293, Rev. Oct/12 7–29 Alstom Signaling Inc.

Parts Catalog

Table 7–7. Frames (Cont.)

Ref

No.

Description Catalog

No.

Drawing No.

11 CAP SCREW, steel 1/2" - 13 x 2" long hex. head

11A LOCK WASHER, steel spring, for a 1/2" dia. screw

12 EYEBOLT, for fastening cover to gear frame P85-434 39319-001-00

P85-413 37539-001-00

P85-380 34232-021-00

12A NUT, for above

13 LUBRICATION FITTING, 1/4" drive type straight

14 SCREW, dowel, for fastening motor end of gear frame to main bed frame

15 LOCK WASHER, steel spring, for a 5/8" dia. screw

P85-252 40811-002-00

P85-251 04811-001-00

16 HEX. NUT, steel 5/8" - 11

17 SCREW, dowel, for fastening throw-bar end of gear frame to main bed frame

18 SCREW, dowel, for fastening throw-bar end of contact frame and hasp brackets to main bed frame

19 LOCK WASHER, steel spring, for an 11/16" dia. screw

20 STUD, for lock rod and point-detector rod guards

21 SCREW, dowel, for fastening contact frame to main bed frame

P85-254

P85-150

P85-253

04811-004-00

00441-020-00

04811-003-00

22 EYEBOLT, for fastening cover to contact frame

22A NUT, for above

P85-435 39319-002-00

P85-413 37539-001-00

23 MACHINE SCREW, stainless steel #10-32 x

1/2" long slotted fillister head

23A LOCK WASHER, steel spring, for a #10 screw

24 BLOCK, filler P85-566 49476-046-00

25 CLIP, for wires

25A MACHINE SCREW, stainless steel #10-32 x

3/8" long slotted pan head

P85-417 38043-009-00

P1293, Rev. Oct/12 7–30 Alstom Signaling Inc.

Parts Catalog

Table 7–7. Frames (Cont.)

Ref

No.

Description Catalog

No.

Drawing No.

26 LUBRICATION FITTING, 1/4" drive type 67-

1/2¯ angled

27 CLIP, for wires

27A MACHINE SCREW, stainless steel #10-32 x

3/8" long slotted pan head

27B LOCK WASHER, steel spring, for a #10 screw

28 CAP SCREW, steel 5/16" - 18 x 5/8" long hex. head

29 CAP SCREW, steel 1/4" - 20 x 3/4" long hex. head

29A LOCK WASHER, steel spring, for a 1/4" dia. screw

P85-416 38043-008-00

P1293, Rev. Oct/12 7–31 Alstom Signaling Inc.

Parts Catalog

MOTOR

CONTROL

CONTACTS

NORMAL AND

REVERSE

CONTACTS

SHUNT

CON-

TACTS

NORMAL AND

REVERSE

CONTACTS

1 2

3 4 5 6

A-FOR MODELS 5E AND 5F SWITCH MACHINES

7 8

MOTOR

CONTROL

CONTACTS

NORMAL AND

REVERSE

CONTACTS

SHUNT

CONTACTS

1 2

B-FOR MODELS 5G AND 5H SWITCH MACHINES

Figure 7–10. Point-Detector Contacts and Movements (Sheet 1 of 2)

P1293, Rev. Oct/12 7–32 Alstom Signaling Inc.

Parts Catalog

36 37

41 42 43 44

48 49

50 51

52 53

Figure 7–10. Point-Detector Contacts and Movements (Sheet 2 of 2)

P1293, Rev. Oct/12 7–33 Alstom Signaling Inc.

Parts Catalog

Table 7–8. Point-Detector Contacts and Movements

Ref

No.

Description Catalog

No.

Drawing No.

POINT-DETECTOR CONTACT GROUP

COMPLETE, having three normal; three reverse; two motor-control contacts and two shunt strips, for Models 5E and 5F switch machines

POINT-DETECTOR CONTACT GROUP

COMPLETE, having two normal; two reverse; two shunt contacts and two motor-control contacts, for Models 5G and 5H switch machines

C POINT-DETECTOR MOVEMENT

COMPLETE, for all switch machines having one point-detector rod

C1 POINT-DETECTOR MOVEMENT

COMPLETE, for all switch machines having two point-detector rods

HEATER COMPLETE, 15 watts, 110 volts

BLOCK, insulation, for contacts

WASHER, for screw Ref. 3

MACHINE SCREW, stainless steel 1/4" -20 x

1-1/4" long slotted pan head

P85-979

P85-740

P85-761

P85-762

P85-927

P85-529

P85-178

51192-014-01

51192-015-01

51326-003-09

51326-003-10

56090-006-02

45589-011-00

00590-017-00

TERMINAL POST COMPLETE, includes post and stop only

MACHINE SCREW HEX. NUT, brass #14-24

P85-753 51198-003-02

WASHER, stainless steel flat, for a 1/4" dia. screw

MACHINE SCREW HEX. NUT, stainless steel

#10-32

7A LOCK WASHER, stainless steel internal tooth, for a #10 screw

8 STRIP, shunt

15 MACHINE SCREW, stainless steel #10-32 x 1" long slotted pan head

P85-322 17378-026-00

P1293, Rev. Oct/12 7–34 Alstom Signaling Inc.

Parts Catalog

Table 7–8. Point-Detector Contacts and Movements (Cont.)

Ref

No.

Description Catalog

No.

Drawing No.

16 MACHINE SCREW, stainless steel #10-32 x

7/16" long slotted pan head

17 LOCK WASHER, steel spring, for a #10 screw

18 STOP, for springs Ref. 20 P85-391 35470-004-00

19 FINGER, only

20 SPRING, only

21 MACHINE SCREW, stainless steel #8-32 x

3/8" long slotted pan head

21A SCREW, stainless steel internal tooth lock washer for a #8

22 MACHINE SCREW, stainless steel #10-32 x

1/4" long slotted pan head

P85-755 51199-005-00

P85-752 51197-003-00

22A LOCK WASHER, stainless steel internal, for a

#10 screw

23 MACHINE SCREW, stainless steel #10-32 x

1/2" long slotted pan head

23A LOCK WASHER, steel spring for a #10 screw

24 STOP, for springs Ref. 20 P85-392 35470-065-00

25 INSULATOR, with short screw

26 INSULATOR, with long screw

27 FINGER COMPLETE

28 FINGER COMPLETE

P65-557

P65-559

P85-747

P85-748

42792-010-00

42792-015-00

51195-027-01

51195-018-01

29 ARM COMPLETE

30 WASHER, for adjuster Ref. 32

31 MACHINE SCREW, stainless steel #8-32 x

5/16" long slotted pan head

31A LOCK WASHER, stainless steel internal tooth, for a #8 screw

32 ADJUSTER, for finger Ref. 28

33 TERMINAL POST COMPLETE, includes post and stop only

P85-869 55153-000-01

P85-217 01601-080-00

P85-355

P85-754

29967-001-00

51198-005-01

P1293, Rev. Oct/12 7–35 Alstom Signaling Inc.

Parts Catalog

Table 7–8. Point-Detector Contacts and Movements (Cont.)

Ref

No.

Description Catalog

No.

Drawing No.

36 OILER FITTING, 1/8" drive type straight

37 PLATE, for movement

38 SCREW, for mounting movement

38A LOCK WASHER, steel spring, for a 5/16" dia. screw

39 MACHINE SCREW, stainless steel #10-32 x

7/8" long slotted fillister head

40 BLOCK, insulating, for yoke

41 ROLLER, for movements

42 BLOCK, filler, for use with switch machine having one detector rod

43 SPRING, for movements

44 ROLLER, for operating yoke from cam bar

45 STUD, for rollers

46 CONTACT YOKE COMPLETE, for switch machines having one detector rod

46A CONTACT YOKE COMPLETE, for switch machines having two detector rods

47 PIN, nickel stainless steel 3/32" x 7/8" long

48 PIN, for roller Ref. 41

49 PIN, for movements

50 YOKE, only

51 PIN, for yoke

52 BUSHING, for pin Ref. 53

53 PIN, for roller

54 LOCK WASHER, stainless steel internal tooth, for a 1/4" dia. screw

55 WASHER, for terminal posts

56 NUT, for terminal posts

57 RESISTOR, only. 15 watts, 110 volts

P85-713 51157-000-00

P85-1084 55470-047-00

P85-484 45526-003-00

P85-726 51174-000-00

P85-821 54227-000-00

P85-200 00786-353-00

P85-919 31942-002-00

P85-284 09665-002-00

P85-706 51149-003-02

P85-707 51149-001-07

P85-187 00730-062-00

P85-305 15350-002-00

P85-708 51151-000-00

P85-304 15350-001-00

P85-437 39533-028-00

P85-188 00730-121-00

P76-108 01225-002-00

P76-131 42843-001-00

P85-929 55291-006-00

P1293, Rev. Oct/12 7–36 Alstom Signaling Inc.

P1293, Rev. Oct/12

Parts Catalog

5 6

FOR SINGLE SWITCH, SINGLE SLIP SWITCH, DERAIL, OR

DOUBLE SLIP SWITCH WITH MACHINE HAVING ONE LOCK ROD

AND ONE POINT DETECTOR ROD

2 4

7 8 9 10

FOR DOUBLE SLIP SWITCH WITH MACHINE HAVING TWO LOCK

RODS AND TWO POINT DETECTOR RODS

11 12

9 10

FOR MOVABLE POINT FROG – LEFT HAND

10 9

8 13

3 2

FOR MOVABLE POINT FROG – RIGHT HAND

Figure 7–11. Lock Rods and Point-Detector Rods

7–37 Alstom Signaling Inc.

Parts Catalog

Table 7–9. Lock Rods and Point-Detector Rods

Ref

No.

Description

LOCK ROD COMPLETE, adjustable

POINT-DETECTOR ROD COMPLETE

LOCK ROD COMPLETE, adjustable

POINT-DETECTOR ROD COMPLETE

HEX. JAM NUT, steel 3/4" - 10 heavy

PLATE, adjusting, for lock rod Ref. A

ROD, only, for lock rod Ref. A.

ROD, with stud, for detector rod Ref. B

HEX. JAM NUT, steel 5/8" - 11 heavy

ROD, adjusting, for detector rod Ref. B

ROD, with stud, for detector rod Ref. C

ROD, only, for detector rod Ref. C

PLATE, adjusting, for lock rod Ref. D

10 ROD, only, for lock rod Ref. D

11 ROD, with stud, for detector rod Ref. E

12 ROD, only, for detector rod Ref. E

13 ROD, only, for detector rod Ref. F

14 ROD, with stud, for detector rod Ref. F

15 HEX. JAM NUT, steel 1" - 8 heavy

16 ARM, for lock rod

Catalog

No.

Drawing No.

P85-468 45512-005-07

P85-764 51327-001-05

P85-765 51327-002-07

P85-469 45512-006-06

P85-763 51327-000-07

P85-766 51327-011-07

P85-482 45525-004-00

P85-471 45519-006-00

P85-881 56931-000-01

P85-729 51176-001-00

P85-883 56931-000-03

P85-730 51176-005-00

P85-483 45525-005-00

P85-470 45519-005-00

P85-882 56931-000-02

P85-728 51176-000-00

P85-731 51176-024-00

P85-884 56931-000-09

P85-717 56854-006-01

P1293, Rev. Oct/12 7–38 Alstom Signaling Inc.

Parts Catalog

Link Motion

Figure 7–12. Link Motion

P1293, Rev. Oct/12 7–39 Alstom Signaling Inc.

Parts Catalog

Table 7–10. Link Motion

Ref

No.

Description Catalog

No.

Drawing No.

P85-769 51329-005-01 LINK MOTION COMPLETE, for detecting movement of second lock rod on movable point frogs of all models

STUD, shouldered, for levers

STUD, shouldered, for links

CLIP, right hand

CLIP, left hand

MACHINE SCREW, steel 5/16" - 18 x 5/8" long slotted flat head

LEVER

LINK

CLIP, for detecting movement of second lock rod in double slip switches

P85-149 00441-012-00

P85-148 00441-011-00

P85-734 51187-001-00

P85-733 51187-000-00

P85-922 50563-006-00

P85-921 00734-031-00

P85-735 51187-002-00

P1293, Rev. Oct/12 7–40 Alstom Signaling Inc.

Parts Catalog

P1293, Rev. Oct/12

Figure 7–13. Biased-Neutral Controller

7–41 Alstom Signaling Inc.

Parts Catalog

Table 7–11. Biased-Neutral Controller

Ref

No.

Description Catalog

No.

Drawing No.

A BIASED-NEUTRAL CONTROLLER

COMPLETE, for 10- or 24-volt control and

110-volt operation

A1 BIASED-NEUTRAL CONTROLLER

COMPLETE, for 10- or 24-volt control and

110-volt operation with heater

A2 BIASED-NEUTRAL CONTROLLER

COMPLETE, for 10- or 24-volt control and 24volt operation

A3 BIASED-NEUTRAL CONTROLLER

COMPLETE, for 10- or 24-volt control and 24volt operation with heater

B RELAY GROUP COMPLETE, includes contactor, overload relay and terminal board, for Ref. A

B1 RELAY GROUP COMPLETE, includes contactor, overload relay and terminal board, for Ref. A1

B2 RELAY GROUP COMPLETE, includes contactor, overload relay and terminal board, for Ref. A2

B3 RELAY GROUP COMPLETE, includes contactor, overload relay and terminal board, for Ref. A3

CONTACTOR COMPLETE, for references see page 6-39

OVERLOAD RELAY COMPLETE, for references, see page 6-39

P85-827

P85-1381

P85-828

P85-1382

P85-832

P85-831

P85-834

P85-833

54532-012-11

54532-012-13

54532-012-12

54532-012-14

54534-007-02

54534-007-01

54534-007-04

54534-007-03

OVERLAND RESISTANCE WIRE, 24V Motor P85-449 42760-199-01

OVERLAND RESISTANCE WIRE, 110 V

Motor

P85-447 42760-174-04

SNUBBING DEVICE COMPLETE

HEATER COMPLETE, 15 watts, 110 volts

P85-838

P85-928

54544-000-01

56090-020-01

P1293, Rev. Oct/12 7–42 Alstom Signaling Inc.

Parts Catalog

Table 7–11. Biased-Neutral Controller (Cont.)

Ref

No.

Description Catalog

No.

Drawing No.

CASE COMPLETE, includes pins Refs. 3, 4, and 18

COVER COMPLETE, with insulation

PIN, long, hinge for cover

PIN, short, hinge for cover

SCREW, used as terminal post

WASHER, for terminal posts

P85-321 17199-000-03

P85-790 52318-020-02

P85-323 17538-001-00

P85-324 17538-002-00

P85-137 00376-010-00

P76-108 01225-002-00

MACHINE SCREW HEX. NUT, brass #14-24

SCREW, steel 5/16" - 24 x 1-1/2" long hex. head

8A LOCK WASHER, stainless steel external tooth, for a 5/16" dia. screw

10 NUT, for terminal posts

11 SCREW, steel 5/16" - 24 x 1" long hex. head

P65-585 42839-008-00

11A LOCK WASHER, stainless steel external tooth, for a 5/16" dia. screw

12 MACHINE SCREW, stainless steel 1/4" -20 x

1-1/4" long slotted fillister head

12A LOCK WASHER, stainless steel internal tooth, for a 1/4" dia. screw

14 CONNECTOR, snub resistor lead, for 110-volt operation

P85-972 42760-224-01

14 CONNECTOR, snub resistor lead, for 24-volt operation

16 NAME PLATE, for controller

P85-973 42760-224-02

P85-139 00401-125-00

16A SCREW, steel #2 x 1/4" long round head drive type

17 SEAL, car, for cover

18 PIN, shouldered, for sealing cover

19A

RECTIFIER, for 110-volt operation

RECTIFIER, for 24-volt operation

PLUG, red plastic 9/16" - 18 threaded

P62-299

P85-155

35285-000-00

00441-409-00

A53-321 29174-011-00

A53-322 29174-010-00

P1293, Rev. Oct/12 7–43 Alstom Signaling Inc.

Parts Catalog

Table 7–11. Biased-Neutral Controller (Cont.)

Ref

No.

Description Catalog

No.

Drawing No.

21 SPACER, for use between terminal board and contact, also between overload relay and terminal board

22 MACHINE SCREW HEX. NUT, stainless steel

#10-32

23 HANDLE, for cover

P85-583 49655-205-00

P85-841 54550-000-00

24 FLAT WASHER, stainless steel, for a #10 screw

25 LOCK WASHER, stainless steel internal tooth, for a #10 screw

26 SPRING, for handle

27 TERMINAL BOARD, only

P85-216 01581-013-00

P85-843 54572-018-00

28 BOLT, for snubbing device

29 HEX. NUT, stainless steel 3/8" - 16 elastic stop

P85-837 54543-000-00

30 NUT, for spring

31 SPRING, for snubbing device

32 WASHER, for spring

33 COLLAR, for washer Ref. 32

34 WASHER, for collar Ref. 33

35 HEX. NUT, steel 5/16" - 18

35A LOCK WASHER, steel spring, for a 5/16" dia. screw

36 RESISTOR, only, 15 watts, 110 volts

P85-822 54247-001-00

P85-195 00786-108-00

P85-179 00590-036-00

P85-142 00420-026-00

P85-183 00626-089-00

P3-235 56086-019-00

P1293, Rev. Oct/12 7–44 Alstom Signaling Inc.

Parts Catalog

P1293, Rev. Oct/12

Figure 7–14. Contactor and Overload Relay

7–45 Alstom Signaling Inc.

Parts Catalog

Table 7–12. Contactor and Overload Relay

Ref

No.

Description Catalog

No.

Drawing No.

A CONTACTOR COMPLETE, for 10-volt control P85-421 38146-003-02

A1 CONTACTOR COMPLETE, for 24-volt control P85-420 38146-003-01

P85-425 38214-000-04 B OVERLOAD RELAY COMPLETE, for 10-volt control

B1 OVERLOAD RELAY COMPLETE, for 24-volt control

P85-426 38214-000-03

CONTACT BLOCK COMPLETE, for contactor

ARMATURE COMPLETE, for contactor

CONTACT COMPLETE

P85-786

P85-433

52256-014-01

39043-038-01

P85-328 18293-002-01

ARMATURE COMPLETE, for overload relay P85-432 39043-025-01

P85-785 52256-008-01

P85-295 13006-062-00

BLOCK COMPLETE, for overload relay

SCREW, for contactor

1A LOCK WASHER, stainless steel internal tooth, for a #10 screw

2 PLATE COMPLETE, with bushing and rivets, for contactor

CONNECTOR COMPLETE

WASHER, strap, for screws Ref. 23

ARM COMPLETE, for contactor

BRACKET, for arm

MACHINE SCREW, stainless steel #10-32 x 1" long slotted fillister head

P85-419

P85-445

P62-260

P85-428

38104-000-02

42760-163-01

22543-020-00

38439-000-01

P85-554 47358-016-00

8A LOCK WASHER, stainless steel internal tooth, for a #10 screw

9 INSULATOR, for terminal posts

10 WASHER, stainless steel flat, for a #10 screw

11 MACHINE SCREW HEX. NUT, stainless steel

#10-32

P62-330 42792-012-00

11A LOCK WASHER, stainless steel internal tooth, for a #10 screw

12 LOCK WASHER, steel spring, for a #10 screw

P1293, Rev. Oct/12 7–46 Alstom Signaling Inc.

Parts Catalog

Table 7–12. Contactor and Overload Relay (Cont.)

Ref

No.

Description Catalog

No.

Drawing No.

13 RECTIFIER COMPLETE, for 10-volt or 24-volt control

A53-324 54728-083-01

14 WASHER, spring, for holding coils tight P62-163 01225-170-00

15 CORE COMPLETE, with yoke, for contactor P85-909 58966-002-01

16 BRACKET, for arm

17 GROMMET EYELET, brass 5/16"

18 HEX. NUT, stainless steel 1/4" - 20 elastic stop

P85-553 47358-014-00

20 SPRING, for arm

21 BRACKET COMPLETE, with core heads, rivets and stud, for contactor

22 PLATE, retaining, for plate Ref. 2

23 MACHINE SCREW, stainless steel #8-32 x

3/8" long slotted fillister head

P85-177 00586-195-00

P85-430 38489-000-02

P85-874 55914-003-00

23A LOCK WASHER, stainless steel internal tooth, for a #8 screw

24 PLATE, armature retaining

25 PLATE, armature bearing

26 MACHINE SCREW, stainless steel #4-40 x

1/4" long slotted fillister head

26A LOCK WASHER, stainless steel internal tooth for a #4 screw

P62-473

P85-873

55914-001-00

55912-014-00

27 MACHINE SCREW, stainless steel #10-32 x

3/4" long slotted flat head

MAGNET, for contactor

STRIP, leakage, for contactor

30 CLAMP, for magnet

31 WASHER, black fiber 1/16" thick, 1-1/2" O.D.,

5/8" I.D.

P85-800 53007-017-00

P85-908 58898-003-00

P85-910 58967-002-00

31A Felt washer 1/16" thick, 1-3/8" O.D., 5/8" I.D.

32 COIL, for use with 10-volt control P85-365 31066-121-07

32A COIL, for use with 24-volt control

33 SHIM, 1/64" thick

34 WASHER, for terminal posts

P85-366 31066-121-08

P85-812 53879-016-00

P76-108 01225-002-00

P1293, Rev. Oct/12 7–47 Alstom Signaling Inc.

Parts Catalog

Table 7–12. Contactor and Overload Relay (Cont.)

Ref

No.

Description Catalog

No.

Drawing No.

35 BLOCK, only

36 SHIM, .010 thick, for contacts

37 CONTACT COMPLETE, long, for block

38 CONTACT COMPLETE, short, for block

39 MAGNET, for contacts

40 PLATE, for contacts

41 LOCK WASHER, stainless steel internal tooth, for a 1/4" dia. screw

P85-557 47508-158-00

P85-185 00626-201-00

P85-451 42799-032-03

P85-452 42799-032-02

P85-896 57157-003-00

P85-399 35845-607-00

42 MACHINE SCREW HEX. NUT, brass #14-24

43 INSULATION, for contacts P85-842 54556-005-00

44 FINGER COMPLETE, with contact P85-835 54541-012-01

45 FLAT WASHER, stainless steel, for a #8 screw

46 SPRING, for fingers P85-197 00786-144-00

WASHER, cup, for spring

SPRING, for fingers

SCREW

49A MACHINE SCREW HEX. NUT, stainless steel

#10-32

50 CONNECTOR, for overload relay

51 HEX. NUT, #10-32 elastic stop

52 WASHER, for spring Ref. 53

53 SPRING, for overload relay

54 SCREW, for overload relay

P85-341 22539-002-00

P85-176 00586-051-00

P85-136 00357-001-00

P85-446 42760-167-01

P85-581 49637-001-00

P85-198 00786-293-00

P85-350 29151-017-00

P62-158 01225-104-00

P85-876 56014-012-01

55 WASHER, spring, for coil

56 CORE AND BRACKET COMPLETE, for overload relay

57 SLUG, for overload relay

58 WASHER, flat, for coil

59 COIL, for overload relay

60 YOKE, for overload relay

P85-978 54960-057-00

P85-207 01225-151-00

P85-369 31066-126-03

P85-453 42836-035-00

P1293, Rev. Oct/12 7–48 Alstom Signaling Inc.

Parts Catalog

Table 7–12. Contactor and Overload Relay (Cont.)

Ref

No.

Description Catalog

No.

Drawing No.

61 MACHINE SCREW, stainless steel 5/16" - 24 x

7/8" long hex. head

61A LOCK WASHER, steel spring for a 5/16" dia. screw

62 COIL, for use with 10-volt control

62A COIL, for use with 24-volt control

63 SCREW, used as terminal post

63A LOCK WASHER, stainless steel internal tooth, for a #10 screw

P85-367 31066-122-01

P85-368 31066-122-02

P85-135 00351-003-00

P85-556 47508-224-00

P85-757 51320-059-01

P85-447 42760-174-04

64 BLOCK, only

65 SUPPORT COMPLETE, for overload relay

66 CONNECTOR COMPLETE, for use with coil

Ref. 59 for 110-volt DC high-speed switch machines

66A CONNECTOR COMPLETE, for use with coil

Ref. 59 for 24-volt DC high-speed switch machines

67 SCREW, for connector Ref. 3 and finger Ref.

67A NUT, for above

67B WASHER, stainless steel internal tooth lock, for a #4 screw

P85-449

P85-308

P85-924

42760-199-01

15753-006-00

12680-001-00

68 CONNECTOR

69 FINGER COMPLETE, with contact

P85-448

P85-836

42760-191-01

54541-013-01

70 SUPPORT COMPLETE, with spring and stop P85-756 51320-058-01

P1293, Rev. Oct/12 7–49 Alstom Signaling Inc.

Parts Catalog

16 17 18 19 C 20 21 22 23 24 25

35 36 37 28 D 39 40 41

28 34

49 49

54 45

P1293, Rev. Oct/12

Figure 7–15. Switch Machine Motors

7–50 Alstom Signaling Inc.

Parts Catalog

Table 7–13. Switch Machine Motors

Ref

No.

Description Catalog

No.

Drawing No.

MOTOR COMPLETE, 110-volt, direct-current, high speed with magnetic detent, no heater

MOTOR COMPLETE, 110-volt, direct-current, high speed with magnetic detent, with 110 V heater

A1 MOTOR COMPLETE, except 24-volt, directcurrent, high speed with magnetic detent, no heater

A1 MOTOR COMPLETE, except 24-volt, directcurrent, high speed with magnetic detent, with

110 V heater

P85-537

P85-536

45630-019-02

45630-019-12

45630-019-01

45630-019-11

A1 MOTOR COMPLETE, except 24-volt, directcurrent, high speed with magnetic detent, with

24 V heater

DETENT COMPLETE, for Models 5E, 5F, 5G

& 5H switch machines

BRUSH HOLDER COMPLETE, does not include brushes

P85-536

P85-981

P85-223

45630-019-13

09040-003-01

02349-005-01

D * ARMATURE COMPLETE, for 110-volt motor P85-538 45631-010-01

D1 * ARMATURE COMPLETE, for 24-volt motor P85-539 45631-010-02

HASP, for cover

VENTILATOR, for case

P85-310

P81-204

16110-009-00

52981-003-00

2A PIPE PLUG

3 STAPLE, for hasp

ROLLPIN, stainless steel 1/4" x 1" long

ROLLPIN, stainless steel 1/4" x 2" long

STRAP, for cover

COVER COMPLETE

ROLLPIN, 1/4" x 2 1/2" long

9 SCREW, for fastening detent to motor

9A LOCK WASHER, steel spring for a 5/16" dia. screw

10 CASE, only

P85-127 00678-002-00

P81-141 16914-016-00

P85-362 30804-018-00

P85-789 52318-019-01

P85-313 17188-003-00

P85-130 00712-002-00

P85-541 45640-027-00

P1293, Rev. Oct/12 7–51 Alstom Signaling Inc.

Parts Catalog

Table 7–13. Switch Machine Motors (Cont.)

Ref

No.

Description Catalog

No.

Drawing No.

11 MACHINE SCREW, stainless steel #10-32 x 1-

1/2" long slotted flat head

11A MACHINE SCREW HEX. NUT, stainless steel

#10-32

11B LOCK WASHER, steel spring for a #10 screw

12 CAP SCREW, nylok 5/8"-24 x 1-1/4" long hex. head

12A LOCK WASHER, stainless steel internal tooth, for a 5/8" dia. screw

13 CONE, only

14 SPACER

15 SPACER

16 GASKET, for case

P85-263 06385-002-00

P85-423 38165-072-00

P85-422 38165-083-00

P85-296 13014-140-00

17 CASE, only

18 GASKET, black sponge rubber 7/16" dia. gasket, order by the foot

P85-542

P85-0460

45640-024-00

43460-022-00

19 FLAT WASHER, stainless steel, for a 3/8" dia. screw; if a new armature is required for an old motor, then order magnet complete (09032-

004-01) and pin (17188-38).

20 SHIELD, for armature

COVER, for commutator

NAME PLATE for motor

22A SCREW, steel #6, x 1/4" long round head drive type

P85-282 09039-000-01

P85-811 58605-037-01

P85-140 00401-697-00

WASHER, fiber, for coils

CASE, only

25 COIL, set, for 24-volt motor, consists of two coils and pole pieces

25A COIL, set, for 110-volt motor, consists of two coils and pole pieces

28 BALL BEARING, light duty single row double shield radial ball, for 25/32 " shaft

29 WOODRUFF KEY, steel 3/16" x 3/4"

P85-307 15541-023-00

P85-540 45640-011-00

P85-936 29999-015-02

P85-935

P85-573

29999-015-01

49536-091-00

P1293, Rev. Oct/12 7–52 Alstom Signaling Inc.

Parts Catalog

Table 7–13. Switch Machine Motors (Cont.)

Ref

No.

Description Catalog

No.

Drawing No.

30 ROLLPIN, stainless steel 3/16" x 1-3/8" long

31 PINION, for 110-volt motor

32 WOODRUFF KEY, steel 5/32" x 5/8"

33 PINION, for 24-volt motor

34 ROLLPIN, stainless steel 3/16" x 1-1/8" long

35 MAGNET COMPLETE

36 MAGNET COMPLETE

37 WASHER, wave, for bearing

39 HEX. NUT, steel 5/16" - 18

39A STEEL SPRING LOCK WASHER, for 5/16" dia. screw

40 CAP SCREW, steel 3/8"-16 x 1-1/2" long hex. head

40A LOCK WASHER, steel spring, for a 3/8" dia. screw

P85-509

P85-507

P85-281

P85-280

45533-019-00

45533-012-00

09037-001-03

09032-004-01

P85-182 00590-101-00

41 CAP SCREW, steel 5/16"-18 x 1-3/4" long hex. head

41A LOCK WASHER, steel spring for a 5/16" dia. screw

44 MACHINE SCREW HEX. NUT, brass #14-24

45 WASHER, for terminal posts P76-108 01225-002-00

47 HOLDER, left hand

48 PIN, for arms

P85-375

P85-214

33595-002-00

01563-000-00

49 BRUSH, right or left hand, for 110-volt motors P85-396 35780-009-00

49A BRUSH, right or left hand, for 24-volt motors P85-395 35780-002-00

50 CONNECTOR, right hand

52 ARM, for brush

53 SPRING, for arm

54 HOLDER, right hand

55 SPACER, for holders

P85-257 04906-054-00

P85-213 01547-000-00

P85-215 01581-000-00

P85-374

P85-582

33594-002-00

49655-097-00

P1293, Rev. Oct/12 7–53 Alstom Signaling Inc.

Parts Catalog

Table 7–13. Switch Machine Motors (Cont.)

Ref

No.

Description

56 SCREW, for fastening holders to block

56A LOCK WASHER, stainless steel internal tooth, for a 1/4" dia. screw

Catalog

No.

Drawing No.

P85-120 00504-004-00

P1293, Rev. Oct/12 7–54 Alstom Signaling Inc.

Parts Catalog

3 4 5 6 7 8 9

+DC

-DC

10 11

Figure 7–16. Terminal Board

P1293, Rev. Oct/12 7–55 Alstom Signaling Inc.

Parts Catalog

Table 7–14. Terminal Board

Ref

No.

Description Catalog

No.

Drawing No.

TERMINAL BOARD COMPLETE, with 20 terminal posts and disconnecting switch

TERMINAL BLOCK, 10-way

SWITCH COMPLETE, disconnecting

TERMINAL BOARD, only

WOOD SCREW, steel #10 x 1-1/4" long slotted head

2A WASHER, stainless steel flat for a #10 screw

2B WASHER, red rubber 7/16" O.D., 3/16" I.D.,

1/16" th.

P85-867 55035-003-24

P85-878 56140-019-00

P85-807 53615-000-03

P85-555 47475-006-00

3 SCREW, for mounting terminal blocks

4 NUT, for terminal posts

4A WASHER, for above

P85-125 00631-004-00

P65-585 42839-008-00

P76-108 01225-002-00

P1293, Rev. Oct/12 7–56 Alstom Signaling Inc.

4 ¼ “

Parts Catalog

WIRE ENTRANCE COUPLINGS

2 3/8 “ DIA.

2 “ DIA.

4 ¼ “

LOCK ROD LUGS

2 ½ “

3 ½ “ 3 ½ “

F G

Figure 7–17. Wire Entrance Couplings, Conduit Lock Rod and Detector Rod Lugs

(Sheet 1 of 2)

P1293, Rev. Oct/12 7–57 Alstom Signaling Inc.

Parts Catalog

DETECTOR ROD LUGS

2 ½ “

3 ½ “

H J

2 ½ “

K L

ENTRANCE COUPLING WITH TELEPHONE JACK

CONDUIT

1 7/8 “ I.D.

2 3/6 “ I.D.

Figure 7–17. Wire Entrance Couplings, Conduit Lock Rod and Detector Rod Lugs

(Sheet 2 of 2)

P1293, Rev. Oct/12 7–58 Alstom Signaling Inc.

Parts Catalog

Table 7–15. Wire Entrance Couplings and Conduit Lock Rod and Detector Rod Lugs

Ref

No.

Description Catalog

No.

Drawing No.

COUPLING, for 2-3/8" I.D., rubber conduit

COUPLING, for 1-7/8" I.D., rubber conduit

COUPLING, offset, for 2" flexible conduit

COUPLING, straight, for 2" flexible conduit

LUG, 3-1/2" spacing, for 1" dia. lock rod

LUG, 2-1/2" spacing, for 1" dia. lock rod

LUG, 3-1/2" spacing, swivel type, for 1" dia. lock rod, includes cup nuts

A85-500

A85-501

A85-502

A85-503

A85-560

A85-561

A85-562

45689-087-00

45689-106-00

45688-096-01

45688-097-01

30908-005-00

30908-014-00

30908-099-00

LUG, 2-1/2" spacing, for 3/4" dia. detector rod A85-563 30908-004-00

LUG, 3-1/2" spacing, for 3/4" dia. detector rod A85-564 59534-000-03

LUG, 2-1/2" spacing, for 3/4" dia. detector rod A85-565 59534-000-01

WIRE ENTRANCE COUPLING, with telephone jack, mounted in case

A85-510 56215-005-01

HOSE, rubber 1-7/8" I.D. 3 ply radiator P85-1322 55274-025-00

CONDUIT, 2" flexible, recommended length 3' A85-530 81088-000-01

HOSE, rubber 2-3/8" I.D. 3 ply radiator

LUBRICATION FITTING, 3/16", 65¯ angled

PLATE, insulating, for jack

COVER, complete

P85-535 55274-023-00

P85-360

P85-791

54106-111-00

52318-046-01

P85-210 01396-034-00

P85-170 00504-393-00

SPRING, for cover

PIN, for cover

SCREW, steel #10-24 x 5/8" long self-tapping slotted flat head

10 JACK, midget

11 GASKET, for cover

12 NIPPLE, for 2-3/8" I.D. rubber conduit

13 COUPLING, for 2" flexible conduit

14 NIPPLE, for 1-7/8" I.D. rubber conduit

15 REDUCING BUSHING, steel 2" to 1-1/2"

P85-298

P85-438

P85-546

P85-564

13014-281-00

40568-003-00

45688-098-01

49034-000-00

P1293, Rev. Oct/12 7–59 Alstom Signaling Inc.

Parts Catalog

P1293, Rev. Oct/12

Figure 7–18. Tools

7–60 Alstom Signaling Inc.

Parts Catalog

Table 7–16. Tools

Ref

No.

Description Catalog

No.

Drawing No.

WRENCH, switch-adjusting, for 1-1/4" throw rod

WRENCH, switch-adjusting, for 1" lock rod

WRENCH, switch-adjusting, for 3/4" lock and detector rods

4 WRENCH, switch-adjusting, for 5/8" detector rods

WRENCH 5

6 WRENCH, for No. 10 and No. 14 terminal post nuts

WRENCH, steel 9/16" open end 7

WRENCH, steel 3/4" and 7/8" double open end

SOCKET WRENCH, insulated, for No. 14

A.A.R. terminal post nuts

10 POINT DETECTOR ROD GAUGE

P85-405 36593-005-00

P85-406 36593-006-00

P85-407 36593-007-00

P85-408 36593-008-00

P85-410 36593-022-00

P65-913 43576-030-00

P65-910 43576-023-00

P85-461 43576-005-00

P65-901 15194-010-02

P85-1216 36183-059-00

P1293, Rev. Oct/12 7–61 Alstom Signaling Inc.

Parts Catalog

THIS PAGE INTENTIONALLY LEFT BLANK.

P1293, Rev. Oct/12 7–62 Alstom Signaling Inc.

Drawings

A. APPENDIX A – DRAWINGS

A.1. OVERVIEW

In this appendix the wiring and circuit application diagrams are separated by model designations and presented in this sequence: 5E, 5F, 5G and 5H.

WARNING

IF THE WIRES TO THE SELECTOR-LEVER CONTACT BLOCK

ASSEMBLY HAVE BEEN REMOVED, THE MOTOR CONTROL WIRES

MUST BE RECONNECTED TO THE OUTER CONTACT (THE

CONTACT FARTHEST FROM THE CENTER OF THE MACHINE).

INTERCHANGING MOTOR CONTROL WIRES AND SWITCH

REPEATER WIRES MAY RESULT IN THE MOTOR UNEXPECTEDLY

DRIVING THE HAND-THROW LEVER. WHILE REPLACING THOSE

WIRES, KEEP AWAY FROM SIDE WHERE HAND-THROW LEVER IS

LOCATED, DISCONNECT ALL POWER TO THE SWITCH MACHINE.

P1293, Rev. Oct/12 A-1 Alstom Signaling Inc.

Drawings

POINT DETECTOR

(NOTE 4)

MOTOR

8 7 6 5 4

2 1

1 2 3

SNUB RESISTOR LEAD

(NOTE 2)

SNUB RECTIFIER

NW(-)

5 6

7 8

GND

CW(+) RED

CRANK

CONTACT

RWR

NWR

SHUNT

STRIPS A

(NOTE 1)

SEE REPEATER

RELAY CIRCUIT

NOTE 1. Shunt strips A are used for polarized switch repeater relay circuits only.

NOTE 2. Snub resistor lead is used in 110-volt machines only.

NOTE 3. 8-amp Fusetrons are used with 110-volt machines.

10-amp Fusetrons are used with 24- to 32-volt machines.

NOTE 4. For block type derails, transpose leads to motor terminals 3 and 4.

WZR

OR s

DC(+)

TO CONTROL RELAYS

FOR SECOND SWITCH

OF CROSSOVER

DC(-)

24 - 32

OR 110 VOLTS

(NOTE 3)

Figure A–1. Typical Right-Hand Point Normally Closed Wiring Diagram and Control

Circuit, Model 5E Switch Machine

POINT DETECTOR

(NOTE 4)

MOTOR

8 7

6 5 4 3 2 1

1 2 3

SNUB RESISTOR LEAD

(NOTE 2)

SNUB RECTIFIER

NW(+)

5 6

7 8

GND

CW(-) RED

CRANK

CONTACT

NWR

RWR

SHUNT

STRIPS A

(NOTE 1)

SEE REPEATER

RELAY CIRCUIT

NOTE 1. Shunt strips A are used for polarized switch repeater relay circuits only.

NOTE 2. Snub resistor lead is used in 110-volt machines only.

NOTE 3. 8-amp Fusetrons are used with 110-volt machines.

10-amp Fusetrons are used with 24- to 32-volt machines.

NOTE 4. For block type derails, transpose leads to motor terminals 3 and 4.

WZR

OR s

DC(+)

TO CONTROL RELAYS

FOR SECOND SWITCH

OF CROSSOVER

DC(-)

24 - 32

OR 110 VOLTS

(NOTE 3)

Figure A–2. Typical Left-Hand Point Normally Closed Wiring Diagram and Control

Circuit, Model 5E Switch Machine

P1293, Rev. Oct/12 A-2 Alstom Signaling Inc.

Drawings

POINT DETECTOR

8 7 6 5

4 3 2

R.H.POINT

NORMALLY

CLOSED

NWP

L.H.POINT

NORMALLY

CLOSED

1 2 3 4

5 6 7 8

DC+

DC-

DC+

NWP

DC-

NOTE: Point-detector contacts are shown in position for right-hand point normally closed.

Figure A–3. Typical Polarized Switch Repeater Relay Circuit Using Shunt Strips A,

Single Switch, Model 5E Switch Machine

POINT DETECTOR

8 7 6 5

4 3 2 1

R.H. POINT

NORMALLY

CLOSED

L.H. POINT

NORMALLY

CLOSED

WP1A

NWP1

WP1

NWP1

NWP WP

POINT DETECTOR

8 7 6 5

4 3 2 1

1 2 3

ENERGY END

C 5

6 7 8

DC+

WP1

DC-

DC+

NWP

WP1A

DC-

1 2

RELAY END

3 4

5 6 7 8

NOTE: Point-detector contacts are shown in position for right-hand point normally closed.

Figure A–4. Typical Polarized Switch Repeater Relay Circuit Using Shunt Strips A,

Crossover, Two Model 5E Switch Machines

P1293, Rev. Oct/12 A-3 Alstom Signaling Inc.

Drawings

R.H.POINT

NORMALLY

CLOSED

CRWP

RWP

L.H.POINT

NORMALLY

CLOSED

CNWP

NWP

POINT DETECTOR

8 7 6 5

SHUNT

STRIPS B

(NOTE 1)

1 2 3 4

7 8

DC+

NWP1

CNWP1

DC-

DC+

RWP1

CRWP1

DC-

NOTE 1. To use neutral switch repeater relay circuit, remove shunt strips A,, Figure 2-31,

and assemble shunt strips B as shown. Shunt strips B are in the cloth bag which

contains the motor ventilators

NOTE 2. Point-detector contacts are shown in position for right-hand point normally closed.

Figure A–5. Typical Neutral Switch Repeater Relay Circuit, Single Switch,

Model 5E Switch Machine

R.H. POINT

NORMALLY

CLOSED

L.H. POINT

NORMALLY

CLOSED

CRWP1

RWP1

CNWP1

NWP1

POINT DETECTOR

8 7 6 5

SHUNT

STRIPS B

(NOTE 1)

1 2 3

ENERGY END

C 5

3 2 1

6 7 8

RWP

CRWP

CNWP

NWP

CRWP

RWP

DC+

NWP1

CNWP1

DC-

DC+

RWP1

CRWP1

DC-

POINT DETECTOR

8 7 6 5

SHUNT

STRIPS B

(NOTE 1)

1 2

RELAY END

3 4

2 1

7 8

NOTE 1. To use neutral switch repeater relay circuit, remove shunt strips A,, Figure 2-31,

and assemble shunt strips B as shown. Shunt strips B are in the cloth bag which

contains the motor ventilators

NOTE 2. Point-detector contacts are shown in position for right-hand point normally closed.

Figure A–6. Typical Neutral Switch Repeater Relay Circuit, Crossover,

Two Model 5E Switch Machines

P1293, Rev. Oct/12 A-4 Alstom Signaling Inc.

Drawings

WZR

NWR

OR s

POINT DETECTOR

SNUB RESISTOR LEAD

(NOTE 2)

SNUB RECTIFIER

NW(-)

(NOTE 4)

8 7 6

5 4

2 1

MOTOR

CRANK

CONTACT

1 2 3 4 5 6

7 8

GND

CW(+) RED

SELECTOR-LEVER

CONTACTS

(NOTE 5)

SHUNT

STRIPS A

(NOTE 1)

RWR

SEE REPEATER

RELAY CIRCUIT o

NOTE 1. Shunt strips A are used for polarized switch repeater relay circuits only.

NOTE 2. For 110-volt machines use snub resistor P/N 42760-224-03.

For 24-volt machines use connector P/N 42760-211-02.

NOTE 3. 8-amp Fusetrons are used with 110-volt machines.

10-amp Fusetrons are used with 24- to 32-volt machines.

NOTE 4. For block type derails, transpose leads to motor terminals 3 and 4.

NOTE 5. See WARNING on page A-1.

TO CONTROL RELAYS

FOR SECOND SWITCH

OF CROSSOVER

DC(+)

DC(-)

24 - 32

OR 110 VOLTS

(NOTE 3)

Figure A–7. Typical Model 5F Wiring Diagram and Control Circuit,

Right-Hand Point Normally Closed

WZR

RWR

OR s

DC(+)

POINT DETECTOR

SNUB RESISTOR LEAD

(NOTE 2)

SNUB RECTIFIER

NW(+)

NWR

(NOTE 4)

8 7

5 4 3 2 1

MOTOR

1 2 3 4

5 6

7 8

GND

CW(-) RED

CRANK

CONTACT

SELECTOR-LEVER

CONTACTS

(NOTE 5)

SHUNT

STRIPS A

(NOTE 1)

SEE REPEATER

RELAY CIRCUIT o

NOTE 1. Shunt strips A are used for polarized switch repeater relay circuits only.

NOTE 2. For 110-volt machines use snub resistor P/N 42760-224-03.

For 24-volt machines use connector P/N 42760-211-02.

NOTE 3. 8-amp Fusetrons are used with 110-volt machines.

10-amp Fusetrons are used with 24- to 32-volt machines.

NOTE 4. For block type derails, transpose leads to motor terminals 3 and 4.

NOTE 5. See WARNING on page A-1.

TO CONTROL RELAYS

FOR SECOND SWITCH

OF CROSSOVER

24 - 32

DC(-)

OR 110 VOLTS

(NOTE 3)

Figure A–8. Typical Model 5F Wiring Diagram and Control Circuit,

Left-Hand Point Normally Closed

P1293, Rev. Oct/12 A-5 Alstom Signaling Inc.

Drawings

POINT DETECTOR

8 7 6 5

4 3 2

R.H.POINT

NORMALLY

CLOSED

NWP

L.H.POINT

NORMALLY

CLOSED

1 2 3 4

5 6 7 8

SELECTOR-LEVER

CONTACT

(See WARNING on page A-1)

DC+

DC-

DC+

NWP

DC-

NOTE: Point-detector contacts are shown in position for right-hand point normally closed.

Figure A–9. Typical Polarized Switch Repeater Relay Circuit Using Shunt Strips A,

Single Switch, Model 5F Switch Machine

POINT DETECTOR

8 7 6 5

4 3 2 1

R.H. POINT

NORMALLY

CLOSED

L.H. POINT

NORMALLY

CLOSED

WP1A

NWP1

WP1

NWP1

NWP WP

POINT DETECTOR

8 7 6 5

4 3 2 1

1 2 3

ENERGY END

C 5

6 7 8

DC+ DC+

1 2

RELAY END

3 4

6 7

NWP

WP1A

DC-

SELECTOR-LEVER

CONTACT

(See WARNING on page A-1)

WP1

DC-

SELECTOR-LEVEL

CONTACT

(See WARNING on page A-1)

NOTE: Point-detector contacts are shown in position for right-hand point normally closed.

Figure A–10. Typical Polarized Switch Repeater Relay Circuit Using Shunt Strips A,

Crossover, Model 5F Switch Machine

P1293, Rev. Oct/12 A-6 Alstom Signaling Inc.

Drawings

R.H.POINT

NORMALLY

CLOSED

CRWP

RWP

L.H.POINT

NORMALLY

CLOSED

CNWP

NWP

POINT DETECTOR

8 7 6 5

SHUNT

STRIPS B

(NOTE 1)

1 2 3 4

6 7

(NOTE 3)

SELECTOR-LEVER

CONTACT

DC+

NWP

CNWP

DC-

DC+

RWP

CRW

DC-

NOTE 1. To use neutral switch repeater relay circuit, remove shunt strips A,

Figure 2-31, and assemble shunt strips B as shown. Shunt strips B are in the cloth bag which contains the motor ventilators.

NOTE 2. Point-detector contacts are shown in position for right-hand point normally closed.

NOTE 3. See WARNING on page A-1.

Figure A–11. Typical Neutral Switch Repeater Relay Circuit, Single Switch,

Model 5F Switch Machine

R.H. POINT

NORMALLY

CLOSED

L.H. POINT

NORMALLY

CLOSED

CRWP1

RWP1

CNWP1

NWP1

POINT DETECTOR

8 7 6 5

SHUNT

STRIPS B

(NOTE 1)

1 2

ENERGY END

3 4

C 5

RWP

CRWP

CNWP

NWP

CRWP

RWP

POINT DETECTOR

8 7 6 5

SHUNT

STRIPS B

(NOTE 1)

1 2

RELAY END

3 4

(NOTE 3)

SELECTOR-LEVER

CONTACT

DC+

NWP1

CNWP1

CWP1

DC-

DC+

RWP1

CRWP1

CWP1

DC-

NOTE 1. To use neutral switch repeater relay circuit, remove shunt strips A,

Figure 2-31, and assemble shunt strips B as shown. Shunt strips B are in the cloth bag which contains the motor ventilators.

NOTE 2. Point-detector contacts are shown in position for right-hand point normally closed.

NOTE 3. See WARNING on page A-1.

SELECTOR-LEVER

CONTACT

Figure A–12. Typical Neutral Switch Repeater Relay Circuit, Crossover,

Two Model 5F Switch Machines

P1293, Rev. Oct/12 A-7 Alstom Signaling Inc.

Drawings

TERMINAL BOARD

1 2 3 4 5 6 7 8 9 10

R.H. POINT

NORMALLY

CLOSED

L.H. POINT

NORMALLY

CLOSED

NWP

DC+

DC-

NWP

DC+

DC-

11 12 13 14 15 16 17 18 19 20

Figure A–13. Typical Polarized Switch Repeater Relay Circuit, Single Switch,

Model 5G Switch Machine

TERMINAL BOARD

1 2 3 4 5 6 7 8 9 10

R.H. POINT

NORMALLY

CLOSED

L.H. POINT

NORMALLY

CLOSED

DC-

DC+

DC-

DC+

WP1A

NWP1

WP1

NWP

WP1

NWP1

WP1A

NWP

TERMINAL BOARD

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

ENERGY END RELAY END

Figure A–14. Typical Polarized Switch Repeater Relay Circuit, Crossover,

Two Model 5G Switch Machines

P1293, Rev. Oct/12 A-8 Alstom Signaling Inc.

Drawings

TERMINAL BOARD

1 2 3 4 5 6 7 8 9 10

R.H. POINT

NORMALLY

CLOSED

RWP

CNWP

CRWP

NWP

DC+

DC-

L.H. POINT

NORMALLY

CLOSED

NWP

CRWP

CNWP

RWP

DC+

DC-

11 12 13 14 15 16 17 18 19 20

NOTE: For neutral switch repeater relay circuits, remove strip from terminals 7C and 8C of point detector. Connect strap between terminals 6C and 7C of point detector.

Figure A–15. Typical Neutral Switch Repeater Relay Circuit, Single Switch,

Model 5G Switch Machine

TERMINAL BOARD

1 2 3 4 5 6 7 8

R.H. POINT

NORMALLY

CLOSED

L.H. POINT

NORMALLY

CLOSED

DC-

DC+

DC-

DC+

RWP1

CNWP1

CRWP1

NWP1

NWP

CRWP

CNWP

RWP

NWP1

CRWP1

CNWP1

RWP1

RWP

CNWP

CRWP

NWP

TERMINAL BOARD

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

ENERGY END

11 12 13 14 15 16 17 18 19 20

RELAY END

NOTE: For neutral switch repeater relay circuits, remove strip from

terminals 7C and 8C of point detector. Connect strap between

terminals 6C and 7C of point detector.

Figure A–16. Typical Neutral Switch Repeater Relay Circuit, Crossover,

Two Model 5G Switch Machines

P1293, Rev. Oct/12 A-9 Alstom Signaling Inc.

Drawings

TERMINAL BOARD

1 2 3 4 5 6 7 8 9 10

R.H. POINT

NORMALLY

CLOSED

L.H. POINT

NORMALLY

CLOSED

NWP

DC+

NWP

DC+

DCDC-

11 12 13 14 15 16 17 18 19 20

Figure A–17. Typical Polarized Switch Repeater Relay Circuit, Single Switch,

Model 5H Switch Machine

TERMINAL BOARD

1 2 3 4 5 6 7 8 9 10

R.H. POINT

NORMALLY

CLOSED

L.H. POINT

NORMALLY

CLOSED

DC+

WP1A

WP1

NWP

DC+

WP1

WP1A

NWP

NWP1

DC-

NWP1

DC-

TERMINAL BOARD

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

ENERGY END

11 12 13 14 15 16 17 18 19 20

RELAY END

Figure A–18. Typical Polarized Switch Repeater Relay Circuit, Crossover,

Model 5H Switch Machine

P1293, Rev. Oct/12 A-10 Alstom Signaling Inc.

Drawings

TERMINAL BOARD

1 2 3 4 5 6 7 8 9 10

R.H. POINT

NORMALLY

CLOSED

RWP

CNWP

CRWP

NWP

DC+

L.H. POINT

NORMALLY

CLOSED

NWP

CRWP

CNWP

RWP

DC+

DCDC-

11 12 13 14 15 16 17 18 19 20

NOTE: For neutral switch repeater relay circuits, remove strap from terminals 7C and 8C of point detector. Connect strap between terminals 6C and 7C of point detector.

Figure A–19. Typical Neutral Switch Repeater Relay Circuit, Single Switch,

Model 5H Switch Machine

TERMINAL BOARD

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

ENERGY END

R.H. POINT

NORMALLY

CLOSED

L.H. POINT

NORMALLY

CLOSED

DC+

RWP1

CNWP1

CRWP1

NWP1

NWP

CRWP

CNWP

RWP

DC-

DC+

NWP1

CRWP1

CNWP1

RWP1

RWP

CNWP

CRWP

NWP

DC-

TERMINAL BOARD

3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

RELAY END

NOTE: For neutral switch repeater relay circuits, remove strap from

terminals 7C and 8C of point detector. Connect strap between

terminals 6C and 7C of point detector.

Figure A–20. Typical Neutral Switch Repeater Relay Circuit, Crossover,

Two Model 5H Switch Machines

P1293, Rev. Oct/12 A-11 Alstom Signaling Inc.

Drawings

THIS PAGE INTENTIONALLY LEFT BLANK.

P1293, Rev. Oct/12 A-12 Alstom Signaling Inc.

FOR QUESTIONS AND INQUIRIES, CONTACT CUSTOMER SERVICE AT

1-800-717-4477

WWW.ALSTOMSIGNALINGSOLUTIONS.COM

ALSTOM SIGNALING INC.

1025 JOHN STREET

WEST HENRIETTA, NY 14586

Hi there! I've gone through the Alstom 5 Series 5E Electric Switch Machine Installation, Operation and Maintenance Manual. I'm familiar with its specifications and procedures for installation, maintenance, and troubleshooting. Feel free to ask me anything about this switch machine.

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Key features

Single and dual control
Hand-crank operation
Hand-throw operation (5F and 5H models)
Robust and reliable
Compatible with various control systems
Detailed installation, operation, and maintenance instructions

Frequently asked questions

The 5 Series Switch Machines come in four models: 5E, 5F, 5G, and 5H. They offer different features and functionalities.

Single control switch machines are operated by a single control system, while dual control machines have two control systems for enhanced safety and redundancy.

The 5 Series Switch Machines can be operated manually using a hand crank or a hand throw lever (for models 5F and 5H). The manual provides instructions for these operations.

The manual outlines a schedule for preventive maintenance checks, including lubrication, inspection, and testing. These procedures are essential for ensuring proper operation and extending the life of the machine.

The manual includes a section dedicated to the parts catalog, which lists all spare parts and accessories for the 5 Series Switch Machines.

User questions

Jennifer H.

What is the procedure to time the hand throw mechanism for Model 5F and 5H Electric Switch Machines?

The timing procedure requires setting the selector lever to POWER, cranking the machine to identify the full throw-bar stroke, and marking the midstroke position. Then, set the lever to HAND, rotate the hand-throw clutch gear to determine and mark the mid-point tooth. Align the hand-throw lever vertically, mesh the idler gear using the 'R' or 'L' alignment marks, and secure the gear plate and associated hardware. Finally, verify the accurate timing using the specified Timing Test procedure.

Patricia Y.

What are the functions of the point detector rod in the 5 Series Switch Machines?

The rod follows the position of the switch points, operates the detector, indicates the point position via its grooves, operates contacts to remove energy from the motor after each stroke, and provides switch point position indications to associated circuits.

John P.

What is the function of the lock rod in the switch machine?

The lock rod mechanically locks the switch points, ensuring that false point detection is not obtained when the switch machine is locked and the lock and detector rods have not moved together. The lock rod works in conjunction with the cam bar and point detector mechanism to ensure the correct and safe movement of switch points.

James U.

What are the voltage requirements and implications for the 5G and 5H Switch Machines?

The 5G and 5H Switch Machines can operate on low or high voltage DC (24 VDC or 110VDC). The higher operating voltage allows faster movement and less line loss in the cables. Control circuits to the machine operate on 10 or 24 VDC.

John P.

How is the hand throw feature operated on dual control switch machines?

To hand operate the 5H Switch Machine, rotate the Hand Throw Selector Lever to the HAND position to remove energy to the motor. Then, rotate the HAND THROW lever 180 degrees to move the switch points. After hand operation, the locations of the letters N and R on the hand-throw lever must correspond to the positions of the switch.

James M.

How do I adjust a 5F switch machine point detector rod?

The adjustment procedure depends on the lock rod notch type (narrow or wide) and whether the lock rod is released. Consult the manual for specific instructions.

James M.

How do I adjust a point detector rod on a wide-notched switch that's out of correspondence?

Adjust the point detector rod and lock rod according to the instructions in Section 3.4.2 of the manual.

Models 5E, 5F, 5G &

5H Electric Switch

Machines: Single and

Dual Control

Models 5E, 5F, 5G &

5H Electric Switch

Machines: Single and

Dual Control

1. SECTION 1 – GENERAL DESCRIPTION

2. SECTION 2 – THEORY OF OPERATION

d

Motor

Hand

Crank

Cover

3. SECTION – INSTALLATION

4. SECTION 4 – SCHEDULED MAINTENANCE

5. SECTION 5 – TROUBLESHOOTING

6. SECTION 6 – CORRECTIVE MAINTENANCE

7. SECTION 7 – PARTS CATALOG

A. APPENDIX A – DRAWINGS

What are the different models of 5 Series Switch Machines?

What is the difference between single control and dual control?

How do I operate the Switch Machine manually?

What maintenance procedures are required for Switch Machines?

Where can I find a parts catalog for Switch Machines?

Jennifer H.

Patricia Y.

John P.

James U.

John P.

James M.

James M.

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