4000 Switch Machine

Transcription

4000 Switch Machine

GRANDMASTER™
4000
Switch Machine
Installation and Maintenance Manual
P2444
GRANDMASTER™
4000
Switch Machine
Copyright© 2000, 2002, 2007 ALSTOM Signaling Inc.
Installation and Maintenance Manual
ALSTOM SIGNALING INC.
P2444, Rev. January 2007 Printed in U.S.A.
LIST OF EFFECTIVE PAGES
P2444, GrandMaster™ 4000 Switch Machine
ORIGINAL ISSUE DATE:
CURRENT REVISION AND DATE:
CURRENT CHANGE AND DATE:
Sep/00
Jan/07
NONE
PAGE
CHANGE OR
REVISION LEVEL
Cover
Title Page
i thru vi
Preface
1-1 thru 1-12
2-1 thru 2-10
3-1 thru 3-34
4-1 thru 4-12
5-1 thru 5-6
6-1 thru 6-22
7-1 thru 7-10
A-1 thru A-32
NONE
NONE
NONE
NONE
NONE
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Page 7-7, item 44 updated from -01 to -02 (-01 is obsolete)
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P2444, Rev. Jan/07
ALSTOM Signaling Inc.
THIS PAGE INTENTIONALLY LEFT BLANK
P2444, Rev. Jan/07
TABLE OF CONTENTS
SECTION 1 - GENERAL DESCRIPTION
SCOPE OF MANUAL ................................................................................................................ 1-1
SWITCH MACHINE OVERVIEW ............................................................................................ 1-1
FEATURES ................................................................................................................................. 1-2
Modular Design ..................................................................................................................... 1-2
Configurable Latchout ........................................................................................................... 1-2
Operating Power Configurations ........................................................................................... 1-2
Manual Operation Switch ...................................................................................................... 1-2
Electronic Clutch ................................................................................................................... 1-3
Slip Link Cam Bar ................................................................................................................. 1-3
Configuration Plug................................................................................................................. 1-3
MAJOR COMPONENTS............................................................................................................ 1-4
Covers .................................................................................................................................... 1-4
Guards .................................................................................................................................... 1-4
Latch Stand Module............................................................................................................... 1-4
Hand Throw Module.............................................................................................................. 1-4
Amplifier................................................................................................................................ 1-6
Electrical Harness .................................................................................................................. 1-6
Motor ..................................................................................................................................... 1-6
5:1 Gearbox............................................................................................................................ 1-6
30:1 Gearbox.......................................................................................................................... 1-7
Main Drive ............................................................................................................................. 1-7
Point Detector Switch Module............................................................................................... 1-7
Point Detector System Module .............................................................................................. 1-7
Lock Rod ............................................................................................................................... 1-8
Point Detector Rod ................................................................................................................ 1-8
Cam Bar ................................................................................................................................. 1-8
Throw Bar .............................................................................................................................. 1-8
Cross Brace ............................................................................................................................ 1-8
SAFETY PRECAUTIONS FOR MAINTAINERS................................................................... 1-10
General Requirements.......................................................................................................... 1-10
Proper Attire ........................................................................................................................ 1-10
General Safety on Transit Property ..................................................................................... 1-10
Safety at Trackside............................................................................................................... 1-11
Safety at Switch Machines................................................................................................... 1-11
P2444, Rev. Jan/07
i
TABLE OF CONTENTS (Cont.)
SECTION 2 - THEORY OF OPERATION
INTRODUCTION ....................................................................................................................... 2-1
DRIVE TRAIN ............................................................................................................................ 2-1
SEQUENCE OF OPERATION ................................................................................................... 2-1
SWITCH MACHINE CONTROL............................................................................................... 2-2
Fail Safe Features................................................................................................................... 2-2
Universal Features ................................................................................................................. 2-3
NORMAL AND REVERSE LOCKING..................................................................................... 2-4
POINT DETECTION .................................................................................................................. 2-5
LATCHOUT ................................................................................................................................ 2-7
SECTION 3 - INSTALLATION
GENERAL................................................................................................................................... 3-1
PROPERTY'S REQUIREMENTS .............................................................................................. 3-2
INSTALLATION PROCEDURES.............................................................................................. 3-2
Switch Machine Inspection.................................................................................................... 3-2
Switch Layout ........................................................................................................................ 3-3
Switch Machine Mounting..................................................................................................... 3-4
Electrical Wiring.................................................................................................................... 3-5
Field Wiring ..................................................................................................................... 3-5
Motor Wiring ................................................................................................................... 3-6
Wiring Configuration....................................................................................................... 3-8
Switch Machine Connecting and Adjusting .......................................................................... 3-9
Throw Rod ....................................................................................................................... 3-9
Lock Rod........................................................................................................................ 3-10
Connect and Initially Adjust Point-Detector Rod.......................................................... 3-12
Motor Limit Adjustment ................................................................................................ 3-14
Switch Machine Operation .................................................................................................. 3-15
Hand Crank .................................................................................................................... 3-15
Hand Throw ................................................................................................................... 3-17
Manual Operating Switch .............................................................................................. 3-18
LEFT-HAND OR RIGHT-HAND CONFIGURATION........................................................... 3-19
Throw Bar ............................................................................................................................ 3-19
Lock and Detector Rods ...................................................................................................... 3-20
Hand Throw Lever and Latch Stands .................................................................................. 3-21
BEFORE PLACING MACHINE IN SERVICE ....................................................................... 3-23
P2444, Rev. Jan/07
ii
SECTION 4 - SCHEDULED MAINTENANCE
INTRODUCTION ....................................................................................................................... 4-1
SPECIAL TOOLS AND TEST EQUIPMENT ........................................................................... 4-1
Hand Crank ............................................................................................................................ 4-1
AFTER FLOODING ................................................................................................................... 4-2
LUBRICATION GUIDELINES ................................................................................................. 4-2
PREVENTIVE MAINTENANCE INDEX ................................................................................. 4-2
SITE INSPECTION..................................................................................................................... 4-3
PREVENTIVE MAINTENANCE CHECKS.............................................................................. 4-3
Point Pressure Test................................................................................................................. 4-4
Switch Obstruction Test # 17................................................................................................. 4-4
Point Detector Check ............................................................................................................. 4-5
External PM Checks .............................................................................................................. 4-5
Internal PM Checks ............................................................................................................... 4-6
LOCK ROD AND POINT DETECTOR ADJUSTMENTS........................................................ 4-9
Lock Rod Adjustment (Narrow Notch) ................................................................................. 4-9
Lock Rod Adjustment (Wide Notch)..................................................................................... 4-9
Point-Detector Rod Adjustment........................................................................................... 4-10
WEAR PLATE REPLACEMENT ............................................................................................ 4-12
SECTION 5 - TROUBLESHOOTING
PHILOSOPHY............................................................................................................................. 5-1
TROUBLESHOOTING............................................................................................................... 5-1
Amplifier LED Display.......................................................................................................... 5-4
Amplifier Fuse ....................................................................................................................... 5-6
SECTION 6 - CORRECTIVE MAINTENANCE
PURPOSE .................................................................................................................................... 6-1
REMOVAL AND REPLACEMENT PROCEDURES ............................................................... 6-1
Covers .................................................................................................................................... 6-2
Cross Brace ............................................................................................................................ 6-3
Amplifier................................................................................................................................ 6-4
Switches ................................................................................................................................. 6-5
Brushless DC Motor and 5:1 Gearbox................................................................................... 6-6
30:1 Gearbox.......................................................................................................................... 6-8
Hand Throw Lever............................................................................................................... 6-10
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iii
Latch Stand .......................................................................................................................... 6-12
Main Drive ........................................................................................................................... 6-13
Lock Rod.............................................................................................................................. 6-15
Point Detector Module......................................................................................................... 6-15
Point Detector Switch Module............................................................................................. 6-17
Point Detector Rod............................................................................................................... 6-18
Housing ................................................................................................................................ 6-19
Throw Bar ............................................................................................................................ 6-20
Cam Bar ............................................................................................................................... 6-21
Throw Bar and Lock Rod Wear Plate Assembly................................................................. 6-22
SECTION 7 - PARTS CATALOG
GENERAL................................................................................................................................... 7-1
PARTS LIST................................................................................................................................ 7-1
APPENDIX A - DRAWINGS
OVERVIEW ............................................................................................................................... A-1
WIRING AND CIRCUIT APPLICATIONS.............................................................................. A-2
INSTALLATION AND SPACE REQUIREMENTS............................................................... A-12
P2444, Rev. Jan/07
iv
LIST OF FIGURES
Figure No.
Description
Page
1-1
1-2
Model GM4000 Switch Machine - Exterior View .............................................. 1-5
Model GM4000 Switch Machine - Interior View ............................................... 1-9
2-1
2-2
Throw Bar Locking Position................................................................................ 2-4
Latch Out Components ........................................................................................ 2-8
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
3-15
3-16
3-17
Typical GM4000 Switch Layout ......................................................................... 3-1
Throw Rod Clearance .......................................................................................... 3-3
Typical Mounting of GM4000............................................................................. 3-4
Typical GM4000 Internal Wiring Components................................................... 3-6
Typical GM4000 Internal Wiring Connections (TB1) ........................................ 3-7
Terminal Wiring and Configuration Plug Location............................................. 3-8
Throw Rod Connection Hardware ..................................................................... 3-10
Lock Rod Connection Hardware ....................................................................... 3-10
Lock Rod Features and Components ................................................................. 3-11
Point-Detector Rod Connection Hardware ........................................................ 3-12
Point-Detector Rod Adjustment Hardware........................................................ 3-14
GM4000 Hand Crank Operation........................................................................ 3-16
Hand Throw Hardware ...................................................................................... 3-17
Manual Operation Hardware ............................................................................. 3-18
Throw Bar (Right and Left-Hand Configuration).............................................. 3-19
Lock and Detector Rod (Right and Left-Hand Configuration).......................... 3-20
Hand Throw Lever and Latch Stand Components............................................. 3-22
4-1
4-2
Internal GM4000 Components ............................................................................ 4-7
Point-Detector Rod Adjustment Components ................................................... 4-11
6-1
6-2
6-3
6-4
6-5
6-6
6-7
6-8
6-9
6-10
Cover Removal and Replacement Components .................................................. 6-2
Cross Brace Removal and Replacement Components......................................... 6-3
Amplifier Removal and Replacement Components ............................................ 6-5
Switch Removal and Replacement Components ................................................. 6-6
Motor and Gearbox Removal and Replacement Components............................. 6-8
Gearbox Removal and Replacement Components .............................................. 6-9
Hand Throw Lever Removal and Replacement Components............................ 6-11
Latch Stand Removal and Replacement Components ....................................... 6-12
Main Drive Removal and Replacement Components........................................ 6-14
Point Detector Module Removal and Replacement Components...................... 6-16
P2444, Rev. Jan/07
v
LIST OF FIGURES (Cont.)
Figure No.
Description
Page
6-11
6-12
Point Detector Switch Module Removal and Replacement Components ......... 6-18
Wear Plate Assembly Removal and Replacement ............................................ 6-22
7-1
Typical GM4000 Switch Machine....................................................................... 7-3
P2444, Rev. Jan/07
vi
LIST OF TABLES
Table No.
Description
Page
2-1
Switch Movement ............................................................................................... 2-5
4-1
Preventive Maintenance Index............................................................................. 4-2
5-1
5-2
Troubles Noticed from the Control Locations ..................................................... 5-2
Trackside Noted Symptoms................................................................................. 5-3
P2444, Rev. Jan/07
vii
P2444, Rev. Jan/07
viii
PREFACE
ABOUT THE MANUAL
This manual is intended to provide the necessary information to maintain and ensure proper
operation of an ALSTOM GrandMaster 4000 (GM4000) Switch Machine. The information
provided is not limited to the components of the switch machine. Most of the drawings within
this manual are final or approved. Some of the drawings that contain hardware not subject to
change have been finalized and call-outs added. The balance of the drawings with call-outs will
be added to this manual upon finalization.
The information in this manual is arranged into sections. The title and a brief description of each
section follow:
Section 1 - General DESCRIPTION: This section gives general information on the
components of the GM4000 Switch Machine. Safety precautions are also provided in this
section.
Section 2 - THEORY OF OPERATION: This section gives general information on the
operation of the GM4000 Switch Machine. Safety precautions are also provided in this section.
SECTION 3 - INSTALLATION: This section describes the field installation and setup of the
GM4000 Switch Machine.
Section 4 - PREVENTIVE MAINTENANCE: This section describes the tools, preventive
maintenance procedures, and functional tests used on the GM4000 Switch Machine. The
frequency and interval, for the performance of the given information, are also included.
Section 5 - TROUBLESHOOTING: This section describes possible failures/symptoms along
with the corrective action for the GM4000 Switch Machine.
Section 6 - CORRECTIVE MAINTENANCE: This section describes the adjustment and
replacement procedures associated with corrective maintenance of the GM4000 Switch Machine.
Section 7 - PARTS CATALOG: This section identifies and lists the spare parts associated with
operations of the GM4000 Switch Machine.
APPENDIX A - DRAWINGS: this section has representative circuit drawings along with an
installation and space requirement drawing of the GM4000 Switch Machine.
P2444, Rev. Jan/07
P2444, Rev. Jan/07
SECTION 1
GENERAL DESCRIPTION
SCOPE OF MANUAL
The purpose of this manual is to describe features of the ALSTOM GrandMaster 4000™
(GM4000) electric switch machine and describe how to properly inspect, service, test, remove,
and replace the recommended spare parts.
SWITCH MACHINE OVERVIEW
The universal design concept of the ALSTOM model GM4000 electric switch machine allows
utilization at interlockings and derails regardless of the variations with existing switch machines,
available power, and weights of rail. It is especially suitable for use in subways or on rapid
transit properties.
The GM4000 weighs approximately 1000 pounds, measures 67.25 inches long, 40.83 inches
wide, and 8.13 inches high and has a 6.5 inch stroke. The switch machine produces 4000 pounds
of thrust utilizing 110V (AC or DC) operating energy.
The GM4000 switch machine incorporates all of the features required to meet interlocking
practices. Some additional features include configurable latchout, operating power
configurations, manual operation switch, an electronic clutch, and a slip link cam bar.
WARNING
Switch Calls, for a duration of 150 milliseconds or greater, will begin
the switch machine unlocking process. If this condition exists, due to
the control system used, a timing relay is required in the circuit
connected to the switch machine.
P2444, Rev. Jan/07
1-1
FEATURES
The GM4000 is designed for long life and low maintenance, and helps reduce inventory due to
its field configurable change-out design. Its long life and low maintenance are attributable to a
low stressed mechanical system, dry film lubrication (DFL), brushless motor, solid state
amplifier, and significantly fewer parts than existing switch machines. The ease of field
configurable change out is the result of a modular design concept with fewer and simplified
adjustments.
The switch machine can be manually operated, utilizing supplied power, through a manual
operation switch located near the motor. The switch machine can be manually operated, without
utilizing supplied power, through the use of the hand-throw lever or hand crank. The hand crank
operation is provided for making or checking setup adjustments when power is not available.
When power is available, manual operation through the use of the manual operation switch is
recommended. These machine operating procedures are described in Section 2 of this manual.
Modular Design
The modular design of the GM4000 allows for ease of assembly and corrective maintenance.
Module locating pins in the switch machine base and a modular weight limit of 85 pounds, with
most module weight less than 50 pounds, make it possible to remove and replace switch machine
modules at trackside. Module removal and replacement procedures are described in Section 6 of
this manual.
Configurable Latchout
The latchout capabilities of the GM4000 are configurable for location requirements and can be
implemented or removed from the GM4000. Implemented latchout can be set for a restorable or
non-restorable configuration. This feature is described in Section 2 of this manual.
Operating Power Configurations
The GM4000 functions without additional hardware in a number of supplied power conditions
(24 VDC, 110 VDC, or 110 VAC). This feature is described in the following sections of this
manual.
Manual Operation Switch
The GM4000 can be field operated under power as long as a switch call is present and the switch
machine amplifier is set in the “Local” operation mode. This operation is described in the
following sections of this manual.
P2444, Rev. Jan/07
1-2
Electronic Clutch
The amplifier, utilized as an electronic clutch, uses current limit to determine the overload trip
point of the motor. When the current limit is reached, a 5-second timer starts. After 5 seconds,
the overload trip point is reached and the overload circuit shuts down power to the motor. To
resume operation, either reverse the switch call or remove and restore supplied operational
power.
Slip Link Cam Bar
When the lock rod is out of position relative to the cam bar locking dog, a fouled condition
occurs. The slip link allows the cam bar to separate so the throw bar can complete stroke
without locking the lock rod or indicating position (normal or reverse). This occurrence allows
switch points to be moved by the hand throw device. With the lock rod out of position, the splitlink feature permits the hand throw lever to be positioned in the latch stand.
Configuration Plug
The configuration plug sets the switch machine for a 3-wire, 4-wire, or 5-wire application
(typical ALSTOM and US&S wiring applications). Two configuration plugs are labeled and
shipped with the machine. The 3-wire plug is utilized for both 3-wire and 5-wire applications.
P2444, Rev. Jan/07
1-3
MAJOR COMPONENTS
The components of a mainline GM4000 switch machine are described in the following
paragraphs and shown in Figures 1-1 and 1-2.
Covers
The GM4000 has three light-weight aluminum covers, as shown in Figure 1-1, that protect
internal switch machine components from unwanted debris, water, or other material. These
covers are attached to the switch machine by a hold-down on the housing and a removable strap
that can be locked. An AAR wrench is required to remove or secure the straps that hold down
the center and end covers. The covers are removable and can be utilized as a tray to hold
hardware or tools during maintenance.
To remove a cover, a pivoting and upward pulling motion is required. The end covers attach to
the housing by slipping the thick cover lip underneath the 3/8-inch diameter rods on either end of
the housing and pivoting cover down to allow housing wall to be captured by the gasket groove
of the cover.
Guards
Guards of the GM4000, as shown in Figure 1-1, protect the space for lateral movement of the
throw bar, lock rod, and point detector rod by keeping away unwanted trackside debris, ballast,
or other material.
Latch Stand Module
The latch stand module, as shown in Figure 1-1, is a support fixture and most importantly, a
locking fixture for the hand throw lever and selector lever. The module bolts directly to the
switch machine housing. The latch stand accommodates right or left hand switch machine
configurations.
Hand Throw Module
The hand throw module, as shown in Figure 1-1, is a manual means of switching tracks without
electrical power. While in a hand throw mode, the switch machine can complete stroke, lock
switch points, and indicate normal or reverse position.
P2444, Rev. Jan/07
1-4
REAR COVER
(GM050-006-00)
HAND THROW
MODULE
(GM050-200-01)
CENTER COVER
(GM050-007-00)
THROW BAR GUARD
FIELD SIDE
(GM050-030-00)
SASIB
SASIB
GRS
RAILWAY
THROW BAR GUARD
TRACK SIDE
(GM050-029-00)
LATCH STAND MODULE
(GM050-400-01)
LOCK ROD GUARD
FIELD SIDE
(GM050-032-00)
LOCK ROD GUARD
TRACK SIDE
(GM050-031-00)
FRONT COVER
(GM050-008-00)
Figure 1-1. Model GM4000 Switch Machine - Exterior View
P2444, Rev. Jan/07
1-5
Amplifier
The amplifier, as shown in Figure 1-2, controls the brushless DC motor by reading the switch
call and configuring the motor power. The configured power causes the motor to turn in the
proper direction. The amplifier monitors the condition of the GM4000 and checks for
obstructions, motor faults, and amplifier faults. LEDs mounted on the amplifier housing display
the switch machine operational status. The amplifier features an electronic clutch, three motor
speeds, two current limits, inhibit circuits to disable the motor in a hand throw or hand crank
mode, and non-restorable latchout.
The amplifier can be set for 4-wire (model 5G/5H), 3-wire (model 5E/5F and M23), or 5-wire
(model M23) switch machine configuration through the use of a configuration plug connected to
the amplifier. The amplifier is mounted to the switch machine housing. All electrical
connections to it are made by removable connectors. The amplifier and electrical connections
are watertight and keyed to prevent damage to the amplifier. The amplifier is 2-1/4 inches wide,
13-1/4 inches long, 5-1/4 inches high, and field replaceable, and weighs approximately 6 pounds.
Electrical Harness
The electrical harness, as shown in Figure 1-2, connects the amplifier to field electrical
connections at a terminal strip located at the point detector end of the switch machine. The
electrical harness also connects limit switches located within some of the GM4000 modules to
the amplifier. These limit switches provide feedback to the amplifier, stopping the motor at
completion of a stroke. The switches and electrical connectors are watertight. The harness is
also connected to configuration jumpers (switch machine speed, current limit, and latch-out) and
the manual operation switch located within the motor end of the switch machine.
Motor
The brushless DC motor, as shown in Figure 1-2, works with the amplifier to drive the switch
machine. The motor connects to the amplifier by a pigtail harness. The two-horsepower motor
produces 110 inch-pounds of torque at 2500 rpm and bolts to the 5:1 gearbox. The motor is 41/2 inches wide, 4-1/2 inches high, and 9 inches long. The motor weighs 12 pounds and is field
replaceable.
5:1 Gearbox
The 5:1 gearbox, as shown in Figure 1-2, reduces motor output speed while increasing motor
torque. This gearbox is basically maintenance-free with spring loaded lip seals, grease packed
sealed bearings, and a synthetic lubricant for the helical gearing.
P2444, Rev. Jan/07
1-6
30:1 Gearbox
The 30:1 gearbox, flex coupled to the 5:1 gearbox as shown in Figure 1-2, reduces motor speed
while increasing drive torque. It uses spring loaded lip seals, synthetic lubricant, and low
stressed worm gearing.
The gearbox has dual input, either the hand crank or the motor. Gearbox output of the spur gear
drives the main gear with up to a possible 10,000 inch-pounds of torque.
Main Drive
The main drive module’s patented low profile design, as shown in Figure 1-2, is the driving
force and mechanical control of the switch machine. The main drive converts the rotating
motion of the motor and gearboxes to linear motion of the cam bar and throw bar, both of which
have cam surfaces designed to achieve proper stroke and timing with the lock rod and point
detector rod.
The hand crank function of the main drive module cuts out operational power to the motor
(indicated by the “Remote/Local” LED of amplifier going off). The non-electrical operation of
the switch machine is performed through the use of a hand crank.
When a faster non-electrical operation of the main drive is desired, the hand throw system is
used. The manual select lever of the hand throw shuts off electrical power prior to permitting
hand throw operation, thus allowing fast manual operation of throw bar, cam bar, lock rod, and
point detection system.
Point Detector Switch Module
The point detector switch module, as shown in Figure 1-2, consists of two rotary cam switches
(right and left) used to indicate the switch point position and switch machine correspondence.
Each switch has six contacts. Two are used in the indication relay circuit for a correspondence
condition; two are used to shunt the relay circuit in mid-stroke; one is used in the latch out
circuit; and one is used in the point detector switch module LED circuit.
Point Detector System Module
The point detector module, as shown in Figure 1-2, bolts to the switch machine base and is the
mechanical link between the point detector switches, lock rod, point detector rod, and cam bar.
The point detector module, along with other modules of the point detector system, indicate to the
train control room if a switch point position has moved off point and can be utilized to indicate
normal and reverse switch positioning.
P2444, Rev. Jan/07
1-7
Lock Rod
The lock rod, as shown in Figure 1-2, locks the front rod in position (normal or reverse) and
consists of two rods (curved and straight) that can be adjusted for varying stroke of 6.5 to 3.5
inches. The lock rod accommodates right- or left-hand switch machine configurations.
The lock rod can be either a wide or narrow notch configuration. A narrow notch will not allow
the machine to lock with a 1/4 inch obstruction, but a wide notch will. The lock rod can also be
ordered with a threaded or spade end connection.
Point Detector Rod
The point detector rod, as shown in Figure 1-2, is used to detect the position or movement of the
switch points and consists of three pieces that provide adjustment for varying (3.5 to 6.5 inches)
switch machine stroke. The point detector rod can be ordered with a solid (threaded), spade, or
threaded swivel end connection.
Cam Bar
The split link cam bar, not visible in Figure 1-2, is located under the main drive module and
point detection modules. The cam bar moves in a machined channel within the switch machine
base plate and is key to the operation of the point detector system. It is the mechanism that, in
conjunction with the lock rod, locks the switch points in position. The cam bar also prevents
indication while the switch machine is unlocked.
The slip link feature allows the cam bar to separate when the cam bar dog interferes with the
lock rod, during completion of stroke. When the lock rod is in adjustment, the cam bar will
automatically reset itself.
Throw Bar
The high strength throw bar, as shown in Figure 1-2, moves the switch points into position. The
linear movement of the throw bar is generated by the integral cam and the rotary movement of
the main drive crank. The high wear-resistant nickel plating eliminates the need of lubrication.
Cross Brace
The cross brace, as shown in Figure 1-2, is connected to the switch machine housing and
supports the covers. Two cross braces are utilized in the switch machine and can be removed
when required to give additional access to switch machine components.
P2444, Rev. Jan/07
1-8
MOTOR
(GM050-020-00)
AMPLIFIER
(GM050-024-00)
5:1 GEARBOX
(GM050-026-00)
CROSS BRACE
(GM050-005-00)
30:1 GEARBOX
(GM050-025-00)
ELECTRICAL HARNESS
(GM050-900-01)
THROW BAR
(GM050-002-00)
MAIN DRIVE
(GM050-100-01)
POINT DETECTOR
SWITCH MODULE
(GM050-800-01)
LOCK ROD
(GM050-300-0_ )
POINT DETECTOR
SYSTEM MODULE
(GM050-700-01)
POINT DETECTOR ROD
(GMO5O-500-0_ )
Figure 1-2. Model GM4000 Switch Machine - Interior View
P2444, Rev. Jan/07
1-9
SAFETY PRECAUTIONS FOR MAINTAINERS
Safe practices and common sense should always be used when working around any equipment.
Remember that good common sense and an understanding of the equipment is essential to any
safety policy. The following describes health and safety standards for testing, alterations,
repairs, improvements, or maintenance and applies to all maintenance personnel.
Note: Only authorized personnel who have reviewed and understand the information
contained in this manual should be working on or around the switch machine.
General Requirements
Maintenance personnel shall comply with all local laws, rules, statutes, and regulations of
governing or regulatory bodies within the geographical area of operation of the property (or
Authority). The requirements of these bodies or the user’s safety manual, whichever is more
stringent, shall apply. When specific standards and details are not set forth in the manual, job
specifications, or in the local laws and regulations referenced, standards published by the
Occupational Safety and Health Administration (OSHA) shall apply.
Proper Attire
1.
2.
3.
4.
Wear hard hats at all times.
Wear work shoes that are in good repair. Sneakers or tennis shoes are unsafe.
Wear clothing of proper fit. Loose fitting clothing is a hazard.
Avoid wearing belt-type key rings, and never carry tools in hip pockets.
General Safety on Transit Property
1. Never go out on a track of an operating railroad alone. Flagmen familiar with operating
procedures and safety regulations must accompany all field maintenance personnel for
maximum safety.
2. Always be alert and watchful as if each man were by himself. Be aware of the area you
and others are in at all times. Yell or signal a warning if a dangerous situation develops.
P2444, Rev. Jan/07
1-10
Safety at Trackside
1. Check for a safe place to go before starting a job and be sure that enough safe places are
available for all personnel on the track. Avoid sudden unplanned moves.
2. Never attempt to complete a job when a train is approaching.
3. Stand along the track in a clear area, stand where the train operator can see you, and take
precautionary measures.
4. When crossing the tracks in front of or behind a stopped train, cross at a great enough
distance from the train to be prepared for the train to proceed in either direction.
5. If boarding or dismounting a train, wait until the train comes to a full stop and the
operator gives his or her permission. When carrying equipment or plans, always hand
them up or down to allow free use of your hands.
6. Never step or walk on rails. Slipping off may result in serious injury.
7. Never lay tools or equipment on the rails. Objects left on a rail may derail or damage a
train and flying debris could endanger personnel along the track.
8. When taking shelter from an approaching train, always watch for a train on the adjacent
track.
9. Exercise special caution in tunnels, curves, and turnouts and on grades, as it is very
difficult to determine the direction from which a train is approaching and its distance
away.
Safety at Switch Machines
1. Keep fingers, feet, tools, and equipment out of switch points. Closing points can trap and
crush hands and feet or damage tools and equipment. A wedge properly inserted between
points will prevent an inadvertently energized switch machine from causing personal
injury or equipment damage.
2. Never step on switch rods. Rod movement can cause serious foot injury or loss of
balance.
3. Because the switch machine is often operated from a remote station (a local control
room), be sure to notify this station that maintainers are working on or around a given
switch machine. This notification may prevent the equipment from being activated
during the reported service.
Note: For safety when working on machine and power is not required: 1) place
"LOCAL/REMOTE" switch on amplifier, in the local position; 2) rotate the hand
crank cover to the open position to inhibit power to the motor.
4. When covers are removed from switch machine and gearing is exposed, keep fingers
away from gearing.
P2444, Rev. Jan/07
1-11
P2444, Rev. Jan/07
1-12
SECTION 2
THEORY OF OPERATION
INTRODUCTION
The following is a functional overview of the GM4000 Switch Machine. The operation of a
functional area is described along with associated modules and components.
DRIVE TRAIN
The GM4000 switch machine drive train consists of a motor, two gearboxes, and a main drive
module. The motor is bolted to and drives a 5:1 gearbox. The 5:1 gearbox is coupled to and
drives a 30:1 gearbox. The 30:1 gearbox drives 1.58:1 open spur gears. The splined main drive
crank converts the rotational movement of gears into a linear movement of the throw bar and
cam bar. This drive train, along with the throw bar, provides the thrust required to throw a
switch in 4, 9, or 15 seconds in 110V (AC or DC) applications and 17 seconds in 24 VDC
applications. Note that the speed of machine switching is dependent on supplied voltage.
SEQUENCE OF OPERATION
The correct order of operation for the GM4000 switch machine is as follows:
1. Break indication
2. Unlock
3. Throw
4. Lock
5. Indicate if switch points are in correct position
P2444, Rev. Sep/00
2-1
SWITCH MACHINE CONTROL
The GM4000 uses a brushless DC motor and amplifier to drive the gear train. A brushless DC
motor contains a permanent magnet armature that rotates and drives the 5:1 gearbox. The motor
contains three field coils that surround the armature. The amplifier energizes and de-energizes
the three field coils in a circular fashion. This creates a rotating magnetic field that pulls the
armature around.
There are three hall sensors that monitor the armature and provide position information to the
amplifier. This information is used to control the circuitry that powers the three field coils.
Together, the hall sensors and the amplifier regulate the motor’s RPM. The motor’s RPM is
independent of the switch machine’s load. This implies that as the switch machine’s load
varies, the switch machine’s throw time remains constant (the switch machine doesn’t slow
down as the load increases).
The amplifier also monitors the motor’s current. Motor current is directly proportional to motor
torque. As the switch machine sees an increased load such as point pressure or an obstruction,
the motor sees an increased load. The amplifier senses the increased load on the motor and
supplies more current to the motor thus increasing the motor torque. This additional motor
torque increases the switch machine’s output force up to 4000 pounds.
Fail Safe Features
The universal switch machine amplifier is fail safe. Fail Safe, as used in the signaling context
means that no failure will cause the system to be less safe than it would be if the failure had not
occurred. That is, a failure will leave the system at least as safe as it was before the occurrence
of the failure. One of the fail safe properties is that the motor cannot turn on at the wrong time.
For example, if the motor uses a transistor as a power switch and the transistor shorts out due to
a surge, the motor cannot be allowed to turn on. The same holds true for the control lines on the
motor controller. If there are transistors or transistor junctions used as switches on the control
lines and one of them shorts out, the motor again cannot be allowed to run. Any failure mode of
any part of the circuitry cannot cause the motor to operate. This includes transistor junctions
shorting, opening or shorting to ground. A failure, or combination of failures, cannot cause or
permit the motor to operate without the presence of a proper control signal (i.e. switch call).
The amplifier consists of two functional blocks. The first is the MOTOR DRIVER. There is one
driver that switches power to each motor coil. If any or all of the drivers short out, the field coil
associated with the damaged driver could be energized but it would not be de-energized at the
appropriate time. The result: the motor would stop running.
P2444, Rev. Jan/07
2-2
The second is the AMPLIFIER, the device controlling the timing signals that control the motor
driver. The amplifier controls the direction and the speed of the motor. The amplifier receives
its power only from the switch machine control lines (i.e. switch call). The amplifier can only
generate the proper sequence of signals when the control lines are energized therefore the motor
can only run when the control lines are energized. Isolation will prevent the motor power from
energizing the amplifier.
When the hand throw cut out limit switch or the hand crank cut out limit switch opens, the power
to the amplifier is removed. This vitally disables the motor. The hand throw switch and the
hand crank switch are both positive break limit switches. A positive break switch contains a
mechanism that breaks open frozen or welded contacts.
Universal Features
The amplifier has a universal power supply. The GM4000 motor will operate at a power voltage
range of 13 to 140 VDC or 88 to 140 VAC. There are no jumpers or special configurations
needed for the amplifier to work over this wide voltage range.
The system has three speed settings available if the supply voltage is above 85 volts (DC or AC).
By installing the proper speed configuration jumper, the amplifier sets the motor RPM to allow
the switch machine to throw in 4, 9, or 15 seconds. Below 85 volts, speeds will decrease
proportionally with voltage.
The system has two current settings. High-current mode allows the machine to push up to 4000
pounds. The peak current is 35 amps. The external fuses must be rated at 17 amps. Lowcurrent mode allows the machine to push up to 2800 pounds. External fuses must be rated at 12
amps.
The optimal installation is the high-voltage, high-current mode since this provides the system
with the most output force and allows for speed configuration. The universal power supply
allows the system to run at high-voltage with the maximum force out and have a low-voltage
battery backup. A low-voltage battery backup could supply a minimum of 2500 pound load
requirement.
The amplifier will run off all input configurations. It can be installed in a 3-wire mode (Model
5E/5F or M23), 4-wire mode (Model 5G/5H), or 5-wire mode (Model M23).
P2444, Rev. Jan/07
2-3
NORMAL AND REVERSE LOCKING
Both the throw bar and lock rod must be locked at end of stroke in the “normal” and “reverse”
switch point positions.
The throw bar is locked when the crank has traveled over the center of the throw bar, as shown
in Figure 2-1. When the crank is in the over-center position any load on the throw bar (point
pressure) drives the crank roller into the locking pocket of the throw bar. The cogging action of
the motor and the gear train hold the crank in the over-center position if there is no load on the
throw bar (point pressure).
The lock rod is locked when the cam bar dog is centered in the notch of the lock rod. If the
crank isn’t over center of the throw bar or the cam bar dog isn’t centered in the lock rod notch
then the motor limit cams must be adjusted per the Motor Limit Switch Adjustment Procedure.
CRANK
POSITION MARKS
(LOCKED POSITION)
THROW
BAR
MID-STROKE
(UN-LOCKED)
POSITION
MARKS
Figure 2-1. Throw Bar Locking Position
P2444, Rev. Jan/07
2-4
POINT DETECTION
There are five modules that interact to perform point detection. They are the point detector
system module, the point detector switch module, the point detector rod, the lock rod, and the
cam bar. See the module descriptions for a detailed explanation.
The point detector switch module contains two “positive break” rotary cam switches. One
switch rotates clockwise and one rotates counter-clockwise. A positive break switch contains a
mechanism that breaks open frozen or welded contacts. Each rotary cam switch consists of six
switches for indication, shunting, latchout, and continuity checking. Switches 1 and 2 are used
to shunt the NWP and WP coils in the indication relays when the switch machine is unlocked.
Switches 3 and 4 are used to indicate that the switch points, switch machine, lock rod, and point
detector rod are either in, or out of, correspondence. Switch number 5 is used for latchout.
Switch 6 is used for the continuity checking LED.
The range of motion for the rotary cam switch is 60 degrees. There is an external spring return
mechanism that returns the switch to the 0 degree position. As the switch rotates, the six
contacts actuate. See Table 2-1 for detailed switch movement.
Table 2-1. Switch Movement
Switch
Type
0°
8°
20°
21°
60°
1 shunt
X-------------------------X
2 shunt
X-------------------------X
3 indicate
X-------------------------X
4 indicate
X----------------X
5 latch out X----------------------------------X
6 LED
X------------------------------(LED on)----------X
(LED off)
NOTE: X-----X = closed switch
Switch 6 is used to check the mechanical interface (continuity) between the point detector switch
actuating lever and rotary cam switch. When the switch machine is indicating a closed point, the
LED is on and at mid-stroke the LED is off.
If contacts 3, 4, and 5 are closed, the switch machine is in correspondence and the switch
machine is indicating. Switches 3, 4, and 5 begin to open at 8 degrees. Switches 3, 4, and 5 are
open at 20 degrees. The variance in switch closure is due to tolerances in the manufacturing
process. Switches 3, 4, and 5 all must be closed before the point detector system indicates.
There is a range where the LED is on and the point detector is not indicating. This range occurs
between 8 degrees and 21 degrees, when one of the indicating switches (3, 4, or 5) is open and
the LED switch is closed.
P2444, Rev. Jan/07
2-5
There are two methods to verify that the point detector is indicating.
Method 1
1. The roller on the pivot arm is not touching the trigger on the point detector switch module.
2. The LED is on.
Method 2
1. Use a meter on TB-1, TB-2, and TB-3 to verify contact closure. Refer to schematic in
Appendix A.
Note: DO NOT use the LED when making point detector adjustments.
The point detector module interfaces between the point detector rod, the lock rod, the cam bar,
and the point detector switch module. The point detector module actuates the rotary cam
switches. As the point detector rod is displaced, the pivot arm rotates and actuates the rotary
cam switch. If it moves the correct amount (1/4 inch or 3/8 inch), the indication switches open
and the indication is broken.
The point detector system interfaces with the lock rod. There is one pin on each point detector
pivot arm that senses the position of the lock rod. If the lock rod is out of correspondence, the
pin on the pivot arm does not fall into the notch on the top of the lock rod and the point detector
system will not indicate.
The cam bar interfaces with the point detector module. The cam bar locks the Lock rod. As the
machine is operated, the first thing that happens is the cam bar separates the Latchout dogs and
the pivot arms. This action rotates both rotary cam switches and thus breaks indication. The
indication is broken before the cam bar dog unlocks the lock rod. In mid-stroke, the cam bar
holds latchout dogs separated on the point detector module. This keeps both rotary cam switches
rotated 25 degrees. Switches 1 and 2 stay closed and the NWP and the WP short out. As the
switch machine reaches end-of-stroke and the machine is locked, the cam bar leaves the latchout
dogs and the pivot arms rotate allowing the point detector switch module to indicate.
P2444, Rev. Jan/07
2-6
LATCHOUT
Latchout is an indication option and a mechanical memory system that stores position
information of points that have moved at least 1/4 inch. Latchout can be configured for 1/4 inch
or 3/8 inch. This section highlights the 1/4 inch latchout. The same principles apply for 3/8 inch
latchout. Refer to the installation section of this manual for 1/4 inch versus 3/4 inch
installations.
If there is a 1/4 inch movement of the switch points in a system without latchout, the point
detector system will not indicate. If the points close back up, the system will re-indicate.
If latchout is used and there is a ¼-inch movement of the points, the point detector system will
not indicate. If the points close back up, the system will not indicate regardless of the point
position. The system is “latched out”.
There are two ways to reset the system once the system is latched out.
1. Restorable latchout - The system can be reset remotely or locally. To reset the system
remotely in restorable latchout mode issue a switch call. To reset the machine locally; hand
throw the machine, move the latchout dog as described in the scheduled maintenance section,
or use the manual control switch. The motor will run in restorable latchout mode.
2. Non-Restorable latchout - The system can only be reset locally. To reset the machine hand
throw the machine or move the latchout dog as described in the scheduled maintenance
section. The motor will not run if the system is latched out in non-restorable latchout mode.
As the switch points open up the point detector rod moves, as shown in Figure 2-2. This
movement causes the pivot arms to rotate. When the switch points are open 1/4 inch, the switch
machine will not indicate. When the point detector rod moves an additional 0.045 inch, the
latchout dog drops behind the retaining ring. The retaining ring and the latchout dog keeps the
pivot arm from rotating even if the points close up. Since the pivot arm cannot rotate once the
system is latched out, the rotary cam switch contact numbers 3, 4, and 5 of the point detector
switch module are held open. If the three rotary cam switch contacts are open, the switch
machine will not indicate.
The motor is disabled if the system is latched out in non-restorable latch out mode. There are
three switches in parallel that are used to disable the amplifier. There is one switch located on
each rotary cam switch (switch number 5) and there is one switch located on the top of the point
detector switch module (latch out switch). If the amplifier is disabled, the motor will not run. If
one of the three switches is closed, the motor will run. If all of the switches are open, the motor
will not run.
In non-restorable latchout, the motor is dependent on the position of the latchout system and the
position of the three latchout switches. The following sequence of events describes the latchout
system under normal operation. Refer to Figure 2-2.
P2444, Rev. Jan/07
2-7
ROTARY
CAM
SWITCH
LATCH
OUT DOG
RETAINING
RING
POINT
DETECTOR
ROD
PIVOT
ARM
Figure 2-2. Latch Out Components
1. The machine is at end-of-stroke (Reverse) - Latch out switch number 5 on the “reverse”
rotary cam switch is closed. The motor can run.
2. The machine moves to mid-stroke - The Latch out switch closes. Switch number 5 on the
“reverse” and “normal” rotary cam switches open. The motor can run.
3. The machine is at end-of-stroke (Normal) - Latch out switch number 5 on the “normal”
4. The points move 1/4” + 0.045” - The mechanical system latches out. Switch number 5 on
the “normal” rotary cam switch opens. (Now all three latchout switches are open.) The
motor cannot run.
5. The latch out is reset - Latchout switch number 5 on the “normal” rotary cam switch closes.
The motor can run.
6. The machine moves to mid-stroke - The Latchout switch closes. Switch number 5 on the
“normal” rotary cam switch opens. The motor can run.
7. The machine is at end-of-stroke (Reverse) - Latchout switch number 5 on the “reverse”
8. The points move 1/4” + 0.045” - The mechanical system latches out. Switch number 5 on
the “reverse” rotary cam switch opens. (Now all three latchout switches are open.) The
motor cannot run.
P2444, Rev. Jan/07
2-8
9. The latchout is reset - Latchout switch number 5 on the “reverse” rotary cam switch closes.
The motor can run.
In restorable latchout mode, the three parallel switches are shorted out via the latchout jumper
located on TB1. The motor operates independently of the latch out system.
P2444, Rev. Jan/07
2-9
P2444, Rev. Jan/07
2-10
SECTION 3
INSTALLATION
GENERAL
There are two types of GM4000 switch machine installations:
•
A new installation
•
Replacement of an existing switch machine
Either type of installation may be performed with or without electrical energy available for
operation of the switch machine. This Section describes both kinds of installations and the
required switch machine adjustments.
Satisfactory operation of a switch layout depends on correct switch machine installation, proper
switch layout adjustments, and periodic maintenance done at prescribed intervals. The Model
GM4000 switch machine should be installed in accordance with the property’s approved switch
layout. Figure 3-1 shows a typical GM4000 switch machine layout with the associated mounting
hardware identified.
THROW BAR
CONNECTION
HARDWARE
EXTENDED
TIES
SWITCH
MACHINE
SASIB
GRS
SASIB
RAILWAY
SWITCH
POINTS
STOCK
RAIL
LOCK ROD &
POINT DETECTION
CONNECTION
HARDWARE
Figure 3-1. Typical GM4000 Switch Layout
P2444, Rev. Jan/07
3-1
PROPERTY’S REQUIREMENTS
Although this publication provides set-up information for a typical machine installation, the
maintainer should always ensure the switch layout is installed in accordance with the property's
own requirements.
INSTALLATION PROCEDURES
Installation of a new switch machine or the replacement of an existing machine consists of the
following elements:
•
Switch Machine Inspection
•
Switch Layout (Requirements and Inspection)
•
Switch Machine Mounting
•
Electrical Wiring
•
Switch Machine Connecting and Adjusting
• Switch Machine Operation
Specific drawings for switch machine wiring are given in Appendix A.
Switch Machine Inspection
The following steps describe visual inspection of external switch machine areas. This procedure
should be performed before proceeding with the installation.
1. Check the configuration of the machine being installed. If the switch machine requires
changing from left-hand to right-hand or vice versa, perform the procedure described in
"Left-Hand or Right-Hand Configuration” in this Section.
2. Check external surfaces for any damage (bent, cracked, or broken housings, hinges, or
brackets).
3. Insure covers are installed properly and fit tightly.
4. Insure wear plates are in place (in the four positions).
5. Check the switch machine control requirements (either single or dual).
6. Check the switch machine for proper lock rod configuration (either narrow- or widenotch).
7. Check the switch machine for proper connection configuration (either spade end or
thread end).
8. Check the switch machine for proper connection hardware.
9. Check for the required wiring harness and hardware.
P2444, Rev. Jan/07
3-2
Switch Layout
The following describes the installation requirements for a typical switch layout. All
requirements should be met and checked before proceeding with the installation.
A maximum clearance of 1/4 inch (less is desirable) between the throw rod and the base of the
stock rail, as shown in Figure 3-2, is essential. During operation, if proper clearance is not
maintained, the points may move up relative to the stock rail (particularly if the stock rail is
beveled for AREA detail 6100 Sampson points) and pry themselves away from the stock rail.
This motion may cause the point-detector rod in a switch machine to move enough to cause the
indication contacts to be pushed open. The tendency of points to move up can be reduced by
keeping ballast under the ties of the switch layout firmly tamped, and maintaining proper
clearance.
THROW
ROD
1/4" (MAX)
Figure 3-2. Throw Rod Clearance
Inspection Points - The following describes the visual inspection points of a typical switch
layout. All points should be checked before proceeding with the installation.
1. Inspect the heel blocks and bolts. Ensure that the thimble bolts in the heel blocks are in
place and secure.
2. Check the heel block surface in relation to the switch by sighting down the rail from the
heel block to switch point.
3. Check that rail braces are tight and tie straps are in place and secure.
4. Check all gauge plates, extension gauge plates, rail braces, and ties.
5. Check that the gauge distance of 56-1/2 inches is correct at the throw-bar and lock-rod
locations.
P2444, Rev. Jan/07
3-3
Switch Machine Mounting
The two extended ties that directly support the switch machine must be reasonably straight and,
where required, properly framed. All ties that support the switch machine must be well tamped
for their entire length to minimize vibration from passing trains. Also, it is important to check
the switch layout plans to verify the installation.
The stock rail and switch machine must be secured to well tamped ties, as shown in Figure 3-3,
to prevent movement of the switch machine and stock rail when connected and operated. More
than 4000 pounds of force can be exerted on the number one rod by the switch machine during
operation.
New Installations - Either the ALSTOM standard mounting hole pattern (3/4-inch diameter bolts
on 15-1/2 inch centers) or the US&S standard mounting hole pattern (7/8-inch diameter bolts on
16 inch centers) can be used. Do not locate the mounting hole pattern on the ties until the switch
machine is positioned in accordance with an approved switch layout drawing.
Replacement Installations - The universal mounting hole pattern interfaces with the 3/4 inch
diameter, 15-1/2 inch on center studs or bolts and 7/8 inch diameter, 16 inch on center studs or
bolts.
STOCK
RAIL
EXTENDED
TIES (2)
MOUNTING
HOLES
SASIB
SASIB
GRS
RAILWAY
SWITCH
MACHINE
Figure 3-3. Typical Mounting of GM4000
P2444, Rev. Jan/07
3-4
Electrical Wiring
The switch machine has internal electrical wiring that integrates the switch machine components
(switches, amplifier, LEDs, and motor) and field wiring requirements that are performed based
upon location specific conditions (supplied motor power, indication circuits, and control
circuits). The switch machine’s internal wiring is completed in the factory with a wiring harness
and watertight connectors. Figure 3-4 identifies the internal wiring components of the GM4000
switch machine. The internal wiring schematic is in Appendix A.
Field Wiring
Field wiring associated with motor power, control, and indications enter the switch machine
through a wire entrance fitting located at either end of the switch machine (motor or detector
compartment).
Motor Power - Field wiring for motor power is connected to posts at terminal TB1 in accordance
with the detail wiring plans that apply to the location. Typical power circuits are in Appendix A.
Control - Field wiring for switch machine control is connected to posts at terminal TB1 in
accordance with the detail wiring plans that apply to the location. Typical power circuits are in
Appendix A.
Indications - Field wiring for point-detector provided indications are connected to posts on
terminals TB1, TB2, and TB3 in accordance with the detail wiring plans that apply to the
location. Typical indication circuits are in Appendix A.
P2444, Rev. Jan/07
3-5
TB2
TB4
TB1
WIRE
ENTRANCE
WIRE
ENTRANCE
TB3
Figure 3-4. Typical GM4000 Internal Wiring Components
Motor Wiring
There are three motor wiring configurations:
•
5-wire (three power lines and two auxiliary lines connected to a single AAR post)
•
4-wire (two power lines and two control lines)
•
3-wire (three power lines)
5-wire configuration - has three power lines that are energized only when the machine is
requested to operate. The power lines are always 24 VDC, 110 VDC, or 120 VAC. These wires
are connected to TB1-1, TB1-2, and TB1-3. The throw bar travels in one direction when power
is applied to TB1-1 and TB1-2 and in the other direction when power is applied to the TB1-2 and
TB1-3. The two auxiliary wires, connected to TB1-8, are common feed.
4-wire configuration - has two energized power lines that can be 24 VDC, 110 VDC, or 120
VAC. These wires connect to TB1-1 and TB1-3. The control lines connect to TB1-4 and TB15. The control lines are only energized when the machine is requested to operate.
3-wire configuration - has three power lines that are energized only when the machine is
requested to operate. Power lines are always 24 VDC, 110 VDC, or 120 VAC. These wires are
connected to TB1-1, TB1-2, and TB1-3. The throw bar travels in one direction when power is
applied to TB1-1 and TB1-2 and in the other direction when power is applied to TB1-2 and
TB1-3.
Power
P2444, Rev. Jan/07
5-wire
TB1-1
4-wire
TB1-1
3-6
3-wire
TB1-1
Power
Power
Control
Control
Aux
TB1-2
TB1-3
TB1-8
(2 wires)
TB1-3
TB1-4
TB1-5
-
TB1-2
TB1-3
-
TB1
TB1-8
TB1-5 TB1-4 TB1-3 TB1-2 TB1-1
Figure 3-5. Typical GM4000 Internal Wiring Connections (TB1)
To operate the switch machine using the manual switch, in the 3-, 4-, or 5-wire configuration, set
the “REMOTE/LOCAL” switch located on the amplifier to “LOCAL”. Send a request to throw
the switch machine in either direction from the control house. Operate the machine with the
manual switch. After completing manual switch operation, set the “REMOTE/LOCAL” switch
to “REMOTE”.
P2444, Rev. Jan/07
3-7
Wiring Configuration
The machine must be configured for 3-wire (ALSTOM model 5E/5F, US&S model M23/M3),
4-wire (ALSTOM model 5G/5H), or 5-wire (US&S model M23A/M23B/M3) operation via a
configuration plug. The GM4000 will not operate if the configuration plug is not installed.
Speed Configuration - The default speed of the GM4000 is four seconds. To configure the
machine for slower speeds, install the appropriate speed select jumper located on terminal TB4,
as shown in Figure 3-6.
Current Configuration - The default current configuration of the GM4000 is the high-current
operation. The GM4000 produces up to 4000 pounds of force at the end of stroke at this current
setting. If external fuses are used to limit the current to the GM4000, they must be rated above
17 amps.
The GM4000 can be configured for low-current operation by installing the low-current jumper
on TB4. The GM4000 produces up to 2800 pounds of force at the end of stroke. If external
fuses are used to limit the current to the GM4000, they must be rated above 12 amps.
LOW
CURRENT
JUMPER
TB4-1
TB4-2
TB4-3
TB4-4
TB4-5
CONFIGURATION
PLUG
OPTION
Low Current
High Current
4 sec
9 sec
15 sec
SPEED
JUMPER
JUMPER
TB4-1 to TB4-2
none
none
TB4-4 to TB4-5
TB4-3 to TB4-4
Figure 3-6. Terminal Wiring and Configuration Plug Location
P2444, Rev. Jan/07
3-8
Switch Machine Connecting and Adjusting
The following describes connecting and adjusting specific switch layout hardware to the switch
machine and assumes that proper mounting of the switch machine per switch layout plan has
been completed together with all electrical wiring.
Note: When working on machine:
1. Place "LOCAL/REMOTE" switch in the “LOCAL” position.
2. Rotate the hand crank cover to the open position to inhibit power to the motor.
Throw Rod
The following describes the throw rod connection and adjustment within a typical switch layout.
Refer to Figure 3-7.
Crank machine to mid-stroke position. Refer to “Switch Machine Operating - Hand Crank” in
this Section.
6. If this is a dual-control machine, move the selector lever to hand-throw mode.
7. Connect the throw rod clevis end to the throw bar coupler using the provided bolt, lock
washer, and nut.
8. Slide the threaded end of throw rod through the “Lost Motion” basket and the connect
rod to the basket using the double nuts provided.
9. Place and lock the switch machine into the “Normal” position. For a dual-control switch
machine, use the hand throw; refer to “Switch Machine Operating - Hand Throw” in this
Section. For a single-control switch machine, use the hand crank or the manual
operating switch; refer to the hand crank procedure of the manual operating switch
procedure in this Section.
Note: Adjust the double nuts at the switch basket if switch points close,
preventing the switch machine from completing stroke.
10. Adjust the double nuts at the switch basket to obtain a slight pressure condition at the
closed switch point with no visible hardware deformation.
11. Secure this position using the switch basket double nuts.
12. Place switch machine into “Reverse” position, using the switch machine hand throw and
repeat steps 6 and 7.
13. Hand throw, hand crank, or manually operate the switch machine back and forth a few
times as a final check.
Note: Points should fit snugly and uniformly against the stock rails without being
stressed by force from the throw bar. Excessive layout stress causes excessive
wear to the switch machine.
P2444, Rev. Jan/07
3-9
LOST MOTION
BASKET
THROW
BAR
THROW
ROD
SASIB
SASIB
GRS
RAILWAY
DOUBLE
NUTS
DOUBLE
NUTS
Figure 3-7. Throw Rod Connection Hardware
Lock Rod
The following describes lock rod connection and adjustment within a typical switch layout and
assumes that proper throw bar connection and adjustment has been completed. Refer to Figures
3-8 and 3-9.
1. Move inner jam nut to end of lock rod thread (inner position).
2. Position the lock rod drop lug in center of threaded Section and install outer jam nut.
Figure 3-8. Lock Rod Connection Hardware
P2444, Rev. Jan/07
3-10
4.
5.
Hand throw, crank, or manually operate the switch machine to mid-stroke position.
Position the lock rod so that the locating marks, above notch, on the straight section, are
centered over the cam bar.
6. Complete the stroke of switch machine so that the track side of the throw bar is drawn
into the switch machine. Verify that the slip link of the cam bar did not separate. If it
did separate, hand throw, crank, or manually operate the switch machine to mid-stroke.
This engages slip-link. Verify that locking dog on cam bar is centered through notch of
lock rod.
7. Assemble lock connecting rod to the front rod and the lock rod drop lug.
8. Adjust drop lug height until the lock connecting rod is aligned parallel to the lock rod.
9. Tighten and lock nuts at lug to keep this adjustment.
10. Crank, hand throw, or manually operate machine to opposite end of stroke, but do not
lock far switch point.
a. Adjust the curved lock rod using double nuts so that locating marks on curved
lock rod are centered over the cam bar. Complete the locking portion of the
switch machine stroke.
b. Check that the cam bar locking dog is centered in the lock rod notch.
c. Tighten and lock field side lock rod nuts to keep this adjustment.
11. Hand throw, crank, or manually operate the switch machine back and forth a few times
and verify that cam bar does not separate.
12. Refer to the adjustments Section of this manual for the proper positioning of wide
notches relative to the cam bar locking dog.
CURVED
LOCK ROD
ADJUSTING
NUTS
CURVED
LOCK ROD
SECTION
LOCK ROD
LOCATING
MARKS
LOCK ROD
NOTCHES
STRAIGHT
LOCK ROD
SECTION
Figure 3-9. Lock Rod Features and Components
P2444, Rev. Jan/07
3-11
Connect and Initially Adjust Point-Detector Rod
When working on the machine:
1. Place the "LOCAL/REMOTE" switch in the “LOCAL” position.
The following describes point-detector connection and adjustment associated with wide- and
narrow-notch lock rods. These procedures assume that connection of the throw bar and lock rod
to the track switch has been completed together with all electrical wiring.
1. Fasten the point-detector connecting rod to the switch point lug and to the lug on the
point-detector rod. Refer to Figure 3-10.
2. Manually operate the switch machine so that the point-detector rod is drawn out from the
track side of the switch machine to close and lock the far switch point.
PO INT-D ET ECTO R
RO D N EC K
POINT-DE TECTO R
R OD
PO IN T-D ETEC TO R
RO D LU G
PO IN T-D ETECTO R
CO NN EC TING
RO D
SW ITCH
PO INT
LU G
Figure 3-10. Point-Detector Rod Connection Hardware
P2444, Rev. Jan/07
3-12
1. Position the spoon gauge into the necked down portion of the point-detector rod (track
side). Use either the ¼-inch end of gauge or the 3/8-inch end (whichever is required by
the railroad). Refer to Figure 3-11.
Note: For narrow-notch lock rods, if a ¼-inch obstruction test is done for point
detection, the lock rod must be disconnected (floated). For wide-notch lock rods,
if the lock rod is adjusted properly, the rod does not have to be disconnected.
2. Adjust position of point-detector rod at the lug end by adjusting the inner jam nut.
Adjust nut until pressure of the spoon gauge against the point-detector pivot arm on the
point-detector system module engages the track-side point-detector switch lever.
Continue adjustment until the indication contacts of the rotary cam switch open
(outward position). If configured with latchout, continue adjusting until the latchout dog
of the point detector system engages (approximately 3/4 more of a turn), as shown in
Figure 3-11.
Note: Check the indication contact status of the cam switch (open or closed circuit
condition) using a meter on TB-2 or TB-3 in accordance with the field wiring.
3. Tighten and lock the jam nuts that hold this adjustment. Remove the spoon gauge. If
configured with latchout, verify that the cam switch indication contacts are still open.
Release the latchout condition by applying a light force to the spring end of the latchout
dog.
4. Crank the machine to the draw the point-detector rod into the machine.
5. Position the spoon gauge in the necked down portion of the point-detector rod (field
side). Use either the ¼-inch end of gauge or the 3/8-inch end (as required by the
railroad).
6. Adjust by loosening the nut and slave (1-1/8-inch open wrenches required) of the pointdetector bar and then by screwing in or out the free end of the rod (slave). Adjust the
nut until the pressure of the spoon gauge against the point-detector pivot arm on the
point-detector system module engages the field side point-detector switch lever.
Continue the adjustment until the cam switch indication contacts open (outward
position). If configured with latchout, continue adjusting until the latchout dog of the
point-detector system engages (approximately a additional 3/4 turn).
Note: Check cam switch indication contact status (open or closed circuit condition)
using a meter on TB-2 or TB-3 in accordance with the field wiring for location.
7. Hold this position by screwing in the free end of point-detector rod. Remove the spoon
gauge and release the latched out condition by applying a light force to the spring end of
the latchout dog.
8. After making adjustments in both directions, manually the operate machine back and
forth a few times. Check that the point-detector pivot arm engages the associated track
P2444, Rev. Jan/07
3-13
or the field side point-detector switch lever at the end of each throw-bar stroke with the
spoon gauge installed and the associated indication contacts open.
9. Remove the spoon gauge and manually operate the machine back and forth a few times.
Check that the point-detector pivot arm engages the associated track or field side pointdetector switch lever at the end of each throw-bar stroke and the cam switch indication
contacts DO NOT OPEN.
POINT-DETECTOR
SWITCH LEVER
ROTARY CAM
SWITCH
LATCHOUT
DOG
SPRING
PIVOT
ARM
SPOON
GAUGE
POINT-DETECTOR
ROD
Figure 3-11. Point-Detector Rod Adjustment Hardware
Motor Limit Adjustment
Cams mounted on the main drive gear are attached by slotted holes and provide motor limit
adjustment. The following describes the motor limit adjustment procedure. This procedure
assumes that connection of the throw bar and lock rod to the track switch has been completed,
connection and adjustment of the point-detector rod has been completed, and all electrical wiring
including speed configuration.
Note: This procedure requires switch machine operation, under electrical power,
utilizing the manual operating switch as described in the following Switch
Machine Operation procedures.
1. Operate the switch machine to end of stroke, utilizing the manual operating switch
described in the Switch Machine Operation procedures. Ensure the machine is
properly locked as described in “Normal and Reverse Locking” in Section 2.
P2444, Rev. Jan/07
3-14
2. Insert the hand crank and check for an additional movement (over-travel) of 1/2 to
1/4 turn before binding.
•
If Less than 1/4 turn of over-travel: Move the cam, actuating the motor limit
switch, toward the switch as described in Step 3. This will cause the cam to
actuate the motor limit switch earlier allowing more over-travel.
•
If Greater than 1/2 turn of over-travel: Move the cam, actuating the motor limit
switch, away from the switch as described in Step 3, and toward the drive gear
timing mark. This will cause the cam to actuate the motor limit switch later
allowing less over-travel.
3. Loosen the two socket head cap screws attaching the cam to the drive gear, move cam
as described in Step 2, and tighten the two socket head cap screws.
4. Repeat Steps 1, 2 & 3 until 1/2 to 1/4 turn of over-travel is met.
Switch Machine Operation
The following describes three manual operating modes of the GM4000 Switch Machine. Two of
these modes (Hand Crank and Hand-Throw Lever) can be performed before or after the supply
power has been connected to the machine. The third operating mode (the Manual Operation
Switch) can only be used after proper electrical connections to the machine have been made and
a switch call is present.
Note: When working on the machine, place the "LOCAL/REMOTE" switch on the
amplifier to “LOCAL”.
Hand Crank
This procedure can be used on a switch machine that has been properly installed:
1. Remove the rear and center machine covers to expose the modules.
2. Check that the “LOCAL/REMOTE” switch position on amplifier is in “LOCAL”.
3. Insert the hand crank into the main drive by aligning the crank hole cover.
4. Manually operate the machine by turning the crank, making sure the lock rod notch is
centered on the cam bar such that interference does not occur.
5. After hand cranking, remove hand crank, re-position crank hole cover to release cut-out
switch, and position the “LOCAL/REMOTE” switch on amplifier to “REMOTE”.
P2444, Rev. Jan/07
3-15
LOCAL/REMOTE
SWITCH
CRANK
HOLE
COVER
LOCK
ROD
LOCK ROD
NOTCH
MARKS
LOCK
ROD
CAM
BAR
Figure 3-12. GM4000 Hand Crank Operation
P2444, Rev. Jan/07
3-16
Hand-Throw
This procedure is used to set up and perform a hand-throw operation on a switch machine that
has been properly installed. Refer to Figure 3-13 for components described in the following.
1. Check that the location of the letters N and R on the hand-throw lever correspond to the
position of the switch points. If the letters are out of correspondence, remove the
mounting hardware holding the N and R letters to the hand-throw lever and properly
position them. Replace mounting hardware to secure letters to lever.
2. Pivot the selector lever of hand throw from “POWER” to “HAND” position. This will
prevent power from energizing the switch machine motor, eliminating the possibility of
a remote switch machine operation and unlocking the hand-throw lever.
3. Pivot the hand-throw lever and lock in the latch stand. The pivot action causes the
eccentric pin and gear of the hand-throw module to move internal mating components of
the main drive module and associated switch machine components.
4. After hand throwing, pivot the selector lever from “HAND” to “POWER” and lock in
the latch stand.
ECCENTRIC
PIN
HAND
THROW
GEAR
GRS
HAND
THROW
LEVER
SELECTOR
LEVER
Figure 3-13. Hand Throw Hardware
P2444, Rev. Jan/07
3-17
Manual Operating Switch
This procedure is used to set up and perform a manual switch machine operation using the
manual operating switch of a properly installed switch machine. Refer to Figure 3-14 for the
location of associated manual operating switch components described in the following
procedure. Refer to the drawing in Appendix A for electrical connections.
1. Remove all covers to expose the modules.
2. Position the “LOCAL/REMOTE” switch on the amplifier to “LOCAL”.
3. Loosen the gold AAR nut of the test link (if used), or remove the DC+ wire from
terminal block to cause an absence of normal or reverse position indication; this absence
of indication will cause a switch call to be automatically issued. Alternatively, request a
switch call from the dispatch office.
4. Place and hold the Manual Operating Switch in the position of the intended move.
5. Release the switch to stop the operation short of stroke completion. The motor will
automatically stop when the stroke is completed if the switch is not released.
6. When finished using the manual operation switch, position the “LOCAL/REMOTE”
switch on the amplifier to “REMOTE”.
LOCAL/REMOTE
SWITCH
TERMINAL
BLOCK
(TB4)
AMPLIFIER
MOTOR
MANUAL
OPERATING
SWITCH
TERMINAL
BLOCK
(TB3)
TERMINAL
BLOCK
(TB1)
Figure 3-14. Manual Operation Hardware
P2444, Rev. Jan/07
3-18
LEFT-HAND OR RIGHT-HAND CONFIGURATION
The following describes the switch machine hardware and procedures required to change switch
machine configurations (right-hand or left-hand). This procedure assumes that all three switch
machine covers and guards are removed.
Throw Bar
This procedure is used to set the throw bar of a properly installed switch machine for left-hand or
right-hand operation. Refer to Figure 3-15 for the location of the associated switch components
described in the following procedure.
1. Place "LOCAL/REMOTE" switch on amplifier in the “LOCAL” position.
3. Change the throw bar coupling from one end of the throw bar to the other.
LOCAL/REMOTE
SWITCH
HAND
CRANK
COVER
THROW
BAR
Figure 3-15. Throw Bar (Right and Left-Hand Configuration)
P2444, Rev. Jan/07
3-19
Lock and Detector Rods
This procedure is used to set the lock and detector rods of a properly installed switch machine,
for left-hand or right-hand operation. Refer to Figure 3-16 for the location of associated switch
components described in the following procedure.
1. Insert hand crank and rotate until a mid-stroke position is obtained.
2. Separate lock rod from lock-rod connecting rod if so connected. Remove lock rod from
switch machine, rotate rod 180 degrees and insert from other end. The lock rod will now
be in the opposite position.
3. Separate point-detector connecting rod and point-detector rod if so connected. Pull the
point-detector rod out of switch machine, rotate the rod 180 degrees, and reinsert.
LOCK
ROD
POINT
DETECTOR
ROD
Figure 3-16. Lock and Detector Rod (Right and Left-Hand Configuration)
P2444, Rev. Jan/07
3-20
Hand-throw Lever and Latch Stands
This procedure is used to set the hand-throw lever and latch stands of a properly installed switch
machine for left-hand or right-hand operation. Refer to Figure 3-17 for the location of the
associated switch components described in the following procedure.
1. Place the selector lever into "HAND" position.
2. Rotate the hand-throw lever 90 degrees (to the vertical position) and remove the two
bolts connecting the hand-throw lever to the hand-throw lever support. This makes it
much easier to accomplish the remaining change-over steps.
3. Remove the eight bolts attaching latch stands to the switch machine housing.
4. Remove hand-throw cover plate from the opposite side of the switch machine housing.
5. Remove the two mount bolts attaching the hand-throw module to the housing.
6. While holding the hand-throw module with the hand-throw lever support in the vertical
position and the select lever in hand position, disengage the bevel gears by pulling the
module away from the housing by approximately 1/2 inch. Continue to remove the
hand-throw module by pulling up and away to allow the hand-throw bevel gear to clear
the motor-limit cam on the gear of the main drive module. Do not use a hammer or pry
bar to separate the module.
7. Move the hand-throw module to the opposite side and reverse the last step. Clear the
motor-limit cam but do not engage the bevel gears.
8. Through the housing opening where the hand-throw module was removed, visually
check that the upper hand-throw dog of the main drive module is engaged in the lower
hand-throw dog gear.
9. Look through the housing opening where the hand-throw module was removed to
visually check that the timing mark on top of the lower hand-throw dog gear is centered
in the housing opening.
10. Note: If the timing mark is not in the proper position, rotate the lower hand-throw dog
gear until it reaches the proper position.
11. With the hand-throw lever support in the vertical position and s the elect lever in the
hand position, engage the bevel gears. The module should slip in and the mounting
flange should be flush with the switch machine housing.
12. Note: Very little pressure is required for this operation. Do not hammer or beat on the
module.
13. Verify proper timing of the hand-throw module by rotating the hand-throw lever support
until the top gears of the main-drive module move. Rotate the hand-throw lever support
to the other side until the top gears of the main drive module move; this motion of the
hand-throw level support should be equal on either side of the vertical position. If not,
disengage the bevel gears and repeat steps 14 - 16.
14. Re-install the mounting flange hardware.
15. Re-install the two latch stands on side of the machine with the hand-throw module,
using existing mounting hardware.
16. Re-install the hand-throw lever.
P2444, Rev. Jan/07
3-21
17. Insert the hand-throw lever into the latch stand and check that the cam-bar dog is
engaged with lock rod.
18. Throw the switch to opposite position and check that the cam-bar dog is engaged with
the lock rod.
19. Re-install the cover plate on the opposite side of the housing.
20. Re-install the connecting rods and lugs and readjust the lock rod and point detector rod.
21. Re-install the guards on the opposite sides.
22. Remove the hand crank and close the hand crank cover.
23. Return the “LOCAL” (remote switch on amplifier) to “REMOTE”.
24. Place the covers back on the machine.
25. Return the selector level on the hand throw to the power position and lock in the latch
stand.
HAND
THROW
LEVER
LATCH
STAND (2)
SELECTOR
LEVER
SASIB
SASIB
RAILWAY
GRS
HAND THROW
COVER PLATE
Figure 3-17. Hand-throw Lever and Latch Stand Components
P2444, Rev. Jan/07
3-22
BEFORE PLACING MACHINE IN SERVICE
Perform the following in the sequence given:
1. Check inside the machine and remove any tools, rags, etc..
2. Insure the electrical harness is properly attached.
3. Clean and lubricate the switch as instructed by the railroad.
4. Check the hand-throw module to ensure that the power lever is in the power mode and
not in the hand-mode position.
5. Check the electrical power to the motor.
6. Place the machine in “LOCAL” mode.
7. Using the Manual Operation Switch, located by the motor, cycle the machine back and
forth to insure proper operation.
8. Return the amplifier switch to the “REMOTE” position.
9. Verify that all terminal jumpers are properly configured.
10. Connect the signal and indication wires to AAR terminals TB1, TB2, and TB3. The
connections are given in Appendix A.
11. Replace the covers on the machine.
12. Insure all external locking features are in place.
13. Verify that the motor limit cams are adjusted correctly.
P2444, Rev. Jan/07
3-23
P2444, Rev. Jan/07
3-24
SECTION 4
SCHEDULED MAINTENANCE
INTRODUCTION
Preventive maintenance (PM) checks by maintainers, as well as periodic inspection of the switch
machine, are required to ensure continued proper operation. This Section identifies the periodic
inspection points of the switch machine and switch layout and describes the functional tests and
related adjustments that should be made; a preventive maintenance index that summarizes the
various checks and proposed intervals is also included.
SPECIAL TOOLS AND TEST EQUIPMENT
Following is a list of special tools and test equipment that will be required to perform scheduled
maintenance as described in this Section. All special tools required to facilitate maintenance are
shown in Section 7.
•
¼- and 3/8-inch Spoon Gauge
•
Hand Crank
•
Multimeter
•
Switch Wrench 1-1/16 inch through 2 inch
•
Terminal Nut Wrench, AAR or ALSTOM
•
Switch Point Obstruction Gauge (1/8, 3/16, 1/4, 3/8)
Hand Crank
A hand crank is used to manually operate the machine to the full normal and reverse positions.
Hand crank operation can be used in either the presence or the absence of switch machine
operational power. To use a hand crank, remove the cover over the amplifier module and turn
the “LOCAL/REMOTE” switch to “LOCAL”. This switches control of the machine from the
control room to the site. Next, remove the cover over the main drive module and rotate the hand
crank cover on the main drive module to allow insertion of the hand crank. Remove the crank
when the operation is complete and restore the hand-crank cover to the position blocking crank
insertion.
Note: The manual operation switch can also be used to operate the machine. This
switch can only be used when switch-machine operational power is present and a
P2444, Rev. Jan/07
4-1
switch call is placed on the machine. Refer to the operational description in
Section 3.
AFTER FLOODING
If the switch machine was flooded, clean and ensure all drain holes are clear. Cleaning consists
of washing down with a water jet of low velocity. Dry out all water -- in cold weather, trapped
water will freeze and prevent the switch from operating.
The amplifier should be removed from a flooded machine, washed out with distilled or deionized water, and replaced as described in Section 6. De-ionized or distilled water (most
commonly used to clean steam irons) can usually be purchased at a grocery store. If flood water
reached the main drive module bearings, replace the drive module as described in Section 6.
LUBRICATION GUIDELINES
The GM4000 is designed with dry-film lubricants and corrosion-resistant coatings on the
external surfaces of high-wear components. These components do not require the use of greases
or lubricating oils. However, the 5:1 and 30:1 gearboxes contain an oil lubricant, and these
gearboxes are sealed so oil-level checks are not required. If gearbox seals appear to be leaking
oil, refer to Section 6 for gearbox replacement.
PREVENTIVE MAINTENANCE INDEX
Table 4-1 lists the recommended intervals, preventive maintenance actions, and references to the
associated maintenance procedures in this Section. If the switch machine is operated with morethan-usual frequency each day, these inspections should be done more often.
Table 4-1. Preventive Maintenance Index
Interval
Preventive Maintenance Action
Reference
Monthly
External Switch Machine Inspection
Site Inspection and PM checks
Quarterly
Wear Plate and Bushing Inspection
PM Checks
Internal Switch Machine Inspection
As Required
Lock Rod Module Adjustment
Obstruction Test Adjustments
As Required
Point Detector Module Adjustment
Obstruction Test Adjustments
P2444, Rev. Jan/07
4-2
SITE INSPECTION
A site inspection consists of making a visual check of the entire switch layout and recording any
problems found. To fix recorded problems, use the corrective maintenance instructions in
Section 6.
WARNING
The switch machine can be remotely activated instantly, possibly
causing personnel injury and equipment damage.
A checklist of primary inspection areas follows:
1. Inspect the switch machine housing, covers, and guards for physical damage or
distortion.
2. Inspect around the complete switch layout, including between the points and stock rail
for foreign material, ballast or excessive dirt, which might block motion of rods or
points.
3. During winter months, check for snow and ice under the cut-away area of a switch point
which meshes with stock rail. Ensure that snowmelters, if installed, are melting snow
and ice.
4. Check that connecting hardware is secure and condition of connecting rods.
PREVENTIVE MAINTENANCE CHECKS
Preventive maintenance checks should be done on each switch machine, whether it operates
independently or in conjunction with another switch machine. Preventive maintenance checks
are intended to serve as a reference for fault isolation procedures. If a problem is found, take the
necessary action to correct it.
WARNING
Keep clear of gears and switch points when machine is under remote
operational control. Power to switch machine can be cut off at the
control room. With covers removed, switch machine control can be
changed from control room to machine. While in machine control, use
caution as the machine can operate in a power mode by the manual
operation switch located near the motor (see Figure 1-2). Either
condition could cause equipment damage or personnel injury.
P2444, Rev. Jan/07
4-3
Point Pressure Test
Check switch points monthly and adjust the point pressure, if required, by performing the
following procedure in the sequence given. Point pressure is the amount of pressure exerted by a
switch point against a stock rail. Proper point pressure is determined by observing and listening
to a point closing operation. Another method is measured by a maintainer through the resistance
felt in the hand throw during point closure. Some resistance is acceptable but excessive
resistance must be avoided.
1. Begin by using the hand crank or manual operation switch to operate machine to the end
of the throw bar stroke (6.5 inches). The switch point should fit snugly against the stock
rail.
2. Use a pry bar to pry the switch point away from the stock rail. The point should move
slightly but not more than 1/8 inch.
3. If the switch point does not fit properly against the stock rail, adjust the nuts at the
switch adjustment basket until the proper position and pressure is achieved.
4. Crank the switch machine to move the points to opposite position and test for proper
pressure.
5. After the adjustments have been made for the normal and reverse positions, crank the
machine back and forth a few times to double-check these adjustments.
Switch Obstruction Test # 17
The switch machine can be configured with a narrow- or wide-notched lock rod. Determine the
type of lock rod and each month perform the following associated procedure in the sequence
given. These tests are performed in accordance with FRA Rule 236.382.
Narrow-Notch Lock Rod:
1. Insert an obstruction gauge (1/4 inch for machines without latchout feature or 3/8 inch
for machines with latchout feature) between the switch point and stock rail, 6 inches
back of the point on the reverse side.
2. Operate the switch point against the obstruction gauge. The switch machine should not
lock and the indication circuit contacts should not close.
3. Operate the switch point open and remove the obstruction gauge.
4. Insert the obstruction gauge between the switch point and stock rail at 6 inches back of
the point on the normal side.
5. Operate the switch machine to move the points to close against the obstruction gauge.
6. The switch machine should not lock and the indication circuit contacts should not close.
7. Operate the machine to open the switch point and remove the obstruction gauge.
8. Operate the switch machine to close and lock points in the normal and reverse positions
without obstruction. Check that point position and point pressure have not been
changed.
9. If the machine fails the obstruction test by locking with the obstruction gauge between
the switch point and stock rail, the lock rod must be adjusted as described in this
Section.
P2444, Rev. Jan/07
4-4
Wide-Notch Lock Rod:
1. Insert an obstruction gauge (1/4 inch for machines without latchout feature or 3/8 inch for
machines with latchout feature) between the switch point and stock rail, 6 inches back of
the point on the reverse side.
2. Operate the switch point against the obstruction gauge. The switch machine should lock
and the indication circuit contacts should close.
3. Operate the switch point open and remove the obstruction gauge.
4. Insert the obstruction gauge between the switch point and stock rail, 6 inches back of the
point on the normal side.
5. Operate the switch machine to move the points to close against the obstruction gauge.
The switch machine should lock and the indication circuit contacts should close.
6. Operate the machine to open the switch point and remove the obstruction gauge.
7. Operate switch machine to close and lock points in the normal and reverse positions
without obstruction. Check that the point position and point pressure have not been
changed.
8. If the switch machine fails the obstruction test by not locking with the obstruction gauge
between the switch point and stock rail, the lock rod must be adjusted as described in this
Section.
Point Detector Check
Check monthly unless otherwise recommended.
1. A Normal (N) or Reverse (R) indication should not be observed when switch points are
operated in either position against a ¼-inch or 3/8-inch obstruction gauge inserted
between the switch point and stock rail.
2. If an indication (N or R) is observed, the point detector rod must be checked and adjusted
using the procedure described in this Section.
External PM Checks
Check monthly unless otherwise recommended:
•
All machine tie-downs must be tight and securely fastened. Replace all damaged or missing
parts per installation instructions.
•
View external surfaces of the switch machine for any damage -- bent, cracked, or broken
housings, hinges, or brackets. Check that all covers fit tightly.
•
Record any out-of-normal conditions of looseness or any broken tie-downs.
•
Put the machine in the hand-throw position. Operate the machine by using the hand throw
while checking the rods extending from the machine for any obstruction and loss of motion
from worn bushings.
P2444, Rev. Jan/07
4-5
Internal PM Checks
Check the following quarterly unless otherwise recommended (refer to Figure 4-1 for location of
internal components):
•
Remove the three covers and inspect for worn or damaged gaskets.
•
Visually check the wear limits of:
1. Point detector flanged bushing
2. Lock rod wear plates
3. Throw bar wear plates
•
Switch the amplifier toggle switch "LOCAL/REMOTE" to 'LOCAL" position. This places
full control of the machine at the machine.
•
Check the two motor-limit switches - Using the manual operation switch, hand throw, or
hand crank, traverse through a complete cycle noting operation of both switches. The
condition of each switch can be determined by using a multimeter at specific terminal block
connections and checking continuity. Refer to the electrical schematic of the switch machine
internal wiring (in Appendix A) for the proper connections.
1. Operate to end-of-stroke and check that the Motor Limit Cam of the main drive actuates
the Latchout and proper Motor Limit Switch.
2. While at end-of-stroke, check the position of timing marks on the main drive gears.
3. While at end-of-stroke, check that the cam bar locking dog is centered in the lock rod
notch.
4. Repeat procedure for opposite position.
•
Check the latch-out, hand-throw, and hand-crank switches. The condition of each switch can
be determined by using a multimeter at specific terminal block connections and checking
continuity. Refer to the electrical schematic of switch machine internal wiring, located in
Appendix A, for proper connections.
1. Latch out switch is located on point detector switch module. Operate machine to midstroke position (main drive gear timing marks align in window of main drive upper
support). Check that the amplifier “Remote/Local” LED is lit. Depress latch out switch.
The "Remote/Local" LED on amplifier module will go out if switch is working.
2. Hand throw switch, located in main drive module, will open (REMOTE/LOCAL LED
on the amplifier module will go out) after the hand throw selector lever is moved out of
the “POWER” position but before the hand throw selector lever is moved into the
"HAND" position. Preferably, mid-way between either position.
3. Hand crank switch is tested by opening hand crank cover to the position that allows
insertion of a hand crank. The “Remote/Local” LED on the amplifier module should go
out when hand crank is inserted.
Note: If the Remote/Local LED is lit, this indicates power is available at the motor.
P2444, Rev. Jan/07
4-6
MOTOR
(GM050-020-00)
AMPLIFIER
(GM050-024-00)
5:1 GEARBOX
(GM050-026-00)
CROSS BRACE
(GM050-005-00)
30:1 GEARBOX
(GM050-025-00)
ELECTRICAL HARNESS
(GM050-900-01)
THROW BAR
(GM050-002-00)
MAIN DRIVE
(GM050-100-01)
POINT DETECTOR
SWITCH MODULE
(GM050-800-01)
LOCK ROD
(GM050-300-0_ )
POINT DETECTOR
SYSTEM MODULE
(GM050-700-01)
POINT DETECTOR ROD
(GMO5O-500-0_ )
Figure 4-1. Internal GM4000 Components
P2444, Rev. Jan/07
4-7
•
View modules for signs of wear or damaged parts. The following can be replaced in the
field:
Amplifier
5:1 Gearbox
Motor
30:1 Gearbox
Main Drive
Point Detector Switch
Point Detector Rod
Point Detector
Latch Stand
Lock Rod
Hand Throw
Switches
Note: Method of removal and replacement of modules is covered in Section 6,
“Corrective Maintenance".
•
Causes for replacement of modules:
− Amplifier - Refer to Section 5.
− Motor - Replace if the RED light on the amplifier module is lit and reset functions
do not clear fault indication.
− Point Detector - Replace if parts are damaged such that point indication will not
occur, if parts are worn or broken causing false indications due to wear or broken
parts, or parts are out of calibration.
− Lock Rod - Replace if rod is bent, fractured or has wear on rubbing surfaces,
which would preclude smooth sliding.
− Point Detector Rod - Replace if the rod is bent, will not slide smoothly in
bushings, or lock nuts will not stay locked.
− Hand Throw Lever - Replace if gear teeth are broken or show excessive wear or
the assembly does not move freely.
P2444, Rev. Jan/07
4-8
LOCK ROD AND POINT DETECTOR ADJUSTMENTS
For safety when working on machine and power is not required:
1. Place the "LOCAL/REMOTE" switch in the local position.
2. Rotate the hand crank cover to the open position to inhibit power to the motor. When
using the manual operation switch while working on machine, place the
"LOCAL/REMOTE" switch in the local position. Use the manual operation switch to
change machine position (normal or reverse).
Lock Rod Adjustment (Narrow Notch)
1. Remove the guards over lock and point-detector rods.
2. Operate the machine to close but not lock near the switch point. Ensure that the cam bar
is centered in the lock rod slot and continue operating the machine until locking is
complete.
3. When properly locked, the cam bar locking dog will be protruding an equal amount on
either side of the lock rod.
4. Center the straight lock rod slot to locking dog using the inner and outer jam nuts
associated with the lock rod drop lug. Tighten and lock nuts at drop lug to keep this
adjustment.
5. Operate the machine to close, but do not lock far switch point. Ensure that the cam bar is
centered in lock rod notch and continue cranking the machine until locking is complete.
6. Center the curved lock rod notch to the locking dog using the inner and outer nuts on the
field side of the lock rod. Tighten and lock the field side lock rod nuts to retain this
adjustment.
Lock Rod Adjustment (Wide Notch)
1. Remove the guards over the lock and point-detector rods.
2. Operate the machine to close near the switch point against a 1/4 inch obstruction. Make
sure cam bar is in the lock rod notch.
3. Note: Spaces between the sides of the notch and the cam bar dog are not equal.
4. When locked, the cam bar locking dog will protrude an equal amount on either side of
the lock rod.
5. Offset the straight lock rod slot to the locking dog using the inner and outer jam nuts
associated with the lock rod drop lug. Tighten and lock nuts at drop lug to retain this
adjustment.
6. Operate the machine to close the far switch point against a 1/4 inch obstruction. Ensure
the cam bar is in the lock rod notch and continue operating the machine until locking is
complete.
7. Offset the curved lock rod notch to the locking dog using the inner and outer nuts on the
field side of the lock rod. Tighten and lock the field side lock rod nuts to retain this
adjustment.
P2444, Rev. Jan/07
4-9
Point-Detector Rod Adjustment
Refer to Figure 4-2 while performing the following.
1. Operate machine to mid-stroke and position a point-detector-rod spoon gauge into the
necked down portion on the track-side end of the point-detector rod. Use either the ¼inch or the 3/8-inch end of the spoon gauge, whichever is required by railroad.
2. Operate machine to close and lock the far switch point. Position the lever against the
spoon gauge. If the track-side indication contacts of the point detector switch module
are on, use the adjusting nut to adjust the position of the point-detector rod at the lug
end.
3. Adjust the nut until the LED on the point detector switch module turns off. Continue
adjusting until latch-out occurs. Tighten and lock the lug nuts to hold this adjustment
and remove the spoon gauge. Release the latch-out condition by applying a light force
to the end of the latch out dog.
4. Operate the machine to mid-stroke and position the point-detector rod spoon gauge into
necked down portion on the field side of the point-detector rod. Use either the 1/4 inch
or 3/8 inch end of the spoon gauge, whichever is required by the railroad.
5. Operate the machine to close and lock near the switch point. Position the lever against
the spoon gauge; if the field side indicating contacts of the point detector switch module
are on, adjustment is required. Adjust by first loosening the nuts on the point-detector
bar and then by either screwing in or out on the free end of the bar. Adjust nut pressure
on the gauge until the light on the field-side switch turns off, immediately followed by
latch-out.
6. Lock the nut in this position by screwing in the free end of point-detector rod. Remove
the spoon gauge. Release the latched-out condition by applying a light force to the end
of the latch-out dog.
7. If point detection requirements cannot be achieved, examine all associated components
for wear or fault before replacing the point detector system module.
8. After making adjustments in both directions, operate the machine back and forth a few
times to check that (1) the light still comes on, at the end of each throw-bar stroke with
the spoon gauge installed, and (2) no light comes on with the spoon gauge removed.
9. Remove the hand crank (if it was used) from the main drive module. Place the machine
in operation.
P2444, Rev. Jan/07
4-10
POINT-DETECTOR
SWITCH LEVER
ROTARY CAM
SWITCH
LATCHOUT
DOG
SPRING
PIVOT
ARM
SPOON
GAUGE
POINT-DETECTOR
ROD
Figure 4-2. Point-Detector Rod Adjustment Components
WEAR PLATE REPLACEMENT
To replace the wear plates on the throw bar and the lock rod module, refer to the Throw Bar and
Lock Rod Wear Plate Assembly procedure described in Section 6.
P2444, Rev. Jan/07
4-11
P2444, Rev. Jan/07
4-12
SECTION 5
TROUBLESHOOTING
PHILOSOPHY
Troubleshooting the GM4000 switch machine can be performed in a control location or at the
wayside. In the control location, an understanding of relay operation and knowledge of circuit
plans is essential. At wayside, an understanding of the switch machine operation along with
knowledge of switch machine setup and layout is essential.
TROUBLESHOOTING
The following troubleshooting information helps determine if a switch machine and its
associated circuit equipment are faulty. Table 5-1 lists troubles/symptoms of abnormal switch
machine circuit and trackside equipment operation as observed from the control location. This
table also describes the corrective action(s) required.
Table 5-2 lists troubles/symptoms of abnormal switch machine circuit and trackside equipment
operation as observed from the wayside location. This table also describes the corrective action
required.
Troubleshooting performed at a wayside location, using the amplifier LED display of a switch
machine, is given in this section together with the required corrective action. The corrective
action repair procedures associated with given switch machine and wayside equipment can be
found in this manual.
P2444, Rev. Feb/02
5-1
Table 5-1. Troubles Noticed from the Control Locations
Trouble/ Symptom
Corrective Action
1. Switch out of correspondence, Reverse or
Normal position relay down (per switch
position request).
1. Check for power at Normal and Reverse
relay coil.
2. Switch out of correspondence, switch
machine(s) failed to move (per switch
position request).
1. Check that Reverse or Normal relay is
up.
2. Check for bad relay.
2. Check for switch operational power at
entrance rack. If none, check for blown
fuse or switch machine amplifier.
3. Check for switch operational power at
switch machine. If none, possible bad
cable, loose hardware and/or
connections.
4. Check for obstruction in rail points.
5. Check rail conditions in area.
6. Check that proper configuration plug is
present.
7. Check switch machine amplifier LEDs
for display. Refer to “Amplifier LED
Display” in this section.
8. Check fuse on underside of amplifier.
P2444, Rev. Jan/07
5-2
Table 5-2. Trackside Noted Symptoms
Trouble/ Symptom
Corrective Action
1. Motor runs but points do not move.
1. Linkage disconnected - reconnect throw
rod to switch points.
2. Throw bar drive train disconnected check from main crank shaft back to
motor.
3. Check Coupler.
2. Motor cuts out and “OVERLOAD” LED on
amplifier lights. Refer to “Amplifier LED
Display” in this section.
1. Obstruction in points - remove
obstructions.
2. Excessive resistance in track point
system - determine cause and correct.
3. Excessive resistance in switch machine
drive train - determine cause and correct.
3. Motor will not run with a proper switch call
and “MOTOR” LED located on amplifier is
not lit, but amplifier “RUN” LED is lit.
Confirm power to motor - “MOTOR” LED
malfunction in conjunction with faulty
motor; replace motor and amplifier module.
4. Motor will not run and “MOTOR” LED
located on amplifier is lit.
1. Reset Amplifier.
2. Check internal switch machine wiring.
3. Replace motor module
5. Points move but switch machine does not
lock and indicate.
Cam bar has separated - determine cause:
friction drag or blockage in cam bar track or
out of adjustment of lock rod.
6. Bent or cracked rods, couplings or lugs
switch caused by a train running through
closed points of layout. (Note: Any train
speed will bend or break fittings.)
Inspect for damage to layout and
components - confirm switch machine
operation.
P2444, Rev. Jan/07
5-3
Table 5-2. Trackside Noted Symptoms (Continued)
Trouble/ Symptom
Corrective Action
7. With selector lever in “HAND” position and 1. Check switch machine layout for
hand throw lever operated in both directions,
obstruction.
the switch machine does not throw.
2. Operate hand throw lever while checking
movement of internal switch machine
components.
3. Remove hand throw module and check
for damaged hand throw eccentric pin.
4. If pin is damaged, replace hand throw
module.
8. “AMPLIFIER” LED on amplifier module is 1. Reset Amplifier.
lit but switch machine operates.
2. Check internal switch machine wiring.
3. Replace motor module.
9. A switch call issued (normal or reverse), no
LEDs lit, motor not operating.
1. Check configuration plug is installed.
2. Check hand throw selector lever is
latched in “POWER” position.
3. Check hand crank cutout switch is not
activated.
4. Check latchout and reset.
5. Check fuse on underside of amplifier.
Amplifier LED Display
The following LED displays help determine faulty switch machine equipment. The LED
displays for Normal operation as well as Abnormal operation are given in Table 5-3.
Note: LED displays occur only while the operation (Normal or Abnormal) is being
performed and operating power is being supplied to the amplifier of the switch
machine. Without operational power, the LEDs of the amplifier remain off.
P2444, Rev. Jan/07
5-4
Table 5-3. Amplifier LED Displays
Amplifier LED
Run
Motor
Amplifier
Overload
Automatic operation
on
off
off
off
Hand operation
off
off
off
off
Hand crank
off
off
off
off
Latch out
off
off
off
off
Overload fault
off
off
off
on
Motor fault
off
on
off
off
Amplifier Fault
off
off
on
off
Normal Operation
Abnormal Operation
Overload Fault
The Overload function is an electronic clutch. The motor current is directly proportional to the
motor torque. If there is an obstruction, the motor will deliver more torque, thus drawing more
current. When the current reaches the current limit threshold, a 5-second timer starts. After 5
seconds, the overload circuit will shut down the motor.
An overload will occur if there is an obstruction in the rails or if the switch machine
mechanically seizes (flooding, mechanical failure, etc.). If there is an overload, the amplifier
will shut down power to the motor and control system. To run the machine, check the rails for
obstructions and the switch machine for mechanical failures. If an obstruction is found and
cleared, the machine can be run by issuing another switch call. The machine will operate
properly and the overload LED will remain lit until the amplifier is reset.
Motor Fault
The Motor Fault function monitors the condition of the brushless DC motor. A Motor Fault can
indicate several problems and can only be reset by the amplifier reset switch.
1. Short in the motor or bad Hall sensors. Hall sensors feed back position information to
the Amplifier. This information helps the Amplifier to control the motor’s rotation. The
motor will not run if the Hall sensors fail. Reset the switch machine. If that does not
resolve the problem, replace the motor.
2. Damaged motor harness. If the motor harness is shorted or open the Motor fault will go
on. Reset the switch machine. If that does not resolve the problem, replace the motor.
P2444, Rev. Jan/07
5-5
Amplifier Fault
The Amplifier fault function monitors the condition of the Amplifier. An amplifier fault can
indicate several problems:
1. Shorted power leads: Check the field terminations. Reset the Amplifier.
2. Amplifier overheated: Turn off the switch machine for several minutes, then reset the
Amplifier.
3. Motor Overheated: Turn off the switch machine for several minutes, then reset the
Amplifier.
4. Under-voltage Condition: Check switch machine supplied voltage and verify it is within
specification.
5. Short in internal wiring harness.
6. Faulty Amplifier: Reset the Amplifier. If that doesn’t work, replace the Amplifier.
There are three methods to reset the amplifier for an overload or amplifier fault.
Note: The amplifier fault LED will remain lit until the amplifier is reset.
1. There is a reset switch on the side of the amplifier. This switch can be used if power is
supplied to the amplifier.
2. The amplifier is reset by removing power from the system and a switch call is issued.
3. The amplifier is reset by calling the machine to move in the opposite direction, (i.e. if the
machine reaches the current limit in the normal direction, the amplifier is reset by calling
the machine to the reverse direction).
A motor fault can only be cleared by depressing the amplifier reset switch while supply power is
applied to the amplifier.
Amplifier Fuse
There is a 1-amp, 3AG fuse located on the bottom of the amplifier. This fuse is in series with the
low-voltage control input on the amplifier. The fuse protects the amplifier from hooking up the
high-voltage motor power to the low-voltage control in the 4-wire configuration.
P2444, Rev. Jan/07
5-6
SECTION 6
CORRECTIVE MAINTENANCE
PURPOSE
This section describes removal and replacement procedures of major components found to be
faulty through inspection and test procedures described in Section 4, Scheduled Maintenance and
Section 5, Troubleshooting. The removal and replacement procedure, for a given component,
describes any adjustment or test along with special tools that may be required to complete the
procedure. Recommended spare parts are identified and shown in "SECTION 7 - PARTS
CATALOG".
REMOVAL AND REPLACEMENT PROCEDURES
The following are removal and replacement procedures for specific switch machine components.
These procedures should be followed in the sequence given. Tools and adjustments, if required,
are described in the procedure.
WARNING
Keep clear of gears and switch points when machine is under
operational control. Power to switch machine must be cut off at control
room before any removal or replacement procedure is performed.
P2444, Rev. Jan/07
6-1
Covers
All three covers are attached and held to the switch machine housing by cover straps and clamps,
as shown in Figure 6-1. The following procedure can be used to remove and replace any one of
the three switch machine covers. No special tools are required.
Removal Procedure
1.
Remove lock from cover strap, if utilized, and release cover clamp.
2.
Pivot cover strap on hinge pin of housing to expose covers.
3.
Pivot cover to a vertical position on hinge pin of housing. Remove cover when pivot
receptacle in cover clears pivot pin in housing.
Replacement Procedure
1.
With cover in vertical position, insert pivot receptacle in cover into hinge pin of housing.
2.
Pivot cover about the hinge pin of housing until cover is horizontal and resting on the
machine housing.
3.
Replace cover strap and lock if utilized.
SASIB
SASIB
GRS
RAILWAY
COVER
STRAP
Figure 6-1. Cover Removal and Replacement Components
P2444, Rev. Jan/07
6-2
Cross Brace
Both cross braces are attached and held to the switch machine housing. The following procedure
can be used to remove and replace either one of the switch machine cross braces. Refer to
Figure 6-2 while performing this procedure. No adjustments or special tools are required.
Removal Procedure
1.
Remove motor end and center covers.
2.
Remove two socket head cap screws on each side attaching cross brace to switch machine
housing.
3.
Remove by pulling upward while separating cross brace from machined cavity in switch
machine housing.
4.
Check cross brace for cracks or fractures that may allow water to enter switch machine or
compromise the strength of cross brace.
1.
Insert cross brace into machined cavity of switch machine housing.
2.
Install two socket head cap screws on each side attaching cross brace to switch machine
housing.
SCREWS (2)
SCREWS (2)
CROSS
BRACE
Figure 6-2. Cross Brace Removal and Replacement Components
P2444, Rev. Jan/07
6-3
Amplifier
Perform the following procedure, in sequence given, to remove and replace the switch machine
amplifier. Refer to Figure 6-3 while performing this procedure. No adjustment procedures or
special tools are required.
WARNING
Power to switch machine must be cut off at control room before
performing this removal or replacement procedure.
Removal Procedure
1.
Remove motor end cover, center cover, and cross brace between covers.
2.
Remove four pan head screws attaching amplifier to switch machine housing.
3.
Remove amplifier by pulling upward while checking wire harness clearance.
4.
Disconnect two wiring harness 23-way amp connectors, and motor wiring three-pin
connector from amplifier. Remove configuration plug.
1.
Connect two wiring harness 23-way amp connectors, and motor wiring three-pin
connector to amplifier. Replace configuration plug.
2.
Carefully lower amplifier into switch machine while checking wire harness clearance.
3.
Visually align amplifier mounting holes with mounting holes in switch housing.
4.
Install four pan head screws into amplifier mounting holes.
5.
Replace motor end and center cover along with cross brace between covers.
6.
Operate switch machine to verify proper operation.
P2444, Rev. Jan/07
6-4
MOTOR
WIRING
CONNECTOR
PAN HEAD
SCREWS (4)
AMPLIFIER
WIRING
HARNESS
CONECTORS (2)
CONFIGURATION
PLUG
Figure 6-3. Amplifier Removal and Replacement Components
Switches
Perform the following procedure, in sequence given, to remove and replace switches. Refer to
WARNING
Removal Procedure
1.
Remove associated switch machine covers.
2.
Remove socket head cap screws attaching access cover to water tight switch housing.
3.
Disconnect wiring harness from the switch and hardware attaching switch to case.
4.
Lift switch out of switch machine and water tight case while checking wire harness
clearance.
P2444, Rev. Jan/07
6-5
1.
Connect wiring harness to replacement switch.
2.
Carefully lower switch into switch machine while checking wire harness clearance.
3.
Visually align mounting holes of switch to mounting holes in the switch machine water
tight case.
4.
Install socket head cap screws through mounting holes attaching switch to case.
5.
Install socket head cap screws attaching access cover to water tight switch housing.
6.
Replace the switch machine cover.
7.
SCREWS (4)
SWITCH
HOUSING
Figure 6-4. Switch Removal and Replacement Components
Brushless DC Motor and 5:1 Gearbox
The motor and gearbox must be removed as an assembly. After the assembly is removed from
the switch machine, the motor can be separated from the gearbox. Perform the following
procedure, in sequence given, to remove and replace the motor and gearbox assembly. Refer to
WARNING
P2444, Rev. Jan/07
6-6
Removal Procedure
1.
Remove motor end and center cover along with cross brace between covers.
2.
Remove motor wiring connector from amplifier.
3.
Remove socket head cap screws and attached manual operation switch.
4.
Remove four socket head cap screws attaching 5:1 gearbox to base plate.
5.
Remove two jig pins from gearbox mounting flange and slide motor with 5:1 gearbox
away from the 30:1 gearbox as far as space will allow or until the drive coupling
between the 5:1 and 30:1 gearbox has separated.
6.
Lift motor and gearbox out of switch machine while checking wire harness and drive
coupling clearance. Remove drive coupler and keys (2).
7.
If required, separate motor from 5:1 gearbox by removing four socket head cap screws
attaching motor to gearbox.
1.
Connect motor to 5:1 gearbox, if separated.
2.
Attach motor wiring to amplifier and install drive coupler to 5:1 gearbox.
3.
Lower motor and 5:1 gearbox assembly into switch machine while checking drive
coupling and wire harness clearance.
4.
Slide motor and 5:1 gearbox toward 30:1 gearbox and drive gear assembly while
aligning the drive coupler located between 5:1 and 30:1 gearboxes. Visually align
mounting holes of 5:1 gearbox to mounting holes in machine base plate.
5.
Install jig pins (2) and manual operation switch.
6.
Install remaining socket head cap screws (4) attaching 5:1 gearbox to base plate.
7.
Replace manual operation switch and attaching socket head cap screws.
8.
9.
P2444, Rev. Jan/07
6-7
MOTOR
MOTOR
WIRING
CONNECTOR
SCREWS (2)
SCREWS (4)
MANUAL
OPERATION
SWITCH
JIG
PIN (2)
DRIVE
COUPLER
30:1
GEARBOX
Figure 6-5. Motor and Gearbox Removal and Replacement Components
30:1 Gearbox
Perform the following procedure, in sequence given, to remove and replace the 30:1 gearbox.
Refer to Figure 6-6 while performing this procedure. No adjustments or special tools are
required.
WARNING
P2444, Rev. Jan/07
6-8
Removal Procedure
1.
2.
Remove manual operation switch and motor with 5:1 gearbox.
3.
Remove four socket head cap screws attaching 30:1 gearbox to machine base plate.
4.
Lift 30:1 gearbox off locating pins in base plate and out of switch machine by pulling
upward while checking wire harness clearance.
1.
Carefully lower 30:1 gearbox into machine while checking wire harness clearance.
2.
Align locating holes of 30:1 gearbox to locating pins in the machine base plate.
3.
Install four socket head cap screws through mounting holes attaching 30:1 gearbox to
machine base plate. Note: Use proper length mounting screws.
4.
Replace manual operation switch and motor with 5:1 gearbox.
5.
6.
30:1
GEARBOX
SCREWS (4)
Figure 6-6. Gearbox Removal and Replacement Components
P2444, Rev. Jan/07
6-9
Hand Throw Lever
Perform the following procedure to remove and replace the hand throw lever. No adjustments
are required; however, a hand crank is required. Set-up instructions, when required, are given in
the removal and replacement procedure. Follow procedure in the sequence given to avoid
equipment damage. Refer to Figure 6-7 while performing the following procedure.
WARNING
Removal Procedure
1.
Remove motor end and center cover.
2.
Note position of switch machine (normal, mid-stroke, reverse). If in normal or reverse
position, insert hand crank and rotate until switch machine is in mid-stroke.
3.
Disengage hand throw from latch stand and position hand throw in mid-position while
removing the two socket head cap screws attaching hand throw to machine housing.
4.
Separate and remove hand throw assembly from switch machine housing.
1.
With replacement hand throw module and switch machine in the mid-position, insert
hand throw into switch machine making sure that the hand throw spur gear meshes
properly with switch machine drive gears and mounting flange on hand throw is
positioned flush to switch housing.
2.
Align mounting holes of hand throw to switch housing and attach to machine housing
using two socket head cap screws.
3.
Secure the hand throw into latch stand, in position noted in step 3 of removal procedure.
4.
Using hand crank, position switch machine as noted in step 2 of removal procedure.
5.
Replace motor end and center cover.
6.
P2444, Rev. Jan/07
6-10
HAND
THROW
HAND
CRANK
LATCH
LATCH
STAND
SCREWS (2)
MID-STROKE
(UN-LOCKED)
POSITION
MARKS
Figure 6-7. Hand Throw Lever Removal and Replacement Components
P2444, Rev. Jan/07
6-11
Latch Stand
Perform the following procedure, in sequence given, to remove and replace the latch stand.
Refer to Figure 6-8 while performing the following procedure. No adjustments or special tools
are required.
WARNING
Removal Procedure
1.
Remove four socket head cap screws attaching latch stand to side of switch machine
housing. Move hand throw if required.
1.
Align replacement latch stand and attach to machine housing using four socket head cap
screws. Move hand throw if required.
2.
Replace hand throw into latch stand.
SCREWS (4)
LATCH
STAND
Figure 6-8. Latch Stand Removal and Replacement Components
P2444, Rev. Jan/07
6-12
Main Drive
Perform the following procedure, in sequence given, to remove and replace the main drive.
Refer to Figure 6-9 while performing the following procedure. No adjustments or special tools
are required.
WARNING
Removal Procedure
1.
2.
Using hand crank, move switch to mid-stroke position and align timing marks on gears
of main drive.
3.
Remove manual operation switch and motor with 5:1 gearbox.
4.
Remove 30:1 gearbox and hand throw.
5.
Remove hand crank and two socket head cap screws attaching hand crank cutout switch
to main drive module.
6.
Remove two socket head cap screws attaching hand throw switch to main drive module.
7.
Remove six socket head cap screws attaching main drive to switch machine base plate.
8.
Lift main drive off locating pins in base plate and out of switch machine by pulling
upward while checking wire harness and switch clearance.
1.
Align timing marks, on gears of replacement main drive.
2.
Check that throw bar and cam bar are at mid-stroke.
3.
Align locating holes of replacement main drive with locating pins in base plate.
4.
Carefully lower main drive into switch machine while checking wire harness and switch
clearance.
5.
Install six large socket head cap screws attaching main drive to machine main drive
module.
P2444, Rev. Jan/07
6-13
6.
Replace two socket head cap screws attaching hand crank cutout switch to main drive
module.
7. Replace two socket head cap screws attaching hand throw switch to base plate.
8. Replace 30:1 gearbox, hand throw, manual operation switch, and motor with 5:1
gearbox.
9. Replace motor end and center cover along with cross brace between covers.
10. Operate switch machine to verify proper operation.
MANUAL
OPERATION
SWITCH
MOTOR
5:1
GEARBOX
30:1
GEARBOX
HAND
THROW
HAND
CRANK
CUTOUT
SWITCH
MAIN
DRIVE
SCREWS
(6)
HAND
THROW
SCREWS
(2)
MAIN
DRIVE
HAND
THROW
SWITCH
MID-STROKE
(UN-LOCKED)
POSITION
MARKS
Figure 6-9. Main Drive Removal and Replacement Components
P2444, Rev. Jan/07
6-14
Lock Rod
Perform the following procedure, in sequence given, to remove and replace the lock rod. No
special tools are required.
WARNING
Removal Procedure
1.
Remove center cover.
2.
Note position of switch machine (normal, mid-stroke, reverse). If in normal or reverse
position, insert hand crank and rotate until switch machine is in mid-stroke.
3.
Remove all connection hardware attaching lock rod to switch points.
4.
Slide lock rod out of switch machine.
1.
With switch machine in the mid-position, slide replacement lock rod into switch machine
and install all connection hardware attaching lock rod to switch points.
2.
Crank switch machine, using hand crank, to position noted in step 2 of removal
procedure.
3.
Perform Lock Rod Adjustment procedure, as described in Section 3.
4.
Replace center cover.
5.
Point Detector Module
Perform the following procedure, in sequence given, to remove and replace the point detector
module. Refer to Figure 6-10 while performing the following procedure. No special tools are
required.
WARNING
Removal Procedure
P2444, Rev. Jan/07
6-15
1.
2.
3.
Remove point detector end cover.
Remove four socket head cap screws attaching point detector module to switch machine
base plate.
Lift point detector module off locating pins in base plate and out of switch machine by
pulling upward while checking wire harness clearance.
1.
Align locating holes of replacement point detector module with locating pins in switch
machine base plate.
2.
Carefully lower point detector module into switch machine while checking wire harness
clearance.
3.
Install four socket head cap screws attaching point detector module to switch machine
base plate.
4.
Replace point detector end cover.
5.
POINT
DETECTOR
MODULE
POINT
DETECTOR
MODULE
SCREW
(4)
Figure 6-10. Point Detector Module Removal and Replacement Components
P2444, Rev. Jan/07
6-16
Point Detector Switch Module
switch module. Refer to Figure 6-11 while performing the following procedure. No special
tools are required.
WARNING
Removal Procedure
1.
Remove point detector end and center cover along with cross brace between covers.
2.
Remove point detector module.
3.
Remove 12 socket head cap screws attaching the two motor limit and one latch out
switch.
4.
Disconnect wiring harness.
5.
Remove two socket head cap screws attaching point detector switch module to switch
machine base plate.
6.
Lift point detector switch module out of switch machine by pulling upward while
checking wire harness clearance.
1.
Carefully lower point detector switch module into switch machine while checking wire
harness clearance.
2.
Align mounting holes of replacement point detector switch module and mounting holes
in switch machine base plate.
3.
Install two socket head cap screws attaching point detector switch module to switch
machine base plate.
4.
Replace switches.
5.
Replace point detector module.
6.
Replace point detector end and center cover along with cross brace between covers.
7.
P2444, Rev. Jan/07
6-17
MOTOR LIMIT AND
LATCHOUT SWITCH (3)
POINT
DETECTOR
SWITCH
MODULE
WIRE
HARNESS
CONNECTION
POINT
DETECTOR
SWITCH MODULE
SCREW (2)
Figure 6-11. Point Detector Switch Module Removal and Replacement Components
Point Detector Rod
rod. No special tools are required.
WARNING
P2444, Rev. Jan/07
6-18
Removal Procedure
1.
Remove all connection hardware attaching point detection rod to switch points.
2.
Slide point detection rod out of switch machine.
1.
Slide replacement point detection rod into switch machine.
2.
Install all connection hardware attaching rod to switch points.
3.
4.
Adjust point detector rod, as described in Section 3, if required.
Housing
Perform the following procedure, in sequence given, to remove and replace the switch machine
housing. Adjustments or special tools, if required, are described in the procedure.
WARNING
Removal Procedure
1.
Remove motor end center and point detector end covers.
2.
Remove hand throw and wiring harness attached to switch machine housing.
3.
Remove amplifier, hand throw, point detector rod, field wiring and wire conduit.
4.
Remove the seven large socket head cap screws attaching switch machine housing to
switch machine base plate.
5.
Lift housing by pulling upward while checking wire harness and switch clearance.
1.
Align replacement housing mounting holes and cavities for throw bar and lock rod wear
plates with corresponding mounting holes and cavities in base plate.
2.
Carefully lower housing onto switch machine base plate while checking wire harness and
component clearance.
3.
Install the seven large socket head cap screws attaching housing to switch machine base
plate.
4.
Replace amplifier, hand throw, point detector rod, field wiring, and wire conduit.
5.
Replace motor end, center, and point detector end covers.
6.
P2444, Rev. Jan/07
6-19
Throw Bar
Perform the following procedure, in sequence given, to remove and replace the throw bar.
Adjustments or special tools, if required, are described in the procedure.
WARNING
Removal Procedure
1.
Remove motor end, center, and point detector end covers along with cross braces
between covers.
2.
Remove all connecting hardware attaching throw bar to switch points.
3.
Remove amplifier, manual operation switch, motor with 5:1 gearbox, 30:1 gearbox, hand
throw, and main drive.
4.
Remove the seven large socket head cap screws attaching switch machine housing to
5.
Raise housing by pulling upward while removing throw bar.
1.
Raise housing by pulling upward while installing replacement throw bar.
2.
3.
Replace the seven large socket head cap screws attaching switch machine housing to
4.
Replace manual operation switch, motor with 5:1 gearbox, 30:1 gearbox, hand throw,
and main drive.
5.
Replace motor end, center, and point detector end covers along with cross braces
between covers.
6.
P2444, Rev. Jan/07
6-20
Cam Bar
Perform the following procedure, in sequence given, to remove and replace the cam bar.
Adjustments or special tools, if required, are described in the procedure.
WARNING
Removal Procedure
1.
Remove motor end, center, and point detector end covers along with cross braces
between covers.
2.
3.
Remove amplifier, manual operation switch, motor with 5:1 gearbox, 30:1 gearbox, hand
4.
Remove throw bar, lock rod, point detection rod, point detection system, point detection
switch module.
5.
Remove switch machine housing.
6.
Raise cam bar from machined cavity in switch machine base plate.
1.
Insert replacement cam bar into machined cavity of switch machine base plate.
2.
Replace throw bar, lock rod, point detection rod, point detection system, and point
detection switch module.
3.
Replace amplifier, manual operation switch, motor with 5:1 gearbox, 30:1 gearbox, hand
4.
Replace motor end, center, and point detector end covers along with cross braces
between covers.
5.
P2444, Rev. Jan/07
6-21
Throw Bar and Lock Rod Wear Plate Assembly
Perform the following procedure, in sequence given, to remove and replace the cam bar. Refer
to Figure 6-12 while performing the following procedure. No adjustments or special tools are
required.
WARNING
Removal Procedure
1.
Remove two socket head cap screws attaching wear plate assembly to side of switch
machine housing.
2.
Slide wear plate assembly out of cavity in switch machine housing and disassemble the
four plates that configure the assembly.
1.
Slide the replacement wear plate assembly into the cavity of the switch machine housing.
2.
Install the two socket head cap screws attaching wear plate assembly to switch machine
housing.
WEAR PLATE
MOUNTING
SCREWS (2)
THROW
BAR
LOCK
ROD
WEAR PLATE
MOUNTING
SCREWS (2)
Figure 6-12. Wear Plate Assembly Removal and Replacement
P2444, Rev. Jan/07
6-22
SECTION 7
PARTS CATALOG
GENERAL
This section identifies and lists the replaceable parts of the GM4000 switch machine along with
kits, associated connecting hardware, and tools. These items and replaceable components are
identified by a 10-digit drawing number. When ordering, always refer to the 10-digit drawing
number.
A sub-assembly is provided as a field replaceable unit. A kit is provided as multiple
components. The kit components are listed and can be ordered singularly. Removal and
replacement instructions for the kit and kit components are provided when ordering.
PARTS LISTS
The illustration of the switch machine is followed by Tables 7-1 through 7-4; these tables are
parts lists giving part descriptions and numbers of the field replaceable parts and kits, connecting
hardware, and tools. Reference numbers are listed to precisely locate referenced parts in the
illustration. This section of the manual covers currently available manufactured spare parts for
field level replacement.
P2444, Rev. Jan/07
7-1
P2444, Rev. Jan/07
7-2
30
34-72
32
40
38
10-11 66-69
45
64-91
44-76-78
53
92-93
43
79-81
24
76-85-86
34-72
73-74
62
89
5
55
53
62
63
TB2 TB1
Remote
Run
Motor
Amplifier
Overload
1
TB3
Local
1
GM050-024-00
6
36
47
77
"A"
36
77
88
"A"
1
TB4
10
12
76-78
66-70
26
9
36-46-77
79-83
25
66-67
66-71
66-68
94
90
54
37
35-80-84
34-72
96
34-72
82
62-89
31
27-65-91
29
41
39
52
6
19-20
51 18 50
8
7
33-49
22
58-79-87
3
28
73
75
21
A
B
C
GRS
4
23
1
SECTION "A-A"
2
42
76-78
GM050-000-00
Figure 7-1. Typical GM4000 Switch Machine
P2444, Rev. Jan/07
Signaling Inc.
7-3 / 7-4 Blank
ALSTOM
Table 7-1. ALSTOM Model GM4000 Switch Machine Replaceable Components
REF.
DESCRIPTION
DRAWING NO.
-
Switch Machine GM4000
GM050-000-01
2
Throw Bar
GM050-002-00
3
Housing
GM050-003-00
5
Cross Brace
GM050-005-00
6
Cover, Rear
GM050-006-00
7
Cover, Center
GM050-007-00
8
Cover, Front
GM050-008-00
9
Strap, Cover
GM050-009-00
10
Strap, Clamp
GM050-010-00
11
Screw, .313-18 x .875 Lg Hex Hd Modified
GM050-011-00
12
Wear Plate, Side Lock Rod
GM050-012-00
13
Wear Plate, Top Lock Rod
GM050-013-00
14
Wear Plate, Bottom Lock Rod
GM050-014-00
15
Wear Plate, Bottom Throw Bar
GM050-015-00
16
Wear Plate, Side Throw Bar
GM050-016-00
17
Wear Plate, Top Throw Bar
GM050-017-00
18
Key, Coupling
GM050-018-00
19
Key, Gearbox/Motor
GM050-019-00
20
Motor
GM050-020-00
21
Bracket, Plate Double Term Strip AAR 12 Post
GM050-021-00
22
Bracket, Angle Term Strip AAR 10 Post
GM050-022-00
23
Screw, .138 x .25 Lg Drive
24
Amplifier, w/Config Plugs and Stand-Offs
GM050-024-00
25
Worm Drive Module, 30:1
GM050-025-00
26
Gearbox Module, 5:1
GM050-026-00
27
Cover, Hand Throw
GM050-027-00
28
Cover, Electrical
GM050-028-00
29
Guard, Throwbar Track Side
GM050-029-00
30
Guard, Throwbar Field Side
GM050-030-00
P2444, Rev. Jan/07
52681-010-00
7-5
Table 7-1. ALSTOM Model GM4000 Switch Machine Replaceable Components (Cont.)
REF.
DESCRIPTION
DRAWING NO.
31
Guard, Lock Rod Track Side
GM050-031-00
32
Guard, Lock Rod Field Side
GM050-032-00
33
Ring, Backing Brg Pd Rod
GM050-033-00
34
Washer, Conical .375 Nom x .630 OD x .039 Thk Serrated
00590-115-00
35
Washer, .164 ID, .293 OD, .05 Thk Lock
01273-003-ON
37
Main Drive Comp
GM050-100-01
38
Hand Throw Lever Comp
GM050-200-01
39
Lock Rod Comp (Threaded End Narrow Notch)
GM050-300-01
39
Lock Rod Comp (Threaded End Wide Notch)
GM050-300-02
39
Lock Rod Comp (Spade End Narrow Notch)
GM050-300-03
39
Lock Rod Comp (Spade End Wide Notch)
GM050-300-04
40
Latch Stand Comp
GM050-400-01
41
Rod Comp, Point Detector (Swivel)
GM050-500-01
41
Rod Comp, Point Detector (Solid)
GM050-500-02
41
Rod Comp, Point Detector (Spade End)
GM050-500-03
42
Cam Bar
GM050-600-01
43
Point Detector System Comp
GM050-700-01
44
Point Detector Switch Comp
GM050-800-02
45
Harness
GM050-900-01
46
Strip, Terminal (10 Way)
56140-019-00
47
56140-022-00
48
Nut, .242-24, .125 Thk, Jam
42839-008-00
49
Bearing, Flanged Garlock 20FDU24
08942-144-00
50
Jaw, Coupling Lovejoy L-095 1.00 Bore
51
Spider, Coupling Lovejoy L-095
52592-010-00
52
Gasket, .625 x .625 x 203 Lg Adh Bk
43460-038-00
P2444, Rev. Jan/07
(Vibratite Screw)
7-6
52592-009-00
REF.
DESCRIPTION
DRAWING NO.
53
Pin, Dowel .250 OD x .50 Lg
00500-057-00
54
Pin, Dowel .375 OD x .75 Lg
00500-058-00
55
Pin, Jig
42737-020-00
56
Washer, .250 ID, .478 OD, .03 Thk Shk’prf
53029-075-00
57
Connector, Terminal
43587-006-00
58
Tie, Cable
29855-014-00
59
Washer, .242 ID, .563 OD, .040 Thk Flat
01225-002-00
60
Nut, .242-24 x .188 Thk, Jam
42839-005-00
61
Nut, .242-24, Binding
42843-001-00
62
Screw, .625-11 x .75 Lg Soc Hd
17708-147-00
62
Washer, .625 ID, 1.072 OD, .16 Thk Lock
01273-011-ON
63
Screw, .625-11 x 3.50 Lg Soc Hd
17708-148-00
64
17708-128-00
65
17708-147-00
66
01273-008-ON
67
17708-146-00
68
17708-145-00
69
17708-124-00
70
17708-122-00
71
17708-121-00
72
17708-143-00
73
01273-007-ON
74
17708-142-00
75
Screw, .313-18 x .75 Lg Hex Hd
00441-006-ON
76
01273-006-ON
77
Screw, .250-20 x 1.00 Lg Soc Hd Self Lock
17708-076-00
78
17708-119-00
79
01273-004-ON
P2444, Rev. Jan/07
7-7
REF.
DESCRIPTION
DRAWING NO.
80
Washer, .164 ID, .375 OD, .03 Thk Flat
01250-006-ON
81
17708-130-00
82
Screw, .190-32 x 1.75 Lg But Hd (Vibratite)
17708-141-00
83
17708-129-00
84
17708-158-00
85
Screw, .250-20 x .88 Lg But Hd
17708-139-00
86
17708-140-00
87
17708-138-00
88
56140-021-00
89
17708-112-00
90
Screw, Shoulder .313-18 Soc Hd .375 OD x 2.0 Lg
17708-156-00
91
Washer, .625 ID, 1.072 OD, .16 Thk Lock
01273-011-ON
92
01273-008-ON
93
17708-122-00
94
Plug Cap
20132-015-00
95
Screw, .313-18 x 2.25 Lg Nylok
17708-157-00
P2444, Rev. Jan/07
7-8
Table 7-2. ALSTOM Model GM4000 Switch Machine Field Replaceable Kits
REF.
QTY
1
-
Kit, Lock Rod Wear Plate
2
Wear Plate, Side Lock Rod
GM050-012-00
1
Wear Plate, Top Lock Rod
GM050-013-00
1
Wear Plate, Bottom Lock Rod
GM050-014-00
-
Kit, Throw Bar Wear Plate
1
Wear Plate, Bottom Throw Bar
GM050-015-00
2
Wear Plate, Side Throw Bar
GM050-016-00
1
Wear Plate, Top Throw Bar
GM050-017-00
-
Kit, Point Detector Rod Bushing
2
Flanged Bearing
08942-144-00
2
Screw, .190-32 x 1.75 Lg. Soc Hd
17708-130-00
-
Kit, Point Detector Pivot Arm Bushing
1
Bearing, Roller .625 Dia.
1
Pin, Pivot Arm
1
E-Ring
-
Kit, Latch-Out Dog Bearing
1
Bearing, Needle
12267-008-00
1
Washer, Lock
01273-004-0N
1
Nut
01272-007-0N
-
Kit, Latch-Out Dog Spring
2
Extension Spring
7
-
Kit, Maintenance Tool
GMK50-000-01
8
-
Kit, M23 Wiring Harness
GMK50-010-01
2
3
4
5
6
P2444, Rev. Jan/07
DESCRIPTION
DRAWING NO.
49536-134-00
GM050-713-00
05713-090-00
01581-052-00
7-9
Table 7-3. ALSTOM Model GM4000 Switch Machine Connecting Hardware
REF.
DESCRIPTION
DRAWING NO.
1
Point Detector Rod Drop Lug
GMA50-003-00
2
Adjustable Lock Rod Drop Lug (Treaded Lock Rod)
GMA50-008-01
3
Adjustable Lock Rod Drop Lug (Spade-End Lock Rod)
GMA50-008-02
4
Throw Bar Coupler (Straight)
GMA50-006-00
5
Throw Bar Coupler (Downset, 3.4-inches)
GMA50-007-00
Table 7-4. ALSTOM Model GM4000 Switch Machine Tools
REF.
DESCRIPTION
DRAWING NO.
1
Handcrank
GMA50-001-00
2
Spoon Gauge
GMA50-002-00
P2444, Rev. Jan/07
7-10
APPENDIX A
DRAWINGS
OVERVIEW
The following drawings are given to assist maintainers with installation, wiring, and
troubleshooting a GM4000 switch machine.
P2444, Rev. Jan/07
A-1
WIRING AND CIRCUIT APPLICATIONS
3-Wire Configuration
(For Replacement of ALSTOM Model 5E & 5F Switch Machines)
WZR
NWR
LR
3E
DC(+)
OR
S
DC(–)
RWR
3E
TO CONTROL RELAYS
FOR SECOND SWITCH
OF CROSSOVER
RW
(NW)
TB1-1
–
NW
(RW)
+
TB1-3
CW
24 - 32 OR
110 VOLTS DC
O
TB1-2
Note:
Connect CW to TB1-2.
Connect RW to TB1-1 and NW to TB1-3.
If the machine travels in the wrong direction, interchange RW and NW.
P2444, Rev. Jan/07
A-2
3-Wire Configuration (Continued)
(For Replacement of ALSTOM Model 5E & 5F Switch Machines)
WZR
RWR
LR
3E
DC(+)
OR
S
DC(–)
NWR
3E
TO CONTROL RELAYS
FOR SECOND SWITCH
OF CROSSOVER
RW
(NW)
TB1-1
–
NW
(RW)
+
TB1-3
CW
24 - 32 OR
110 VOLTS DC
O
TB1-2
Note:
Connect CW to TB1-2.
Connect RW to TB1-1 and NW to TB1-3.
If the machine travels in the wrong direction, interchange RW and NW.
P2444, Rev. Jan/07
A-3
(For Replacement of US&S Model M23A or M3 Switch Machine)
External connections are shown to the main terminal board for a switch having the right-hand
point normal closed. For a switch having the left-hand point normally closed, interchange the
external leads to terminals 35 and D.
Typical circuit control of standard GM4000 brushless DC motor switch machine for connection
to US&S high and low voltage, series-parallel field motor application using DP-25 and OR-11
shelf type of PNP-69 and ORP-60 plug in type relays.
N-WR
TO
CONTROL
CIRCUITS
-WR
+
-WR1
WR
+
OR-11
or
ORP-60
RELAY
–
O
OR
–
P
DP-25
or
PNP-69
RELAY
NW
C
TB1-2
+
BW
+
S
D
35
TB1-1
TB1-3
Note: If the machine travels in the wrong direction, interchange D and 35 connection.
P2444, Rev. Jan/07
A-4
(For Replacement of ALSTOM Model 5G & 5H Switch Machines)
Typical GM4000 wiring diagram for ALSTOM Model 5G/5H switch machine control circuit
applications with left-hand point normally closed.
1
1
16 TO 140 VDC
OR
85 TO 140 VAC
TB1-1 TB1-3
1
NWR
WR
10
TB3
12
12
TB2
TB1
Note: If the machine travels in the wrong direction, interchange NWR and WR.
P2444, Rev. Jan/07
A-5
(For Replacement of ALSTOM Model 5G & 5H Switch Machines)
Typical GM4000 wiring diagram for ALSTOM Model 5G/5H switch machine control circuit
applications with right-hand point normally closed.
1
1
16 TO 140 VDC
OR
85 TO 140 VAC
TB1-1 TB1-3
1
WR
NWR
10
TB3
12
12
TB2
TB1
Note: If the machine travels in the wrong direction, interchange NWR and WR.
P2444, Rev. Jan/07
A-6
(For Replacement of US&S Model M23A, M23B, or M3 Switch Machines)
external leads to terminals 5 and 10.
to US&S high and low voltage, series-parallel field motor application using DP-25 and OR-11
shelf type or PNP-69 and ORP-60 plug in type relays.
N-WR
TO
CONTROL
CIRCUITS
-WR
-WR1
–
+
–
+
OR-11 OR
ORP-60
RELAY
O
WR
P
DP-25 OR
PNP-69
RELAY
NW
OR
S
+
D
TB1-2
BW
+
B
TB1-8/TB4-6*
TB1-1
5
10
C
TB1-3
TB1-8/TB4-6*
Note: If the machine travels in the wrong direction, interchange wires 5 and 10.
P2444, Rev. Jan/07
A-7
(For Replacement of US&S Model M23A, M23B, or M3 Switch Machines)
external leads to terminals 5 and 10.
to US&S high and low voltage, series-parallel field motor application using PP-151, PN150BM
and N-150SO relays.
N-WR
TO
CONTROL
CIRCUITS
+
-WR1
+
PN-15050
RELAY
-WR
–
O
–
PN-151
RELAY
OR
S
+
-WRPR
–
PN-1508M
RELAY
N110
D
TB1-2
+
B110
+
B
5
10
C
TB1-8/TB4-6*
TB1-1
TB1-3
TB1-8/TB4-6*
Note: If the machine travels in the wrong direction, interchange wires 5 and 10.
P2444, Rev. Jan/07
A-8
Terminal Block Pin Outs
1
1
POWER
SHUNT
1
POWER
POWER
12V CONTROL
INDICATION
12V CONTROL
HAND THROW
HAND THROW
AUX
*
LO
**
LO
10
TB3
12
12
TB2
TB1
* MOTOR LIMIT
*
**
Motor Limit
Hand Crank
P2444, Rev. Jan/07
A-9
Restorable Latch Out Circuit
AMPLIFIER
NORMAL POINT
DETECTOR
ROTARY CAM
SWITCH 5
LATCH OUT
SWITCH
REVERSE POINT
DETECTOR
ROTARY CAM
SWITCH 5
AAR TERMINAL POST
LATCH OUT JUMPER
MOTOR
DRIVER
MACHINE AT REVERSE
NOT LATCHED OUT
MOTOR
DRIVER
MACHINE AT MID-STROKE
NOT LATCHED OUT
MOTOR
DRIVER
MACHINE AT NORMAL
NOT LATCHED OUT
MOTOR
DRIVER
MACHINE LATCHED OUT
P2444, Rev. Jan/07
A-10
Non-Restorable Latch Out Circuit
AMPLIFIER
NORMAL POINT
DETECTOR
ROTARY CAM
SWITCH 5
LATCH OUT
SWITCH
REVERSE POINT
DETECTOR
ROTARY CAM
SWITCH 5
AAR TERMINAL POST
NO LATCH OUT
JUMPER
MOTOR
DRIVER
MACHINE AT REVERSE
NOT LATCHED OUT
MOTOR
DRIVER
MACHINE AT MID-STROKE
NOT LATCHED OUT
MOTOR
DRIVER
MACHINE AT NORMAL
NOT LATCHED OUT
MOTOR
DRIVER
MACHINE LATCHED OUT
P2444, Rev. Jan/07
A-11
INSTALLATION AND SPACE REQUIREMENTS
19.88
8.13
15.50 WITH
.781 DIA HOLES
OR
16.00 WITH
.906 DIA HOLES
2.00
33.90
24.42
2.00
6.50
THROW
1.65
8.50
67.25
11.00
11.50
17.00
2.00
20.00
2.75
2.80
4.74
18.43
22.25
***
P2444, Rev. Jan/07
A-12
Typical Polarized Switch Repeater Circuit, Single Switch
Point detector contacts are shown in position for
right hand point normally closed.
INDICATION IN HAND THROW
TB-3
1
TB-2
TB-1
1
1
shunt
power
2
2
LH point
normally
closed
To verify indication for left hand point
normally closed, connect a meter to TB2
and or TB3 as follows:
power
shunt
2
RH point
normally
closed
3
3
NWP / WP
shunt
3
4
4
4
NWP
control
shunt
5
(TB2-7 / TB2-5)
WP
5
indicate
5
6
hand thr
indicate
6
To verify indication for right hand point
6
7
7
WP / NWP
indicate
7
8
8
aux
indicate
8
9
9
9
motor limit
latch out
10
10
Note 1
DC+
DC+
WP
NWP
When using shunt
contacts connect the
bold wires as shown
motor limit
10
11
11
right
hand crk
aux
12
12
left
P2444, Rev. Jan/07
(TB2-7 / TB2-5)
DC-
DC-
Note 1: A fuse is required for short circuit
protection on the positive energy used for
indication. Fuse: 10 amp, type SC, Form 1,
class J or equivalent.
A-13 / A-14 Blank
Typical Polarized Switch Repeater Relay Circuit Crossover
Point detector contacts are shown in position
for right hand point normally closed.
point detector
end
point detector
end
energy end
TB-2
TB-1
TB-3
1
1
shunt
power
2
2
1
shunt
2
RH point
normally
closed
WP1A
LH point
normally
closed
WP1
TB-2
TB-1
TB-3
1
1
shunt
power
2
2
1
shunt
power
3
relay end
NWP1
3
NWP1
2
shunt
3
4
shunt
4
5
6
indicate
6
7
NWP
4
WP
3
control
shunt
5
4
8
6
5
hand thr
indicate
7
6
9
8
aux
DC+
DC+
WP
NWP
4
4
control
5
5
To verify indication for right hand
point normally closed, connect a
meter to TB2 and or TB3 as follows:
6
6
hand thr
7
7
NWP / WP
NWP1 / WP1A
NWP1 / WP1
(TB2-6 / TB2-8)
(TB2-7 / TB2-5)
(TB3-7 / TB3-5)
7
8
8
9
9
motor limit
latch out
10
10
10
11
11
right
hand crk
aux
12
12
aux
indicate
9
9
motor limit
latch out
10
10
WP1
8
WP1A
9
motor limit
When using shunt
contacts connect
the bold wires as shown
motor limit
10
11
11
right
hand crk
aux
12
12
left
P2444, Rev. Jan/07
3
(TB2-6 / TB2-8)
(TB2-7 / TB2-5)
(TB3-7 / TB3-5)
indicate
Note 1
indicate
8
3
indicate
indicate
7
WP / NWP
NWP1 / WP1
NWP1 / WP1A
power
shunt
indicate
5
To verify indication for left hand
DC-
DC-
Note 1: A fuse is required for short
circuit protection on the positive energy
used for indication. Fuse: 10 amp,
type SC, Form 1, class J or equivalent.
left
A-15 / A-16 Blank
Typical Polarized Switch Repeater Relay Circuit Crossover
NO INDICATION IN HAND THROW
point detector
end
point detector
end
energy end
TB-2
TB-1
TB-3
1
1
shunt
power
2
2
1
WP1A
LH point
normally
closed
WP1
power
shunt
2
RH point
normally
closed
3
relay end
TB-2
TB-1
TB-3
1
1
shunt
power
2
2
1
NWP1
3
NWP1
2
shunt
3
4
shunt
4
5
6
indicate
6
7
NWP
4
WP
3
control
shunt
5
4
8
6
5
hand thr
indicate
7
6
9
4
4
control
5
5
6
6
hand thr
7
7
8
aux
DC+
DC+
WP
NWP
7
8
8
9
9
motor limit
latch out
10
10
aux
indicate
9
9
motor limit
latch out
10
10
WP1
8
WP1A
9
motor limit
motor limit
10
11
11
right
hand crk
aux
12
12
left
When using shunt
contacts connect
indicate
Note 1
indicate
8
3
indicate
indicate
7
3
shunt
indicate
5
power
shunt
DC-
DC-
10
11
11
right
hand crk
aux
12
12
WP / NWP
NWP1 / WP1
NWP1 / WP1A
(TB2-6 / TB2-8)
(TB2-7 / TB2-5)
(TB3-7 / TB3-5)
NWP / WP
NWP1 / WP1A
NWP1 / WP1
(TB2-6 / TB2-8)
(TB2-7 / TB2-5)
(TB3-7 / TB3-5)
left
P2444, Rev. Jan/07
A-17 / A-18 Blank
Typical Polarized Switch Repeater Circuit, Single Switch
TB-3
1
TB-2
TB-1
1
1
shunt
power
2
2
LH point
normally
closed
power
shunt
2
RH point
normally
closed
3
3
NWP / WP
shunt
3
4
4
4
NWP
control
shunt
5
(TB2-7 / TB2-5)
WP
5
indicate
5
6
hand thr
indicate
6
6
7
7
WP / NWP
indicate
7
8
8
aux
indicate
8
9
9
9
motor limit
latch out
10
10
Note 1
DC+
DC+
WP
NWP
When using shunt
bold wires as shown
motor limit
10
11
11
right
hand crk
aux
12
12
left
P2444, Rev. Jan/07
(TB2-7 / TB2-5)
DC-
DC-
A-19 / A-20 Blank
Typical 6 Wire Polarized Switch Repeater Relay Circuit Crossover
point detector
end
point detector
end
energy end
TB-2
TB-1
TB-3
1
1
shunt
power
2
2
1
WP1A
3
4
shunt
4
WP1
5
relay end
TB-2
TB-1
TB-3
1
1
shunt
power
2
2
1
3
4
NWP1
NWP1
NRWP1
NRWP1
NWP
WP
2
6
indicate
6
7
3
control
shunt
5
4
8
6
5
hand thr
indicate
7
6
9
8
aux
DC+
DC+
WP
NWP
4
4
control
5
5
6
6
hand thr
7
7
NWP / WP
(TB2-6 / TB2-8)
NRWP1 / RWP1 (TB2-7 / TB2-5)
NWP1 / WP1
(TB3-7 / TB3-5)
7
8
8
9
9
motor limit
latch out
10
10
10
11
11
right
hand crk
aux
12
12
aux
indicate
9
9
motor limit
latch out
10
10
WP1
8
WP1A
9
motor limit
When using shunt
contacts connect
motor limit
10
11
11
right
hand crk
aux
12
12
left
P2444, Rev. Jan/07
3
(TB2-6 / TB2-8)
(TB2-7 / TB2-5)
(TB3-7 / TB3-5)
indicate
Note 1
indicate
8
3
indicate
indicate
7
WP / NWP
NRWP1 / WP1
NWP1 / WP1A
shunt
indicate
5
power
shunt
shunt
3
LH point
normally
closed
power
shunt
2
RH point
normally
closed
DC-
DC-
left
A-21 / A-22 Blank
Typical Neutral Switch Repeater Circuit, Single Switch
TB-3
1
TB-2
TB-1
1
1
shunt
power
2
2
LH point
normally
closed
power
shunt
2
RH point
normally
closed
3
CRWP
3
CNWP
shunt
3
4
shunt
4
4
NWP
control
5
WP
CNWP / NWP
(TB2-7 / TB2-5)
RWP / CRWP
(TB3-6 / TB3-8)
5
indicate
5
6
hand thr
indicate
6
6
7
7
indicate
7
8
8
aux
indicate
8
9
9
9
motor limit
latch out
10
10
motor limit
10
11
11
right
hand crk
aux
12
12
left
P2444, Rev. Jan/07
Note 1
DC+
DC+
NWP
RWP
CNWP
CRWP
DC-
DC-
CRWP / RWP
(TB2-7 / TB2-5)
NWP / CNWP
(TB3-6 / TB3-8)
When using shunt
bold wires as shown
A-23 / A-24 Blank
Typical Neutral Switch Repeater Circuit, Single Switch
TB-3
1
TB-2
TB-1
1
1
shunt
power
2
2
LH point
normally
closed
power
shunt
2
RH point
normally
closed
3
3
CRWP
CNWP
RWP
NWP
CNWP / NWP
(TB2-7 / TB2-5)
RWP / CRWP
(TB3-6 / TB3-8)
shunt
3
4
control
shunt
4
4
5
5
indicate
5
6
indicate
6
7
6
hand thr
CRWP / RWP
(TB2-7 / TB2-5)
7
NWP / CNWP
(TB3-6 / TB3-8)
indicate
7
8
8
aux
indicate
8
9
9
9
motor limit
latch out
10
10
motor limit
10
11
11
right
hand crk
aux
12
12
left
P2444, Rev. Jan/07
Note 1
DC+
DC+
NWP
RWP
CNWP
CRWP
DC-
DC-
When using shunt
bold wires as shown
A-25 / A-26 Blank
Typical Neutral Switch Repeater Relay Circuit Crossover
point detector
end
point detector
end
energy end
TB-2
TB-1
TB-3
1
1
shunt
power
2
2
1
CRWP1
LH point
normally
closed
CNWP1
power
shunt
2
RH point
normally
closed
3
relay end
TB-2
TB-1
TB-3
1
1
shunt
power
2
2
1
RWP1
3
NWP1
2
shunt
3
4
shunt
4
5
6
indicate
6
7
4
RWP
NWP
3
control
CRWP
CNWP
shunt
5
CNWP
CRWP
4
NWP
RWP
8
6
5
hand thr
indicate
7
6
9
8
aux
DC+
DC+
NWP1
RWP1
CNWP1
CRWP1
CWP1
CWP1
DC-
DC-
(TB2-5 / TB2-7)
(TB3-6 / TB3-8)
(TB2-7 / TB2-5)
(TB3-6 / TB3-8)
4
control
5
5
6
6
hand thr
7
7
7
8
8
9
9
motor limit
latch out
10
10
10
11
11
right
hand crk
aux
12
12
aux
When using shunt
contacts connect
indicate
9
9
motor limit
latch out
10
10
motor limit
8
9
motor limit
10
11
11
right
hand crk
aux
12
12
left
P2444, Rev. Jan/07
4
indicate
Note 1
indicate
8
RWP / CRWP
NWP / CNWP
CRWP1 / RWP1
NWP1 / CNWP1
indicate
indicate
7
3
shunt
indicate
5
3
(TB2-5 / TB2-7)
(TB3-6 / TB3-8)
(TB2-7 / TB2-5)
(TB3-6 / TB3-8)
power
shunt
NWP / CNWP
RWP / CRWP
CNWP1 / NWP1
RWP1 / CRWP1
left
Note 1: A fuse is required
for short circuit protection
on the positive energy used
for indication. Fuse: 10 amp,
type SC, Form 1, class J or
equivalent.
A-27 / A-28 Blank
Typical Neutral Switch Repeater Relay Circuit Crossover
point detector
end
point detector
end
energy end
TB-2
TB-1
TB-3
1
1
shunt
power
2
2
1
shunt
2
RH point
normally
closed
CRWP1
LH point
normally
closed
CNWP1
TB-2
TB-1
TB-3
1
1
shunt
power
2
2
1
shunt
power
3
relay end
RWP1
3
NWP1
2
shunt
3
4
shunt
4
5
RWP
NWP
3
control
CRWP
CNWP
shunt
5
CNWP
CRWP
4
NWP
RWP
indicate
5
6
indicate
6
7
8
6
5
hand thr
indicate
7
6
9
4
8
aux
Note 1
DC+
DC+
NWP1
RWP1
CNWP1
CRWP1
DC-
DC-
control
5
5
6
6
hand thr
7
7
7
8
8
9
9
motor limit
latch out
10
10
aux
When using shunt
contacts connect
indicate
9
9
motor limit
latch out
10
10
motor limit
8
9
motor limit
10
11
11
10
11
11
right
hand crk
aux
right
hand crk
aux
12
12
12
12
left
P2444, Rev. Jan/07
(TB2-5 / TB2-7)
(TB3-6 / TB3-8)
(TB2-7 / TB2-5)
(TB3-6 / TB3-8)
4
indicate
indicate
8
RWP / CRWP
NWP / CNWP
CRWP1 / RWP1
NWP1 / CNWP1
indicate
indicate
7
3
shunt
4
(TB2-5 / TB2-7)
(TB3-6 / TB3-8)
(TB2-7 / TB2-5)
(TB3-6 / TB3-8)
power
3
NWP / CNWP
RWP / CRWP
CNWP1 / NWP1
RWP1 / CRWP1
left
circuit protection on the positive
energy used for indication.
Fuse: 10 amp, type SC, Form 1,
A-29 / A-30 Blank
1
POWER
2
POWER
3
4
CONTROL
5
CONFIGURATION
MODULE
P2-1
HAND THROW
P2-2
P2-3
6
TB17
POWER
P1-1
8
P1-16
12 VOLT
CONTROL
9
LATCH OUT
MANUAL
SWITCH
10
2-3
2-4
11
1-4
1-3
12
P1-2
P1-18
MANUAL CONTROL
P1-10
AUX
MOTOR
HARNESS
BRUSHLESS
DC MOTOR
P1-21
P1-4
12
INHIBIT
HAND CRANK
MOTOR AMPLIFIER
11
10
MOTOR LIMIT
9
P1-9
PDR CONNECTOR
8
MOTOR LIMIT (L)
GND
12
P1-11
8
8
LIMIT -
7
7
12 VOLT P1-20
OUT
6
6
5
5
4
4
3
3
2
2
1
1
11
21
22
INDICATE
7
TB36
INDICATE
5
4
SHUNT
12
11 10
9
12
11 10
9
PDR
CONNECTOR
MOTOR LIMIT (R)
22
BUTT
SPLICE
21
LIMIT +
P1-3
12
11 21
22
HAND THROW
SWITCH
LED
3
P1-19
12
12 VOLT
OUT
11
2
TB4-
P1-15
SHUNT
1
1
2
4
3
5
6
7
8
9
10
11
INHIBIT
12
CURRENT P1-5
SELECT
P1-12
12V
HAND CRANK
SWITCH
1
2
1
RIGHT POINT DETECTOR ROTORY CAM SWITCH
2
11
12
3
P1-23
LATCH OUT
SWITCH
LEFT POINT DETECTOR ROTORY CAM SWITCH
TB2-
SPEED
SELECT
INHIBIT
21
SPEED 1
12V
SPEED 2
22
P1-13
P1-17
4
P1-6
1
5
GND
SHUNT
2
1
2
3
4
5
6
7
8
9
10
11
12
P1-7
AUX
6
3
DIAGNOSTIC
OUTPUTS
SHUNT
PDL
CONNECTION
4
5
INDICATE
6
7
1
1
2
2
3
3
12
4
4
11
5
5
6
7
6
7
8
8
INDICATE
8
LED
PDL
CONNECTION
12
11
10
10
9
9
BUTT
SPLICE
9
MOTOR
LIMIT
WIRING DIAGRAM
GM050-040-00
10
P2444, Rev. Jan/07
A-31 / A-32 Blank

4000 Switch Machine

Transcription

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