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SM-6444 - Ansaldo STS

1. Suggested Point of Type of Application Toute t Commercial Method Apply To Remarks Products Pressure Gun Alemite Solidified Oil Grease Grease Apply until surplus is A Grease 32 Alemite Temprite Gun Fittings visible at edges of Solidified Oil E P bearing Prime Mfg Co Either Pressure Same as above Grease Surface Gun Grease Gun OR m B Auto Transmission Pour Surface Heavy Oil and rear end lubricant Viscosity120 to S A E 140 200 at 99 Texaco Novatex Medium Body Oil Automobile Engine Oil Oil Can Bearings amp A few drops periodically Viscosity 185 to S A E 30 Oil Holes as required Recess Fill recess periodically as top crank required bearing Low Temperature Low Temperature Oil Can Surface Apply very light film to all D Oil Lubricating Oil contact segments at Texaco Spindura frequent intervals after Oil 22 Code 788 thorough cleaning Low Temperature Lubriplate 5555 Fiske Pour Spur Gear Apply light coat to teeth E Lubricating Cil Brothers Refining Co Teeth as required Worm Gear Pour in Fill only to top of Compartment worm gear Regular and systematic lubrication is recommended However the period between times of lubricating depends upon the frequency of operation and upon climatic and local conditions and therefore can be established from experience by the Supervisory Department 5 18 SM 6444 Rev 1 0 May 2008 2y 74 AnsaldoSTS Un
2. YOLOATAS 92 06 3A331S Td rd Q3TIOHINOO SIOVINOO D Ye H vi E JVLSONWMS3H L L qasn N3HA yg 18 B YOLOW AVNIINSHLL NIVIN A0 Z AINIM Gasn NAHM ASLL OEZ HOS H3 1V3H INSWLYVdNOS YOLOW NOEZ Figure 2 7 Internal Wiring and Typical Control Circuits Sheet 1 SM 6444 Rev 1 0 May 2008 2 10 N 74 AnsaldoSTS Union Switch amp Signal Installation and Adjustment US amp S s PP 151 and PN 150BM relays are the standard switch control relays used in the M 3 control circuits The PP 151 is a magnetic stick relay used for reversing the polarity of the switch motor and keeping the operating winding and stick winding of the overload relay in agreement The PN 150BM is a biased relay with magnetic heavy duty contacts This relay is used for closing the switch motor circuit and opening the circuit under abnormal operating conditions The PN 150BM can break stalled switch motor current in excess of 50 amps at 110 volts DC The PP 151 PN 150BM combination is self checking because of the bias feature on the PN 150BM relay Earlier model US amp S relays can be used for the M 3 switch control circuit Relays equivalent to the PP 151 include the shelf type DP 25 or the earlier style plug in type PNP 69 The DP 25 is available with two neutral magnetic blowout contacts for a double break switch motor circuit Refer
3. POINT DETECTOR BAR IN ORIGINAL POSITION Figure 5 7 Contacts Latched Out and in the Open Position SM 6444 Rev 1 0 May 2008 5 21 lt N 74 AnsaldoSTS Shop Maintenance Union Switch amp Signal 5 8 2 Motor Cutout Contacts Adjust the length of push rod A so that when the hand crank cover hasp is in the notch in the pad lock staple the yoke B is against the machined stop surface on the top bearing C It is necessary to take off the gearbox cover to check that the yoke is against the stop Assemble eyebolt L to yoke B so that threaded end of eyebolt is just flush or one thread below surface of boss on yoke B Tighten nut M Adjust nuts N so that there is a space of 3 8 in to 7 16 in between nuts M and N Lock nuts N in place Remove the screw from the screw jaw D with the spring E driving the yoke B against the other side of the top bearing C Adjust the length of the push rod F by turning the screw jaw D so that the latch G clears the L shaped bracket H attached to the motor cutout contact insulation J by 1 16 in or slightly over With the hand crank cover closed and hasp in the staple notch adjust the contact springs K so that there is 1 16 in clearance between the angle bracket H and the push rod F With this clearance the contacts will be closed with a pressure of approximately three pounds In order to adjust the contacts a T shaped sprin
4. Figure 7 5 Motor Assembly SM 6444 Rev 1 0 May 2008 7 19 E 4 AnsaldoSTS Parts Lists Union Switch amp Signal S 1 AnsaldoSTS Union Switch amp Signal 7 20 SM 6444 Rev 1 0 May 2008 j AnsaldoSTS Rail Team and Technical Support Union Switch amp Signal 8 Rail Team and Technical Support The Rapid Action Information Link RAIL Team is comprised of experienced product and application engineers ready to assist and resolve technical issues concerning any US amp S product Any questions regarding the contents of this service manual can be answered by contacting the RAIL Team via e mail at railteam switch com or a toll free call to 800 652 7276 SM 6444 Rev 1 0 May 2008 8 1 E 4 AnsaldoSTS Rail Team and Technical Support Union Switch amp Signal Ay 74 AnsaldoSTS Union Switch amp Signal 8 2 SM 6444 Rev 1 0 May 2008
5. y AnsaldoSTS Technology Dri Pittsburgh PA 15219 Union Switch amp Signal 645 Batesburg Se 29006 SM 6444 M 3 Electric Switch Machine Standard Low Profile Model US amp S Part No Left Hand N4511601401 Right Hand N4511601501 Installation Description and Operation Maintenance Copyright 2008 SM 6444 Rev 1 0 Union Switch amp Signal Inc May 2008 N 74 AnsaldoSTS Union Switch amp Signal Notices Proprietary Notice This document and its contents are the property of Union Switch amp Signal Inc hereinafter US amp S This document has been furnished to you on the following conditions no right or license under any patents or any other proprietary right in respect of this document or its content is given or waived in supplying this document This document or its content are not to be used or treated in any manner inconsistent with the rights of US amp S or to its detriment and are not to be copied reproduced disclosed to others or disposed of except with the prior written consent of US amp S Important Notice US amp S constantly strives to improve our products and keep our customers apprised of changes in technology Following the recommendations contained in the attached service manual will provide our customers with optimum operational reliability The data contained herein purports solely to describe the product and does not create any warranties Within the scope of
6. Each cam is driven by a stud in the side of the gear Each cam also has two slots so that each can be engaged with its corresponding stud in either of two positions The cams are held with their respective studs by spring force and an 8 32 Allen Head setscrew adjacent to slots This screw is tightened against the gear hub after adjustments have been made 2 6 2 Procedure The two cams must be shifted individually Each cam can be shifted from one position to the other as follows 1 Loosen the 8 32 Allen head setscrew adjacent to the slots 2 To avoid distortion of the contact springs carefully insert two screw drivers between the cam and the gear 3 Force the cam away from the gear against the force of its coil spring 4 Rotate the cam to the alternate position until it snaps in place see Figure 3 8 view A 5 Tighten the setscrews 2 8 SM 6444 Rev 1 0 May 2008 N 74 AnsaldoSTS Union Switch amp Signal Installation and Adjustment 6 Repeat this procedure for the other cam 2 7 Electric Connections and Control Wiring 2 7 1 General Description of Internal and Control Circuits Figure 2 7 shows the internal wiring and typical control wiring schemes for operating the M 3 switch machine The internal wiring diagram is also shipped with the machine The Control Wiring section Figure 2 7 is provided for reference only Make certain to read the specific circuit application sheets for the switch machine location when
7. 620 755 575 B c ad 300 385 415 45 415 20 SECTION C C ao 45 400 730 135 420 430 lt 235 215 440 Wi iu NSS 200 405 580 4 SECTION J J VIEW Z Z a 400 480 440 SECTION 605 160 15 750 145 255 FOR 15W 115V 30 540 250 25 MOTOR COMPT HEATER 110 2422274 365 ZZ 22277202 G PZZZ LK Z SECTION G G 375 410 425 400 415 175 Figure 7 1 M 3 Switch Machine Assembly SM 6444 Rev 1 0 May 2008 7 7 7 8 N 74 AnsaldoSTS Union Switch amp Signal JEN ASST FS 22222494 eee H ie VIEW Z Z FOR 15W 115V MOTOR COMPARTMENT HEATER See Figure 7 1 for the location of the above section views on the main switch assembly Figure 7 2 M 3 Switch Machine Section Views SM 6444 Rev 1 0 May 2008 7 9 E 4 AnsaldoSTS Parts Lists Union Switch amp Signal A 1 AnsaldoSTS Union Switch amp Signal 7 10 SM 6444 Rev 1 0 May 2008 N 74 AnsaldoSTS Union Switch amp Signal 7 2 Gearbox Assembly N287485003 Parts Lists Table 7 2 is the parts list for gearbox assembly N287485003 The figure associated with this gearbox assembly is Figure 7 3 Table 7 2 Gearbox Assembly N287485003 Description Number Number 5 Gear Box Complete N287085 10 Bearin
8. Process Section Reference Remove from the machine Remove brushes from the motor Friction Clutch Remove from the machine Assembly Circuit Remove from the machine 5 5 4 Controller Remove from the machine Gearbox Remove the main crank 5 2 Special Tools The tools listed in Table 5 2 Table 5 3 and Table 5 4 are required to perform shop maintenance on the M 3 switch machine The ordering reference for a complete set of tools is X49125301 X49125302 and X49125303 Table 5 2 Required Maintenance Tools Basic Set X49125301 Tool Part Number Ratchet 1 2 Drive 10 long J0390000129 Handle Hinge 15 3 4 long J0390000131 J0390000130 J03900001 41 Socket Set 1 2 Drive J0390000140 Screwdriver WAGO No 210 119 J0390000134 Screwdriver 1 4 Slotted 6 long J0390000144 Screwdriver 1 2 Slotted 10 long J0390000143 Screwdriver Phillips No 2 10 long J0390000142 Wrench Adjustable 6 long J0390000132 Extension 1 2 Drive 10 long Hex Bit 3 8 SM 6444 Rev 1 0 May 2008 5 1 NU 74 AnsaldoSTS Shop Maintenance Union Switch amp Signal 5 2 Tool Part Number Wrench Adjustable 10 long J0390000133 Seater Brush 1 2 W x 1 4 T J0390000136 NOTE Tool Set X49125302 includes all of Tool Set X49125301 plus these additional tools Table 5 3 Maintenance Tools Basic Set with Track Tools X49125302 Tool Part Number Wrench Switch
9. 150 130 135 SECTION C C 390 415 gt 365 Hi ef 370 420 945 410 1 260 a 335 lt 9 m c DIAGRAM SHOWING z SETTING OF SEGMENTS 425 385 320 SECTION B B Figure 7 4 Circuit Controller N4518170501 SM 6444 Rev 1 0 May 2008 7 17 Parts Lists 7 4 Motor Assembly N4511611701 NU 74 AnsaldoSTS Union Switch amp Signal Table 7 4 is the parts list for motor assembly N4511611701 The figure associated with this assembly is Figure 7 5 Item Number Description Table 7 4 Motor Assembly N4511611701 Part Number 5 Motor Frame Adapter M41000602 10 Motor Electric 110 Vac J7172160301 25 Screw 3 8 x 1 Fil Hd SS J5001240002 30 Gear 1 1 2 Steel Rd M4511611601 35 Key 3 16 Square Steel M4511611305 40 Screw 10 32 x 1 4 Allen Hd J507363 45 Ring External Retaining Snap J792852 55 7 18 Washer 3 8 Lock External Tooth Countersunk J4751430002 SM 6444 Rev 1 0 May 2008 2y 74 AnsaldoSTS Union Switch amp Signal Parts Lists Li T no 1 I gt lu Ha dy 12 13 32 Q41000601 n N4511611701 TT TNT TIT 7 5 32 lt 9 16
10. 3 16 x 2 Spring Steel J048636 215 Ring External Retaining J790076 220 Seal Garlock 556 OL J790261 221 Clutch Plate M146573 225 Worm Gear M074805 Not shown in Figure 7 3 See Figure 7 1 for the location of these items SM 6444 Rev 1 0 May 2008 74 AnsaldoSTS Union Switch amp Signal 125 165 175 6A2 0008 00 SM 6444 Rev 1 0 May 2008 200 Parts Lists 15 180 10 ZR TTE ANTES I x oo EA H HIP 2 Y H a 170 155 120 95 135 215 90 80 60 65 55 30 35 25 20 D RST S722 A SNF Z a SW a xj il S A ZZ A 195 185 205 85 190 220 130 150 VIEW OF 189 TO 1 GEAR RATIO ASSEMBLY Figure 7 3 Gearbox Assembly N287485003 7 13 Parts Lists 7 3 Circuit Controller N4518170501 NU 74 AnsaldoSTS Union Switch amp Signal Table 7 3 is the parts list for circuit controller N4518170501 The figure associated with this controller assembly is Figure 7 4 Table 7 3 Circuit Controller N4518170501 Item Description US amp S Part No 5 Frame Component N284499 10 Bearing Idler PN338004 15 Bracket M I M284493 20 Yoke Comp PN284681 25 LH Crank PN284650 30 RH Crank PN284649 35 Rod Connecting PN33800
11. TIE 1 Ait T comme a dE a seme anj jpm mmm mmm Jm 15 16 TBD TO BE DETERMINED BY R R ALL DIMENSIONS ARE SUBJECT TO CHANGE PER R R REQUIREMENT ALL DIMENSIONS ARE IN INCHES Figure 2 2 Typical Left Hand Layout Point Closed SM 6444 Rev 1 0 May 2008 2 3 NU 74 AnsaldoSTS Installation and Adjustment Union Switch amp Signal Ties 10 20 25 8 gt 1 s 51 4 95 8 TBD TO BE DETERMINED BY R R ALL DIMENSIONS ARE SUBJECT TO CHANGE PER R R REQUIREMENT ALL DIMENSIONS ARE IN INCHES Figure 2 3 Typical Right Hand Layout Point Closed 2 4 SM 6444 Rev 1 0 May 2008 N 74 AnsaldoSTS Union Switch amp Signal Installation and Adjustment 2 3 Switch Rod Installation and Adjustment Connect the switch operating rod and adjust the rod nuts at the switch basket to obtain the proper pressure at the switch points It is not necessary to apply more than normal pressure at the points 2 4 Lock Rod Installation and Adjustment With the covers removed and machine at mid stroke apply the lock rods Be sure that the flat plate snow cover is assembled on the track side where applicable when applying the lock rods Also be sure the rods are so assembled that the locking dogs in the lock box will enter the narrow notches first Refer to Figure 3 2 and Figure 3 3 Preliminary adjustments should be made by setting the nuts so tha
12. requirements for the switch machines a Apply pressure gun grease Point detector bar bearings use gun on grease fittings 2 Operating bar wearing plates use gun on grease fittings 3 Selector and hand throw lever shaft bearings use gun on grease fittings 4 Surfaces of slide bar and lock box and rack G using brush or paddle for application a heavy oil viscosity 120 200 SAE 140 may be used as an alternate on these surfaces 5 Circuit controller trunnions use gun on grease fittings b Apply medium body motor oil viscosity 54 4 C 185 220 SAE 30 to the following parts 1 Yoke bearings and point detector linkage 2 Spur gear journals machines are equipped with Oilite bushings a Holes in box casting b Holes in reduction gears and in clutch gear SM 6444 Rev 1 0 May 2008 5 15 b AnsaldoSTS Shop Maintenance Union Switch amp Signal Note Oil should be applied sparingly to clutch gear bearing to prevent seepage through clutch shaft packing to the friction discs 3 Main crank shaft remove oil plug in top cover Oil will collect in a recess and be led to shaft surfaces needing lubrication 4 Linkage connections for motor cutout 5 recess on top crank bearing c Apply a light oil See Table 5 5 1 Tocontact segments of indication circuit controller segments and contact springs should be thoroughly cleaned before application 2 Sparingly to motor commutator
13. 3 Clearance Switch Machine SM 6444 Rev 1 0 May 2008 1 3 lt N 74 AnsaldoSTS General Information Union Switch amp Signal 1 3 Specifications 1 3 1 Mechanical Length P 3 1 2 Width 19 less bars and covers Height Without mounting plate 9 5 8 With mounting plate 9 7 8 Weight 810 Ibs 1 3 2 Operational Operating Time 5 seconds Gear Ratio 189 1 Clutch Setting 14 A Operating Bar Stroke 6 1 3 3 Electrical Motor Type Permanent Magnet Horsepower 0 68 Voltage 110 Vdc RPM 1 430 full load 1 4 SM 6444 Rev 1 0 May 2008 N 74 AnsaldoSTS Union Switch amp Signal Installation and Adjustment 2 Installation and Adjustment 2 1 Machine Preparation M 3 switch machines are assembled and shipped from the factory for left or right hand switch layouts per customer order However either type of machine can be converted in the field to the alternate layout Refer to Section 2 4 2 for the conversion procedure After the machine is assembled for the layout check the following a Two 3 8 pipe plugs are enclosed in a bag tied in the motor compartment If the switch machine is used in an area with excessive blowing sand or dust install the pipe plugs in the two drain holes in the cover under the crank case compartment Figure 5 3 The plugs will help keep this debris out of the machine The plugs should be periodically removed to allow drainage of the crankcase especially prior to fre
14. Burndy HP 8N J700590 525 Screw 8 32 x 1 1 4 Rd Hd Steel J525111 530 Screw 8 32 x 1 2 Fil Hd J052256 535 Not Referenced SM 6444 Rev 1 0 May 2008 N 74 AnsaldoSTS Union Switch amp Signal Parts Lists Table 7 1 Switch Machines N4511601401 and N4511601501 Parts List THe DOS bte 540 Heater Component N253225 545 Plug 1 8 Square Hd Steel J032900 550 Plastic Bag 60F 0404 J078399 555 Tag Form S000169 560 Not Referenced 565 Cable Clamp 3 POS ring 1 1 2 Dia J700589 Max 570 Washer SS Lock No 10 J4751210109 575 Tag Form S001857 580 Cover Lock Rod N4511611902 LH or N4511611904 RH 585 595 Not Referenced 600 M I Cast N072832 605 Tag Instruction S000264 610 Pipe 1 4 Galv M4511614005 615 Screw 3 8 x 1 1 2 Hex Hd J050057 620 Pin 420 Spring Slotted 1 8 x 7 8 J487025 625 Screw 1 4 20 x 3 4 Hex Hd SS J50009701 12 630 Not Referenced 635 Screw 5 16 18 x 1 Hex Hd J050038 640 Not Referenced 645 Screw 3 8 16 x 1 Hex Hd J050053 650 Nut WABCO 502369 J048356 655 695 Not Referenced 700 M 3 Gearbox Assembly Section A 2 N287485003 Parts List 705 Bracket Angle M4511619701 710 Screw 5 16 18 x 1 1 4 Hex Hd J050040 715 Spacer 3 8 Rd Hd Brass J725920 720 Plate Cover M4511612401 725 Washer 3 8 Lock SS J4751210113 730 Washer
15. Flt SS Commercial 3 8 J475126 SM 6444 Rev 1 0 May 2008 7 5 NU 74 AnsaldoSTS Parts Lists Union Switch amp Signal Table 7 1 Switch Machines N4511601401 and N4511601501 Parts List Part Number Description Plate Rat M4511614401 Stud Hasp M387732 Washer 1 2 Steel Plate J047503 Nut Molded J048300 Washer 1 4 Steel Lock Med J047775 Washer M4513740301 Wire Tag 12 Bundle 705 11 Terminal Board N184425 Screw 12 13 x 2 1 2 Hex Hd J050101 7 6 SM 6444 Rev 1 0 May 2008 AnsaldoSTS Union Switch amp Signal Parts Lists y 710 465 705 235 TN 215 280 285 290 190 370 570 ve T 355 LO lI i e i Vir e a A zN 475 460 610 390 415 i a gt SECTION B B E B oe TN Keci me 600 160 400 415 d aie x Lue LJ Pretec 645 650 725 1 1 J A 740 8l 6 S Jb gt u cT J lt c j 295 I 40 635 465 470 1 0 65 a o e d 8 o 290 615 625 t n 435
16. Signal Table of Contents General Information ids Sa au aa aaa 1 1 ENE EE 1 1 PY i RE EE 1 1 GOS Kall eens sock TM 1 1 Operating Mechanism I 1 2 amp VERSER CRT 1 4 Mechanical eer A EET 1 4 Operational id eec aaa teste totu di tessuto ke edite eta connate andes O e 1 4 Electrical sec PETERS 1 4 Installation and Adjustment 2 1 Machine Preparation apu aaa ete aee edet edd 2 1 MOUNTING u u 2 1 Switch Rod Installation and 2 5 Lock Rod Installation and Adjustment sse 2 5 Inverting Bock BOx x iac dede et e aed eed 2 5 Changing Operation from LH to RH RH to LH 2 5 Point Detector Bar Installation and Adjustment u 2 7 Shifting Indication Cams L L nsn 2 8 INTOQUCTION EE 2 8 Proced te 2 uu D bd ua ave a de etd av ea de 2 8 Electric Connections and Control Wiring L 2 9 General Description of Internal and Control Circuits sse 2 9 Connection of Wiring and Modifications 2 11 Initial Lubrication ocior tae a
17. clear b Check that commutator brushes are free in their holders and are not excessively worn 4 3 Cleaning The M 3 switch machine does not require external cleaning However it is important that the circuit controller compartment be cleaned during inspection to ensure proper electrical operation Refer to Sections 4 3 1 and 4 3 2 for cleaning procedures SM 6444 Rev 1 0 May 2008 4 3 lt N 74 AnsaldoSTS Field Maintenance Union Switch amp Signal 4 3 1 Required Equipment Materials The following items are required to clean the circuit controller compartment a Household degreaser b Lint free cloths 4 3 2 Procedure Clean the circuit controller compartment as follows 1 Dampen the lint free cloth with the household degreaser and wipe motor control and indication and motor cutout contact springs free of any accumulated dirt Then dry with a clean lint free cloth 2 Repeat Step 1 with the motor control segments indication cams yoke operating levers and point detector connecting rods crank and crank springs Dry these with another clean lint free cloth do not reuse the first cloth NOTE If the contact springs motor control segments or indication cams show any signs of pitting corrosion or general deterioration they must be replaced Refer to 5 for procedures 3 Lubricate all cleaned areas per Section 5 7 4 4 Lubrication After the switch machine has been inspected and cleaned it must be lubri
18. crank will release the worm gear and the slide bar 1 Remove the bottom cover and the wear plates supporting the operating bar This allows the operating bar and crank roller to drop down 2 Rotate the crank turn the friction clutch by hand until the bottom end is perpendicular to the machine 3 Unscrew the nut at the top of the main crankshaft This will permit the crank to drop out through the bottom 5 5 7 Worm Shaft Removal 1 Take the gearbox off the base casting NOTE This step is necessary to prevent the end of the worm shaft from striking the wall of the circuit controller compartment 2 Remove the lock box and motor 3 Remove the slide bar through the motor compartment 5 5 8 Final Disassembly After removing all major subassemblies per Sections 5 5 1 through 5 5 7 disassemble the remaining components as required by referring to Figure 7 1 and the associated parts list Disassemble only to the degree necessary to repair the switch machine SM 6444 Rev 1 0 May 2008 5 7 lt N 74 AnsaldoSTS Shop Maintenance Union Switch amp Signal 5 6 Assembly 5 6 1 Installation of Gearbox To install the gearbox use the following procedure See Figure 7 1 1 Place the gearbox onto the switch machine base 2 Align the mounting holes in the gearbox with the holes in the base 3 Install four screws Items 380 400 and 405 4 Install the push rod Item 120 by inserting the pin into the
19. housing and lowering the push rod 5 Install push rod Item by sliding the cutout contact end through the pipe Item 140 6 Align the holes at the end of the push rod with their respective swivels and install the two screws 7 Mount and adjust the knob to the yoke 5 6 2 Installation of Motor Brushes Install the motor brushes by proceeding as follows See Figure 7 1 1 Before installing the motor brushes check that the motor commutator is smooth and free from grease and oil 2 To dress the commutator use a fine grain commutator stone or a piece of No 00 sandpaper Never use emery cloth for cleaning the commutator or brushes These commutators must not be undercut 3 Fit the brushes to the commutator using No 00 sandpaper 4 Install the motor commutator brush in holder 5 Install the spring hold down by pushing it into the slot beside the brush and hooking it over the end of the brush holder 6 Repeat Steps 1 through 5 for the other brush 7 Check that the motor commutator brushes are free in their holders 8 Install the motor brush commutator covers with two screws on each cover 9 Install the motor cover Item 180 10 Operate the switch machine motor to determine if the brushes are properly installed 5 8 SM 6444 Rev 1 0 May 2008 N 74 AnsaldoSTS Union Switch amp Signal Shop Maintenance 5 6 3 Installation of Motor To install the motor perform the steps below See Figure 7 1 1 Lower the motor brack
20. problems with the machine these troubleshooting steps address the most common problems that occur with an M 3 switch machine Table 6 1 Troubleshooting the M 3 Switch Machine Problem Cause Solution Motor power is present from the wayside yet motor does not run A Hand crank cover is in the open or un locked position Close the hand crank cover such that the hasp is in the staple recess 2 Depress the motor cutout contact restoring the latch in the circuit controller compartment B Motor cutout 1 Confirm that the hand crank cover located on the gear box contacts are open cover is closed and that the hasp is in the staple notch 2 Depress the motor cutout contact restoring latch in the circuit controller compartment 3 Check adjustment of motor cutout contacts Readjust per Section 5 8 2 and Figure 5 8 C Motor cutout 1 Visually inspect the motor cutout contacts and if they are contacts are broken broken or cracked replace them This is not recommended as a field service procedure and should be done in the Service Shop only 2 Remove the wire leads from the motor cutout and the circuit controller 3 Remove the hardware and lift out the circuit controller Refer to Section 5 5 4 and Figure 7 1 4 Remove the hardware from the cutout contact assembly 5 Install a new motor cutout contact assembly 6 Adjust per Section 5 8 2 7 Reinstall circuit controller Refer to Section 5 6 5
21. proper direction and the corresponding switch point must be closed properly as checked by the point detector before the corresponding indication contacts can close It also has segmental type motor control contacts for opening the motor circuit when the machine is in its full normal or full reverse position SM 6444 Rev 1 0 May 2008 3 11 RN 74 AnsaldoSTS Description and Operation Union Switch amp Signal As illustrated in Figure 3 5 the circuit controller has a total of eight sets of contacts operated by cams and segments on shaft R which is rotated by the slide bar motion transmitted through the lock box rack teeth the idler pinion and the shaft gear The two sets of contacts at the left side viewed from lock rod end of the machine Figure 3 7 and the two at the right side comprise the motor control contacts while the four intervening sets comprise the indication contacts The motor control contacts are operated solely by the shaft carried segments but the indication contacts are also subject to point detector operation The shaft assembly shown in Figure 3 7 consists of a square shaft on which the two end insulating washers the four motor control segment insulating bushings the two eccentric bushings and the gear each have square holes to force them to rotate with the shaft To ensure proper relative assembly of the gear and eccentric bushings the shaft is made with unlike ends so that it can go into the controller on
22. the attached manual it is impossible to take into account every eventuality that may arise with technical equipment in service Please consult your local US amp S Account Executive in the event of any irregularities with our product We expressly disclaim liability resulting from any improper handling or use of our equipment even if these instructions contain no specific indication in this respect We strongly recommend that only approved US amp S spare parts be used as replacements SM 6444 Rev 1 0 May 2008 i Revision History Rev Date AM 74 AnsaldoSTS Union Switch amp Signal Revision History Nature of Revision Original October 1990 May 2008 Initial Issue Revised per ECO 139712 32 Updated various parts lists and illustratrions Revised per ECO CRS01220 Changed 1 8 clearance to 1 16 in step 8 of Section 5 7 2 and changed contact insulation Item J to angle bracket Item H also added a Note after step 8 on using a padlock Added Normal Release Lever When Used to Item G in Figure 5 4 Modified most illustrations in Sectiosn 1 through 6 to increase clarity Updated Section 7 Parts Lists figures and tables Revised to incorporate additional engineering review comments from Ed Edwards and Kevin McQuisten SM 6444 Rev 1 0 May 2008 74 AnsaldoSTS N a a S o m N NNN P gt Union Switch amp
23. the main crank thus driving the slide bar to its full reverse position The lock box rests on and is operated from an extension of the slide bar as shown in Figure 3 2 During the first 40 degrees of rotation of the main crank the corresponding motion of the slide bar withdraws the lower locking dog of the lock box from the lower notch of the lock rod thus unlocking the switch points SM 6444 Rev 1 0 May 2008 3 1 j w 7 AnsaldoSTS Description and Operation Union Switch amp Signal SLIDE BAR BOTTOM VIEW SLIDE BAR III riot l T ae n P EL Enc qu Ll dh h T pes li m m m Wi HU 4 ROLLER 3 lt oe mi d ROLLER 2 p iul a es TT ROLLER 1 V ies J T MAIN CRANK LUG 1 Z T Th in ROLLER 4 Figure 3 1 Switch Operating Mechanism 3 2 SM 6444 Rev 1 0 May 2008 m bd 7 AnsaldoSTS i Union Switch amp Signal Description and Operation MOTOR END SLIDE ROLLER 3 CIRCUIT CONTROLLER BAR IS OPERATED BY THESE RACK TEETH ROLLER 2 CENTER ROLLER 1 LINE OF CIRCUIT LOCI RODS CONTROLLER LUG 2 A ROLLER 4 PME LOWER LOCKING Buc RADIAL DOG PORTION i STRAIGHT PORTION SEE DETAILA SWITCH OPERATING BAR UPPER LOCKING GROOVE C DOG AS le 272
24. the mechanism latched all indication contacts should be in the open position Figure 5 7 8 Adda sufficient amount of shims as required to enable latch to clear the top of the yoke in both switch positions and latch properly Check indication contacts in latched positions to ensure that they are open a minimum of 0 05 in SM 6444 Rev 1 0 May 2008 5 19 lt N 74 AnsaldoSTS Shop Maintenance Union Switch amp Signal 9 45 lt M 3 M 23 HDB 0 055 tht v Y 1 0 4 POINT DETECTOR GAGE FOR USE WITH M 3 M 23A amp 3 SWITCH amp LOCK MOVEMENTS Figure 5 4 Point Detector Gage N295326 LATCH MUST BE UNLATCHED FEELER GAGE US amp S PART NO N295326 POINT DETECTOR BAR ji Figure 5 5 Latch in Unlatched Position 6A2 0014 00 5 20 SM 6444 Rev 1 0 May 2008 2y 74 AnsaldoSTS Union Switch amp Signal Shop Maintenance CLEARANCE BETWEEN LATCHING NE POINT DETECTOR BAR IN ORIGINAL POSITION SLEEVE GAGE US amp S PART NO N295326 Figure 5 6 Inserting the Sleeve Gage
25. to US amp S Service Manual SM 2378N for conversion of a DP 25 relay with one magnetic blowout contact without low voltage neutral contacts to a relay with two magnetic blowout contacts The DP 25 and PNP 69 can also break stalled switch motor current in excess of 50 amps at 110 volts DC Pole changing contacts and other circuits not shown for control of the WR relay should be arranged in accordance with the circuits designed for the specific installation NOTE If the latch refer to Section 3 3 is arranged to be self restoring examine the control and indication circuits before installing the switch machine to ensure the circuits will not prevent the machine from restoring the latch automatically after a latch out occurs 2 7 2 Connection of Wiring and Modifications Connect external wiring to the M 3 terminal board according to the wiring diagram for the particular location If the layout calls for a left hand point normally closed interchange the leads as indicated in the note at the bottom of Figure 2 8 Refer to Section 2 6 when reversing the circuit controller cams for the indication contacts All M 3 machines have two leads from the main terminal board to the circuit controller compartment to operate a circuit controller heater Refer to Section 3 8 for additional information on use of the heater 2 8 Initial Lubrication Apply a light coat of this lubricant to the teeth of the machine s spur gear only Pour the rem
26. 15 Screw 5 16 18 x 3 Fil Hd J0523620001 420 Nut 1 2 20 Thick Slotted J048057 425 Washer Lock 5 16 Steel Extra Heavy J047767 7 16 SM 6444 Rev 1 0 May 2008 RN 74 AnsaldoSTS Union Switch amp Signal Parts Lists 330 175 185 0 375 325 365 390 415 310 3 ip 2190 25 aye E o jS Sl a a Ral in TH Tam L AA 220 uni lt 20 250 s 255 225 m 219 ao 200 B 2 365 195 390 415 410 160 325 445 Quse 375 1185 100 110 305 120 155 55 125 40 50 105 Nx 60 425 gt he p 2265 2 70 400 405 DEUM LN ENR T 340 L Ge gt lt 285 WSs 235 9 7245 BLOCK 300 290 120 140 295
27. 4 iqu 4 4 Performance cec iie te a aet e e HORE d 4 4 Corrective Maintenance Adjustments I a 4 4 SM 6444 Rev 1 0 May 2008 Table of Contents AnsaldoSTS Table of Contents Union Switch amp Signal 4 6 1 Faeton CUON 2354 icis ted re hama aya ha hua za P d ee 4 4 4 6 2 Additional Adjustments eese eene 4 5 4 7 Repair Procedures 2 u l ege pep tmc ee RE ern ecd ete dun E YR 4 5 5 Shop Maintenance eec PLE 5 1 5 1 Maintenance Checklist certo ela iae veste dus et chess i ree eaae evo iret cdd 5 1 5 2 SPOClal TOONS 5 1 5 3 Gomponent Clearing tte tte ire i itte Ur attic te 5 3 5 4 Component Inspection teo ote it etie ae team e gato 5 3 5 5 DISASSEMDIY MEER 5 4 5 5 1 Motor Brushes Removal ceret c tee teinte Done ERE et Ne e ua ERA eme 5 4 5 5 2 Motor Removal usu a tero xa u tula c rere i a h 5 4 5 5 8 Friction Clutch Assembly Removal 5 4 5 5 4 Circuit Controller Removal sessed erena ho ere eda den nag eta e e 5 5 5 5 5 Gearbox Removal sisse riii tti eee x ER e Ra Uk ha ee Chad av Ra quas te as sack 5 6 5 5 6 tinte eee de tt nn aaa Pao IR eed ar ek ct
28. 4 Adjustable Lock Rods 3 8 SM 6444 Rev 1 0 May 2008 AnsaldoSTS Union Switch amp Signal Description and Operation k MOTOR CONTROL LEFTSIDE H N L CONTACTS TWO SETS T T g MOTOR EL CUTOUT CONTACTS TWO SETS 17 Ltd RESET eel 1 2 GAGING HOLE s A ee T I ec gt NS uS ded z a B H K MOTOR CONTROL RIGHT SIDE CONTACTS TWO SETS S TUTTI Ue SIDE VIEW G LEGEND D ROLLER N INDICATION CAM G LOCK BOX O MOTOR CUTOUT CONTACTS H EYE ROD P INDICATION CAM J SCREW R SHAFT K MOTOR CONTROL CONTACTS S SHUNTING STRIP L INDICATION CONTACTS LEFT T BOLTS M INDICATION CONTACTS RIGHT X LATCH Figure 3 5 Indication Circuit Controller SM 6444 Rev 1 0 May 2008 3 9 lt N 74 AnsaldoSTS Description and Operation Union Switch amp Signal W L N R pres Tu cel t I G LEGEND F IDLER PINION GEAR G LOCK BOX L INDICATION CONTACTS LEFT N INDICATION CAM R SHAFT W HEATER ASSEMBLY OPTIONAL INSTALLED
29. 5 40 Latch Blank M284495 45 Bushing Component N284653 50 Coil Spring M142167 55 Support Cast Brass M074427001 60 Eyebolt Drop Forged M164921 65 Spring Lever SS J068952 70 Board Terminal J077705 75 Terminal M146475 80 Terminal Connector M146476 85 Terminal Connector PN146478 90 Insulation 1 4 Lam Plastic M142173 100 Terminal Post M138723 105 Nut 437 Brass Hex 026545 110 Terminal Post M048854001 115 Washer 17 64 x 9 16 Copper J047818 120 Nut 14 24 Hex Brass NP J480300 125 Spring Indication PN284721 130 Spring 16 x 376 Bronze M074783 135 Spring 16 x 376 Bronze M138718 140 Spring 16 x 376 Bronze 074777 7 14 SM 6444 Rev 1 0 2008 N 74 AnsaldoSTS Union Switch amp Signal Table 7 3 Circuit Controller N4518170501 Parts Lists Item Description US amp S Part No 145 Spring 14 x 1 2 Bronze M138696 150 Spring 0575 x 18 x 96 Sheet Steel M045269 155 Spring 14 x 1 2 Bronze M172380 160 Strip 1 8 x 1 2 Phos Bronze M175725 170 Plate 0428 x 48 x 120 Steel M146775 175 Screw 7 16 Hex Hd Steel M056236 180 Trunnion M055305 185 Trunnion M285410 190 Nut 11 x 1 2 Brass M050258 195 Washer M042627 200 Washer M042585 205 Washer M048692 210 Segment 11 Gauge x 3 25 Copper SJ M045942 215 Insulation J078019 220 Cam Indication M284494 225 Washer Plated Flat Ste
30. 501 180 Cover Motor N4511613801 185 Clip Cable Burndy CH18 J700934 190 Washer 10 Flat Steel Commercial J475077 195 Washer M002423 200 Washer M286594 205 Spring Steel for Lk Movement M181001 210 End Cover Component N439013 215 Screw Locking N242122 220 Protector Snow M4511613402 225 Not Referenced E SM 6444 Rev 1 0 May 2008 N 74 AnsaldoSTS Union Switch amp Signal Parts Lists Table 7 1 Switch Machines N4511601401 and N4511601501 Parts List Tus Description Number 230 Spring Compression J680204 235 Cover Point Detector PN4511613204 240 Not Referenced s 245 Nut Lock 2 1 8 Steel Rd M223351 250 Collar 2 Rd CF Steel M074741 255 Nut 1 8 Jam M074742 260 Operating Crank M071158 265 Not Referenced 270 Washer M067454 275 Cover Crankcase N4511612402 280 Cut out Trigger Component N146670 285 Stud 5 16 Steel Rd M146675 290 Nut 5 16 18 UNC 2B Jam J048007 295 Latch C Brass Cut out M186209 300 Stud 1 4 Steel Hex M181032 305 Harness N4518170401 310 Lead N281552 315 Not Referenced 320 Terminal Connector M120343 325 Terminal Connector 022725 330 Clamp J703005 335 Bushing Point Detector M4511611801 340 Bar Lock Bearing M4511613607 345 Washer W 08 SK Lock J047821 350 Fitting 1610 Alem Hyd J039137 355 Lug Bung Cap W 14X J320015 360 Rivet 1 8 x 1 4 Rd
31. 518170501 U enne nnns 7 14 7 4 Motor Assembly N4511611701 L 7 18 8 Rail Team and Technical Support 8 1 iv SM 6444 Rev 1 0 May 2008 74 AnsaldoSTS Union Switch amp Signal Table of Contents List of Figures Figure 1 1 General Arrangement of the Clearance Switch 1 3 Figure 2 1 Installation Dimensions I U 2 2 Figure 2 2 Typical Left Hand Layout Point Closed sese 2 3 Figure 2 3 Typical Right Hand Layout Point 1 eene 2 4 Figure 2 4 Basic Positions of Lock Box sssssssssssssseee eene ener nennen en nens 2 6 Figure 2 5 Snow Scraper and Bearing Bracket Installation 2 6 Figure 2 6 Left and Right Hand Adjustable Lock Rods 2 7 Figure 2 7 Internal Wiring and Typical Control Circuits Sheet 1 2 10 Figure 2 8 Internal Wiring and Typical Control Circuits Sheet 2 2 12 Figure 3 1 Switch Operating Mechanism sse ener enses tense 3 2 Figure 3 2 Driving Part
32. AT TOP LEVEL ASSEMBLY Figure 3 6 Sectional View of Circuit Controller 3 10 SM 6444 Rev 1 0 May 2008 2y 74 AnsaldoSTS Union Switch amp Signal Description and Operation 2 2 1 2lb WHEN F2 IS HELD CLEAR CAN BE SEPARATED FOR REASSEMBLY IN THE OPPOSITE POSITION SIMPLY BY FORCING AGAINST THE SPRING VIEWA INDICATION CAM 1 1 2lb MIN SHUNTING STRIP 3 64 MIN 375 DIA LEFT SIDE SECT W W amp X X 5 64 MAX 3 64 MIN INDICATION CAM lo SEE VIEW A S5 SECT N N HE SHUNTING STRIP GEAR TIS Ziz s COIL SPRING EN 8 2 Z fh JE ZN EIS 0 Q z OPERATING LEVER 771 ISSSSNSNI ECCENTRIC BUSHING INSULATING BUSHING MOTOR CONTROL RIGHT SIDE SEGMENT 401 DIA SEE VIEW B DIAGRAM SHOWING SHAFT ASSEMBLY SETTING OF SEGMENTS 90 TEETH SPACED 4 flim SEPARATION FOR READJUSTMENT REQUIRES LOOSENING OR V f REMOVAL OF SHAFT END NUTS VIEWB MOTOR CONTROL SEGMENT SECT Y Y amp Z Z Figure 3 7 Sectional View of Indication Circuit Controller 3 3 Circuit Controller The circuit controller has indication contacts that are operated jointly by the lock box and the point detector mechanism The contacts are operated in such a manner that the machine as checked by the lock box must have completed its throwing and locking stroke in the
33. Adjustable 2 1 16 J0390000125 Wrench Switch Adjustable 1 5 16 J0390000126 and 1 11 16 SM 6444 Rev 1 0 May 2008 74 AnsaldoSTS Union Switch amp Signal Shop Maintenance 5 3 Component Cleaning All major mechanical parts should be thoroughly cleaned to remove accumulation of dirt grease and grime Use only appropriate cleaning agents for the material being cleaned and follow manufacturer s recommendations for use CAUTION The use of cleaning fluids on electrical components such as the motor heaters wiring harness or circuit controller should be minimized otherwise damage to these parts will occur NOTE Tool Set X49125303 includes all of Tool Set X49125302 plus these additional tools parts and is required to adjust the current controller contacts Table 5 4 Maintenance Tools Basic Set with Track and Circuit Controller Tools X49125303 5 4 Component Inspection During disassembly of the M 3 switch machine carefully examine each part for signs of damage All damaged components regardless of the degree of damage should be replaced with new components After cleaning carefully check case cover and other structural components for hair line cracks breaks weak points or any other signs of physical damage SM 6444 Rev 1 0 May 2008 5 3 lt N 74 AnsaldoSTS Shop Maintenance Union Switch amp Signal 5 5 Disassembly 5 5 1 Motor Brushes Removal To remove the
34. G SHAFT ASSEMBLY SETTING OF SEGMENTS 90 TEETH SPFACED ae Mmmm SEPARATION FOR READJUSTMENT REQUIRES LOOSENING OR mcs REMOVAL OF SHAFT END NUTS VIEW B MOTOR CONTROL SEGMENT Figure 3 8 Circuit Controller Adjustment and Shaft Assembly SM 6444 Rev 1 0 May 2008 3 17 3 18 74 AnsaldoSTS Union Switch amp Signal Description and Operation POINT DETECTOR ROLLER B CRANK SPRING CIRCUIT CONTROLLER SHAFT OPERATING LEVER lt A SN CONNECTING ROD OPERATING PIN POINT DETECTOR BAR CONNECTING RODS INDICATION CAMS SHAFT GEAR CRANK SPRING POINT DETECTOR OPERATING PIN ROLLER A Figure 3 9 Point Detector Parts in Normal Position POINT DETECTOR ROLLER B CIRCUIT CONTROLLER SHAFT CRANK SPRING OPERATING LEVER CONNECTING ROD OPERATING PI CAM ON YOKE SHAFT GEAR YOKE OPERATING PIN OPERATING LEVER ECCENTRIC BUSHING CONNECTING ROD CRANK SPRING POINT DETECTOR ROLLER A OPERATING PIN Figure 3 10 Point Detector Parts in Mid Stroke Position SM 6444 Rev 1 0 May 2008 3 19 74 AnsaldoSTS Description and Operation Union Switch amp Signal POINT DETECTOR ROLLER B CRANK SPRING CIRCUIT CONTROLLER SHA OPERATING LEVER 4 CONNECTING ROD Qu n F 4 POINT DETECTOR BAR OPERATING PIN ET CONNECTIN
35. G RODS LU INDICATION CAMS GEAR aa YOKE OL A Y oPERATNG PIN O T OPERATING LEVER lir lo CRANK ECCENTRIC BUSHING CRANK SPRING CONNECTING ROD POINT DETECTOR OPERATING PIN ROLLER A YOKE STOP Figure 3 11 Point Detector Parts in Reverse Position POINT DETECTOR ROLLER B CIRCUIT CONTROLLER CRANK SPRING SHAFT CONNECTING ROD LATCH LATCH SPRING OPERATING PIN SHIELD E E q a O SHAFT GEAR INTERLOCK CAM ON YOKE OPERATING LEVER CRANK SPRING ECCENTRIC BUSHING POINT DETECTOR CONNECTING ROD ROLLER A OPERATING PIN Figure 3 12 Point Detector Parts in Reverse Position and Latched Up YOKE STOP 3 20 SM 6444 Rev 1 0 May 2008 7 AnsaldoSTS Union Switch amp Signal Description and Operation 3 5 Gear Train The reduction gear train between the motor and the worm gear consists of a A pinion on the end of the motor shaft b One or two reduction gears c A clutch gear d A friction clutch e A worm shaft and worm gear Note that each reduction gear actually comprises two gears a large gear and a small gear made as a unit The reduction gear specifications are as follows e Nominal Speed 4 5 seconds e Gear Ratio 189 1 e Number of Teeth on Clutch Gear 43 e Reduction Gear 43 e Pinion 22 e Motor Pinion 12 The pinion end of the motor is supported in an opening in the gearbox This opening positio
36. Hd Aluminum J049910 365 Screw 1 4 20 x 3 4 Fil Hd J052025 370 Screw 10 32 x 9 16 Fil Hd J522151 375 Screw 3 8 16 x 1 1 4 Hex Socket J0523620003 380 Screw 1 2 13 x 2 Hex Head J050098 SM 6444 Rev 1 0 May 2008 7 3 Parts Lists 7 4 NU 74 AnsaldoSTS Union Switch amp Signal Table 7 1 Switch Machines N4511601401 and N4511601501 Parts List NLIS Description teh 385 Screw 1 2 13 x 3 4 Hex Head J050086 390 Screw Cap 1 2 13 x 1 Hex Head J050088 400 Screw 1 2 13 x 1 1 2 Hex Head J050092 405 Screw 1 2 x 1 1 2 SCH J050236 410 Washer 3 8 Steel Lock Ex J047768 415 Washer 1 2 Plated Steel Lock J047769 420 Washer 7 8 Steel Lock Ex J047773 425 Not Referenced 430 Nut 7 8 9 UNC 2B Heavy J048136 435 Cotter 1 8 x 3 4 Spring Steel J048618 440 Cotter 3 16 x 2 Spring Steel J048636 445 Not Referenced J032911 450 Nut Lock 3 4 Conduit J048415 455 Not Referenced 225 460 Screw 5 16 x 2 1 4 J050194 465 Washer 5 16 Steel Lock Ex J047767 470 Nut 5 16 18 UNC 2B J048006 475 Washer 5 16 Steel Plate J047642 480 Stat O Seal 7100 1 2 J792450 485 Slushing Compound M 7646 A041390 490 Lubricant Can N320264 495 Tape 0 010 M 7136 50 A773010 500 Not Referenced 505 Tag M4516408001 510 Resistor 800 ohms 30 watt N294241 515 Tag S000333 520 Clip Cable
37. SWITCH OPERATING ROD WIDE NOTCH LOWER NARROW NOTCH LOWER DETAIL A NOTE DIRECTION OF MOVEMENTS SHOWN ARE FOR A LEFT HAND SWITCH MACHINE THE DIRECTION OF MOVEMENTS ARE REVERSED FOR A RIGHT HAND MACHINE THE SLIDE BAR AND OPERATING BAR STROKE TIMING RELATIONSHIPS REMAIN THE SAME Figure 3 2 Driving Parts SM 6444 Rev 1 0 May 2008 3 3 A 4 AnsaldoSTS Description and Operation Union Switch amp Signal A e AnsaldoSTS Union Switch amp Signal 3 4 SM 6444 Rev 1 0 May 2008 AV 747 AnsaldoSTS Union Switch amp Signal Description and Operation A SLIDE BAR INITIAL POSITION MAIN CRANK a SWITCH OPERATING BAR SWITCH ROLLER 4 OPERATING BAR SWITCH OPERATING BAR B a MID POSITION SLIDE BAR Se aS Z guitar RN w D i MS LUG 2 AW SLIDE BAR LUG 1 2 e NS ROLLER 1 SWITCH gt OPERATING S 27 BAR SWITCH OPERATING C MAIN CRANK C BAR x OPPOSITE SWITCH OPERATING Figure 3 3 Driving Parts Continued SM 6444 Rev 1 0 May 2008 3 5 3 6 2y 7 AnsaldoSTS Union Switch amp Signal Description and Operation The following 140 degrees of rotation of the crank operates the switch and the lock rod stops with its upper notch aligned to receive the upper locking dog of the lock box The final 40 degr
38. Union Switch amp Signal heavy coil spring The spring force is contained between the adjusting nut and Oilite thrust plate supported on the tapered shoulder on the worm shaft Note that the clutch gear hub has a three finger engagement with the clutch housing tubular neck This allows the clutch housing to driven by the motor The friction discs provide the drive action between the clutch housing and the worm shaft 3 6 Hand Crank Operation The M 3 switch machine can be hand operated by inserting a removable hand crank through the hand hole in the gearbox cover The motor cutout contacts Figure 3 5 Item O are operated through a linkage to open the motor circuit and in some cases to open a control circuit This occurs when the hasp for the hand hole cover is released and the crank inserted Latch X holds the motor cutout contacts latched out until they are reset manually This latch can be removed if not needed 3 7 Motor Overload Protection The standard plug in relay for overload protection of the M 3 switch machines is the PN I50SO relay This relay is used in conjunction with the PN 150BM or the SML 110 switch control relays and the Style PP 151 magnetic stick relay for overload and short circuit protection refer also to Section 2 7 1 Earlier model US amp S relays used for these functions include the OR 11 relay for overload protection and the DP 25 relay for switch control 3 8 Heaters Heaters are available for the circuit contr
39. ainder of the lubricant into the worm gear compartment It is not necessary to lubricate any other parts of the machine These parts are thoroughly lubricated at the factory However if the machine is being reassembled following maintenance more extensive lubrication is required Refer to Section 5 7 for these lubrication procedures SM 6444 Rev 1 0 May 2008 2 11 Union Switch amp Signal 74 AnsaldoSTS VN Installation and Adjustment GYVOd 1TVNIINH3 L NIVIN SHL NO 8 STVNIINH3 L OL ANY SE STVNIINH3 L OL SQV31 TVNH3IX3 JHL SDNVHOYSLNI 35010 ATIVWHON LNIOd QNVH L331 SHL 9NIAVH HOLIMS V HOS a3S0 19 ATIVINHON LNIOd QNVH LHOIH 3HL ONIAVH HOLIMS V QHVOG TVNIINHAL NIVIN 3H L OL NMOHS 3HY SNOILOANNOO TIVNHAI LLX3 3LON g 1 Yv lOd WNINYAL NIVIN S3NIHOVIN HOLIMS quvog TIVNIINH3LL NIVIA 3NIHOVIA HOLIMS OLIN Ava TT waosi Na WoW way 8081 Nd LINDYIO LINDYIO TOU LNOO v V IHM 1OHLNOO OL YMN YM N ONIHIM TOULNOO SM 6444 Rev 1 0 May 2008 Figure 2 8 Internal Wiring and Typical Control Circuits Sheet 2 2 12 N 74 AnsaldoSTS Union Switch amp Signal Installation and Adjustment NOTE The machine contains a small quantity oil slushing compound to protect components from corrosion during extended storage Do not remove this compound during initial lubrication Also lubricate t
40. arrangement When the machine reaches the end of its stroke the notch in cam P goes on top and thus permits the reverse pair of contacts to close except when prevented by point detection Cams that control these contacts are factory set and sealed 3 3 2 Motor Control Contacts Of the four sets of motor control contacts Figure 3 5 the two on the right side viewed from lock rod end of machine are open and the two on the left side are closed when the machine is in the position shown When the machine reaches full opposite position the closed contacts have been opened to break the motor circuit and the open contacts are closed to provide a circuit for operating the machine back to its original position Each set of motor control contacts provides two parallel circuit paths one through direct contact of opposing spring fingers F1 and F2 Figure 3 7 and the other through finger F1 the conducting segment and finger F3 The circuit through the segment opens last as the notch passes under the V end of the finger F1 finger F2 being stopped first before the V end clears the segment altogether This arrangement protects the direct finger contact from having to open the motor circuit under normal conditions yet ensures a circuit in case the segment should become coated with frost Referring to Figure 3 7 note that each motor control segment is nested on the tapered hub of its insulating bushings The cone engagement has teeth in bot
41. as Sa 5 7 5 5 7 Wom Shaft Removal neither uei d hee euh ed en tu 5 7 5 5 8 Final Disassembly i tr tete ee ter ti ce E eee 5 7 5 6 ASSOImbIy rt eb e e be e eee ie Do oret E akanta A ree sts 5 8 5 6 1 Installation G GearDOX ade age enr vd De e saul 5 8 5 6 2 Installation of Motor Brushes nennen enne nnne en 5 8 5 6 3 Installati ri of MOITOL ri aser tereti tenete t ertt ea Bree net ed rsen adea ava eso er ed chases Hed 5 9 5 6 4 Installation of Friction Clutch Assembly sse 5 9 5 6 5 Installation of Circuit Controller enne 5 12 5 7 5 15 5 8 Ad UStmibehts c u ee ei eub CR d e EE eR DER c i E 5 19 5 8 1 Point BLEIKA Er lu kun assum n aki atan 5 19 5 8 2 Motor GCutout COnLacls e renti 5 22 6 Troubleshooting 6 1 7 P rts Lists indes E E A E E E 7 1 7 1 Switch Machines N4511601401 and 4511601501 7 1 7 2 Gearbox Assembly N287485003 U 7 11 7 8 Circuit Controller N4
42. aused by dragging equipment or by traffic running through the switch improperly while the machine is in the locked up position The point detector apparatus in this circuit controller is selective like the locking The point detector bar must shift to correspond with the switch operating stroke when the machine is reversed It also has a latch out feature that will hold the indication contacts open until reset when the point detector bar is displaced while the machine is in the locked up position The latch is arranged to take advantage of the considerable displacement of the point detector bar This displacement occurs when the switch points are being deflected by improperly trailing traffic or by dragging equipment so that the contacts are prevented from making an indication even though the points may subsequently spring back and leave the point detector bar near its original position Thus protection is provided in case the switch points are damaged and unsafe for facing point traffic yet distorted so as to leave very little net shift of the point detector bar The latch is equipped with a self restoring feature This feature is provided in case the latch becomes unnecessarily latched up due to unusual traffic shocks that do not affect the fit of the switch point against the rail The latch resets automatically with the next operation of the machine to withdraw the locking dog from the lock rod notch The latch self restoring fea
43. cated to ensure optimum operation Refer to Section 5 7 for lubrication procedures 4 5 Performance Test Conduct a performance test on the switch layout s This test should be done in accordance with customer s operating rules The test should include mechanical operation of the switch machine and electrical tests of power distribution and switch control and indication circuits 4 6 Corrective Maintenance Adjustments 4 6 1 Friction Clutch The friction clutch see also Figure 5 1 must slip at just the right amount of torque This torque must be 4 4 SM 6444 Rev 1 0 May 2008 74 AnsaldoSTS Union Switch amp Signal Field Maintenance a Sufficient to carry the machine s operational loading during driving of the switch points b Notso tight that the mechanism is unprotected from shock To check the friction clutch adjustment refer to Section 5 6 4 4 CAUTION Make sure to keep the friction disks free of oil contamination Oil on the disks could cause excessive clutch slippage In turn this could cause motor damage Replace the disks if oil contamination occurs NOTE Oil contamination of the disks could be caused by oil running along the shaft If this is observed replace felt packing in the clutch housing as described in Section 5 6 4 2 4 6 2 Additional Adjustments Table 4 2 lists section references for additional field adjustments to the M 3 switch machine Table 4 2 Switch Machine Field A
44. ctor lug Replace and reconnect the connecting rod to the point detector lug and the switch machine point detector bar Readjust per Section 5 8 1 G The latch out device was not reset from a prior incident Reset the latchout device in the circuit controller compartment H The rail braces are loose allowing for movement of the stock rail Tighten the rail braces Switch machine operates however the machine does not lock clutch slips A Lock rod connecting rod is out of adjustment Adjust the lock rod as follows 1 2 Close the far switch point Loosen the hardware to allow for independent movement of the lock rods Adjust the lock rod so that the notch in the lock rod assembly is roughly centered about the lock box dog Refer to Figure 3 2 and Figure 3 3 Tighten the connecting rod hardware for the far point connection Repeat the above process for the near point side Tighten the lock rod assembly hardware to lock the adjustment B Lock rod connecting rod is broken Replace the lock rod connecting rod as follows 1 Remove the field side jam nuts at the threaded end of the lock rod connecting rod assembly Remove the jam nuts at the threaded end of the switch machine internal lock rod assembly Hand crank the switch machine to its mid stroke position Remove and replace the lock rod connecting rod assembly Replace all hardware removed above Readju
45. d of the near point detector bar NOTE The switch operating rod point detector rod and lock rods should be kept in adjustment to meet AREMA Signal Section or railroad specifications Refer to Section 5 8 1 for using a gauge to check the point detector between periodic obstruction tests SM 6444 Rev 1 0 May 2008 2 7 4 AnsaldoSTS Installation and Adjustment Union Switch amp Signal Check that the indication cam N in Figure 3 5 on the left side of machine center line as viewed from controller end has its notch up when machine is in the Normal position Also check that indication cam P in Figure 3 5 on the right side has its notch up when machine is in the reverse position If it is found that these cams are not in agreement with the foregoing shift them in accordance with instructions in Section 2 6 2 6 Shifting Indication Cams Disconnect the motor and indication power before attempting to shift the indication cams Failure to observe this warning could result in personal injury and or equipment damage 2 6 1 Introduction Indication cams N and P in Figure 3 5 are arranged so that either cam can have its notch up when the slide bar is at either end of its stroke This is done to a Permit standardized wiring b Always have the indication contacts on the left side of the circuit controller indicate Normal regardless of which end of the slide bar and lock box stroke is designated Normal
46. djustments Adjustment Section Reference Machine to Switch 2 8 2 4 2 5 Motor Control Contacts 5 6 5 2 Indication Contacts 5 6 5 3 Motor Cut Out Contacts 5 8 2 4 7 Repair Procedures Field repair of the M 3 switch machine is limited to removal and replacement of the motor brushes and major switch machine assemblies Table 4 3 lists section references for the field repair procedures Component level disassembly of the machine should only be performed in the shop not in the field SM 6444 Rev 1 0 May 2008 4 5 NU 74 AnsaldoSTS Field Maintenance Union Switch amp Signal NOTE Before removing the M 3 Switch Machine from service the proper authority must be informed and railroad rules for this procedure must be followed Otherwise a major service disruption could be created Table 4 3 Field Repair Procedures Component Section Reference Motor Brushes 5 5 1 5 62 Motor 5 5 2 5 6 3 Friction Clutch Assembly 5 5 3 Circuit Controller 5 5 4 5 6 5 4 6 SM 6444 Rev 1 0 May 2008 N 74 AnsaldoSTS Union Switch amp Signal Shop Maintenance 5 Shop Maintenance 5 1 Maintenance Checklist The switch machine should be removed from service and subjected to shop maintenance at a frequency of no less than every three years but not more than five years depending on usage The various items to be checked are listed in Table 5 1 Table 5 1 Shop Maintenance Checklist
47. dog in the corresponding lock rod notch The manner in which the crank imparts these motions can be understood by referring to Figure 3 1 and Figure 3 2 Assuming that Figure 3 3A shows the Normal position a reverse movement is started by a clockwise rotation of the main crank Lug 1 on the main crank acting against roller 1 on the slide bar effects the unlocking of the lock rod by causing the slide bar to move to the left one half of its stroke Meanwhile roller 4 on the underside of the main crank is moved through an arc of 40 degrees in the radial portion of groove in the switch operating bar thus freeing the bar for the reverse stroke During the next 140 degrees of rotation of the main crank roller 4 engages the straight reverse operating face of the groove in the switch operating bar and moves the bar to the reverse position Figure 3 3B shows the relative mid stroke positions of the switch operating bar and the slide bar with the main crank still rotating clockwise but not transmitting motion to the slide bar as lug 1 has become disengaged from roller 1 The surfaces of the slide bar are radial to the center of the shaft and prevent the slide bar from moving The full reverse position is shown by Figure 3 3C Roller 4 on the main crank acting in the groove has moved the switch operating bar to the reverse position and secured it against back thrust lug 2 has come into contact with roller 2 during the last 40 degrees of rotation of
48. ees of rotation of the crank completes the stroke of the slide bar driving the upper locking dog into the lock rod notch to lock the switch points in the reverse position 3 2 Switch Point Locking The lock rods shown in Figure 3 4 are comprised of two rectangular rods side by side Each has a narrow notch only slightly wider than the locking dogs this narrow notch in one rod being on top and in the other rod on the bottom To allow for variations in switch throw the two rods are adjustable longitudinally with respect to each other and each has a wide notch located alongside the narrow notch of the other The notch is on top of the lock rods for one position of the switch and on the bottom for the other position The lock box likewise has one dog on top and the other on the bottom It thus follows that the slide bar with its lock box can complete its stroke only if the lock rods are shifted by the switch points to the position corresponding to proper point closure When the stroke is completed the switch is secured by the locking The stroke of the slide bar and its lock box is such that the locking dogs provide adequate interlock with only the lock rod that the locking dog enters first Therefore the lock box and the lock rods must be assembled so that the dogs will enter the narrow notches first SM 6444 Rev 1 0 May 2008 3 7 NU 74 AnsaldoSTS Description and Operation Union Switch amp Signal RIGHT HAND LEFT HAND Figure 3
49. el J475180 230 Spring Steel Coil J068281 235 Gear Component PN284679 245 Shaft 1 2 Steel Rd M282431 250 Screw 8 32 x 5 16 Safset J050731 255 Pin Operating M285389 260 Washer Plated Flat Steel J475186 265 Nut 5 16 24 Hex J048005 270 Latch Pin M284718 275 Screw 3 8 24 x 1 1 4 Socket M285432 280 Screw 9 16 steel Rd M236061 285 Shim 29 Steel Sheet M134595 290 Contact Spring M251938 295 Stop Spring 16 x 376 Bronze M251939 300 Stop Spring 16 x 376 Bronze M251940 305 Spring Seat M285393 310 Washer M339088 SM 6444 Rev 1 0 May 2008 7 15 NU 74 AnsaldoSTS Parts Lists Union Switch amp Signal Table 7 3 Circuit Controller N4518170501 Item Description US amp S Part No 315 Screw 5 16 18 x 1 5 8 FI Hd J052362 320 Screw 5 16 18 Hex Hd M4513583324 325 Washer Lock 5 16 Plated Steel J047526 330 Washer 1 4 Plated Steel Lock J047766 335 Washer 3 8 Lock SS J4751210113 340 Cotter 1 16 x 1 2 SS Kelknotters J048686 345 Pin Cotter 3 34 x 1 SS J048613 350 Cotter 1 8 x 1 1 2 SS J486001 355 Ring External Retaining J790074 360 Washer M056203 365 Cover Stop Stud M4511616204 370 Nut Molded J048300 375 Fitting Hydraulic 90 deg ELL J039150 385 W 18 Soft Black Iron A043025 390 Washer Lock 5 16 SS J4751210131 400 Shim M4511614903 405 Shim M4511614902 410 Spacer 5 8 x 1 25 Steel M4511616203 4
50. et onto the base of the switch machine so that the pinion end of the motor is inserted through the motor shaft opening 2 Position the motor so that the pinion is mated properly with the reduction gear 3 Align the mounting holes in the motor bracket at commutator end with the holes in the base of the switch machine 4 Insert two 1 2 x 2 hex head cap screws Item 380 and two associated 1 2 plain lock washers in the motor s mounting bracket commutator end 5 Reattach the wires to the motor connections 6 Install the motor cover Item 180 5 6 4 Installation of Friction Clutch Assembly 5 6 4 1 General Proceed as follows while making reference to Figure 5 1 1 Before assembly check that the friction disks Item 6 are free of oil If the disks are oily check for oil that might be entering along the shaft 2 If oil is entering along the shaft replace the felt packing in the clutch housing Refer to Section 5 6 4 2 for the replacement procedure If oil is not entering along the shaft continue with Sections 5 6 4 2 and 5 6 4 3 5 6 4 2 Application of New Felt Packing in Clutch Housing To apply new felt packing in the clutch housing perform the following steps See Figure 5 2 1 Measure the length of the clutch spring before disassembling and record this dimension for use during reassembly 2 Swing the terminal board out of the way remove the adjusting nut and clutch spring and slide the clutch housing off the sha
51. ev 1 0 May 2008 RN 74 AnsaldoSTS Union Switch amp Signal Shop Maintenance 5 Remove the plate and the gasket Item 1 6 Pull the clutch housing tubular neck Item 7 out of engagement with the gear hub Continue to pull the housing until the tubular neck is clear of the opening in the gearbox exposing the worm shaft 5 5 4 Circuit Controller Removal To remove the circuit controller follow these steps See Figure 7 1 1 Remove the circuit controller cover Item 160 2 Tag and remove the wires attached to the circuit controller terminals and heater 3 Position the wiring harness out of way by removing the four wire clamps screws and lock washers 4 Remove the two screws Item 20 and washers Items 410 730 attached to the feet of the circuit controller nearest the motor compartment 5 Remove the two screws Item 390 lock washers Item 415 and plate Item 30 between the point detector cranks 6 Lift and remove the circuit controller from the compartment 7 If further disassembly is required see Figure 7 4 AN Ld KG Vy N MES 5777777777222 ZA SITAE A Cu Zo 28 2 2 LZ ZZ 14 13 12 SM 6444 Rev 1 0 May 2008 5 5 NU 74 AnsaldoSTS Shop Maintenance Union Switch amp Signal Item No Description US amp S Part No Gasket M245192 Felt Washer Clutch Plate Clutch Plate Clutch Disk Clutch Housing Clutch End Plate Clutch Spring Clutch Adjusting N
52. eventive maintenance consists of periodic inspection cleaning lubrication and performance testing A recommended schedule is shown in Table 4 1 This schedule is only intended as a general guide Factors such as the machine s operating environment frequency of usage and the customer s own maintenance regulations should define the actual schedule Table 4 1 Preventive Maintenance Schedule Routine Action Frequency Equipment ti nspecuon Clean Lubrication Performance Monthly Switch Layout X Semiannually Switch Machine Semiannually Machine Circuit x Controller Compartment Semiannually Switch Machine X Monthly Switch Machine X Maximum allowable interval 4 2 Inspection 4 2 1 General Both the M 3 switch machine and the switch layout area should be visually inspected on a scheduled basis The inspection should cover the condition switch points switch rods connecting rods electrical connections and the interior of the switch machine The switch layout should also be inspected for potential switch obstructions Any and all substandard components should be immediately replaced SM 6444 Rev 1 0 May 2008 4 1 lt N 74 AnsaldoSTS Field Maintenance Union Switch amp Signal 4 2 2 Switch Layout Perform switch layout inspection as follows l 2 4 4 2 3 Check that ties are well tamped to withstand vibration and strain caused by passing trains Check that t
53. ezing weather If excessive sand or dust is not a problem leave these plugs out to allow continual drainage b Two other drain plugs Figure 7 1 Items 45 and 415 and Figure 5 3 are provided in the circuit controller compartment These consist of slotted head bolts with lock washers and are shipped in place but not fully tightened The plugs should be periodically removed to allow drainage of the crankcase especially prior to freezing weather In non dust prone areas leave these plugs out to allow continual drainage c For machine installations on elevated structures drain plugs may remain installed to prevent oil seepage that is staining onto objects below 2 2 Mounting Figure 2 1 shows the installation dimensions for the M 3 switch machine while Figure 2 2 and Figure 2 3 show typical layouts These figures are provided for general reference only Refer to the detailed layout plans supplied with the machine when installing the machine SM 6444 Rev 1 0 May 2008 2 1 2 2 2A AnsaldoSTS Installation Adjustment Union Switch amp Signal 2 5 8 HOLES FOR 7 8 PIN POINT DET BAR G Lock ROD lt 5 3 1 2 gt 2 15 16 Figure 2 1 Installation Dimensions SM 6444 Rev 1 0 May 2008 74 AnsaldoSTS Union Switch amp Signal Installation and Adjustment 5 1 4 MAX m m 4 7 8 MIN 11 1 2 8 1 2 a nl 2
54. ft 3 Remove the disks and plates 4 Remove the old packing and clean the shaft and the inside of the clutch housing with a non flammable grease solvent SM 6444 Rev 1 0 May 2008 5 9 lt N 74 AnsaldoSTS Shop Maintenance Union Switch amp Signal 5 Apply two new felt washers US amp S part no J047335 to the housing recess and assemble the press in oil seal Coat the rubbing surfaces of packing rings with gearbox lubricant Attach the housing to the shaft Clean the excess lubricant from the shaft surface inside the clutch space Old fabric discs should be discarded and replaced Old clutch plates should be thoroughly cleaned in a non flammable grease solvent to remove any accumulation of lubricant and then reassembled as shown in Figure 5 2 Note that a fabric disk goes in the bottom of the housing The first metallic disc has the teeth engaging the shaft ADJUSTING NUT CLUTCH SPRING CLUTCH HOUSING GEAR FELT WASHER OIL SEAL CLUTCH DISC CLUTCH PLATE Figure 5 2 Friction Clutch Assembly 5 6 4 3 Assembly of Friction Clutch To assemble the friction clutch perform the following procedure See Figure 5 1 1 2 Install the gasket Item 1 in the gearbox opening Install the plate Item 2 with two 1 4 20 x 3 4 hex head cap screws Item 13 Align the tubular neck of the clutch assembly and the worm shaft Item 12 Insert the tubular neck of the clutch assembly partially over the worm
55. g Top Component PN146606 15 Shaft Worm M286612 20 Housing Clutch N172752 25 Plate End M146575 30 Plate Clutch M146574 35 Disc Lining 3 16 Thk M146650 45 Spring Steel Friction Clutch M239322 50 Nut Adj M286615 55 Gasket Felt J047335 60 Washer M245192 65 Plate 0966 x 48 x 120 Steel M147400 70 Gasket 1 32 x 36 M147410 75 Cap Bearing Cast lron M274596 80 Gear Clutch N286583 85 Gear Bevel M286995 90 Pinion Hand Crank M146377001 95 Shaft 3 4 Dia Steel M149700 100 Reduction Gear M286576 120 Shaft End Plate M286587 125 Pin 1 4 x 1 1 4 Dowel J048925 130 Bushing Oilite 2 Dia X 1 4 J079694 135 Cover Spur Gear N4511612102 140 Gear Shaft M292426 145 Hasp Lug M165738 150 Screw 1 4 20 x 3 4 Hex Hd SS J50009701 12 SM 6444 Rev 1 0 May 2008 Parts Lists 7 12 NU 74 AnsaldoSTS Union Switch amp Signal Table 7 2 Gearbox Assembly N287485003 NE Description NE 155 Screw 5 16 x 3 4 Hex Hd J050036 160 Screw 1 2 13 x 1 1 4 Hex Hd J050090 165 Screw 1 2 13 x 1 1 2 Hex Hd J050092 170 Washer 5 16 Lock Plated Steel J047526 175 Washer 1 2 Lock Plated Steel J047783 180 Plug 1 2 Pipe Steel J032904 Bearing Ball Angular Contact Double 185 Row 35mm J066032 190 Bearing Ball Single Row J066246 195 Washer Lock WH 07 SKF J047810 200 Nut Lock N 07 SKF J048575 205 Key 9WDF 3 4 x 3 16 J048755 210 Cotter
56. g bender Figure 5 9 is required to get at the bottom contact See Table 5 4 CAUTION Use of a padlock on the gearbox hasp with a shackle diameter of less than 3 8 in may result in the motor cutout contacts opening if the hasp is disengaged from the notch in the staple 5 22 SM 6444 Rev 1 0 May 2008 AnsaldoSTS Union Switch amp Signal Shop Maintenance CIRCUIT CONTROLLER COMPARTMENT GEAR BOX S H 9 0 Of Qo _ O Oj T K B O WHEN USED NORMAL RELEASE LEVER Item Number Description Item Number Description A Push Rod H Bracket B Yoke J Contact Insulation C Bearing K Contact Spring D Screw Jaw L Eyebolt E Spring M Nut F Push Rod N Nuts G Latch O Cotter Pin Figure 5 8 Adjustment of Motor Cutout Contacts SM 6444 Rev 1 0 May 2008 5 23 Shop Maintenance 5 24 AM 74 AnsaldoSTS Union Switch amp Signal SHAFT HANDLE l Y Figure 5 9 T Shaped Spring Bender R439056 SM 6444 Rev 1 0 May 2008 74 AnsaldoSTS Union Switch amp Signal 6 Troubleshooting Shop Maintenance Table 6 1 presents troubleshooting information for the M 3 switch machine Because it is impossible to foresee or predict all possible
57. h elements that prevent the segment from rotating relative to the shaft when the shaft end nuts are pulled up but that permit the segment to be shifted angularly around the shaft in 4 degree steps when the shaft end nuts are backed off These segments are set in the factory to provide approximately 1 4 in opening between the segment ring and the V end of the contact finger Fl Section Y Y and Z Z and approximately 1 8 in margin against opening under finger F3 Sect W W and X X when the machine is in its full stroke position That is operated as far as it will go by rotating the friction clutch by hand with the hand crank cover in the Open position The motor control contacts are set at the factory Ordinarily readjustment will not be required as long as the assembly remains undisturbed If an adjustment is required it would be best to adjust the machine in the maintenance shop Refer to Section 5 6 5 1 for these procedures 3 4 Point Detector 3 4 1 General Description The indication contacts are positively opened by the lock box action and close when the cam notches are aligned unless closure is prevented by a point detector action The point detector check switch point closure separately from the lock rod connection and is used to SM 6444 Rev 1 0 May 2008 3 13 lt N 74 AnsaldoSTS Description and Operation Union Switch amp Signal a Check the switch point when it is first closed b Detect damage to a switch point c
58. has the slide bar toward the lock rod end of machine and in other applications must indicate that end of the stroke that has the slide bar toward the motor end of the machine The right pair of contacts M Figure 3 5 similarly must indicate sometimes one end and sometimes the other end of the slide bar stroke so as to indicate reverse Referring to Figure 3 6 when cam N has its notch up the associated normal pair of contacts L closes as shown except when prevented by point detection as explained later For a right hand layout with right hand point normally closed cam N has its notch up when the slide bar is at that end of its stroke where it is nearest the motor end of the machine At the same time cam P is holding its associated pair of contacts up Sect P P and Sect N N of Figure 3 7 When the machine is operated towards the opposite end of its stroke the notch in cam N rotates counterclockwise out from under the follower forcing the contacts up 3 12 SM 6444 Rev 1 0 May 2008 N 74 AnsaldoSTS Union Switch amp Signal Description and Operation While the switch is in transit both the normal and the reverse indication contacts are up engaging the shunting strip S Figure 3 5and Figure 3 7 to provide a shunt for the indication relay When the machines leave the factory this strip is assembled to shunt both normal and reverse contacts but may be reassembled to shunt two inside contacts when indication circuits require such
59. he pins that hold the lock rod control rod point detector control rod and operating rod These pins are equipped with grease fittings Use Alemite brand grease for lubricant 2 9 Final Pre Operation Checks Before putting the M 3 switch machine into service make the following checks 1 2 Check the compartment lids for proper fit and adjust if necessary Check the motor cutout to be certain it is operating properly Make sure the crank cannot be inserted without the cutout contacts being latched out Adjust if necessary per Section 5 8 2 Check all wiring for proper connections Check the clutch adjustment Check the machine s response to an obstruction between the switch points Place an obstruction between the switch point and the stock rail a b Connect an ammeter to the motor power terminals e Electrically operate the machine e When the switch point Jams against the obstruction the worm gear and worm shaft will be stopped but the motor should continue to run during the overload time delay period slipping the friction clutch e The motor current drawn during this period should be 14 amps 10 f If necessary readjust the friction clutch spring to obtain the specified clutch slip current Refer to Section 5 6 4 4 for the adjustment procedure SM 6444 Rev 1 0 May 2008 2 13 lt N 74 AnsaldoSTS Installation and Adjustment Union Switch amp Signal 2 14 NOTE If the friction clutch
60. ie plates tie straps rail braces and switch fittings are secure Check that there are no signs of water accumulation around switch machine If water is found drainage is inadequate Remove any material within layout that could obstruct switch movement Switch Machine Perform switch machine inspection as follows 1 Remove covers from switch machine circuit controller gearbox and motor compartments 2 Using hand crank operate switch back and forth as needed to check for a f Proper and smooth operation of switch points No excessive drag or spring points riding on all slide plates Also check for switch point obstructions at this time Loose or damaged electrical connections Burned frayed or broken insulation Proper movement of switch machine main crank slide bar lock box switch operating bar circuit controller shaft and circuit controller point detector connecting rods Excessive wear lost motion or accumulation of foreign or conductive material Excessive or unusual vibration and noise 3 Electrically operate the switch machine and check for 4 2 a b Smooth movement of the switch machine motor and gears No binding or related faults should be observed Conditions listed in Step 2 above SM 6444 Rev 1 0 May 2008 AV 74 AnsaldoSTS Union Switch amp Signal Field Maintenance 4 Make sure no water has accumulated in the switch machine compartments For switch machine
61. if brushes chatter d From the container shipped with the machine apply the gear lubricant See Table 5 5 This is a low temperature all weather lubricant that has little change in consistency with temperature variations It will retain its lubricating properties at the highest temperatures encountered and not become so stiff at low operating temperatures as to require thinning If sustained abnormally low temperatures are anticipated a special lubricant may be ordered Contact your salesman or the Engineering Department for an ordering reference number 1 Apply a light coat of gear lubricant to spur gear teeth The gear lubricant must be packed well around the worm gear and the selector clutch in the worm gear compartment It must be replaced as necessary to keep the worm gear covered Scheduled lubrication is recommended however the period between times of lubricating depends upon the frequency of operation and upon climatic and local conditions and therefore can be established from experience with the switch machine and its specific operation 5 16 SM 6444 Rev 1 0 May 2008 2y 74 AnsaldoSTS Union Switch amp Signal Shop Maintenance DRAIN HOLE BOTH SIDES DRAIN HOLE B Figure 5 3 M 3 Switch Machine Lubricants and Lubrication Points Refer to Table 5 5 SM 6444 Rev 1 0 May 2008 5 17 NU 74 AnsaldoSTS Shop Maintenance Union Switch amp Signal Table 5 5 Preventive Maintenance Schedule
62. igure 3 8 and slide the finger in or out until a point where any additional cam rotation will open the contact 6 Retighten the nuts When a 15 32 0 2 x 24 steel bar is used for this test the contacts should be open SM 6444 Rev 1 0 May 2008 5 13 ay 74 AnsaldoSTS Shop Maintenance Union Switch amp Signal 7 Repeat the procedure for the other three motor control contacts Check to see that adjacent control contacts open simultaneously Contact finger Fl should be adjusted to bear against the segment with 2 to 2 1 2 165 pressure while finger F2 is held clear 1 Adjust finger stop Fla to have 1 32 1 64 clearance from finger F1 when the latter is riding the segment 2 Adjust finger F2 to bear on finger Fl with 1 3 4 to 2 Ibs pressure when finger Fl is on the segment 3 Adjust stop F2a to clear finger F2 by 1 32 1 64 when the contacts are closed as shown in sections W W and X X This also permits finger Fl to clear finger F2 by 1 16 minimum when contacts are open as shown in sections Y Y and Z Z 4 Adjust finger F3 to bear on the segment with 1 3 4 to 2 Ibs pressure 5 6 5 3 Contact Pressures and Clearances Contact pressure and clearances must be in accordance with Sections P P and N N of Figure 3 8 These clearances are obtained by performing the following procedure 1 With the switch machine at the end of stroke to enable the roller to drop into the cam notch adjust the reinforcing spring Item N b
63. ind a dL dpud e tee Lage 2 11 Final Pre Operation Checks ennt enhn 2 13 Description and Operation 3 1 Switch Operating and Locking 3 1 owitch POINt LOCKING eset con ir iere to heb ERO titan te edm tis ores anaes 3 7 CIRCUIT COMICON us E ES 3 11 lifeifezWenuerentucfrce RR 3 12 Motor Control GontaglSu u u u um uuu anaku enne nnne sinn enne nnns 3 13 loin Detector x on dete Ent IER SU Pesaro 3 13 General Description 3 13 Operati P EE 3 14 UD 3 21 Hand Crank Operation sse enne 3 22 Motor Overload Protection L nn nennen nnne nnne 3 22 ric LEE 3 22 Field Maintenance s 4 1 Preventive 4 1 WIS POCO EE 4 1 CUIR 4 1 Switch FAY OUP icio ene dente Mand eiat cai esu deba ER iden 4 2 Switch MACHINES aa 4 2 Gleanlrigr e Detienen sue e o ets 4 3 Required Equipment Materials nnne 4 4 ERE 4
64. installing the control wiring Figure 2 7shows the switch machine s internal wiring diagram In this figure the circuit controller indication cams are shown for a switch having the right hand point normally closed and in the Normal position However this is applicable to right or left hand installations Figure 2 7 shows typical application circuits for the control of the switch machine using standard US amp S PN 150SO the PN 150BM and PP 151 plug in relays Part B shows a polar circuit with the PP 151 and PN 150BM in combination Part C shows a neutral circuit with two PN 150BM relays These circuits show wiring of the relays that corresponds to internal wiring diagrams applied to single switches SM 6444 Rev 1 0 May 2008 2 9 lt 74 AnsaldoSTS Union Switch amp Signal Installation and Adjustment 3A33 S qasn N3HMW MOV 3NOHd NOILVLOMS LX3N 3O as ana rz 8 H3TIOHLNOO E LINDYID G v1 G1 dIYLS ONILNNHS 91 D 2 GD f Gi es te 6 s ks x h D _ 9 bw q3sn NAHM H3 1V3H YSTIONLNOD LInO3IO p SM3SHOS ONILNNOW YATIONLNOD LINDYID YSQNN NMOHS NOILISOd NI Q3 1SWASSV 38 OL 500 0 SdWV10 SSINYYH v 1 3 HIM HO LOIN I3NOVMW LN3NVIA H3d GaddINO A 3NIHOVIN HOLIMS ADVLIOA H9IH W 3 IALS HO uma ee 131V3H 6 Se SION ZH Lg 0 Gs vz gc gr oz e 16470 9 os Lb Lo 6 r4
65. intenance Tools Basic 56 49125301 5 1 Table 5 3 Maintenance Tools Basic Set with Track Tools 49125302 5 2 Table 5 4 Maintenance Tools Basic Set with Track and Circuit Controller Tools 49125303 5 3 Table 5 5 Preventive Maintenance Schedule a 5 18 Table 6 1 Troubleshooting the M 3 Switch Machine a 6 1 Table 7 1 Switch Machines N4511601401 and N4511601501 Parts List 7 1 Table 7 2 Gearbox Assembly N287485008 sese 7 11 Table 7 3 Circuit Controller N451 8170501 sse enne nnne 7 14 Table 7 4 Motor Assembly N4511611701 ener nennen nennen enn 7 18 vi SM 6444 Rev 1 0 May 2008 N 74 AnsaldoSTS Union Switch amp Signal General Information 1 General Information 1 1 Introduction This service manual covers the Standard Low Clearance M 3 Electric Switch Machine M 3 The machine is similar to the Standard M 3 Electric Switch Machine refer to SM 6263 but is 5 8 lower vertically This switch machine is designed for applications where the maximum clearance is lower between the vehicle and the machine For example on third rail transit properties the Standard Low Clearance M 3 provides optimum clearance with the vehicle s pick up sh
66. ion Switch amp Signal Shop Maintenance 5 8 Adjustments 5 8 1 Point Detector Point detector rollers should be maintained to clear the small diameter of the point detector bar by not more than 0 03 in If necessary adjust the screwing eyebolts 19 Figure 7 4 in or out screws 67 must first be removed 1 Use point detector gauge N295326 Figure 5 4 to check latch operation in normal and reverse switch positions 2 Ensure that the point detector latching mechanism is unlatched i e the latch must be clear to allow the yoke to rest against the yoke stop see Figure 5 5 3 Check that the space between the point detector roller and the bevel of the point detector bar is sufficient to permit the insertion of the feeler gage Figure 5 5 If not adjust the point detector bar per Section 2 4 4 Pry the point detector roller out of the way and insert the sleeve gage over the narrow diameter of the point detector bar Figure 5 7 The sleeve gauge must be tight against the bevel of the point detector bar The insertion of the sleeve lifts the connecting rod and rotates the yoke so that the latch snaps over the top of the yoke midsection 5 Swing the latch so that the yoke clears the latch and rests against the yoke stop 6 Release the latch The latch must clear the yoke and snap over the top of the yoke midsection If not adjust the point detector bar per Section 2 4 7 Remove the sleeve gage from the point detector bar With
67. lip at a current value above the minimum current rating of the relay otherwise no protection will be obtained 1 Attach a temporary jumper across the binding posts of the pick up coil on the overload relay NOTE If a bridge rectifier is used all 6 1 4 amp Fusetrons on the 110Vdc side of a bridge rectifier should also be temporarily jumpered out 2 Insert an ammeter in the motor circuit as follows SM 6444 Rev 1 0 May 2008 5 11 ay 74 AnsaldoSTS Shop Maintenance Union Switch amp Signal a Connect the negative ammeter lead to binding post A on the switch machine terminal board b Connect the positive ammeter lead to binding post 5 or 10 depending upon the switch point position c Read the motor current with the clutch slipping The meter should show 14 amps 10 A variance of approximately 1 to 3 amps may exist due to mechanical alignments and motor characteristics The current should be checked in both directions d Ifthe current reading is out of specification remove cotter and screw the friction clutch spring adjusting nut see Figure 5 2 in or out to obtain desired current e Remove temporary jumper s 5 6 5 Installation of Circuit Controller Perform the procedure in Section 5 6 5 1 while making reference to Figure 7 1 5 6 5 1 General l 2 Lower the circuit controller into the circuit controller compartment Align the mounting holes Reinstall the two screws Ite
68. ly one way The shaft has one corner flattened for a distance of 2 inches at one end and 3 inches at the other end and the gear and the eccentric bushings have dowel pins that can be assembled only in these flats With the exception of the indication cams and their coil springs the two arms of the yoke and the operating levers all the parts are pulled up solidly end to end by the nuts on the ends of the shaft The indication cams and their respective springs ride on the gear hub and are held against the gear face by action of the springs and locked in place with set screws The cams may have either of two operating positions as determined by slots in the cam hub engaging the stud in the gear face The yoke is free to rotate around the concentric hub portions of the eccentric bushings and the operating levers are free to rotate around the eccentric portions or be held stationary while the shaft and eccentric bushings rotate 3 3 1 Indication Contacts The four sets of indication contacts operate as two pairs one pair indicating the normal position and the other indicating the reverse position Each pair is operated by a single cam and both are subject to point detector operation Wiring and wire nomenclature are standardized so that the left pair of contacts L Figure 3 5 Sect N N Figure 3 7 are used to indicate normal on all installations This means that in some applications the left pair of contacts must indicate that end of the stroke that
69. m 410 and 3 8 lock washers in the holes nearest the motor compartment Reinstall the plate Item 30 two 1 2 13 x 1 hex head cadmium plated steel cap screws Item 20 and washers Items 410 730 between the point detector cranks With the wire harness in clamps reinstall the four wire clamps with four 5 16 x 1 5 8 fillister head machine screws cadmium plated and four 5 16 plain steel lock washers extra heavy tin plated Refer to the tags and reattach the harness wires to correct the circuit controller terminals and the heater connections Tighten all screws securely and make sure the gearing on the circuit controller meshes properly with the crank teeth on the movement lock box Using the hand crank operate the movement to the end of its stroke This places the slide bar and lock box toward the motor Make sure the circuit controller shaft assembly is in the angular position as shown in section Y Y of Figure 7 4 checking specifically the relation shown in the schematic diagram for setting of 5 12 SM 6444 Rev 1 0 May 2008 74 AnsaldoSTS Union Switch amp Signal Shop Maintenance segments for contacts 24 25 and 26 27 This should place the cam block Item 57 of the main shaft gear Item 56 in the position shown in Figure 7 4 The next move should rotate the cam block away from rather than into the pinion gear Item 59 10 Install three of the circuit controller frame hold down bolts but do not tigh
70. motor brushes perform the following steps See Figure 7 1 1 Remove the motor compartment cover Item 180 2 Remove the motor brush commutator covers by removing two screws on each side of the cover 3 Lift and push to release the spring holder 4 Remove the motor brush from case 5 Repeat above procedure for other the brush 5 5 2 Motor Removal To remove the motor proceed as follows See Figure 7 1 1 Remove the motor compartment cover Item 180 2 Tag and remove the wires attached to the connections at the motor s end closest to the conduit outlet 3 Position the wiring harness out of the way 4 Remove two 1 2 13 x 2 hex head cap screws Item 380 at the rear of the motor s mounting bracket commutator end 5 Remove the two associated 1 2 plain lock washers Item 415 6 Lift the motor assembly Item 10 up and pull towards the conduit outlet until the pinion gear on the motor shaft is clear of the motor opening If required remove the pinion from the shaft and motor from the bracket using Allen wrenches 5 5 3 Friction Clutch Assembly Removal To remove the friction clutch assembly perform the following steps See Figure 5 1 1 Remove the cotter key Item 11 from the clutch adjusting nut Item 10 2 Remove the clutch adjusting nut Item 10 from the worm shaft Item 12 3 Remove the clutch spring Item 9 4 Remove the two cap screws Item 13 securing the plate Item 2 5 4 SM 6444 R
71. nd recheck to make sure it is not greater than 11 pounds or less than 8 pounds 5 14 SM 6444 Rev 1 0 May 2008 N 74 AnsaldoSTS Union Switch amp Signal Shop Maintenance 6 With contacts made against the short circuiting strip check at the front end of the contact fingers with a push scale for a load of 1 1 2 pounds to 4 pounds 5 7 Lubrication Before leaving the factory all working parts of the machine except the worm gear compartment are well lubricated Unpainted and unplated parts are coated with a special lubricant designed to protect these parts against corrosion until installation This lubricant need not be removed since it will mix readily when new lubricants are added For best results only lubricants complying with strict specifications are recommended The recommended lubricants can be purchased in convenient quantities from US amp S Additionally for optimum performance of the gear box remove the lubricant the from the gear box clean the gear box and refill it to the recommended level at least every five years CAUTION Lubrication at proper intervals is essential to ensure proper equipment operation Do Not Permit Grease Or Oil To Enter Spring End Of Friction Clutch Otherwise Friction Clutch May Malfunction Figure 5 3 identifies the areas of the switch machine that need lubrication These points and the proper lubrication are further described in Table 5 5 The following steps present the general lubrication
72. ns the pinion relative to the other gear centers The reduction gears are assembled on shafts supported in Oilite bearings The ends of these shafts are supported by an end plate slotted to fit over a neck in each shaft The clutch gear which is the final spur gear is supported on the worm gear shaft with an Oilite bushing This gear is connected to the worm shaft through the friction clutch The worm shaft meshes with the worm gear on the main crankshaft and is supported at the end adjacent to the controller by a double row ball bearing This bearing takes both radial load and end thrust The shaft is also supported by a single row ball bearing in the wall between the worm gear compartment and the spur gear compartment Both ball bearings are lubricated by the worm gear lubricant A cap on the outside seals the outer side of the double row ball bearing An oil seal pressed into the opening is provided on the spur gear side of the single row ball bearing The friction clutch housing has a tubular neck supported in an Oilite bushing This bushing is pressed into the gearbox bore The inside diameter provides slight clearance for the worm shaft The housing has felt packing to prevent oil seepage into the friction clutch The worm shaft is grooved and the housing has ribs to drive alternate friction discs These discs are compressed by the action of the SM 6444 Rev 1 0 May 2008 3 21 w 4 AnsaldoSTS Description Operation
73. oe The Standard Low Clearance M 3 Electric Switch Machine is also similar to the special machine built exclusively for NYCT refer to SM 6260 Both machines have the same overall height However the NYCT machine is equipped with special contactors for motor operation NOTE In this manual the term M 3 is used for the Standard Low Clearance M 3 Electric Switch Machine 1 2 Description 1 2 1 General The M 3 consists of a motor a gear train a cam arrangement for operating and locking the switch and a circuit controller that includes a point detector with latch out device For installations with little horizontal space around the machine 1 subway tunnels the internal point detector bar can be removed vertically Components are contained in a cast iron housing The machine has no permanent attachments for hand operation but may be manually operated by inserting a removable crank Machine N451160 1401 is used for left hand layouts while machine N451160 1501 is used for right hand layouts The M 3 is provided with a single type of motor 110 Vdc and a single gear ratio of 189 1 The machines are fully wired at the factory with internal wiring connected to a main terminal board in the motor compartment A typical wiring diagram is enclosed with each shipped machine The diagram shows how external connections should be made to the main terminal board for a particular application To allow standardized wiring the circui
74. oller compartment and the motor compartment Fifteen watt heaters are used in both compartments and are energized by the 110 Vdc power feed to the machine A dual element heater is also available The controller compartment heater mounts at the end of the controller opposite the wire inlet as shown in Figure 3 13 This heater is held in place by the same four screws that fasten the controller terminal board at that end The motor compartment heater is mounted on the motor assembly cradle as shown in Figure 3 13 3 22 SM 6444 Rev 1 0 May 2008 N 74 AnsaldoSTS Union Switch amp Signal Description and Operation HEATER O 29 7 7 55 15W 115 230 VOLTS HEATER 15W 115 VOLTS OR B HEATER FOR MOTOR COMPARTMENT SW 24 VOLTS Figure 3 13 Circuit Controller and Motor Compartment Heaters SM 6444 Rev 1 0 May 2008 3 23 A 4 AnsaldoSTS Description and Operation Union Switch amp Signal A 1 AnsaldoSTS Union Switch amp Signal 3 24 SM 6444 Rev 1 0 May 2008 74 AnsaldoSTS Union Switch amp Signal Field Maintenance 4 Field Maintenance Disconnect motor power before any work is performed on the M 3 switch machine or switch layout Failure to observe this warning could result in personal injury and or equipment damage 4 1 Preventive Maintenance Preventive maintenance of the M 3 switch machine is performed to minimize the chance of an in service failure of the machine Pr
75. ontroller Section 7 3 N4518170501 Parts List 20 Screw 3 8 16 x 1 1 4 Hex Hd J507372 25 Name Plate Aluminum J0631 17 30 Plate 1 8 x 1 CF Steel M146595 35 Plate Wrap around M4511612201 40 Lug M4516144502 45 Screw 1 2 13 x 1 2 Rd Hd J507366 50 Roller CF Steel Rd M108315 55 Roller 1 3 4 Steel 074737 60 Locking N178100 65 Slide Bar Cam R146444 70 Roller 2 1 8 Steel Alloy M061066 75 Operating Bar M146441 80 Lug Switch Point M146443 SM 6444 Rev 1 0 May 2008 Parts Lists 7 2 NU 74 AnsaldoSTS Union Switch amp Signal Table 7 1 Switch Machines N4511601401 and N4511601501 Parts List NE Description 85 Wearing Bracket M189024 90 Key 3 8 x 1 Steel M146782 95 Tubing Fiber 1 1 4 I D 30 Long J034625 100 Conduit Outlet Component N238223 105 Not Referenced m 110 Bolt 3 8 16 x 8 Hex Hd J507369 115 Support Terminal Board CI M172662 120 Push Rod Component N180861 125 Strap 1 8 x 7 8 Steel M162242 130 Contact Motor N226029 135 Bolt 7 8 9 x 8 Hex Hd J460113 140 Pipe SMLS Steel Tubing M146723 145 Gasket 1 4 Felt M147398 150 Washer M147409 155 Cover Slide Bar Cast lron M074911 156 Component Formagasket 2 J041505 160 Cover Circuit Controller N4511612701 165 Hood 0 0677 x 48 x 120 Steel M148141001 170 Cover End Closed R159272 175 Cover Crankcase Bottom R4511613
76. right cam portion of the yoke engages the roller on the underside of both indication contact assemblies This lifts the reverse contact assembly to open the reverse indication contacts and close the indication contacts against the short circuiting strip The latch can be restored manually or by operating the machine to the opposite position so that the cam on the controller shaft gear in mid stroke lifts the latch This permits the yoke to be restored to its horizontal position resting against the yoke stop SM 6444 Rev 1 0 May 2008 3 15 A 4 AnsaldoSTS Description and Operation Union Switch amp Signal A 1 AnsaldoSTS Union Switch amp Signal 3 16 SM 6444 Rev 1 0 May 2008 AM 77 AnsaldoSTS Union Switch amp Signal Description and Operation 1 32 1 64 1 9 4 20 2 2 1 2lb WHEN F2 IS HELD CLEAR 2 1 4lb MAX 1 1 2lb MIN SHUNTING STRIP 3 64 MIN 410 MAX 1 1 216 MIN 3 64 MIN SHUNTING STRIP 6A2 0016 00 SECT Y Y amp ZZ CAN BE SEPARATED FOR REASSEMBLY IN THE OPPOSITE POSITION SIMPLY BY FORCING AGAINST THE SPRING VIEW A INDICATION CAM 375 DIA LEFT SIDE INDICATION CAM SEE VIEW A TTTTITTTHTTTTT PINS GEAR COIL SPRING MOTOR CONTROL CONTACTS 2 z 2 a z OPERATING LEVER ECCENTRIC BUSHING E 7 INSULATING Z BUSHING 1 Nj MOTOR CONTROL RIGHT SIDE SEGMENT 401 DIA SEE VIEW B DIAGRAM SHOWIN
77. s eps n haha I e kits qe o n de da Toa au a da 3 3 Figure 3 3 Driving Parts Continued I enne nennen snnt enne 3 5 Figure 3 4 Adjustable Lock Rods 2 aisi 3 8 Figure 3 5 Indication Circuit Controller oo cece L ener 3 9 Figure 3 6 Sectional View of Circuit Controller essen 3 10 Figure 3 7 Sectional View of Indication Circuit Controller sss 3 11 Figure 3 8 Circuit Controller Adjustment and Shaft Assembly 3 17 Figure 3 9 Point Detector Parts in Normal Position a 3 19 Figure 3 10 Point Detector Parts in Mid Stroke Position a 3 19 Figure 3 11 Point Detector Parts in Reverse Position aaa 3 20 Figure 3 12 Point Detector Parts in Reverse Position and 0 3 20 Figure 3 13 Circuit Controller and Motor Compartment 3 23 Figure 5 1 Friction Clutch Assembly nre 5 6 Figure 5 2 Friction Clutch Assembly a sa aa q a enne nennen 5 10 Figure 5 3 Switch Machine Lubricants and Lubrication Points 5 17 Figure 5 4 Point Detector Gage N295326 sssssssssssss
78. s with installed drain plugs a If there is water in the crankcase compartment remove the two 3 8 inch pipe plugs from the base of the compartment and allow water to drain b Ifthere is water in the circuit controller compartment remove the slotted head bolts with lock washers at the base of the compartment and allow water to drain CAUTION Make sure to perform the above checks for water prior to sub freezing weather Frozen water within the switch machine could result in improper operation or equipment damage c Reinstall plugs in drain holes where required by the application NOTE The drain plugs are only installed when the switch machine is used in a highly dusty or sandy area or when the machine is installed on an elevated structure where drainage could contaminate objects below the structure Otherwise the drain holes should be left open to permit continual drainage 5 Check that motor control contacts indication contacts motor cutout contacts and associated cams and linkages are clean and do not show excessive wear refer also to Section 4 3 6 Check that all switch machine parts requiring lubrication are lubricated in accordance with Section 5 7 7 Check that the conduit between switch machine motor compartment and junction box is not crimped nicked cut or otherwise damaged 8 Remove the two screws that secure the access plate over the motor commutator a Check that commutator is smooth and
79. salt 2 1 Perform a point to point continuity test on each wire lead Tighten any loose connections and replace damaged terminals are loose or wire s or terminal s broken E Motor control 1 Confirm the contact pressure Refer to Section 5 8 2 contacts are out of 2 Replace any damaged contact spring s adjustment damaged or broken SM 6444 Rev 1 0 May 2008 6 1 Shop Maintenance NU 74 AnsaldoSTS Union Switch amp Signal Problem Cause Solution F Motor stopped running Check for sufficient brush length and that motor commutator is smooth and free of grease Refer to Section 5 6 2 2 Replace the motor brushes Refer to Section 5 6 2 3 IfSteps 1 and 2 do not restore motor operation then replace the motor Refer to Section 5 5 2 for motor removal G General failure of 1 Remove the switch machine from service and take it to a the circuit controller service shop for an overhaul or replacement of the circuit controller Refer to Section 5 5 4 Motor runs but notin A Incorrect motor 1 Reverse the motor wires Refer to the Control Wiring the proper direction polarity Diagrams Figure 2 7 and Figure 2 8 friction B Control circuit is 1 Check all wiring connections against the circuit diagram p incorrect Switch machine A Indication contact 1 Confirm contact spring pressures and gaps Refer to operates and locks springs are out of Section 5 6 5 3 ho
80. se contacts open the motor circuit and may also control a line circuit when the hand crank is inserted In addition to the above elements a slide bar runs longitudinally in the base of the machine This bar is driven by the main crank and operates the lock box in the circuit controller compartment A switch operating bar runs at right angles to the mechanism and beneath the slide bar The switch operating bar is also driven by the main crank and is connected to the switch operating rod See Figure 3 1 The point detector rod and lock rods operated by connections to the switch points are supported crosswise in the circuit controller compartment Switch operation switch locking and circuit controller operation are all performed by the vertical main crank in the gearbox The main crank is driven either by the motor or by the hand crank Refer to Section 3 for a detailed operating description of the M 3 Switch Machine SM 6444 Rev 1 0 May 2008 m 7 AnsaldoSTS Union Switch amp Signal General Information CIRCUIT CONTROLLER GEAR MOTOR COMPARTMENT BOX COMPARTMENT P AVV 4 SLIDE BAR SWITCH MAIN HAND CRANK OPERATING CRANK INSERTED HERE BAR LOCK BOX MOTOR ROTATES WORM GEAR FOR POINT DETECTOR ROD WIRE OUTLET CIRCUIT CONTROLLER IS OPERATED BY THESE RACK TEETH INDICATION CONTACTS ARE AFFECTED ALSO BY POINT DETECTOR MAIN CRANK ROLLER Figure 1 1 General Arrangement of the M
81. shaft and through the gearbox bushing Align the three finger end of the tubular neck with the matching slots in the clutch gear hub 5 10 SM 6444 Rev 1 0 May 2008 N 74 AnsaldoSTS Union Switch amp Signal Shop Maintenance 6 Push the tubular neck into the gear hub slots until the neck hub is in the clutch gear hub 7 Push the tubular neck into the gear hub slots until the neck hub is solidly engaged 8 Install the following items on the worm shaft as follows a Insert the clutch disc until it sets against the inner wall of the clutch housing b Insert the clutch plate in the groove on the worm shaft until it mates with the clutch disc c Insert another clutch disc d Insert another clutch plate e Repeat Steps c and d for three remaining clutch discs and two remaining clutch plates f Insert the clutch end plate on the worm shaft 9 Slide the clutch spring over the worm shaft until it rests against the clutch end plate 10 Install the clutch adjusting nut on the worm shaft 11 Tighten the clutch adjusting nut in accordance with the friction clutch adjustment procedures 12 Recheck this adjustment after a brief wearing in period 5 6 4 4 Friction Clutch Adjustment NOTE The friction clutch adjustment should be checked to ensure that the clutch slips at a torque that is adequate to carry normal operating loads and also protects the mechanism from shock For proper operation of the overload relay the clutch must be set to s
82. slips too easily the motor current may not operate the overload relay As a result the battery may be exhausted If the friction clutch adjustment is too tight mechanical parts may wear out prematurely due to the lack absence of shock protection During routine operation without obstruction of the switch points some clutch slippage at both ends of the power stroke is normal SM 6444 Rev 1 0 May 2008 N 74 AnsaldoSTS Union Switch amp Signal Description and Operation 3 Description and Operation 3 1 Switch Operating and Locking Mechanism The main crank drives both the switch operating bar and the slide bar The latter carries the lock box with its locking dogs which enter notches in the lock rods when the switch points are in proper position and also carries rack teeth which operate the circuit controller Assuming the machine to be at one end of its stroke operation to the opposite end of the stroke involves rotation of the main crank by the motor or by the hand crank As the main crank turns it first shifts the slide bar so as to withdraw the locking dog from the lock rod notch before the switch points start to move The main crank then holds the slide bar in the mid position both locking dogs clear of the lock rods while driving the switch operating bar full stroke to its opposite position Finally the main crank holds the switch operating bar while driving the slide bar to its full stroke position engaging the top locking
83. ssseeeeee eene nennen nnne nene ns 5 20 Figure 5 5 Latch in Unlatched Positiones n a yeu aa asa aasawa akawa sasa s s 5 20 Figure 5 6 Inserting the Sleeve Gage asss 5 21 Figure 5 7 Contacts Latched Out and in the Open 5 21 Figure 5 8 Adjustment of Motor Cutout Contacts L 5 23 Figure 5 9 T Shaped Spring Bender R439056 5 24 Figure 7 1 M 3 Switch Machine Assembly a 7 7 Figure 7 2 M 3 Switch Machine Section Views 7 9 Figure 7 3 Gearbox Assembly N287485003 u 7 13 Figure 7 4 Circuit Controller N4518170501 aaa 7 17 Figure 7 5 Motor ASSembly rrt dace rms aka d ee a da a e eee 7 19 SM 6444 Rev 1 0 May 2008 74 AnsaldoSTS Table of Contents Union Switch amp Signal List of Tables Table 4 1 Preventive Maintenance Schedule I a 4 1 Table 4 2 Switch Machine Field Adjustments nn 4 5 Table 4 3 Field Repair 4 6 Table 5 1 Shop Maintenance Checklist 5 1 Table 5 2 Required Ma
84. st per the lock rod adjustment solution above SM 6444 Rev 1 0 May 2008 6 3 Shop Maintenance NU 74 AnsaldoSTS Union Switch amp Signal Problem Cause Solution C Switch machine internal lock rod assembly is out of adjustment Adjust the lock rod assembly as follows 1 2 Close the far switch point Loosen the hardware to allow for independent movement of the lock rods Adjust the lock rods so that the notch in the lock rod assembly is roughly centered about the lock box dog Refer to Figure 3 2 and Figure 3 3 Tighten the connecting rod hardware for the far point connection Repeat the above process for the near point side Tighten the lock rod assembly hardware to lock the adjustment D Switch machine internal lock rod assembly is broken Replace the internal lock rod assembly as follows 1 Loosen the jam nuts that lock the position of the threaded end of the lock rod connecting rod to the front rod assembly lug 2 Hand crank the switch machine to its mid stroke position 3 Separate the lock rod connecting rod from the switch machine lock rod assembly 4 Remove the lock rod assembly from the field side of the switch machine 5 Replace the lock rod assembly with a new lock rod assembly Refer to Table 7 1 and Figure 7 1 6 Reconnect the lock rod assembly to the lock rod connecting rod Refer to Table 7 1 and Figure 7 1 7 Readjust per the lock rod adjustmen
85. t controller is designed so that certain contacts always indicate Normal regardless of which end of the operating stroke is established as Normal The internal wiring includes wires for an electric heater that can be added in the circuit controller An electric heater for the motor compartment is also available SM 6444 Rev 1 0 May 2008 14 lt N 74 AnsaldoSTS General Information Union Switch amp Signal 1 2 2 Operating Mechanism As Figure 1 1 shows the M 3 consists of the following compartments J Motor The motor compartment houses the motor the main terminal board and has a wire outlet for external wiring The friction clutch of the gear train projects into this compartment Gearbox The gearbox compartment houses the gears Actually there are two compartments in the gearbox one for the spur gear portion of the reduction gearing and the other for the main crank and worm gear drive The connection between the spur gears and the worm shaft is through the friction clutch which projects into the motor compartment The friction clutch protects the mechanism from shock at the end of the stroke or when travel is suddenly stopped by an obstruction in the switch point or by lock rod fouling The gearbox also houses the mechanism for hand crank operation Circuit Controller The circuit controller compartment contains the circuit controller locking features point detector device and a separate set of motor cutout contacts The
86. t solution above E Obstruction 1 Clear out any obstructions between the switch 2 Cycle the switch machine several times to ensure normal ET and the stock operation 3 Inspect the layout and switch machine for signs of damage F Switch machine mounting hardware is loose Tighten all mounting hardware G Friction clutch discs have become contaminated oil grease etc Replace all clutch plates and discs See service manual for instructions Section 5 5 3 and Section 5 6 4 6 4 SM 6444 Rev 1 0 May 2008 N 74 AnsaldoSTS Union Switch amp Signal T Parts Lists 7 1 Switch Machines N4511601401 and N4511601501 Parts Lists Table 6 1 is the parts list for the left hand model N4511601401 and the right hand model N4511601501 of the M 3 switch machine The figure associated with this table is Figure 7 1 NOTE The right hand model N4511601501 of the switch machine is identical to the left hand model except that Item 75 Operating Bar and its attached components are mounted on the direct opposite side of the machine Item 580 Lock Rod Cover is also mounted on the opposite side of the right hand machine Table 7 1 Switch Machines N4511601401 and N4511601501 Parts List NER Doseupdon NS 5 Machine Base Assembly N4511601601 10 Motor Assembly Subsection 7 4 N4511611701 Parts List 15 Circuit C
87. t the narrow notches are approximately centered on the locking dogs at each end of the stroke The upper narrow notch can be seen directly Index marks are provided on the top surface opposite the notched ends for the lower notch Make final adjustments in accordance with applicable railroad standards 2 4 4 Inverting Lock Box Normally the lock box dogs must enter the narrow notches of the lock rod before reaching the wide notch refer also to Section 3 1 Sometimes it may be necessary to invert the lock box to obtain this configuration The procedure is as follows see Figure 3 5 1 Remove the lock rods 2 Place the machine in the end stroke position which brings lock box G nearest the motor 3 Note which of the indication cams N or P has its notch up and that this notch is centered about roller D 4 Unscrew the four bolts T that hold the circuit controller to the case 5 Liftthe controller upward pivoting it around the edge of the case adjacent to the wire conduit 6 Turn lock box G upside down taking care that it is replaced properly on the driving studs of the slide bar 7 Replace the circuit controller checking that pinion gear F in Figure 3 6 meshes with the rack teeth on the lock box so as to place the indication cam with its notch up and centered about roller D This returns the equipment to the configuration before the circuit controller was removed 8 Fasten the circuit controller in place with the fo
88. tector rollers A and B stand clear of the point detector bar thus preventing wear of point detector parts under traffic conditions However roller is in position to deflect the yoke downward should the point detector bar be displaced When the machine is moved out of its normal position the controller shaft rotates in a counterclockwise direction viewed from right hand side The operating levers are shifted by the eccentric bushings to move point detector roller A away from the point detector bar This permits movement of the point detector bar from the normal position to the reverse position without contacting either roller Reverse position a Both rollers are again clear of the bar b Roller B is in position to deflect the yoke downward should the point detector bar become displaced Latched out position 1 The point detector bar is shifted from its reverse position due to deflection of the switch points caused by improper trailing The large diameter section of the point detector bar is brought into contact with point detector roller B As a result the connecting rod shifts the operating levers thereby rotating the yoke downward about the controller shaft until the latch as biased by the latch spring snaps over the top of the yoke midsection If the latch does not clear the top of the yoke and operate add shims under the yoke stop until the latch operates see Figure 3 12 As the yoke is rotated downward the up
89. ten 11 Using the hand crank operate the movement slowly checking that the cam block moves in the proper direction 12 Before tightening the circuit controller frame hold down bolts check that full stroke controller shaft rotation gives symmetrical contact relationship at both ends of the stroke Shift the gear tooth engagement if necessary to obtain this condition 13 Install and tighten all hold down bolts CAUTION When removing the old circuit controller the movement must be hand cranked Also the lock box must be toward the motor end before installing the circuit controller into the switch movement otherwise the controller may be damaged 5 6 5 2 Motor Control Contact Adjustment The motor control contacts are set at the factory to ensure that the switch machine is locked in accordance with AAR specifications Ordinarily readjustment should not be required as long as the assembly remains undisturbed If an adjustment is required proceed as follows See Figure 3 8 Clean and degrease the contacts with a suitable cleaner 2 With the machine in an unlocked position insert a 1 2 0 01 x 2 x 24 steel bar into the lock rod slot 3 Turn the clutch housing by hand until the lock dog bears against the 1 2 wide bar In this position the machine is fully locked 4 Connect an ohmmeter or test light across one of the appropriate control contacts 5 Loosen the nuts that hold the V end of finger Fl F
90. ture may be removed If the latch is latched up as the result of damage to the switch point the machine cannot complete its stroke in either direction due to lock rod fouling The latch can also be reset manually 3 4 2 Operation The following figures are provided to illustrate the operation of the point detector mechanism Figure 3 9 Relative positions of the eccentric bushings operating rods and point detector rollers for the Normal position of the switch machine In the Normal position parts are illustrated for a machine in which cams are assembled so that the Normal end of the stroke places switch points to the right Figure 3 10 Mid stroke positions of the various parts Figure 3 11 Reverse positions of the various parts Figure 3 12 Various parts latched up in the reverse position The right and left hand operating crank springs hold the yoke which is pivoted on the controller shaft up against the yoke stop on the latch bracket This occurs for all controller positions except when the point detector bar is displaced due to improperly positioned switch points As shown in Figure 3 9 through Figure 3 12 the yoke assembly remains in a fixed position for normal operation of the machine with the switch points in proper adjustment With the switch machine in the normal position as shown in Figure 3 9 3 14 SM 6444 Rev 1 0 May 2008 lt bd 4 AnsaldoSTS m Union Switch amp Signal Description and Operation 1 Point de
91. ur bolts T removed in Step 4 2 4 2 Changing Operation from LH to RH RH to LH 1 Invert the lock box as described in Section 2 4 1 See Figure 2 4 for correct positioning SM 6444 Rev 1 0 May 2008 2 5 NU 74 AnsaldoSTS Installation and Adjustment Union Switch amp Signal 2 Change the snow scraper and bearing bracket to the opposite side and reassemble per Figure 2 5 3 Remove the left hand lock rod and insert the right hand lock rod The rods are marked LH and RH See also Figure 2 6 LOCK BOX LOCK BOX MOTOR MOTOR END END R H NORMAL L H NORMAL Figure 2 4 Basic Positions of Lock Box BEARING BRACKET SCRAPER gt BRACKET WASHER SPRING WASHER HEX SCREW Figure 2 5 Snow Scraper and Bearing Bracket Installation 2 6 SM 6444 Rev 1 0 May 2008 N 74 AnsaldoSTS Union Switch amp Signal Installation and Adjustment RIGHT HAND LEFT HAND Figure 2 6 Left and Right Hand Adjustable Lock Rods 2 5 Point Detector Bar Installation and Adjustment Apply the point detector bar remove shipping closures in the housing and their connecting rods Adjust to check far and near switch point opening in accordance with AREMA Signal Section or railroad instructions When making adjustments be sure to work first with adjustments for the far switch point using the nuts on the track end of the far point detector bar then adjust for the near switch point working at the field en
92. ut M 3 Cotter 3 16 x 2 Tin PI a E Worm Shaft Cap Screw 1 47 20 Hex Head Tin PL Figure 5 1 Friction Clutch Assembly 5 5 5 Gearbox Removal Remove the gearbox by performing the following steps See Figure 7 1 1 2 5 6 Disconnect the pull knob from the yoke Remove the two screws on either side of the cotter key Item 435 that links the push rods and the motor cutout contact controls Remove the push rod Item 120 by holding it at the end nearest the motor compartment and pulling until the opposite end clears the pipe Item 140 Remove the push rod by lifting and pulling until the pin at the other end clears the hold in the side of the housing Remove the four screws Items 380 400 and 405 that secure the gearbox to the base Remove the cotter pin Item 440 1 8 nut Item 255 and steel collar Item 250 from the threaded top of the main crank Lift the gearbox from the base of the switch machine If further disassembly of the gearbox is required see Figure 7 3 SM 6444 Rev 1 0 May 2008 N 74 AnsaldoSTS Union Switch amp Signal Shop Maintenance NOTE Before proceeding with further disassembly of the machine review Sections 1 2 and 3 of this manual The information in these sections will aid in the final disassembly of the machine 5 5 6 Main Crank Removal NOTE The main crank can only be taken out of the bottom of the machine Removal of the main
93. wever no adjustment indication is given B Indication contact 1 Replace with new indication contact spring assemblies springs broken Refer to Section 5 6 5 3 C Obstruction 1 Remove the obstruction Check for damage to the switch between switch points points layout connecting rods and switch machine and stock rail 2 Cycle the switch machine several times to confirm normal operation of the switch machine Confirm that the switch points are against the stock rail D Point detector bar is broken Replace the point detector bar as follows Refer to layout drawing 1 Remove the connection to the point detector connecting rod Remove the broken point detector bar Check the switch machine for any visible signs of damage Replace with a new point detector bar The bar must slide freely in its bushings Reconnect the point detector bar to the point detector connecting rod Readjust the point detector bar to both near and far closed switch points E Point detector bar is out of adjustment Readjust the point detector bar Refer to Section 5 8 1 6 2 SM 6444 Rev 1 0 May 2008 74 AnsaldoSTS Union Switch amp Signal Shop Maintenance Problem Cause Solution F Point detector connecting rod is broken Replace the point detector connecting rod as follows 1 2 3 Remove the connection at the switch machine Remove the connection at the layout point dete
94. y relieving tension with a spring bender to break away from the contact spring at a load of 8 to 11 pounds 2 Check that clearance between the cam and the roller with the roller in the cam notch is 3 64 to 5 64 If not readjust the reinforcing spring to obtain the correct clearance and recheck the reinforcing spring breakaway load to make sure it is not greater than 11 pounds or less than 8 pounds 3 Check that the slotted ends of the contact springs Figure 3 8 Item M are in alignment bear evenly on fixed contact Item W and on the short circuiting strip and both contact springs of each pair make and break at the same time It may be necessary to slightly bend the contact fingers to meet this requirement 4 Check for a 1 8 minimum space between the end of the indication contact spring Item M and the short circuiting strip Check for 3 64 minimum clearances between the spring Item M and the fixed contact and between the spring M and the short circuiting strip No adjustment should be necessary to obtain these dimensions if the spring Item M is adjusted properly 5 With contacts at indicating position check the gap clearances at section Y for 3 64 to 5 64 and check the contact pressure between the indication contact spring Item M and the fixed contact with spring scale at section X to see if the pressure is 1 1 2 pounds to 2 1 4 pounds Adjust the reinforcing spring breakaway load if necessary to meet these requirements a

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