ELECTRIC SWITCH MACHINE YM·4· OVERLOAD CUTOUT RELAY 4.6 TRAILING OPERATION V ... W'l t t:1 Ope t'"l t L ng 'L't; ... wiring diagram applying to the particular location

SERVICE MANUAL 6231

ELECTRIC SWITCH MACHINE YM·4

DUAL CONTROL, TRAILABLE

THIS MANUAL SUPERSEDES SM-6231 DATED OCTOBER, 1982

November, 1986 (Rev. 1/87)

ID1149A/DN0007A

D 11/87-75-2430-3 UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD INC I PITISBURGH, PA 15237

SERVICE MANUAL 6231



THIS MANUAL SUPERSEDES SM-6231 DATED OCTOBER, 1982


ID1149A/DN0007A

D 11/87-75-2430-3 UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD INC I PITISBURGH, PA 15237

UNION SWITCH & SIGNAL

REVISIO~ INDEX

This service manual supersedes all J?reviously issued 6231 manuals, and has been reissued to provide new and/or corrected data. l)estroy all previously issued 6231 manuals. Future revisions to this manual will be handled by addendum, wherein a Revision Index page will be provided listing all revised oages.

?l\GE '3-8

REVISED 1/87

. J

contents section

I GENERAL INFORMATION

1.1 INTRODUCTION 1.2 DESCRIPTION 1.3 SPECIFICATIONS

1.3.1 Physical Characteristics 1.3.2 Operating characteristics 1.3.3 Electrical Data for components

II INSTALLATION AND ADJUSTMENT

2.1 GENERAL 2.2 MOUNTING 2.3 HANDLEVER CUTOUT SWITCH 2.4 SWITCH ROD ADJUSTMENT 2.5 ELECTRIC AND CONTROL ADJUSTMENTS

2.5.1 Motor Limit and Indication switch 2.5.2 Electromagnetic clutch Adjustment

2 .6 INI'rIAL LUBRICATION

[[I OPRRATION

3.1 MODES OP OPERATION 3.2 MANUAL OPERATION

IV OPERATING PRINCIPLES

4.1 GEl\lERAL 4.2 SWITCH OPERATING MECHANISM 4.3 MANUAL OPERATION 4.4 HANDLEVER CUTOUT DEVICE 4.5· OVERLOAD CUTOUT RELAY 4.6 TRAILING OPERATION

V FIELD MAINTENANCE

5.1 GENERAL

VI SHOP MAINrENANCE

6 .1 GENERAL 6.2 BEVELED GEAR WEAR PATTERN 6.3 ALTERNATE BEVELED GEAR ALIGNMENT

VII RECOMMENDED TOOL LIST

VII[ DIAGRAMS

APPEN!HX A PARTS LIST

i


Page

1

l l 1 1 1 2

5

5 5 6 6 8

Adjustment 8 9

10

12

12 12

u

11 13 13 15 16 16

17

17

18

18 18 18

21

22

m UNION SWITCH & SIGNAL

,,rr

Withbut Position Indicator Lights /

With Position Indicator Lights YM-4 oual Control Electric switch Machine

ii

1.1 INTRODUCTION

SECTION I GENERAL INFORMATION

UNION SWITCH & SIGNAL ffi

The YM-4 is a trailable, dual control electric switch machine for rail transit systems and yards where an electrically powered machine is required. It is designed for use in transit yards, receiving and departure areas of classification yards, industrial sidings and flat switching or storage yards.

1.2 DESCRIPTION

The mechanism of the YM-4 is totally enclosed in a weatherproof all steel case measuring, with standard cover, 13-1/16" high x 12-7/8" wide x 43-1/2" long. Mounting lugs are provided on both sides of the case for firmly securing the machine between the ties, providing a mounting arrangement that lowers the machine profile to 7-5/16" above the top of the ties. The same machine and operating rod can be used in right hand or left hand applications. The typical YM-4 track layout has a straight operating rod which connects to the basket. The stroke of the operating rod is internally adjustable from 3-1/2" to 6" and allows the YM-4 to be utilized with different switch throws.

The major components of the YM-4 switch machine (Figure 1-1) are the case, motor/clutch/gearbox/main shaft assembly, main crank assembly, toggle spring assembly, hand-throw assembly, and controls/wire harness.

Two pairs of independently adjustable control switches are provided. One pair consists of SPDT switches which are used in a holding circuit, and one pair Jf DPDT switches which are used for motor cutout, non-vital point indication, and local indication (lights). (Also optional with NWP/RWP relay control.)

A hand throw lever is provided to operate the switch machine when manual operation becomes necessary, or desired.

An optional cover is available with position indicator lights (bulbs are to be ordered separately.) Either cover can be removed to provide conveniP.nt access for maintenance and adjustments.

The serial number is stamped on the mounting flange (see Figure 1-1).

1.3 SPECIFICATIONS

1.3.1 Physical characteristics

a. Overall Dimensions b. Weight (Approx.)

1.3.2 Operating Characteristics

a. Stroke b. Operating Time c. Force on Switch Rod,

Extreme Position a. Trailing speed

see Figure 1-2 450 pounds

Adjustable from 3-1/2 to 6 inches 2 seconds 1,000 pound minimu~

5 MPH Max.

6231, p. l


l.3.3 Electrical D~ta

a. Motor

Voltage Horsepower Hz Phase Current:

Full Lo11d

115 VAC 1

60 1

14.6

230 VAC 1

60 l

7.1

115 VDC l

10.0 In Rush

Clutch Slip (Max.) 42.0 (lOOm sec.) 16.0

28.5 (125m sec.) 8.0

44.0 (200m sec.) 12.5

* Motor will op·er9.te s9.tisfoctorily on volt9.ges within 10% of m.mepl9.te V9. lue.

b. Reversing Contactor - AC Control (115 VAC) (Contactor will operate at 70% of rated voltage.)

R9.ting Coil Current Cont'lcts@ ll5 volts 9.C Auxili'lry Cont'3.cts@ 115 volts ac

c. Reversing Contactor - DC Control

1 HP 150 Mill hmps

15 Amps 5 Arnps

(Contactor wi.11 oper'3.te at 80% of nomin<il volhge with 10% overload.)

24-28Vdc

Rating 1 HP Coil Current Voltage (Minimum) Cont9.cts

.192 Amps 22.5Vdc 15 Amps

Auxili~ry Contacts 5 Amps

d. Control '3.nd Indic9.tion Switches Sl, S2, SL, SR Type: 3n'3.p Action Switches (SPDT, DPDT) Rating - 10 Amps@ 125/250 VAC

e. Clutch

Vibration Resistance 25G's@ 2,000 CPS M:ech'lnic<i l [,ife 10,000,000 Cycles Minimum Elec. Life 750,000 Cycles Overtr'3.vel 0.015 Min. Release Force 4 oz. ~in. Ambient Temp. R<:1.nge -65°F to 275°F

121/dc

1 HP .375 Amps

9.6 Vdc 15 Amps

5 Amps

Volt'l.ge 90 VDC Rated (Oper'3.ted from Clutch OperSJ.ting Volt9.ge

DC or rectified 28 Vdc + 2Vdc 452

AC)

Resist·rnce (Ohms) Amps W'l t t:1

Ope t'"l t L ng 'L't;rnp. Be 1 r ing:1

6231, p. 2

0.199 ·=i.t 90 Vdc l8 -80°1'' to JOIJ') [•'

"CS . w

HAND THROW ASSEMBLY

FROST HEATER AND TOGGLE SWITCH

(OPTIONAL)

TERMINAL STRIP

MOUNTING FLANGE/

LIFTING HOLE

Figure 1-1. 115V AC YM-4 Electric ·switch Machine, Internal View, cover Removed

c z 0 z I ; • 0 i5 z > r-


20" I

r 12-7/8"

, _____ 10"---- 13/16" DIA.

I I

-;-0

3-9/16" fl__

I ____ T_·_-e-______ :.112·-·-511

-------~---i-l

6231, p. 4

CENTER OF TIE

• 1

I

. f I I / '

V ' I !

22" --------~

CENTER OF TIE

Figure 1-2. Mounting Dimensions

_,

2. l Gt:;NEHAL

SEC'l'.LON 11

lNS'l'ALLA'l' !ON AND ADJUSTl•1EN'r


A tyf:-)1.c..:a.1 ttack. Layout µlan ut the YM-4 °,;witch machiri~ 1.s ::;huwn 1.n £,'igure 8-2 with opt.:.ona:.. U:, circuit controller and junction box. Detail. 111ocmt1.ng plans a1.,prov•::d by the railroad shoui.d be followed when installing the n1<.1chine. No special toul.s are required for instaliatiou. Mounting dimensions for the switch machin(~ are sho.vn .u1 :r~igure l-2. ARFA yard signal equipment clearance diagram 1s shown 1.n Fi.gur~ 2-l.

2. 2 t10UN'l'1NG

AREA YARD SIGNAL EQUIPMENT CLEARANCE DIAGRAM

YM-4 WITH POSITION INDICATOR LIGHTS

---,fri

AREA YARD SIGNAL EQUIPMENT CLEARANCE DIAGRAM

YM-4 WITHOUT POSITION INDICATOR LIGHTS

r'iyure 2-1. Clearance Diagram

Ai:t:tr the 111achine has been properly assembled for the lHyout, f:Jroceeu as fol lows:

NO'rE 'l'he throw of the machine is r ecornmended to be .i..-inch greuter than the th.co..1 of the poi11ts.

a. Place the rubber boot (bellows) 1.tr~m 32, Figure A-1 (in the Appendix) on the operat1.ng rod, having the open e11d facing aw;,y from the Gwitch.

b. P.i.ctce t;1e metal bracket, 1.tem 33, OV<.!t top ot th~! rubber hoot.

c. ln:;ta.L.1. rod on switch auJuster bracket.

c.1. Sliue operating rod through opening in case and mate with the eyebolt.

6231, p. ~


e. Mount ci:1d fasten the machine un ties .in accurdance with luyout }Jlam; applyi.1y to the particular location.

i:. Con11ect the external wir 1ng to the terminal boara in accordance with the wiring diagram applying to the particular location. Main terminal board wiring scher.1e 1.s stia.vn in Figures 8-3 throug:1 9-9. Approved wiring plan:; should be foll.ow,~ for actual wiring. However, these aiagr ams can serve as an &iu in developing th~ master pld;)S.

g. Adjust the eyebolt according to t::1e total movement of the switch points. l<efer to Figure 2-2, anct proceed as follows:

l. Rerer to the table in F.1.gure 2-2 and determine "A" dimension. "A" a:.mension wil.L vary depending on thra,., uf points. .r'or exam?le, 1 t the throw of the points is 4-3/4 inches, "A" uimension shou.!.<1 be 3. 95 inches.

2. Adj..ts t eycbol t to proper "A" di.mens io,1 by turuiny eyebo!. t in or out. "A" dimension i::; the distance from the mach1i11::ct sur tace ot the s!ia. ft lo the t1. p o i the 12yebo.L t.

h. Attach the operating rod to the adjustable eyebolt with pin provided. Secure \vith cotter pin.

i. Att<.1:;h meta.l urdcket and rubbt:r boot to ca~e with screws that dre holcting the sh,pprng 1,1latc.· over the case opening.

2. 3 HA.ND LcVEl{ CU'l'OU'l' Sr~ l'l'CH

a. Check tht! a<.1Juctme11c of the hano-lever cutout switch to make certain the switch uperates as the foot-pedal is depressed. '1'::1e ::;witch muse "cli.ck" before the top uf the foot-pedal clears the hand-throw lever to assure that simultaneous handlever and power operation ';'ill not occur.

b With tne hand-tht aw lever out of the foot-pedal stand, try to close the foot-peual to make sure the pedal will not close and the switch does not 11c.:.1ck ti.

2. 4 SW l'l'CH i<UlJ AUJUS'l'MEN'l'

WARN!NG

\'Jhile making switch rod adjustments, make sure the handlever cutout switch is operating per paragraph 2.3 anc. foot-1,1eual is rully depressed. inadvertent operation could cause personal injury.

/\lt.t.!r the switch nuchine hal::> oeen instal.leo c1nd wirco in <1ccurd<.1nce with the Lippruv,.Jd swi.tch plans, 1c mm;t be adjusted to obtai11 proper operation and uevcloµ the, 1 equ.ueu turc;es 011 the uperat111g rod. Use the following procedure to µroduct.• the :;i'ec1i11]d ho1d1ny Loree 011 the switch rud (::;ce k'1gure H-2).

a. ::ict ths: tl,.mdiever Ho the opera ting rod is in the ti in" pos i. t1on .:.in.J r.he switch t,1:J.u1t against the near rail. 'l'ighten the far basket nut until au the sli.tck 1s 1. emoveu from the switch rou com2(Jtwn ts.

6131, p. 6

.·

UNION SWITCH & SIGNAL m Throw Recommende1 Play Throw of

of Points In Basket (Total) "A" Dim. Machine

Inches "Inches Inches

2 1" 2 3 2-1 /4 1" 2.18 3-1/4 2-1/2 1" 2.36 3-1 /2 2-3/1~ 1" 2.54 3-3/4 3 1" 2. 71 4 3-1/4 1" 2.89 4-1/4 3-1/2 1" 3.01 4-1/2 3-3/4 1" 3.25 4-3/ 1~

4 1" 3.43 5 4-1/4 1" 3.60 5-1/4 1~-1 /2 1" 3. 78 5-1/2 1~-3/4 1" 3.96 5-3/4 5 1" 4 .14 6

DIM.A

1

Note: Adjust "A" Dimensiori to Corresponding Throw of Points

Fi.gure 2-2. Machine Stroke Adjustment

623 1, p. 7


b. Move the oper'3. tiag rod to the "out" position with the hand lever 'lnd move the switch points against the far rail. Tighten the near basket nut until all the slack is removed from the switch rod components.

c. Return the operating rod to the "in" position by the handlever. Thls should move the near point up against the ne3.r stock r'3.il. Tighten the f"l.r basket nut until the main crank has rotated approximately 5 degrees.

d. Fasten the opers.ting boot to the operating rod with the band clamp. Compress the boot to a comfort9.ble position in toward the machine.

e. [fove the operating rod to the "out" position by the handlever. Check to make sure the boot is not overextended. Tighten the near basket nut until the main cr3.nk has rotated approximately 5 degrees.

f. Operate the switch several times by hand to see if the tensiou is m3.i.ntained. If it is, tighten the basket lock nuts and again check for tensions.

2.5 ELECTRIC AND CONTROL ADJUSTMENTS

After completion of the switch rod adjustments described in paragraph 2-4, check the motor limit '3.nd inclication switches as follows (these switches ·1re preset at the factory):

2.5.l Motor Limit and Indication Switch Adjustment

a. Loosen button head cap screw on four cams on the miiin crank (item 14, "Figure A-1).

b. lfotate cams to ins11re limit switches "click" on and off.

c. If switches don't click, loosen the two 1/4-20 nuts and bolts 3.nd adjust the switches in or out from the cr11nk until the cams will activate the appropriate switch. Tighten the 1/4-20 nuts and boltr3.

Note

Maintain proper over travel on switch after adjustment (See paragraph 1.3.3.d.).

d. Throw the switch machine so the main crank is at mid-stroke (toggle point). Rotate the two inside cams for switch Sl and S2, to activate, (deactivate) the switches simultaneously, then tighten screws.

e. Complete stroke to the "out" position. Rotate the cam, for switch SL, (c·lse side), to '3.ctiv-ite switch. Rotate cam <.1.n addition'll 10°.

r. H•1nd th,·uw thn ffi'lchino to tho "in" po3i.tion or ttw m~1ln cr:111k. Rot,1to the c~m, for switch SR, (on the ge'lr side), to ~ctivat~ the switch. Rotate the c':l.m an addition'3.l 10°.

g. Tighten the (4) four button head cap screws.

UNION SWITCH & SIGNAL m 2.5.2 Electromagnetic clutch Adjustment

a. Clutch Operating Voltage

CAUTION

THE FOLLOWING MEASUREMENTS ARE MADE WITH THE MACHINE IN OPERATION. BE CAREFUL NOT TO COME IN CONTACT WITH ANY MOVING PARTS OR ELECTRICAL TERMINAL POSTS.

NOTE

Step 1 is needed only on 230 volt machines.(N451613-0103,-0107,-0lll)

1. Measure the line voltage across AAR terminals 13 and 15 with the machine in operation.

NOTE: Make several measurements to confirm readings.

2. Measure the DC clutch operating voltage, (+) lead to clutch wire on variable resistor (-) lead to Pin 1 on base of plug-in power supply (see Figure 2-3 for Pin 1 reference).

0 0

0 8 8

0 0 0 8 CLUTCH MINUS(·) TEST POINT

0

Figure 2-3. Top View of Octal Socket Pin Layout

6231, p. 9


For all 115 VAC and 115 voe machines, the clutch voltage is in within tolerance if it is 28 + 0.2 Vdc.

For the 230 VAC machines (N451613-0103, -0107 and -0111), the clutch voltage is in tolerance if it falls within the limit shown in Table 2-1.

Table 2-1

AC Input Voltage DC clutch voltage

200 - 205 26.0 - 26.7 205 - 210 25.7 - 27.3 210 - 215 27.3 - 27.8 215 - 220 - NOMINAL - 27.8 - 28.2 220 - 225 28.2 - 28.7 225 - 230 28.7 - 29.2 230 - 235 29.2 - 29.8 235 - 240 29.8 - 30.0

b. Clutch Voltage Adjustment

1. The clutch voltage may be adjusted by removing power from the switch machine and relocating the position of the slider on the wirewound resistor (item 71 on page A-5/A-6 or B-5).

2. Re-test the clutch voltage to verify that the voltage is wit~iA limits of 28 + 0.2 voe for 115 volt machines, or Table 2-1 for 230 volt machines-:-

.NOTE: Be sure to tighten the set-screw on the resistor slider when final adjustment is complete.

2.6 INITIAL LUBRICATION

Before leaving the factory, all working parts of the machine are well lubricated. Unpainted and unplated parts are coated with a special lubricant designed to protect these parts against corrosion.

To insure reliable operation, lubricate the switch machine according to this section before placing in service. ouring service, lubricate at periodic intervals determined by the railroad. use the following lubrication chart.

6231, p. 10

UNION SWITCH & SIGNAL m LUBRICATION CHART

Point of Type of Application Lubricant Method Apply To

A. (6 Locations) Grease, Alemite M7650-0l Grease Gun Grease Fittings (A041089)

8. (2 Locations) Grease, stazon M M7652-2 Brush All gear tooth (A041477) surfaces

c. (1 Location) Machine Oil (lOW-30 Oil can Bushing, Pin or equivalent)

Figure 2-4. Lubrication Points

6231, p. 11


3.1 MODES OF OPERATION

SECTION IIT OPERATION

The switch machine has basically three modes of operation: power operation, hand-throw operation, and trailing operation.

a. The power mode electrically drives the main shaft 1aoo and rotates the main crank 90°.to move the operating rod and switch points.

b. The hand-throw mode manually operates the points the same as electrically by rotating the main shaft. But during the hand-throw operation, only the gearbox is driven. The motor is disconnected from the drive trai~ due to the electro-magnetic clutch. This clutch is only energized {engaged) when the motor is energized. The cutout switch will break the circuit to the motor reversing contactor preventing the motor from being energized.

c. When the switch points are trailed, the operating rod rotates the main crank, thus compressing the toggle spring to mid-stroke and then allows the toggle spring to complete the operation.

3.2 MANUAL OPERATION

To operate the YM-4 manually, follow this procedure:

1. Remove padlock from foot-pedal latch.

2. oepress foot-pedal to unlatch the hand-throw l~ver.

3. 1 Raise hand-throw lever and complete the movement to operate the switch. Note that slightly beyond mid-stroke, the spring toggle action becomes operative to complete the stroke.

4. Rotate lever counterclockwise and engage lever into latch stand and secure with lock.

The electric motor does not function during manual operation. And during electric operation, the hand-throw lever does not go through the cycle. The hand throw lever must be in its latch with the foot pedal closed during trailing operation {see paragraph 4.6).

6231, p. 12

4.1 GENERAL

SECTION IV OPERATING PRINCIPLES

UNION SWITCH & SIGNAL m

The switch points are either thrown electrically (refer to para. 4.2) or manually (refer to para. 4.3). The points are held in position by a 600J/in. toggle spring mounted on the main crank, which is compressed 1-2/3 inches. (NOTE: The clutch is deenergized (disengaged) when the motor is deenergized to facilitate trailing and hand operation.) The toggle spring maintains a minimum holding force to the closed points of 1,000 pounds. The switch throw is adjustable from 3-1/2" (with basket) to a full 6 inches. Operating time is approximately 2 seconds. Motor control and switch indication are obtained from contacts operated by cams on the main crank and are directly associated with the switch position.

The following paragraphs provide brief operating principles of the YM-4 Switch Machine. This information may be helpful in troubleshooting and maintaining the switch machine.

4.2 SWITCH OPERATING MECHANISM (See Figure 1-1)

The electric motor, controlled by an electromagnetic, reversing contactor, drives the gear box through an electromagnetic clutch. An output gear in the gear box meshes with the spur gear on the main shaft assembly, rotating the main shaft 180°. Through a set of bevel gears, the main shaft drives the main crank, rotating the main crank 90°. The operating rod, which is connected to the eyebolt on the main crank, is then driven a predetermined distance.

During the first half, (45°), of the switch operating stroke, the toggle sp~ing is compressed and the toggle mechanism is rotated to dead-center. As the machine continues, the toggle mechanism is driven past center, where upon the spring force assists the motor in completing the stroke. Since the holding force of the spring is equal to that used at spring switches, the motor is turned off and the clutch disengaged at the end of the stroke. The clutch is engaged only while throwing the switch by power.

4.3 MANUAL (HAND LEVER) OPERATION (See Figure 4-1)

Removal of the padlock from the foot-pedal latch and subsequent foot depression of the latch will unlatch the hand-throw lever. A plunger is directly connected to this latch which will, through a limit switch, interrupt the electrical circuit to the motor reversing contactor and open a circuit to inform the controller that the switch machine is in manual mode of operation. An external interlocking lever prevents accidental closure of the latch while the hand-throw lever is out of the lever stand. When the hand-throw lever is removed from its stand, the cam surface on the lever hub forces the interlocking lever in a clockwise direction, thus not allowing the latch stand to be closed.

6231, P• 13


B

A

B

~ < a.) ( b.> ---~-(d.) (C.)

D A

Figure 4-1. Disengagement Feature of the Hand-Throw Lever

6231, p. 14

UNION SWITCH & SIGNAL m The hand-throw lever rotates the main crank through bevel gears. Use of a disengagement collar on the main shaft permits the machine to complete its strol{e after the toggle spring goes over dead center, without reaction on the hand-throw lever. The h.9.nd-throw lever does not move d11ring power operation of the switch, '.llth.ough the main shaft does rotate. Figure 4-1 illustrates the disengagement fe3.ture of the hand-throw lever. With the hand-throw lever in the latch st-'lnd, the stud D in the lever hub is positioned in the rear tM.ck of the m9.in shaft-h9.nd-throw shaft collar P. Figure 4-1 (a) shows the stud Din this position and the hand-throw shaft in the position that corresponds with the switch operating rod in its "out" position (near switch point open). During oper'ltion of the hand-throw lever Figure 4-1 (a) and (b), lever stud D engages the colhr P, rotating the main shaft-hand-throw shaft clockwise. At slightly beyond mid-stroke, however, the toggle 'lction becomes effective in completing the switch st rol{e.

Through the crank and bevel ge1r arrangement, the main shaft, hand-throw shaft is thereby rotated the remainrier of the stoke by the spring force with no reaction on the lever. It should be noted that while the lever stud D is still in the rear track of the collar P, Figure 4-1 (b), the hand-throw lever can be returned to the latch stand without further operating the hand-throw lever. ~owever, continuation of the lever stroke (clockwise) from the position shown in (b) engages cam A on the lever hub with the shifting stud C, forcing the hand-throw lever out into the "out" position shown in Figure 4-1 ( c). Now stud D is Ln the ft'ont track: of the shi.ft collar and in <J. position to rotate the m9.in shaft, hand-throw shaft, when the lever is returned to the latch stand. The clockwisa stroke of the lev,=.lr Ls li.mited by the eng11gement of the flat surface of the cam A with stud D, Figure 4-1 (c).

In returnLne the h>1nd-throw lever to the latch stand, the oper'ltion is r3Lmihr to the clockwise stroke in th<J.t ·1gain at slightly beyond mid-stroke the toggle~ spring, through its ':lction on the main cr,:1.nk, completes the motion of the switch points and the rotation of the main shaft. As the h"lnd-throw lever is returned to the latch stand, cam Bon the lever hub engages with stud D, Figure 4-1 (d), forcing the lever back into its original position on t~e shaft, with stud D, Figure 4-1 (d), in the rear track of the shaft coll:'3.r. This allows the interlocking lever to rotate counter-clockwise to close the latch st9.nd and allow t~e machine to return to power operation.

4.4 HANDLEVER CUTOUT DEVICE

The handlever cutout switch, COS, is opened when the padlock is removed from the • handlever locking device and the device is pulled out to clear the bandlever.

This switch, COS, will break the electrical circuit thus preventing the motor reversing con tac tor to energize. This switch also supplies indication through :..11

open circuit that the machine is in the manual mode of operation. 'rhe handlever cutout switch can be locked in the open position by installing the p8.dlock behind the post pedal locking device, thus disabling the machine electrically.

6231, p. 15


4.5 OVERLOAD CUTOUT RELAY

~ thermal overload ambient compensated relay senses continuous motor current. If the clutch slips for any reason before stroke completion, the overload relay is designed to remove power from the motor and clutch via the reversing contactor, approximately 2 minutes after the start of the switching cycle. The overload relay heater can be sized to increase or decrease the approximate 2 min. trip time. Once the overload relay has actuated, it will recycle in approximately 3 minutes.

The overload can be set for either automatic or manual operation. In automatie operation, the overload relay will automatically reset itself: in manual operation, the relay must be reset manually.

4.6 TRAILING OPERATION

Trailing a switch equipped with a YM-4 machine merely reverses the mechanism. In doing so, the toggle spring is driven over dead center by the main crank. oepending upon the control scheme used, power may or may not be admitted to the electric motor. Regardless of whether power is admitted, the toggle spring force at first opposes the initial shift of the switch points, the same as at an ordinary spring switch, but unlike action at the latter, the force required to throw the switch decreases as the switch points approach mid-stroke. ouring the last half of the stroke, the toggle spring assists the shift to point closure.

6231, p. 16

CAUTION

The YM-4 switch machine is designed to operate in 2 seconds. Therefore, the trailing speeds should

not force the machine to throw in less than 2 seconds(5 MPH). Trailing speeds in excess of this

time will produce abnormally high forces within the machine, thus decreasing the life of the machine.

To avoid personal injury or damage to the machine, the hand throw lever must be in its latch with the

foot pedal closed during trailing operation.


5.1 GENERAL

SECTION V FIELD MAINTENANCE

This section outlines recommended procedures for periodic inspection and maintenance of the YM-4 switch machine.

WARNING

Remove all operating power at the nearest local breakpoint to avoid personal injury.

1. connection to the switch points, including the holding force of switch rod, should be checked for proper adjustment. Refer to paragraph 2.4.

2. Check to insure all bolts are tight inside the switch machine, i.e., (8) bolts holding plates for main crank, (2) bolts for toggle spring, (4) bolts for hand-lever support, (4) bolts for gear box, (1) cotter pin for toggle spring.

3. Periodically check the "electrical and control adjustments, paragraph 2.5, and hand-lever cutout switch, paragraph 2.3, for proper operation in accordance with instructions.

4. No maintenance can be performed on the internal components of the motor. Motor oiling is only required once every 5 to 10 years.

5. Lubricating the switch machine at periodic intervals is essential. The frequency of lubrication should be determined by experience and specific applications and amount of operations. Minimum lubrication should occur not less than once every 6 months, more frequent might be necessary in specific applications. Refer to paragraph 2-6 and Figure 2-4.

6231, p. 17


6.1 GENERAL

SECTION VI SHOP MAINTENANCE

Shop maintenance consists of restoring a damaged switch machine to an operable state. This is accomplished by repairing and/or replacing damaged parts. Refer to the parts list for ordering information and the lowest replaceable unit. The exploded view in the parts list section will aid in disassembling and reassembling the switch machine.

6.2 BEVELED GEAR WEAR PATTERN

Mar~ the teeth of the two beveled gears of the crank assembly with a suitable marking compound. Throw the switch machine a few times. Check the contact pattern as shown in Figure 6-1. Gears are cut with a contact pattern about half the length of the tooth, the location slightly favoring the toe end of the tooth. Under load the pattern will shift somewhat toward the heel of the tooth, and will thus become more central. Under no circumstances must the pattern be concentrated on the ends of the teeth. If an adjustment is needed, the crank assembly (Item 14, Figure A-1) can be adjusted by loosening the eight mounting bolts (17) and repositioning the crank.

The bevel gears are mated together as shown in Figure 6-2. Notice that the prick points in both gears are in alignment. Should maintenance be required that separates the bevel gears, re-assemble the machine with prick points aligned for proper gearmesh. In the event that the prick points have been worn off, see paragraph 6.3 for an alternate method of aligning the bevel gears.

6.3 ALTERNATE BEVELED GEAR ALIGNMENT

Referring to Figure 6-3, mate the first gear tooth of the half moon segment gear (as viewed from the operating bar end) with the seventh groove counterclockwise from the keyway of the pinion gear.

6231, p. 18


Desirable Bearing Pattern

PROFILE ERROR To correct: decrease mounting distance

~ CONVEX SIDE LOW HEEL CONTACT

ERROR-j r-,,... _ -,f~---

_/ l -~-

"1:-,~' 1 -= ~ .tt:: - l CONCAVE SIDE ~... LOW TOE

CONVEX SIDE CONCAVE SIDE CONTACT HIGH TOE HIGH HEEL CONTACT CONTACT

CROSS CONTACT To correct: move pinion down

~ CONVEX SIDE HEEL CONTACT

-'$ ""\

CONVEX SIDE TOE CONTACT

"'\f----,. ~

CONCAVE SIDE HEEL CONT ACT

CONCAVE SIDE TOE CONTACT

.SHAFT ANGLE ERROR To correct: decrease shaft angle

~ CONVEX SIDE TOE CONTACT

~ CONVEX SIDE TOE CONTACT

,tr ERROR CONCAVE SIDE ~ TOECONTACT

CONCAVE SIDE TOE CONTACT

PROFILE ERROR To correct: increase mounting distance

ERROR~-~-~

_/ . ·, .. J\~

~CONVEX SIDE HIGH TOE CONTACT

~ CONVEX SIDE LOW HEEL CONTACT

CROSS CONTACT

~ ::==-; CONCAVE SIDE +,:::l HIGH HEEL

CONCAVE SIDE CONTACT LOW TOE CONTACT

To correct: move pinion up

~ ~ ..

CONVEX SIDE HEEL CONTACT~

~ CONCAVE SIDE TOE CONTACT

CONVEX SIDE TOE CONTACT

CONCAVE SIDE HEEL CONTACT

SHAFT ANGLE ERROR To correct: increase shaft angle

· ERROR

Jt;;-:;\, CONVEX SIDE HEEL CONTACT

CONCAVE SIDE HEEL CONTACT

CONVEX SIDE CONCAVE SIDE HEEL CONTACT HEEL CONTACT

Figure o-1. Beveled Gear Pattern

6231, p. 19

'12JI. o. 20 ?igure •-2 Beoe1 Gear Al!gnmen,

Viewed from operating bar end of the machine, mesh the first tooth of the half-moon gear into the seventh groove of the pinion gear. This groove is located by starting at the keyway and counting seven positions in a counter clockwise direction.

NOTE: Rotate gears to verify that the prick points align. CRANK GEAR SEGMENT

Figure 6-3. Alternate Bevel Gear Alignment


OPERATING...._ ARM~

6231, p. 20A

7.1 GENERAL

SECTION VII RECOMMENDED TOOL LISJ


The following tabulation is~ list of tools required for servicing the YM-4 Switch Machine. The part number provided is a Snap-On number but any equivalent tool may be used (tools are not supplied by US&S).

Snap-On Description Pa.rt No.

Screw Driver .037 x 1/4 Tip 4" Blade SSD4 .032 x 3/16 Tip 2-7/8" Bla1e SSD2

Combination Wrenches 1/2" OEB 160 9/16" OEX 180 11/16" OEX 220 3/4" OEX 240

Ratchet 3/8" Drive F723

Ex:tension 3/8" Urive x 12" FXll

Sockets 1/2" FS161 9/16" FSl81 ~

11/16" FS221 3/4" FS241

Hex Key Wrench 1/8" AWL4

"T" Handle Hex Key Wrench 1/8" GA.Wl608

Adjustable Wrench 6" DA.26

Adjustable Wrench 10" DA.210

Retaining Ring Pliers w/Right Angle Tip PR349A

Slip Joint Pliers 46

Ball Peen Hammer BP20A

A.AR Wrench

'forque Wrench - 15 lt'oot Pound Mid-Range

3/8" Drive Hex Bit Hollier with a 4-Inch x 5/32 Hex: BLt

-·---

6231. p. 21


SECTION VIII DIAGRAMS

The following diagr~ms are included in this section.

Figure 8-1. Timing Diagram

Figure 8-2. Typical Layout, RH or LH YM-4 Switch Ma.chine Applied to Insulated 16'-6" Single Split Switch, #15 Turnout

Figure 8-3. Typical Circuit Diagram for 115 VAC Machine, 115 VAC Control YM-4 Switch Machine.





l<'igure 8-8. Typical Circuit Diagram for 115 VDC Machine, 24-28 VDC Control YM-4 Switch Machine.

l<'igure 8-<). Typical Circuit Diagram for 115 VDC Machine, 12 VDC Controi YM-4 Switch r.fachine.

~ L

-SL

~ ,; (DR\

SR

\2V S1

(LC\ OR

CR S2~

B

CRANK POSITION

c

UNION SWITCH & SIGNAL m o o o o o o o o o o o ·O o o o o 00000000

D R

-

CONTACTOR

TO TERM. #1

HORIZONTAL LINES INDICATE THAT PORTION OF THE CRANK MOVEMENT DURING WHICH THE CIRCUIT IS CLOSED THROUGH THE INDICATED CONTACTS.

Figure 8-1. 'riming Diagram

6231, p. 23/24

I 7 j (a') -,·

( Ol'TIONt>-L)

TYP\CI\L LAYOUT \./ITH OPTIONJ\L U-5 C\RC\J\T CONTROLLER AND "3UNCT\ON BOX, \NCLUDING-SEP..LT\TE CONDUIT AND A.LL A5SCX:IA.TEDMOUNT\NG-HAADWAAE.

-t -+ 9 14

.. L.H. LAYOUT, L.H. POINT CLOSED

Drawing 0451567 Sh. 81~ Rev. 0

· Figure 8-2.


DESCRIPTION DRAWING ..... 451 .. 13 01

.. 1 \. , I. & 1 z. ') 1 I.

10 1 I. II l I. 12. 1 l. 13 l 4. 14- I II. J 050347 IS l 4.

'" 1 4. 17 1 4. .J 04&2Z':I "'II"'!, ~/4 SQ S•\.. \& 1 4. J 041772. I') 1 2.. 1'12.44552. z.o 1 2. J 0411030 21 1 2. J 041774 22 l z. J 04& .. 43 C.O, 1/4 Y. 1•1/z S"'II.. 23 1 3. J 04750b

1'10,ES:

I. ?1'R"'IS S\\O'W"' 11'117\J\..L -''•'<-S '0 'oE \7\J'i<."'\51\'c.1) 'o~ \JS&-. s.

&c.vl"\70U~(4)1"1C.'A't.S ,ROI-\ S'<I\"((.\\ 't."11) 0\7 S'-1\""\"C.\\ ROI> "lo.,, ~'11.\0'II. ,o \,_.S,t>.1..1..l>."<:\O"I ,,o O'o"<:1'.\"' .._ll'o.Q\ll'."<:'ic. C.l..'<.1'.\'sl>. .. C.'ic..

& l'"OR 5 314 •\\'11.0\tl O'I' YIW:.\\IWi. SI':., "i..'('c.~O\."<: @ 41/1(., 11" i...N~ vi,..1w,:."IC.'E. O', "'1111'.0"' \S 1'.'E.!;;). S't.'E. S'E..'11.'J\C.'E.. """"'"""-·

& ~\N (.l"t'i:.YI 31) c.i...N 0"-1..'( 'oE. \'I\S•"-1..1..E'I) \\-1 0\-li:.1)\1',.'ic.C.,\ON, \..OCl',."ti;: ?\N ?£1<. ?\.. ... N Vlt.'W ol" l'\l'.C\1.1\-lt..

& 'o'E.l"OR'E '1'1..1>.C-\NG. S\,,/\,C..I l'\l>,.C.\>,\l-lt. 11.. 1-SS'<.'t\'e>l..\'I\G, O'l'll:.'11.1'., "'"''"' '11.0'I>, 'o'ic.\..\..O"'S e. S'-11"'1 C.\\ 'i>O\W'( 1'.1),:,us,:i;:1',. R'c.l"'c.'l't,O \NS"'l'il.\JC.,\0\-1 l'\1'.N\Ji...\.. C.231 l"Ol'. O'l''c..1'... \'I-IS"i1'..\lC."i10'!-15.'

&,. JUNCTION BOX (ITEM 7) TO BE LOCATED TO SUIT. FIELD CONDITIONS. :

Typic-al LayO:ut, RR or LR YM-4

1ns1Jl.qtec;i 11' .. 6" Sing!fl_ ~!>~~t Switch Machine Applied to Switch, tlS Turnout

6231, p. 25/26 I

ES-20 { CONTROL

INDICATION{ CONTROL

CONTROL CIRCUITS

{

BXI ISM

MOTOR NX I I SM POWER

6

3 I I I

r, I I I 0,-1--+-..., 111 I I I I I I I I I 1® 119 1 I I ......

CDNTACTOR IL L

CONT ACTOR R

R

L

R

CONTACTOR

L

R

MOTOR

r----------------------, ,---. 4 I I

-JUt.f'ER

LEAD TS

START WINDING

CAPACITOR

REVERSING

MAIN WINDING

I I I I I I I I I I I

L-------------'-------"-"L-f--..;::..-+---l.£1.~--ll--•2::.....JL--l' SWITCH

I

L ._ __ ------------------

•

CL

JUt.f'ER

£.

'-='----'C:...J ovlRtlAD

NOTES,

£. ~fHE~o~i:~i~o 2. FIRST USED ON

N4Sl 613-0101.


/!. JUt.f'ER SUPPLl ED WI TH WTIJR

(BK)

(R)

Drawing 0451325 Sh. 1201, Rev. 4

Figure 8-3. , 'l.'ypical Circuit Diagram for 115 VAC Machine, ~15 VAC Control

I 6231, p. 27/28 ..

•. f

TS

{r:- 9

POIERMAND THROW lggll ~ij__ -------------------------------------, INDICATION I -;;.~_14 _______ _ ,l l PLUG ti4: NORMAL

~ l'r' +1.-_Y+l...--,KITTi1!LJrL-4-)--t•---------1rnL7L~··~-~·_LllT17~----------------, POINT OPEN rs, I i~ ~ 181 I 7 j '81

12311!,! ja '51

'--"'r.,4"-l!----43.)411----, INDICATION{: 85 -,.!-.!.!;fifl6!.L--------:::-----, I

4 "l CONTROL 6 I REVERSE .. __ .,

CONTROL CIRCUITS

_, m

' I

CIRCUIT I -

~· r-~-, /LB'\ • ~2

~ I /LB'\ I ~ II

1'" : : ~ :!!:' !~! ~ 41 ~.

L---.J

!i!!' 17 SR

r-~! !'!Q2 5

~ /jjR'\ I '~

J : ~4 \\ i \!:V I 2

-r \!:V J L---

N04 r-~-, N03 rzi' • lw- lfl1 ~· ·~ I \£V I

L---..1

R

""". liiil

4R 48

L

l?.j1 1"91 4L 4A

No3 r-U-, No4 ifij ; /CR'. • l2iJ ~· ·~ I \!bl I

L---..1 · 1 HOLDING {It~ 1,..,!-l~11~l~Lj.-4-.j._1-+-l-----------f---------~ ,·'o}~E.Ql...lm...1-!_.J__j_j_j. _______ +------------..J I I ,rn

CONTROL a r ii\ ~ INDICATION I l'-"'-;.L.+-<----<--

POWER NXIISC I f lj'31

CONTACTOR -

L ff L

JUt,f'ER

£

CONTACTOR ,_ !7'il R ?R

R

~ ,.~lo, ~ 14 I I 9 µ ,-: I I I I I I I I I I I I

~~ 1~8 ' ' l--.J

~ IRB OP LB

[?

•

]])

~F, OVERLOAD RF PROT.

[TI

2

UNION SWITCH a SIGNAL m

Pl~ U&ID Oii •t51613•01GI fell c•11

{

BXI ISC l _.t ITTl

112~1~Ett?!12?]__...l-._-t._+------------------------:------------------'

I I •

I l JIVm F.-----~!.2'!..-----, I I CONTACTOR CONTACTOR - - .... I I IL L I R IR r:m I 1 .4 I l : l ft-,! 1n1f !,! i 6 : ; :

{

~exu1~,s~M~·~-H·~~""·~3-J----l--+--------t-----~·= ~ I •3 I f I t3 I !ize! 1a111 l I f I

MOTOR NXIISM!1_lil I I I f POWER •T' I I I I I i.- JUMPER

'-""'-""'IL,' s!l...._+---1---1--, ~ "' : I : I 5

2L L ~J R "' 1351 I f1irl I 1 -LEAD T5

.~· l'ffi I' 7 I I I I I li7I

<>---!. 1.----'---. • ZR I 5 I ' l I I -.- -.- I I I g STARTING lo MAIN

~ I I I ~ WINDING 8WINDING

I I I ' CAPAC! TOR

ITT! I r m ; 12 ~ IJ rR\v,mscwG

12-. ' " I @ ~ tii1 I I m 11 i R ffii1 3~ - I I I • I I

13411 1 m, 1 ...i-i 4 I 1

5 i '• •• I I THERB=-MAl CUTOUT !m mi.sf i 31..- .. ,_j L-1\. lojl 1.:-------------J

Drawing 0451325 Sh. 1801, Rev. 0

ill RECTIFIER OCTAL ,--- '!!i~ll£K!,T

I I s I I I I I b I •DC 6 I I a i ! I I -vs 7 I

J I I I I I I I i I

_____ J l'EST -- LUG

I

Figure 8-4A

i ·- I

y (BK)

JCLUTCHl (R)

Typical Circuit Diagram for llSVJIC Machine, llSVAC Control

.. ' ..

TS

POWER/HANO THROW{~ I 9

INDICATION l<lt-f-"-l-"4--------------------------------------------------------~ NOTES,

A lYfHE2g,.¥~rraA EO 114

I

ES-20 {L CONTROL l<IH~~----------------,

{'®8+-~--------------.

INDICATION 11

5 CONTROL QH~~---------:-----,

I 6 I I I I •®1...-"-'-'-+---+--'-'-'-+-~~_. ....... =--+---+-----"=-+-' I

CONTROL I CIRCUITS I

I I I

MOTOR{::::;,,;, POWER I I

I 0--!l-"1=-+--+--~ psi _ _,

r::, I IT I I I I I IT 119 I I

1201 SW I I HEATER 12w~-1~([1-~VV'~--~ C::.J

CONT ACTOR IL L

l

-.-3

CONT ACTOR R

R

-.-

R

L

R

CONTACTOR

l

R

MOTOR ,-,::..;-----------------, 4 I I

2

I I I I I

1 •

I s I

I I

s I

-JUt.f'ER &,

LEAD TS

START WINDING

CAPACITOR

REVERSING SWITCH

~--+<.._..,,.,, THERMAL CUTOUT

MAIN WINDING

~--J . L----------------------

I

-A

r--1 I I I I I I I I I I

'5''----'f_.J_

TEST LUG

°1RR6'r~AO

2. FIRST USED ON N451613-0106.

It,. JUMPER SUPPLIED WITH WTOR

Dr~wing 0451325 Sh. 1601, Rev. l

Figure 8-5. ,. Typical Circuit Diagram for 115 VAC Machine, US VA.C Control ! 6231, p. 31/32

TS {r,6 POWER /HAND THROW I 6 INDICATION I 1

h I I I I I I I I I I I

NW

BXIISC.

RW

10 SW

NXI 15(. CW 5 5

CONT ACTOR IL L

l

6 4R

4L

CONT ACTOR R

R

R

8 4B

L

9 4A

3R

CONT ACTOR

L

l

R

R

CL

JUl.f'ER

Ji

MOTOR

1----------------------r-- ... I 4 I

I I

3 I

LEAO TS

START WINDING

CAPACITOR

REVERSING SWITCH

MAIN WINDING

I I I I I

.--~~-"'-'-'-......l...---<1~.---'-"-'--1-__.__.__s~f--' ~HJfo'tfi I I I ._ __ J I

L----------------------J

NOTES• I\ J!Jt.f'ER SUPPLIED l!l WITH CONTACTOR


A JUMPER SUPPLIED WITH MOTOR


Drawing 0451325 Sh. 1301, Rev. 1

Figure 8-6. .~ypical l~S VAC

1

Circuit Diagram for 230 VAC Machine, Cont,:ol

6231, P• 33/34 I

-:""-·.

TS

{r:- 9

POWER /HAND THROW I 9 I INOICAHON I ~~1~4~----------~--------------------------------

114 I 7 I I

CONTROL CIRCUlTS

,~w{ INDICATION

3

I I 2

CONTROL 8 {BX I I SC

POWER ..:.:N:.:..X 1:...:.1.:.SC"-!--®tll-''-"'--+-'

{

BX230M

MOTOR NX230M POWER

.... ,,',

.. -1 ®JL.-...0~---J

111 I I I I I 11

CONT ACTOR IL L

L 3

"-~ / HEATER

B

4R

4L

CONT ACTOR R

R

L

46 L

4A R

CONTACTOR

CL

L

JUt.f'ER

IA

R

2

MOTOR r-F.~-------------4 I

I I 3

I I I I I

JUMPER

,----<.>---="-i,..._-i-'-"-'-+--tl,__-4-..,.-- LEAD TS

STARTING MAIN WINDING WINDING

CAPACITOR

REVERSING SWITCH

R ®

THERMAL CUTOUT

I I ... ,_J I --------------J

Drawing D451325 Sh. 1701, Rev. 0


NOTES•

IA ~V~~V:rtA~0

2. FIRST USED ON N451613-0l07

Fig~re 8-7,, Typical Circuit Diagram for 230 VAC Machine, ll$ VAC control

6231, p. 35/36

... 1¢

I

TS

POWER/HAND THROW I 9 1 {r:- 9

INDICATION I ®-i...-"lc:,4,__ ________ ~~---------------------------------

114 I

: I 7

ES-20 {· 7 I CONTROL I ®-.,-1-"'-'----------------~

{·~8"'----'-"-'---------------~

INDICATION I 5 I CONTROL I 00-1-""-'---------------

CONTROL 8

CONTROL CIRCUITS

CIRCUIT ="'" {

INDICATION r POWER N24C

6 I I I I I

3

121

I I

2

I CONT ACTOR JUMPER

I ILF L ILR IRR

I I -,-

{""" 13

131 JUMPER

MOTOR 16 1 POWER NI I SM I JUMPER

I 15

~=-· 2LF L 2LR 2RR

-,-

r-, JUMPER

I ~ I

171

I 3LF L

I I 3LR 3RR

I I 17 JUMPER

191 £ I

-J

R

48 L

L

4A R

R

DC MOTOR

CONT ACTOR c.-------------, R r-,6'

BLACK I I I I JONES !STRIP

TERM. I I

R I

-,-

R

-,- I I I I .3 I

._ __ J

Drawing 0451325 Sh. 1401, Rev. 2

NOTES: A JUMPERS SUPPL! ED m rnTH CONTACTOR

2. FIRST USED ON N451613-0201

(BK)


Figure 8-8. Typical Circuit Diagram for 115 VDC Machine, 24-28 voe control

6231, p. 37/38

~,

ES-20 {: 7 CONTROL I @-I-'-"-'------------------,

{

1®8+--'-=--'--------------. INDICATION II 5

· CONTROL @-I-'-~-----------:::-----, 6

R

4R

CONTROL CIRCUITS

L

HOLOING {

2

CIRCUIT ! 61

4

..,__-=<'--1'----+--I--+----------------------'

1101---"""--l--+--+-1-------------------------'

INDICATJON >-"'-"--!--+----'

CONT ACTOR

4B L

L

R

R

CONTROL 8 {Bl 2C

1

11

POWER N1~2~C-~>-'--"-"'--lf----+---------------------------------------------,

{

81 lSM

MOTOR NI I SM POWER

I

16

I I 1s

151 -.J

r.:, I 17 I

I I

19

17

ILF

2LF

3LF

CONT ACTOR JUMPER L ILR IRR

--,-13

JUMPER

JUMPER

2LR 2RR

--,-

JUMPER

£

3LR 3RR

JUMPER

!'!.

CONT ACTOR R

--,-

R

--,-

R

--,-

DC MOTOR c.----.--------, r-1s'1

I I I

BLACK

I JONES

I-STRIP

TERM. I I I

I I I

03 I

I ._ __ J

NOTES:

A ~v~E~3N¥~m~ ED


(BK)


Drawing 0451325 Sh. 1501, Rev~ 0

Figure 8-9~; Typical Circuit Diagram for 115 voe Machine, 12 voe control ./';, 6231, p. 39/40

Parts Lis.t

SERVICE MANUAL 6231 Appendix A



FOR SWITCH MACHINES MANUFACTURED AFT.ER JANUARY 1, 1984

THIS MANUAL Sl:JPERSEDES SM-6231 DATED OCTOBER, 1982


ID1149A/DN0007A

D-11 /87 -75-::>430-3

UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD INC/ PITTSBURGH. PA 15237

UNION SWITCH & SIGNAL ffi YM-4 SWITCH MACHINE ASSEMBLIES

Motor/control Power Indication Lights US&S Part No. Code

115 V 115 v 230 v 115 v 115 v 115 v 230 v 115 v 115 v 115 v 230 v 115 v 115 v 115 v 115 v

Item

1 2

3 4

5 6 7 8 g

10 11 12 13 14 14 15

AC/115V AC control -- N451613-0101 AC/115V AC control Green/Yellow (Glass) N451613-0102 AC/115V AC control -- N451613-0103 AC/115V AC control Lunar White/Red (Plastic) N451613-0104 AC/115V AC control Green/Yellow (Plastic) N451613-0105 AC/115V AC control Green/Yellow (Glass) N451613-0106 AC/115V AC control Green/Yellow (Plastic) N451613-0107 AC/115V AC Control Red/Yellow/Green (PLastic) N451613-0108 AC/24-28V DC control Green/Red/Yellow (Plastic) N451613-0109 AC/12V DC Control -- N451613-0110 AC/115V AC Control Green/Red/Yellow (Glass) N451613-0111 AC/115V AC Control Green/Red (Glass) N451613-0112 DC/24-28V DC control -- N451613-0201 DC/12V DC control -- N451613-0301 DC/12V DC control Green/Yellow (Glass) N451613-0302

YM-4 SWITCH MACHINE ASSEMBLY PARTS LIST Part No.'s 451613-0101, -OXXX

(See Figure A-1)

Description Part No.

case R451614-0902 cover N451614-1402 cover, with Position Indicating Lights N451614-4401

( See Figure A-6) Cover Assembly N451614-4402 cover Assembly N451614-4403 cover Assembly N451614-4405 cover Assembly N451614-7001 cover Assembly N451614-7002 Plug, Pipe 3/14-14 NPT J032906 120 Gear Box and Motor Assembly N451614-6001

(See Fig. A-3) Gear Box and Motor Assembly (See Figure A-3) N451614-6002 Gear Box and Motor Assembly (See Figure A-2) N451614-6101 Bolt, 3/8-16 x 1-1/4 Hex. Hd J050056 washer, LK. 3/8 J475121-0113 Pin oowel J703412 Spring, Toggle (See Figure A-4) N451614-0401 Pin, Spring Block M451614-2303

'Pin, Toggle Spring M451614-2302 Bolt, l/2-13xl-3/4 Hex. Hd J050095 washer, LK. 1/2 J047783 Pin, cotter 1/4 x 2 J048645 shaft, output crank (See Figure A-5) N451614-0501 shaft, output crank N451614-0503 Plate, crank Shaft Mtg. R451614-0103

A B c D F G I J K L M N E H 0

used on Code

All A,C,E,H,L B,G,0

D F,I N J,K M 1\11 A,B,D,F,G, J,K,L,N C, I ,M E,H,0 All All All All All Ul All I\ ll All I\ 11 except c c All

6231, p. A-1


Item

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

53 54

55 'j6 57 58 59

Description

Shim Bolt, 3/8-16xl" Hex. Hd. washer, LK 9/16 Screw, 10-32 x 5/16 RD Trough, Wire Pin, Hinge Brkt. Limit sw. Mtg. Bolt, 1/4-20 x 5/8 Hex. Hd. washer, LK 1/4 Nut, 1/4-20 Hex. Bolt, l/4-20xl Hex. Hd. Brkt., Limit switch Brkt., Limit Switch Switch Limit Switch Limit Insulators Bellows Plate, Bellows Mtg. Bolt, 1/4-20 x 1-1/4 Hex. Hd. Nut, 1/4-20 Hex. Washer, 1/4 PL. support, Lever Cam Shaft Bolt, 3/8-16 x 1-1/2 Hex. Ha. Lever, Hand Throw washer, LK l" stud, Lever Lever, Interlocking Bolt, 5/8-11 x 3-1/4 Hex. Galv. Nut, 5/8-11 slotted Hex Washer, 5/8 Pl. Brass Washer, LK 5/8 Latch, Hand Throw Nut Pin, Cotter 1/8 x 1• Stl. Bushing Bolt, 1/2-13 x 1-1/4 Hex. Hd. Brkt. cut-out sw. Mtg. Brkt. cut-out sw. Mtg. Screw, 4-40 x 1-1/2 Rdh. st. Contact.or, Motor Rev.

contactor - 24 voe Coils Cont.actor - 12 voe coils

---Screw, 10-32 x 5/8 ROH Strip, Term. ~AR 12 pole Strip, Term. AAR 4 pole connector, Term. Strip Brkt. Term. Strip Mtg. Brkt. Term. Strip Mtg.

623l, p. A-2

Part No.

M451614-0104 J050053 J475209 J052562 M451614-3205 N451614-3105 M451614-3204 J050013 J047775 J048203 J050019 M451614-3202 M451614-3203 J725666 J725707-0193 M451614-3208 J751327 M451614-3601 J050021 J048002 J047501 R451614-1802 J050057 R451614-3403 J047823 M192069 N451614-2108 M451614-2107 J048074 J475189 J047822 N451614-3001 M451614-3102 J048620 M451393-0701 J050090 M451614-3201 M451614-5801 J525093 J706448

J709599 J7 09599-0001 J052566 J077653 Ml07471 M451614-3206 M451614-3207 M451614-3209

used on Code

All All All E,H .All All .a.ll All A 1.1. All A 1.1 All All All except c .a.11 All All All All All All All All All All All All All All All All All All All All All

except c

All except G G All A,B,C,D,F,G, I ,.J ,M, N E,K H,L,O All All All All c All except C

Item

60 61 62 63 64 65 66 67 68 69 70

71

72

73 74 75 76

77 78 79 80 81

82 83 85 86 87 88 90

91

92 94

Description

Screw, 10-32 x 7/8 Fil. Hd. Nut, 10-32 Hex. Stl. washer LK HO Screw, 410-32 x 3/8 RDH Nut, AAR Nut, AAR Jam washer, AAR Nut, Insulating Strip, Jones Term. Protector, overload Heater Heater Heater Resistor, 2K ohms 25 watt

Resistor, 7.5K ohms 25W Harness Harness Harness Harness Harness Harness Harness Harness Harness washer, #8 Shakeproof LK Lead Clamp, Trough Spring Spring Test Link Nut, 9/16-18 Lead screw, 6-32 x 1/4 Rd. Hd. Stl. screw, 6-32 x 1 Rd. Hd.

Term., Ins. Faston 250 Term., Amp (#6 Post) Clamp Screw, #3-48 x 3/4 Rd. Hd. Ventilator Cap, Plug Power Supply Power supply Sockel, Octal

Spiral Pin Cover, Gear Box

Part No.

J052299 J048172 J047733 J052564 J480301 J480300 J047818 JO 48 300 J724351 J726153-0016 J713154-0004 J713154-0006 J713154-0005 ,J0738 l 7

J735519-0616 N451614-3801 N451614-5201 N451614-4901 N451614-5701 N451614-5501 N451614-5901 N451614-7101 N451614-7701 N451614-7901 J047892 N438713-001 N451614-4806 M451614-4803 M451614-4804 J071626 J480315 N438431-007 J525055 J5 25097

J7 31443 J730077 J709590 J525234 N070109 J703392 J725709-0070 J725709-0085 J792847

J487318 M451614-6601

UNION SWITCH & SIGNAL m used on

Code

All All ;\ 11 All All All All All All All A,B,D,F,G,J,L,~,N I,C E,H,K,O A,B,D,E,F,G,H,J, K,L,N,O c' I I,.., A,B,D,F,N c E G H,O I J,M K L All A,B,C,D,F,G,I,J,M,N All A,B,D,F,G,J,K,L,N C, I ,M All All A,B,C,D,F,G,I,J,M,N All A,B,C,D,F,G I,J,K,L,M,N All All All All All All A,B,D,F,G,J,K,L,N C, I ,M A,B,C,D,F,G,I,J, K,L,M,N i\11 All

6231, p. A-3

ffi UNION SWITCH & SIGNAL

Item

95 96 97 98 99 100 101 102 103 104 105 106

107 108 109

llO lll ll3 ll4 ll5 ll6 ll7 118 ll9 120 121 122 123 124 125 126 127 128 129 131 132 133

Description

Resistor, 800 ohms 30 watt Nut, Jam 3/8-16 Nut, 1/4-20 Hex. Stl. Heater Plate-Name Lubricant, Stazon-M Spacer Pin, Cotter 3/16 x 1-1/2 Stl. Ties, cable Shim screw, 1/4-20 x 7/8 Hex. screw, 10-32 x 1/2 In. Rd Plate, cont. Adapter Plate, cont. Adapter screw, 10-32 x 1/4 Rd. washer, 6 Shprf. Lk. switch, 6-amp 125V SP ST

Lead Label (Not Shown) stud, Hasp screw, 3/8 x 1-1/2 Hex. Hd. Pin-Roll Elas. Stp. Nt. washer Hasp washer, 10 Shprf. Lk washer, 10 Flt. Stl. carol. Clamp, cable Bracket, standoff Grommet, Rubber Insulator, overload Protector Tubing, Spiral wrap Black strip, Term. AAR 8 Pole Thermostat washer, 10 Stl. Lk screw, 10-32 x 3/16 Rd. Hd. cable clamp screw, 8-32 x 3/16 Rd. Shim, Top and Bottom shim, Side

G23l, p. A-4

Part No.

J720074 J048010 J048631 M451607-7101 A041477 M451614-2106 J048634 J703360 M451614-0105 J050017 J052565 M451614-5103 M451614-5105 J052563 J047713 J724515

M438876 M451523-2501 M387732 J050057 J487025 M391200 N072832 J047715 J475077 J709556 M451614-5603 J075487 J780059 A774186 M223608 J620940 J047733 J052561 J700651 J052601 M45ll 74-0601 M45ll74-0701

used on code

C,G,H,I,O All !\11 C,G,H,I,O All All 11..11 All ~ll All 11..ll All except G G All All C,G,H,I,O

C,G,H,I,O c All All All All 11..ll All A,B,C,D,F,G,I,J,M,N All 11..ll All i\ ll All All except C G G G G G All All

,.

tj,--ss ~118

F. 1.gure A-l.

124

121 122

132 133

/' (AS REQUIRED)

YM-4 El ----~~~~~~~~~--ectr · --ic Switch Ma . chine, - ------ . Exploded V. --· iew

6231 - , P. A-C:./A-f..

Item

5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95

100 105 110 115 120 125 130 135 14-0 145 150 155 160 165 170 175 .. 180 185 190 195 200 205 '.?10 2l 1J

:1 2d 22'j

GEAR BOX AND MOTOR ASSEMBLY PARTS LIST P'irt No. N451614-6101

(See Figure A-2)

Description

Frame, Ge1:1.r Box Shaft, Gear Box Shaft, Gear Box Shaft, Gear Box Be':lring, Ball Single Row Bearing, Ball Single Row Be':lring, B<J.11 Single Row CUP, BRG Single Row Be':lring, Cone Single Row Gear Gear Washer Screw, 3/8 x 1-1/4 Hex HD Ring, Retaining Snap Ext. Ring, Retaining Sn':lp Ext. Ring, Retaining Snap Ext. Gefir Bearing, Needle RLR Cage Key Key Key Gear Ring, Retaining Bowed Ext. Modul,~-Elec t. Clutch Motor-Perm. M':lg. 115V Ge'.3.r Screw, 1/4 x 1/4 SAF Set Washer, 3/8 Stl. LK Med. Grommet Spacer Termin'.11 PR-INSUL DMDGRP Card, Quik L'.lbel Code Ca rd, Qui k L.9. be 1 Code Bushing, Insul. 1/2" Ge'.lr, Bevel Key Nut, 3/8-16 Hex. J'.lm Screw, 3/8-16 x 1-1/4 Hex. Hd. Washer, Lock Nut, Lock Shaft, H·1nd Throw Be·1ring, B9.ll Ring, l?c t,1 i 11 i.ng W:rnh0 r Ri.ng, Rcbiini.ng


P'irt No.

N451614-6301 M451614-1701 N451614-1702 M:451614-1703 J066419 J066418 J066417 J066420 J066421 M451614-2501 M451614-2504 ~451614-3510 J050056 J792852 J792853 J792854 M451614-2503 J066416 M451614-3504 M:451614-3505 M451614-3506 M451614-2502 ~ J792849 J792843 J717250 M451614-2505 J050500 J47512l-0113 J751127 M451614-3511 J730053 J063646-0001 J063646-0002 J690429 M451614-2701 M451614-3508 J048010 ,J046428 J047786 J048573 R451614-6402 J066368 J790544 1'445lnl4-'5505 J0'79388

·-

6231, p. A-7


GEAR BOX AND MOTOR ASSEMBLY PARTS LIST (Cont'd.)

Item Description P>lrt No.

230 Gear M451614-2506 235 Key M451614-3507 240 Bushing M451593-0203 245 Ring, RetainirJ.g J792964 250 Block, Lever Be'lring R451614-2203 255 Spacer M451614-3513 260 :&ill Be'lring J066426

..

i):~51, p. A-8

SECTION°D·D·

VIEW 'A

FOR Atii»e'""'aLY Of' -.,M,.,_f"T W\'tM. Gl£ .. R11, -'S.£~ Vl&W •A•

FOR A'S.'S,EM81.Y OF 'S,M ... l"T WITM Qi.EAR'-- ,_EE VIEW .. C"'

SECTIOM°F·F"

FOR A'S.'S,EMe~v OP' $MA.F'T Wl'TM GEAR, -S.!.~ Vl~'W •e,•

VIEW'B"

I --~

Drawing F451614 Sh. 61, Rev. 1

19

VIEW"C'

Figure A-2.

SECTION 'II-II"


55 TAl&S

SUPPLIEO W1,-1< MOTOR

Gear Box and Motor Assembly

~ 6232, p. A-9/A-l~i

Item

5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 BO 85 90 95

LOO 105 llO ll5 120 125 130 135 140 145 150 155 150 165 170 175 180 185 190 195 200 205 210 215 220 225 210 235

GEAR BOX AND MOTOR ASSEMBLY PARTS r..rs·r Part Nos. N451614-6001 & -6002

(See Figure A-3)

Description

Frame, Gear Box Shaft, Gear aoic Shaft, Gear Box Shaft, Gear 130K

Bearing, Ball Single Row Bearing, Ball Single Row Bearing, Ball Single Row Cup, Bearing Single Row Bearing, cone Single Row Gear Gear washer Screw, 3/8 K 1-1/4 Hex Hd. Ring, Retaining snap Ext. Ring, Retaining snap Ext. Ring, Retaining snap Ext. Gear Bearing, Needle RLR Cage Key Key Key Gear Ring, Retaining Bowed Ext. Module, Electro clutch Motor, 1 HP ll5/230Vac Gear screw, 1/4 ic 1/4 SAF set washer, 3/8 Stl. LK Med. Grommet Lead Lead Lead Lead Lead r..ead Spacer Bushing, Insulating 1/2" Gear, Pinion Bevel Key Nut, 3/8-15 UNC-28 Jam screw, 3/8-16 x 1-1/4 Hex Hd. washer, W-06 SKF Lock Nut-N-06 SKF LK Shaft, Hano ~brow Bearing, Ball DBl w/seals Rings, Waldes Retaining washer


Part No.

N451614-6301 N451514-1701 N451614-1702 N451514-1703 J066419 J066418 J066417 J066420 J066421 M451614-2501 M451614-2504 M451514-3510 J050056 J792852 J792853 J792854 M451614-2503 JO 66416 M451614-3504 M451614-3505 M451614-3506 M451614-2502 J792849

~

J792843 J717245-0001 M451614-2505 J050500 ,J475121-0113 J751127 N438713-003 N438713-004 N438713-005 N438713-006 N438713-007 N438713-008 :4.451614-3511 J690429 M451614-2701 M451614-3508 J048010 J046428 J047786 J048573 -q451614-6402 ,J066 368 J790344 M4516l4-3503

6231, p. A-11


Item Description Part No.

240 Ring, External Ring J079388 245 Gear M451614-2506 250 Key M451614-3507 255 Bushing 1\1451393-0203 260 Ring, Intern'll Ring J792964 265 Block, Lever Bearing R451514-2203 270 Spacer M451614-3512 280 Tubing, Heat Shink 3/16 ID A774169 285 Be'lring, B'lll Single Row J066428

(i?'H, p. A.-12

VIEW 'A

SECTION"o-o·

f"OR A'oY.EMBI.'<' OF '1!.M.0.FT WITM GE.AR.ft -~£E. V\€W .. A."

FOR A1&'-EMISL'I" OF 'SHAF'l' w'ITM GEAR'!, -'l>EE VIEW "C."

$1'.CTIO>l "E·E.'" SECTION "F • F"

FOR AY.Y.EM61.Y OF 'o><p,.FT \JlTM 6,EA.J:t'b-4SE'E V1£'1w•8"'

CS£C.1tON. ~G - G"

'&C.AI.E: ~ IN.• 111\1..

VIEW'B'

5

IS


UNION SWITCH & SIGNAL m s

20

VIEW"C"

Figure A-3. Gear Box and r.t>tor Assembly

6231, p. A-13/A-14

Item

1 2 3 4 5 6 7

ENC>\111:.W

G)

TOGGLE SPRING ASSEMBLY Part No. N451614-0401

(See Figure A-4)

Descri.ptlm

Spring, Toggle Retainer, Spring Cap, Spring Retainer Rod, Sprtng Retainer Nut, Spring Retainer Fitting, 3/16 Alan. Str. Bushing, 2 O.D.xl-1/4 I.D. Ball

I \. ,I ---\ / --

. -----1 -T-

Figure A.-4. Toggle Spring A.ssanbly


Part No.

J680196 M451614-2801 M45l 614-2101 M451614-l 301 Ml91309 J039139 J066415

6231, p. A-15


Item

1 2 3 4 5 6 7 8

* 9 10 11

6231, p. A-16

Description

OUTPUT CRANK SHAFT (See Figure A-5)

Fitting, 3/16 Alemite Bolt, ~djustable Eye Shaft, Crank searing, Ball Bushing Bolt, Hex., 3/8-16 Nut, Hex., 3/8-16 Bearing, Ball Bushing Cam, Limit switch cam, Limit switch Screw, BTN. HD., 10-32x5/8 Washer, #10 Shprf. Lock

* For output crank shaft assembly Part No. N451614-0501 only

Part No.

J039l39 N451614-3106 R451614-0502 J0664 l5 J050053 ,J048010 J066414 J776705 J776706 J507373 J047715

. . .

•.

"A"

1 I

.J

''A''

Dwg. No. D451614 sh. 5, Rev. 3

,, PRE.SS~t> IN


VIEW '')(''

Figure A-5. output Crank Shaft

6231, P• A-17/A-18

Item

5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 85 90 95

COVER ASSEMBLY WITH TWO COLOR POSITION LIG"fl'rS (See Figure A-6)

Description

cover Gasket Hood Ring, Lens Module, Lamp Lens, Green, 4-1/2 in. *Glass Lens, Yellow, 4-1/2 in. *Glass Screw, Thumb, 10-32 x 3/8 Screw, Rd. Hd., 10-32 x 5/8 screw, Rd. Hd., 1/4-20 x 1/2 washer, steel Pl., #10 washer, Steel Pl., 1/4 in. washet, Spring steel LK, #10 washer, Spring Steel LK, 1/4 in. Plate, Mounting socket, Lamp Clamp, Cable Harness


Part No.

R451614-4101 A.690969 N451614-4202 M451614-4203 M451614-4302 J053142 J053151 J507384 J525281-0ll0 J525269-0l08 J475132-0110 J475132-0112 J475 l 31-0109 J475131-0lll M451614-460 l J725895 J709556 N451614-4701

*Lens listed are for cover assembly, N451614-4401. If lens other than thes~ are required, please specify color, material, and lens location when ordering. see tabulation below.

LENS

Color Material Part No.

Green Glass J053142 Yellow Glass JO 53151 Red Glass J053141 Green Plastic J531506 Yellow Plastic J531507 Red Plastic J531505 Lunar White Plastic J531504

6231, p. A-19/A-20

5

30

[JETAIL' B" SC.ALE: 1/1 30

.J

T£R.HllNAL POST

i TAGS

't Gl [?]

!El r,g1

[fil l:fil

35

TAGS PLUG • r--,

( I

COMMf'lN

( I I I ___ J

V...~VE.R.SE 'REVERSE

NC'l$it.'tl\.t,..\_ ~O'R.'°'"'-L

HAN"" THPt"'W SID!.

CIN'CUJT 0/1 ,:_;:·1\IA

FOR Cov::..F w,.,, L,5;-,-;:

(FRONT& BACK) Se E oe TAI\.·· a··

'ilEV o~OR COM

MALE END

SHt1w11JG r£'-/tMl/iLS OF" PLUGS. Po~ v 11RrAJG Pt1R.P,.s C.S

(BOTH ENDS) $EE.. OF..TA\'-''8''

S\JFFl'A N.O.

-4-4-0\

-4402..

·4403

-4404

15

l,\.Olt'tl\.""-L 'REVE'I\SE

LE.>IS laol C.OLOV... 1..Ew.s asJ COLOR

.)053\4-2. G.i.£.t.l-\ .)053\51 '<ELLO'W

.)53\504- ~':'.':'.!'-:-, l53\S05 'RS.:!)

.l531SO<o ~Ii.EE~ .)531507 '<E\..\..0¥1

J5~l50fo Gl((HI J5"S>,505 R.1:.0

f="=---V1Ev/ IN j)1i,.£_ -, )"< OF ARROW

,:,r ...... , ... 11~,..,N .r II/AME PLAT:E

$d<i1-E:: I /z.


Lt.NS l#\"'-\"E ... \"-~

G.LJl,,.SS

"'L"51:\C.(O?"i\C."4

~,._S,\C.(O?"i1c."L)

PLA$Tl<.(OPTICAl

Drawing F45lnl4 Sh. 44, Rev. 8

Col1~ \ssemhly Witj Tw~ F'osi tion tiehts

6231, p. A-21/A-22

UNION SWITCH & SIGNAL m COVER ASSEMBLY WITH THREE POSITION LIGHTS

(See Figure A-7)

Item Description P>3.rt No.

Cover Assembly (Complete) N451614-7001 Cover Assembly (Complete) H451614-7002

5 Cover, Case R451614-6901 10 Hood, Complete 1{451614-4-202 15 Lens Ring M45l614-4203 20 Lamp Module M4516l4-4302 25 Lens, 4-1/2 in. Pl~stic Green (-7001) J531506

Lens, 4-1/2 in. Glass Green (-7002) J053142 30 Lens, 4-1/2 in. Plastic Yellow (-7001) J531507

Lens, 4-1/2 in. Glass Yellow (-7002) J053151 35 Screw, 10-32 x 3/8 Thumb J507334 40 Screw, 10-32 x 5/8 Rd. Hd. ,}525281-0110 45 Screw, 1/4-20 x 1/2 Rd. Hd. J525269-0108 50 Washer, #10 Steel Pl. ,}475132-0110 55 Washer, 1/4 in. Steel Pl. J475132-0112 60 W~sher, #10 Spring Steel LK J475131-0109 65 Washer, 1/4 in. Spring Steel LK J475131-0111 70 Mounting Plate M451614-4601 75 Lamp Socket J725895 80 C1:1.ble Clamp J709556 85 Harness N451614-6701 90 Lens, 4-1/2 Plastic Red (-7001) J531505

Lens, 4-1/2 Glass Red (-7002) J053141 95 G':lsket, l/2x5/8 A690969 ~

100 Contact Adhesive A041988

-

6231, p. A-23/A-24

s

[>ETAIL .. B"

-#])

TERH\INAL POST i TAt

G] [y)

1i3! 1i2J

~ ® 8 li'.i)

30

[·

I

MOll1'1t.\.. 'l'Oll1'\"'\.. HAM!: TMP."W SIO:.

CIRCUIT DIAGRAM

FOR COVER \NITH LlGt-4TS

~

--+

'"'A.l.i:. £NO

S/101.111,JG TE1Ct11tN11tS OF' PLUGS J:01< r.,.)/RIUG Ptll(POSl!!S

VIEW IN DJRE:CTION OF AP.ROW APPLICATION 0/." NAME PLATE

'----1H"- SHOP H~AD


'~11 9+~\i

. -

_SEC.i\01'1 'A·A·· '::;(.A.LE: 1/1


,.·--.:;: ,, ,,

!I

Figure J\.-7. Cover Assembly with Three Position Lights

6231, P• A-25/A-26

SERVICE MANUAL 6231 Appendix B

Parts l,..ist

ELECTRIC SWITCH MACHINE . .

YM-4 DUAL CONTROL, TRAILABLE

FOR SWITCH MACHINES MANUFACTURED BEFORE JANUARY 1, 1984


ID1149A/DN0007A

D·l 1/87-75-2430-3

UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD INC I PITTSBURGH, PA 15237


YM-4 swrrat MAOilNE ASSEMBLIES

Motor indication Liqhts US& s Par t lb •

115 V AC/115V AC Control -- N451613-0101 115 V AC/ll5V AC Caltrol Green/Yellow (Glass) N451613-0102 230 V AC/115V AC Control -- N451613-0103 115 V AC/ ll5V AC Control Ulnar White/Red (Plastic) N451613-0104 115 V DC/24-28V DC Control -- N451613-0201

YM-4 SW lTCH MACHINE ASSEMBLY PAR'IS L1S'l' Part lb. 's 451613-0101, -OlXX,

item

l 2

3 4

5 6 7 8 ~

10 11 12 13 14 14 15 16 17 18 19 20 21 22 ;u 24 25 2& 27 28

(See Figure B-1)

Description

Case Cover, w/out Position indicating Lights Cover Cover, with Position indicating Lights

(See Figure B-6) Cover Assembly Plug, Pipe 3/14-14 NPr Gear Box w/Motor Assembly (See Fig. B-3) Gear Box w/Motor Gear Box w/Motor Bolt, 3/8-16 x 1-1/4 Hex. Rd wash er , LK. 3/ 8 Pin Dowel Spring, •roggle (f>ee Figure B-4) Pin, Spr ing Block Pin, •roggle Spring Bolt, l/2-13xl-3/4 Hex. Rd

wash er , LK. 1/2 Pin, Cotter 1/4 x 2 Shaft, output Crank (See Figure B-5) $haft, output Crank Plate, Crank Shaft Mtg. Shim

Bolt , 3/ 8-16 xl " Hex. Rd • Sha ft, Hand 'l'hr ow (See Figure B- 2) Bolt, l-13x6 Hex. Rd. •rrough, Wire Pin, Hinge 13rk t. Limit Sw. Mtg. Bolt, 1/4-20 x 5/8 Hex. Rd. Washer , LK 1/ 4 Nut, 1/4-20 Hex. llol t, 1/ 4- 20xl Hex. Hd. Brkt., Limit switch Brkt., Limit Switch

6231, p. B-2

Pact lb.

R451614-0901 N451614-1401 N451614-1402 N451614-4401

N451614-4402 J032906 N451614-0301 N451614-0302 N451614-5001 J050056 J04 7779 J703412 N451614-040l M451614-2303 1'1451614-2302 J050095 J047783 J048645 N451614-0501 N451614-0503 R451614-0103 M451614-0104

J050053 N451614-0601 J050251 M451614-3205 N451614-3105 M451614-3204 J050013 J047775 J048203 J050019 M451614-3202 M451614-3203

Code

A B c D E

Used Ol Code

All A,E c B

D All A, ll, D

c ~ r:

All All All All All. All All

All All A,li,D,E

c All All

All All All All All All All All. All All All All

Item

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70

71

Description

Switch Limit Switch Limit Insulators Bellows Plate, Bellows Mtg. Bolt, 1/4-20 x 1-1/4 Hex. Hd. Nut, 1/4-20 Hex. Washer, 1/4 PL. support, Lever cam Shaft Bolt, 3/8-16 x 1-1/4 Hex. Hd. Lever , Hand Thr CM

Washer, LK l" Stud, Lever Lever, interlocking Bolt, 5/8-11 x 3-1/4 Hex. Galv. Nut, 5/8-11 Slotted Hex Washer , 5/8 Pl. Br ass Washer, LK 5/8 Latch, Hand Thr CM

Nut Pin, Cotter 1/8 x l" Stl. Groowet Bolt, 1/2-13 x 1-1/4 Hex. lk:I. Brkt. Cut-out Sw. Mtg. Screw, 4-40 x 1-1/2 Rdh. St. Con tactor, Motor Rev. Con tac tor - Rev. 7. 5 Hb Screw, 10-32 x 5/8 ROH Strip, Term. AAR 12 pole Strip, Term. MR 4 p:>le Connector, Term. Strip Brk t. Term. Strip Mtg. Screw, 10-32 x 3/4 Fil. Hd. Nut, 10-32 Hex. Stl. Washer LK 110 Screw, 110-32 x 3/8 ROH Nut, AAR Nut, MR Jam washer, AAR Nut, lnsu!.ating Strip, Jones Term. Protector , o., er load Heater Heater Heater Res is tor , 2K ohms 2 dA Resistor, 7.SK ohms 2 dA

Part it>.

J725666 J725707-0l93 M451614-3208 J751327 M451614-3601 J050021 J048002 J047501 R451614-1802 J050056 R451614-3403 J047823 M.192069 R451614-2108 M.451614-2107 J048074 J475189 J047822 N451614-3001 M451614-3102 J048620 J751324 J050090 M451614-3201 J525093 J706448 J709599 J052566 J077653 Ml07471 M451614-3206 M451614-3207 J052299 J048172 J047733 J052564 J480301 J480300 J047818 J048300 J724351 J726153-0016 J713807 J713154-0006 J713154-0005 J073817


Used On Code

A,B,D,E All A,B,D,E All All All All All All All All All All All All All All All All All All All All All All A,B,C,D E All All All All All All All All All All All All All All All A,B,D c E A,B,D,E c

6231, p. B-3


Item Description Part No. U$ed On code

72 Harness N451614-3801 A,13,D Harness N451614-5201 c Harness N451614-4901 E

73 Washer, lt8 Shakeproof LK J047892 All 74 Lead N438713-001 A,B,C,D

Lead N451614-5101 E 75 Clamp, Trough N451614-4802 All 76 Spring M451614-4803 A,B,D

Spring M451614-4804 c 77 Test Link J071626 All 79 Lead N4 38 713-007 A,B,C,D

Lead M451614-5102 E 80 Screw, 6-32 X 1/8 Rd. Hd. J525241 All 81 Screw, 6-32 x 1 Rd. Hd. J525097 All 82 Term., Ins. Faston 250 J731443 1\1 l 83 Term. Amp. (#6 Post) J730077 All 84 Plate, cover M451614-1302 1\11 85 Clamp J709590 All 86 Screw, lt3-48 x 3/4" Rd. Hd. J525234 All 87 Ventilator N070109 All 88 cap., Plug J703392 All 90 Power supply J725709-0070 A,B,D

Power supply J725709-0085 c 91 Socket, Octal J792847 A,B,C,D 94 cover, Gear Box M451614-1303 All 95 Resistor, 800 ohms, 30 watt J720074 c -96 Nut, Jam 3/8-16 J048010 All 97 Latch, Assembly with Hasp J792898 All 98 Bolt, 1/4-20 x 3/4 Hex. Hd. J050016 1\ll 100 Spacer M451614-2106 All 101 Pin, cotter 5/32 x 1-1/2 Stl. J048627 ?\ll

Lubricant stazon-M A041477 All Ties, cable J703360 1\11

103 Plate-Name N451607-7101 All 104 Lead M4 38876 c 105 Screw, 10-32 X 1/2 In. Rd. J052565 c 106 Screw, 10-32 X 9/16 Rdh. st. J525046 c 107 washer, 10 Stl. Lk. Med. J047733 c 108 Resistor, 800 Ohms 30 watt J720074 c 109 Switch, 6-amp 125V SP ST J724515 c 110 Bracket, HTR Mounting M451563-5101 c 112 Screw, 10-32 x 7/8 Rd. Hd. J052568 E 113 Stud, Hasp M387732 All 114 Screw, 3/8 x 1-1/2 Hex. Hd. J050057 All 115 Pin-Roll Elas. Stp. Nt. J487025 1\ll 116 washer M391200 All 117 Hasp N072832 l\.ll 118 washer, 10 ShprE. Lk J047715 11.11 119 Washer, 10 Flt. Stl. Coml. J475077 A,B,C,D 120 Clamp, Cable J709556 All 121 Shim, Top and Bottom M45117 4-0601 1\ ll 122 Shim, Side M451174-0701 All

62 31, p. B-4

,_.. l-" UNION SWITCH & SIGNAL m

2

121 122 (AS REQUIRED)

Figure B-1. YM-4 Electric switch Machine, Exploded View

6231, p. B-5


item

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17

22 23 24 25

6231, p. B-6

HAND THROW SHAFT PARTS LlST Part No. N451614-0601

(See Figure B-2)

Description

Gear, Bevel Key Nut, 3/8-16 Hex. Jam Ser f:M, 3/3-16 x 1-1/4 Hex. Rd. Washer , IDck Nut, IDck Shaft Bearing, Ball Ring, RWG washer Ring, R'ffiG Gear Key Brg., Ball Bushing Ring, R'ffiG Bracket, Mtg. Housing, Upper BRG.

Part No.

M4516l4-2701 M451614-3508 J048010 J050056 J407786

J048573 ~,</ 1<'..fit'.4 51614

J066368 J079344 M451614-3503 J079388 M451614-2506 M4516 l4-3507 J066426 J792964 R451614-2203 M451614-0802

(The following items are for reference only)

Screw, 3/8-16 x 1-1/4 Hex. Rd. Washer, 3/ 8 Stl. Lk. Med. Case, YM-4 Switch Machine Support, Lever Shaft

J050056 J047779 R451614-0901 k451614-1802

.. 't) . 0, I

...J

: ... ; ·.: :--..::·:·.:. s- ~ ~e. ·

17

8 PRE.SSE.t:> INTO

IT. Ii BEFORE. A. 'S.'5.E.1'11\'BLY

4

' f

$£.CTION "A·/'\

( FOll.. ~E.f. °"'L'<)

r·igurt: b-2. ttana 1·r1row ::>naft

7

c z 5 z I ~ ::c • 0 t5 z > ,...


Item

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

I 25

26 27 28 29

6231, p. B-8

GEAR BOX AND MOTOR ASSEMBLY PARTS LIST (See Figure B-3)

Description

Frame, Gear Box Shaft Shaft Shaft Bearing, Ball Bearing, Ball Bearing, Ball Cup, Bearing Ball Bearing, Gear Gear washer screw, 3/8-16 x 1-1/4 Hex Hd. Ring, Retaining Ring, Retaining Ring, Retaining Gear Bearing, Needle RLR Cage Key Key Key Gear Ring, Retaining Module, Electro Clutch Motor, 1 HP 115/230 vac Motor, Perm. Magnet 115 Vdc Gear, Pinion Screw, 1/4-20 x 1/4 SAF. Set washer, 3/8 Lock Grommet

Part No.

R4516H-0201 M451614-1701 M451614-l 702 M451614-1703 J066419 J066418 J066417 J066420 J066421 M451614-2501 M451614-2504 M451614-3510 J050056 J792852 J792853 J792854 M451614-2503 J066416 M451614-3504 M451614-3505 M451614-3506 M451614-2502 -J792849 J792843 J717245-0001 J717250 M451614-2505 J050500 J047779 J7 51127

(Rev. 1/87)

121

VIEW SHOWING. MOUNTIN~ OF Pll'IION ~'°'" ON C:\.U"TC.11

NIODU\.S.

11

VIEW~

Dwg. No. F451614, Sh. 3, Rev.3 (AC Motor, Dwg. No. F451614, Sh. !iO, Rev. 0 (DC Motor)

2

10 14 1

7' 5

SECTION ·o-o·

17

./.J

1

I -..

-

-

.....---~

-1--~

1

I ---

1--

-

.....---~

--~

UNION SWITCH & SIGNAL m 22

22 16 17

8

4

3

6 .3 6

4

SECilON "E·E." SECTION °ie • F"

VIEW ·s· v1Ew·c·

13,28 25

24

I . '

~ ......-- "

' U. --

i, -I

!::=::;-- -,-. -

II

II AC MOTOR ,-.

LJ - ,.....__ -

I

· 115 VAC AND 230V AC MOTOR

13, 28 25

24~ I ,__ -- --

It---I

~ -f:! - I

II DC MOTOR II

LJ - ;

'--- - !

115V DC MOTOR FOR MOTOR PART NUMBER SUFFIX -0103 ONLY•

Figufe B-3. Gear Box and Motor Assembly

.L .. · 1 6231, p. B-9/8-10

.. . .

l te,11

l 2 3 4 5 6 7

© , __ _ (o

'l'OGGLE SPRING ASSFMBLY Part to. N451614-040l

(See Figure B-4)

Des er i pt ion

Spring, '!bggle Retainer, b'pr ing Cap, Spr ing Re ta iner Rod, Spring Retainer Nut, Spring Retainer Fitting, 3/16 Alem. Str. Hushing, 2 O.D.xl-1/4 1. D. Ball

Figure B-4. 1bggle Spring Assembly


Part to.

J680196 M451614-2801 M451614-2101 M451614-1301 Ml91309 J039139 J066415

6231\, p. B-11


Item

1 2 3 4 5 6 7 8

* 9 10 11

5 2 3 1 , p • B-12

Description

OUTPUT CRANK SHAFT (See Figure B-5)

Fitting, 3/16 Alemite Bolt, Adjustable Eye shaft, crank Bearing, Ball Bushing Bolt, Hex., 3/8-16 Nut, Hex., 3/8-16 Bearing, Ball Bushing cam, Limit switch cam, Limit switch screw, BTN. HD., 10-32x5/8 washer, #10, Shprf. tock

* For output cam shaft assembly Part No. N451614-0501 Only

Part No.

J039139 N451614-3106 R451614-0502 J066415 J050053 J048010 J066414 J776705 J776706 J507373 J047715

I

l \

Dwg. No. 0451614 Sh. 5, Rev. 3

PRESSED IN

VIEW•)(~

,.. PRE.SSl::t> IN


Figure B-5. o t u put crank Shaft

6231, p. B-13/B-14

Item

5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 85 90 95


COVER ASSEMBLY WITH GREEN/YELLOW-GLASS COLOR POSITION LIGHTS (See Figure B-6)

Description

covet Gasket Hood Ring, Lens Module, Lamp Lens, Green, 4-1/2 in. *Glass Lens, Yellow, 4-1/2 in. *Glass Screw, Thumb, 10-32 x 3/8 Screw, Rd. Hd., 10-32 x 5/8 Screw, Rd. Hd., 1/4-20 x 1/2 washer, steel,Pl., #10 washer, steel Pl., 1/4 in. washer, Spring steel LK, #10 washer, Spring steel LK, 1/4 in. Plate, Mounting socket, Lamp Clamp, cable Harness

Patt No.

R451614-4101 A690969 N451614-4202 M451614-4203 M451614-4302 J053142 J053151 J507384 J525231-0ll0 J525269-0l08 J475132-0110 J475132-0l 12 J475131-0109 J475131-0lll M451614-4601 J725895 J709556 N451614-4701

*Lens listed are for cover assembly, N451614-4401. If lens othet than these are required, please specify colot, material, and lens location when ordering. see tabulation below.

LENS

Color Material Part No.

Green Glass J053142 Yellow Glass J053151 Red Glass J053141 Green Plastic J531506 Yellow Plastic J531507 Red Plastic J531505 Lunar White Plastic J531504

6231, p. B-15/8-16

... 41:

OETAIL.00

8" SC.ALE: 1/1

TLIII.HIIHAL. P'OST

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0 [?]

T"'GS .. 171

li2l

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T"'GS PLUG .. r--,

I ( I

I I I c I I I I c I I I L __ .J

._i.VE .. Si.

llO._ ... .._,._ llOII. ...... L

HA"I'" TMRnw SIOaa

CIRCUIT DIAGRAM

FOR COVER \NITJ1 LIGHTS

,.,,.

llo•.Q•i.'11- -- O•o .. COM COM

FEMALE M.4L£ l!NO CHO

SHow1NG rc,r,.,,11111,s 01" PLUGS /:o,'< .,.,,,.,Ale; PllltPOS~S.

12 .. 2 ...

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16

(FRONT. 8ACIC) SEE. D!TAlt.''8 ..

(i!>OTH E"l)S) ';,EE OET._,\\..'~S"

S\l\'n"I. "O.

-440\

·-4-41-011.

-440.3

-"404

UNION SWITCH a SIGNAL

".-. ......... \l.~EU~

~l'!IOI C.0\..0'11. \.£"51351 C.OU)\l. \.£'MS ¥11o,."t~\l.\-

.)OQ\4'. .U.'i.'M .)055151 'tltUJ:l"w I.L"'-S1'

.3531504- ":-~.!"-~ .35!11505 \l.£1) ......st \C.(OV'I\C.'°4

.)~ISO(o <a!LE'l'l .)5!5150"1 -n;:1,,.\..0'0I ~·nc.(.on1c....::,

.15~1S06' GRtE,. Jll'!USOS su.o PLASTI<.(OPTIUIII.

Vl/!.W IN OIR£CTION OF ARP.OW Al'l'LICATION Ot: NAME PLATE

""----

ALL 01MEN$10N'<> Ml'.Rll£0 * ARE FOR REF. ONLY.


Fi ure B-6. Cover Assembly With Green/~ellow Color Position Lighhts

Documents

ELECTRIC SWITCH MACHINE YM·4· OVERLOAD CUTOUT RELAY 4.6 TRAILING OPERATION V ... W'l t t:1 Ope t'"l t L ng 'L't; ... wiring diagram applying to the particular location