GM4000Aâ - Switch Machine - Alstom

GM4000A
Switch Machine
Copyright © 2005, 2007, 2011 Alstom Signaling Inc.
Operation and Maintenance Manual

P2496
GM4000A
Switch Machine
Copyright © 2005, 2007, 2011 Alstom Signaling Inc.
Operation and Maintenance Manual

Alstom Signaling Inc.
P2496, Rev. 6, July 2011, Printed in U.S.A.

LIST OF EFFECTIVE PAGES
P2496, GM4000A Switch Machine Operation and Maintenance Manual
ORIGINAL ISSUE DATE: February 2005
CURRENT REVISION AND DATE: July 2011
CURRENT CHANGE AND DATE: July 2011, Added instructions for the
installation of the secondary point monitor kit.
PAGE CHANGE OR REVISION LEVEL
Cover Jul/11
Title page Jul/11
Preface Jul/11
i thru x Jul/11
1-1 thru 1-36 Jul/11
2-1 thru 2-20 Jul/11
3-1 thru 3-54 Jul/11
4-1 thru 4-42 Jul/11
5-1 thru 5-12 Jul/11
6-1 thru 6-50 Jul/11
7-1 thru 7-28 Jul/11
A-1 thru A-24 Jul/11
P2496, Rev. 6, Jul/11 Alstom Signaling Inc.

THIS PAGE INTENTIONALLY LEFT BLANK.

PREFACE
NOTICE OF CONFIDENTIAL INFORMATION
Information contained herein is confidential and is the property of Alstom

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

1–800–717–4477
OR
WWW.ALSTOMSIGNALINGSOLUTIONS.COM
ALSTOM SIGNALING INC.

1025 JOHN STREET
WEST HENRIETTA, NY 14586
GM4000A™ is a trademark of Alstom Signaling Incorporated. All other

trademarks referenced herein are trademarks of their respective owners.

REVISION LOG
Revision Date Description By Checked Approved

0 February 2005 Original issue. MAS RR NI
1 March 2005 Updated terminals, lock MAS PP NI
rod guards, and
associated drawings and
wiring.
2 June 2005 Updated maintenance, MAS ZD NI
field wiring, configurator
and drawings.
3 July 2007 Added tools, updated MAS ZD NI
maintenance procedures
and drawings.
4 August 2007 Updated metric tools. MAS ZD NI
5 February 2011 Added new Cam Bar MAS ZD/AB NI
Detection Switch, Point
Detection System
Module, Hand Crank
Cutout Switch, Non-
Restorable Latch Out,
and updated associated
drawings and parts list.
6 July 2011 Added/updated Sections JF RR NI
2.6, 3.22, 4.3, 4.5.4, &
A.2.7 to support
Secondary Point Montior
Kit.

ABOUT THE MANUAL
This manual is intended to provide the necessary information to maintain and ensure
proper operation of an Alstom GM4000A™ Switch Machine. The information provided is
not limited to the components of the switch machine.
The information in this manual is arranged into sections. The title and a brief description
of each section follow:
Section 1 – GENERAL DESCRIPTION: This section gives general information on the

components of the GM4000A Switch Machine. Safety precautions are included in this
section.
Section 2 – THEORY OF OPERATION: This section gives general information on the

operation of the GM4000A Switch Machine. Safety precautions are included in this
section.
Section 3 – INSTALLATION: This section describes the field installation and setup of
the GM4000A Switch Machine.
Section 4 – PREVENTIVE MAINTENANCE: This section describes the tools,

preventive maintenance procedures, and functional tests used on the GM4000A Switch
Machine. The frequency and interval, for the performance of the maintenance
procedures and functional tests, are also included. Safety precautions are included in
this section.
Section 5 – TROUBLESHOOTING: This section describes possible failures/symptoms

along with the corrective action for the GM4000A Switch Machine.
Section 6 – CORRECTIVE MAINTENANCE: This section describes the adjustment

and replacement procedures associated with corrective maintenance of the GM4000A
Switch Machine. Safety precautions are included in this section.
Section 7 – PARTS CATALOG: This section identifies and lists the spare parts
associated with operation of the GM4000A Switch Machine.
Appendix A – DRAWINGS: This section has representative circuit drawings along with
an installation and space requirement drawing of the GM4000A Switch Machine.

MANUAL SPECIAL NOTATIONS
In the Alstom manuals, there are three methods used to convey special informational
notations to the reader. These notations are warnings, cautions, and notes. Both
warnings and cautions are readily noticeable by boldface type two lines beneath the
caption.
Warning
A warning is the most important notation to heed. A warning is used to tell the reader
that special attention needs to be paid to the message because if the instructions or
advice is not followed when working on the equipment then the result could be either
serious harm or death. The sudden, unexpected operation of a switch machine, for
example, or the technician contacting the third rail could lead to personal injury or death.
An example of a typical warning notice follows:
WARNING
DISCONNECT THE MOTOR ENERGY WHENEVER WORKING ON

SWITCH LAYOUT OR SWITCH MACHINE. UNEXPECTED OPERATION
OF MACHINE COULD CAUSE INJURY FROM OPEN GEARS,
ELECTRICAL SHOCK, OR MOVING SWITCH POINTS.
Caution
A caution statement is used when an operating or maintenance procedure, practice,

condition, or statement, which if not strictly adhered to, could result in damage to or
destruction of equipment. A typical caution found in a manual is as follows:
CAUTION
Turn power off before attempting to remove or insert circuit boards into a
module. Boards can be damaged if power is not turned off.
Note
A note is normally used to provide minor additional information to the reader to explain
the reason for a given step in a test procedure or to provide a background detail. An
example of the use of a note follows:
NOTE
A capacitor may be mounted on the circuit board with a RTV adhesive.

Use the same color RTV.

TABLE OF CONTENTS
Topic Page
1. SECTION 1– GENERAL DESCRIPTION ............................................................... 1-1

1.1. SCOPE OF MANUAL ........................................................................................ 1-1
1.2. SWITCH MACHINE OVERVIEW....................................................................... 1-1
1.3. STANDARD FEATURES................................................................................... 1-2
1.4. FAIL SAFE FEATURES..................................................................................... 1-5
1.4.1. Motor Driver .................................................................................................... 1-5
1.4.2. Controller ........................................................................................................ 1-5
1.5. UNIVERSAL FEATURES .................................................................................. 1-6
1.5.1. Power Supply.................................................................................................. 1-6
1.5.2. Speed ............................................................................................................. 1-6
1.5.3. Current............................................................................................................ 1-6
1.5.4. Power Input..................................................................................................... 1-6
1.6. SPECIFICATIONS............................................................................................. 1-7
1.7. MAJOR COMPONENTS ................................................................................... 1-9
1.7.1. Cam Bar........................................................................................................ 1-12
1.7.2. Cam Bar Detection Switch ............................................................................ 1-13
1.7.3. Condensation Heater .................................................................................... 1-14
1.7.4. Controller ...................................................................................................... 1-15
1.7.5. Covers .......................................................................................................... 1-16
1.7.6. Cross Brace .................................................................................................. 1-16
1.7.7. DC Motor and 172:1 Gear Box Assembly ..................................................... 1-17
1.7.8. Guards .......................................................................................................... 1-17
1.7.9. Hand Crank................................................................................................... 1-18
1.7.10. Hand Crank Cutout Switch............................................................................ 1-19
1.7.11. Hand Crank Door .......................................................................................... 1-19
1.7.12. Hand Throw Module...................................................................................... 1-20
1.7.13. Hand Throw Cutout Switch ........................................................................... 1-21
1.7.14. Latch Stands................................................................................................. 1-21
1.7.15. Lock Rod....................................................................................................... 1-22
1.7.16. Main Drive..................................................................................................... 1-23
1.7.17. Motor Gear Box Heater................................................................................. 1-24
1.7.18. Motor Limit Switches..................................................................................... 1-24
1.7.19. Point Detector Module .................................................................................. 1-25
1.7.20. Point Detector Switch Module....................................................................... 1-26
1.7.21. Point Detector Rod........................................................................................ 1-27
1.7.22. Throw Bar ..................................................................................................... 1-28
1.7.23. Throw Bar and Lock Rod Wear Plates.......................................................... 1-29
1.7.24. Wire Harness ................................................................................................ 1-30
P2496, Rev. 6, Jul/11 i Alstom Signaling Inc.

1.8. SAFETY PRECAUTIONS FOR MAINTAINERS.............................................. 1-32
1.8.1. General Requirements.................................................................................. 1-33
1.8.2. Proper Attire.................................................................................................. 1-33
1.8.3. General Safety on Property .......................................................................... 1-33
1.8.4. Safety at Track Side...................................................................................... 1-34
1.8.5. Safety at Switch Machines............................................................................ 1-35
2. SECTION 2 – THEORY OF OPERATION.............................................................. 2-1

2.1. INTRODUCTION ............................................................................................... 2-1
2.2. SEQUENCE OF OPERATION .......................................................................... 2-1
2.3. POWER OPERATION....................................................................................... 2-2
2.4. DRIVE TRAIN.................................................................................................... 2-3
2.5. NORMAL AND REVERSE LOCKING ............................................................... 2-4
2.6. POINT DETECTION.......................................................................................... 2-6
2.6.1. Latch Out ........................................................................................................ 2-8
2.6.1.1. Non-Electrical Restorable Latch Out............................................................... 2-9
2.6.1.2. Mechanical Non-Restorable Latch Out ......................................................... 2-11
2.7. MANUAL SWITCH MACHINE OPERATION ................................................... 2-14
2.7.1. Hand Crank Operation .................................................................................. 2-14
2.7.2. Hand Throw Operation.................................................................................. 2-17
2.7.3. Local Operation ............................................................................................ 2-19
3. SECTION 3 – INSTALLATION............................................................................... 3-1

3.1. GENERAL ......................................................................................................... 3-1
3.2. GM4000A SWITCH MACHINE ORDERING...................................................... 3-1
3.3. PROPERTY’S REQUIREMENTS...................................................................... 3-1
3.4. WARNINGS....................................................................................................... 3-2
3.5. COMPONENTS................................................................................................. 3-3
3.6. TOOLS .............................................................................................................. 3-4
3.7. INSTALLATION ................................................................................................. 3-5
3.8. SWITCH MACHINE INSPECTION .................................................................... 3-7
3.9. SWITCH LAYOUT INSPECTION ...................................................................... 3-9
3.10. LEFT-HAND OR RIGHT-HAND CONFIGURATION........................................ 3-10
3.11. SWITCH MACHINE MOUNTING .................................................................... 3-18
3.12. ELECTRICAL WIRING .................................................................................... 3-19
3.12.1. Field Wiring................................................................................................... 3-20
3.12.1.1. Field Motor Control Wiring.......................................................................... 3-21
3.12.2. Controller Wiring Configuration Options........................................................ 3-23
3.12.3. Switch Machine Wiring.................................................................................. 3-26
3.13. SWITCH MACHINE HARDWARE INSTALLATION AND ADJUSTMENT ....... 3-27
3.14. THROW ROD INSTALLATION AND ADJUSTMENT ...................................... 3-29
3.15. LOCK ROD INSTALLATION AND ADJUSTMENT.......................................... 3-32
3.16. POINT DETECTOR ROD CONNECTOR INSTALLATION AND
ADJUSTMENT ................................................................................................ 3-34
3.17. MOTOR LIMIT ADJUSTMENT ........................................................................ 3-37
3.18. SWITCH MACHINE VERIFICATION............................................................... 3-39
3.19. APPLY TOPCOAT OF PAINT TO THE SWITCH MACHINE EXTERIOR ....... 3-40
P2496, Rev. 6, Jul/11 ii Alstom Signaling Inc.

3.20. OPTIONAL SWITCH MACHINE AND LAYOUT SENSING KIT ...................... 3-41
3.21. OPTIONAL TEST BAR INSTALLATION AND REMOVAL............................... 3-44
3.22. OPTIONAL SECONDARY POINT MONITOR INSTALLATION....................... 3-47
4. SECTION 4 – PREVENTIVE MAINTENANCE ....................................................... 4-1

4.1. GENERAL ......................................................................................................... 4-1
4.2. INTRODUCTION ............................................................................................... 4-1
4.3. PREVENTIVE MAINTENANCE INDEX ............................................................. 4-2
4.3.1. Special Tools and Test Equipment ................................................................. 4-3
4.3.2. After Flooding ................................................................................................. 4-5
4.3.3. Warnings......................................................................................................... 4-6
4.4. EVERY 7500 OPERATIONS (OR SEMI-ANNUALLY, WHICHEVER COMES
FIRST) ............................................................................................................... 4-7
4.4.1. 7500 Operations Switch Machine Lubrication................................................. 4-7
4.5. MONTHLY MAINTENANCE .............................................................................. 4-9
4.5.1. External Switch Machine Inspection ............................................................... 4-9
4.5.1.1. Hand Crank Cutout Operation Verification.................................................... 4-11
4.5.2. Hand Throw Operation Verification ............................................................... 4-13
4.5.3. Primary Point Detector Verification ............................................................... 4-16
4.5.4. Secondary Point Detector Verification (Optional).......................................... 4-17
4.5.5. Point Pressure Test ...................................................................................... 4-19
4.5.6. Switch Obstruction Test ................................................................................ 4-20
4.5.7. Latch Out Verification Test............................................................................ 4-27
4.6. QUARTERLY MAINTENANCE........................................................................ 4-28
4.6.1. Internal Switch Machine Inspection............................................................... 4-28
4.7. SEMI-ANNUAL MAINTENANCE ..................................................................... 4-32
4.7.1. Back Linkage and Gear Box Lubrication....................................................... 4-32
4.8. ANNUAL MAINTENANCE ............................................................................... 4-34
4.8.1. Switch Machine Lubrication .......................................................................... 4-34
4.9. AS REQUIRED MAINTENANCE..................................................................... 4-35
4.9.1. Lock Rod and Point Detector Adjustments ................................................... 4-35
4.9.2. Point Detector Rod Adjustment..................................................................... 4-37
4.9.3. Gear Box Lubricant Replacement ................................................................. 4-40
4.9.4. Main Drive Roller Inspection ......................................................................... 4-41
4.9.5. Gear Box Output Shaft and Key Inspection .................................................. 4-41
5. SECTION 5 – TROUBLESHOOTING..................................................................... 5-1

5.1. GENERAL ......................................................................................................... 5-1
5.2. PHILOSOPHY ................................................................................................... 5-1
5.3. POSSIBLE SYMPTOMS AND CORRECTIVE ACTIONS.................................. 5-1
5.3.1. Symptoms Noticed from the Control Locations............................................... 5-2
5.3.2. Symptoms Noticed from the Wayside Locations, Standard Controller............ 5-3
5.3.3. Symptoms Noticed from the Wayside Locations, Enhanced Controller .......... 5-5
5.3.4. Controller LED Display.................................................................................... 5-7
5.3.4.1. Standard Controller LED Display .................................................................... 5-8
5.3.4.2. Enhanced Motor Controller LED Display ........................................................ 5-9
5.3.4.3. Controller Fault ............................................................................................. 5-12
P2496, Rev. 6, Jul/11 iii Alstom Signaling Inc.

6. SECTION 6 – CORRECTIVE MAINTENANCE ...................................................... 6-1
6.1. GENERAL ......................................................................................................... 6-1
6.2. REMOVAL AND REPLACEMENT PROCEDURES........................................... 6-1
6.2.1. Covers ............................................................................................................ 6-2
6.2.2. Cross Brace .................................................................................................... 6-3
6.2.3. Controller ........................................................................................................ 6-4
6.2.4. DC Motor and 172:1 Gear Box ....................................................................... 6-6
6.2.5. Main Drive....................................................................................................... 6-9
6.2.6. Motor Limit Switch(es) .................................................................................. 6-12
6.2.7. Cam Bar Detection Switch ............................................................................ 6-13
6.2.8. Hand Throw Cutout Switch ........................................................................... 6-15
6.2.9. Hand Crank Cutout Limit Switch ................................................................... 6-17
6.2.10. Hand Throw Module...................................................................................... 6-20
6.2.11. Latch Stand(s) .............................................................................................. 6-26
6.2.12. Lock Rod....................................................................................................... 6-27
6.2.13. Point Detector System Module ..................................................................... 6-28
6.2.14. Point Detector Switch Module....................................................................... 6-37
6.2.15. Point Detector Rod........................................................................................ 6-39
6.2.16. Point Detector Rod Bushing.......................................................................... 6-41
6.2.17. Throw Bar ..................................................................................................... 6-43
6.2.18. Throw Bar and Lock Rod Wear Plate Assembly ........................................... 6-45
6.2.19. Condensation Heater .................................................................................... 6-47
6.2.20. Motor Gear Box Heater................................................................................. 6-48
7. SECTION 7 - PARTS CATALOG ........................................................................... 7-1

7.1. GENERAL ......................................................................................................... 7-1
7.2. PARTS LISTS.................................................................................................... 7-1
A. APPENDIX A - DRAWINGS ...................................................................................... 1

A.1. OVERVIEW .......................................................................................................... 1
A.2. WIRING AND CIRCUIT APPLICATIONS ............................................................. 2
A.2.1. 2-Wire Configuration For Replacement of Alstom Model 55E Switch
Machines ........................................................................................................... 2
A.2.2. 3-Wire Configuration For Replacement of Alstom Model 5E & 5F Switch
Machines ........................................................................................................... 3
A.2.3. 3-Wire Configuration For Replacement of US&S Model M23A or M3 Switch
Machine ............................................................................................................. 5
A.2.4. 4-Wire Configuration For Replacement of Alstom Model 5G and 5H Switch
Machines ........................................................................................................... 6
A.2.5. 5-Wire Configuration For Replacement of US&S Model M23A, M23B, or M3
Switch Machines ................................................................................................ 8
A.2.6. Terminal Block Pin Outs .................................................................................. 10
A.2.7. Secondary Point Monitor Circuit ...................................................................... 11
A.2.8. Typical Polarized Switch Circuits ..................................................................... 12
A.2.9. Typical Neutral Switch Circuits......................................................................... 17
A.2.10. GM4000A Wiring Diagram ............................................................................... 21
P2496, Rev. 6, Jul/11 iv Alstom Signaling Inc.

LIST OF FIGURES
Figure No. Title Page
Figure 1-1. GM4000A Switch Machine......................................................................... 1-1

Figure 1-2. GM4000A Switch Machine With Covers Closed and Guards Installed ...... 1-7
Figure 1-3. GM4000A Switch Machine Dual Control – Exterior View ......................... 1-10
Figure 1-4. GM4000A Switch Machine Dual Control – Interior View .......................... 1-11
Figure 1-5. Cam Bar................................................................................................... 1-12
Figure 1-6. Cam Bar Detection Switch ....................................................................... 1-13
Figure 1-7. Condensation Heater ............................................................................... 1-14
Figure 1-8. Controller ................................................................................................. 1-15
Figure 1-9. Cross Brace ............................................................................................. 1-16
Figure 1-10. DC Motor and 172:1 Gear Box Assembly .............................................. 1-17
Figure 1-11. Hand Cranks .......................................................................................... 1-18
Figure 1-12. Hand Crank Cutout Switch..................................................................... 1-19
Figure 1-13. Hand Throw Lever and Selector Lever................................................... 1-20
Figure 1-14. Hand Throw Cutout Switch .................................................................... 1-21
Figure 1-15. Latch Stands .......................................................................................... 1-21
Figure 1-16. Lock Rods .............................................................................................. 1-22
Figure 1-17. Main Drive.............................................................................................. 1-23
Figure 1-18. Motor Gear Box Heater .......................................................................... 1-24
Figure 1-19. Point Detector Module............................................................................ 1-25
Figure 1-20. Point Detector Switch Module ................................................................ 1-26
Figure 1-21. Point Detector Rods ............................................................................... 1-27
Figure 1-22. Throw Bar .............................................................................................. 1-28
Figure 1-23. Throw Bar and Lock Rod Wear Plates ................................................... 1-29
Figure 1-24. Wire Harness ......................................................................................... 1-31
Figure 2-1. GM4000A Lengthwise Cross Section ........................................................ 2-3

Figure 2-2. Throw Bar Locking Position ....................................................................... 2-5
Figure 2-3. Non-Restorable Latch Out, GM4000A at Mid Stroke ............................... 2-11
Figure 3-1. Typical GM4000A Switch Layout ............................................................... 3-2

Figure 3-2. GM4000A Internal Wiring Components ................................................... 3-19
Figure 3-3. TB1 Terminal Locations ........................................................................... 3-22
Figure 3-4. GM4000A Controller Wiring Configuration Options.................................. 3-25
Figure 3-4. Secondary Point Monitor Kit (P/N GMK50-023-01).................................. 3-47
Figure 5-1. Enhanced Controller Reset Location ......................................................... 5-2
Figure 7-1. GM4000A Switch Machine Assembly Drawing, Sheet 1 of 8 ..................... 7-3
Figure 7-2. Alstom Model GM4000A Wire Harness, P/N GMV00-900-00 .................. 7-21
Figure 7-3. Tools and Kits .......................................................................................... 7-25
Figure A-1. 2-Wire Circuit For Replacement of Alstom Model 55E Switch Machines...A-2
Figure A-2. 3-Wire Circuit For Replacement of Alstom Model 5E and 5F
Switch Machines, Right Hand Point Normally Closed ...............................A-3
P2496, Rev. 6, Jul/11 v Alstom Signaling Inc.

Figure A-3. 3-Wire Circuit For Replacement of Alstom Model 5E and 5F Switch
Machines, Left Hand Point Normally Closed ............................................A-4
Figure A-4. 3-Wire Circuit For Replacement of US&S Model M23A or M3 Switch
Machine.....................................................................................................A-5
Figure A-5. 4-Wire Circuit For Replacement of Alstom Model 5G and 5H Switch
Machines, Right Hand Point Normally Closed ...........................................A-6
Machines, Left Hand Point Normally Closed .............................................A-7
Figure A-7. 5-Wire Circuit For Replacement of US&S Model M23A, M23B, or M3
Switch Machines, Right Hand Point Normally Closed, with Plug In Type
Relays .......................................................................................................A-8
Figure A-8. 5-Wire Circuit For Replacement of US&S Model M23A, M23B, or M3 Switch
Machines, Right Hand Point Normally Closed, with PP-151, PN150BM or
N-150SO Relays........................................................................................... 9
Figure A-9. Terminal Block Pinouts ............................................................................... 10
Figure A-10. Secondary Point Monitor Circuit ............................................................... 11
Figure A-11. Typical Polarized Switch Repeater Circuit, Single Switch, Indication in
Hand Throw ................................................................................................ 12
Figure A-12. Typical Polarized Switch Repeater Relay Circuit Crossover, Indication in
Hand Throw ................................................................................................ 13
Figure A-13. Typical Polarized Switch Repeater Relay Circuit Crossover, No Indication
in Hand Throw ......................................................................................................... 14
Figure A-14. Typical Polarized Switch Repeater Circuit, Single Switch, No Indication in
Hand Throw ................................................................................................ 15
Figure A-15. Typical 6 Wire Polarized Switch Repeater Relay Circuit Crossover,
Indication in Hand Throw ......................................................................... 16
Figure A-17. Typical Neutral Switch Repeater Circuit, Single Switch, Indication in Hand
Throw....................................................................................................... 18
Figure A-18. Typical Neutral Switch Repeater Relay Circuit Crossover, No Indication in
Hand Throw ............................................................................................. 19
Figure A-19. Typical Neutral Switch Repeater Relay Circuit Crossover, Indication in
Hand Throw ............................................................................................. 20
Figure A-20. GM4000A Wiring Diagram, Sheet 1 of 4................................................... 21
P2496, Rev. 6, Jul/11 vi Alstom Signaling Inc.

LIST OF TABLES
Table No. Title Page
Table 2-1. Switch Movement........................................................................................ 2-7

Table 2-2. Non-Electrical Restorable Latch Out Sequence .......................................... 2-9
Table 2-3. Reset Mechanical Non-Restorable Latch Out Procedure.......................... 2-12
Table 2-4. Hand Crank Operation Procedure............................................................. 2-14
Table 2-5. Hand Throw Operation Procedure ............................................................ 2-17
Table 2-6. Local Operating Procedure for GM4000A Machines Equipped with a
Standard Controller (P/N GMV00-043-00) ................................................. 2-19
Table 2-7. Local Operating Procedure for GM4000A Machines Equipped with an
Enhanced Controller (P/N GMV00-044-00)................................................ 2-20
Table 3-1. Switch Machine Installation Outline............................................................. 3-5

Table 3-2. Switch Machine Inspection Procedure ........................................................ 3-7
Table 3-3. Switch Layout Inspection Procedure ........................................................... 3-9
Table 3-4. Switch Machine Right/Left Hand Reconfiguration Procedure.................... 3-11
Table 3-5. Switch Machine Mounting Procedure ........................................................ 3-18
Table 3-6. Field Wiring Configurations ....................................................................... 3-21
Table 3-7. Controller Wiring Connections................................................................... 3-24
Table 3-8. Switch Machine Wiring Procedure ............................................................ 3-26
Table 3-9. Throw Rod Installation and Adjustment Procedure ................................... 3-29
Table 3-10. Lock Rod Connector Installation and Adjustment Procedure .................. 3-32
Table 3-11. Point Detector Rod Connector Installation and Adjustment Procedure ... 3-34
Table 3-12. Motor Limit Adjustment Procedure .......................................................... 3-37
Table 3-13. Switch Machine Verification Procedure ................................................... 3-39
Table 3-14. Apply Topcoat of Paint to the Switch Machine Exterior Procedure ......... 3-40
Table 3-15. Throw Rod Point Pressure Verification Procedure .................................. 3-41
Table 3-16. Test Bar Installation and Removal Procedure ......................................... 3-44
Table 3-17. Secondary Point Monitor Kit Installation Procedure ................................ 3-48
Table 4-1. Preventive Maintenance Index .................................................................... 4-2

Table 4-2. 7500 Operations Switch Machine Lubrication Procedure............................ 4-7
Table 4-3. External Switch Machine Verification Procedure......................................... 4-9
Table 4-4. Hand Crank Cutout Operation Verification Procedure............................... 4-11
Table 4-5. Hand Throw Operation Verification Procedure.......................................... 4-13
Table 4-6. Primary Point Detector Verification Procedure .......................................... 4-16
Table 4-7. Secondary Point Detector Verification Procedure ..................................... 4-18
Table 4-8. Point Pressure Test Procedure ................................................................. 4-19
Table 4-9. Narrow Notch Lock Rod Switch Obstruction Test Procedure For Lock
Rod With 2.13" (5.4 cm) Wide Notch.......................................................... 4-20
Table 4-10. Wide Notch Lock Rod Switch Obstruction Test Procedure For Lock Rod
With 2.31" (5.9 cm) Wide Notch .............................................................. 4-24
Table 4-11. Latch Out Verification Test Procedure .................................................... 4-27
Table 4-12. Internal Switch Machine Inspection Procedure ....................................... 4-28
Table 4-13. Back Linkage and Gear Box Lubrication Procedure................................ 4-32
P2496, Rev. 6, Jul/11 vii Alstom Signaling Inc.

Table 4-14. Annual Switch Machine Lubrication Procedure ....................................... 4-34
Table 4-15. Narrow Notch Lock Rod Adjustment Procedure For Lock Rod With 2.13"
(5.4 cm) Wide Notch................................................................................ 4-35
Table 4-16. Wide Notch Lock Rod Adjustment Procedure For Lock Rod With 2.31"
(5.9 cm) Wide Notch................................................................................ 4-36
Table 4-17. Point Detector Rod Adjustment Procedure.............................................. 4-37
Table 4-18. Gear Box Lubricant Replacement Procedure.......................................... 4-40
Table 4-19. Main Drive Roller Inspection Procedure .................................................. 4-41
Table 4-20. Gear Box Output Shaft and Key Inspection Procedure ........................... 4-41
Table 5-1. Symptoms Noticed from the Control Locations ........................................... 5-2
Table 5-2. Symptoms Noticed from the Wayside Locations, Standard Controller ....... 5-3
Table 5-3. Symptoms Noticed from the Wayside Locations, Enhanced Controller ..... 5-5
Table 5-4. Controller LED Functions ............................................................................ 5-7
Table 5-5. Standard Controller LED Displays............................................................... 5-8
Table 5-6. Enhanced Controller LED Displays ............................................................. 5-9
Table 5-7. Overload Fault Symptoms......................................................................... 5-10
Table 5-8. Motor Fault Symptoms .............................................................................. 5-11
Table 5-9. Controller Fault Symptoms........................................................................ 5-12
Table 6-1. Cover Removal and Replacement Procedure ............................................. 6-2

Table 6-2. Cross Brace Removal and Replacement Procedure................................... 6-3
Table 6-3. Controller Removal and Replacement Procedure ....................................... 6-4
Table 6-4. DC Motor and Gear Box Removal and Replacement Procedure ................ 6-6
Table 6-5. Main Drive Removal and Replacement Procedure ..................................... 6-9
Table 6-6. Motor Limit Switch Removal and Replacement Procedure ....................... 6-12
Table 6-7. Cam Bar Detection Switch Removal and Replacement Procedure........... 6-13
Table 6-8. Hand Throw Cutout Switch Removal and Replacement Procedure .......... 6-15
Table 6-9. Hand Crank Cutout Limit Switch Removal and Replacement Procedure .. 6-17
Table 6-10. Hand Throw Module Removal and Replacement Procedure .................. 6-20
Table 6-11. Latch Stand Removal and Replacement Procedure ............................... 6-26
Table 6-12. Lock Rod Removal and Replacement Procedure ................................... 6-27
Table 6-13. Point Detector System Module Removal and Replacement Procedure .. 6-28
Table 6-14. Point Detector System Module Adjustment Procedure ........................... 6-30
Table 6-15. Point Detector Switch Module Removal and Replacement Procedure.... 6-37
Table 6-16. Point Detector Rod Removal and Replacement Procedure .................... 6-39
Table 6-17. Point Detector Rod Bushing Removal and Replacement Procedure ...... 6-41
Table 6-18. Throw Bar Removal and Replacement Procedure .................................. 6-43
Table 6-19. Throw Bar and Lock Rod Wear Plate Removal and Replacement Procedure
............................................................................................................... 6-45
Table 6-20. Condensation Heater Removal and Replacement Procedure................. 6-47
Table 6-21. Motor Gear Box Heater Removal and Replacement Procedure.............. 6-48
P2496, Rev. 6, Jul/11 viii Alstom Signaling Inc.

Table 7-1. Alstom Model GM4000A Switch Machine Replaceable Components ....... 7-11
Table 7-2. GM4000A™ Configuration Key For Model Number Determination ........... 7-19
Table 7-3. Alstom Model GM4000A Wire Harness, P/N GMV00-900-01 ................... 7-23
Table 7-4. Alstom Model GM4000A Switch Machine Connecting Hardware.............. 7-24
Table 7-5. Alstom Model GM4000A Switch Machine Wire Entrance Couplings......... 7-24
Table 7-6. Alstom Model GM4000A Switch Machine Tools and Kits.......................... 7-27
P2496, Rev. 6, Jul/11 ix Alstom Signaling Inc.

P2496, Rev. 6, Jul/11 x Alstom Signaling Inc.

General Description
1. SECTION 1– GENERAL DESCRIPTION
1.1. SCOPE OF MANUAL
The purpose of this manual is to describe the features of the Alstom GM4000A™ Switch
Machine (GM4000A) and to explain how to properly inspect, service, test, install,
remove, and replace the recommended spare parts. See Table 7-2, GM4000A™
Configuration Key For Model Number Determination, to configure a GM4000A switch
machine with the model number (P/N WM_ _ _ _ _ _ _ _ _ _ _ _) that includes the
options for the application.
1.2. SWITCH MACHINE OVERVIEW
The GM4000A, shown in Figure 1-1, is an electric switch machine designed for use at
interlockings and derails regardless of the existing switch machine footprint, available
power, and weight of rail. A low profile makes it well suited for mainline freight or
subway and rapid transit applications. The machine footprint matches all industry
standard layouts. The machine uses 50% fewer parts than traditional electric switch
machines and it is easily field-modified to match specific site requirements.
Figure 1-1. GM4000A Switch Machine
The GM4000A is capable of delivering more than 4000 lbs. (1814.37 kg) of thrust. This
driving force makes it an ideal solution for long turnouts, installations plagued by snow
and ice, and short turnouts with welded heel blocks.
P2496, Rev. 6, Jul/11 1-1 Alstom Signaling Inc.

General Description
1.3. STANDARD FEATURES
The GM4000A is designed for long life and low maintenance, and helps reduce
inventory due to its field configurable change-out design. It is engineered with a low
stressed mechanical system, brushless motor, solid-state controller, and significantly
fewer parts than existing switch machines. The ease of field configurable change out is
the result of a modular design concept with fewer and simplified adjustments.
The GM4000A incorporates all of the features required to meet standard interlocking
practices.
NOTE
Upon receiving a switch call of 150 milliseconds or greater, the switch

machine unlocking process begins. The control system for the switch
machine application should be configured so it only generates a pulse
lasting 150 milliseconds or longer when a switch call is being made.
Standard features include:
 Modular Design
 Module locating pins in the switch machine base make it possible to remove and
replace switch machine modules at tracks
 Compact design of these modules results in an overall switch machine height of

approximately 8-3/4" (22.22 cm)
 Hand throw and hand crank options permit track switching without electrical power
 Integral Latch Stand Module
 Left or right hand configurable
 Bolted directly to the machine, no adjustment required for tie shifting
 Main Drive Module
 Single and dual control versions
 Gear Box Motor Complete
 Gear Box Heater (24 VDC, 110 VDC, or 110 VAC)

General Description
 Maintenance Free Motor and Controller
 Brushless DC motor and solid state controller
 No dynamic snubbing wire
 No magnetic detent
 LED fault indicator
 Current overload protection for high current mode
NOTE
For low current mode an external overload relay or timer must be installed
to disrupt the current to motor when the machine operates against an
obstruction.
 Heavy duty lightning protection
 Multiple operating power configurations, 24 VDC, 110 VDC, or 110 VAC
 Electronic clutch provided by a controller that uses current limit to determine the
overload trip point of the motor
 An optional enhanced controller allows field activation under power
 Advanced Drive Train
 User selectable speed
 Low maintenance gear box
 Point Detection System
 Indicates normal or reverse position
 Breaks indication if point moves away from stock rail
 Configurable latch out can be used or disabled
 Configurable latch out can be set for a restorable or non-restorable electrical

configuration
 Configurable latch out can be set for a restorable or non-restorable mechanical

configuration

General Description
 Lock Rod Module
 Wide or narrow notch configuration
 Left or right hand configurable
 Adjustable stroke
 3.5" to 6.5" (8.89 cm - 16.51 cm) for standard lock rod and point detector rod
 4.5" to 6.0" (11.43 cm -15.24 cm) stroke for optional lock rod
P/N GM050-300-05 and point detector rod P/N GMV00-500-04
 3.0" to 6.5" (7.62 cm – 16.51 cm) stroke for optional lock rod
P/N GM050-300-07 and standard point detector rod
 Split Link Cam Bar
 Allows flagging over a fouled switch without damaging hand throw arm
 Permits throw bar to complete full stroke when lock rod is fouled
 Can separate so the throw bar can complete stroke without locking the lock rod
or indicating position (normal or reverse)
 Heavy duty spring prevents premature cam bar separation
 Thick bar and knife blade end cut through ice
 Raised pads elevate cam bar from water and foreign material
 Water barrier channel and drain hole placement reduce ice build up in critical
areas

General Description
1.4. FAIL SAFE FEATURES
The universal switch machine controller is designed to be Fail Safe. Fail Safe, as used
in the signaling context, means that no single point failure causes the system to be less
safe than it would be if the failure had not occurred. That is, a single point failure leaves
the system at least as safe as it was before the occurrence of the failure.
One of the fail-safe properties is that the motor cannot turn on at the wrong time. For
example, if the motor uses a transistor as a power switch and the transistor shorts out
due to a surge, the motor is not allowed to turn on. The same holds true for the control
lines on the controller. If there are transistors or transistor junctions used as switches on
the control lines and one of them shorts out, the motor again is not allowed to run. Any
failure mode of any part of the circuitry does not cause the motor to operate. This
includes transistor junctions shorting, opening or shorting to ground. A failure, or
combination of failures, does not cause or permit the motor to operate without the
presence of a proper control signal (for example, a switch call).
Two functional blocks, the motor driver and the controller govern the fail-safe features.
1.4.1. Motor Driver
One motor driver switches power to each motor coil. If any or all drivers short out, the
field coil associated with the damaged driver(s) could be energized but would not de-
energize at the appropriate time to provide power to the motor. Therefore, the motor
stops running and remains stopped.
1.4.2. Controller
The controller is the device controlling the timing signals that control the motor driver. It
regulates the direction and the speed of the motor. The controller receives its power
only from the switch machine control lines (for example, a switch call). It can only
generate the proper sequence of signals when the control lines are energized, therefore
the motor can only run when the control lines are energized. Isolation prevents the
motor power from energizing the controller.
When the hand throw cutout limit switch or the hand crank cutout limit switch opens,
power to the controller is removed. This vitally disables the motor. The hand throw
switch and the hand crank switch are both positive double break bifurcated limit
switches. A positive double break switch contains a mechanism that breaks open frozen
or welded contacts.

General Description
1.5. UNIVERSAL FEATURES
1.5.1. Power Supply
The controller has a universal power supply. The GM4000A motor operates at a power
voltage range of 16 to 160 VDC or 85 to 140 VAC. There are no jumpers or special
configurations needed for the controller to work over these wide voltage ranges.
1.5.2. Speed
The system has two speed settings available if the supply voltage is above 110 volts
(DC or AC). Speed setting is selected by configuring the wire harness connection to the
controller.
The controller sets the motor RPM to allow the switch machine to throw against an
AREMA specified 2500 lbs. (1133.98 kg) load in a nominal 4 or 15 seconds. At 24 VDC
the switch machine throws against the AREMA specified 2500 lbs (1133.98 kg) load in a
nominal 24 seconds. Actual switch speed is dependent on several variables including
load and operating temperatures.
1.5.3. Current
The system has two current settings. High-current mode allows the machine to push up
to 4000 lbs (1814.37 kg). Low-current mode allows the machine to push up to 2500 lbs
(1133.98 kg). External fuses for both applications must be rated at 20 amps.
NOTE
For high current mode, the controller detects overload to disrupt the
current to motor when the machine operates against an obstruction.
obstruction.
The optimal installation is the high-voltage, high-current mode since this provides the
system with the most output force and allows for speed configuration. The universal
power supply allows the system to run at high-voltage with the maximum force out and
have a low-voltage battery backup. A low-voltage battery backup could supply a
minimum of 2500 lbs (1133.98 kg) load requirement.
1.5.4. Power Input
The controller runs off all input configurations. It runs in 2-wire, 3-wire, 4-wire, or 5-wire
mode depending on the controller wiring configuration.

General Description
1.6. SPECIFICATIONS
The GM4000A measures roughly 67" long, 41" wide, and 8.75" high (170.18 cm x
104.14 cm x 22.23 cm). It weighs approximately 1000 lbs (453.59 kg). Figure 1-2 shows
a top view of the switch machine with field and track sides labeled.
TRACK SIDE FIELD SIDE
67 INCHES LONG
(170.18 cm)
41 INCHES WIDE
(104.14 cm)
Figure 1-2. GM4000A Switch Machine With Covers Closed and Guards Installed

General Description
GM4000A specifications include:
 Applications – single switch, single slip switch, double slip switch, derail
 Clutch – not required
 Dynamic Snubbing – not required
 Control – single or dual
 Control Scheme – 2, 3, 4, or 5 wire
 Control Voltage – 9–35 VDC
 Control Current – 60 mA – 200 mA
 Fuse Rating – external fuses should be rated at 20 amps
 Hand Crank – available option for emergency use; with ‘pushbutton’ release of
hand crank contacts and an independent access cover
 Layout – field configurable for left or right hand throw
 Lock Rod Stroke –
 3.5" to 6.5" (8.89 cm – 16.51 cm) for standard lock rod and point detector rod
 or 4.5" to 6.0" (11.43 cm – 15.24 cm) for optional lock rod

P/N GM050-300-05 and point detector rod P/N GMV00-500-04
 or 3.0" to 6.5" (7.62 cm – 16.51 cm) stroke for optional lock rod
P/N GM050-300-07 and standard point detector rod
 Magnetic Detent – inherent in switch machine
 Motor Type – maintenance free, brushless, DC servo motor
 Mounting Requirements – universal footprint matches all industry standards
 Operating Voltage – 85-140 VAC, 16-160 VDC, machine operates at 50Hz, 60Hz,
or 100Hz AC
 Operating Current – 25A peak or 35A peak
 Operating Time (nominal) – 4 seconds or 15 seconds at 110V, configurable by

controller wiring, or 24 seconds at 24V

General Description
 Overload Protection (for high current mode only) – 5 second overload timing
begins at 20A
 Throw Bar Stroke – 6.5" (16.51 cm)
 Thrust – maximum 4000 lbs. (1814.37 kg) achievable at 85 VAC or VDC minimum,
and 35A setting
1.7. MAJOR COMPONENTS
The GM4000A contains the following field replaceable components and modules:
 Cam Bar
 Cam Bar Detection Switch
 Condensation Heater
 Controller
 Cross Brace
 DC Motor and 172:1 Gear Box Assembly
 Hand Crank
 Hand Crank Cutout Switch
 Hand Throw Lever and Selector Lever
 Hand Throw Cutout Switch
 Latch Stands
 Lock Rod
 Main Drive
 Motor Gear Box Heater
 Point Detector Module
 Point Detector Switch Module
 Point Detector Rod
 Throw Bar

General Description
 Throw Bar and Lock Rod Wear Plates
 Wire Harness
An exterior view of the top of a dual control switch machine is provided in Figure 1-3.
The guards and covers are labeled including part numbers.
An interior view from above a dual control GM4000A is provided in Figure 1-4. The main
components visible from this view are labeled including part numbers.
Inclusion of a # symbol in a part number indicates there are multiple versions (groups)
of the component; refer to the parts list in Section 7 for the correct part number for the
required configuration.
HAND CRANK HAND CRANK DOOR

(GMA50-012-00) OPEN
(GMV00-070-01)
LONG COVER
(GMV00-045-01)
GUARD, THROWBAR
GUARD, THROWBAR
TRACK SIDE
FIELD SIDE
(GM050-029-00)
(GM050-030-00)
GUARD, LOCK ROD GUARD, LOCK ROD

(GMV00-031-00) (GMV00-032-00)
SHORT COVER
(GMV00-046-01)
Figure 1-3. GM4000A Switch Machine Dual Control – Exterior View

General Description

(GMA50-012-00) (OPEN) (GMV00-070-01)
CONTROLLER,
STANDARD (GMV00-043-00)
ENHANCED, SHOWN (GMV00-044-00)
WIRE HARNESS
(GMV00-900-01)
MOTOR AND
172:1 GEAR BOX
(GMV00-025-01)
LATCH STAND
(GMV00-400-01)
THROW BAR
(GMV00-002-00)
MAIN DRIVE
(GMV00-100-01) HAND THROW LEVER,
COMPLETE
CAM BAR DETECTION
(GMV00-200-01)
SWITCH
(GMA50-107-00) LATCH STAND
POINT DETECTOR (GMV00-400-01)
SWITCH MODULE
(GM050-800-02) LOCK ROD
(GM050-300-0#)
POINT DETECTOR ROD

(GMV00-500-0#)
CONDENSATION HEATER
(55290-041-00, 24VDC or VAC POINT DETECTOR COMPLETE
OR (GMV00-700-01)
55290-042-00, 110 VDC or VAC)
Figure 1-4. GM4000A Switch Machine Dual Control – Interior View

General Description
1.7.1. Cam Bar
The split link cam bar is located under the main drive module and point detection
modules. Figure 1-5 shows top and side views of the cam bar. The cam bar is visible in
the assembly drawing, Figure 7-1 sheet 2.
TOP VIEW
SIDE VIEW
Figure 1-5. Cam Bar
The cam bar moves in a machined channel within the switch machine base and is key
to the operation of the point detector system. It is the mechanism that, in conjunction
with the lock rod, locks the switch points in position. The cam bar also prevents
indication while the switch machine is unlocked.
When the lock rod is out of position relative to the cam bar locking dog, a fouled
condition occurs. The split link allows the cam bar to separate so the throw bar can
complete stroke without locking the lock rod or indicating position (normal or reverse).
This occurrence allows switch points to be moved by the hand throw device. With the
lock rod out of position, the split-link feature permits the hand throw lever to be
positioned in the latch stand.
When the lock rod is in adjustment, the cam bar automatically resets itself when
operated once manually or electrically.

General Description
1.7.2. Cam Bar Detection Switch
The GM4000A can be configured with or without a cam bar detection switch used to
detect when the cam bar is fully engaged. The switch is normally closed and opens
when activated.
Figure 1-6 shows the cam bar detection switch, while Figure 1-4 shows its location.
12 22
11 21
Figure 1-6. Cam Bar Detection Switch

General Description
1.7.3. Condensation Heater
The GM4000A can be configured with at least one condensation heater. There are two
heaters available, and the switch machine may be ordered with one, both, or none:
1. The 24 VDC heater produces approximately 30 watts at 19.2 ohms (± 10%).
2. The 110 VDC/110 VAC heater produces approximately 30 watts at 441.0 ohms
(± 10%).
The condensation heater is used to reduce moisture caused by condensation in the
GM4000A and prevent ice from forming in the cam bar slot.
Figure 1-7 shows the condensation heater, while Figure 1-4 shows its location on a
mounting plate in the switch machine. The 24 VDC version faces the motor end, and the
110 VDC/110 VAC version faces the terminal end. When both versions are installed,
they are located on both sides of the mounting plate.
EACH ASSEMBLY IS IDENTIFIED BY ITS PART NUMBER AND OPERATING VOLTAGE.
ALSTOM PART NO.

VOLTAGE
VOLTAGE
VOLTAGE
THE WIRES FOR EACH ASSEMBLY IDENTIFY 110 OR 24 VOLT OPERATION.
PRESSURE SENSITIVE ADHESIVE

(THIS SIDE ONLY)
Figure 1-7. Condensation Heater

General Description
1.7.4. Controller
The controller controls the brushless DC motor by reading the switch call and
configuring the motor power. The configured power causes the motor to turn in the
proper direction. The controller monitors the condition of the GM4000A and checks for
obstructions, motor faults, and controller faults. LEDs mounted on the controller housing
display the switch machine operational status. The controller features an electronic
clutch, two motor speeds, two current limits, inhibit circuits to disable the motor in a
hand throw or hand crank mode, and non-restorable latch out.
Two versions of the controller are available. A standard version (P/N GMV00-043-00)
provides all of the features listed above. An enhanced version (P/N GMV00-044-00)
includes the ability to field activate the switch machine under power and includes
additional LEDs used during troubleshooting.
Figure 1-8 shows top and isometric views of both versions of the controller, while Figure
1-4 shows an advanced controller installed in a switch machine.
STANDARD CONTROLLER
RUN FAULT
POWER CONTROL MOTOR

ENHANCED CONTROLLER
REMOTE F ORWARD
RUN LOCAL REMOTE OVER CTRL MOTOR

LOCAL STOP
LOAD FAULT FAULT
RESET FAULT REVERSE
BEFORE CLOSING COVER

SWITCH TO REMOTE
Figure 1-8. Controller
A controller acts as an electronic clutch that detects the current limit of the motor. When
the current limit is reached, a 5–second timer starts. After 5 seconds, the overload trip
point is reached and the overload circuit reverses the motor for approximately one
second and then shuts down power to the motor. To resume operation, either reverse
the switch call or remove and restore supplied operational power.

General Description
The wiring of the controller configures the switch machine wiring, operation voltage, and
speed. The controller can be set for 2-wire (Model 55E), 3-wire (Model 5E/5F and Model
M23/M3), 4-wire (Model 5G/5H), or 5-wire (Model M23/M23A/M23B) power through the
wiring configuration. See Figures A–1 through A–8 for circuit drawings. See Section 3,
Installation, for wiring configuration options.
The controller is field replaceable, mounted to the switch machine case. All of its
electrical connections are made with color coded connectors. The controller electrical
connections are keyed to prevent damage to the controller.
1.7.5. Covers
The GM4000A has two lightweight aluminum covers, as shown in Figure 1-3, that
protect internal switch machine components from unwanted debris, water, or other
material. These covers are attached to the switch machine by a quick release hasp that
can be locked. The removable covers can be utilized as a tray to hold hardware or tools
during maintenance.
To remove a cover, remove all locks being used on the hasp and release the strap by
pulling up and away from the switch machine.
1.7.6. Cross Brace
The cross brace is connected to the switch machine case and supports the covers. The
cross brace can be removed to give additional access to switch machine components.
Figure 1-9 shows top view and cross section of a cross brace. The cross brace location
is shown in the assembly drawing, Figure 7-1 sheets 7 and 8.
A
A-A
Figure 1-9. Cross Brace

General Description
1.7.7. DC Motor and 172:1 Gear Box Assembly
The brushless DC motor and 172:1 gear box can be ordered as an assembly
(P/N GMV00-025-01) and installed as a single unit. The gear box (P/N GMV00-025-00)
and the motor (P/N GMV00-042-00) can also be ordered and replaced separately.
Figure 1-10 shows an isometric view of the assembly, while Figure 1-4 shows the
location of the assembly in the switch machine.
MOTOR
GEAR BOX
SPUR GEAR
Figure 1-10. DC Motor and 172:1 Gear Box Assembly
The motor works with the controller to drive the switch machine. The motor connects to
the controller by a wiring harness.
The 172:1 gear box reduces output speed while increasing output torque. The gear box
has dual input, either the hand crank or the motor. Gear box output of the spur gear
drives the main gear.
This gear box is low maintenance with spring loaded lip seals, grease packed sealed
bearings, and a synthetic lubricant for the helical gearing.
One heater is provided on the side of the gear box (see Figure 7-1, sheet 5). This
heater is used to maintain oil temperature.
1.7.8. Guards
The GM4000A has four guards that cover the throw bar, lock rod, and point detector rod
as shown in Figure 1-3. These guards may be removed during maintenance
procedures.

General Description
1.7.9. Hand Crank
When an optional hand crank is inserted, hand crank cutout limit switch is activated and
power is removed from the motor. The hand crank is used to manually operate the
switch machine so the maintainer can check adjustments and verify undue strain is not
placed on the switch layout or switch machine parts when operation by power is not
desired or is not possible.
Two hand cranks are available:
 Typical Hand Crank (P/N GMA50-012-00)
 Hex End Hand Crank (P/N GMA50-013-00)

and Ratcheting Crank (P/N 50570-015-00)
Both hand cranks activate the hand crank cutouts when installed.
Figure 1-11 shows both hand cranks, while Figure 1-3 shows the location of a hand
crank in use in a switch machine.
Hand Crank (Typical) (P/N GMA50-012-00)
Hex End Hand Crank (P/N GMA50-013-00)

and Ratcheting Crank (P/N 50570-015-00)
Figure 1-11. Hand Cranks

General Description
1.7.10. Hand Crank Cutout Switch
The GM4000A can be configured with or without hand crank capability. All models that
include hand crank capability also include a hand crank cutout switch. When the hand
crank is inserted, the cutout switch removes power from the motor.
Figure 1-12 shows the hand crank cutout switch components.
HAND CRANK CUTOUT LIMIT SWITCH
HAND CRANK CUTOUT CONTACT
HAND CRANK
Figure 1-12. Hand Crank Cutout Switch
1.7.11. Hand Crank Door
The hand crank door provides access for the hand crank. The door is shown open in
Figures 1-3 and 1-4. The door can be padlocked closed to prevent access by
unauthorized personnel.

General Description
1.7.12. Hand Throw Module
The optional hand throw module provides a manual means of switching tracks without
electrical power. It includes a hand throw lever used to hand throw the switch machine
and a hand selector lever used to select manual or power operation.
While in a hand throw mode, the switch machine can complete the stroke, lock the
switch points, and indicate normal or reverse position. The lever position is labeled and
visible from above the switch machine.
The hand throw selector lever must be in the POWER position for energy to be supplied
to the motor, enabling power operation of the switch machine. Figure 1-13 shows the
HAND and POWER positions of the selector lever.
SELECTOR LEVER HAND THROW LEVER
HAND
Figure 1-13. Hand Throw Lever and Selector Lever
For switch machines configured without a hand crank, place the hand throw lever
selector in the hand position to remove power from the switch machine motor during
maintenance procedures.

General Description
1.7.13. Hand Throw Cutout Switch
The GM4000A can be configured with or without a hand throw. All models that include a
hand throw also include a hand throw cutout switch. The switch is used to detect when
the hand throw selector lever is in the HAND position, removing power from the motor.
Figure 1-14 shows the hand throw cutout switch. The switch includes the quick connect
leads used to attach the switch to the wire harness. The switch is visible in the
assembly drawing, Figure 7-1 sheet 2.
Figure 1-14. Hand Throw Cutout Switch
1.7.14. Latch Stands
The latch stand module provides support and is a locking fixture for the hand throw
lever and selector lever. The module consists of two latch stands, that lock the selector
lever in the HAND or POWER position while locking the hand throw lever in normal or
reverse position. The latch stands bolt directly to the switch machine case. The module
accommodates right or left hand switch machine configurations.
Figure 1-15 shows the location of the latch stands.
LATCH STANDS FOR HAND THROW LEVER AND SELECTOR LEVER
Figure 1-15. Latch Stands

General Description
1.7.15. Lock Rod
The lock rod locks the front rod in position (normal or reverse) and consists of two rods
(curved and straight) that can be adjusted to vary machine stroke:
 3.5" to 6.5" (8.89 cm – 16.51 cm) for standard lock rod and point detector rod
 4.5" to 6.0" (11.43 cm – 15.24 cm) for optional lock rod P/N GM050-300-05 and
point detector rod P/N GMV00-500-04
 3.0" to 6.5" (7.62 cm – 16.51 cm) stroke for optional lock rod P/N GM050-300-07
and standard point detector rod
The lock rod accommodates right- or left-hand switch machine configurations.
The lock rod can be either a wide or narrow notch configuration. A narrow notch does
not allow the machine to lock with a 1/4" (approx. 0.635 cm) obstruction, but a wide
notch does. The lock rod can also be ordered with a threaded or spade end connection.
Figure 1-16 shows top and side views of the lock rod, while Figure 1-4 shows the
location of the lock rod in the switch machine.
THREADED END
TOP VIEW
SIDE VIEW
SPADE END
TOP VIEW
SIDE VIEW
Figure 1-16. Lock Rods

General Description
1.7.16. Main Drive
The main drive module’s patented low profile design is the driving force and mechanical
control of the switch machine.
Figure 1-17 shows the main drive, while Figure 1-4 shows the location of the main drive
in the switch machine.
Figure 1-17. Main Drive
The main drive converts the rotating motion of the motor and gear box to linear motion
of the cam bar and throw bar, both of which have cam surfaces designed to achieve
proper stroke and timing with the lock rod and point detector rod.
In the dual control main drive module, the hand throw selector lever in the HAND
position actuates a limit switch that removes electrical power to the motor permitting
hand throw operation. When the hand throw selector lever is in the POWER position,
electrical power is restored through the limit switch allowing the switch machine to be
operated electrically.

General Description
1.7.17. Motor Gear Box Heater
The GM4000A can be configured with or without a motor gear box heater. The available
heater operates at 24 VDC or 110 VAC/VDC.
The motor gear box heater is used to maintain the temperature of the motor gear box in
very cold climates.
Figure 1-18 shows the Motor Gear Box Heater. The heater is shown installed on the
motor gear box in Figure 7-1, sheet 5, detail “G.”
THERMOSTAT
Figure 1-18. Motor Gear Box Heater
1.7.18. Motor Limit Switches
Two motor limit switches are part of the wire harness. They provide feedback to the
controller, stopping the motor at completion of a stroke. One switch is open and one
switch is closed when the switch machine is at the end of stroke in the “normal” position.
When the switch machine is at the end of stroke in the “reverse” position the switch
position is reversed (the first one is closed and the second one is open). Both switches
are closed in mid stroke.
Figure 1-3 shows the location of the motor limit switches. Figure 1-24 shows the wire
harness.

General Description
1.7.19. Point Detector Module
Figure 1-19 shows the point detector module, while Figure 1-4 shows the location of the
module in the switch machine.
TOP VIEW FRONT VIEW
Figure 1-19. Point Detector Module
The point detector module rollers and pins detect the positions of the cam bar, lock rod,
and point detector rod. The point detector module pivot arm drives the rotary switch in
the point detector module to the correct position when the cam bar, lock rod, and point
detector rod move to the correct position. Then the point detector switch module
indicates normal or reverse position of the switch point.

General Description
1.7.20. Point Detector Switch Module
The point detector switch module consists of two rotary cam switches (right and left)
used to indicate the switch point position and switch machine correspondence.
Figure 1-20 shows the point detector switch module, while Figure 1-4 shows the
location of the module.
TOP VIEW
SIDE VIEW
Figure 1-20. Point Detector Switch Module
The point detector switch module bolts to the switch machine base and it is driven by
the point detector module pivot arm.
The point detector switch module, along with other components of the point detector
system, indicate to the train control room if a switch point position has moved off point
and can be utilized to indicate normal and reverse switch positioning.
Each switch has five contacts. Two are used in the indication relay circuit for a
correspondence condition; two are used to shunt the relay circuit in mid-stroke; and one
is used in the latch out circuit.

General Description
1.7.21. Point Detector Rod
The point detector rod is used to detect the position or movement of the switch points
and consists of three pieces that provide adjustment to vary switch machine stroke:
 3.5" to 6.5" (8.89 cm – 16.51 cm) for standard lock rod and point detector rod
 4.5" to 6.0" (11.43 cm – 15.24 cm) for optional lock rod P/N GM050-300-05 and
point detector rod P/N GMV00-500-04
 3.0" to 6.5" (7.62 cm – 16.51 cm) stroke for optional lock rod P/N GM050-300-07
and standard point detector rod
To meet various location configurations, there are multiple types of the point detector
rod, as shown in Figure 1-21. Figure 1-4 shows the location of the point detector rod in
the switch machine
SPADE END TOP VIEW
SIDE VIEW
SWIVEL END WITH RIVET TOP VIEW
SIDE VIEW
TOP and SIDE VIEW

THREADED ENDS NON-SWIVEL are the same
REPLACEABLE SWIVEL END WITH SHORT POINT DETECTOR ROD

TOP VIEW
SIDE VIEW
REPLACEABLE SWIVEL END WITH LONG POINT DETECTOR ROD

TOP VIEW
SIDE VIEW
Figure 1-21. Point Detector Rods

General Description
1.7.22. Throw Bar
The high strength throw bar moves the switch points into position. The integral cam and
the rotary movement of the main drive crank produce linear movement of the throw bar.
Figure 1-22 shows top and side views of a throw bar, while Figure 1-4 shows the
location of the throw bar in the switch machine.
TOP VIEW
SIDE VIEW
Figure 1-22. Throw Bar

General Description
1.7.23. Throw Bar and Lock Rod Wear Plates
Wear plates are located around the switch machine frame holes for the throw bar and
lock rod. The plates are designed to prevent premature wearing of the components.
Figure 1-23 shows the wear plate locations.
WEAR PLATES
Figure 1-23. Throw Bar and Lock Rod Wear Plates

General Description
1.7.24. Wire Harness
The wire harness connects the controller to field electrical connections at a terminal
strip located at the point detector end of the switch machine. Two sets of connectors are
provided for the optional motor gear box heater. One set of connectors hooks up to the
auxiliary terminals to provide power to another set that hooks up to the heater.
The wire harness includes connections to two motor limit switches that provide
feedback to the controller, stopping the motor at completion of a stroke. One switch is
open and one switch is closed when the switch machine is at the end of stroke in the
“normal” position. When the switch machine is at the end of stroke in the “reverse”
position the switch position is reversed (the first one is closed and the second one is
open). Both switches are closed in mid stroke.
The wire harness includes connectors to the limit switches for the optional hand throw
and hand crank features.
 The hand crank option includes a normally closed hand crank cutout switch that
opens when the optional hand crank is inserted. The switch is closed when the
hand crank is removed and the hand crank reset button is activated.
 The hand throw option includes a normally closed hand throw switch that opens
when the power selector of the optional hand throw is moved into the hand mode.
The switch is closed when the power selector is moved into the power mode.
Figure 1-24 shows the wire harness, while Figure 1-4 shows the location of the wire
harness the switch machine.
In addition, the wired harness contains connection for the Cam Bar Detection Switch
used to detect when the Cam Bar is fully engaged.

P2496, Rev. 6, Jul/11
RIGHT POINT DETECTOR
MOTOR LIMIT SWITCHES WITH

TERMINAL CONNECTIONS
QUICK DISCONNECTS
1-31
CONFIGURATION JUMPERS
General Description
Figure 1-24. Wire Harness

LEFT POINT DETECTOR
MOTOR GEARBOX HEATER

CONNECTIONS TO HEATER
MOTOR GEARBOX HEATER ACCESSORY

TERMINAL CONNECTIONS
Alstom Signaling Inc.

General Description
1.8. SAFETY PRECAUTIONS FOR MAINTAINERS
Safe practices and common sense should always be used when working around any
equipment. Remember that good common sense and an understanding of the
equipment is essential to any safety policy. The following describes health and safety
standards for testing, alterations, repairs, improvements, or maintenance and applies to
all maintenance personnel.
NOTE
Only authorized personnel who have reviewed and understand the

information contained in this manual should be working on or around the
switch machine.
The following warnings apply when working with the GM4000A switch machine.
WARNING
UNLESS OTHERWISE INDICATED, ALWAYS INHIBIT POWER TO THE

SWITCH MACHINE BEFORE WORKING ON THE MACHINE.
UNEXPECTED OPERATION OF THE MACHINE COULD CAUSE
INJURY FROM OPEN GEARS, ELECTRICAL SHOCK, OR MOVING
SWITCH POINTS.
WARNING
REMAIN CLEAR OF GEARS AND SWITCH POINTS WHEN INSERTING

HAND CRANK. UNTIL THE HAND CRANK CUTOUT LIMIT SWITCH IS
ACTIVATED THE SWITCH MACHINE CAN BE REMOTELY ACTIVATED
INSTANTLY, POSSIBLY CAUSING PERSONAL INJURY AND
EQUIPMENT DAMAGE.
WARNING
BE AWARE THAT WHEN POWER HAS NOT BEEN REMOVED FROM

THE SWITCH MACHINE, IT CAN BE REMOTELY ACTIVATED
EQUIPMENT DAMAGE.
WARNING
WHEN THE HAND CRANK IS REMOVED AND THE PUSHBUTTON IS

RESET, ALWAYS BE PREPARED FOR IMMEDIATE SWITCH
MOVEMENT. FAILURE TO DO SO COULD CAUSE INJURY BY
UNEXPECTED OPERATION.

General Description
WARNING
KEEP CLEAR OF GEARS AND SWITCH POINTS WHEN MACHINE IS

UNDER REMOTE OPERATIONAL CONTROL. POWER TO SWITCH
MACHINE CAN BE CUT OFF AT THE CONTROL ROOM. WITH
COVERS REMOVED, SWITCH MACHINE CONTROL CAN BE
CHANGED FROM CONTROL ROOM TO MACHINE.
BE AWARE THAT MACHINES WITH THE ENHANCED CONTROLLER

CONTAIN A MANUAL JOG OPERATION SWITCH THAT MAY BE
ACTIVATED WHEN THE SWITCH MACHINE COVER IS REMOVED.
EITHER CONDITION COULD CAUSE EQUIPMENT DAMAGE OR

PERSONAL INJURY.
1.8.1. General Requirements
Maintenance personnel shall comply with all local laws, rules, statutes, and regulations
of governing or regulatory authorities within the geographical area of operation of the
property (customer or authority). The requirements of these authorities or the user’s
safety manual, whichever is more stringent, shall apply. When specific standards and
details are not set forth in the manual, job specifications, or in the local laws and
regulations referenced, standards published by the Occupational Safety and Health
Administration (OSHA) shall apply.
1.8.2. Proper Attire
1. Wear hard hats at all times.
2. Wear work shoes that are in good repair. Sneakers or tennis shoes are unsafe.
3. Wear clothing of proper fit. Loose fitting clothing is a hazard.
4. Avoid wearing belt-type key rings, and never carry tools in hip pockets.
1.8.3. General Safety on Property
1. Never go out on a track of a property alone. Flaggers familiar with operating

procedures and safety regulations should accompany all field maintenance
personnel for maximum safety.
2. Always be alert and watchful as if each person were alone. Be aware of all persons
in the area at all times. Yell or signal a warning if a dangerous situation develops.

General Description
1.8.4. Safety at Track Side
1. Check for a safe place to go before starting a job and be sure that enough safe
places are available for all personnel on the track. Avoid sudden unplanned moves.
2. Never attempt to complete a job when a train is approaching.
3. Stand along the track in a clear area, stand where the train operator can see you,
and take precautionary measures.
4. When crossing the tracks in front of or behind a stopped train, cross at a great
enough distance from the train to be prepared for the train to proceed in either
direction.
5. If boarding or dismounting a train, wait until the train comes to a full stop and the
operator gives his or her permission. When carrying equipment or plans, always
hand them up or down to allow free use of your hands.
6. Never step or walk on rails. Slipping off may result in serious injury.
7. Never lay tools or equipment on the rails. Objects left on a rail may derail or damage
a train and flying debris could endanger personnel along the track.
8. When taking shelter from an approaching train, always watch for a train on the
adjacent track.
9. Exercise special caution in tunnels, curves, and turnouts and on grades, as it is very
difficult to determine the direction from which a train is approaching and its distance
away.

General Description
1.8.5. Safety at Switch Machines
1. Keep fingers, feet, tools, and equipment out of switch points. Closing points can trap
and crush hands and feet or damage tools and equipment. A wedge properly
inserted between points prevents an inadvertently energized switch machine from
causing personal injury or equipment damage.
2. Never step on switch rods. Rod movement can cause serious foot injury or loss of
balance.
3. Because the switch machine is often operated from a remote station (a local control
room), be sure to notify this station that maintainers are working on or around a
given switch machine. This notification may prevent the equipment from being
activated during the reported service.
NOTE
There are four versions of this switch machine; each version includes a
hand throw and/or a hand crank to inhibit power to the motor for safety
when working on the machine when power is not required.
To inhibit power to the motor:
 insert the hand crank, if available
 otherwise place the hand throw in the HAND position
4. When covers are removed from switch machine and gearing is exposed, keep
fingers away from gearing.

General Description

Theory of Operation
2. SECTION 2 – THEORY OF OPERATION
2.1. INTRODUCTION
This Section contains a functional overview of the GM4000A Switch Machine. Operation
is described with associated modules and components.
2.2. SEQUENCE OF OPERATION
The mechanical order of operation for the GM4000A Switch Machine is as follows:
1. Break indication
2. Unlock Points
3. Throw Points
4. Lock Points
5. Indicate if Switch Points are in Correct Position

Theory of Operation
2.3. POWER OPERATION
The GM4000A uses a brushless DC motor and a controller to drive the gear train.
 The motor starts and stops depending on the control signal received from the
control house and on the state of the machine. It runs counter clockwise or
clockwise depending on the signal present from the control house and on the state
of the machine.
 The controller decodes control signals, accepting input for motor operation
direction (clockwise and counter clockwise). It stops the motor when the limit
switch is activated. Controller failure prohibits motor operation.
The brushless DC motor contains a permanent magnet armature that rotates and drives
the gear box. The motor contains three field coils that surround the armature. The
controller energizes and de-energizes the three field coils in a circular fashion. This
creates a rotating magnetic field that pulls the armature around.
The switch machine contains three hall sensors that monitor the armature and provide
position information to the controller. This information is used to control the circuitry that
powers the three field coils. Together, the hall sensors and the controller regulate the
motor’s RPM. The motor’s RPM is independent of the switch machine’s load. This
implies that as the switch machine’s load varies; the switch machine’s throw time
remains constant (the switch machine does not slow down as the load increases).
The controller also monitors the motor’s current. Motor current is directly proportional to
motor torque. As the switch machine sees an increased load such as point pressure or
an obstruction, the motor sees an increased load. The controller senses the increased
load on the motor and supplies more current to the motor thus increasing the motor
torque. This additional motor torque increases the switch machine’s output force up to
4000 lbs. (1814.37 kg).

Theory of Operation
2.4. DRIVE TRAIN
The GM4000A Switch Machine drive train consists of a motor, a 172:1 gear box, and a
main drive module. The motor is bolted to and drives the gear box. The splined main
drive crank converts the rotational movement of gears into a linear movement of the
throw bar and cam bar. This drive train, along with the throw bar, provides the thrust
required to throw a switch in 4 or 15 seconds in 110 VDC or VAC applications and
approximately 24 seconds in 24 VDC applications. The speed of machine switching is
dependent on supplied voltage and controller configuration.
Figure 2-1 is a lengthwise cross section down the center of the GM4000A showing the
gear box and components that interact with the drive train module.
MAIN GEAR
TOP BEARING LOCK ROD
GEAR BOX CAM BAR SLOT

THROW BAR
OUTPUT GEAR CAM BAR TONGUE
Figure 2-1. GM4000A Lengthwise Cross Section

Theory of Operation
2.5. NORMAL AND REVERSE LOCKING
The throw bar and lock rod must be locked at end of stroke in the Normal or Reverse
switch point positions.
The throw bar is locked when the crank has traveled over the center of the throw bar, as
shown in Figure 2-2. When the crank is in the over-center position, any load on the
throw bar (point pressure) drives the crank roller into the locking pocket of the throw bar.
The cogging action of the motor and the gear train hold the crank in the over-center
position if there is no load on the throw bar (point pressure).
The lock rod is locked when the cam bar dog is centered in the notch of the lock rod. At
end of stroke, if the crank is not over center of the throw bar or the cam bar dog is not
centered in the lock rod notch, then the motor limit cams must be adjusted per the Motor
Limit Switch Adjustment Procedure.

Theory of Operation
POSITION MARKERS
THROW BAR
CRANK
POSITION MARKERS DETAIL
Figure 2-2. Throw Bar Locking Position

Theory of Operation
2.6. POINT DETECTION
Five components interact to perform point detection:
1. Point Detector System Module
2. Point Detector Switch Module
3. Point Detector Rod
4. Lock Rod
5. Cam Bar
See the individual component descriptions for detailed explanations of how they
function.
If additional point monitoring is required, a Secondary Point Monitor Kit

(P/N GMK50-023-01) can be installed. This optional kit provides secondary monitoring
of switch points. It can signal a 1/8” movement of switch points to help predict loss of
correspondence prior to failure at rush hour. This kit is Non-Vital and can be retrofitted
onto a GM4000A Switch Machine. It operates on 88 VDC to 132 VDC input. See
Heading 3.22 for more information.
The point detector switch module contains two positive double break rotary cam
switches. One switch rotates clockwise and one rotates counter clockwise. A positive
double break switch contains a mechanism that breaks open frozen or welded contacts.
Each rotary cam switch consists of five switches for indication, shunting, latch out, and
continuity checking.
 Switches 1 and 2 are used to shunt the NWP and WP coils in the indication relays
when the switch machine is unlocked.
 Switches 3 and 4 are used to indicate that the switch points, switch machine, lock
rod, and point detector rod are either in or out of correspondence.
 Switch number 5 is used for latch out. If the latch out function is not required, then
this contact can be used as an auxiliary contact.
The range of motion for the rotary cam switch is 60 degrees. An external spring return
mechanism returns the switch to the 0 degree position. As the switch rotates, the five
switches actuate. See Table 2-1 for detailed switch movement.

Theory of Operation
Table 2-1. Switch Movement
Switch Type 0 8 20 21 60

1 Shunt X-------------------X
2 Shunt X--------------------X
3 Indicate X---------------------------X
4 Indicate X----------------------X
5 Latch Out/ X------------------------------------–X
Auxiliary
NOTE: X-----------X = Closed Switch
If switches 3, 4, and 5 are closed (at 8 degrees or less), then the switch machine is in
correspondence and the switch machine is indicating. Switches 3, 4, and 5 are open by
21 degrees. A variance in the angle at switch opening (between 8 and 21 degrees)
occurs due to dimension tolerances for the components. Switches 3, 4, and 5 all must
be closed before the point detector system indicates.
To verify that the point detector is indicating use a multimeter on TB-1, TB-2, and TB-3
to verify contact closure. Refer to the switch machine schematic in Appendix A.
The point detector system module interfaces between the point detector rod, the lock
rod, the cam bar, and the point detector switch module. The point detector module
actuates the rotary cam switches. As the point detector rod is displaced, the pivot arm
rotates and actuates the rotary cam switch. If it moves the correct amount to 1/4" or 3/8"
(0.635 cm or 0.952 cm), the indication switches open and the indication is broken.
The point detector system interfaces with the lock rod. One pin on each point detector
pivot arm senses the position of the lock rod. If the lock rod is out of correspondence,
the pin on the pivot arm does not fall into the notch on the top of the lock rod and the
point detector system does not indicate.
The cam bar interfaces with the point detector module. The cam bar locks the lock rod.
As the machine is operated, the first thing that happens is the cam bar separates the
latch out dogs and the pivot arms. This action rotates both rotary cam switches and thus
breaks indication. The indication is broken before the cam bar dog unlocks the lock rod.
In mid-stroke, the cam bar holds latch out dogs separated on the point detector module.
This keeps both rotary cam switches rotated 25 degrees. Switches 1 and 2 stay closed,
while the NWP and the WP short out. As the switch machine reaches end-of-stroke and
the machine is locked, the cam bar leaves the latch out dogs and the pivot arms rotate
allowing the point detector switch module to indicate.

Theory of Operation
2.6.1. Latch Out
Latch out is an indication option and a mechanical memory system that stores position
information of points that have moved at least 1/4" (0.635 cm). Latch out can be
configured for 1/4" or 3/8" (0.635 cm or 0.952 cm). This discussion focuses on the 1/4"
(0.635 cm) latch out. The same principles apply for 3/8" (0.952 cm) latch out.
A switch machine without latch out responds differently to 1/4" or 3/8" (0.635 cm or
0.952 cm) movement of the switch points:
 Without Latch Out – If there is a 1/4" (0.635 cm) movement of the switch points in a
system without latch out, the point detector system does not indicate. If the points
close back up, the system re-indicates.
 With Latch Out – As the switch points open up the point detector rod moves, this
causes the pivot arms to rotate. When the switch points are open 1/4" (0.635 cm),
the switch machine does not indicate. When the point detector rod moves an
additional 0.045" (0.114 cm) the latch out dog drops behind the retaining ring. The
retaining ring and the latch out dog keep the pivot arm from rotating even if the
points close up. The pivot arm cannot rotate once the system is latched out; the
rotary cam switch numbers 3, 4, and 5 of the point detector switch module are held
open. The system is considered latched out.
The GM4000A latch out options are configured by the use of hardware:
 No Latch Out (latch out disabled) is configured by removing the retaining nuts and
rings from the point detector module as shown in Table 2-2, Step 1 and connecting
TB1–9 and TB1–10 (as shown in typical drawings in Appendix A) with a latch out
jumper. A switch machine with this configuration does not latch out.
 Mechanical Non-Restorable Latchout is configured by adding a key and dog to the

point detector module. A switch machine with this configuration can only be
restored by resting the mechanical key as shown in Table 2-3.
 Electrical Restorable Latch Out is configured by keeping the retaining nuts and
rings from the point detector module and connecting TB1–9 and TB1–10 (as
shown in typical drawings in Appendix A) with a latch out jumper. A switch machine
with this configuration can be restored remotely by issuing a switch call.
 Non-Electrical (Mechanical) Restorable Latch Out is configured by keeping the

retaining nuts and rings and removing the latch out jumper from TB1–9 and TB1–
10 (as shown in typical drawings in Appendix A). A switch machine with this
configuration can be restored remotely or locally. The system is reset remotely by
issuing a switch call. The system is reset locally by hand throwing or hand cranking
the machine, then moving the latch out dog as described in the Point Detector
System Module Adjustment procedure in Table 6-14, or by using the manual
control switch. The motor runs in restorable latch out mode.

Theory of Operation
2.6.1.1. Non-Electrical Restorable Latch Out
Table 2-2 describes the non-electrical restorable latch out system steps under normal
operation.
Table 2-2. Non-Electrical Restorable Latch Out Sequence
Step Action
1 The machine is at end-of-stroke (Normal):
 latch out switch number 5 on the Normal rotary cam switch is closed
 motor can run
ROTARY CAM
SWITCHES
CAM BAR MOTOR LIMIT

DETECTION SWITCHES
SWITCH
LATCH OUT
DOGS
RETAINING
RINGS
PIVOT ARMS
POINT DETECTOR ROD
2 The points move 1/4” + 0.045” (0.635 cm +0.114 cm):

 mechanical system latches out
 latch out switch number 5 on the Normal rotary cam switch opens
 normal motor limit switch remains open
 motor cannot run

Theory of Operation
Table 2-2. Non-Electrical Restorable Latch Out Sequence (Cont.)
Step Action
3 The latch out is reset:
 latch out switch number 5 on the Normal rotary cam switch closes
 motor can run
4 The machine moves to mid-stroke:

 latch out switch number 5 on the Normal rotary cam switch opens
 both motor limit switches are closed
 motor can run
5 The machine is at end-of-stroke (Reverse):

 latch out switch number 5 on the Reverse rotary cam switch is closed
 motor can run
6 The points move 1/4” + 0.045” (0.635 cm +0.114 cm):

 mechanical system latches out
 latch out switch number 5 on the Reverse rotary cam switch opens
 reverse motor limit switch remains open
 motor cannot run

 latch out switch number 5 on the Reverse rotary cam switch closes
 motor can run

Theory of Operation
2.6.1.2. Mechanical Non-Restorable Latch Out
Mechanical Non-Restorable latch out is an optional feature provided by the installation

of kit GMK50-020-01. Figure 2-3 shows a GM4000A with the feature installed.
This option allows a more restrictive use of the machine after a latch out situation has
occurred. A trainman is allowed to physically operate the machine (via hand throw or
hand crank), without the restoration of the correspondence circuit that has been "cut" by
the point detection system module mechanism.
Configuration with this feature in conjunction with the point detection system module,
requires a maintainer's intervention in order to restore the correspondence circuit. As
the maintainer is the only person with access to inside the GM4000A, a trainman can
not restore correspondence to a machine or track condition that has been
compromised.
Figure 2-3. Non-Restorable Latch Out, GM4000A at Mid Stroke
If latch out is triggered on a GM4000A equipped with restorable latch out, follow the
procedure in Table 2-3 to reset latch out.

Theory of Operation
Table 2-3. Reset Mechanical Non-Restorable Latch Out Procedure
Step Action
1 Resetting Latch Out from Position 1
Lift the key above bolt head and reset the dog back onto the linkage. The
dog and stop assembly returns to its normal position.
KEY
DOG
2 Lower the key and let it rest on the bearing of the left-hand dog stop
assembly,

Theory of Operation
Table 2-3. Reset Mechanical Non-Restorable Latch Out Procedure (Cont.)
Step Action
3 Resetting Latch Out From Position 2
In the locked position as illustrated, lift the key up using the handle to
disengage it from the stop.
KEY
DOG
The dogs snap back to a closed position.

4 Then reset system as described in Steps 1 and 2.
 latch out switch number 5 on the Normal rotary cam switch closes
 motor can run

Theory of Operation
2.7. MANUAL SWITCH MACHINE OPERATION
The following describes the methods for manual operation of the GM4000A Switch
Machine. All machines are equipped with a Hand Throw and/or a Hand Crank; see the
configurator in Table 7-2. Both the Hand Crank and Hand Throw Lever methods can be
performed before or after the supply power has been connected to the machine.
2.7.1. Hand Crank Operation
Hand crank operation is available on switch machines equipped with the hand crank
option. Follow the procedure in Table 2-4 to hand crank operate the GM4000A.
Table 2-4. Hand Crank Operation Procedure
Step Action
1 Unlock and open the Hand Crank Door. It is not necessary to remove the top
cover.
HAND CRANK DOOR
WARNING
REMAIN CLEAR OF GEARS AND SWITCH POINTS WHEN

INSERTING HAND CRANK. UNTIL THE HAND CRANK
CUTOUT LIMIT SWITCH IS ACTIVATED THE SWITCH
MACHINE CAN BE REMOTELY ACTIVATED INSTANTLY,
POSSIBLY CAUSING PERSONAL INJURY AND EQUIPMENT
DAMAGE.

Theory of Operation
Table 2-4. Hand Crank Operation Procedure (Cont.)
Step Action
2 Insert the hand crank into the hand crank opening and engage the shaft
protruding from the gear box. The illustration below shows the location of the
various components with the cover removed, however the hand crank may
be inserted and used with the top cover(s) closed.
HAND CRANK DOOR

(OPEN)
HAND CRANK
HAND CRANK CUTOUT
LIMIT SWITCH
HAND CRANK
SHAFT
GEAR BOX
NOTE
When the Hand Crank is inserted, the hand crank cutout limit
switch contact opens the motor power circuit. Keeping the
switch machine hand crank in place during maintenance
provides a primary safety precaution, assuring that the switch
machine does not operate electrically.
NOTE
A hex end hand crank (P/N GMA50-013-00) and a ratcheting

crank (P/N) are also available to be used as an alternate
method for hand cranking the GM4000A. This hex end hand
crank is installed in the same manner as the traditional hand
crank. The ratcheting crank is then placed on the hex end of
this hand crank.

Theory of Operation
Table 2-4. Hand Crank Operation Procedure (Cont.)
Step Action
3 Manually operate the machine by turning the crank.
NOTE
For the hex end hand crank and ratcheting crank, manually
operate the machine with the ratcheting crank.
4 After hand cranking, remove the hand crank (or the hex end hand crank and
ratcheting crank), press the Reset Button to reset the cutout switch, then
close and lock the hand crank door.
HAND CRANK RESET BUTTON
HAND CRANK
CAUTION
If the Reset Button is not pressed, the hand crank cutout limit switch does
not reset to their original POSITION and power operation is not RESTORED
to the switch machine. Closing the hand crank door does not activate the
reset button; it must be activated manually.

Theory of Operation
2.7.2. Hand Throw Operation
Hand throw operation is available on switch machines equipped with the hand throw
option. Follow the procedure in Table 2-5 to hand throw operate the GM4000A.
Table 2-5. Hand Throw Operation Procedure
Step Action
1 Release the hand throw selector lever from the latch stand and pivot it from
POWER to HAND position.
SELECTOR LEVER POWER AND HAND POSITIONS
HAND
2 Lock the selector lever in position in the latch stand.

Placing the selector lever in the HAND position:
 prevents power from energizing the switch machine motor, disabling
switch machine operation under power
 allows the main drive bevel gear to engage with the manual gear

Theory of Operation
Table 2-5. Hand Throw Operation Procedure (Cont.)
Step Action
3 Release the hand throw lever from the latch stand and pivot it to the opposite
latch stand and lock it in the latch stand. The pivot action causes the bevel
gear of the hand throw module to move internal mating components of the
main drive module and associated switch machine components.
ECCENTRIC PIN
HAND THROW GEAR
HAND THROW LEVER
SELECTOR LEVER
CORRESPONDENCE LETTER
 If the HAND THROW moves freely (no resistance), the switch

machine and the points are out of correspondence with the lever.
 To reset correspondence move the hand throw lever 180 degrees.

Once the lever clicks into place, move it back 180 degrees to move
the switch points.
4 For those machines equipped with the optional hand throw lever letter kit,
Verification that the location of correspondence letters N and R on the hand
throw lever correspond to the position of the switch points.
If the letters are out of correspondence, remove the mounting hardware
holding the N and R letters to the hand throw lever and properly position
them. Replace mounting hardware to secure letters to lever.
5 After hand throwing, release the selector lever from the latch stand, pivot the
selector lever from HAND to POWER to enable switch machine power
operation, and lock it in the latch stand.

Theory of Operation
2.7.3. Local Operation
Local operation is field activating the switch machine under power. Follow Table 2-6 for
local operation of switch machines equipped with the standard controller (P/N GMV00-
043-00) and Table 2-7 for local operation of switch machines equipped with the
enhanced controller (P/N GMV00-044-00).
Table 2-6. Local Operating Procedure for GM4000A Machines Equipped with a
Standard Controller (P/N GMV00-043-00)
Step Action
1 Remove all covers exposing modules.
2 Remove one of the DC+ wires from terminal block to cause an absence of
normal or reverse position indication. This absence of indication causes a
switch call to be automatically issued.
OR
Request a switch call from the dispatch office.
3 If during Step 2 the DC+ wire was removed from terminal block, reinstall the
DC+ wire to the terminal block.
4 Replace and lock all covers.

Theory of Operation
Table 2-7. Local Operating Procedure for GM4000A Machines Equipped with an
Enhanced Controller (P/N GMV00-044-00)
Step Action
1 Remove all covers exposing modules.
2 Position LOCAL/REMOTE/RESET switch on controller to LOCAL.
REMOTE F ORWARD

LOCAL STOP
LOAD FAULT FAULT
RESET FAULT REVERSE

SWITCH TO REMOTE
3 Place and hold the FORWARD/STOP/REVERSE switch in the position of the

intended move.
REMOTE F ORWARD

LOCAL STOP
LOAD FAULT FAULT
RESET FAULT REVERSE

SWITCH TO REMOTE
4 Release the FORWARD/STOP/REVERSE switch to stop operation short of

stroke completion, if desired. Motor automatically stops when stroke is
completed if switch is not released.
5 When finished using the manual operation switch, position the
LOCAL/REMOTE/RESET switch on controller to REMOTE.
6 Replace and lock all covers.

Installation
3. SECTION 3 – INSTALLATION
3.1. GENERAL
This Section describes GM4000A installation including the required switch machine
adjustments.
3.2. GM4000A SWITCH MACHINE ORDERING
See Table 7-2, GM4000A™ Configuration Key For Model Number Determination, for
the part number to order this switch machine for the required application.
3.3. PROPERTY’S REQUIREMENTS
Satisfactory operation of a switch layout depends on correct switch machine installation,

proper switch layout adjustments, and periodic maintenance done at recommended
intervals. Model GM4000A Switch Machines should be installed in accordance with the
property’s approved switch layout, addressing the property's requirements and
specifications.
Initial installation may be performed with or without electrical energy available for
operation of the switch machine; however, some adjustments require power. Figure 3-1
shows a typical GM4000A layout with the associated mounting hardware identified.

Installation
THROW BAR CONNECTION HARDWARE

SWITCH MACHINE EXTENDED TIES
NUMBER ONE ROD
SWITCH POINTS POINT DETECTOR ROD

STOCK RAIL
LOCK ROD & POINT DETECTION CONNECTOR HARDWARE LOCK ROD
Figure 3-1. Typical GM4000A Switch Layout
3.4. WARNINGS
When performing the installation procedures, the following warnings must be heeded:
WARNING

EQUIPMENT DAMAGE.
WARNING

SWITCH POINTS.

Installation
3.5. COMPONENTS
Depending on the switch machine options ordered, the following components are used
during installation:
 GM4000A Switch Machine
 Main Drive
 Wire Harness
 Wear Plates
 Throw Bar
 Throw Bar Connector
 Throw Rod
 Lock Rod
 Lock Rod Connecting Rod
 Point Detector Rod
 Point Detector Connecting Rod
 Standard or Enhanced Controller
Components based on options chosen:
 Gear Box Heater
 Condensation Heater (24 Volt or 110 Volt)
 Hand Throw Lever
 Selector Lever
 Latch Stand
 Hand Throw Letter Kit
 Wire Harness Adapter Kit
 Cam Bar Detection Switch
 Hand Crank

Installation
3.6. TOOLS
The following tools are required for installation of the GM4000A switch machine:
 1/4" and 3/8" Spoon Gauge (P/N GMA50-002-00) (approx. 0.635 cm and 0.952
cm)
 Multimeter
 Crescent Wrenches
 Switch Wrench 1–1/16" through 2" (approximately 2.70 cm – 5.08 cm)
 Terminal Nut Wrench, AREMA or Alstom
 Drill for Switch Machine Mounting
 Optional Hand Crank (P/N GMA50-012-00)
OR
Optional Hand Crank, Hex End (P/N GMA50-013-00) for use with Ratcheting
Crank (P/N 50570-015-00)
 Optional Switch Machine and Layout Load Sensing Kit (P/N 59649-218-00)
 Optional Test Bar (P/N 59517-006-00)

Installation
3.7. INSTALLATION
Detailed GM4000A installation instructions are provided in the tables summarized in

Table 3-1. Unless otherwise indicated, perform these procedures in the order provided.
Each step is covered in further detail in the remainder of this Section, in the identified
tables.
Table 3-1. Switch Machine Installation Outline
Installation Procedure Table

Switch Machine Inspection 3-2
Switch Layout Inspection 3-3
Switch Machine Hand Reconfiguration (only when the switch 3-4
machine must be changed from left to right hand operation or right
to left hand operation to meet layout requirements)
Switch Machine Mounting 3-5
Switch Machine Wiring 3-8
Throw Rod Installation and Adjustment 3-9
Lock Rod Connector Installation and Adjustment 3-10
Point Detector Rod Connector Installation and Adjustment 3-11
Motor Limit Adjustment 3-12
Switch Machine Verification 3-13
Apply Topcoat of Paint to the switch machine Exterior 3-14
Field Wiring Configurations are summarized in Table 3-6 and Controller Wiring
Connections are summarized in Table 3-7.
There are three accessories discussed at the end of this Section:
 The Switch Machine and Layout Load Sensing Kit is available to detect point
pressure at each point to verify the force generated against the points when the
switch machine is thrown. See Table 3-15, Throw Rod Point Pressure Verification
Procedure that describes how to use this kit.
 The Test Bar is available to actuate the switch machine when it is not attached to
the rails so that the Throw Bar, Lock Rod, and Point Detector Rod move as if
attached to the rails. See Table 3-16 for the Test Bar Installation and Removal
Procedure.

Installation
 The Secondary Point Monitor Kit provides secondary monitoring of switch points. It
can signal a 1/8” movement of switch points to help predict loss of correspondence
prior to failure at rush hour. See Table 3-17 for the Secondary Point Monitor Kit
Installation Procedure.
NOTE
During some of the installation procedures it is necessary to manually

move the switch machine into various mid stroke positions. Moving the
switch machine to these positions can be accomplished as follows:
 Use the optional hand crank.
 If power is available to the switch machine and the machine is equipped with
the enhanced controller, verify the hand throw selector lever is in the POWER
position (if equipped) and/or the hand crank is removed and the hand crank
cut out switch is reset. Then use the controller’s local operation feature to
reach the designated position.
 In dual control machines, place the hand throw selector lever in the HAND
position and then use the hand throw.

Installation
3.8. SWITCH MACHINE INSPECTION
A visual inspection of external switch machine areas should be performed prior to

installation. Follow the procedure in Table 3-2 to perform the pre-installation switch
machine inspection.
Table 3-2. Switch Machine Inspection Procedure
Step Action
1 Check the configuration of the machine being installed. If the switch machine
requires reconfiguration from left-hand to right-hand or vice versa, perform the
reconfiguration procedure provided in Table 3-3.
2 Check the switch machine control requirements (single or dual). Compare the
configuration number of the machine to the configuration key in Section 7 to
verify control configuration.
3 Check the switch machine for proper lock rod configuration (narrow notch or
wide notch). Compare the configuration number of the machine to the
configuration key in Section 7 to verify lock rod configuration.
4 Check the switch machine for proper point detection rod connection
configuration (spade end or threaded end). Compare the configuration number
of the machine to the configuration key in Section 7 to verify connection
configuration.
5 Check the switch machine for proper connecting hardware and wire entrance
coupling, see Table 3-6 and Table 3-7.
6 Check external surfaces for any damage (bent, cracked, or broken case,
hinges, or brackets).
7 Insure covers are installed properly and fit tightly. Adjust as needed by
adjusting the T bolts and hasp.
T BOLTS
HASP

Installation
Table 3-2. Switch Machine Inspection Procedure (Cont.)
Step Action
8 Insure wear plates are in place on both sides of the switch machine case.
WEAR PLATES
9 Insure point detector rod bushings are in place on both sides of the switch
machine case.
POINT DETECTOR ROD BUSHING

Installation
3.9. SWITCH LAYOUT INSPECTION
The switch layout must be inspected before installation of a switch machine. Follow the
procedure in Table 3-3 and correct any discrepancies prior to installing the GM4000A.
Table 3-3. Switch Layout Inspection Procedure
Step Action
1 Inspect the heel blocks and bolts. Insure that the thimble bolts in the heel
blocks are in place and secure.
2 Examine the heel block surface in relation to the switch by sighting down the
rail from the heel block to switch point. Verify that the surface is uniform.
3 Check that rail braces are tight and tie straps are in place and secure.
4 Verify that all gauge plates, extension gauge plates, rail braces, and ties
conform to the layout.
5 Check that the track gauge distance is correct per customer standards at the
throw-bar and lock rod locations.
TRACK GAUGE DISTANCE
SWITCH POINTS STOCK RAIL

Installation
3.10. LEFT-HAND OR RIGHT-HAND CONFIGURATION
To change the configuration of the GM4000A from left to right hand, or right to left hand,
follow the procedure provided in Table 3-4. During this procedure the following
components are moved or adjusted:
 Throw Bar Coupling (Steps 1 to 3)
 Lock Rod (Steps 4 to 6)
 Point Detector Rod (Step 7)
 Hand Throw Lever and Latch Stand, optional components (Steps 9 to 29)

Installation
Table 3-4. Switch Machine Right/Left Hand Reconfiguration Procedure
Step Action
1 Remove power to the switch machine by inserting the hand crank or placing
the hand throw selector lever in the HAND position.
2 Remove all covers and guards to expose the modules.
(GMA50-012-00) OPEN
(GMV00-070-01)
LONG COVER
(GMV00-045-01)
GUARD, THROWBAR
GUARD, THROWBAR
TRACK SIDE
FIELD SIDE
(GM050-029-00)
(GM050-030-00)

(GMV00-031-00) (GMV00-032-00)
SHORT COVER
(GMV00-046-01)

Installation
Table 3-4. Switch Machine Right/Left Hand Reconfiguration Procedure (Cont.)
Step Action
3 Change the throw bar coupling from one end of the throw bar to the other. See
the layout for coupling location.
(GMA50-012-00) (OPEN) (GMV00-070-01)
CONTROLLER,
STANDARD (GMV00-043-00)
ENHANCED, SHOWN (GMV00-044-00)
WIRE HARNESS
(GMV00-900-01)
MOTOR AND
172:1 GEAR BOX
(GMV00-025-01)
LATCH STAND
(GMV00-400-01)
THROW BAR
(GMV00-002-00)
MAIN DRIVE
(GMV00-100-01) HAND THROW LEVER,
COMPLETE
(GMV00-200-01)
LATCH STAND
POINT DETECTOR (GMV00-400-01)
SWITCH MODULE
(GM050-800-02) LOCK ROD
(GM050-300-0#)
REMOVAL DIRECTION
REMOVAL DIRECTION 
POINT DETECTOR ROD

(GMV00-500-0#)
CONDENSATION HEATER
(55290-041-00, 24VDC or VAC POINT DETECTOR COMPLETE
OR (GMV00-700-01)
55290-042-00, 110 VDC or VAC)
4 Manually place the machine in mid stroke position (see Page 3–6).
5 Separate lock rod from lock rod connecting rod. Remove lock rod from switch
machine, rotate rod 180 degrees and insert from other end. The lock rod is
now in the opposite position.

Installation
Step Action
6 Separate point detector connecting rod and point detector rod if so connected.
Pull the point detector rod out of switch machine, rotate the rod 180 degrees,
and reinsert from the other side of the switch machine.
7 If the switch machine is equipped with a hand throw lever, continue to
Step 8.
If the machine is not equipped with a hand throw lever, jump to Step 29.
8 Place the selector lever into the HAND position. Keep this lever in the HAND
position for this whole procedure.
LATCH STAND SELECTOR LEVER LATCH STAND HAND THROW LEVER
9 Rotate the hand throw lever 90 degrees (to the vertical position) and remove
the two bolts connecting the hand throw lever to the hand throw lever support.
This makes it much easier to accomplish the remaining change over steps.
10 Remove the eight bolts attaching latch stands to the switch machine case and
remove the latch stands.
11 Remove the switch machine hasp by removing the screw through the plate
attaching it to the switch machine. Slide the hasp off the pin on the switch
machine frame and set aside.
PLATE
SCREW

Installation
Step Action
12 Remove hand throw cover plate from the opposite side of the switch machine
case.
HAND THROW COVER PLATE
13 Remove the two mount bolts attaching the hand throw module to the case.
14 While holding the hand throw module with the hand throw lever support in the
vertical position, disengage the bevel gears by pulling the module away from
the case by approximately 1/2" (1.27 cm).
HAND THROW LEVER AT 90 DEGREE

VERTICAL POSITION
15 Continue to remove the hand throw module by pulling up and away to allow
the hand throw bevel gear to clear the motor-limit cam on the gear of the main
drive module. Do not use a hammer or pry bar to separate the module.
16 Move the hand throw module to the opposite side and reverse the last step.
Clear the motor limit cam but do not engage the bevel gears.

Installation
Step Action
17 Through the case opening where the hand throw module was removed,
visually check that the shifter dog of the main drive module is engaged in the
hand throw dog gear.
18 Look through the case opening where the hand throw module was removed to
visually check that the timing mark on top surface of the lower hand throw dog
gear is centered in between the two timing marks on the hand throw bevel
gear.
•
•
If the timing mark is not in the proper position, rotate the hand throw dog gear
until it reaches the proper position.

Installation
Step Action
19 With the hand throw lever support in the vertical position, engage the bevel
gears.
The module should slip in and the mounting flange should be flush with the
switch machine housing.
NOTE
Very little pressure is required for this operation. Do not hammer

or beat on the module.
20 Verify proper timing of the hand throw module by rotating the hand throw lever
support until the top gears of the main-drive module move. Rotate the hand
throw lever support to the other side until the top gears of the main drive
module move; this motion of the hand throw lever support should be equal on
either side of the vertical position. If the motion is not equal, disengage the
bevel gears and repeat Steps 17 to 19.
21 Re-install the mounting flange hardware.
22 Re-install the two latch stands on side of the machine with the hand throw
module, using existing mounting hardware.

Installation
Step Action
23 Re-install the hand throw lever, reversing the lever orientation from the
previous orientation to make sure the lever does not interfere with the point
detector rod or lock rod.
24 Insert the hand throw lever into the latch stand and check that the cam-bar
dog is engaged with lock rod.
25 Use the hand throw lever to throw the switch to the opposite position and
check that the cam-bar dog is engaged with the lock rod.
26 If this procedure is being performed prior to switch machine mounting, it is
complete, skip to Table 3-5.
If this procedure is being performed on a switch machine previously installed
and adjusted, continue with Steps 27 through 29.
27 Re-install the hasp by sliding it onto the pin on the switch machine frame.
Then insert the screw (shown in Step 11) through the plate attaching it to the
switch machine.
28 Re-install the cover plate on the opposite side of the case.
29 Re-install the connecting rods and lugs and readjust the lock rod and point
detector rod.

Installation
3.11. SWITCH MACHINE MOUNTING
The stock rail and switch machine must be secured to well tamped ties to prevent
movement of the switch machine and stock rail when connected and operated. More
than 4000 lbs. (1814.37 kg) of force can be exerted on the number one rod, shown in
Figure 3-1, by the switch machine during operation.
Gauge plates, extension gauge plates, rail braces, and tie positions must be correct.
Points must fit snugly and uniformly against the stock rails without being bent by force
from the throw bar. Excessive throw bar force disturbs the layout and causes excessive
wear to the switch machine.
Follow the procedure provided in Table 3-5 to mount the GM4000A.
Table 3-5. Switch Machine Mounting Procedure
Step Action
1 Verify that the two extended ties are reasonably straight and, where required,
properly framed. Correct, if necessary.
2 Verify that all support ties are well tamped for their entire length to minimize
vibration from passing trains.
3 Review the approved switch layout drawing(s) and position the switch
machine in the correct location.
4 Locate and mark the mounting hole pattern on the ties.
For new installations either the Alstom standard mounting hole pattern of 3/4"
(1.904 cm) diameter bolts on 15 1/2" (39.37 cm) centers or the US&S
standard mounting hole pattern of 7/8" (2.22 cm) diameter bolts on 16" (40.64
cm) centers can be used.
For replacement installation the universal mounting hole pattern interfaces
with the both the Alstom standard and US&S standard hole patterns.
5 Drill the switch machine mounting holes and mount the switch machine using
hardware identified in the machine layout drawings (hardware is layout
specific).
6 Keep the clearance between the number one rod (see Figure 3-1) and the
base of the stock rail 1/4" (0.635 cm) maximum (less is desirable) to prevent
the switch points from moving up relative to the stock rail.
.06 to .25 CLEARANCE

Installation
3.12. ELECTRICAL WIRING
The switch machine has a factory installed wire harness and connectors that integrate
the switch machine components (switches, controller, and motor). Figure 3-2 identifies
the internal wiring components of the GM4000A Switch Machine shown with enhanced
controller and hand crank cutout options. The internal wiring schematic is provided in
Appendix A.
WIRE HARNESS CONNECTOR TO

CONTROLLER
CONTROLLER
CONNECTOR
DETAIL
WIRE HARNESS
HAND CRANK WIRE ENTRANCES

CUTOUT SWITCH
Figure 3-2. GM4000A Internal Wiring Components

Installation
3.12.1. Field Wiring
Field wiring associated with motor power, control, and indications enter the switch
machine through a wire entrance fitting located at either end of the switch machine
(motor or detector compartment). Typical power, control, and indication circuits are
given in Appendix A.
 Motor Power wiring is connected to posts at TB1 in accordance with the detail
wiring plans that apply to the location.
 Control wiring is connected to posts at TB1 in accordance with the detail wiring
plans that apply to the location.
 Point detector indications wiring is connected to posts on TB1, TB2, and TB3 in
accordance with the detail wiring plans that apply to the location.
NOTE
The primary function of the motor limit switches is to provide closed loop
feedback to the switch machine’s controller. As such, the primary set of
contacts in the motor limit switches are wired through the wire harness
into the controller. A second set of motor limit switch contacts are wired to
the TB-2 and TB-3 terminal posts and are available for test purposes.
Note that this second set of motor limit switch contacts are not guaranteed
to operate when the voltage is below 24 volts while the switch machine is
under load.

Installation
3.12.1.1. Field Motor Control Wiring
Four motor control wiring configurations determine how incoming wiring is connected to
the TB1 terminals AND must be configured through the controller wiring connection.
The power lines are 24 VDC, 110 VDC, or 110 VAC. The four field wiring configurations
described below are summarized in Table 3-6. Figure 3-3 shows the TB1 terminal
locations.
 The 5-wire configuration has three power lines that are energized only when the
machine is requested to operate. These wires are connected to TB1–1, TB1–2,
and TB1–3. The throw bar travels in one direction when power is applied to TB1–1
and TB1–2 and in the other direction when power is applied to the TB1–2 and
TB1–3. The two auxiliary wires, connected to TB1–8, are common feed. (US&S
model M23A/M23B/M3)
 The 4-wire configuration has two energized power lines. These wires connect to
TB1–1 and TB1–3. The control lines connect to TB1–4 and TB1–5. The control
lines are only energized when the machine is requested to operate. (Alstom model
5G/5H)
 The 3-wire configuration has three power lines that are energized only when the
machine is requested to operate. These wires are connected to TB1–1, TB1–2,
and TB1–3. The throw bar travels in one direction when power is applied to TB1–1
and TB1–2 and in the other direction when power is applied to the TB1–2 and
TB1–3. (Alstom model 5E/5F, US&S model M23/M3)
 The 2-wire configuration has two power lines that are energized only when the
machine is requested to operate. These wires are connected to TB1–1, and TB1–
2. A jumper is added between TB1–1 and TB1–3. The throw bar travels in one
direction when power is applied to TB1–1 and in the other direction when power is
applied to the TB1–2. (Alstom model 55E)
Table 3-6. Field Wiring Configurations
2-wire 3– Wire 4-wire 5-wire

Power TB1–1 TB1–1 TB1–1 TB1–1
Power TB1–2 TB1–2 TB1–2
Power Jumper between TB1–3 TB1–3 TB1–3
TB1–1 and TB1–3
Control TB1–4
Control TB1–5
Auxiliary TB1–8 (2 wires)

Installation
1-1 P
1-2 P
1-3 P
1-4 C
1-5 C
1-6 HT
1-7 HT
1-8 AX
1-9 L0
1-10 L0
1-11 AX
1-12AX
Figure 3-3. TB1 Terminal Locations

Installation
3.12.2. Controller Wiring Configuration Options
The Controller wiring is dependent upon the desired switch machine configuration.
Controller wiring reflects control, speed, current, and voltage. Table 3-7 describes the
wiring connections required for the optional configurations and Figure 3-4 shows the
connections.
Motor control supports 2-, 3-, 4- and 5-wire configurations, as discussed under Field
Wiring. Use Table 3-7 to determine the controller wiring connections for the
configuration. The default configuration is 3-wire.
Switch machine speed at 24 VDC is approximately 24 seconds. However, at 110 VDC

or VAC there are two (2) available speeds: 4 seconds and 15 seconds. Default at 110
VDC or VAC is 15 seconds. To set the switch machine for 4 second operation perform
the wiring connection for high speed as summarized in Table 3-7.
The suggested current configuration of the GM4000A is the high-current operation

option. At this setting, the switch machine produces up to 4000 lbs. (1814.37 kg) of
force at the end of stroke. If external fuses are used to limit the current to the GM4000A,
they must be rated 20 amps.
 Low current mode - The 5 second timer shall start at 20 amps. The motor can draw
up to 25 amps. To configure the GM4000A for low current mode, perform the
wiring connection for low current as described in Table 3-7.
 High current mode - The 5 second timer shall start at 20 amps. The motor can
draw up to 35 amps. This is the default configuration.
The GM4000A is shipped with the controller configured for low voltage shutoff [with J7
(GRAY) to J6 (GRAY) disconnected]. In this configuration, the controller does not allow
the motor to operate if the supply voltage is less than 88 VDC.
To configure the switch machine for an alternate configuration, perform appropriate

wiring connection as described in Table 3-7.
NOTE
For high current mode, the controller detects overload to disrupt the
current to motor when the machine operates against an obstruction.
obstruction.

Installation
Table 3-7. Controller Wiring Connections
Configuration Wiring Connection

2-wire Mode Motor Control Connect J1 (BLACK) to J2 (BLUE), Jumper wire
between TB1–1 and TB1–3.
3-wire Mode Motor Control Connect J1 (BLACK) to J2 (BLUE)
4-wire Mode Motor Control Connect J3 (WHITE) to J2 (BLUE)
5-wire Mode Motor Control For the three control wires connect J1 (BLACK) to J2
(BLUE)
THEN
Verify that the two auxiliary wires are connected to
post TB1–8 (see Figure 3-3 for the location of TB-1)
High Speed Operation Connect J7 (GREEN) to J8 (GREEN)
Low Speed Operation Disconnect J7 (GREEN) to J8 (GREEN)
High Current Operation Connect J11 (RED) to J10 (RED)
Low Current Operation Disconnect J11 (RED) to J10 (RED)
Disable Low Voltage Operation Disconnect J7 (GRAY) to J6 (GRAY)
Enable Low Voltage Operation Connect J7 (GRAY) to J6 (GRAY)

Installation
MOTOR
CONTROLLER
J3 P1-7 J10 J11

P1-3
J2 WHITE 4W CURRENT SELECT RED RED
HC-11 BLUE J1 J8 J9
P1-15 P1-10
BLACK 3W SPEED SELECT GREEN GREEN
P1-11 J6 J7
88V SELECT GRAY GRAY
P1-17
12V SELECT
Figure 3-4. GM4000A Controller Wiring Configuration Options

Installation
3.12.3. Switch Machine Wiring
Use Table 3-7, Controller Wiring Connection, in combination with the location detail
wiring plans as reference, while performing the switch machine wiring procedure
provided in Table 3-8.
Table 3-8. Switch Machine Wiring Procedure
Step Action
1 Review the location detail wiring plans.
2 Wire the motor power to posts at terminal TB1 in accordance with the detail
wiring plans that apply to the location.
Typical power circuits are in Appendix A.
3 Wire the point detector provided indications to posts on terminals TB1, TB2,
and TB3 as shown in the detail wiring plans for the location. Typical indication
circuits are in Appendix A.
4 Wire the wire harness connector to the controller according to the detail wiring
plans for the location.
Controller wiring depends on the switch machine configuration, as
summarized in Table 3-7. To simplify the wiring, each of the wire harness
connectors is color-coded.
5 Complete the wire harness connections according to the detail wiring plans for
the location.

Installation
3.13. SWITCH MACHINE HARDWARE INSTALLATION AND ADJUSTMENT
The following tables provide the procedures for connecting and adjusting specific switch
layout hardware to the switch machine. Prior to performing these procedures, mount the
switch machine per the switch layout plan and complete the electrical wiring.
These procedures include:
 Throw Rod Installation and Adjustment (Table 3-9)
 Lock Rod Installation and Adjustment (Table 3-10)
 Point Detector Rod Installation and Adjustment (Table 3-11)
 Motor Limit Adjustment (Table 3-12)
WARNING

SWITCH POINTS.
To inhibit power to a GM4000A configured with a hand crank, unlock and open the
Hand Crank Door and install the hand crank. When the Hand Crank is installed, the
hand crank cutout limit switch opens the motor power circuit. Keeping the switch
machine hand crank in place during maintenance provides a primary safety precaution,
assuring that the switch machine does not operate electrically.
To inhibit power to the GM4000A on a machine with the hand throw option, place the
hand throw selector lever in the HAND position to open the motor power circuit. Keeping
the selector lever in the HAND position during maintenance provides a primary safety
precaution, assuring that the switch machine does not operate electrically.

Installation
NOTE
During some of the installation procedures it is necessary to move the

switch machine manually into various mid stroke positions. Moving the
switch machine to these positions can be accomplished as follows:
 Use the optional hand crank.
position and then use the controller’s local operation feature to reach the
designated position.
 For dual control machines, place the hand throw selector lever in the HAND
position and then use the hand throw.

Installation
3.14. THROW ROD INSTALLATION AND ADJUSTMENT
Table 3-9 provides the procedure for throw rod connection and adjustment within a
typical switch layout. This procedure assumes that the switch machine mounting (Table
3-5) and switch machine wiring (Table 3-8) procedures have been completed.
NOTE
During operation, if proper clearance between the top of the number one
rod (see Figure 3-1) and the base of the stock rail is not maintained, the
points may move up relative to the stock rail and pry themselves away
from the stock rail (particularly if the stock rail is beveled for AREA detail
6100 Sampson points). This motion may cause the point detector rod in
a switch machine to move enough to cause the indication contacts to be
pushed open.
The tendency of points to move up can be reduced by keeping ballast

under the ties of the switch layout firmly tamped, and maintaining proper
#1 rod clearance.
Table 3-9. Throw Rod Installation and Adjustment Procedure
Step Action
1 Verify power is removed from the switch machine by the insertion of the hand
crank or the hand throw selector lever in the hand position.
WARNING

DAMAGE.
2 Manually place the machine in mid stroke position (see Page 3–6).
3 Verify that a maximum clearance of 1/4" (0.635 cm) (less is desirable) exists
between the #1 rod and the base of the stock rail.
.06 to .25 CLEARANCE

Installation
Table 3-9. Throw Rod Installation and Adjustment Procedure (Cont.)
Step Action
4 Connect the throw rod clevis end to the throw bar coupler using the provided
bolt, lock washer, nut and cotter pin per the layout drawing.
5 Slide the threaded end of throw rod through the lost motion basket and
connect rod to the basket using the double nuts provided.
LOST MOTION BASKET THROW ROD THROW BAR
DOUBLE NUTS
6 Hand throw or hand crank the switch machine into the Normal position.
NOTE
Adjust the double nuts at the switch basket if switch points close,
preventing the switch machine from completing stroke.
7 Adjust the double nuts at the switch basket to obtain a slight pressure
condition at the closed switch point with no visible hardware deformation.
8 Secure this position using the switch basket double nuts.
9 Hand throw or hand crank the switch machine into Reverse position and
repeat Steps 7 and 8.

Installation
Table 3-9. Throw Rod Installation and Adjustment Procedure (Cont.)
Step Action
10 Hand throw, hand crank, or electrically operate the switch machine back and
forth a few times as a final check.
WARNING
WHEN THE HAND CRANK IS REMOVED AND THE

PUSHBUTTON IS RESET, ALWAYS BE PREPARED FOR
IMMEDIATE SWITCH MOVEMENT. FAILURE TO DO SO
COULD CAUSE INJURY BY UNEXPECTED OPERATION.
NOTE
Points should fit snugly and uniformly against the stock rails
without being stressed by force from the throw bar. Excessive
layout stress causes excessive wear to the switch machine.

Installation
3.15. LOCK ROD INSTALLATION AND ADJUSTMENT
Table 3-10 provides the procedure for lock rod connection and adjustment within a
typical switch layout and assumes that proper throw bar connection and adjustment
(Table 3-9) has been completed.
Table 3-10. Lock Rod Connector Installation and Adjustment Procedure
Step Action
WARNING

INSERTING HAND CRANK. UNTIL THE HAND CRANK CUTOUT
LIMIT SWITCH IS ACTIVATED THE SWITCH MACHINE CAN BE
REMOTELY ACTIVATED INSTANTLY, POSSIBLY CAUSING
PERSONAL INJURY AND EQUIPMENT DAMAGE.
2 Remove the two outer 1.000–8 adjusting nuts.

CURVED LOCK ROD LOCK ROD NOTCH
ADJUSTING NUTS (.750 - 10) LOCATING MARKS LOCK ROD THREADED SECTION
ADJUSTING PLATE ADJUSTING NUTS (1.000 - 8)
3 Position the lock rod drop lug in the center of the threaded section and reinstall
the outer two adjusting nuts tightly.
SWITCH MACHINE
LOCK ROD DROP LUG

LOCK ROD
OUTER ADJUSTING NUT
INNER ADJUSTING NUT
LOCK CONNECTING ROD
4 Manually move the switch machine to mid stroke position (see Page 3–6).
5 Position the lock rod so that the notch locating marks, on the straight lock rod
section, are centered over the cam bar.

Installation
Table 3-10. Lock Rod Connector Installation and Adjustment Procedure (Cont.)
Step Action
6 Complete the stroke of switch machine so that the track side of the throw bar
is drawn into the switch machine. Verify that the split link of the cam bar did
not separate. If the split link did separate, then hand throw, hand crank, or
manually operate the switch machine (with the enhanced controller by
following the procedure in Table 2-7) to mid stroke. Returning to mid stroke
engages the cam link. Verify that locking dog on cam bar is centered through
notch of lock rod.
7 Assemble lock connecting rod to the front rod and the lock rod drop lug
according to the layout drawing.
8 Tighten and lock nuts at drop lug and front rod lug.
9 Manually move the switch machine to opposite end of stroke, but do not lock
far switch point:
 Adjust the adjusting plate using the field side .750–10 nuts so that
locating marks on adjusting plate (shown in Step 2) are centered over
the cam bar. Complete the locking portion of the switch machine stroke.
 Verify that the cam bar locking dog is centered in the lock rod notch.
 Tighten and lock field side lock rod nuts to keep this adjustment.
10 Hand throw or hand crank the switch machine back and forth a few times and
verify that the cam bar does not separate.
WARNING
WHEN THE HAND CRANK IS REMOVED AND THE

PUSHBUTTON IS RESET, ALWAYS BE PREPARED FOR
IMMEDIATE SWITCH MOVEMENT. FAILURE TO DO SO
COULD CAUSE INJURY BY UNEXPECTED OPERATION.
11 Refer to Section 4, Periodic Maintenance, for the proper positioning of wide

notches relative to the cam bar locking dog.

Installation
3.16. POINT DETECTOR ROD CONNECTOR INSTALLATION AND ADJUSTMENT
Table 3-11 provides the point detector connection and adjustment procedure associated
with wide- and narrow notch lock rods and assumes the lock rod connector installation
and adjustment (Table 3-10) has been completed.
Table 3-11. Point Detector Rod Connector Installation and Adjustment Procedure
Step Action
WARNING

DAMAGE.
2 Position the point detector rod lug on the track end of the point detector rod
and secure the lug by placing nuts on both sides of the lug as shown below.
FIXED END
TOPVIEW
SWIVEL END
TOPVIEW
POINT DETECTOR ROD LUG

POINT DETECTOR ROD ADJUSTING NUTS, 4 (1.000-8)
POINT DETECTOR CONNECTING ROD
SWITCH POINT LUG
3 Connect the point detector connecting rod to the switch point lug and to the
point detector rod lug.

Installation
(Cont.)
Step Action
4 Manually operate the machine (see Page 3–6) so the point detector rod is
drawn out from the track side of the switch machine to close and lock the far
switch point.
5 Position the spoon gauge into the necked down portion of the point detector
rod (track side).
Use either the 1/4" (0.635 cm) end of gauge or the 3/8" (0.952 cm) end,
whichever is required by the customer and its governing authorities.
POINT DETECTOR ROTARY CAM

SWITCH LEVER SWITCH
LATCHOUT
DOG
SPRING
PIVOT
ARM
SPOON POINT DETECTOR ROD SLAVE

GAUGE
6 Adjust position of point detector rod by turning the inner nuts at the drop lug
until pressure of the spoon gauge against the point detector pivot arm on the
point detector system module engages the track side point detector switch
lever.
Continue adjustment until the indication contacts of the rotary cam switch
open (outward position). If configured with latch out, continue adjusting until
the latch out dog of the point detector system engages (approximately an
additional 2/3 turn).
NOTE
Check the indication contact status of the cam switch (open or

closed circuit condition) using a multimeter on TB-2 or TB-3 in
accordance with the field wiring.

Installation
(Cont.)
Step Action
7 Tighten and lock the four nuts at the drop lug that hold this adjustment.
Remove the spoon gauge. If configured with latch out, verify that the cam
switch indication contacts are still open. Release the latch out condition by
applying a light force to the spring end of the latch out dog.
8 Manually move the machine to draw the point detector rod into the machine.
9 Position the spoon gauge in the necked down portion of the point detector rod
(field side). Use either the 1/4" (0.635 cm) end or the 3/8" (0.952 cm) end of
the spoon gauge, as required and defined by the authority.
10 Adjust by loosening the nut and slave (1–1/8" [2.86 cm] open wrenches
required) of the point detector bar and then by screwing in or out the free end
of the rod (slave). Adjust the slave until the pressure of the spoon gauge
against the point detector pivot arm on the point detector system module
engages the field side point detector switch lever. Continue the adjustment
until the cam switch indication contacts open (outward position). If configured
with latch out, continue adjusting until the latch out dog of the point detector
system engages (approximately an additional 2/3 turn).
NOTE
Check cam switch indication contact status (open or closed

circuit condition) using a multimeter on TB-2 or TB-3 in
accordance with the field wiring for location.
11 Hold this position by tightening the nut snug against the slave. Remove the
spoon gauge and release the latched out condition by applying a light force to
the spring end of the latch out dog.
12 After making adjustments in both directions, manually operate machine back
and forth a few times. Check that the point detector pivot arm engages the
associated track or the field side point detector switch lever at the end of each
throw-bar stroke with the spoon gauge installed and the associated indication
contacts open.
13 Remove the spoon gauge and manually operate the machine back and forth a
few times. Check that the point detector pivot arm engages the associated
track or field side point detector switch lever at the end of each throw-bar
stroke and the cam switch indication contacts DO NOT OPEN.

Installation
3.17. MOTOR LIMIT ADJUSTMENT
Cams mounted on the main drive gear are attached by slotted holes and provide motor
limit adjustment. Table 3-12 provides the motor limit adjustment procedure and
assumes that the point detector rod connector installation and adjustment provided in
Table 3-11 has been completed.
Table 3-12. Motor Limit Adjustment Procedure
Step Action
1 NOTE
This procedure requires switch machine operation under

electrical power.
If the switch machine is equipped with the enhanced controller, operate the
switch machine to the end of one continuous stroke utilizing the manual jog
switch described in the Switch Machine Operation procedures.
If the switch machine is equipped with standard motor controller, contact the
control room to request switch operation to the opposite position.
2 Insure the machine is properly locked as described in “Normal and Reverse
Locking” in Section 2.
3 For machines configured with a hand crank, use the hand crank to throw the
switch machine and check for an additional movement (over-travel) of 1/2 to
1/4 turn before binding.
WARNING

CUTOUT LIMIT SWITCH IS OPENED THE SWITCH MACHINE
CAN BE REMOTELY ACTIVATED INSTANTLY, POSSIBLY
CAUSING PERSONAL INJURY AND EQUIPMENT DAMAGE.
ACTIVATED MOTOR CAM
LIMIT SWITCH
For machines configured without a hand crank, remove power from the
machine by removing the power connector to the controller. Then rotate the
shaft 1/2 to 1/4 turn, to check for an additional movement (over-travel).

Installation
Table 3-12. Motor Limit Adjustment Procedure (Cont.)
Step Action
4 If less than 1/4 turn of over-travel, loosen the two socket head cap screws
attaching the cam to the drive gear. Move the cam, actuating the motor limit
switch, toward the switch. This causes the cam to actuate the motor limit
switch earlier allowing more over-travel. Re-tighten the cap screws.
If greater than 1/2 turn of over-travel, move the cam, actuating the motor limit
switch, away from the switch and toward the drive gear timing mark. This
causes the cam to actuate the motor limit switch later allowing less over-
travel.
CAM
GEAR
SOCKET HEAD CAP SCREWS ATTACHING CAM TO GEAR

NOTE
Misadjustment of the motor limit cams can result in insufficient

locking or damage to the switch machine:
 When over-travel of the hand crank is more than 1/2 turn, the switch
machine throw bar and lock rods may not be completely locked.
 When over-travel of the hand crank is less than1/4 turn, repeated

use of the switch machine may damage the main drive assembly.
5 Repeat Steps 3 and 4 until 1/2 to 1/4 turn of over-travel is met on both motor
limit switches.
6 Follow all steps in Table 3-13, Switch Machine Verification Procedure to
complete installation.

Installation
3.18. SWITCH MACHINE VERIFICATION
Before placing a machine in service verify switch machine performance by performing

the steps in Table 3-13 in the sequence provided.
Table 3-13. Switch Machine Verification Procedure
Step Action
1 Verify power is not applied to the switch machine; check inside the machine
and remove any tools or rags.
2 Insure the electrical harness is properly attached.
3 Clean and lubricate the switch as instructed by the property.
4 Verify that all terminal jumpers are properly configured.
5 Connect the signal and indication wires. The connections are provided in
Appendix A.
6 If the switch machine is equipped with a hand throw, return the selector lever
on the hand throw to the POWER position and lock in the latch stand.
7 For a switch machine equipped with enhanced controller P/N GMV00-044-00,
place the LOCAL/REMOTE switch on the controller in the REMOTE position.
8 Install the switch machine covers and guards.
9 Verify that the covers close completely and fit tightly. Adjust the nuts at the T
bolts for the covers and/or latch, if necessary, to achieve a tight fit.
T BOLTS
HASP

Installation
Table 3-13. Switch Machine Verification Procedure (Cont.)
Step Action
10 To restore power to a switch machine with a hand crank installed, remove the
hand crank and press the reset button, then close and lock the hand crank
cover.
HAND CRANK
11 Contact the control room and request a switch machine call, verify the points
perform a full move. Also, verify that switch machine position is correctly
indicated at the control location, if applicable.
Repeat the control room request for a switch machine call and verify the
points move back correctly. Also, verify that switch machine position is
correctly indicated at the control location, if applicable.
12 Insure all external locking features are in place.
3.19. APPLY TOPCOAT OF PAINT TO THE SWITCH MACHINE EXTERIOR
To complete the installation procedure, apply a top coat of paint to the entire visible
exterior of the switch machine by following the procedure in Table 3-14.
Table 3-14. Apply Topcoat of Paint to the Switch Machine Exterior Procedure
Step Action
1 Apply paint to the entire visible exterior of a clean, dry switch machine as
follows:
 For brush application use Sherwin-Williams brand F88B142 Flat Black, 5-
15 units gloss.
 For spray application use Rustoleum brand V2178 Flat Black.

Installation
3.20. OPTIONAL SWITCH MACHINE AND LAYOUT SENSING KIT
A Switch Machine and Layout Sensing Kit (P/N 59649-218-00) for detecting point
pressure at each point is available from Alstom. It can be used during switch machine
installation, maintenance, or troubleshooting to verify the force generated against the
points when the switch machine is thrown. The kit includes a clevis pin, portable load
indicator, and a cable. For a procedure on use of this kit, see Table 3-15.
Table 3-15. Throw Rod Point Pressure Verification Procedure
Step Action
1 Remove the bolt connecting the jaw rod to the throw bar connector.
Jaw Rod Throw Bar Connector Throw Bar

Installation
Table 3-15. Throw Rod Point Pressure Verification Procedure (Cont.)
Step Action
2 Replace the bolt removed in Step 1 with the clevis pin from the switch
machine and layout load sensing kit.
Align the arrows on the sides of the Clevis Pin in the direction of force
(towards the point).
3 Connect the switch machine and layout sensing kit cable to the clevis pin
and portable load indicator.

Installation
Table 3-15. Throw Rod Point Pressure Verification Procedure (Cont.)
Step Action
4 Turn on the portable load indicator from the switch machine and Layout load
sensing kit.
On/Off Knob
PORTABLE
LOAD INDICATOR
MODEL PLN- D2
S/N 0746
OFF BAL CAL-CHK
STRAIN
W EST CONSHOHOCKEN PA., USA.
5 Observe the indicator while actuating the switch machine to determine the
point pressure generated when the switch is thrown.
6 Perform any adjustments and repeat Step 5 to obtain desired force.
7 Turn off portable load indicator and disconnect the switch machine and
layout sensing kit cable from the clevis pin and portable load indicator.
8 Remove the clevis pin from the jaw rod.
9 Reinstall the bolt connecting the jaw rod to the throw bar connector.
10 Return switch machine back to service if no further testing or verification is

required.

Installation
3.21. OPTIONAL TEST BAR INSTALLATION AND REMOVAL
The maintainer can use an optional Test Bar (P/N 59517-006-00) to actuate the switch
machine when it is not attached to the rails so that the throw bar, lock rod, and point
detector rod move as if attached to the rails. This test bar must be used in conjunction
with an Alstom Drop Lug (P/N GMA50-006-00).
Table 3-16. Test Bar Installation and Removal Procedure
Step Action
1 Remove the throw bar and lock rod guards from the track side of the switch
machine, if installed.
GUARD, THROWBAR GUARD, THROWBAR

TRACK SIDE
FIELD SIDE
(GM050-029-00)
(GM050-030-00)

(GMV00-031-00) (GMV00-032-00)
SHORT COVER
(GMV00-046-01)
2 Install an Alstom Drop Lug onto the lock rod. Use a bolt and nut to firmly attach
the drop lug to the throw bar.
BOLT AND NUT
DROP LUG FITS BELOW THROW BAR

Installation
Table 3-16. Test Bar Installation and Removal Procedure (Cont.)
Step Action
3 Remove the outer nuts from the lock rod and point detector rod on the track side
of the machine.
NUTS
DROP LUG THROW BAR LOCK ROD POINT DETECTOR ROD
4 Slide the lock rod and point detector rod through the holes in the side of the test
bar and against the throw bar. Move the inner nuts, if necessary, and reinstall the
outer nuts removed in Step 3 to firmly attach the test bar to the rods.
TEST
BAR
THROW BAR WITH DROP LUG LOCK ROD POINT DETECTOR ROD

Installation
Table 3-16. Test Bar Installation and Removal Procedure (Cont.)
Step Action
5 Use two bolts and nuts through the outer two holes of the test bar and drop lug to
firmly connect the test bar to the throw bar with drop lug, see figure below. The
center holes of the test bar and drop lug may remain empty.
BOLTS AND NUTS

TEST BAR
THROW BAR WITH DROP LUG LOCK ROD POINT DETECTOR ROD
6 Actuate the switch machine and the throw bar, lock rod, and point detector rod
move together, as they would if attached to the rails.
7 When maintenance or troubleshooting is completed, remove the nuts and bolt(s)
from Step 5 and the outer nuts from the lock rod and point detector rod.
8 Remove the test bar from the throw bar, lock rod, and point detector rod.
9 Reinstall the outer nuts on the rods.
Reinstall lock rod and point detector rod guards removed in Step 1, if used.

Installation
3.22. OPTIONAL SECONDARY POINT MONITOR INSTALLATION
The Secondary Point Monitor Kit (P/N GMK50-023-01) provides secondary monitoring
of switch points. It can signal a 1/8” movement (or width as specified by the customer or
governing authority) of switch points to help predict loss of correspondence prior to
failure. This kit is Non-Vital and can be retrofitted into a GM4000A Switch Machine. The
kit operates on 88 VDC to 132 VDC input. See Figure A-10.
The Secondary Point Monitor Kit consists of a circuit board, two limit switches with
normally closed contacts, and a mounting bracket.
Two green LEDs on the circuit board provide status indications:
 One green LED closest to the closed limit switch is ON when the switch points are
fully closed (depending on configuration) in either the normal or reverse position.
 Both green LEDs are OFF when either the normal or reverse switch point is open
1/8” or more (as specified by the customer or governing authority).
LIMIT SWITCH LIMIT SWITCH

LEDs
MOUNTING +110 VDC

BRACKET
-110 VDC
Figure 3-4. Secondary Point Monitor Kit (P/N GMK50-023-01)
Installation can be performed at a workstation suitable for switch machine repair or in

the field.

Installation
The following materials are required to install the Secondary Point Monitor Kit:
 Secondary Point Monitor Kit (P/N GMK50-023-01)
 3/16” T-Handle Allen Wrench
 5/16” T-Handle Allen Wrench
 11/32” Open or Box Wrench
Follow Table 3-17 to install the Secondary Point Monitor Kit in the GM4000A Switch
Machine.
Table 3-17. Secondary Point Monitor Kit Installation Procedure
Step Action
1 Remove power to the switch machine.
2 Unlock the switch machine and remove the cover (or covers).
3 Use the 3/16” T-Handle Allen wrench to remove the two screws holding Terminal
Board 3 and the heater bracket in place. Save the screws.
REMOVE TWO SCREWS
4 Pull Terminal Board 3 and the heater bracket away from the base.

Installation
Table 3-17. Secondary Point Monitor Kit Installation Procedure (Cont.)
Step Action
5 If the GM4000A Switch Machine is equipped with a cam bar stop:
Use the 5/16” T-Handle Allen wrench to remove the cam bar stop. Discard the
screws.
REMOVE AND DISCARD
THESE SCREWS
CAM BAR STOP
Install the Secondary Point Monitor Kit with the cam bar stop on top as shown
below. Use the two supplied 3/8”-16x1.25” screws and the 5/16” T-Handle Allen
wrench.
CAM BAR STOP SECONDARY POINT
INSTALLED ON TOP OF KIT MONITOR KIT
SECURE CAM BAR STOP WITH

SUPPLIED 3/8"-16X1.25" SCREWS
NOTE
If the cam bar stop is uninstalled and then reinstalled after the
Secondary Point Monitor Kit is installed, readjust the limit switches
on the the Secondary Point Monitor Kit after the cam bar stop is
reinstalled.

Installation
Step Action
5 (Step 5 continued)
If the GM4000A Switch Machine is not equipped with a cam bar stop:
Install the Secondary Point Monitor Kit as shown below. Use the supplied
3/8”-16x1.00” screws and the 5/16” T-Handle Allen wrench.
SECONDARY POINT
MONITOR KIT
INSTALL KIT WITH SUPPLIED

3/8"-16X1.00" SCREWS
6 Place the heater bracket, then Terminal Board 3, on top of the Secondary Point
Monitor Kit. Secure Terminal Board 3 and the heater bracket in place with the
screws removed in Step 3. Torque the screws to 30 in-lbs to 32 in-lbs.
7 Connect the limit switch cables to the screw terminals on the kit circuit board.
LEFT SWITCH RIGHT SWITCH
RED RED
CABLE FROM CABLE FROM

LEFT SWITCH BLACK RIGHT SWITCH

Installation
Step Action
8 Use tie wraps to secure the cables to the wire harness on either side of the
GM4000A’s case. See the figure below.
CAUTION
Be sure to dress the limit switch cables as shown in the figure to

prevent the cables from interfering with the operation of the Point
Detector Rod, Lock Rod or other moving parts inside the GM4000A
case.
TIE WRAP SWITCH CABLE

TO WIRE HARNESS WIRE HARNESS
SWITCH CABLE
LOCK ROD
SWITCH CABLE
POINT DETECTOR ROD

Installation
Step Action
9 Connect the wires labeled “+110 VDC” and “-110 VDC” from the circuit board to
TB1-1 and TB1-3.
CAUTION
Terminals TB1-1 and TB1-3 can be used to interchangeably

connect +110 VDC or -110 VDC. Be sure to connect the wires from
the circuit board to the terminals with wires of the same voltage
polarity.
-110 VDC
+110 VDC
TB3
TB2
TB1
12 11 10 9 8 7 6 5 4 3 2 1
10 Reapply power to the switch machine.

Installation
Step Action
11 To adjust the limit switches:
Use a 11/32” wrench to loosen the nuts holding the limit switch on the left side of
the bracket. Move the limit switch so that roller engages the beveled surface of
the Point Detector Rod. Adjust the limit switch until the green LED turns off with a
1/8” obstruction (or as specified by the customer or governing authority) in the
switch point. Retighten the nuts.
Move the switch to the opposite position and repeat this step to adjust the limit
switch on the right side.
POINT DETECTOR ROD BEVELED SURFACES ON
INSIDE GM4000A POINT DETECTOR ROD
LEDs
ADJUST LIMIT SWITCHES

ON BOTH SIDES OF
SECONDARY POINT
MONITOR KIT FOR
NORMAL AND REVERSE
SWITCH POSITIONS
SECONDARY POINT MONITOR KIT
12 When installation is complete, follow the Switch Machine Verification procedure in

Table 3-13 to verify normal switch machine operation.

Installation

.

Preventive Maintenance
4. SECTION 4 – PREVENTIVE MAINTENANCE
4.1. GENERAL
This Section provides the required preventive maintenance procedures to be performed

by maintainers to keep the GM4000A in good working order, including recommended
interval of each procedure.
4.2. INTRODUCTION
Preventive maintenance (PM) checks include the periodic inspection points of the
switch machine and switch layout, functional tests, and related adjustments that should
be made. These checks are intended to serve as a reference for fault isolation
procedures. If a problem is found, take the necessary corrective action.
PM checks should be done on each switch machine, whether it operates independently

or in conjunction with another switch machine.

4.3. PREVENTIVE MAINTENANCE INDEX
The preventive maintenance index summarizes the maintenance tasks, their required
intervals, and the Tables that contain the procedures for performing the tasks. If the
switch machine is operated with more-than-usual frequency each day, these procedures
should be done more often. Perform all maintenance tasks on a schedule based on the
information in the preventive maintenance index provided in Table 4-1 and the property
requirements.
Table 4-1. Preventive Maintenance Index
Interval Preventive Maintenance Action Table

Every 7500 Operations 7500 Operations Switch Machine 4-2
or Semi-Annually Lubrication
(whichever comes first)
Monthly External Switch Machine Inspection 4-3
(1250 Operations) Hand Crank Cutout Operation Verification 4-4
Hand Throw Operation Verification 4-5
Point Detector Verification 4-6
Secondary Point Detector Verification 4-7
Point Pressure Verification 4-8
Lock Rod Switch Obstruction Test 4-9 and 4-10
Latch Out Verification Test 4-11
Quarterly Internal Switch Machine Inspection 4-12
(3750 Operations)
Semi-Annually Back Linkage and Gear Box Lubrication 4-13
(7500 Operations)
Annually Annual Switch Machine Lubrication 4-14
(15,000 Operations)
As Required Lock Rod Adjustment 4-15 and 4-16
Point Detector Rod Adjustment 4-17
Gear Box Lubricant Replacement 4-18
Main Drive Roller Inspection 4-19
(at 150,000 Operations)
Gear Box Output Shaft and Key Inspection 4-20
(at 150,000 Operations)
Component Replacement See Section 6,
Corrective
Maintenance

NOTE
One operation is a single switch machine throw from normal to reverse

OR a single switch machine throw from reverse to normal position.
4.3.1. Special Tools and Test Equipment
Following is a list of special tools, test equipment, and supplies required to perform
maintenance as described in this manual.
 1/4" and 3/8" Spoon Gauge (P/N GMA50-002-00)
 Multimeter
 Switch Wrench 1–1/16" through 2" (approximately 2.70 cm – 5.08 cm)
 Terminal Nut Wrench, AREMA or Alstom
 Switch Point Obstruction Gauges: 1/8", 3/16", 1/4", 3/8" (approximately 0.317 cm,
0.476 cm, 0.635 cm, 0.952 cm)
 Paint Brush (for lubrication)
 Isopropyl Alcohol
 Aerosol Greaseless Lubricant (LPS-1)
 Fiske Brothers Lubriplate Mag 1 Extreme Pressure Lithium Grease
 LPS-3 heavy-duty Corrosion Inhibitor (P/N 81379-100-11)
 Mobil SHC 626 Lubricant
 Permeate Industrial 133K Anti-Seize Lubricant (P/N 81379-050-06)
 Optional Hand Crank (P/N GMA50-012-00)
OR
Optional Hand Crank, Hex End (P/N GMA50-013-00) for use with Ratcheting
Crank (P/N 50570-015-00)
For customers that prefer metric gauges:
 4.5mm and 6.0mm Spoon Gauge (P/N GMA50-014-00)
 Metric Switch point Obstruction Gauge: 2.0mm, 3.0mm, 4.5mm, 6.0mm, 12.0mm
(P/N 36183-061-00)

During maintenance procedures power is removed from the switch machine motor by
installing the hand crank or placing the hand throw selector lever in the HAND position.
The hand crank and hand throw can be used to manually operate the switch machine
during maintenance procedures.
To use the hand crank follow Table 2-4, Hand Crank Operation Procedure, located in
Section 2, Theory of Operation. When the hand crank is installed, the hand crank cutout
switch contacts are opened and power is removed from the switch machine motor.
Once the hand crank is removed, the reset button just above the entrance hole for the
hand crank must be pressed to reset the contacts and restore power to the switch
machine motor.
To use the hand throw follow Table 2-5, Hand Throw Operation Procedure, located in
Section 2, Theory of Operation. When the selector lever is placed in the hand position,
the hand throw cutout switch contacts are opened and power is removed from the
switch machine motor. Once the selector lever is placed back in the POWER position,
power is restored to the motor.
NOTE
During some of the installation procedures it is necessary to move the

switch machine manually into various mid stroke positions. Moving the
switch machine to these positions can be accomplished by any of the
following:
 If the machine is equipped with a hand crank, use the hand crank to reach the
designated position, OR
 If the machine is equipped with a hand throw, place the hand throw selector
lever in the HAND position and then use the hand throw to reach the
designated position, OR
position and then use the controller’s local operation feature to reach the
designated position.

4.3.2. After Flooding
If the switch machine was flooded, clean and insure all drain holes are clear. Cleaning
consists of washing down with a water jet of low velocity. Dry out all water. In cold
weather, trapped water freezes and prevents the switch from operating.
The controller should be removed from a flooded machine, washed out with distilled or
de-ionized water, and reinstalled as described in Section 6. De-ionized or distilled water
(most commonly used to clean steam irons) can be purchased at most grocery stores.
If floodwater reached the main drive module bearings, replace the drive module as
described in Section 6.

4.3.3. Warnings
WARNING

UNDER REMOTE OPERATIONAL CONTROL. POWER TO SWITCH
MACHINE CAN BE CUT OFF AT THE CONTROL ROOM. WITH
COVERS REMOVED, SWITCH MACHINE CONTROL CAN BE
CHANGED FROM CONTROL ROOM TO MACHINE.
BE AWARE THAT MACHINES WITH THE ENHANCED CONTROLLER

CONTAIN A MANUAL JOG OPERATION SWITCH THAT CAN BE
ACTIVATED WHEN THE SWITCH MACHINE COVER IS REMOVED.
EITHER CONDITION COULD CAUSE EQUIPMENT DAMAGE OR

PERSONAL INJURY.
WARNING

EQUIPMENT DAMAGE.
WARNING

EQUIPMENT DAMAGE.
WARNING

SWITCH POINTS.
WARNING
WHEN THE HAND CRANK IS REMOVED AND THE PUSHBUTTON IS

RESET, ALWAYS BE PREPARED FOR IMMEDIATE SWITCH
MOVEMENT. FAILURE TO DO SO COULD CAUSE INJURY BY
UNEXPECTED OPERATION.

4.4. EVERY 7500 OPERATIONS (OR SEMI-ANNUALLY, WHICHEVER COMES

FIRST)
4.4.1. 7500 Operations Switch Machine Lubrication
Table 4-2. 7500 Operations Switch Machine Lubrication Procedure
Step Action
1 Remove all power to the switch machine.
2 Unlock and pivot the hasp open, then remove both switch machine covers.
3 Apply Fiske Bros. Lubriplate Mag 1 Grease to all grease fittings:
 One fitting on the crank roller
 One fitting in the detector rod (swivel type)
 Four fittings on the lever latch stands (on dual control machines only)
 One fitting on the hand throw lever (on dual control machines only)
LATCH STAND
GREASE FITTINGS
CRANK ROLLER
GREASE FITTING
HAND THROW LEVER

GREASE FITTING
LATCH STAND
GREASE FITTINGS
POINT DETECTOR ROD

GREASE FITTING

Table 4-2. 7500 Operations Switch Machine Lubrication Procedure (Cont.)
Step Action
4 Apply grease to the beveled sliding surfaces of the cam bar tongue.
TOP VIEW
SIDE VIEW
5 Replace both switch machine covers, pivot hasp closed, and re-install lock.
6 Restore power.

4.5. MONTHLY MAINTENANCE
4.5.1. External Switch Machine Inspection
An external switch machine inspection consists of making a visual check of the entire
switch layout and recording any problems found. To fix recorded problems, use the
corrective maintenance instructions in Section 6.
WARNING

EQUIPMENT DAMAGE.
Table 4-3. External Switch Machine Verification Procedure
Step Action
1 Check external surfaces for any damage (bent, cracked, or broken case,
hinges, or brackets).
2 Insure covers and guards are installed properly and fit tightly. Tighten
associated bolts as necessary.
(GMA50-012-00) OPEN
(GMV00-070-01)
LONG COVER
(GMV00-045-01)
GUARD, THROWBAR
GUARD, THROWBAR
TRACK SIDE
FIELD SIDE
(GM050-029-00)
(GM050-030-00)

(GMV00-031-00) (GMV00-032-00)
SHORT COVER
(GMV00-046-01)

Table 4-3. External Switch Machine Verification Procedure (Cont.)
Step Action
3 If located in a climate with freezing temperatures during the winter months,
check for snow and ice under the cut-away area of a switch point that
meshes with stock rail. Insure that snowmelters, if installed, are melting
snow and ice.
4 Insure wear plates are in place (plates located below). Replace any plates
that are broken or worn 1/32" (0.079 cm) or more by following the procedure
provided in Table 6-19, Throw Bar and Lock Rod Wear Plate Removal and
Replacement Procedure.
WEAR PLATES
5 Inspect point detector rod bushings (one each side). Replace any bushings
provided in Table 6-17, Point Detector Rod Bushing Removal and
Replacement Procedure.

6 Inspect around the complete switch layout, including between the points and
stock rail for foreign material, ballast or excessive dirt, which might block
motion of rods or points.
7 Record any out-of-normal conditions of looseness or any broken tie-downs.
8 All machine tie-downs must be tight and securely fastened. Replace all
damaged or missing parts per installation instructions.
9 Check that connecting hardware is secure.
10 Check the condition of connecting rods (lock rod connecting rod and point
detector connecting rod) and replace if cracked or broken.

4.5.1.1. Hand Crank Cutout Operation Verification

For machines with a hand crank, the hand crank cutout operation must be verified once
a month. The hand crank option includes a normally closed hand crank cutout switch
that opens when the optional hand crank is inserted. The switch is closed when the
hand crank is removed and the hand crank reset button is activated. Follow the steps in
Table 4-4, in the sequence provided, to perform the Hand Crank Cutout Operation
Verification Procedure.
Table 4-4. Hand Crank Cutout Operation Verification Procedure
Step Action
1 Unlock and open the hand crank door.
RESET BUTTON
HAND CRANK
2 Insert the hand crank.

3 Verify there is no power to the motor, the machine cannot operate electrically,
and there is no continuity between terminals TB2–11 and TB2–12.
TB2-11
TB2-12
4 Remove the hand crank.

Table 4-4. Hand Crank Cutout Operation Verification Procedure (Cont.)
Step Action
5 Insert a 0.110 thick gauge between the plunger and the case and push the hand
crank cutout switch reset button.
PLUNGER
CASE
HAND CRANK
6 Verify there is no power to the motor, the machine can not operate electrically,
and there is no continuity between terminals TB2–11 and TB2–12. Remove the
gauge.
7 Insert the hand crank and place a 0.020 thick gauge between the plunger and
the case.
8 Remove hand crank and push the hand crank cutout switch reset button.
9 Verify there is power to the motor, the machine can operate electrically, and
there is continuity between terminals TB2–11 and TB2–12.
10 Remove the gauge.
11 Press the reset button to reset the cutout switch and verify that the switch
machine does run when power is applied.
12 Close and lock the hand crank door.

4.5.2. Hand Throw Operation Verification
For dual control switch machines, the hand throw operation must be verified once a
month. Follow the steps in Table 4-5, in the sequence provided, to perform the Hand
Throw Operation Verification Procedure.
Table 4-5. Hand Throw Operation Verification Procedure
Step Action
1 Hand Throw Operation Verification
Release the hand throw selector lever from the latch stand and pivot it from
POWER to HAND position.
HAND
This action unlocks the hand throw lever and prevents power from energizing
the switch machine motor, disabling remote switch machine operation.

Table 4-5. Hand Throw Operation Verification Procedure (Cont.)
Step Action
2 Pivot the hand throw lever and lock it in the latch stand. The pivot action
causes the bevel gear of the hand throw module to move internal mating
components of the main drive module and associated switch machine
components.
If the throw bar does not move and the hand throw lever rotates without
resistance, the shifter dog may not engage the hand throw dog gear.
Pivot the hand throw lever until they engage, then pivot the hand throw lever
in the opposite direction to move the throw bar.
3 Verify the point detector connector rod and lock rod connector rods
extending from the machine are unobstructed and move freely. If movement
is restricted due to an obstruction, remove the obstruction and repeat
Step 2.

Table 4-5. Hand Throw Operation Verification Procedure (Cont.)
Step Action
4 Hand Throw Cutout Switch Verification
(for machines equipped with a hand throw cutout switch)
Turn hand throw selector lever to the vertical position. Verify there is no
power to the motor and machine cannot operate electrically, and there is no
continuity between terminals TB1–6 and TB1–7.
TB1-6
TB1-7
5 Turn hand throw selector lever to the power side. Verify there is power to the
motor and machine can operate electrically, and there is continuity between
terminals TB1–6 and TB1–7.
6 After hand throwing, pivot the selector lever from the HAND to POWER
position and lock in the latch stand.

4.5.3. Point Detector Verification
Verify the point detector operation monthly unless otherwise recommended by the
governing authority. A Normal (N) or Reverse (R) indication should not be observed
when switch points are operated in either position against an obstruction gauge inserted
between the switch point and stock rail. The width of the obstruction gauge is specified
by the customer and its governing body. Follow the steps in Table 4-6 in the sequence
provided to perform the Point Detector Verification Test.
Table 4-6. Point Detector Verification Procedure
Step Action
1 Insert an obstruction gauge between the switch point and stock rail,
6" (15.24 cm) behind the point as illustrated below.
6 inches
(15.24 cm)
NOTE
The width of the obstruction gauge is specified by the customer

and its governing authorities.
2 Operate the switch point against the obstruction gauge.

3 If an indication (N or R) is observed, then the point detector rod must be
checked and adjusted using the procedure described in Table 4-17.
4 Repeat Steps 1 through 3 for the opposite switch point.

4.5.4. Secondary Point Detector Verification (Optional)
NOTE
Perform this procedure if the optional Secondary Point Monitor Kit

(P/N GMK50-023-01) is installed on the GM4000A Switch Machine.
The Secondary Point Monitor Kit (P/N GMK50-023-01) provides secondary monitoring
of switch points. It can signal a 1/8” movement (or width as specified by the customer or
governing authority) of switch points to help predict loss of correspondence prior to
failure. This kit is Non-Vital and can be retrofitted into a GM4000A Switch Machine.
Verify the secondary point detector operation monthly unless otherwise recommended
by the governing authority. A Normal (N) or Reverse (R) indication should not be
observed when switch points are operated in either position against an obstruction
gauge inserted between the switch point and stock rail. The width of the obstruction
gauge (typically 1/8”) is specified by the customer and its governing authority. Follow
the steps in Table 4-7 in the sequence provided to perform the Secondary Point
Detector Verification Test.

Table 4-7. Secondary Point Detector Verification Procedure
Step Action
1 Two green LEDs on the circuit board provide status indications:
 One green LED closest to the closed limit switch is ON when the switch
points are fully closed (depending on configuration) in either the normal
or reverse position.
 Both green LEDs are OFF when either the normal or reverse the switch
point is open 1/8” or more (as specified by the customer or governing
authority).
Insert an obstruction gauge between the switch point and stock rail,
6" (15.24 cm) behind the point as illustrated below.
6 inches
(15.24 cm)
2 Unlock the lock on the switch machine and remove the cover (or covers).
3 Operate the switch point against the obstruction gauge.
4 See Figure 3-4 for the location of the LEDs on the Secondary Point Monitor
Kit. If both green LEDs are not off, adjust the limit switches according to
Table 3-17, Step 11.
5 Repeat Steps 1 through 4 for the opposite switch point.
6 Replace the cover (or covers) removed in Step 2, and relock the switch
machine.

4.5.5. Point Pressure Test
Check the point pressure of the switch points monthly and adjust the point pressure, if
required, by performing the steps in Table 4-8 in the sequence given. Point pressure is
the amount of pressure exerted by a switch point against a stock rail. Proper point
pressure is determined by observing a point closing operation. A maintainer can also
assess the resistance felt in the hand throw during point closure. Some resistance is
acceptable but excessive resistance must be avoided.
Table 4-8. Point Pressure Test Procedure
Step Action
1 Use the hand crank, hand throw, or the manual operation switch located on
the enhanced controller to operate machine to the end of the throw bar
stroke, 6.5" (16.51 cm). The switch point should fit snugly against the stock
rail.
WARNING

DAMAGE.
2 Use a pry bar to pry the switch point away from the stock rail. The point
should move slightly but not more than 1/8" (0.317 cm).
3 If the switch point does not fit properly against the stock rail, adjust the nuts
at the switch adjustment basket until the proper position and acceptable
pressure is achieved. Upon repeating Step 2 the point can move slightly but
not more than 1/8" (0.317 cm).
4 Crank the switch machine to move the points to opposite position and test
for proper pressure.
5 After the adjustments have been made for the normal and reverse positions,
crank the machine back and forth a few times to double check these
adjustments.

4.5.6. Switch Obstruction Test
The switch machine can be configured with a narrow- or wide notched lock rod.
Determine the type of lock rod used in the switch machine and perform the appropriate
switch obstruction test monthly.
Identify the type of lock rod in use by comparing the configuration number of the switch
machine to the configuration key in Section 7. Table 4-9 provides Narrow Notch Lock
Rod Switch Obstruction Test Procedure for the lock rod with a 2.13" (5.4 cm) wide
notch. Table 4-10 contains the Wide Notch Lock Rod Switch Obstruction Test
Procedure for the lock rod with a 2.31" (5.9 cm) wide notch.
These procedures first verify that the switch machine does not lock or indicate when an
obstruction gauge of a size specified by the customer and its governing authorities is
encountered. Then, a spoon gauge (P/N GMA50-002-00) is used to simulate
displacement of the point detector rod by a 1/4 inch (approx. 0.635 cm) obstruction to
verify that the point detector rod adjustment independent of the lock rod: machine
should lock, but not indicate. Finally, the spoon gauge is used to verify that the switch
machine latches and locks, but not indicate, when encountering a 3/8" (approx. 0.952
cm) obstruction.
Each customer must review the procedure with their governing body for compliance to
applicable signal rules. Customers under FRA authority should meet with their
governing FRA inspector to verify that this procedure satisfies FRA rule 236.334.
Table 4-9. Narrow Notch Lock Rod Switch Obstruction Test Procedure
For Lock Rod With 2.13" (5.4 cm) Wide Notch
Step Action
1 To verify switch machine does not lock or indicate when an obstruction is
encountered insert an obstruction gauge between the switch point and stock
rail, 6" (15.24 cm) behind the point on the reverse side.
NOTE


Table 4-9. Narrow Notch Lock Rod Switch Obstruction Test Procedure (Cont.)
Step Action
2 Operate the switch point against the obstruction gauge. The switch machine
should not lock and the indication circuit contacts should not close.
3 Operate the switch point open and remove the obstruction gauge.
4 Insert the obstruction gauge between the switch point and stock rail at 6"
(15.24 cm) behind the point on the normal side.
5 Operate the switch machine to close the points against the obstruction
gauge.
6 The switch machine should not lock and the indication circuit contacts should
not close. Otherwise, see Step 9.
7 Operate the machine to open the switch point and remove the obstruction
gauge.
8 Operate the switch machine to close and lock points in the normal and
reverse positions without obstruction. Check that point position and point
pressure have not been changed. The indication circuit contacts should
close.
9 If the machine fails the obstruction test by locking with the obstruction gauge
between the switch point and stock rail, the narrow notch lock rod must be
checked for excess wear or misadjustment. (See Table 4-15 for adjustment
procedure, if required.) If excess wear (notch width is greater than 1.465"
[3.72 cm]) or damage is observed, the narrow notch lock rod must be
replaced by following the procedure provided in Table 6-12.
10 To verify point detector rod adjustment independent of the lock rod:
Remove all power to the switch machine. Operation of the switch machine
from this point forward is by hand crank or hand throw.

Step Action
12 Operate machine to mid-stroke and position the 1/4" (0.635 cm) end of the
spoon gauge into the necked down portion of the point detector rod (track
side).

SWITCH LEVER SWITCH
LATCHOUT
DOG
SPRING
PIVOT
ARM

GAUGE
13 Operate the machine to track side. The switch machine should lock and the
indication circuit contacts should not close. Otherwise, see Step 16.
spoon gauge into the necked down portion of the point detector rod (field
side).
15 Operate the machine to field side. The switch machine should lock and the
indication circuit contacts should not close.
16 If the machine fails the obstruction test by indicating with the 1/4" (0.635 cm)
end of the spoon gauge positioned into the necked down portion of the point
detector rod as described, then re-adjust point detection (see Table 3-11,
Point Detector Rod Connector Installation and Adjustment Procedure).
17 To verify latch out operate machine to mid-stroke and position the 3/8" (0.952
cm) end of the spoon gauge into the necked down portion of the point
detector rod (track side).

Step Action
18 Operate the machine to track side. The switch machine should lock and
latch, the indication circuit contacts should not close. Otherwise, see
Step 21.
side).
20 Operate the machine to field side. The switch machine should lock and latch,
the indication circuit contacts should not close.
21 If the machine fails this part of the obstruction test by indicating or not locking
and latching with the 3/8" (0.635 cm) end of the spoon gauge positioned into
the necked down portion of the point detector rod as described, then re-
adjust point detection (see Table 3-11, Point Detector Rod Connector
Installation and Adjustment Procedure).
22 Remove spoon gauge from switch machine.
24 Restore power.

Table 4-10. Wide Notch Lock Rod Switch Obstruction Test Procedure
For Lock Rod With 2.31" (5.9 cm) Wide Notch
Step Action
1 Insert an obstruction gauge between the switch point and stock rail, 6"
(15.24 cm) behind the point on the reverse side.
NOTE

2 Operate the switch point against the obstruction gauge. The switch machine
may lock and the indication circuit contacts should not close.
NOTE
The notch in the wide notch lock rod is 2.31" (5.87 cm) wide.
Therefore, depending on the adjustment of the lock rods and
customer preference, the switch machine may lock with an
obstruction of 1/4 " (0.635 cm) wide. For adjusting wide notch
lock rods to lock with a 1/4" (0.635 cm) obstruction, see
Table 4-16.
3 Operate the switch point open and remove the obstruction gauge.
4 Insert the obstruction gauge between the switch point and stock rail at 6"
(15.24 cm) behind the point on the normal side.

Table 4-10. Wide Notch Lock Rod Switch Obstruction Test Procedure (Cont.)
Step Action
5 Operate the switch machine to close the points against the obstruction
gauge.
6 The switch machine may lock, DEPENDING ON LOCK ROD ADJUSTMENT,
and the indication circuit contacts should not close. Otherwise, see Step 9.
7 Operate the machine to open the switch point and remove the obstruction
gauge.
8 Operate the switch machine to close and lock points in the normal and
reverse positions without obstruction. Check that point position and point
pressure have not been changed.
9 If the switch machine fails the obstruction test, the lock rod may be adjusted
by following the procedure provided in Table 4-16.
10 To verify point detector rod adjustment independent of the lock rod:
Remove all power to the switch machine. Operation of the switch machine
from this point forward is by hand crank or hand throw.
spoon gauge into the necked down portion of the point detector rod (track
side).
SWITCH LEVER SWITCH
LATCHOUT
DOG
SPRING
PIVOT
ARM

GAUGE
13 Operate the machine to track side. The switch machine should lock and the
indication circuit contacts should not close. Otherwise, see Step 16.

Table 4-10. Wide Notch Lock Rod Switch Obstruction Test Procedure (Cont.)
Step Action
side).
15 Operate the machine to field side. The switch machine should lock and the
indication circuit contacts should not close.
16 If the machine fails the obstruction test by indicating with the 1/4" (0.635 cm)
end of the spoon gauge positioned into the necked down portion of the point
detector rod as described, then re-adjust point detection (see Table 3-11,
Point Detector Rod Connector Installation and Adjustment Procedure).
17 To verify latch out operate machine to mid-stroke and position the 3/8" (0.952
cm) end of the spoon gauge into the necked down portion of the point
detector rod (track side).
18 Operate the machine to track side. The switch machine should lock and
latch, the indication circuit contacts should not close. Otherwise, see Step 21.
side).
20 Operate the machine to field side. The switch machine should lock and latch,
the indication circuit contacts should not close.
21 If the machine fails this part of the obstruction test by indicating or not locking
and latching with the 3/8" (0.635 cm) end of the spoon gauge positioned into
the necked down portion of the point detector rod as described, then re-
adjust point detection (see Table 3-11, Point Detector Rod Connector
Installation and Adjustment Procedure).
22 Remove spoon gauge from switch machine.
24 Restore power.

4.5.7. Latch Out Verification Test
Table 4-11. Latch Out Verification Test Procedure
Step Action
1 Induce a latch out event and verify that latch out is in effect.
WARNING

DAMAGE.
2 If the machine is equipped with restorable latch out proceed as follows,

otherwise skip to Step 3:
 Issue a switch call and verify remote reset.
 Induce a latch out event.
 Hand throw the machine (if equipped)), manually move the latch out
dog, or use the manual control switch on an enhanced controller (if
equipped) and verify local reset.
If machine does not reset, perform the Point Detector System Module
Adjustment provided in Table 6-14.
Verification is complete.
3 If the machine is equipped with non-restorable latch out proceed as follows:
 Issue a switch call and verify latch out is not restored.
 Reset the latch out mechanism by following the procedure provided in

Table 2-3.
 Issue a switch call and verify latch out is now restored.
If machine does not reset, perform the Point Detector System Module
Adjustment provided in Table 6-14.
Verification is complete.

4.6. QUARTERLY MAINTENANCE
4.6.1. Internal Switch Machine Inspection
Table 4-12. Internal Switch Machine Inspection Procedure
Step Action
1 Remove power from the switch machine by inserting the hand crank or
placing the hand throw selector lever in the HAND position.
WARNING
BE AWARE THAT WHEN POWER HAS NOT BEEN

REMOVED FROM THE SWITCH MACHINE, IT CAN BE
REMOTELY ACTIVATED INSTANTLY, POSSIBLY CAUSING
PERSONAL INJURY AND EQUIPMENT DAMAGE.
2 Insure wear plates are in place (plates located below) and visually check
their condition. Replace any plates that are broken or worn 1/32" (0.079 cm)
or more by following the procedure provided in Table 6-19.
WEAR PLATES
3 Inspect point detector rod bushings (one each side). Replace any bushings
provided in Table 6-17.


Table 4-12. Internal Switch Machine Inspection Procedure (Cont.)
Step Action
5 Check the two motor-limit switches – Using the manual operation switch on
the enhanced controller, hand throw or hand crank, go through a complete
cycle noting operation of both switches. The condition of each switch can be
determined by using a multimeter at specific terminal block connections and
checking continuity. Refer to the electrical schematic of the switch machine
internal wiring (in Appendix A) for the proper connections.
 Operate to end-of-stroke and check that the motor limit cam of the main
drive actuates the proper motor limit switch (see illustration below).
 While at end-of-stroke, check that the cam bar locking dog is centered
in the lock rod notch.
ACTIVATED MOTOR CAM

LIMIT SWITCH
6 Repeat Step 5 for opposite position.

7 Check the hand throw cutout and hand crank cutout switches. The condition of
each switch can be determined by using a multimeter at specific terminal block
connections and checking continuity.
Refer to the electrical schematic of switch machine internal wiring, located in
Appendix A, for proper connections.
In the figure below the main drive is removed for a clear view of the hand
throw cutout switch and the cross brace is removed for a clear view of the
motor limit switches.
HAND THROW CUTOUT SWITCH
HAND CRANK CUTOUT SWITCH CAM BAR DETECTION SWITCH

MOTOR LIMIT SWITCHES (2)

Step Action
8 If installed, check the cam bar detection switch operation. See Step 7 for cam
bar detection switch location.
Using the manual operation switch on the enhanced controller, hand throw or
hand crank, go through a complete cycle noting operation of both switches.
The condition of each switch can be determined by using a multimeter at
specific terminal block connections and checking continuity. Refer to the
electrical schematic of the switch machine internal wiring (in Appendix A) for
the proper connections.
 Operate to end-of-stroke and check that the cam bar actuates the cam
bar detection switch.
 While at end-of-stroke, verify that the cam bar locking dog is centered
in the lock rod notch.
9 Repeat Step 8 for opposite position.

10 View modules for signs of wear or damaged parts. Method of removal and
replacement of modules is covered in Section 6, Corrective Maintenance. The
following can be replaced in the field:
1. Motor and Gear Box: Replace if confirmed defective during
troubleshooting. See Table 6-4 for replacement procedure.
2. Controller: Replace if confirmed defective during troubleshooting. See

Table 6-3 for replacement procedure.
3. Main Drive: Replace if confirmed defective during troubleshooting. See

Table 6-5 for replacement procedure.
4. Point Detector Switch: Replace if confirmed defective during

5. Point Detector Rod: Replace if the rod is bent, does not slide smoothly in
bushings, or lock nuts do not stay locked. See Table 6-16 for replacement
procedure.
6. Point Detector System Module: Replace if parts are damaged such that
point indication does not occur, if parts are worn or broken causing false
indications due to wear or broken parts, or parts are out of calibration. See
Table 6-13 for module replacement procedure.
7. Latch Stand: Replace if stand is damaged and can no longer lock the hand
throw or selector lever in place. See Table 6-11 for replacement procedure.

Step Action
10 8. Lock Rod: Replace if rod is bent, fractured or shows wear on rubbing
(Cont.) surfaces, which precludes smooth sliding. See Table 6-12 for replacement
procedure.
9. Hand Throw Lever: Replace if gear teeth are broken or show excessive
wear or the assembly does not move freely. See Table 6-10 for
replacement procedure.
10. Condensation Heater, if equipped: Replace if confirmed defective during

11. Motor Gear Box Heater, if equipped: Replace if confirmed defective during

4.7. SEMI-ANNUAL MAINTENANCE
4.7.1. Back Linkage and Gear Box Lubrication
Table 4-13. Back Linkage and Gear Box Lubrication Procedure
Step Action
3 Lubricate the 4 stainless steel rollers and pins in the point detector back
linkage as identified below with Aerosol Greaseless Lubricant (LPS-1).
BACK LINKAGE
(4 STAINLESS STEEL ROLLERS WITH PINS)
Spray the lubricant on the back linkage of the point detector module while it
is in mid-stroke.
4 Open the oil fill hole cover and the oil level hole cover.
OIL FILL HOLE COVER

OIL LEVEL HOLE COVER

Table 4-13. Back Linkage and Gear Box Lubrication Procedure (Cont.)
Step Action
5 Add Mobil SHC 626 Lubricant through oil fill hole until it reaches the oil level
hole.
OIL FILL HOLE
OIL LEVEL HOLE
6 Re-install the oil fill hole cover and the oil level hole cover.
7 Wipe up any spilled oil, particularly any oil that spilled on the main gear.
9 Restore power.

4.8. ANNUAL MAINTENANCE
4.8.1. Switch Machine Lubrication
Table 4-14. Annual Switch Machine Lubrication Procedure
Step Action
3 Apply Mag-1 Lubricant to throw bar, lock rod, cam bar, main gear, and the
cam bar slot in base.
 Coat the four surfaces of the throw bar and lock rod that slide in and
out of the wear plates.
 Apply a heavy coating to the cam bar slot in the base.
 Coat the teeth on the main gear.
MAIN GEAR
TOP BEARING LOCK ROD
GEAR BOX CAM BAR SLOT

THROW BAR
OUTPUT GEAR CAM BAR TONGUE
4 Spray Corrosion Inhibitor. Other than the main drive module and electrical
components, spray the entire inside of the machine with corrosion inhibitor
after removing any visible surface corrosion.
6 Restore power.

4.9. AS REQUIRED MAINTENANCE
4.9.1. Lock Rod and Point Detector Adjustments
Table 4-15. Narrow Notch Lock Rod Adjustment Procedure For Lock Rod With
2.13" (5.4 cm) Wide Notch
Step Action
3 Manually have the machine close but not lock the near switch point. Insure
that the cam bar is centered in the lock rod slot and continue operating the
machine until locking is complete.
4 Center the straight lock rod slot to locking dog using the inner and outer
adjusting nuts associated with the lock rod drop lug. Tighten and lock nuts at
drop lug to keep this adjustment.
SWITCH MACHINE
LOCK ROD DROP LUG

LOCK ROD
OUTER ADJUSTING NUT
INNER ADJUSTING NUT
LOCK CONNECTING ROD
5 Operate the machine to close, but do not lock the far switch point. Insure that
the cam bar is centered in lock rod notch and continue cranking the machine
until locking is complete.
6 Center the curved lock rod notch to the locking dog using the inner and outer
nuts on the field side of the lock rod. Tighten and lock the field side lock rod
nuts to retain this adjustment.
8 Restore power.

Table 4-16. Wide Notch Lock Rod Adjustment Procedure For Lock Rod With
2.31" (5.9 cm) Wide Notch
NOTE
The following procedure describes how wide notch lock rods are adjusted
to lock with a 1/4" (approx. 0.635 cm) obstruction. The customer and its
governing authorities determine the obstruction width at which the wide
notch lock rods are adjusted to lock.
Step Action
3 Manually have the machine close the near switch point against a 1/4"
(approx. 0.635 cm) obstruction; see Table 4-5. Make sure cam bar is in the
lock rod notch.
NOTE
Spaces between the sides of the notch and the cam bar dog
are not equal.
4 Offset the straight lock rod slot to the locking dog using the inner and outer
adjusting nuts associated with the lock rod drop lug. Tighten and lock nuts at
drop lug to retain this adjustment.
SWITCH MACHINE
LOCK ROD DROP LUG

LOCK ROD
OUTER ADJUSTING NUT
INNER ADJUSTING NUT
LOCK CONNECTING ROD

5 Operate the machine to close the far switch point against a 1/4" (approx.
0.635 cm) obstruction. Insure the cam bar is in the lock rod notch and
continue operating the machine until locking is complete.
6 Offset the curved lock rod notch to the locking dog using the inner and outer
nuts on the field side of the lock rod. Tighten and lock the field side lock rod
nuts to retain this adjustment.
8 Restore power.

4.9.2. Point Detector Rod Adjustment
Table 4-17. Point Detector Rod Adjustment Procedure
Step Action
1 Remove all power to switch machine.
3 Operate machine to mid-stroke and position a point detector rod spoon
gauge into the necked down portion on the trackside end of the point
detector rod. Use either the 1/4" or 3/8" (0.635 cm or 0.952 cm) end of the
spoon gauge, whichever is required by the customer and its governing
authorities.
4 Operate machine to close and lock the far switch point. Position the lever
against the spoon gauge. If the trackside indication contacts of the point
detector switch module are closed, use the adjusting nuts at the point
detector rod drop lug to adjust the position of the point detector rod.
SWITCH LEVER SWITCH
LATCHOUT
DOG
SPRING
PIVOT
ARM

GAUGE
NOTE
Check the indication contact status of the cam switch (open or

closed circuit condition) using a multimeter on TB2 or TB3 in
accordance with the field wiring.

Table 4-17. Point Detector Rod Adjustment Procedure (Cont.)
Step Action
5 Adjust the nuts until the indication contacts on the point detector switch
module open. Continue adjusting until latch-out occurs. Tighten and lock the
nuts to hold this adjustment and remove the spoon gauge. Release the
latch-out condition by applying a light force to the end of the latch out dog.
6 Operate the machine to mid-stroke and position the point detector rod spoon
gauge into necked down portion on the field side of the point detector rod.
Use either the 1/4" or 3/8" (0.635 cm or 0.952 cm) end of the spoon gauge,
whichever is required by the customer and its governing authorities.
7 Operate the machine to close and lock near the switch point. Position the
lever against the spoon gauge. If the field side indicating contacts of the
point detector switch module are closed, adjustment is required.
8 Adjust by loosening the nut and slave 1–1/8" (2.86 cm) (open wrench
required) of the point detector bar and then by screwing in or out the free
end of the rod (slave). Adjust the slave until the pressure of the spoon gauge
against the point detector pivot arm on the point detector system module
engages the field side point detector switch lever. Continue the adjustment
until the cam switch indication contacts open (outward position). If configured
with latch out, continue adjusting until the latch out dog of the point detector
system engages (approximately an additional 2/3 turn).
NOTE
Check cam switch indication contact status (open or closed

circuit condition) using a multimeter on TB2 or TB3 in
accordance with the field wiring for location.
9 Hold this position by tightening the nut snug against the slave. Remove the
spoon gauge and release the latched out condition by applying a light force
to the spring end of the latch out dog.
10 If point detection requirements cannot be achieved, examine all associated
components for wear or fault before replacing the point detector system
module.
11 After making adjustments in both directions, operate the machine back and
forth a few times to verify that (1) the indication contacts are closed at the
end of each throw-bar stroke with the spoon gauge removed and (2) the
indication contacts are open with the spoon gauge installed.

Table 4-17. Point Detector Rod Adjustment Procedure (Cont.)
Step Action
12 Restore power operation:
 Remove the hand crank and press the reset button if the hand crank
was used.
 Place the hand throw selector lever back in the POWER position if the
hand throw was used.
 Place the LOCAL/REMOTE switch on the enhanced controller to the

REMOTE position if it was placed in the LOCAL position for manual
operation.

4.9.3. Gear Box Lubricant Replacement
Table 4-18. Gear Box Lubricant Replacement Procedure
Step Action
1 Remove all power from the switch machine.
3 Remove the motor/gear box module from the switch machine by removing
the four screws connecting it to the switch machine frame.
4 SCREWS
GEARBOX HEATER OIL FILL HOLE COVER
(IF USED)
4 Disconnect gearbox heater, if connected.

5 Open the oil fill hole and the oil level hole covers. Tip the motor/gear box and
drain out the used Mobil SHC 626 Lubricant from the gear box.
NOTE
Dispose of the lubricant according to local regulations.
6 Add Mobil SHC 626 Lubricant through oil fill hole until it reaches the oil level
hole.
OIL FILL HOLE
OIL LEVEL HOLE
7 Re-install the oil fill hole cover and the oil level hole cover.

Table 4-18. Gear Box Lubricant Replacement Procedure (Cont.)
Step Action
8 Wipe up any spilled oil, and reinstall the motor gear box module into the
switch machine with the four screws removed in Step 3.
9 Reconnect gearbox heater, if disconnected in Step 4.
11 Restore power.
4.9.4. Main Drive Roller Inspection
Table 4-19. Main Drive Roller Inspection Procedure
Step Action
1 Remove the main drive from the machine by following Steps 1 through 7 in
Table 6-5, Main Drive Removal and Replacement Procedure.
2 Inspect the main drive roller. Replace the roller if it is worn greater than 1/32"
(0.079 cm).
3 Perform Steps 8 through 13 in Table 6-5, Main Drive Removal and
Replacement Procedure to reinstall the main drive and verify switch machine
performance.
4.9.5. Gear Box Output Shaft and Key Inspection
Table 4-20. Gear Box Output Shaft and Key Inspection Procedure
Step Action
1 Remove the gear box and motor by following Steps 1 through 7 in
Table 6-4. DC Motor and Gear Box Removal and Replacement Procedure,
separating the motor from the gear box.
2 Rotate the gear in the gear box while observing the output shaft and key,
which should move together smoothly. If the gear moves, but output shaft
and key do not move or move at a different rate, then replace the gear box.
3 Perform Steps 8 through 15 in Table 6-4, DC Motor and Gear Box Removal
and Replacement Procedure to reinstall the gear box and motor and verify
switch machine performance.


Troubleshooting
5. SECTION 5 – TROUBLESHOOTING
5.1. GENERAL
This Section is intended as a guide for troubleshooting the GM4000A Switch Machine.
5.2. PHILOSOPHY
Troubleshooting the GM4000A can be performed in a control location or at the wayside.

In the control location, an understanding of relay operation and knowledge of circuit
plans is essential. At wayside, an understanding of the switch machine operation along
with knowledge of switch machine setup and layout is essential.
5.3. POSSIBLE SYMPTOMS AND CORRECTIVE ACTIONS
The following troubleshooting information helps determine if a switch machine and its
associated circuit equipment are faulty. Table 5-1 lists possible symptoms of abnormal
switch machine circuit and trackside equipment operation as observed from the control
location. This table also describes the corrective action(s) required.
Tables 5-2 and 5-3 list possible symptoms of abnormal switch machine circuit and
trackside equipment operation as observed from the wayside location. Troubleshooting
performed at a wayside location, using the controller LED display of a switch machine,
is given in this section together with the required corrective action.
Table 5-2 covers troubleshooting a switch machine containing the standard controller.
Table 5-3 covers troubleshooting a switch machine containing the enhanced controller
that includes additional LEDs used for troubleshooting.
An optional Switch Machine and Layout Sensing Kit (P/N 59649-218-00) is available
from Alstom that can be used during troubleshooting, installation, or maintenance to
detect point pressure at each point. For a procedure on use of this kit, see Table 3-15
for the Throw Rod Point Pressure Verification Procedure.
NOTE
After corrective action is implemented:
 The FAULT LED on the standard controller is reset by removing energy to the
controller. (Energy is typically removed after a switch call is made; therefore,
the LED should reset for the next call.)
 The OVERLOAD FAULT, MOTOR FAULT, and CTRL FAULT LEDs on the
enhanced controller are reset by applying energy to the controller via a switch
call and rotating the controller NORMAL/LOCAL/RESET FAULT switch to the
RESET FAULT position while the energy is applied (see Figure 5-1).

Troubleshooting
REMOTE F ORWARD

LOCAL STOP
LOAD FAULT FAULT
RESET FAULT REVERSE

SWITCH TO REMOTE
Figure 5-1. Enhanced Controller Reset Location
5.3.1. Symptoms Noticed from the Control Locations
Table 5-1. Symptoms Noticed from the Control Locations
Symptom Corrective Action

1. Switch out of correspondence, Reverse 1. Check for power at Normal and Reverse
or Normal position relay down (per switch relay coil.
position request). 2. Check for bad relay.
2. Switch out of correspondence, switch 1. Check that Reverse or Normal relay is

machine(s) failed to move (per switch up.
position request). 2. Check for switch operational power at
entrance rack.
3. Check for switch operational power at
switch machine. If none, possible bad
cable, loose hardware and/or connections.
4. Check for obstruction in rail points.
5. Check rail conditions in area.
6. Verify motor control wiring is properly
configured at the switch machine terminals
and wire harness.
7. Check switch machine controller LEDs
display. Refer to “Controller LED Display”
in this section.

Troubleshooting
5.3.2. Symptoms Noticed from the Wayside Locations, Standard Controller
Table 5-2. Symptoms Noticed from the Wayside Locations,

Standard Controller

1. Motor runs but points do not move. 1. Linkage disconnected; reconnect throw
rod to switch points.
2. Throw bar drive train disconnected;
check from main crank shaft back to motor.
3. Check coupler.
2. Motor cuts out and the FAULT LED on 1. Obstruction in points; remove
controller illuminates. Refer to “Controller obstructions.
LED Display” in this section. 2. Excessive resistance in track point
system; determine cause and correct.
3. Excessive resistance in switch machine
drive train; determine cause and correct.
3. Motor does not run with a proper switch 1. Confirm power to motor.
call, the controller RUN LED is lit. 2. Verify motor control wiring is properly
configured at the switch machine terminals
and wire harness.
3. Replace motor.
4. Replace controller.
4. Points move but switch machine does 1. Cam bar has separated; determine
not lock and indicate. cause: friction drag or blockage in cam bar
track or out of adjustment of lock rod.
5. Bent or cracked rods, couplings or lugs 1. Replace damaged components and
discovered upon inspection; most likely adjust as appropriate.
caused by a train running through closed 2. Confirm switch machine operation.
points of layout.
(Note that any train speed will bend or
break fittings.)

Troubleshooting
Table 5-2. Symptoms Noticed from the Wayside Locations

Standard Controller (Cont.)

6. With selector lever in the HAND position 1. Check switch machine layout for
and hand throw lever operated in both obstruction.
directions, the switch machine does not 2. Operate hand throw lever while
throw. checking movement of internal switch
machine components.
3. Remove hand throw module and check
for damaged hand throw eccentric pin.
4. If pin is damaged, replace hand throw
module.
7. A switch call issued (normal or reverse), 1. If hand throw option is installed, check
no LEDs illuminate, and motor is not hand throw selector lever is latched in
operating. POWER position.
2. If hand crank option is installed, check
hand crank cutout switch is not activated
and press its reset button.
3. If latch out is activated, check latch out
and reset.
8. GM4000A does not respond to a switch 1. Place a jumper between TB1–9 and
call (and is configured for non-restorable TB1–10.
latch out). 2. Request a switch call. If the machine
operates, the motor and controller are
functioning properly and latch out is reset.
3. Remove jumper.
OR
1. Hand throw or hand crank the machine
to the opposite direction to reset latch out.
2. Operate the machine electrically to
verify that the motor and controller are
functioning properly.

Troubleshooting
5.3.3. Symptoms Noticed from the Wayside Locations, Enhanced Controller

Enhanced Controller

1. Motor runs but points do not move. 1. Linkage disconnected; reconnect throw
rod to switch points.
2. Throw bar drive train disconnected;
check from main crank shaft back to motor.
3. Check coupler.
2. Motor cuts out and the OVER LOAD 1. Reset the controller.
LED on controller illuminates. Refer to 2. Obstruction in points; remove
“Controller LED Display” in this section. obstructions.
3. Excessive resistance in track point
system; determine cause and correct.
4. Excessive resistance in switch machine
drive train; determine cause and correct.
3. Motor does not run with a proper switch 1. Confirm power to motor.
call, the MOTOR FAULT LED located on 2. Verify motor control wiring is properly
controller is not lit, and the controller RUN configured at the switch machine terminals
LED is lit. and wire harness.
3. Replace motor.
4. Replace controller.
4. Motor does not run and the MOTOR 1. Reset the controller.
FAULT LED located on controller is 2. Verify motor control wiring is properly
illuminated. configured at the switch machine terminals
and wire harness.
3. Replace motor module.
5. Points move but switch machine does 1. Cam bar has separated; determine
not lock and indicate. cause: friction drag or blockage in cam bar
track or out of adjustment of lock rod.
6. Bent or cracked rods, couplings or lugs 1. Replace damaged components and
discovered upon inspection. Most likely adjust as appropriate.
caused by a train running through closed 2. Confirm switch machine operation.
points of layout.
(Note that any train speed will bend or
break fittings.)

Troubleshooting

Enhanced Controller (Cont.)

7. With selector lever in the HAND position 1. Check switch machine layout for
and hand throw lever operated in both obstruction.
directions, the switch machine does not 2. Operate hand throw lever while
throw. checking movement of internal switch
machine components.
3. Remove hand throw module and check
for damaged hand throw eccentric pin.
4. If pin is damaged, replace hand throw
module.
8. A switch call issued (normal or reverse), 1. If optional hand throw is installed, check
no LEDs illuminate, and motor is not hand throw selector lever is latched in
operating. POWER position.
2. If optional hand crank is installed, check
hand crank cutout switch is not activated;
press its reset button.
3. Check latch out and reset.
9. GM4000A does not respond to a switch 1. Place a jumper between TB1–9 and
call (and is configured for non-restorable TB1–10.
latch out). 2. Request a switch call. If the machine
operates, the motor and controller are
functioning properly and latch out is reset.
3. Remove jumper.
OR
1. Hand throw or hand crank the machine
to the opposite direction to reset latch out.
2. Operate the machine electrically to
verify that the motor and controller are
functioning properly.

Troubleshooting
5.3.4. Controller LED Display
LED displays help determine faulty switch machine equipment. The standard and
enhanced controllers have different LEDs. Table 5-4 provides the LED functions of both
controllers.
Table 5-4. Controller LED Functions
LED Function Controller Latched Reset Method

FAULT Illuminates when OVERLOAD, Standard Yes Remote
CONTROLLER, or MOTOR
fault occurs
RUN Indicates that the motor is Standard and No N/A
running Enhanced
OVER Illuminates when the current Enhanced Yes Local
LOAD threshold has been exceeded
CTRL Illuminates when the controller Enhanced Yes Local
FAULT has detected a fault
MOTOR Illuminates when the motor has Enhanced Yes Local
FAULT a fault
LOCAL Illuminates when switch is in Enhanced No N/A
local mode
REMOTE Illuminates when switch is in Enhanced No N/A
remote mode
NOTE
LED displays occur only while the operation (Normal or Abnormal) is being
performed and operating power is being supplied to the controller of the
switch machine. Without operational power, the LEDs of the controller
remain off.
Table 5-5 is a summary of when the two standard controller LEDs display and
Table 5-6 is a summary of when the six enhanced controller LEDs display.

Troubleshooting
5.3.4.1. Standard Controller LED Display
The standard controller FAULT LED is lit when an overload, motor, or controller fault is
detected. To troubleshoot the fault, follow the troubleshooting guidelines in Table 5-5.
Table 5-5. Standard Controller LED Displays
Controller LED RUN FAULT
Normal Operation
Automatic Operation On Off
Hand Operation Off Off
Hand Crank Off Off
Latch Out Off Off
Abnormal Operation
Overload Fault Off On
Motor Fault Off On
Controller Fault Off On

Troubleshooting
5.3.4.2. Enhanced Motor Controller LED Display
The enhanced controller has separate LEDs to indicate when an overload, motor, or
controller fault is detected. To troubleshoot the fault, follow the troubleshooting
guidelines in Tables 5-7, 5-8, and 5-9.
Table 5-6. Enhanced Controller LED Displays
Controller LED RUN LOCAL REMOTE OVER CTRL MOTOR

LOAD FAULT FAULT
Normal Operation
Automatic Operation On Off On Off Off Off
Hand Throw Operation Off Off Off Off Off Off
Hand Crank Off Off Off Off Off Off
Manual Operation On On Off Off Off Off
Latch Out Off Off Off Off Off Off
Abnormal Operation
Overload Fault Off On/Off On/Off On Off Off
Controller Fault Off On/Off On/Off Off On Off
Motor Fault Off On/Off On/Off Off Off On

Troubleshooting
5.3.4.2.1. Overload Fault
The Overload Fault function is an electronic clutch. The motor current is directly
proportional to the motor torque. If there is an obstruction, the motor delivers more
torque, thus drawing more current. A 5-second timer starts when the current reaches
the current limit. After 5 seconds, the overload trip point is reached and the overload
circuit reverses the motor for approximately one second and then shuts down power to
the motor.
Table 5-7. Overload Fault Symptoms
Symptom Reason Corrective Action

Overload 1. Obstruction in/on the rails. Clear obstruction(s).
Fault 2. Switch machine is physically Check the switch machine for
seized. mechanical failure, replacing seized
components, if necessary.
If that does not resolve the problem,
replace the motor.
NOTE
 The OVERLOAD FAULT LED on the enhanced controller is reset by applying

energy to the controller via a switch call and rotating the controller
NORMAL/LOCAL/RESET FAULT switch to the RESET FAULT position while
the energy is applied (see Figure 5-1).

Troubleshooting
5.3.4.2.2. Motor Fault
The motor fault function monitors the condition of the brushless DC motor.
Table 5-8. Motor Fault Symptoms

Motor Fault 1. Short in the motor or bad Hall Replace the motor.
sensors.
(Hall sensors feed back position
information to the controller.
This information helps the
controller to control the motor’s
rotation. The motor does not
run if the Hall sensors fail.)
2. Shorted or open wire If problem is verified, replace the wire
harness. harness.
(If the motor harness is shorted
or open, the MOTOR FAULT
illuminates.)
NOTE
 The MOTOR FAULT LED on the enhanced controller is reset by applying


Troubleshooting
5.3.4.3. Controller Fault
The controller FAULT LED illuminates when conditions of high voltage, low voltage or
overheating of the controller are detected. See Table 5-9 for a summary of symptoms,
reasons, and corrective actions.
Table 5-9. Controller Fault Symptoms

Controller 1. Low Voltage Check the field terminations. Minimum
Fault voltage must be approximately 12
VDC unless the wire harness is
configured for 88 VDC minimum.
(Approximately 65 VAC minimum.)
2. High Voltage Check input voltage. Maximum voltage

is approximately 198 VDC or 140
VAC.
3. Controller Overheated Remove switch machine power for
several minutes, and then restore
power to reset the controller.
4. Defective Controller Although unlikely, it is possible that the
FAULT is the result of a defective
controller. Replace the controller.
NOTE
 The CRTL FAULT LED on the enhanced controller is reset by applying


Corrective Maintenance
6. SECTION 6 – CORRECTIVE MAINTENANCE
6.1. GENERAL
This section describes removal and replacement procedures of major components

found to be faulty through inspection and test procedures described in Section 4,
Scheduled Maintenance and Section 5, Troubleshooting. The removal and replacement
procedure for a given component describes any adjustment or test along with special
tools that may be required to complete the procedure. Recommended spare parts are
identified and shown in Section 7, Parts Catalog.
6.2. REMOVAL AND REPLACEMENT PROCEDURES
The following are removal and replacement procedures for specific switch machine
components. These procedures should be followed in the sequence given. Adjustments
or special tools, if required, are described in the procedure.
WARNING
THESE PROCEDURES ARE PERFORMED WITH THE POWER

REMOVED FROM THE SWITCH MACHINE UNLESS OTHERWISE
INDICATED.
WARNING

UNDER OPERATIONAL CONTROL. OTHER THAN WHEN REMOVING
COVER (S) OR CROSS BRACE, POWER TO SWITCH MACHINE MUST
BE CUT OFF AT CONTROL ROOM BEFORE ANY REMOVAL OR
REPLACEMENT PROCEDURE IS PERFORMED.
WARNING

EQUIPMENT DAMAGE.
See Section 4, Heading 4.3.1. for a list of special tools, test equipment, and supplies
required to perform maintenance as described in this manual.

6.2.1. Covers
The GM4000A has two covers, a short one and a long one. The switch machine covers
are attached and held to the switch machine case by a single quick release hasp.
No tools are required to remove these covers. The following procedure can be used to
remove and replace either switch machine cover. The remaining procedures assume
that a lock (optional) is used with the hasp.
Table 6-1. Cover Removal and Replacement Procedure
Step Action
1 Remove lock from hasp, if utilized.
HASP
LOCK HOLE
2 Pivot hasp on the case hinge pin.

3 Pivot cover to a vertical position on hinge pins of case. Remove cover when
pivot receptacle in cover clears pivot pin in case.
4 To install, hold cover in vertical position and insert pivot receptacle in cover
into hinge pin of case.
5 Pivot cover about the case hinge pin until cover is horizontal and resting on
the machine case.
6 Pivot hasp closed and lock (if a lock is used).

6.2.2. Cross Brace
The cross brace is attached and held to the switch machine case. The following
procedure can be used to remove and replace the switch machine cross brace.
Table 6-2. Cross Brace Removal and Replacement Procedure
Step Action
HASP ASSEMBLY
LONG COVER SHORT COVER
CROSS BRACE SCREWS
2 Remove the four socket head cap screws and lock washers attaching cross
brace to switch machine case, two on each side of the cross brace.
3 Remove the cross brace by pulling it upward from machined cavity in switch
machine case.
4 Check cross brace for cracks or fractures that may allow water to enter switch
machine or compromise the strength of cross brace.
5 To install, insert cross brace into machined cavity of switch machine case.
6 Install two socket head cap screws and lock washers on each side attaching
cross brace to switch machine case.

6.2.3. Controller
Perform the following procedure, in sequence given, to remove and replace the switch
machine controller.
Table 6-3. Controller Removal and Replacement Procedure
Step Action
1 CAUTION
Power to switch machine must be cut off at control room before

performing this procedure.
Unlock and pivot the hasp open, then remove both switch machine covers.
2 Disconnect the two wire harness 23-way control and motor connectors and
the three-pin power wire connector from the controller. These connectors are
the same in both the standard and enhanced versions of the controller.
STANDARD CONTROLLER
RUN FAULT
POWER CONTROL MOTOR

ENHANCED CONTROLLER
REMOTE F ORWARD

LOCAL STOP
LOAD FAULT FAULT
RESET FAULT REVERSE

SWITCH TO REMOTE
3 Remove the four socket button head screws and lock washers attaching the
controller to the side of the switch machine case.
4 Remove the controller by pulling upward while checking wire harness

clearance.

Table 6-3. Controller Removal and Replacement Procedure (Cont.)
Step Action
5 To install the replacement controller, first connect the two wire harness 23-
way control and motor connectors and three-pin power wire connector to the
controller.
6 Carefully lower the controller into the switch machine while checking wire
harness clearance.
7 Visually align the controller mounting holes with mounting holes in switch
machine case.
8 Install four socket button head screws and lock washers into the controller
mounting holes (36-40 in-lbs, 4-4.5 N.m torque spec).
9 Replace both switch machine covers, pivot the hasp closed, and re-install
lock.
10 Restore power to switch machine from control room.
11 Operate switch machine to verify proper operation.

6.2.4. DC Motor and 172:1 Gear Box
The brushless DC motor and gear box must be removed as an assembly. After the
assembly is removed from the switch machine, the motor can be separated from the
gear box. Perform the following procedure, in sequence given, to remove and replace
the motor and gear box assembly.
Table 6-4. DC Motor and Gear Box Removal and Replacement Procedure
Step Action
1 CAUTION

Unlock and pivot the hasp open, then remove the long switch machine cover.
2 Remove motor wire harness connector from the controller.

WIRE HARNESS CONNECTOR TO
CONTROLLER
CONTROLLER

Table 6-4. DC Motor and Gear Box Removal and Replacement Procedure (Cont.)
Step Action
3 Disconnect the wire harness from the gear box heater, if installed.
TOP VIEW GEAR BOX HEATER CONNECTION

TO WIRE HARNESS
SIDE VIEW
4 Remove the four socket head cap screws and lock washers attaching gear box
to switch machine case.
4 SCREWS
GEARBOX HEATER OIL FILL HOLE COVER
(IF USED)
5 Lift and slide motor and gear box out of switch machine while checking wire
harness and main drive clearance.

Table 6-4. DC Motor and Gear Box Removal and Replacement Procedure (Cont.)
Step Action
6 If required, separate motor from gear box by removing four socket head cap
screws and lock washers attaching motor to gear box. If not required, continue
to Step 9.
7 Remove the used RTV with a putty knife and then clean the area with
isopropyl alcohol.
8 To install, be certain the surfaces are clean and apply RTV (Flange Sealant
P/N 81361-401-11) between the motor and gear box. Attach the motor using
the four socket head cap screws and lockwashers.
9 Lower motor and gear box assembly into switch machine while checking for
wire harness clearance.
10 Slide the gear box toward the main drive and onto the locating pins in the
base. Verify gear box output gear engages main drive gear.
11 Install remaining socket head cap screws (4) and lockwashers attaching gear
box to switch machine case.
Torque the screws to 40 ft-lbs (54 N.m).
12 Reattach motor connectors to the controller and the gear box heater wiring.
13 Replace long switch machine cover, pivot the hasp closed, and re-install lock.

6.2.5. Main Drive
Perform the following procedure, in sequence given, to remove and replace the main
drive.
Table 6-5. Main Drive Removal and Replacement Procedure
Step Action
1 CAUTION

2 Manually move the switch machine into mid stroke position (see Page 4–4)
and align the position of marker locations on the main drive gears. They must
be in line with the center line (CL) of the switch machine for the machine to be
at true mid-stroke position.
ALIGNED POSITION
THROW BAR MARKERS DETAIL
CRANK
POSITION MARKER
LOCATIONS
3 If a hand throw module is not installed, continue to Step 4, otherwise remove

the hand throw module following Table 6-10, Steps 3 through 8.

Table 6-5. Main Drive Removal and Replacement Procedure (Cont.)
Step Action
4 Remove the six socket head cap screws and washers attaching the main drive
to the case bottom. Remove the four shouldered screws and washers
attaching the main drive to the side wall of the case.
HAND THROW LEVER HAND THROW MODULE

SCREWS (2) SCREWS (2)
SHOULDERED SCREWS (4)

ATTACH MAIN DRIVE TO
SIDE WALL OF CASE
SOCKET HEAD CAP SCREWS (6)

ATTACH MAIN DRIVE TO
BOTTOM OF CASE
5 Remove the four socket head cap screws and lock washers attaching gear
box to switch machine case. Lift and slide gear box backward to allow
clearance of main drive (see Table 6-4).
6 Disconnect hand throw cutout switch wire harness connectors.

Table 6-5. Main Drive Removal and Replacement Procedure (Cont.)
Step Action
7 Lift the main drive off the locating pins in switch machine case and out of
switch machine by carefully pulling upward, being sure that clearance of wire
harness is achieved.
MAIN DRIVE
8 Place the replacement main drive on the locating pins, reinstalling the screws
and washers attaching the main drive to the case.
9 Reinstall the motor and gear box.
Torque the main drive and gear box socket head cap screws and washers to
40 ft-lbs (54 N.m). Torque the two socket head cap screws securing the hand
throw cutout switch mounting plate to 15 ft-lbs (20.34 N.m).
10 Reconnect the hand throw cutout switch wire harness connectors.
11 Reinstall the hand throw module, following Table 6-10, Steps 9 through 21.

6.2.6. Motor Limit Switch(es)
Perform the following procedure, in sequence given, to remove and replace the limit
switches.
Table 6-6. Motor Limit Switch Removal and Replacement Procedure
Step Action
1 CAUTION

Unlock and pivot the hasp open, then remove both switch machine covers and
cross brace.
2 Remove socket head cap screws and lockwashers attaching limit switch to
point detector switch module and mounting plates.
LIMIT SWITCHES (2)
SOCKET HEAD CAP SCREWS

(2 PER LIMIT SWITCH)
3 Remove cover and loosen screws holding wires in place.

4 Loosen the nut on coupler and loosen waterproof rubber grommet to allow
wire to be pulled through, being careful not to lose sleeve identification tags.
5 To install, run wires in reverse order keeping the sleeve tags in mind.
6 Visually align the limit switch mounting holes with mounting holes in point
detector switch module.
7 Install socket head cap screws and lockwashers into point detector switch
module mounting holes.
10 Perform motor limit switch adjustment per Table 3-12. Operate switch
machine multiple times and observe limit switch to verify proper operation.
11 Re-install cross brace, replace both switch machine covers, pivot the hasp
closed, and re-install lock.

6.2.7. Cam Bar Detection Switch
Perform the following procedure, in sequence given, to remove and replace the limit
switches.
Table 6-7. Cam Bar Detection Switch Removal and Replacement Procedure
Step Action
1 CAUTION

cross brace.
2 Remove socket head cap screws and lockwashers attaching cam bar
detection switch to point detector switch module and mounting plates.
CAM BAR DETECTION

SWITCH
SOCKET HEAD CAP SCREWS (2)
3 Remove cover and loosen screws holding wires in place.

4 Loosen the nut on coupler and loosen waterproof rubber grommet to allow
wire to be pulled through, being careful not to lose sleeve identification tags.
5 To install, run wires in reverse order keeping the sleeve tags in mind.
6 Visually align the cam bar detection switch mounting holes with mounting
holes in point detector switch module.
7 Install socket head cap screws and lockwashers into point detector switch
module mounting holes.

Table 6-7. Cam Bar Detection Switch Removal and Replacement Procedure (Cont.)
Step Action
10 If the machine is equipped with a cam bar detection switch, operate switch
machine multiple times and observe limit switch to verify proper operation.
11 Re-install cross brace, replace both switch machine covers, pivot the hasp
closed, and re-install lock.

6.2.8. Hand Throw Cutout Switch
Perform the following procedure, in sequence given, to remove and replace the hand
throw cutout switch module.
Table 6-8. Hand Throw Cutout Switch Removal and Replacement Procedure
Step Action
1 CAUTION

Unlock and pivot the hasp open, then remove long switch machine cover.
2 Place the hand throw selector lever in the POWER position, releasing the
hand throw cutout switch.
3 The switch is mounted on a plate attached to the main drive. The plate is
removed with the limit switch.
If the machine is configured for left hand operation, access the limit switch
through the hand throw bore in the case that has a cover on it. Remove the
two socket head cap screws attaching cover to base.
If the machine is configured for right hand operation, place the machine in mid
stroke and remove the hand throw module (see Table 6-10, Steps 4 through
8).
4 Disconnect the wires to the limit switch.
Remove the two screws and lockwashers holding the switch and plate to the
main drive and slide through the bore in the side of the switch machine case.
SCREWS (2) HAND THROW CUTOUT SWITCH
PLATE

Table 6-8. Hand Throw Cutout Switch Removal and Replacement Procedure (Cont.)
Step Action
5 Remove the cutout switch from the plate by removing two socket head cap
screws and lockwashers attaching cutout switch to the plate.
SOCKET HEAD CAP
HAND THROW CUTOUT SWITCH
SCREWS (2)
6 To install, reverse these directions, attaching the new cutout switch to the
plate, reinstalling the plate into the switch machine with 15 ft-lbs
(20.34 N.m) torque, then reinstalling the cover plate (left hand machine) or
hand throw module (right hand machine).
7 If hand throw module was removed and replaced (right hand machine), verify
proper timing per Table 3-4, Step 20.
9 Using a continuity tester at terminals TB1–6 and TB1–7, verify that when the
hand throw selector lever is at the 90 degree position between POWER and
HAND, continuity is broken.
If continuity is not broken, loosen the two socket head cap screws securing
the cutout switch mounting plate, then reposition the plate and switch so that
continuity is broken. Torque screws to 15 ft-lbs (20.34 N.m) and retest.
10 Move the hand throw selector lever from the POWER to HAND position and
back again several times, verifying that the hand throw cutout switch is
activated when the selector lever is in the HAND position and deactivated
when the selector lever is in the POWER position.

6.2.9. Hand Crank Cutout Limit Switch
Perform the following procedure, in sequence given, to remove and replace the hand
crank cutout limit switch.
Table 6-9. Hand Crank Cutout Limit Switch Removal and Replacement Procedure
Step Action
1 CAUTION

2 Disconnect wire harness and mounting hardware from the hand crank cutout
switch.
HAND CRANK CUTOUT SWITCH

WIRING
3 Remove contacts. (Reinstall replacement contacts at this time, if required.)

4 Connect wire harness to replacement contacts terminals.

(Cont.)
Step Action
5 Insert hand crank into the machine. Verify there is no power to the motor, the
machine cannot operate electrically, and there is no continuity between TB2-
11 and TB2-12.
6 Remove hand crank from switch machine.
7 Insert a 0.110 inches thick gauge (P/N 36183-066-00) between the plunger
and case, it should fit freely.
PLUNGER
CASE
HAND CRANK
8 Push the hand crank reset button. Verify there is no power to the motor, the
machine cannot operate electrically, and there is no continuity between TB2-
11 and TB2-12.
9 Remove the gauge.
10 Insert the hand crank and place a 0.020 thick gauge (P/N 36183-066-00)
between the plunger and the case.
11 Remove the hand crank and push the hand crank cutout switch reset button.
Verify there is no power to the motor, the machine cannot operate electrically,
and there is no continuity between TB2-11 and TB2-12.
HAND CRANK

(Cont.)
Step Action
12 Remove the gauge.
Verify that cutout switch is tripped (contacts rise) when a hand crank is inserted in the
switch machine. There must be 1/4" (0.635 cm) minimum contact opening.

6.2.10. Hand Throw Module
Perform the following procedure to remove and replace the hand throw module. Follow
procedure in the sequence given to avoid equipment damage.
Table 6-10. Hand Throw Module Removal and Replacement Procedure
Step Action
1 CAUTION

2 Manually move the switch machine into mid stroke position (see Page 4–4).
3 Place hand throw selector lever in the HAND position.
HAND

Table 6-10. Hand Throw Module Removal and Replacement Procedure (Cont.)
Step Action
4 While machine is at mid-stroke, with hand throw lever at 90° vertical position,
loosen the two socket head cap screws and lock washers that attach the hand
throw lever to the hand throw module.
HAND THROW LEVER AT 90 DEGREE

VERTICAL POSITION
HAND THROW LEVER HAND THROW MODULE

5 Remove top screw and lock washer, holding the hand throw lever and
allowing it to rotate in toward the ground, while supporting the weight of the
lever.

Step Action
6 Once the weight has been removed, remove the second screw and the hand
throw lever. Set aside the hand throw lever.
HAND THROW GEAR
HAND THROW LEVER
SELECTOR LEVER
CORRESPONDENCE LETTER
7 Remove the two socket head cap screws and lock washers attaching hand
throw module to case.
8 Carefully slide the hand throw module out using a twisting motion while
pulling. Use a soft blow mallet, if necessary, to remove any rust that may have
occurred.
9 Remove the optional correspondence letters, if used, from the removed hand
throw lever and install them onto the replacement hand throw lever.
10 Through the case opening where the hand throw module was removed,
visually check that the shifter dog of the main drive module is engaged in the
hand throw dog gear.

Step Action
11 Look through the case opening where the hand throw module was removed to
visually check that the timing mark on top surface of the hand throw dog gear
is centered in between the two timing marks on the hand throw bevel gear.
•
•
If the timing mark is not in the proper position, rotate the hand throw dog gear
until it reaches the proper position.

Step Action
12 With the hand throw lever support in the vertical position, engage the bevel
gears.
BEVEL GEARS
MOUNTING FLANGE
The module should slip in and the mounting flange should be flush with the
switch machine case.
NOTE
Very little pressure is required for this operation. Do not hammer

or bang on the module.
13 Verify proper timing of the hand throw module by rotating the hand throw lever
support until the top gears of the main-drive module move. Rotate the hand
throw lever support to the other side until the top gears of the main drive
module move; this motion of the hand throw lever support should be equal on
either side of the vertical position. If not, disengage the bevel gears and repeat
Steps 10-12.
14 Re-install the mounting flange hardware.
15 Align the mounting holes of hand throw lever to the hand throw lever support
and attach to using the bolts removed in Step 4.

Step Action
16 Secure the hand throw lever and hand throw selector lever in the latch stand.
17 Using a continuity tester at terminals TB1–6 and TB1–7, verify that when the
hand throw selector lever is at the 90 degree position between POWER and
HAND, continuity is broken.
If continuity is not broken, loosen the two socket head cap screws securing
the cutout switch mounting plate, then reposition the plate and switch so that
continuity is broken. Torque screws to 15 ft-lbs (20.34 N.m) and retest.
18 Move the hand throw selector lever from the POWER to HAND position and
back again several times, verifying that the hand throw cutout switch is
activated when the selector lever is in the HAND position and deactivated
when the selector lever is in the POWER position.
19 Operate switch machine with hand throw to verify proper operation.
21 Place hand throw selector lever in the POWER position.
23 Have the control room throw the switch machine a few times to verify
operation.

6.2.11. Latch Stand(s)
Perform the following procedure, in sequence given, to remove and replace a latch
stand. No adjustments or special tools are required.
Table 6-11. Latch Stand Removal and Replacement Procedure
Step Action
1 CAUTION

Unlock and pivot the hasp open.

2 Remove four socket head cap screws and lockwashers attaching latch stand
to side of switch machine case. Rotate hand throw selector lever or hand
throw lever if they are in the way.
LATCH STANDS FOR HAND THROW LEVER AND SELECTOR LEVER
3 To install, align replacement latch stand and attach to switch machine case
using four socket head cap screws and lockwashers.
4 Replace hand throw selector lever and hand throw lever into latch stand.
5 Pivot the hasp closed, and re-install lock.

6.2.12. Lock Rod
Perform the following procedure, in sequence given, to remove and replace the lock
rod.
Table 6-12. Lock Rod Removal and Replacement Procedure
Step Action
1 CAUTION

Unlock and pivot the hasp open, then remove the short switch machine cover.
2 Manually move the switch machine to mid-stroke position (see Page 4–4).
3 Remove all connection hardware attaching lock rod to switch points, including
all jam nuts (inner and outer).
SWITCH MACHINE
LOCK ROD DROP LUG

LOCK ROD
OUTER JAM NUT
INNER JAM NUT
DIRECTION OF MOVEMENT LOCK CONNECTING ROD
4 Slide lock rod out of switch machine.

5 To install, with switch machine in mid-position, slide the replacement lock rod
into switch machine and install all connection hardware attaching lock rod to
switch points.
6 Perform Lock Rod Adjustment procedure, in Table 4-154 (narrow notch) or
Table 4-16 (wide notch).
7 Replace short switch machine cover, pivot the hasp closed, and re-install lock.

6.2.13. Point Detector System Module
Perform the procedure provided in Table 6-13 to remove and replace the point detector
system module. To adjust the point detector system module perform the procedure
provided in Table 6-14. Read the entire procedure before proceeding.
NOTE
The point detector system module is factory set and only requires
adjustment if either the Point Detector System Module,
P/N GM050-700-01, or the Point Detector Switch Module,
P/N GM050-800-02, is replaced.
Table 6-13. Point Detector System Module Removal and Replacement Procedure
Step Action
1 CAUTION

2 Remove the lock rod and point detector rod. See replacement procedures in
Tables 6-12 and 6-16.
3 Manually move the switch machine to the normal or reverse position.
4 Remove four socket head cap screws and lock washers attaching point
detector system module to switch machine base plate.
POINT DETECTOR MODULE SCREWS

(4, 2 NOT VISIBLE IN THIS VIEW)

Table 6-13. Point Detector System Module Removal and Replacement Procedure
(Cont.)
Step Action
5 Lift point detector module off locating pins in base plate and out of switch
machine by pulling upward while checking wire harness clearance.
TOP VIEW FRONT VIEW
6 To install, align locating holes of replacement point detector module with

locating pins in switch machine base plate.
7 Carefully lower point detector module into switch machine while checking wire
harness clearance.
8 Install four socket head cap screws and lock washers attaching point detector
module to switch machine base plate.
9 Reconnect point detector rod and lock rod.
10 Perform the Point Detector System Module Adjustment Procedure provided in
Table 6-14.

Table 6-14. Point Detector System Module Adjustment Procedure
Step Action
1 CAUTION

2 Hand crank, hand throw lever or manual switch may be used to actuate the
switch machine.
Hand crank machine to mid-stroke and position a point detector rod spoon
gauge into the necked down portion on the trackside end of the point detector
rod. Use the 4.5 mm (0.18") end of the spoon gauge.
NOTE
Insert spoon gauge to prevent damage to bearing on the pivot

arm caused by bearing contact surface moving when turning nut
in next Step.
LATCHOUT
DOG PIVOT
ARM
SPRING
SPOON
POINT DETECTOR ROD GAUGE
There should be continuity from TB3–5 to TB3–6 and from TB3–7 to TB3–8.
This may be in the normal or reverse position depending on a right hand or left
hand installation and whether normal is the near or far point.
The pivot arm on the right while standing at the point detector end of the
machine should be in the tapered portion of the point detector rod.

Table 6-14. Point Detector System Module Adjustment Procedure (Cont.)
Step Action
3 Rotate point detector switch lever 1/16” (0.160 cm) past breakage of
indication:
Connect multimeter to TB3–5 and TB3–6.
If machine is configured as a right hand machine, use the slave rod to actuate
pivot arm.
FIXED END
TOPVIEW
SLAVE ROD SWIVEL END

TOPVIEW
EXTERNAL NUTS WITH DETAIL

POINT DETECTOR ROD JAM NUTS, 4 (1.000-8)
SWITCH POINT LUG
If machine is left handed, use external nuts to actuate pivot arm. Turn nut to
move taper into pivot arm. Turn slowly as point detector switch lever starts to
rotate. Stop when continuity is broken. Check TB3–7 and TB3–8 for continuity.
If continuity exists, continue to turn adjusting nut or external nut until continuity
is broken.
NOTE
There may be some slight variation between the two contact

sets due to tolerance of the rotary cam switch.
Now, turn the hex nut or slave rod an additional 2/3 of a complete turn or
approximately 4 flats (between 2 and 6 flats) of the hex nut.

Step Action
4 Set latch out to occur at this position.
STAINLESS NUT,
.750-16 X 42
SPLIT RETAINING RINGS
LATCHOUT NUT
NUT, .313-18 X 31 LATCH OUT DOG
LOCK ROD
PIVOT ARM POINT

DETECTOR ROD
SLAVE ROD
SPOON GAUGE
Loosen the .313-18 and .750-16 nuts located against the latchout nut to unjam
the latchout nut.
Pull the latch out dog away from split retaining ring and turn the latchout nut
until dog rests on ring, then turn until dog just drops behind ring.
Loosen the .313-18 and .750-16 nuts located against the latchout nut.
If split on split retaining ring is where latch out dog engages, then move split
on ring to vertical position. A box wrench can be used to hook ring at split and
rotate in groove. Be careful not to separate splitting ring or to turn the large
threads and change adjustment.

Step Action
5 Apply light pressure to pivot arm and remove spoon gauge. Check primary
criteria in Step 6.
6 Primary Adjustment Criteria:
When properly adjusted and latched out, indication switches are open, shunt
switches may be open or closed. Optimum condition is when softly latched out
(when dog gently slides into position), the shunt switches are closed.
7 Unlatch by pulling latch out dog away from ring and do Steps 8 and 9.
NOTE
The hex nut on the right side of the point detector rod has 6
facets or flats. When the rod rotates as the machine moves to
latch-out position after indication break, the hex nut movement
must be between 2 and 6 flats which corresponds to <1/8” (0.32
cm) of point detector rod movement.
NOTE
Due to tolerances of the components that comprise this system,

it may not be possible to always achieve optimum conditions.
8 Secondary Adjustment Criteria:

When properly adjusted, under vibration simulation, there is no intermittent
breakage of indication.
INDICATING SIDE
PIVOT ARM POINT DETECTOR SWITCH

CORRESPONDENCE PIN MODULE LEVER
PIVOT ARM
LOCK ROD
POINT DETECTOR SYSTEM MODULE

BALL BEARING
POINT DETECTOR ROD
POINT DETECTOR ROD 45

DEGREE RAMP

Step Action
8 Optimum condition is a 0.0” to 0.03” (0.0 cm – 0.076 cm) gap between the ball
(Cont.) bearing on the point detector system module and the lever on the point
detector switch module. This is measured on the indicating side of the pivot
arm when the other pivot arm correspondence pin is touching the lock rod.
Perform vibration simulation by grasping and rapidly moving the non-indicating
pivot arm back and forth. Range of motion is restricted on one side by the
correspondence pin on the non-indicating pivot arm touching the lock rod and
on the other side by the ball bearing on the indicating pivot arm touching the
45 degree taper on the point detector rod.
9 Tertiary Adjustment:
When properly adjusted, there is a 0.0” to 0.150”, >0.060” optimum) (0.0 cm –
0.38 cm, > 0.15 cm optimum) gap between the ball bearing on the point
detector system module and the 45 degree ramp on the point detector rod
(see figure in Step 8). This is measured on the indicating side pivot arm when
the other pivot arm correspondence pin is pushed against the lock rod.
10 Throw switch to opposite side from Step 2.
Hand crank, hand throw lever, or manual switch may be used to actuate the
machine.
INDICATING SIDE
POINT DETECTOR SWITCH PIVOT ARM

MODULE LEVER CORRESPONDENCE PIN
PIVOT ARM
LOCK ROD
POINT DETECTOR SYSTEM MODULE POINT DETECTOR ROD

BALL BEARING
POINT DETECTOR ROD

45 DEGREE RAMP

Step Action
11 Rotate point detector switch lever 1/16” (0.16 cm) past breakage of indication:
Connect multimeter to TB2–5 and TB2–6.
If machine is configured as a left hand machine, use the slave rod to actuate
pivot arm.
If machine is right handed, use external connection nuts to actuate pivot arm.
Turn nut to move taper into pivot arm. Turn slowly as point detector switch
lever starts to rotate. Stop when continuity is broken. Check TB2–7 and TB2–
8 for continuity. If continuity exists, continue to turn adjusting nut or external
nut until continuity is broken.
Now, turn the hex nut or slave rod an additional 2/3 of a complete turn (4 flats
of the hex nut).
12 Set latch out to occur at this position.
Loosen the .313-18 and .750-16 nuts located against the latchout nut to unjam
the latchout nut.
Turn the latchout nut without moving the large threads on the right side of
linkage until latch out dog drops behind split retaining ring. If dog is already
behind ring, pull dog away from ring and turn nut until dog rests on ring, then
turn until dog just drops behind ring. Tighten the .313-18 and .750-16 nuts
located against the latchout nut, being careful not to change the adjustment.
NOTE
A modified 7/16” wrench may be required (bend handle about 30

degrees.
Check primary criteria in Step 6.

13 Unlatch by pulling latch out dog away from ring and check criteria in Steps 8
and 9.
NOTE
Due to tolerances of the components that comprise this system,

it may not be possible to always achieve optimum conditions.
Check primary criteria (Step 6) and secondary criteria (Steps 8 and 9) on the
other side.

Step Action
13 While checking secondary adjustment criteria (Step 8), if roller is contacting
(Cont.) lever enough to break indication, turn hex nut or slave rod back 1/6 turn (one
flat of the hex nut).
While checking tertiary adjustment criteria (Step 9), if roller is too close to the
point detector rod ramp, turn hex nut or slave rod forward 1/6 turn (one flat of
the hex nut).
NOTE
The hex nut on the right side of the point detector rod has 6
facets or flats. When the rod rotates as the machine moves to
latch-out position after indication break, the hex nut movement
must be less than 7 flats which corresponds to <1/8” (0.32 cm)
of point detector rod movement, and more than 2 flats.
14 Repeat Steps 5 through 8 on both sides until no further adjustment is required.

15 Adjust the point detector rod and test per local standards.

6.2.14. Point Detector Switch Module
Perform the following procedure, in sequence given, to remove and replace the point
detector switch module.
Table 6-15. Point Detector Switch Module Removal and Replacement Procedure
Step Action
1 CAUTION

the cross brace.
2 Remove the four (4) socket head cap screws and lock washers attaching the
two motor limit switches (2 screws for each limit switch) and swing the
switches off either side of the machine. Set spacer plates from under limit
switches aside.
LIMIT SWITCHES (2)
SOCKET HEAD CAP SCREWS

(2 PER LIMIT SWITCH)
3 Remove the point detector system module per Table 6-13, Steps 2 to 5.
4 Disconnect the two switch module connectors at either end of the module.
5 Remove the two socket head cap screws and lockwashers attaching the
switch module to the case.
6 Lift the switch module off the locating pins by pulling at both ends of the
module and lifting up.

Table 6-15. Point Detector Switch Module Removal and Replacement Procedure
(Cont.)
Step Action
7 Lift point detector switch module out of switch machine by pulling upward
while checking wire harness clearance.
8 To install, align the locating pin holes in the switch plate and push onto the
pins in the case. Start the two screws and washers and tighten.
9 Replace the point detector system module per Table 6-13, Steps 6 to 10.
10 Reinstall the limit switches, spacer plates, and wire connectors.
11 Perform the Point Detector System Module Adjustment Procedure provided in
Table 6-14.
12 Once all adjustments have been made, restore power to switch machine from
control room.
13 Check adjustment of the motor limit switch cams per Table 3-12.
14 Operate switch machine several times to verify proper operation.
15 Reinstall cross brace and both switch machine covers, pivot the hasp closed,
and re-install lock.

6.2.15. Point Detector Rod
Perform the following procedure, in sequence given, to remove and replace the point
detector rod.
Table 6-16. Point Detector Rod Removal and Replacement Procedure
Step Action
1 CAUTION

2 Remove all connection hardware attaching point detection rod to the switch
point lug.
FIXED END
TOPVIEW
SWIVEL END
TOPVIEW

POINT DETECTOR ROD JAM NUTS, 4 (1.000-8)
SWITCH POINT LUG

Table 6-16. Point Detector Rod Removal and Replacement Procedure (Cont.)
Step Action
3 Slide point detection rod out of switch machine.
LOCK ROD
POINT DETECTOR
ROD
4 To install, slide replacement point detection rod into switch machine.

5 Install all connection hardware attaching point detector rod to switch points.
6 Adjust point detector rod, as described in Table 4-17.

6.2.16. Point Detector Rod Bushing
Perform the following procedure, in the sequence given, to remove and replace the
point detector rod bushing.
Table 6-17. Point Detector Rod Bushing Removal and Replacement Procedure
Step Action
1 CAUTION

2 Remove point detection rod per Table 6-16, Steps 2 and 3.
3 Use tool GMA50-100-01, Bushing Puller (available in P/N GMK50-000-01,
Maintainer Tool Kit) to loosen the point detector rod bushing from the switch
machine case.
BOLT PULLER
PLACED OUTSIDE SWITCH MACHINE FRAME PLACED INSIDE SWITCH MACHINE FRAME
The half of the tool containing the bolt is placed against the outside of the
switch machine case at the hole for the point detector rod.
The puller part of the tool is placed against the inside of the switch machine
case, and lined up with the bolt.
4 Thread the puller onto the bolt and tighten the bolt, drawing the puller through
the hole until the bushing is released from the hole in the case.
5 Loosen the bolt until it separates from the puller, releasing the bushing.

Table 6-17. Point Detector Rod Bushing Removal and Replacement Procedure (Cont.)
Step Action
6 Slide a new bushing from the outside of the switch machine case into the point
detector rod hole on the case.
7 Repeat Steps 4 through 6 on the other point detector bushing, if necessary.
8 Reinstall the point detection rod into switch machine, per Table 6-16, Steps 4
to 6.

6.2.17. Throw Bar
Perform the following procedure, in sequence given, to remove and replace the throw
bar.
Table 6-18. Throw Bar Removal and Replacement Procedure
Step Action
1 CAUTION
Power to switch machine must be cut off at the control room

before performing this procedure.
Remove snow guards, if equipped.
2 Remove all connecting hardware attaching throw bar to switch points.
3 Remove the main drive per Table 6-5.
4 Remove the outside two screws and washers attaching each of the filler
blocks to the case, back set screws out of wear plates, and remove the filler
blocks.
THROW BAR
FILLER BLOCKS
REMOVE THE OUTSIDE

SCREWS AND LOCK WASHERS
5 Remove wear plates.

6 Slide out throw bar.
7 Slide replacement throw bar into position.
8 Replace wear plates and filler blocks; adjust set screw.

Table 6-18. Throw Bar Removal and Replacement Procedure (Cont.)
Step Action
9 Replace the main drive per Table 6-5. Reinstall the motor with 172:1 gear box
and reconnect the wiring to the hand throw cutout switch.
lock. Reinstall snow guards, if equipped.

6.2.18. Throw Bar and Lock Rod Wear Plate Assembly
throw bar and lock rod wear plates.
Step Action
1 CAUTION

2 To remove the throw bar wear plates, back off the two set screws above each
wear plate. Slide the wear plates out. (Wear plates look like four puzzle
pieces.) They slide out easier when weight from the throw bar is removed by
hand.
3 To remove the lock rod wear plates remove two socket head cap screws and
lock washers attaching wear plate assembly to side of switch machine case.
Back off one set screw above each wear plate.
4 Slide the wear plate assembly out of cavity in switch machine case.
WEAR PLATES
5 To install, slide the wear plate assemblies into the cavities of the switch
machine case. Be aware that the throw bar wear plates slide in easier when
weight from the throw bar is removed by hand.
6 Install the two socket head cap screws and lock washers attaching the lock
rod wear plate assemblies to switch machine case. Retighten all set screws
and then back off set screws 1/4 turn.

(Cont.)
Step Action
lock.

6.2.19. Condensation Heater
condensation heater.
Table 6-20. Condensation Heater Removal and Replacement Procedure
Step Action
1 CAUTION

Unlock and pivot the hasp open, then remove short switch machine cover.
2 To remove the condensation heater, disconnect it from the switch machine
terminals and peel it off the switch machine terminal block support bracket.
CONDENSATION HEATER
(55290-041-00, 24VDC OR
55290-042-00, 110VDC)
3 Clean any residual glue on the switch machine with isopropyl alcohol. Area
must be free of moisture, grease and grit for proper adhesion of heater.
4 To affix the new condensation heater, peel half of the wax paper from the
pressure sensitive adhesive on the back of the heater. Place the heater in
position on the switch machine and pull off the remaining wax paper while
pressing the heater firmly in place. Connect the heater to the switch machine
terminals.
THE WIRES FOR EACH ASSEMBLY IDENTIFY 110 OR 24 VOLT OPERATION.
PRESSURE SENSITIVE ADHESIVE

(THIS SIDE ONLY)

6.2.20. Motor Gear Box Heater
motor gear box heater.
Table 6-21. Motor Gear Box Heater Removal and Replacement Procedure
Step Action
1 CAUTION

Unlock and pivot the hasp open, then remove long switch machine cover.
2 To remove the motor gear box heater, disconnect it from the switch machine
wire harness and scrape it off the motor gear box.
TOP VIEW GEAR BOX HEATER CONNECTION

TO WIRE HARNESS
SIDE VIEW
3 Clean any residual adhesive on the switch machine with isopropyl alcohol.
Area must be free of moisture, grease and grit for proper adhesion of heater.
4 Identify the aluminum side of the new heater. The back of the heater is
aluminum, the front side is covered with foam; the foam should be left intact.
ALUMINUM PLATE
POLYURETHANE FOAM
SIDE VIEW

Table 6-21. Motor Gear Box Heater Removal and Replacement Procedure (Cont.)
Step Action
5 Center the heater in position on the side of the gear box. Use heat conductive
RTV silicone adhesive/sealant (P/N 81361-061-11) on the aluminum side of
the heater to affix the heater to the switch machine, pressing the heater firmly
in place.
The red RTV adhesive cures to the consistency of rubber.
NOTE
The RTV adhesive container is printed with an expiration date.

Do not apply adhesive after the expiration date, or it may not
cure.
6 Connect the heater to the switch machine wire harness.

lock.


Parts Catalog
7. SECTION 7 - PARTS CATALOG
7.1. GENERAL
This section identifies and lists the replaceable parts of the GM4000A Switch Machine
and the available kits, associated connecting hardware, and tools. A 10-digit drawing
number identifies each item. When ordering, always refer to the 10-digit drawing
number.
7.2. PARTS LISTS
Figure 7-1 is an 8 page assembly drawing of the GM4000A covering the various switch
machine configurations. Table 7-1 includes the reference numbers associated with the
various figures along with their part descriptions, part numbers, and quantities required
to assemble the machine. In addition, the table includes some parts required for
assembly that are not referenced in the drawing(s). Table 7-2 is the configuration key
that can be used to order a GM4000A based on the required configuration.
Figure 7-2 shows the GM4000A wire harness and is followed by Table 7-3 that lists
parts used in the wire harness. In addition, Table 7-4 lists the GM4000A connecting
hardware parts and Table 7-5 lists the available GM4000A tools and kits.
Reference numbers are listed to precisely locate referenced parts in the illustration. This
section of the manual covers currently available manufactured spare parts for field level
replacement.
NOTE
All measurements are in inches unless otherwise noted.

Parts Catalog

Parts Catalog
ABCD
NOTE 1:- STAMP NAME PLATE (REF.4) WITH ALSTOM MODEL NUMBER, REVISION NUMBER AND SERIAL NUMBER. NOTE 16:- DRILL SIZE 3/32 INCH PRIOR TO INSTALLATION.
NOTE 2:- SEE WIRING DIAGRAM GMV00-040-00 FOR CONNECTION OF LEADS. NOTE 17:- USE FIVE MINUTE EPOXY (81361-201-05) PER 90A0025 FOR INSTALLATION OF THE SCREEN VENTS (REF.6). TRIM SCREEN TO FIT.
NOTE 3:- COVER OPENING WITH DUCT TAPE. NOTE 18:- APPLY RUST VETO (81379-085-06) PER 91A0004, ON ALL BARE MACHINED METAL SURFACES INSIDE MACHINE.
NOTE 4:- APPLY VIBRATITE PER 90B0005 TO SCREW (REF.82&19) AND SHOULDER BOLTS (REF.90). NOTE 19:- PAINT EXTERIOR OF MACHINE, INCLUDING MACHINED UPPER LIP OF CASE, FEDERAL COLOR #37038,
NOTE 5:- ORIENT BUSHING (REF.49) SO SPLIT IS AT BOTTOM OF BORE. BLACK PER FS-299-06. SHEET 1 OF 8
NOTE 6:- PLACE CONNECTORS #43587-006-00, TWO WASHERS (REF.73) AND TWO SCREWS (REF.75) IN BAG. NOTE 20:- IF WIRE HARNESS KIT GMK50-013-01 IS REQUIRED, ASSEMBLE INTO MACHINE PER WIRE TABLE
NOTE 7:- APPLY LOCTITE 222 TO SCREWS (REF. 116) PER ALSTOM SPEC. 90B0006. ON GMK50-013-00, AFTER FACTORY TEST AND PRIOR TO SHIPPING. SWITCH MACHINE GMV01-000-00
NOTE 8:- TORQUE TO 40 FT-LBS WET WITH CORROSION INHIBITOR PER 91A0020. NOTE 21:- SEAL JOINT BETWEEN FILLER BLOCK (REF.10) AND CASE (REF.1). APPLY SEALANT 90B0020 TO
S W M C H G M 4 0 0 0 A
NOTE 9:- TORQUE TO 15 FT-LBS. JOINT LINE ON TOP AND SIDE SURFACES OF REF.10 (BOTH SIDES OF MACHINE). 39
NOTE 10:- TORQUE TO 30-32 IN-LBS.
NOTE 11:- TAPE THE .875 BOLT #38186-004-00, .875 WASHER #01273-014-ON, .875 SLOTTED NUT #47191-009-00 AND
COTTER PIN #00046-001-ON TOGETHER AND PLACE IN THIS AREA FOR SHIPMENT. 2 41
NOTE 12:- PLACE PLUGS (REF. 94) AS NEEDED IN ALL OPEN LATCH STAND SCREW HOLES,THROW BAR SNOW
40
GUARD SCREW HOLES AND LOCK ROD WEAR PLATE SCREW HOLE.
64 91
NOTE 13:- ALL DIMENSIONS SHOWN ARE APPROXIMATE, UNLESS OTHERWISE SPECIFIED. 38
NOTE 15:- CENTER HEATER ON SIDE OF GEAR BOX AS SHOWN ON SHEET 5. USE HEAT CONDUCTIVE 66 93 NOTE 4
RTV PER 90B0041 TO ATTACH. FOLLOW INSTALLATION INSTRUCTIONS PER AD71-14. NOTE 9
53
50
33 66 72 (FOR SNOW GUARDS)
49 (NOTE 5)
1
62 85 76 NOTE 2
24 (NOTE 23)
26
NOTE 24
A A
(SEE NOTE 24
DETAIL
SECTION
N-N)
"Y"
19 23
11
NOTES 6, 11
58 87 28 73 75 25
37 21 (NOTE 10)
27 66 93
NOTE 21:- SEAL JOINT BETWEEN FILLER BLOCK (REF.10) AND CASE (REF.1). APPL Y SEALA NT
66 71 36
90B0020 TO JOINT LINE ON TOP AND SIDE SURFACES OF REF.10 (BOTH SIDES
OF MACHINE ).
(NOTE 22) 49 22
NOTE 22:- SEAL JOINT BETWEEN COVER (REF.27) AND CASE (REF.1) WITH SEALANT 90B0020 . (NOTE 8) 66 68 (NOTE 5) 88
NOTE 23:- TORQUE TO 36-40 IN-LBS . 5 93 18 36
(NOTE 8)
66 71 19 77
NOTE 24:- FOR ALL "WMD" AND "NO LATCH" (OPTION A) CONFIGURED MACHINES, REMOVE LATCH OUT RINGS AND LATCH OUT
NUT WITH JAM NUT FROM POINT DETECTOR COMPLETE (REF.43).
10 66 90 65 91 (NOTE 16) 77
(NOTE 21) (NOTE 4)
NOTE 26:- ADJUST THE HAND THROW CUT-OUT SWITCH BY LOOSENING THE SCREWS ON THE MOUNTING PLATE AND 88 (NOTE 10)
POSITION THE SWITCH UNTIL THE CONTACTS OF SWITCH BREAKS AND MAKES PROPERLY.
FIGURE 1
NOTE 27:- AT FINAL TEST, VERIFY PROPER FUNCTIONING OF THE HAND CRANK CUT-OUT SWITCH AND HAND THROW R.H. SWITCH MACHINE
CUT-OUT SWITCH PER DRGMV01-000-00.
DUAL CONTROL
(COVERS REMOVED FOR CLARITY)
NOTE 3
21
SECTION A-A 42 53 76 78
Figure 7-1. GM4000A Switch Machine Assembly Drawing, Sheet 1 of 8

Parts Catalog
13
2 17 ABCD
12 SHEET 2 OF 8
SWITCH MACHINE GMV01-000-00

71 SW MCH GM4000A
16
66
70
20
20 66 71
14 DETAIL E
DETAIL C
VIEW SHOWING MOUNTING OF WEAR PLATES
AROUND THROW BAR (REF. 2)
VIEW SHOWING MOUNTING OF WEAR PLATES
AROUND LOCK ROD COMPLETE (REF.39)
VIEW SHOWING MOUNTING OF LOCK ROD COVER (REF.70)
FOR SWITCH MACHINE WITHOUT LOCK ROD 62 63 11 15 11
(SNOW GUARD REMOVED FOR CLARITY)
23
END VIEW SHOWING HAND CRANK DOOR (REF. 62) END VIEW SHOWING WIRING ACCESS CUTOUT
VIEW SHOWN WITH HAND THROW LEVER , LATCH STANDS, VIEW SHOWN WITH HAND THROW LEVER , LATCH STANDS,
RODS AND GUARD COVERS REMOVED RODS AND GUARD COVERS REMOVED
CAM BAR DETECTION

SWITCH (GMA50-107-01)
SECTION N-N 82 97 120
VIEW SHOWING MOUNTING OF TAG (REF.4) NOTES 9 & 26
(NOTE 24)
42 6 79 83 79 81 45 44 121 43 53 76 78
24 85 76
N
N
SEE DETAIL "Y"

(SHEET 4)
WEAR PLATES
53 6 35 51 53 76 78 SEE DETAIL "C"
3 18 19
(NOTE 17)
(NOTE 4)

Parts Catalog
20.00 2.80 ABCD

2.00 6.50 7.50
SHEET 3 OF 8

SW MCH GM4000A
6.50
33.67 THROW
18.63
16x 1.09 THRU 2.00
18.50
15.81
CL
18.25
17.01
19.35
21.00
BOTTOM VIEW
10.98
35.92
67.00
8.75
E C
28 1.50 94 (NOTE 12) 1.92 66 71 3.00 (SHEET 2)
(SHEET 2)

Parts Catalog
HEATER APPLICATION:
STEP 1:- PREPARE ANGLE BRACKET (REF.21& 22) SURFACE BY LIGHTLY SANDING AREA FOR HEATER WITH
ABCD
COARSE EMERY CLOTH. WIPE CLEAN WITH ISOPROPYL ALCOHOL. AREA MUST BE FREE OF
MOISTURE, GREASE AND GRIT FOR PROPER ADHESION OF HEATER. SHEET 4
STEP 2:- APPLY HEATERS BY PEELING BACK ABOUT TWO INCHES OF WAX PAPER BACKING ON HEATER AND
FOLD BACK, BEING CAREFUL NOT TO TOUCH EXPOSED ADHESIVE. POSITION HEATER AS SHOWN
ON ANGLE BRACKET (WIRES WILL BE ON YOUR LEFT). PRESS ON HEATER WHILE REMOVING WAX S W M C H G M 4 0 0 0 A
PAPER. USE ROLLER TO REMOVE ANY TRAPPED AIR AND TO FIRMLY APPLY HEATER TO ANGLE BRACKET.
STEP 3: COIL UP WIRES FOR EACH HEATER INTO BUNDLES AND PLACE THEM AS SHOWN ON SHEET 5.
TOOLS REQ'D: WALLPAPER SEAM ROLLER.

MATERIALS REQ'D: ADHESIVE BACKED HEATER, EMERY CLOTH, PAPER TOWELS AND ISOPROPYL ALCOHOL
61
59 61
80
110V 48 59
56 56
80
24V
59 60
59
56
56 60
48
59
36 59
36
DETAIL B
VIEW SHOWING ASSEMBLY OF HEATERS (REF.80)
METHOD OF ASSEMBLING METHOD OF ASSEMBLING

NUTS, WASHERS & TAG ON NUTS, WASHERS & TAG ON
TERMINAL BLOCKS WHERE (3) RING TERMINALS 10 & 12 WAY TERMINAL BLOCKS
ARE REQUIRED (1-9L0 & 1-10L0) (REF. 21 & 22)
111 112 113 114
109
88
99
107
21 108
36
119
DETAIL "Y" 116 117 118
ENLARGED VIEW SHOWING PLACEMENT
OF TAG GROUP (REF. 36) TO TERMINAL STRIPS NOTES 7 & 25

Parts Catalog
ABCD
SHEET 5

S W M C H G M 4 0 0 0 A
RIGHT SIDE
22 21
58 87
TB3 TB2 TB1
1 1
12
12
(STEP 3)
HEATER WIRES COILED
LEFT SIDE 24V OR 110V HEATER
(SEE DETAIL "B")
UP AND PLACED HERE
CAM BAR DETECTION

SWTICH (GMA50-107-01)
TOP VIEW
HEATER INSTALLATION
NOTE 15 DETAIL G
VIEW SHOWING ASSEMBLY OF
GEAR BOX AND MOTOR HEATER
SIDE VIEW

Parts Catalog
ABCD
LUBRICATING INSTRUCTIONS
PART NUMBER COATING INSTRUCTIONS MATERIAL
AND NAME
CASE 1. CAM BAR SLIDING SURFACE

MAG-1 GREASE
(81379-013-05)
30 32 SHEET 6
(GMV00-001-00) 2. HAND CRANK HOLE PER 91A0012
MAIN DRIVE 1. ROLLER GREASE FITTING MAIN GEAR AS ABOVE
(GMV00-100-01) TEETH.
S W M C H G M 4 0 0 0 A
THROW BAR 1. SLIDING SURFACES ON BOTH ENDS
(GM050-002-00) CONTACTING WEAR PLATES. AS ABOVE
2. ROLLER CAM PROFILE. FIELD SIDE 33 66 72
CAM BAR 1. SLIDING SURFACES.
COMPLETE AS ABOVE
2. ROLLER CAM PROFILE.
(GMV00-600-01)
LOCK ROD
COMPLETE
1. SLIDING SURFACES ON BOTH ENDS
CONTACTING WEAR PLATES.
AS ABOVE 7
(GMV00-300-01)
PD ROD 1. SLIDING SURFACES ON BOTH ENDS
COMPLETE CONTACTING BUSHING. AS ABOVE
(GMV00-500-01)
GEAR BOX 1. OUTPUT GEAR AS ABOVE
ASSEMBLY
(GMV00-025-01)
HAND CRANK 1. RESET SPRING (REF. 99) AS ABOVE
SWITCH 2. PLUNGER (REF. 109)
3. RESET PIN (REF. 108)
SWITCH MACHINE AS ABOVE
(GMV01-000-01) 1. ALL OTHER GREASE FITTINGS
1. CROSS BRACE MOUNTING PADS.

2. PD ROD BUSHING HOLE. ANTI-SIEZE
CASE 3. HAND THROW BORE. LUBRICANT
(GMV00-001-00) 4. GEAR BOX MOUNTING PADS.
5. MAIN DRIVE MOUNTING PADS.
(81379-050-06) J J
PER 91A0020
6. PD SWITCH MOUNTING PADS.
7. PD SYSTEM MOUNTING PADS.
DOWEL PINS
00500-057-00 & 1. ALL LOCATING PINS. AS ABOVE
00500-058-00
CROSS BRACE 1. CASE MOUNTING PADS AS ABOVE

(GMV00-018-00)
1. ANY TAPPED HOLES THAT RECEIVE
SOCKET HEAD CAP SCREWS THAT
SWITCH MACHINE DON'T HAVE TORQUE
GMV01-000-01 REQUIREMENTS. AS ABOVE
(TAPPED HOLES) 2. GEARBOX MOUNTING PAD
TAPPED HOLES.
3. MAIN DRIVE MOUNTING PAD
TAPPED HOLES.
1. OTHER THAN MAIN DRIVE COMPLETE CORROSION

SWITCH MACHINE COMPONENTS UNDER THE SUPPORT, INHIBITOR
GMV01-000-01 SPRAY THE ENTIRE INSIDE OF THE (81379-100-11)
MACHINE WITH CORROSION PER 91A0022 8
INHIBITOR
TRACK SIDE 33 66 72
29 31
TOP BEARING
HAND LOCK ROD
THROW
COVER
CASE
CASE GEAR BOX OUTPUT GEAR THROW BAR MAIN GEAR CAM BAR CAM BAR SLOT
TONGUE
SECTION J-J

Parts Catalog
LOCK ROD
COMPLETE DETECTOR ROD
COMPLETE
ABCD
SHEET 7
29 SWITCH MACHINE GMV01-000-00
S W M C H G M 4 0 0 0 A
31
THROW BAR
65 91 27
CONTROLLER
MOTOR GEAR BOX

MAIN DRIVE
COMPLETE CROSS BRACE
(SINGLE CONTROL)
31
FIGURE 2
R.H. SWITCH MACHINE
29 SINGLE CONTROL WITH HAND CRANK
(OTHERWISE SAME AS FIGURE 1)
63
END VIEW OF SINGLE CONTROL SWITCH MACHINE

WITH HAND CRANK

Parts Catalog
ABCD
SHEET 8 OF 8

SWITCH MACHINE GM4000A
3 - 11 A X
3- 12 A X
FIGURE 3
DUAL CONTROL SWITCH MACHINE WITHOUT HAND CRANK CAPABILITY
(OTHERWISE SAME AS FIGURE 1)
47
END VIEW OF DUAL CONTROL SWITCH MACHINE

WITHOUT HAND CRANK CAPABILITY

Parts Catalog
Table 7-1. Alstom Model GM4000A Switch Machine Replaceable Components
Ref. Description Qty Drawing No.

1 Case 1 GMV00-001-00
3 Pin 2 01118-049-00
4 Plate, Name 1 GMV00-004-00
5 Cross Brace 1 GMV00-018-00
6 Vent, Screen 2 36022-002-00
7 Cover Comp, LONG 1 GMV00-045-01
8 Cover Comp, SHORT 1 GMV00-046-01
10 Block, Filler, Throw Bar 2 GMV00-010-00
11 Bolt, .375-16 x 3.69 Lg. T-Head 4 00874-014-00
15 Nut, .375-16 x .234 Thk. Hex 4 37539-001-00
16 Wear Plate, Side Throw Bar 4 GMV00-016-00
17 Wear Plate, Top & Bottom Throw Bar 4 GMV00-017-00
18 Pin, Spiral .094 x 1.00 Lg. 2 17188-095-00
19 Screw,.375-16 Set (Dog Nose) 6 17708-166-00
20 Washer, .390 ID, .625 OD, .03 Thk. Flat 4 01250-015-ON
21 Bracket, Plate Double Term Strip AAR 12 Post 1 GM050-021-00
22 Bracket, Angle Term Strip AAR 12 Post 1 GM050-022-00
23 Screw, .138 x .25 Lg Drive (Name Plate) 2 52681-010-00
25 Gear Box Assembly, 172:1 1 GMV00-025-01
28 Cover, Electrical 1 GM050-028-00
33 Washer, .391 ID, 1.000 OD, .063 Thk. Flat 8 01250-017-ON
36 Tag Sheet 1 GMV00-039-00
42 Cam Bar Comp 1 GMV00-600-01
43 Point Detector Comp 1 GMV00-700-01
44 Point Detector Switch Comp 1 GM050-800-02
45 Wire Harness 1 GMV00-900-01
49 Bushing, Split Flange 2 08942-144-00
50 Hasp Complete 1 GMV00-050-03
51 Plate, Limit Switch Spacer 2 GMV00-034-00
53 Pin, Dowel .250 OD x .50 Lg 8 00500-057-00
54 Clip, Tie 14 18547-111-00

Parts Catalog
Table 7-1. Alstom Model GM4000A Switch Machine Replaceable Components (Cont.)

58 Tie, Cable 2 29855-014-00
48 Nut, .242-24, .125 Thk, Jam 38 42839-008-00
56 Washer, .250 ID, .478 OD, .03 Thk Shk’prf 72 53029-075-00
59 Washer, .242 ID, .563 OD, .040 Thk Flat 108 01225-002-00
60 Nut, .242-24 x .188 Thk, Jam 34 42839-005-00
61 Nut, #14-24 x 5/16 Thk Hex Terminal 72 42843-001-00
63 Screw, .250-20 x .63 Lg. Flat Hd. 3 17708-169-00
68 Screw, .375-16 x 3.25 Lg Socket Hd 6 17708-145-00
71 Screw, .375-16 x 1.00 Lg Socket Hd 14 17708-121-00
72 Screw, .375-16 x .63 Lg Socket Hd 8 17708-143-00
73 Washer, .313 ID, .583 OD, .08 Thk Lock 2 01273-007-ON
75 Screw, .313-18 x .75 Lg Hex Hd 2 00441-006-ON
77 Screw, .250-20 x 1.00 Lg Socket Hd Self Lock 6 17708-076-00
78 Screw, .250-20 x .75 Lg Socket Hd 6 17708-119-00
82 Screw, .164-32 x 1 1/4 Lg Socket Hd Stainless 4 17708-175-00
Steel
85 Screw, .250-20 x 1.25 Lg Socket Button Hd 4 17708-170-00
87 Screw, .190-32 x .50 Lg But Hd 16 17708-138-00
88 Strip, Terminal (12 Way) 3 56140-021-00
90 Screw, .313-18, .375 OD x 2.00 Lg Shoulder 4 17708-156-00
Soc Hd
91 Washer, .625 ID, 1.072 OD, .16 Thk Lock 4 01273-011-ON
97 Washer, .172 ID, .375 OD, .031 Thk Flat 4 01250-006-ON
121 Screw, #10-32 x 5/8 Lg Flat, Socket Hd Cap 8 17708-171-00
Cloth Bag 1 53148-001-00
Bolt, .875-9 x 3.25 Lg Sq Hd 1 38186-004-00
Washer, .875 ID, 1.455 OD, .22 Thk Lock 1 01273-014-ON
Nut, .875-9 x .86 Thk Slotted Hex 1 47191-009-00
Pin, Cotter .188 Dia x 2.00 Lg 1 00046-001-ON
Connector, Terminal 2 43587-006-00

Parts Catalog

Vibration and Damping Compound (Per As Req’d 81361-066-05
90B0005)
Thread Locking Compound (Per 90B0006) As Req’d 81361-047-05
Anti-Seize Lubricant (Per 91A0020) As Req’d 81379-050-06
Corrosion Inhibitor (Heavy Duty) (Per 91A0022) As Req’d 81379-100-11
Sealant, Silicone Construction (Per 90B0020) .10 81361-109-05
Wiring Diagram (Place in Machine) 1 Print GMV00-040-00
Manual (Place in Machine) 1 Copy
WM4K Skid 1 65011-006-03
THE FOLLOWING PARTS ARE NOT INCLUDED IN GMV01-000-01,
BUT MUST BE SPECIFIED IN MODEL NUMBER PER CONFIGURATION KEY
LOCK RODS - AS REQUIRED
12 Wear Plate, Side Lock Rod 4 GMV00-012-00
13 Wear Plate, Top Lock Rod 2 GMV00-013-00
14 Wear Plate, Bottom Lock Rod 2 GMV00-014-00
39 Lock Rod Comp (Threaded End Narrow Notch) 1 GM050-300-01
39 Lock Rod Comp (Threaded End Wide Notch) 1 GM050-300-02
39 Lock Rod Comp (Spade End Narrow Notch) 1 GM050-300-03
39 Lock Rod Comp (Spade End Wide Notch) 1 GM050-300-04
39 Lock Rod Comp (Spade End Wide Notch, 4.5-6 1 GM050-300-05
Inch)
39 Lock Rod Comp (Threaded End Narrow Notch, 1 GM050-300-07
3.0-6.5 inch)
70 Cover, Lock Rod 2 GMV00-011-00
POINT DETECTOR - AS REQUIRED
41 Rod Comp, Point Detector (Swivel W/ Rivets) 1 GMV00-500-01
41 Rod Comp, Point Detector (Spade End) 1 GMV00-500-02
41 Rod Comp, Point Detector (Swivel W/ Grease 1 GMV00-500-03
Pin)
41 Rod Comp, Point Detector (Swivel W/ Grease 1 GMV00-500-04
Pin, 4.5-6 inches long)
41 Rod Comp, Point Detector (Threaded End / 1 GMV00-500-05
Non Swivel)

Parts Catalog

CONTROLLER - AS REQUIRED
24 Controller, Standard 1 GMV00-043-00
24 Controller, Enhanced 1 GMV00-044-00
GEARBOX HEATER - AS REQUIRED
Gear Box Heater, 24VDC & 110VDC/AC 1 55290-040-00
CONDENSATION HEATERS - AS REQUIRED
80 Heater, Condensation, 24 Volts 1 55290-041-00
80 Heater, Condensation, 110 Volts 1 55290-042-00
LATCH STANDS - AS REQUIRED
40 Latch Stand Comp. 2 GMV00-400-01
TOOLS - AS REQUIRED
Kit, Maintenance Tool 1 GMK50-000-01
26 Hand Crank 1 GMA50-012-00
Gauge, Spoon (.38/.25) 1 GMA50-002-00
Hand Crank, Hex End Extension 1 GMA50-013-00
Crank, Hand Ratchet, .50 Hex 1 50570-018-00
Gauge, Spoon (6.0/4.5mm) 1 GMA50-014-00
HAND THROW LETTER KIT - AS REQUIRED
Kit, Letters For Hand Throw 1 GMK50-004-01
HARNESS ADAPTER OPTION - AS REQUIRED
Kit, Wire Harness Adapter for Motor End Wire 1 GMK50-010-01
Entrance (Place in Machine)
Kit, Single Switch, Polarized Switch Repeater 1 GMK50-013-01
Harness
LATCH OUT – AS REQUIRED
Cam Bar Detection Switch Kit 1 GMA50-107-01
Latch-Out Upgrade Kit 1 GMK50-020-01

Parts Catalog

ACCESSORY OPTION – AS REQUIRED
Puller Complete, Bushing 1 GMA50-100-01
Cam Bar Detection Switch Kit 1 GMA50-105-01
Hand Crank Lock 1 GMA50-108-00
Hand Crank, Torque Limiting 1 GMA50-109-01
Gauge, Hand Cut Out Switch 1 36183-066-00
Control Configuration ‘A’: GMV00-000-01 (GMV01-000-00 FIGURE 1)
FOR MODEL NUMBERS REQUIRING DUAL CONTROL VERSION, (With Hand Crank
Capability), SELECT APPROPRIATE GUARD AND THE FOLLOWING ADDITIONAL
PARTS MUST BE INCLUDED. WIRING DIAGRAM REFERS TO GMV00-040-00 FIG.1
2 Throw Bar 1 GM050-002-00
32 Guard, Lock Rod, Field Side 1 GMV00-032-00
29 Guard, Throw Bar, Track Side 1 GM050-029-00
30 Guard, Throw Bar, Field Side 1 GM050-030-00
31 Guard, Lock Rod Track Side 1 GMV00-031-00
27 Cover, Hand Throw 1 GMV00-027-00
35 Hand Throw Switch Comp. 1 GMV00-901-01
37 Main Drive Complete, Dual Control 1 GMV00-100-01
38 Hand Throw Lever Comp. 1 GMV00-200-01
62 Hand Crank Door 1 GMV00-070-01
64 Screw, .625-11 x 1.50 Lg Soc Hd 2 17708-128-00
65 Screw, .625-11 x .75 Lg Soc Hd 2 17708-147-00
79 Washer, .200 I.D., .334 O.D., .047 Thk. Lock 4 01273-004-ON
81 Screw, .190-32 x 1.75 Lg Soc Hd 2 17708-130-00
83 Screw, .190-32 x 1.50 Lg Soc Hd 2 17708-129-00
93 Screw, .375-16 x 1.25 Lg Soc Hd 12 17708-122-00
94 Plug, Cap 12 20132-015-00
Hand Crank Cut Out Switch Kit 1 GMK50-016-02

Parts Catalog
AB
Control Configuration ‘B’: GMV00-000-02 (GMV01-000-00 FIGURE 3)
FOR MODEL NUMBERS REQUIRING DUAL CONTROL VERSION (No Hand Crank
Capability), THE FOLLOWING ADDITIONAL PARTS MUST BE INCLUDED. WIRING
DIAGRAM REFERS TO GMV00-040-00 FIG.2
2 Throw Bar 1 GM050-002-00
32 Guard, Lock Rod, Field Side 1 GMV00-032-00
30 Guard, Throw Bar, Field Side 1 GM050-030-00
31 Guard, Lock Rod, Track Side 1 GMV00-031-00
27 Cover, Hand Throw 1 GMV00-027-00
35 Hand Throw Switch Complete 1 GMV00-901-01
37 Main Drive Complete, Dual Control 1 GMV00-100-01
38 Hand Throw Lever Comp 1 GMV00-200-01
47 Cover, Plate, Hand Crank 1 GMV00-006-00
64 Screw, .625-11 x 1.50 Lg Soc Hd 2 17708-128-00
65 Screw, .625-11 x .75 Lg Soc Hd 2 17708-147-00
79 Washer, .200 I.D., .334 O.D., .047 Thk. Lock 4 01273-004-ON
81 Screw, .190-32 x 1.75 Lg Soc Hd 2 17708-130-00
83 Screw, .190-32 x 1.50 Lg Soc Hd 2 17708-129-00
93 Screw, .375-16 x 1.25 Lg Soc Hd 12 17708-122-00
94 Plug, Cap 12 20132-015-00

Parts Catalog

Control Configuration ‘C’: GMV00-000-03 (GMV01-000-00 FIGURE 2)
FOR MODEL NUMBERS REQUIRING SINGLE CONTROL VERSION, (No Hand
Throw, W/Hand Crank) THE FOLLOWING ADDITIONAL PARTS MUST BE
INCLUDED. WIRING DIAGRAM REFERS TO GMV00-040-00 FIG.3
2 Throw Bar 1 GM050-002-00
27 Cover, Hand Throw 2 gmV00-027-00
31 Guard, Lock Rod, Track Side 2 GMV00-031-00
37 Main Drive Complete, Single Control 1 GMV00-100-02
62 Hand Crank Door 1 GMV00-070-01
65 Screw, .625-11 x .75 Lg Soc Hd 4 17708-147-00
93 Screw, .375-16 x 1.25 Lg. Socket Hd 4 17708-122-00
94 Plug Cap 20 20132-015-00
Hand Crank Cutout Switch Kit See Detail GMK50-016-02
Y
99 Spring, Hand Crank 1 00786-210-00
107 Ring, Retaining, External 1 05713-093-00
108 Pin, Hand Crank 1 GMV00-068-00
109 Plunger, Hand Crank Switch 1 GMV00-067-00
111 Spring, Contact 1 49589-108-00
112 Screw, #10-32 x 1/2 Lg Socket Hd Cap 1 17708-110-00
116 Screw, #8-32 x 1-1/4 Lg CK 2 17708-175-00
119 Limit Switch Kit 1 GMV00-904-01

Parts Catalog

Control Configuration ‘D’: GMV00-000-04 (GMV01-000-00 FIGURE 2)
FOR MODEL NUMBERS REQUIRING SINGLE CONTROL VERSION (No Hand Throw,
AB
W/Hand Crank, No Latch Out) USE SAME PARTS AS GMV00-000-03 (GMV01-000-00
FIGURE 2). EXCEPT REFERENCE NO. 2 & 27 AS SHOWN IN FOLLOWING TABLE.
WIRING DIAGRAM REFERS TO GMV00-040-00 FIG. 4
2 Throw Bar 1 GMV00-002-00
27 Cover, Hand Throw 2 GMT00-027-00

Parts Catalog
Table 7-2. GM4000A™ Configuration Key For Model Number Determination

Code MODEL NUMBER WM
CONTROL CONFIGURATION
A GMV00-000-01 Dual Control (Hand Throw, With Hand Crank Capability)
B GMV00-000-02 Dual Control (Hand Throw, W/O Hand Crank Capability)
C GMV00-000-03 Single Control (No Hand Throw, With Hand Crank Capability)
GMV00-000-04 Single Control (No Hand Throw, With Hand Crank Capability,
D
No Latch Out)
MACHINE ORIENTATION
L Left Hand
R Right Hand
LOCK RODS
N GM050-300-01 Narrow Notch Threaded End 3.5 – 6.5 Inch Adjustment
W GM050-300-02 Wide Notch Threaded End 3.5 – 6.5 Inch Adjustment
S GM050-300-03 Narrow Notch Spade End 3.5 – 6.5 Inch Adjustment
B GM050-300-04 Wide Notch Spade End 3.5 – 6.5 Inch Adjustment
C GM050-300-05 Wide Notch Spade End 4.5 – 6.0 Inch Adjustment
E GM050-300-07 Narrow Notch Threaded End 3.0 – 6.5 Inch Adjustment
For lock rods –01 thru -07 add: (4) GMV00-012-00, (2) GMV00-013-00 and (2) GMV00-014-00
X No Lock Rod Add: Only (2) Covers GMV00-011-00
POINT DETECTOR ROD
T GMV00-500-01 Swivel Threaded End With Rivets
S GMV00-500-02 Solid Spade End
P GMV00-500-03 Swivel Threaded End With Grease Pin
C GMV00-500-04 Swivel Threaded End With Grease Pin 4.5-6 inch
D GMV00-500-05 Threaded End Non Swivel
CONTROLLER CONFIGURATION
S GMV00-043-00 Standard Controller
E GMV00-044-00 Enhanced Controller
GEAR BOX HEATER
B 55290-040-00 (24VDC & 110VAC/DC) Gear Box Heater
N No Gear Box Heater
CONDENSATION HEATERS
A 55290-041-00 24 Volt Heater
B 55290-042-00 110 Volt Heater
C Both Heaters
N No Condensation Heater
LATCH STANDS
L GMV00-400-01 (2) Required Per Machine
N No Latch Stands
TOOLS (OPTIONAL ACCESSORY)
B Hand Crank & Spoon Gauge (.38/.25) & Tool Kit (GMA50-012-00, GMA50-002-00, GMK50-000-01)
S GMA50-002-00 Spoon Gauge (.38/.25)
H GMA50-012-00 Hand Crank
E GMA50-013-00 Hand Crank, Hex End And: 50570-018-00 Ratcheting Crank
C GMA50-014-00 Spoon Gauge (6.0/4.5mm)
K GMK50-000-01 Maintainer Tool Kit
N No Tools
HAND THROW LETTER KIT (OPTIONAL ACCESSORY)
K GMK50-004-01 Letters “N” & “R”
N No Hand Throw Letter Kit
HARNESS ADAPTER OPTION
A GMK50-013-01 Kit, Polarized Switch Repeater Harness
H GMK50-010-01 Wire Harness Adapter for Motor End Wire Entrance
N No Harness Adapter
LATCH OUT
A No Latch Out
B Restorable Latch Out
C Restorable Latch Out
D Non-Restorable Latch Out, Cam Bar Detection Switch Kit
GMA50-105-01 For switch machines manufactured with PD Switch Module (GM050-800-02) Rev.’s A, B & C
GMA50-107-01 For switch machines manufactured with PD Switch Module (GM050-800-02) Rev. D and later
E Non-Restorable Latch Out, Mechanical (GMK50-020-01)

Parts Catalog
Table 7-2. GM4000A™ Configuration Key For Model Number Determination (Cont.)
Code MODEL NUMBER WM
ADDITIONAL ACCESSORIES THAT CAN BE ORDERED SEPARATELY
GMA50-100-01 Puller Complete, Bushing
GMA50-105-01 Cam Bar Detection Switch Kit (For switch machines manufactured with PD Switch Module (GM050-800-02) Rev.’s
A, B & C, AND Configured with non-restorable latch out
GMA50-107-01 Cam Bar Detection Switch Kit (For switch machines manufactured with PD Switch Module (GM050-800-02) Rev. D
and Later, AND Configured with non-restorable latch out
GMA50-108-00 Hand Crank Lock
GMA50-109-01 Hand Crank, Torque Limiting
36183-066-00 Hand Crank Cutout Switch Adjustment Gauge

Parts Catalog
Figure 7-2. Alstom Model GM4000A Wire Harness, P/N GMV00-900-00

Parts Catalog

Parts Catalog
Table 7-3. Alstom Model GM4000A Wire Harness, P/N GMV00-900-01

1 Tubing, Split Loom .25 Dia. 4.5 81409-026-01
2 Tubing, Split Loom .38 Dia. 7 81409-027-01
3 Tubing, Split Loom .50 Dia. 6 81409-029-01
4 Switch, Heavy Duty Limit (MLR, MLL) PG13.5 2 35934-081-00
5 Tie, Cable 90 01232-000-ON
9 Receptacle, (P1) 1 58920-489-00
10 Terminal, Pin 19 59825-239-00
11 Receptacle, 12 Pin Housing (PDR, PDL) 2 58920-491-00
12 Receptacle, Lock Plate 2 54656-043-00
13 Terminal, Socket (16-20) 24 55871-172-00
14 Receptacle, Wire Seal, Rubber 24 29417-012-00
15 Clamp, Cable 1 59594-047-00
16 Receptacle, Plug 1 58920-579-00
17 Terminal, Socket 3 55871-081-00
18 Connector, Watertight, Straight, PG13.5 2 56353-069-00
22 Adhesive (Per 90A0042) .1 81361-300-05
23 Tubing, .250 Dia., Heat Shrink (Per 82P0004) 2 81411-017-01
24 Terminal, Ring, .250 (16-14) 39 59825-132-00
25 Terminal, Ring, .250 (12-10) 3 59825-199-00
26 Tag, Marker, .250 6 55085-703-00
27 Tag, Marker, .125 100 55085-708-00
28 Sleeve, Tag (Harness Information) 1 44983-203-00
30 Sleeve, Tag, .44 x 1.25 Lg 2 44983-201-00
31 Receptacle, Yellow 2 58920-239-00
32 Receptacle, Red 3 58920-139-00
33 Receptacle, Green 3 58920-581-00
34 Receptacle, Black 2 58920-582-00
35 Receptacle, White 2 58920-583-00

Parts Catalog
Table 7-3. Alstom Model GM4000A Wire Harness, P/N GMV00-900-01 (Cont.)

36 Receptacle, Blue 1 58920-584-00
37 Receptacle, Gray 2 58920-585-00
38 Terminal, 15-Amp, High Detent, Superflex Reel 15 55871-178-00
39 Terminal, Amp, .250 Tab (22-18) Red 3 59825-256-00
Wire, #16 Awg, Tefzel, Black (Per 82A0006) 198.8 80556-067-01
Tape, Teflon .50 Wide (Per 99G0001) As 82425-068-05
Req’d
Wire Table 1 Print 31574-505-00
Table 7-4. Alstom Model GM4000A Switch Machine Connecting Hardware
Description Drawing No.

Point Detector Rod Drop Lug GMA50-003-00
Adjustable Lock Rod Drop Lug (Treaded Lock Rod) GMA50-008-01
Adjustable Lock Rod Drop Lug (Spade-End Lock Rod) GMA50-008-02
Throw Bar Coupler (Straight) GMA50-006-00
Throw Bar Coupler (Downset, 3.4-inches) GMA50-007-00
Table 7-5. Alstom Model GM4000A Switch Machine Wire Entrance Couplings
Description Catalog No. Drawing No.

Coupling, for 2-3/8" I.D., rubber conduit A85-500 45689-087-00
Coupling, for 1-7/8" I.D., rubber conduit A85-501 45689-106-00
Coupling, offset, for 2" flexible conduit A85-502 45688-096-01
Coupling, straight, for 2" flexible conduit A85-503 45688-097-01

Parts Catalog
A C E
Figure 7-3. Tools and Kits

Parts Catalog

Parts Catalog
Table 7-6. Alstom Model GM4000A Switch Machine Tools and Kits
Ref. Description Drawing No.

A Maintainer Tool Kit GMK50-000-01
B Hand Crank GMA50-012-00
C Spoon Gauge, 1/4" and 3/8" GMA50-002-00
C Spoon Gauge, 4.5mm and 6.0mm GMA50-014-00
D Bushing Puller GMA50-100-01
E Hand Throw Letter Kit GMK50-004-01
F Wire Harness For Motor End Wire Entrance GMK50-010-01
G Hand Crank, Hex End (Intended to be used with GMA50-013-00
Ratcheting Crank, below)
H Ratcheting Crank (Intended to be used with Hand Crank, 50570-015-00
Hex End, above)
-- Cam Bar Detector Switch Kit (For machines GMA50-105-01
manufactured prior to July 2006 AND configured with
non-restorable latch-out)
-- Metric Switch point Obstruction Gauge: 2.0mm, 3.0mm, P/N 36183-061-00
4.5mm, 6.0mm, 12.0mm

Parts Catalog

Drawings
A. APPENDIX A - DRAWINGS
A.1. OVERVIEW
The following drawings are provided to assist maintainers with installation, wiring, and
troubleshooting a GM4000A switch machine.
P2496, Rev. 6, Jul/11 A-1 Alstom Signaling Inc.

Drawings
A.2. WIRING AND CIRCUIT APPLICATIONS
A.2.1. 2-Wire Configuration For Replacement of Alstom Model 55E Switch Machines
1OR 1RWR 1NWR

WHB
- - TB1-1
1WR O
DC+ for reverse,
DC- for normal
DC+ for normal, 1NWR

WHC
DC- for reverse
WHB
TB1-2
Connect RW to TB1-1 and NW to TB1-2.

If the machine travels in the wrong direction, interchange RW and NW.
Figure A-1. 2-Wire Circuit For Replacement of Alstom Model 55E Switch Machines

Drawings
A.2.2. 3-Wire Configuration For Replacement of Alstom Model 5E & 5F Switch

Machines
WZR
NWR LR
3E DC(+)
OR
S
DC(–)
RWR
3E
NW TO CONTROL RELAYS
(RW) FOR SECOND SWITCH
OF CROSSOVER
TB1-1
–
RW 24 - 32 OR
(NW) 110 VOLTS DC
+
TB1-3
CW O
TB1-2
Connect CW to TB1-2.
Connect NW to TB1-1 and RW to TB1-3.
Machines, Right Hand Point Normally Closed

Drawings
WZR
RWR LR
3E DC(+)
OR
S
DC(–)
NWR
3E
RW TO CONTROL RELAYS
(NW) FOR SECOND SWITCH
OF CROSSOVER
TB1-1
–
NW 24 - 32 OR
(RW) 110 VOLTS DC
+
TB1-3
CW O
TB1-2
Connect CW to TB1-2.
Connect RW to TB1-1 and NW to TB1-3.
Machines, Left Hand Point Normally Closed

Drawings
A.2.3. 3-Wire Configuration For Replacement of US&S Model M23A or M3 Switch

Machine
External connections are shown to the main terminal board for a switch having the right-
hand point normal closed. For a switch having the left-hand point normally closed,
interchange the external leads to terminals 35 and D.
Typical circuit control of standard GM4000A brushless DC motor switch machine for
connection to US&S high and low voltage, series-parallel field motor application using
DP-25 and OR-11 shelf type or PNP-69 and ORP-60 plug in type relays.
N-WR
TO
CONTROL -WR
CIRCUITS
-WR1 + – DP-25
or
WR P PNP-69
+ – RELAY
NW TB1-2
OR-11 C
or +
ORP-60 O BW
RELAY OR
S +
TB1-1
D
TB1-3
35
If the machine travels in the wrong direction, interchange D and 35 connection.
Figure A-4. 3-Wire Circuit For Replacement of US&S Model M23A

or M3 Switch Machine

Drawings
A.2.4. 4-Wire Configuration For Replacement of Alstom Model 5G and 5H Switch

Machines
16 to 160 VDC
OR
85 to 140 VAC
TB1-1 TB1-3
WR
NWR
If the machine travels in the wrong direction, interchange NWR and WR.
Machines, Right Hand Point Normally Closed

Drawings
16 to 160 VDC
OR
85 to 140 VAC
TB1-1 TB1-3
NWR
WR
If the machine travels in the wrong direction, interchange NWR and WR.
Machines, Left Hand Point Normally Closed

Drawings
A.2.5. 5-Wire Configuration For Replacement of US&S Model M23A, M23B, or M3

Switch Machines
Figure A-7 shows a 5-wire circuit for typical circuit control of standard GM4000A
brushless DC motor switch machine for connection to US&S high and low voltage,
series-parallel field motor application using DP-25 and OR-11 shelf type or PNP-69 and
ORP-60 plug in type relays
For a switch having the left-hand point normally closed, interchange the external leads
to terminals 5 and 10.
N-WR
TO
CONTROL -WR
CIRCUITS -WR1
+ –
– DP-25 OR
+
WR P PNP-69
RELAY
OR-11 OR
O NW TB1-2
ORP-60 OR D
RELAY +
S BW
+
TB1-12* / TB3-11** / TB3-12***
B
TB1-1
5
TB1-3
10
TB1-12* / TB3-11** / TB3-12***
C
If the machine travels in the wrong direction, interchange wires 5 and 10.
* TB1-12 in both locations, or
** TB3-11 in both locations, or
*** TB3-12 in both locations
Figure A-7. 5-Wire Circuit For Replacement of US&S Model M23A, M23B,
or M3 Switch Machines, Right Hand Point Normally Closed,
with Plug In Type Relays

Drawings
Figure A-8 shows typical circuit control of standard GM4000A brushless DC motor
switch machine for connection to US&S high and low voltage, series-parallel field motor
application using PP-151, PN150BM and N-150SO relays. External connections are
shown to the main terminal board for a switch having the right-hand point normal
closed.
For a switch having the left-hand point normally closed, interchange the external leads
to terminals 5 and 10.
N-WR
TO
CONTROL
CIRCUITS + –
+ – -WR PN-151
-WR1 RELAY
PN-15050 O OR
RELAY
S
+ –
-WRPR PN-1508M
RELAY
N110 TB1-2
D
+
B110
+ TB1-12* / TB3-11** / TB3-12***
B
TB1-1
5
TB1-3
10
TB1-12* / TB3-11** / TB3-12***
C
If the machine travels in the wrong direction, interchange wires 5 and 10.
* TB1-12 in both locations, or
** TB3-11 in both locations, or
*** TB3-12 in both locations
Figure A-8. 5-Wire Circuit For Replacement of US&S Model M23A, M23B,
or M3 Switch Machines, Right Hand Point Normally Closed,
with PP-151, PN150BM or N-150SO Relays

Drawings
A.2.6. Terminal Block Pin Outs
POWER
[ SHUNT ]
POWER
POWER
12V CONTROL
12V CONTROL
[INDICATION]
HAND THROW
HAND THROW
AUX
LO
[ * * ] [ * ]
LO
* MOTOR LIMIT
** HAND CRANK
Figure A-9. Terminal Block Pinouts

Drawings
A.2.7. Secondary Point Monitor Circuit
88 VDC to 132 VDC (-)
#18AWG WIRE
E4
DS1 DS2
GREEN GREEN
- + + -
E1
E2 E3
#18AWG WIRE
R1
4.7K
25W
5%
#18AWG WIRE
88 VDC to 132 VDC (+)
Figure A-10. Secondary Point Monitor Circuit

Drawings
A.2.8. Typical Polarized Switch Circuits
Typical Polarized Switch Repeater Circuit, Single Switch

Point detector contacts are shown in position for
right hand point normally closed.
INDICATION IN HAND THROW
TB-3 TB-2 TB-1

RH point LH point
1 1
1 normally normally
shunt power closed closed
shunt
2 2 To verify indication for left hand point
2 normally closed, connect a meter to TB2
power
and or TB3 as follows:
3 3
3
shunt NWP / WP (TB2-7 / TB2-5)
shunt
4 4
4
control NWP WP
5 5
5
indicate
indicate To verify indication for right hand point
6 6
hand thr and or TB3 as follows:
7 7
7
indicate WP / NWP (TB2-7 / TB2-5)
indicate
8 8 aux
8 Note 1
DC+ DC+
9 9
9
motor limit latch out WP NWP
motor limit
10 10
10
When using shunt
contacts connect the
11 11 11
bold wires as shown
aux hand crk aux DC- DC-
12 12 12
right left Note 1: A fuse is required for short circuit

protection on the positive energy used for
indication. Fuse: 10 amp, type SC, Form 1,
class J or equivalent.
Figure A-11. Typical Polarized Switch Repeater Circuit, Single Switch, Indication in Hand Throw

Drawings
Typical Polarized Switch Repeater Relay Circuit Crossover

Point detector contacts are shown in position
for right hand point normally closed.
energy end point detector relay end point detector

end end
TB-3 TB-2 TB-1 RH point LH point TB-3 TB-2 TB-1
normally normally
1 1 closed closed 1 1 To verify indication for left hand
1 1
shunt power shunt power point normally closed, connect a
shunt shunt meter to TB2 and or TB3 as follows:
2 2 WP1A WP1 2 2
2 2
power power
WP / NWP (TB2-6 / TB2-8)
NWP1 / WP1 (TB2-7 / TB2-5)
NWP1 / WP1A (TB3-7 / TB3-5)
3 3 NWP1 NWP1 3 3
3 3
shunt shunt
shunt shunt
4 4 NWP WP 4 4
4 4
control control
5 5 5 5 To verify indication for right hand

5 5
indicate indicate
point normally closed, connect a
indicate indicate meter to TB2 and or TB3 as follows:
6 6 6 6
6 6
hand thr hand thr
NWP / WP (TB2-6 / TB2-8)
NWP1 / WP1A (TB2-7 / TB2-5)
NWP1 / WP1 (TB3-7 / TB3-5)
7 7 7 7
7 7
indicate indicate
indicate Note 1 indicate
8 8 aux DC+ DC+ 8 8 aux
8 8
WP NWP
9 9 9 9 When using shunt
9 9
motor limit latch out motor limit latch out
contacts connect
motor limit WP1 WP1A motor limit the bold wires as shown
10 10 10 10
10 10
DC- DC-
11 11 11 11 11
11 Note 1: A fuse is required for short
aux hand crk aux hand crk aux circuit protection on the positive energy
aux
used for indication. Fuse: 10 amp,
12 12 12 12 12 type SC, Form 1, class J or equivalent.
12
right left right left
Figure A-12. Typical Polarized Switch Repeater Relay Circuit Crossover, Indication in Hand Throw

Drawings
Typical Polarized Switch Repeater Relay Circuit Crossover

NO INDICATION IN HAND THROW

end end

normally normally
1 1 closed closed 1 1
1 1
shunt power shunt power
shunt
shunt
2 2 WP1A WP1 2 2
2 2
power power
3 3 NWP1 NWP1 3 3
3 3
shunt shunt
shunt
shunt
4 4 NWP WP 4 4
4 4
control control When using shunt
contacts connect
5 5 5 5 the bold wires as shown
5 5
indicate indicate
indicate
indicate
6 6 6 6
6
6 hand thr hand thr
7 7 7 7
7
7 indicate indicate
indicate Note 1 indicate To verify indication for left hand
8
8 meter to TB2 and or TB3 as follows:
WP NWP
9 9 9 9
9 WP / NWP (TB2-6 / TB2-8)
9 motor limit latch out motor limit latch out
NWP1 / WP1 (TB2-7 / TB2-5)
WP1 WP1A motor limit
NWP1 / WP1A (TB3-7 / TB3-5)
motor limit
10 10 10 10
10 To verify indication for right hand
10
DC- DC-
11 11 11 11 meter to TB2 and or TB3 as follows:
11 11
hand crk aux aux hand crk aux
aux NWP / WP (TB2-6 / TB2-8)
12 12 12 12 NWP1 / WP1A (TB2-7 / TB2-5)
12 12 NWP1 / WP1 (TB3-7 / TB3-5)
Note 1: A fuse is required for short
circuit protection on the positive energy
type SC, Form 1, class J or equivalent.
Figure A-13. Typical Polarized Switch Repeater Relay Circuit Crossover, No Indication in Hand Throw

Drawings
Typical Polarized Switch Repeater Circuit, Single Switch

TB-3 TB-2 TB-1

RH point LH point
1 1
1 normally normally
shunt
2 2 To verify indication for left hand point
power
3 3
3
shunt NWP / WP (TB2-7 / TB2-5)
shunt
4 4
4
control NWP WP
5 5
5
indicate
indicate To verify indication for right hand point
6 6
hand thr and or TB3 as follows:
7 7
7
indicate WP / NWP (TB2-7 / TB2-5)
indicate
8 8 aux
8 Note 1
DC+ DC+
9 9
9
motor limit latch out WP NWP
motor limit
10 10
10
When using shunt
contacts connect the
11 11
11 bold wires as shown
hand crk aux DC- DC-
aux
12 12
12
right left Note 1: A fuse is required for short circuit

protection on the positive energy used for
Figure A-14. Typical Polarized Switch Repeater Circuit, Single Switch, No Indication in Hand Throw

Drawings
Typical 6 Wire Polarized Switch Repeater Relay Circuit Crossover


end end
normally normally
1 1 closed closed 1 1 To verify indication for left hand
1 1
shunt power shunt power point normally closed, connect a
shunt shunt meter to TB2 and or TB3 as follows:
2 2 WP1A WP1 2 2
2 2 WP / NWP (TB2-6 / TB2-8)
power power
NRWP1 / WP1 (TB2-7 / TB2-5)
NWP1 / WP1A (TB3-7 / TB3-5)
3 3 NWP1 NWP1 3 3
3 3
shunt NRWP1 NRWP1 shunt
shunt shunt
4 4 NWP WP 4 4
4 4
control control
5 5 5 5 To verify indication for right hand

5 5 point normally closed, connect a
indicate indicate
indicate indicate meter to TB2 and or TB3 as follows:
6 6 6 6
6 6
hand thr hand thr
NWP / WP (TB2-6 / TB2-8)
NRWP1 / RWP1 (TB2-7 / TB2-5)
7 7 7 7 NWP1 / WP1 (TB3-7 / TB3-5)
7 7
indicate indicate
8 8
WP NWP
9 9 9 9 When using shunt
9 9
contacts connect
motor limit WP1 WP1A motor limit the bold wires as shown
10 10 10 10
10 10
DC- DC-
11 11 11 11 11 11
Note 1: A fuse is required for short
aux hand crk aux aux hand crk aux circuit protection on the positive energy
12 12 12 12 12 12 type SC, Form 1, class J or equivalent.
Figure A-15. Typical 6 Wire Polarized Switch Repeater Relay Circuit Crossover, Indication in Hand Throw

Drawings
A.2.9. Typical Neutral Switch Circuits
Typical Neutral Switch Repeater Circuit, Single Switch

TB-3 TB-2 TB-1

RH point LH point
1 1
1 normally normally
shunt
2 2
2 To verify indication for left hand point
power normally closed, connect a meter to TB2
3 3 CRWP CNWP and or TB3 as follows:
3
shunt
shunt CNWP / NWP (TB2-7 / TB2-5)
4 4
4 RWP / CRWP (TB3-6 / TB3-8)
control NWP WP
5 5
5
indicate
indicate
6 6 To verify indication for right hand point
6
hand thr normally closed, connect a meter to TB2
7 7
7
indicate
indicate CRWP / RWP (TB2-7 / TB2-5)
8 8 aux
8 Note 1 NWP / CNWP (TB3-6 / TB3-8)
DC+ DC+
9 9
9
motor limit latch out NWP RWP
motor limit
10 10 When using shunt
10 contacts connect the
CNWP CRWP bold wires as shown
11 11
11
aux
12 12
12 Note 1: A fuse is required for short circuit
left protection on the positive energy used for
right indication. Fuse: 10 amp, type SC, Form 1,
Figure A-16. Typical Neutral Switch Repeater Circuit, Single Switch, No Indication in Hand Throw

Drawings
Typical Neutral Switch Repeater Circuit, Single Switch

TB-3 TB-2 TB-1

RH point LH point To verify indication for left hand point
1 1
1 normally normally normally closed, connect a meter to TB2
shunt power closed closed and or TB3 as follows:
shunt
2 2
2
power CNWP / NWP (TB2-7 / TB2-5)
3 3 CRWP CNWP RWP / CRWP (TB3-6 / TB3-8)
3
shunt
shunt
4 4
4
control RWP NWP
To verify indication for right hand point
5 5
indicate and or TB3 as follows:
indicate
6 6
6
hand thr CRWP / RWP (TB2-7 / TB2-5)
7 7 NWP / CNWP (TB3-6 / TB3-8)
7
indicate
indicate
8 8 aux
8 Note 1
DC+ DC+
9 9
9
motor limit latch out NWP RWP When using shunt
motor limit contacts connect the
10 10
10 bold wires as shown
CNWP CRWP
11 11
11
aux Note 1: A fuse is required for short circuit
12 12 protection on the positive energy used for
12
right left class J or equivalent.
Figure A-17. Typical Neutral Switch Repeater Circuit, Single Switch, Indication in Hand Throw

Drawings
Typical Neutral Switch Repeater Relay Circuit Crossover

To verify indication for left hand
meter to TB2 and or TB3 as follows:
energy end
point detector relay end point detector
end end
NWP / CNWP (TB2-5 / TB2-7)
RWP / CRWP (TB3-6 / TB3-8)
TB-3 TB-2 TB-1 RH point LH point TB-3 TB-2 TB-1 CNWP1 / NWP1 (TB2-7 / TB2-5)
RWP1 / CRWP1 (TB3-6 / TB3-8)
normally normally
1 1
shunt shunt To verify indication for right hand
2 2 CRWP1 CNWP1 2 2 point normally closed, connect a
2 2 meter to TB2 and or TB3 as follows:
power power
3 3 RWP1 NWP1 3 3 RWP / CRWP (TB2-5 / TB2-7)

3 3 NWP / CNWP (TB3-6 / TB3-8)
shunt shunt CRWP1 / RWP1 (TB2-7 / TB2-5)
shunt shunt NWP1 / CNWP1 (TB3-6 / TB3-8)
4 4 RWP NWP 4 4
4 4
control CRWP CNWP control
5 5 CNWP CRWP 5 5
5 5
indicate NWP RWP indicate
indicate indicate
6 6 6 6
6 6
hand thr hand thr
7 7 7 7
indicate indicate
contacts connect
8 8 aux DC+ DC+ 8 8 aux the bold wires as shown
8 8
NWP1 RWP1
9 9 9 9
9 CNWP1 CRWP1 9
motor limit CWP1 CWP1 motor limit
10 10 10 10
10 10
DC- DC- Note 1: A fuse is required

11 11 11 11 11 11
for short circuit protection
aux hand crk aux aux hand crk aux on the positive energy used
for indication. Fuse: 10 amp,
12 12 12 12 12 12 type SC, Form 1, class J or
right left right left equivalent.
Figure A-18. Typical Neutral Switch Repeater Relay Circuit Crossover, No Indication in Hand Throw

Drawings
Typical Neutral Switch Repeater Relay Circuit Crossover

To verify indication for left hand
meter to TB2 and or TB3 as follows:
energy end
point detector point detector
relay end NWP / CNWP (TB2-5 / TB2-7)
end end
RWP / CRWP (TB3-6 / TB3-8)
TB-3 TB-2 TB-1 RH point LH point TB-3 TB-2 TB-1 CNWP1 / NWP1 (TB2-7 / TB2-5)
RWP1 / CRWP1 (TB3-6 / TB3-8)
normally normally
1 1
shunt shunt To verify indication for right hand
2 2 CRWP1 CNWP1 2 2 point normally closed, connect a
2 2 meter to TB2 and or TB3 as follows:
power power
3 3 RWP1 NWP1 3 3 RWP / CRWP (TB2-5 / TB2-7)

3 3 NWP / CNWP (TB3-6 / TB3-8)
shunt shunt CRWP1 / RWP1 (TB2-7 / TB2-5)
shunt shunt NWP1 / CNWP1 (TB3-6 / TB3-8)
4 4 RWP NWP 4 4
4 4
control CRWP CNWP control
5 5 CNWP CRWP 5 5
5 5
indicate NWP RWP indicate
indicate indicate
6 6 6 6
6 6
hand thr hand thr
7 7 7 7
indicate indicate
contacts connect
8 8 aux DC+ DC+ 8 8 aux the bold wires as shown
8 8
NWP1 RWP1
9 9 9 9
9 CNWP1 CRWP1 9
motor limit DC- DC- motor limit
10 10 10 10
10 10
11 11 11 11 Note 1: A fuse is required for short

11 11
circuit protection on the positive
hand crk aux hand crk aux
aux aux energy used for indication.
12 12 12 12 12 12 Fuse: 10 amp, type SC, Form 1,
Figure A-19. Typical Neutral Switch Repeater Relay Circuit Crossover, Indication in Hand Throw

Drawings
A.2.10. GM4000A Wiring Diagram
Figure A-20. GM4000A Wiring Diagram, Sheet 1 of 4

Drawings

Drawings

Drawings

FOR QUESTIONS AND INQUIRIES, CONTACT CUSTOMER SERVICE AT
1-800-717-4477
OR
WWW.ALSTOMSIGNALINGSOLUTIONS.COM
ALSTOM SIGNALING INC.

1025 JOHN STREET
WEST HENRIETTA, NY 14586

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GM4000A

Operation and Maintenance Manual

Operation and Maintenance Manual

P2496, Rev. 6, July 2011, Printed in U.S.A.

P2496, GM4000A Switch Machine Operation and Maintenance Manual

ORIGINAL ISSUE DATE: February 2005

CURRENT REVISION AND DATE: July 2011

PAGE CHANGE OR REVISION LEVEL

Title page Jul/11

1-1 thru 1-36 Jul/11

2-1 thru 2-20 Jul/11

3-1 thru 3-54 Jul/11

4-1 thru 4-42 Jul/11

5-1 thru 5-12 Jul/11

6-1 thru 6-50 Jul/11

7-1 thru 7-28 Jul/11

A-1 thru A-24 Jul/11

P2496, Rev. 6, Jul/11 Alstom Signaling Inc.

P2496, Rev. 6, Jul/11 Alstom Signaling Inc.

NOTICE OF CONFIDENTIAL INFORMATION

Information contained herein is confidential and is the property of Alstom

FOR QUESTIONS AND INQUIRIES, CONTACT CUSTOMER SERVICE AT

ALSTOM SIGNALING INC.

GM4000A™ is a trademark of Alstom Signaling Incorporated. All other

P2496, Rev. 6, Jul/11 Alstom Signaling Inc.

Revision Date Description By Checked Approved

P2496, Rev. 6, Jul/11 Alstom Signaling Inc.

Section 1 – GENERAL DESCRIPTION: This section gives general information on the

Section 2 – THEORY OF OPERATION: This section gives general information on the

Section 4 – PREVENTIVE MAINTENANCE: This section describes the tools,

Section 5 – TROUBLESHOOTING: This section describes possible failures/symptoms

Section 6 – CORRECTIVE MAINTENANCE: This section describes the adjustment

P2496, Rev. 6, Jul/11 Alstom Signaling Inc.

DISCONNECT THE MOTOR ENERGY WHENEVER WORKING ON

A caution statement is used when an operating or maintenance procedure, practice,

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

P2496, Rev. 6, Jul/11 Alstom Signaling Inc.

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

P2496, Rev. 6, Jul/11 i Alstom Signaling Inc.

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

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

P2496, Rev. 6, Jul/11 ii Alstom Signaling Inc.

4. SECTION 4 – PREVENTIVE MAINTENANCE ....................................................... 4-1

5. SECTION 5 – TROUBLESHOOTING..................................................................... 5-1

P2496, Rev. 6, Jul/11 iii Alstom Signaling Inc.

7. SECTION 7 - PARTS CATALOG ........................................................................... 7-1

A. APPENDIX A - DRAWINGS ...................................................................................... 1

P2496, Rev. 6, Jul/11 iv Alstom Signaling Inc.

Figure 1-1. GM4000A Switch Machine......................................................................... 1-1

Figure 2-1. GM4000A Lengthwise Cross Section ........................................................ 2-3

Figure 3-1. Typical GM4000A Switch Layout ............................................................... 3-2

Figure 5-1. Enhanced Controller Reset Location ......................................................... 5-2

P2496, Rev. 6, Jul/11 v Alstom Signaling Inc.

P2496, Rev. 6, Jul/11 vi Alstom Signaling Inc.

Table 2-1. Switch Movement........................................................................................ 2-7

Table 3-1. Switch Machine Installation Outline............................................................. 3-5

Table 4-1. Preventive Maintenance Index .................................................................... 4-2

P2496, Rev. 6, Jul/11 vii Alstom Signaling Inc.