GM4000Aâ¢ Switch Machine - Alstom

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1.8. SAFETY PRECAUTIONS FOR MAINTAINERS.............................................. 1-321.8.1. General Requirements.................................................................................. 1-331.8.2. Proper Attire.................................................................................................. 1-331.8.3. General Safety on Property .......................................................................... 1-331.8.4. Safety at Track Side...................................................................................... 1-341.8.5. Safety at Switch Machines............................................................................ 1-352. SECTION 2 – THEORY OF OPERATION.............................................................. 2-12.1. INTRODUCTION ............................................................................................... 2-12.2. SEQUENCE OF OPERATION .......................................................................... 2-12.3. POWER OPERATION....................................................................................... 2-22.4. DRIVE TRAIN.................................................................................................... 2-32.5. NORMAL AND REVERSE LOCKING ............................................................... 2-42.6. POINT DETECTION.......................................................................................... 2-62.6.1. Latch Out ........................................................................................................ 2-82.6.1.1. Non-Electrical Restorable Latch Out...............................................................2-92.6.1.2. Mechanical Non-Restorable Latch Out .........................................................2-112.7. MANUAL SWITCH MACHINE OPERATION ................................................... 2-142.7.1. Hand Crank Operation .................................................................................. 2-142.7.2. Hand Throw Operation.................................................................................. 2-172.7.3. Local Operation ............................................................................................ 2-193. SECTION 3 – INSTALLATION............................................................................... 3-13.1. GENERAL ......................................................................................................... 3-13.2. GM4000A SWITCH MACHINE ORDERING...................................................... 3-13.3. PROPERTY’S REQUIREMENTS...................................................................... 3-13.4. WARNINGS....................................................................................................... 3-23.5. COMPONENTS................................................................................................. 3-33.6. TOOLS .............................................................................................................. 3-43.7. INSTALLATION ................................................................................................. 3-53.8. SWITCH MACHINE INSPECTION .................................................................... 3-73.9. SWITCH LAYOUT INSPECTION ...................................................................... 3-93.10. LEFT-HAND OR RIGHT-HAND CONFIGURATION........................................ 3-103.11. SWITCH MACHINE MOUNTING .................................................................... 3-183.12. ELECTRICAL WIRING .................................................................................... 3-193.12.1. Field Wiring................................................................................................... 3-203.12.1.1. Field Motor Control Wiring..........................................................................3-213.12.2. Controller Wiring Configuration Options........................................................ 3-233.12.3. Switch Machine Wiring.................................................................................. 3-263.13. SWITCH MACHINE HARDWARE INSTALLATION AND ADJUSTMENT ....... 3-273.14. THROW ROD INSTALLATION AND ADJUSTMENT ...................................... 3-293.15. LOCK ROD INSTALLATION AND ADJUSTMENT.......................................... 3-323.16. POINT DETECTOR ROD CONNECTOR INSTALLATION ANDADJUSTMENT ................................................................................................ 3-343.17. MOTOR LIMIT ADJUSTMENT ........................................................................ 3-373.18. SWITCH MACHINE VERIFICATION............................................................... 3-393.19. APPLY TOPCOAT OF PAINT TO THE SWITCH MACHINE EXTERIOR ....... 3-40P2496, Rev. 6, Jul/11 ii Alstom Signaling Inc.
3.20. OPTIONAL SWITCH MACHINE AND LAYOUT SENSING KIT ...................... 3-413.21. OPTIONAL TEST BAR INSTALLATION AND REMOVAL............................... 3-443.22. OPTIONAL SECONDARY POINT MONITOR INSTALLATION....................... 3-474. SECTION 4 – PREVENTIVE MAINTENANCE ....................................................... 4-14.1. GENERAL ......................................................................................................... 4-14.2. INTRODUCTION ............................................................................................... 4-14.3. PREVENTIVE MAINTENANCE INDEX............................................................. 4-24.3.1. Special Tools and Test Equipment ................................................................. 4-34.3.2. After Flooding ................................................................................................. 4-54.3.3. Warnings......................................................................................................... 4-64.4. EVERY 7500 OPERATIONS (OR SEMI-ANNUALLY, WHICHEVER COMESFIRST)............................................................................................................... 4-74.4.1. 7500 Operations Switch Machine Lubrication................................................. 4-74.5. MONTHLY MAINTENANCE .............................................................................. 4-94.5.1. External Switch Machine Inspection ............................................................... 4-94.5.1.1. Hand Crank Cutout Operation Verification....................................................4-114.5.2. Hand Throw Operation Verification............................................................... 4-134.5.3. Primary Point Detector Verification ............................................................... 4-164.5.4. Secondary Point Detector Verification (Optional).......................................... 4-174.5.5. Point Pressure Test ...................................................................................... 4-194.5.6. Switch Obstruction Test ................................................................................ 4-204.5.7. Latch Out Verification Test............................................................................ 4-274.6. QUARTERLY MAINTENANCE........................................................................ 4-284.6.1. Internal Switch Machine Inspection............................................................... 4-284.7. SEMI-ANNUAL MAINTENANCE ..................................................................... 4-324.7.1. Back Linkage and Gear Box Lubrication....................................................... 4-324.8. ANNUAL MAINTENANCE ............................................................................... 4-344.8.1. Switch Machine Lubrication .......................................................................... 4-344.9. AS REQUIRED MAINTENANCE..................................................................... 4-354.9.1. Lock Rod and Point Detector Adjustments ................................................... 4-354.9.2. Point Detector Rod Adjustment..................................................................... 4-374.9.3. Gear Box Lubricant Replacement................................................................. 4-404.9.4. Main Drive Roller Inspection ......................................................................... 4-414.9.5. Gear Box Output Shaft and Key Inspection .................................................. 4-415. SECTION 5 – TROUBLESHOOTING..................................................................... 5-15.1. GENERAL ......................................................................................................... 5-15.2. PHILOSOPHY ................................................................................................... 5-15.3. POSSIBLE SYMPTOMS AND CORRECTIVE ACTIONS.................................. 5-15.3.1. Symptoms Noticed from the Control Locations............................................... 5-25.3.2. Symptoms Noticed from the Wayside Locations, Standard Controller............ 5-35.3.3. Symptoms Noticed from the Wayside Locations, Enhanced Controller .......... 5-55.3.4. Controller LED Display.................................................................................... 5-75.3.4.1. Standard Controller LED Display ....................................................................5-85.3.4.2. Enhanced Motor Controller LED Display ........................................................5-95.3.4.3. Controller Fault .............................................................................................5-12P2496, Rev. 6, Jul/11 iii Alstom Signaling Inc.
Page 1: GM4000ASwitch MachineCopyright © 2
Page 5 and 6: LIST OF EFFECTIVE PAGESP2496, GM400
Page 7 and 8: PREFACENOTICE OF CONFIDENTIAL INFOR
Page 9 and 10: ABOUT THE MANUALThis manual is inte
Page 11: TopicTABLE OF CONTENTSPage1. SECTIO
Page 15 and 16: LIST OF FIGURESFigure No. Title Pag
Page 17 and 18: LIST OF TABLESTable No. Title PageT
Page 19 and 20: Table 7-1. Alstom Model GM4000A Swi
Page 21 and 22: General Description1. SECTION 1- GE
Page 23 and 24: General DescriptionMaintenance Free
Page 25 and 26: General Description1.4. FAIL SAFE F
Page 27 and 28: General Description1.6. SPECIFICATI
Page 29 and 30: General DescriptionOverload Protect
Page 31 and 32: General DescriptionHAND CRANK(GMA50
Page 33 and 34: General Description1.7.2. Cam Bar D
Page 35 and 36: General Description1.7.4. Controlle
Page 37 and 38: General Description1.7.7. DC Motor
Page 39 and 40: General Description1.7.10. Hand Cra
Page 41 and 42: General Description1.7.13. Hand Thr
Page 43 and 44: General Description1.7.16. Main Dri
Page 45 and 46: General Description1.7.19. Point De
Page 47 and 48: General Description1.7.21. Point De
Page 49 and 50: General Description1.7.23. Throw Ba
Page 51 and 52: General DescriptionCONFIGURATION JU
Page 53 and 54: General DescriptionWARNINGKEEP CLEA
Page 55 and 56: General Description1.8.5. Safety at
Page 57 and 58: Theory of Operation2. SECTION 2 - T
Page 59 and 60: Theory of Operation2.4. DRIVE TRAIN
Page 61 and 62: Theory of OperationPOSITION MARKERS
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Theory of OperationTable 2-1. Switc
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Theory of Operation2.6.1.1. Non-Ele
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Theory of Operation2.6.1.2. Mechani
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Theory of OperationTable 2-3. Reset
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Theory of OperationTable 2-4. Hand
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Theory of Operation2.7.2. Hand Thro
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Theory of Operation2.7.3. Local Ope
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Installation3. SECTION 3 - INSTALLA
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Installation3.5. COMPONENTSDependin
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Installation3.7. INSTALLATIONDetail
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Installation3.8. SWITCH MACHINE INS
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Installation3.9. SWITCH LAYOUT INSP
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InstallationTable 3-4. Switch Machi
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Installation3.12. ELECTRICAL WIRING
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Installation3.12.1.1. Field Motor C
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Installation3.12.2. Controller Wiri
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InstallationMOTORCONTROLLERHC-11J2B
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Installation3.13. SWITCH MACHINE HA
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Installation3.14. THROW ROD INSTALL
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InstallationTable 3-9. Throw Rod In
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InstallationTable 3-10. Lock Rod Co
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InstallationTable 3-11. Point Detec
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Installation3.17. MOTOR LIMIT ADJUS
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Installation3.18. SWITCH MACHINE VE
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Installation3.20. OPTIONAL SWITCH M
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InstallationTable 3-15. Throw Rod P
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InstallationTable 3-16. Test Bar In
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Installation3.22. OPTIONAL SECONDAR
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InstallationTable 3-17. Secondary P
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Preventive Maintenance4. SECTION 4
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Preventive MaintenanceNOTEOne opera
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Preventive Maintenance4.3.2. After
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Preventive Maintenance4.4. EVERY 75
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Preventive Maintenance4.5. MONTHLY
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Preventive Maintenance4.5.1.1. Hand
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Preventive Maintenance4.5.2. Hand T
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Preventive MaintenanceTable 4-5. Ha
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Preventive Maintenance4.5.4. Second
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Preventive Maintenance4.5.5. Point
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Preventive MaintenanceTable 4-9. Na
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Preventive MaintenanceTable 4-9. Na
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Preventive MaintenanceTable 4-10. W
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Preventive Maintenance4.5.7. Latch
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Preventive MaintenanceTable 4-12. I
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Preventive MaintenanceTable 4-12. I
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Preventive MaintenanceTable 4-13. B
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Preventive Maintenance4.9. AS REQUI
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Preventive Maintenance4.9.2. Point
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Preventive MaintenanceStepTable 4-1
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Preventive MaintenanceTable 4-18. G
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Troubleshooting5. SECTION 5 - TROUB
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Troubleshooting5.3.2. Symptoms Noti
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Troubleshooting5.3.3. Symptoms Noti
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Troubleshooting5.3.4. Controller LE
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Troubleshooting5.3.4.2. Enhanced Mo
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Troubleshooting5.3.4.2.2. Motor Fau
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Corrective Maintenance6. SECTION 6
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Corrective Maintenance6.2.2. Cross
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Corrective MaintenanceTable 6-3. Co
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Corrective MaintenanceTable 6-4. DC
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Corrective Maintenance6.2.5. Main D
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Corrective MaintenanceTable 6-5. Ma
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Corrective Maintenance6.2.7. Cam Ba
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Corrective Maintenance6.2.8. Hand T
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Corrective Maintenance6.2.9. Hand C
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Corrective MaintenanceTable 6-9. Ha
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Corrective MaintenanceStepTable 6-1
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Corrective MaintenanceStepTable 6-1
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Corrective MaintenanceTable 6-10. H
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Corrective Maintenance6.2.12. Lock
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Corrective MaintenanceTable 6-13. P
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Corrective Maintenance6.2.14. Point
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Corrective Maintenance6.2.17. Throw
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Corrective Maintenance6.2.18. Throw
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Corrective Maintenance6.2.19. Conde
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Corrective MaintenanceTable 6-21. M
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Parts Catalog7. SECTION 7 - PARTS C
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Parts CatalogNOTE 1:- STAMP NAME PL
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Parts Catalog2.006.50 7.5020.00 2.8
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Parts CatalogABCDSWITCH MACHINESHEE
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Parts Catalog29LOCK RODCOMPLETEDETE
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Parts CatalogTable 7-1. Alstom Mode
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Parts CatalogTable 7-2. GM4000A Con
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Parts CatalogFigure 7-2. Alstom Mod
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Parts CatalogDBACEGFHFigure 7-3. To
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DrawingsA. APPENDIX A - DRAWINGSA.1
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DrawingsA.2.2.3-Wire Configuration
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DrawingsA.2.3.3-Wire Configuration
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Drawings16 to 160 VDCOR85 to 140 VA
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DrawingsFigure A-8 shows typical ci
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DrawingsA.2.7.Secondary Point Monit
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DrawingsTypical Polarized Switch Re
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DrawingsTypical Polarized Switch Re
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DrawingsA.2.9.Typical Neutral Switc
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DrawingsTypical Neutral Switch Repe
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DrawingsA.2.10. GM4000A Wiring Diag
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DrawingsFigure A-20. GM4000A Wiring
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GM4000Aâ¢ Switch Machine - Alstom

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GM4000Aâ¢ Switch Machine - Alstom