technical note - tn 041: 2016 · pdf filethis is the base model point machine which is...

Technical Note - TN 041: 2016


Subject: Withdrawal of legacy RailCorp signalling maintenance manuals

Issued date: 17 October 2016

Effective date: 17 October 2016

For queries regarding this document [email protected]

www.asa.transport.nsw.gov.au

This technical note is issued by the Asset Standards Authority (ASA) to notify that the following

legacy RailCorp signalling maintenance manuals have been withdrawn:

• TMG E1083 Lamp Proving Module Maintenance Manual, version 1.1

• TMG E1340 The Claw Lock Mechanism Description and Operation, version 2.2

• TMG E1341 Claw Lock Mechanism – Safety and Functional Tests – Routine Maintenance,

version 2.3

• TMG E1342 The Claw Lock Mechanism – Overhaul, version 3.0

• TMG E1360 Jeumont Schneider Track Circuits, version 1.1

• TMG E1400 Electro-pneumatic Points – Style 'S' Control Valve, version 1.2

• TMG E1401 Pneumatic Points Control Valve Style 'A', version 1.4

• TMG E1402 Pneumatic Points Control Valve Style 'N', version 1.3

• TMG E1403 Pneumatic Points Control Valve Style 'T', version 1.4

• TMG E1580 Electric Points Machine – Westinghouse 84M Mechanism, version 1.1

• TMG E1585 HLM Point Lock Detectors Maintenance Manual, version 1.0

• TMG E1590 Signal Structures – Examination and Maintenance, version 1.2

• TMG E1630 Signalling Compressed Air System, version 1.0

• TMG E1632 Pulsating Indications, version 1.0

Note: All enquiries regarding the technical content of the manuals listed in this technical note

should be directed to [email protected]

© State of NSW through Transport for NSW of 2

mailto:[email protected]

mailto:[email protected]

http://www.asa.transport.nsw.gov.au/


Authorisation:

Technical content prepared by

Checked and approved by

Interdisciplinary coordination checked by

Authorised for release

Signature

Date

Name Russell Freeman Peter McGregor Andrea Parker Graham Bradshaw

Position Principal Engineer Mechanical

Lead Signals and Control Systems Engineer

Chief Engineer Director Network Standards and Services

© State of NSW through Transport for NSW of 2

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ELECTRIC POINTS MACHINE - WESTINGHOUSE 84M MECHANISM

TMG E1580

Engineering Manual Signals Maintenance

Version 1.1

Issued February 2012

Owner: Chief Engineer, Signals and Control Systems

Approved by:

Warwick Allison Chief Engineer Signals and Control Systems

Authorised by:

Paul Szacsvay Principal Engineer Signals Technology

UNCONTROLLED WHEN PRINTED Page 1 of 42

Disclaimer This document was prepared for use on the RailCorp Network only. RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by RailCorp. RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes any liability which arises in any manner by the use of this document. Copyright The information in this document is protected by Copyright and no part of this document may be reproduced, altered, stored or transmitted by any person without the prior consent of RailCorp.

Engi

neer

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Man

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RailCorp Engineering Manual — Signals — Maintenance Electric Points Machine - Westinghouse 84M Mechanism TMG E1580

© RailCorp Page 2 of 42 Issued February 2012 UNCONTROLLED WHEN PRINTED Version 1.1

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Document control

Version Date Summary of change 1.0 9 January 2012 New document. 1.1 7 February 2012 Pages 9 & 10 removed reference to oil on detector slides.

Summary of changes from previous version

Summary of change Section Removed reference to lubrication of detector slides in section 2.1.4 2.1.4 Removed reference to lubrication of shaft on RHS of Figure 2.2 2.2



Contents

1 Introduction .............................................................................................................................5 1.1 Purpose.....................................................................................................................................5 1.2 Scope ........................................................................................................................................5 1.3 Referenced documents .............................................................................................................5 1.4 Definitions and terms ................................................................................................................5 1.5 Specification..............................................................................................................................6 1.6 Construction ..............................................................................................................................6 2 Routine Maintenance..............................................................................................................7 2.1 Westinghouse 84M Series Switch Machines............................................................................7

2.1.1 Tools ..........................................................................................................................7 2.1.2 External Checks.........................................................................................................7 2.1.3 Internal Checks..........................................................................................................8 2.1.4 Lubrication .................................................................................................................9 2.1.5 Clutch Adjustment....................................................................................................11

2.1.5.1 Non Trailable Machines 84M and D84M..................................................11 2.1.5.2 Trailable Machines T84M and TD84M.....................................................14

3 Clutch and Snubber Overhaul .............................................................................................17 3.1 General....................................................................................................................................17 3.2 Clutch (and Snubber) Replacement 84M and D84M Mechanisms ........................................18

3.2.1 Replace clutch springs (*)........................................................................................18 3.2.2 Renew clutch and snubber friction disks (*) ............................................................20 3.2.3 3.2.3 Renew Electric Brake Disks ...........................................................................23

3.3 Clutch and Snubber Replacement T84M and TD84M Machines ...........................................24 3.3.1 Snubber Replacement (*) ........................................................................................24 3.3.2 Clutch Replacement ................................................................................................24

3.3.2.1 Gearbox Removal – T84M (*) .................................................................24 3.3.2.2 Clutch Dis-assembly (#) ...........................................................................28 3.3.2.3 Clutch Reconditioning and Reassembly (#) .............................................29 3.3.2.4 Gearbox Replacement (*).........................................................................31 3.3.2.5 Clutch Adjustment ....................................................................................32 3.3.2.6 Alternative Clutch Adjustment Procedure ................................................32

4 Hand Throw Mechanism Removal or Change of Hand - D84M and TD84M Machines................................................................................................................................33

4.1 Removal ..................................................................................................................................33 4.2 Replacement - Same or Opposite Hand .................................................................................35 5 Detector Slide Bearing Renewal (*)4 ...................................................................................36 6 Throw Bar Bearing Renewal (#)...........................................................................................37 7 Upgrading a D84M MkI to a D84M MkIII Point Machine.....................................................37 7.1 Disassembly............................................................................................................................37 7.2 Reassembly ............................................................................................................................38 8 Spare Parts 84M Series Machines.......................................................................................39 8.1 8 4M Series Of Mechanisms – Common Parts.......................................................................39

8.1.1 84M Non Trailable, Non Dual Control Machine.......................................................39 With

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8.1.2 T84M Trailable, non dual control machine ..............................................................39 8.1.3 D84M Non trailable, dual control machine...............................................................39 8.1.4 TD84M Trailable, Dual Control Machine .................................................................40

9 Appendix A – Lubrication Alternatives for Claw Locks and 84M Series Switch Machines ...................................................................................................................41

10 Appendix B – Detection Gauge – Westinghouse Detectors.............................................42

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1 Introduction

1.1 Purpose This manual defines maintenance requirements for electric point machines with Westinghouse* 84M mechanisms.

* Note: ‘Westinghouse Signals Australia’ is now known as ‘Invensys Rail’.

1.2 Scope This manual defines general maintenance provided to electric point machines with Westinghouse 84M mechanisms.

This manual doesn’t cover gearbox dismantling or bearing renewal. Where major mechanism overhaul is contemplated refer to the Manufacturers Manuals (eg. TTTO_84M).

* Note: Where metric dimensions are used in this document they represent the nearest imperial sizes.

1.3 Referenced documents TTTO_84M WSA – 84M Series Point Machines Workshop Manual.

1.4 Definitions and terms WSA Westinghouse Signals Australia

84M This is the base model point machine which is equipped for emergency hand crank rotation of the motor drive but is non-trailable.

T84M This model point machine has the features of the base machine plus it allows trailable operation.

D84M Similar to the 84M point machine but uses two levers for manually:

– Selecting between motor and hand operation. – Moving the turnout blades when hand operation is selected.

Note: Interlocking between the levers ensures the turnout is returned to the “Normal” position before the motor/hand lever can be moved to the ‘Motor’ position. A switch cuts power to the motor as the motor/hand lever is moved to the ‘Hand’ postion.

TD84M This model point machine has the features of the base machine plus it has dual control operation and is trailable. The TD84M uses two levers for manually:

– Selecting between motor and hand operation. – Moving the turnout blades when hand operation is selected.

CAUTION TD84M machines must NOT be trailed while the motor/hand selector is in

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1.5 Specification Weight 205 kg to 220 kg typical.

Operating stroke 180 mm.

Operating thrust – Trailable Adjustable over three ranges (low, standard and high) to suit application.

Operating thrust – Non-trailable Factory preset at 3.5 kN (707 lb); Clutch slip at 5 kN (1124 lb). Can be adjusted to 12 kN maximum.

Operating time 4 seconds to 7 seconds depending on load and motor.

Environment -20oC to +70oC

Motor Type Voltage Nominal Current* Permanent magnet 24 Vdc 10 A Split field 110 Vdc 4.5 A Single phase 110 Vac to 120 Vac 7 A Single phase 220 Vac to 240 Vac 4 A

Note: other motors are available to special order.

1.6 Construction Case is a casting with integral mounting lugs, apertures, bosses and tapped holes required for all versions of the 84M point machines.

Cover is fully removable and fixed into place by an integral hinge and latch plate. It features:

• Gasket seal all round • Anti-condensate finish on the interior.

Hand crank aperture cover seals the aperture where the emergency hand crank is inserted. Note: Dual control point machines do not use a hand crank.

Throw bar drives the movable blades of the turnout. It is threaded at both ends (M36) and is supplied with two hexagonal nuts. The nuts locate and fix in place the throw bar connected to the turnout blades.

Detector Bars can be inserted into either side of the point machine. They are connected to and move with the turnout blades. The detection switches monitor correct point closure by the position of these bars.

Cable entry this is the point of entry of electric cables into the point machine. Normally a flexible conduit tube (containing the cables) is slide over and fixed to this component by a suitable hose clip.

Drain plug for draining accumulated moisture from the case. WSA recommends that unless the machine is installed in an area subject to flooding, that plug be permanently removed.

Dual Control Levers there are two levers which are:

• Hand/Motor Lever Selects between motor and hand operation. • Hand Throw Lever Moves the turnout blades when hand operation is

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Note: Interlocking between these levers ensures the turnout is returned to the required position before the motor/hand lever can be moved to its ‘active’ position. A switch cuts power to the motor as the motor/hand lever is moved away from the ‘active’ position.

Lever Stop & Latch The motion of both dual control levers is limited in each direction by these stops and latches. The latches can be locked with standard padlocks to prevent unauthorised operation of the levers.

Fortress Lock Optional feature to prevent operation of the dual control levers by unauthorised persons.

2 Routine Maintenance

2.1 Westinghouse 84M Series Switch Machines

2.1.1 Tools 30 mm open ended spanners 2 off Adjustable spanners 450 mm 2 off Adjustable spanners 600 mm 2 off Or 55 mm open ended spanners 2 off Nut driver insulated 5 mm 1 off Nut driver insulated 1/4 BSW 1 off Pliers combination 200 mm 1 off

2.1.2 External Checks Carry out the external checks and inspections listed in the TMP (baseline or tailored) applying to the locality.

• To check that nuts and locknuts on either side of the drive lug are tight two spanners must be used, one on the nut and one on the locknut. Attempting to use a single spanner can loosen the bond between the nuts.

• Note that it is permissible for the drive lug to be able to rotate on the mechanism throw bar and on the drive rod provided that there is zero end float. Loctite 242 or similar can be used on nut and locknut threads to assist locking.

• Allowing the drop lug to rotate on the mechanism throw bar will reduce the effect of stockrail movement on throw bar/coupling bar misalignment.

• Detector rods must be firm in the lugs on the end of the detector slides but not so tight that the dished washers become ineffective. Again two spanners must be used when tightening locknuts against nuts.

• There must also be less than 1mm of movement between detector rod and switch or swing nose. Replace bushes and/or pins where necessary.

• If the baseplate holding down bolts on concrete beams are removed for any reason, and these are stainless steel bolts, an anti-seize compound must be applied to the bolt before it is re-inserted. While not essential for galvanised or zinc plated bolts its use will still be beneficial.

• When checking emergency crank handle operation, examine the condition of the indexed bearing sleeve. If the wear is such that a differently indexed handle could be forced into the machine, the bearing sleeve must be replaced.

• With dual control machines, before inserting the EOL key into the machine, lift the latch and attempt to move the selector lever. Only a few degrees of movement W

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should be possible. If the lever can be moved more than a few degrees then the Emergency Operation Lock and slide is defective and must be replaced.

• With the selector lever in the ”motor” position, attempt to move the hand throw lever. Again the lever should not move more than a few degrees. If it does the interlocking between the two levers is defective and must be repaired or replaced.

• To check correct operation of the Emergency Operation Lock and key:

– Move the selector lever to the “hand” position. – The slide must not be able to be pushed in and the EOL key must be retained in

the lock. – Move the hand throw lever to the reverse position. – Try to restore the selector lever to the “motor” position. This should not be

possible. In some cases, e.g. SSI Interlockings, this is achievable due to the fact that the ball bearing has been taken out.

– Move the hand throw lever back to the normal position. The slide must not be able to be pushed in and the key must be retained in the lock.

– Return the selector lever to the “motor” position. – It should now be possible to push the slide fully in and turn and remove the EOL

key.

2.1.3 Internal Checks Carry out the internal checks and inspections listed in the TMP (baseline or tailored) applying to the locality:

• Detector rollers should be examined to ensure that they are rotating freely and that there are no evident flat spots on the roller.

• Detector, motor control and motor cut-out switches are semi-sealed units and can only be visually examined or checked with a meter for contact resistance. Initially, a visual examination is usually sufficient to determine if a problem is developing. Internal discolouration of the case, particularly blackening, or any discolouration of the contact springs is an indication that a fault is developing and that the contact block should be changed.

• Wear in detector and motor control contact linkages will result in light contact pressures and “bobbing contacts”. These linkages need to be examined periodically to check the degree of free play of pivots and pins and to check that the throw-over action of the motor control contacts is a “snap” action without any hesitation.

• Use the appropriate nut drivers to check that wiring and terminations within the machine are secure.

• Ensure that the detection configuration plug is secure in its socket. • Arrange for the machine to operate normal to reverse and back and listen for any

unusual noise(s) from the motor or gears. Motors cannot be field serviced and must be changed and forwarded for overhaul if any defect such as worn or dry bearings is suspected.

• If the noise appears to be coming from the gears, examine the condition of the gear teeth. Signs of sharp edges at the top of gear teeth indicates heavy wear and that imminent gear replacement will be necessary. If the gears appear OK, the problem is most likely a dry or worn bearing. This will necessitate either gearbox replacement or machine replacement for overhaul.

• Check the side float in the detector slides where they pass through the mechanism case. This should not exceed 1 mm. Replace either the detector slide bearing or detector slide, whichever is worn.

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Check for movement In direction of arrows

Fig 2.1 84M Series detector slides

If it has not already been removed, the drain plug located under the gearbox in the centre of the machine case should be removed as required to drain any accumulation of water.

2.1.4 Lubrication The lubricants required are:

• Petroleum Jelly or a ‘Valve and O-ring lubricant’ for 84M and T84M machines only. • Grease selected from the list in Appendix A. • Mobil DTE 19 oil with 5 % to 10% Molybond 2.5 additive or Shell “Tonna Oil S 220”

(Included in Appendix A).

Lubricate where shown in figure 2.2.

The recommended maximum lubrication intervals are:

• For a machine which operates less than 75 times per day:

– 6 months.

• For a machine which operates more than 75 times per day:

– 3 months.

• For the throw bar, additional lubrication after severe storms or prolonged periods of heavy rain.

Where machines are operating in severe environments, such as in areas with salt air or where heavy condensation is experienced, maximum lubrication intervals will need to be reduced.

CAUTION Take care not to contaminate the clutch facings with oil or grease. In

particular trail clutch facings in T84M and TD84M machines must not be contaminated.

Additional lubrication is required if these mechanism are dismantled and overhauled. For details refer to chapter 3 “Overhaul” and Westinghouse Signals Australia* Manual MH3408.

* Note: ‘Westinghouse Signals Australia’ is now known as ‘Invensys Rail’.


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All Machines

Petroleum jelly on O ring Oil Grease – rack and pinion Oil pivots

Oil pivots

Oil pivots Grease gears

Grease – worm and worm wheel Oil

Grease

Figure 2.2 Lubrication - Additional lubrication points on D84M and TD84M Machines only

Note that the internal appearance, motors in particular, and the location of capacitors may vary from that shown above. This has no effect on required lubrication.


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2.1.5 Clutch Adjustment Unless there have been suspected clutch slip problems, it should only be necessary to check the clutch at installation and at a minimum of yearly intervals thereafter.

2.1.5.1 Non Trailable Machines 84M and D84M The clutch is located on the end of the extended worm shaft and may be adjusted by tightening or loosening the castellated nut. (The nut is at the opposite end of the worm shaft to the detection configuration plug and sockets).

2.3 Non-trailable Clutch including Electric Brake


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Figure 2.4 84MKIII with Electric Brake

The clutch should be set for a slip load of 4.5 kN to 5.5 kN for Mk 1 machines and 7 kN for Mk 3 machines (or Mk1 machines with Mk3 clutches fitted).

The clutch may be checked and adjusted by using the WB&S clutch setting tool, Part No 3335801201. Proceed as follows:

Disconnect the drive bar from the points. Fit the clutch setting tool to the fully extended end of the drive bar and screw on one nut to just touch the outer collar of the tool but not compress the spring. The inner end of the tool should be bearing against the side of the mechanism case.

Check that the tool is reading zero plus or minus 0.25 kN. If not, the tool spring has been damaged and must be replaced.

Operate the machine under power and read off the load at which the clutch slips.

If the torque is too low then: adjust


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2.1.6 Motor protection clutch slip (Non-trailable machines only) This clutch is on the end of the worm shaft.

Adjust clutch slip by turning the adjustment screw to change the pre-load of the Belleville washers. The washers must not be fully compressed (or almost so) to achieve the required slip load.

Figure 2.5 Motor protection clutch (non-trailable only): adjusting slip

To adjust the clutch:

a) Loosen the locknut while holding the adjustment screw steady.

b) Turn the adjustment screw to set the clutch slip (clockwise to increase). The machine should drive the throw bar, without clutch slip, against the “Motor Clutch Slip” load specified in table 6.2. The clutch should slip when driving a load as little above the specified load as possible.

c) Tighten the locknut while restraining the screw.

2.1.7 Trail-Motor clutch slip (Trailable machines only) This clutch is located in the hub of the worm wheel.

a) Measure the maximum load the machine will drive without clutch slip. The measured load must not be less than (preferably grater than) the “Test Load” specified in table 6.2.

b) Measure the minimum load at which the machine will trail. The measured load must not be greater than the “Maximum Trail Load”

Adjustments are performed through the opening in the spring housing on the mainshaft.

Alternatively


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A less accurate, but simpler, method of clutch adjustment, which does not require the machine to be disconnected from the points, may be used.

Use a tong type ammeter around the motor common wire to the machine.

Measure the motor operating current normal to reverse and reverse to normal.

If the motor operating current is measured at 8.5 A or more, there is either binding in the claw lock mechanism or in the turnout itself. These faults must be corrected at the earliest opportunity. Do not simply adjust the clutch to compensate.

Block the points and measure the clutch slip current.

• The slip current must be at least 1 A, and preferably 1.2 A to 1.4 A, more than the operating current.

• The slip current must not be less than 7.5 A. • The slip current must not be more than 10.5 A.

If the slip current is too low, adjust by tightening the castellated nut. Ensure that a new split pin is re-fitted.

2.1.7.1 Trailable Machines T84M and TD84M The multi-plate trail/motor clutch is contained within the worm-wheel casting and acts as both a breakaway clutch for trailing movements and a motor protection clutch.

Adjustment is carried out at the window provided in the spring housing contained on the main worm-wheel shaft.

To adjust the clutch:

• Use a 6 mm diameter x 150 mm steel rod to rotate the pressure plate in the spring housing until the locking socket head grub screw is visible through the window.

• Loosen the socket head grub screw. • Using one of the 6 mm x 150 mm bars in one of the holes in the edge of the

adjustment ring and the other in a hole on the edge of the pressure plate, adjust the clutch by turning the adjustment ring while holding the pressure plate stationary.

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Spring Housing

Adjusting ring

Pressure Plate

Worm Shaft

Main Shaft

Figure 2.6 – Main Shaft & Worm Shaft Sub-Assembly Exploded View

Adjusting ring

Pressure plate

Grub screw

Figure 2.7 T84M and TD84M Trail Clutch


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Viewed from the worm-wheel end, turning the adjusting ring clockwise increases the clutch slip load.

Load may be measured by using the Westinghouse clutch setting tool Part No 33358801201 in the manner described in clause 1.3.1.

• When the desired setting is obtained, re-tighten the grub screw.

There are three clutch springs for T84M and TD84M machines. These are:

Clutch Spring P/N Trail Setting Drive Setting 4177300801 Low 1.25 kN to 2.0 kN 4177300701 Medium 2.2 kN to 3.2 kN 4177300901 High 3.5 kN to 4.5 kN T84M and TD84M machines used in New South Wales are normally fitted with the high trail setting spring P/N 4177300901.

Alternatively


Use a tong type ammeter around the motor common wire to the machine.

Measure the motor operating current normal to reverse and reverse to normal.

If the motor operating current is measured at 8.5 A or more, there is either binding in the claw lock mechanism or in the turnout itself. These faults must be corrected at the earliest opportunity. Do not simply adjust the clutch to compensate.

Block the points and measure the clutch slip current.

• The slip current must be at least 1 A more than the operating current. • The slip current must not be less than 7 A. • The slip current must not be more than 10 A.

A slip current in excess of 10 A will indicate a defect within the clutch which must be changed.

If a clutch with a high trail setting spring cannot be adjusted to exceed a 7 amp slip current, then it is defective and must be changed.

Clutch change procedure is described in chapter 4 “Overhaul”. (TMG E1342).


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3 Clutch and Snubber Overhaul

3.1 General This section describes only clutch and snubber overhaul and machine hand changeover. It does not describe gearbox dismantling or bearing renewal and does not contain a comprehensive list of parts.

A detailed Workshop Manual, document TTTO_84M, is available from Westinghouse Signals Australia. This should be obtained and used where major mechanism overhaul is contemplated.

The intervals at which a switch machine requires overhaul will depend on:

• Usage. • Type of turnout or swing nose being driven. • Rail traffic types and tonnages. • Variation in turnout and road bed condition over time.

Since all of the above will vary from area to area and may vary from location to location, overhaul is to be carried out on an “as required” basis.

Virtually all of the moving parts in an 84 series machine will, at some stage, wear to the point that operation will be compromised. Examples of these parts are:

• Clutch disks and springs. • On hand crank machines, the crank bearing sleeve and switch linkage. • Detector slide bearings in the case. • Detector rollers and roller linkages. • Motor control contact rollers and throwover linkages. • Throw bar bearings in the case. • Pinion teeth and throw bar rack teeth. • Gearbox mainshaft bearings. • Worm and worm wheel teeth. • Worm gear shaft bearings. • Wormshaft gear, intermediate pinion and intermediate gear teeth. • Shaft or bearings for the intermediate pinion and gear. • The snubber friction disk. • Detents in the throw bar.

All of these parts can be replaced provided that the wear has not been allowed to extend into cast components such as the case and gearbox castings. If this happens, the machine has little more than scrap value.

Where a (*) symbol is shown against a procedure, the procedure can be carried out without removing the machine from the points.

Where a (#) symbol is shown against a procedure, the procedure is best carried out in a workshop.

However, where a machine requires attention to more than one assembly, eg clutch and hand throw mechanism, then it would be advisable to remove the machine from site for overhaul. With

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3.2 Clutch (and Snubber) Replacement 84M and D84M Mechanisms This clutch is located on the end of the worm shaft on the same side of the mechanism as the motor pinion.

3.2.1 Replace clutch springs (*)

Tools Parts Combination pliers Disk spring p/n TBA 200 mm screwdriver 4 mm dia split pin 25 mm long 19 mm socket or ring spanner

• Remove the split pin and retaining nut from the end of the clutch shaft. • Remove the old spring (bellville washer assembly). • Fit the new spring, refit the locknut, adjust the clutch to slip with a load of 6.5 kN to

7 kN and ensure washers are arranged correctly. • Fit a new split pin.

Fig 3.1 Sleeve Assembly: Trailable


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Fig 3.2 Sleeve Assembly: Dual-Control Trailable

Fig 3.3 Gearbox


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3.2.2 Renew clutch and snubber friction disks (*)

Tools Parts Combination pliers Clutch disk spring p/n TBA 200 mm Screwdriver Clutch friction disks (3) p/n 4335303001#

19 mm socket or ring spanner Split pin 4 mm dia. 25 mm long 13 mm socket with extension Grease External circlip pliers Bush, final gear p/n TBA Drift 10 mm dia 175 mm long solvent 0.5 kg ball pein hammer Lint free cloth

# Note: This part number is for the Mk 1 point machines. The part number varies according to the model and machine version. See pages B25 to B27 in the Mk 3 workshop manual.

Removal

• Disconnect and remove the motor (complete with pinion). • Remove the two M8 screws from the snubber assembly and remove the mounting

plate and springs. • Remove the circlip retaining the intermediate gear shaft and, with a suitable drift,

gently tap the shaft out of the gearbox (try not to dislodge the bearing from the gearbox housing). A 3/8” BSP plug in the side of the case gives access for the drift.

• Remove the intermediate gears and the snubber plate and friction disk. • Remove the split pin, nut, outer pressure ring, spring assembly and inner pressure

ring from the clutch shaft. • Remove the clutch plate and outer friction disk. • Slide the final gear off the shaft and remove the inner friction disk. • Thoroughly clean both sides of the final gear and the inner and outer clutch plates.

Use an approved solvent wetted cloth taking care not to splash the solvent on other parts of the machine.

Check the condition of the bush in the centre of the gear and relace if necessary (unless there has been considerable clutch slip, wear on this bush should be minimal).

Replacement

a) Fit a new inner friction disk and refit the final gear.

b) Fit a new outer friction disk and refit the outer clutch plate.

c) Replace the inner pressure ring, disk spring, outer pressure ring and retaining nut.

d) Position the intermediate gears, snubber friction disk and snubber plate and drive the intermediate shaft back into the gearbox.

e) Refit the circlip.

f) Refit the snubber mounting plate and springs.

g) Refit the motor and reconnect.

h) Adjust the clutch to slip with a load of 6.5 kN to 7 kN.

i) Fit a new split pin to the clutch retaining nut. With

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Fig 3.4 Mainshaft Assembly: Trailable – Pinion End

Fig 3.5 Mainshaft Assembly: Trailable – Worm Wheel End


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Fig 3.6 Trailable Clutch: Assembly Bearing

Fig 3.7 Trailable Clutch Assembly: Clutch Plates and Friction Disks


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3.2.3 3.2.3 Renew Electric Brake Disks

Fig 3.8 Electric Blake and Plug Plate

Fig 3.9 Electric Brake and Plug Plate: Pre Assembly Sequence


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Fig 3.10 Worm Shaft Locknuts

3.3 Clutch and Snubber Replacement T84M and TD84M Machines As the clutch replacement on T84M and TD84M machines requires removal of the gearbox from the machine, there are other tasks which should be carried out while the gearbox is out of the machine. These tasks are included in this section under “clutch replacement”.

3.3.1 Snubber Replacement (*) Refer to clause 3.2.2

3.3.2 Clutch Replacement

3.3.2.1 Gearbox Removal – T84M (*) a) Remove two nuts retaining detent spring cover to relieve pressure on detent

ball.

b) Undo and remove screws fastening the gear box to the case.

c) Lift the gear box away from the case.

– The gear box might stick to the case. Use a suitable tool (such as a large flat blade screw driver) to prise it loose.

– The dowel pins might jamb in their holes if the gearbox is not lifted. – The dowel pins might come away from the case with the gearbox. Recover

them from the gearbox and put them back where they came from.

CAUTION The gear box is heavy and weighs 45 kg approximately.

Use a light crane or similar assistance.


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WARNING Since the points are essentially free when the gearbox is removed, the

protecting signals must be placed at, and held at, stop before commencing gearbox removal. Points must be clipped before any train is allowed to pass over them. Note also that there will be interference with detection

circuits which will affect signals on the other road if work is being carried out on one end of a crossover.

Tools Parts

19 mm socket None required

13 mm socket 24 mm socket 150 mm or 200 mm screwdriver Ratchet and extension for sockets 2 m to 3 m of 8 mm or 10 mm rope

d) Disconnect and remove the motor.

e) Disconnect external wiring (all circuits must be isolated before disconnection). Remove the screws holding the terminal chassis and motor control switch plates into the case.

f) Carefully drape these plates over the side of the case with internal wiring remaining connected.

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Fig 3.11 Non Dual Control – Trailable


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Fig 3.12 Dual Control Trailable

a) Remove the handing plug from the plug plate on the side of the gearbox. Alternatively remove the handing plug and plate from the gearbox.

b) The gearbox and bearing housing must be removed as a unit.

c) Remove the seven M12 screws securing the gearbox assembly and, using a rope looped around the gearbox, lift vertically from the locating dowels and out of the case.

Gearbox Removal TD84M

Tools Parts 19 mm socket None required 13 mm socket 24 mm socket 150 mm or 200 mm screwdriver


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Ratchet and extension for sockets 2 m to 3 m of 8 mm or 10 mm rope

a) Disconnect and remove the motor.

b) Remove the screws holding the terminal chassis and motor control switch plates into the case. There is no need to disconnect wiring.

c) Carefully drape these plates over the side of the case.

d) Remove the handing plug from the plug plate on the side of the gearbox. Alternatively remove the handing plug and plate from the gearbox.

e) Place the machine in hand throw mode and operate the hand throw lever until the machine is in mid stroke. Mark the hand throw gears where they mesh to assist in re-assembly.

f) Remove the two M8 screws holding the yoke pin in place.

g) Remove the top plate and slide the yoke pin up to remove it.

h) Slide the yoke forward off the selector, rotate it and remove it.

i) Remove the selector bearing.

j) Remove the bolts securing the switch mounting plate and move the plate and switch complete sufficiently to clear the hand throw clutch.

k) The gearbox and bearing housing must be removed as a unit.

l) Remove the seven M12 screws securing the gearbox assembly and, using a rope looped around the gearbox, lift vertically from the locating dowels and out of the case.

3.3.2.2 Clutch Dis-assembly (#)

Tools Parts 13 mm socket None Required 24 mm socket Ratchet and extension for socket 150 mm or 200 mm screwdriver 300 mm G clamp

a) Remove the gearbox assembly to a workshop or depot.

b) Remove the cover plate on the main shaft bearing housing.

WARNING: On non dual control machines (T84M), the clutch assembly/ main shaft is

pre-loaded. Use a 300 mm G clamp or similar across the back of the spring housing and gearbox to prevent components springing apart.

c) Remove the bearing locknut (note the locking washer tabs) and remove the housing from the shaft. W

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d) Release the G clamp slowly and carefully. d) Release the G clamp slowly and carefully.

e) Slide the pinion, spacer and spring housing off the shaft. e) Slide the pinion, spacer and spring housing off the shaft.

f) Clutch plates and friction disks can now be removed. f) Clutch plates and friction disks can now be removed.

3.3.2.3 Clutch Reconditioning and Reassembly (#) 3.3.2.3 Clutch Reconditioning and Reassembly (#)

Tools Tools Parts Parts 13 mm socket Clutch friction disks p/n 4335314401 24 mm socket Clutch plate inner p/n 4335314601 Ratchet and extension for socket Clutch plate outer p/n 4335314501 150 mm or 200 mm screwdriver Ball bearing 4405/35 * Brass Drifts (various diameters) Ball bearing 4405/36 * 300 mm G clamp Lock (tab) washer p/n 4405/38 * Circlip pliers

*Only where examination shows it to be necessary.

Check all main shaft bearings for roughness or side play. If the machine has been in service for more than 5 years or if there is any suspected defect, remove the bearings and wash to remove all grease and contamination.

Cover plate Nut Tab washer

Bearings

Bearing housing

Detent ball and housing

Clutch disk outer Friction disk Clutch disk inner Friction disk Bearing Worm wheel

Figure 3.4 Trail clutch assembly

a) Examine the bearings and replace if worn or damaged.

b) Re grease the bearings with Shell “Retinax AM” or Molybond “Ultraplex M” or Caltex “Molygrease EP2”.


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c) Clean the main shaft. c) Clean the main shaft.

d) If the bearings at the worm wheel end of the main shaft have been removed, replace and refit the main shaft into the gearbox casting. Refit the thrust washer, bearing spacer, worm wheel and bearing.

d) If the bearings at the worm wheel end of the main shaft have been removed, replace and refit the main shaft into the gearbox casting. Refit the thrust washer, bearing spacer, worm wheel and bearing.

e) Thoroughly clean the clutch plates. Replace any damaged plates. e) Thoroughly clean the clutch plates. Replace any damaged plates.

f) Renew friction disks. f) Renew friction disks.

g) Before commencing clutch re-assembly, examine the condition of the detent ball and spring casing fitted to the main shaft bearing housing. Replace if there is visible wear or damage to either ball or housing.

g) Before commencing clutch re-assembly, examine the condition of the detent ball and spring casing fitted to the main shaft bearing housing. Replace if there is visible wear or damage to either ball or housing.

Spring Pressure plate assembly

Thrust washer Pinion Spacer Spring housing

Fig 3.5 Trail Clutch order of assembly

a) Replace the clutch plates and friction disks on the shaft noting the correct order from the worm wheel end. Friction disk, clutch plate inner, friction disk, clutch plate outer, repeated four times, then finishing with friction disk, clutch plate inner.

b) Replace the spring sleeve and pressure plate assembly back onto the shaft.

c) If a T84M, replace the spacer, pinion and thrust washer onto the shaft.

d) If a TD84M, replace the hand throw clutch, bevel pinion, thrust washer, pinion and thrust washer onto the shaft.

e) Replace the bearing housing onto the shaft and slide the bearings into the housing. Bearings fit “back to back”.

f) Refit the tab washer and locknut.


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g) Note that on T84M machines it is necessary to clamp the gearbox and clutch assembly to refit the tab washer and nut.

h) Secure the nut using previously unused tabs on the tab washer. (Replace his washer if all tabs have been previously used).

i) The gearbox is now ready for refitting into the machine.

3.3.2.4 Gearbox Replacement (*)

Tools Parts 19 mm socket Throw bar p/n 3335305001* (Mk 1 model) 19 mm socket Throw bar p/n 3335354401 (Mk 3 model) 13 mm socket 24 mm socket * if examination determines necessary Ratchet and extension for sockets 150 mm or 200 mm screwdriver 2 m to 3 m of 8 mm or 10 mm rope

Before replacing the gearbox into the machine examine the condition of the detent recesses in the throw bar. If the recesses show significant wear or if there is significant grooving between recesses, replace the throw bar.

a) Place the gearbox back into the machine ensuring that it seats correctly on the locating dowels.

b) Fit and tighten the M12 bolts securing the gearbox and main shaft bearing housings into the case.

For 84M and T84M machines

a) Refit the handing plug to the side of the gearbox.

b) Refit the motor operating switch plate and terminal chassis.

c) Refit the motor and re-connect.

For D84M and TD84M machines

a) Refit the hand switch plate.

b) Refit the selector bearing.

c) Refit the yoke.

d) Refit the yoke pin.

e) Replace the top plate and bolts and tighten.

f) Refit the handing plug to the side of the gearbox.

g) Refit the motor operating switch plates and terminal chassis.

h) Reconnect external wiring.

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3.3.2.5 Clutch Adjustment 3.3.2.5 Clutch Adjustment For T84M and TD84M Machines For T84M and TD84M Machines

a) Using the 6mm diameter rods, rotate the pressure plate until the grub screw is visible in the window in the housing.

a) Using the 6mm diameter rods, rotate the pressure plate until the grub screw is visible in the window in the housing.

b) Loosen the grub screw. b) Loosen the grub screw.

c) With one bar in the pressure plate and one in the adjusting ring, turn the adjusting ring. Viewed from the worm wheel end, turning clockwise increases the load.

c) With one bar in the pressure plate and one in the adjusting ring, turn the adjusting ring. Viewed from the worm wheel end, turning clockwise increases the load.

d) Set to give a thrust at the throw bar of 4 kN to 4.5 kN. d) Set to give a thrust at the throw bar of 4 kN to 4.5 kN.

e) Re-tighten the grub screw. e) Re-tighten the grub screw.

Grub screw Adjusting ring Pressure plate

Fig 3.6 Clutch adjusting ring

3.3.2.6 Alternative Clutch Adjustment Procedure For T84M and TD84M Machines


a) Use a tong type ammeter around the motor common wire to the machine.

b) Measure the motor operating current normal to reverse and reverse to normal.

c) If the motor operating current is measured at 8.5 A or more, there is possible binding in the claw lock mechanism or in the turnout itself. These faults must be corrected at the earliest opportunity. Do not simply adjust the clutch to compensate.


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d) Measure the drive current of a lubricated layout and adjust clutch to 200% of operating current not exceeding maximum readings below for trailable points:

i) The slip current must not be less than 7 A.

ii) The slip current must not be more than 10 A.

e) A slip current in excess of 10 A will indicate a defect within the clutch which must be changed.

f) If a clutch with a high trail setting spring cannot be adjusted to exceed a 7 amp slip current, then it is defective and must be changed.

g) Measure the drive current of a lubricated layout and adjust clutch to 200% of operating current not exceeding maximum readings below for Non trailable points:

i) The slip current must not be less than 7.5 A.

ii) The slip current must not be more than 10.5 A.

4 Hand Throw Mechanism Removal or Change of Hand - D84M and TD84M Machines

4.1 Removal a) If changing hand, remove the blanking plates from the opposite side of the

machine to the levers. Clean the inner and outer mounting faces in the case.

b) Place the machine into hand throw mode and operate the hand throw lever until the machine is in mid stroke. Mark the hand throw bevel gears to assist in re-assembly (marking gear to gear, as close to mesh point as possible, is best).

c) If changing hand, remove the lever supports.

d) Remove the M16 nut securing the selector lever and remove the lever along with the interlocking ball bearing and woodruff key.

e) Remove the two screws at the bottom of the interlocking plate and remove the plate.

f) Withdraw the hand throw lever taking care not to loose the keys from the shaft.

g) Remove the two screws from the hand throw bearing plate and remove the plate. (A light tap with a mallet may be necessary).

h) If changing hand, disconnect the wires from the motor/hand detection switch. (These wires are positioned in the loom so that they are suitable for right or left hand operation).

i) Remove the screws securing the yoke pin top plate and remove the plate.

j) Slide the yoke pin up and remove it.

k) Slide the yoke forward off the selector, rotate and remove it. Remove the selector bearing.

l) If changing hand, remove the screws securing the switch plate and yoke mounting and remove. W

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m) Unbolt the bearing housing and lift off the locating dowels.

Fig 3.7 LH hand throw assembly


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4.2 Replacement - Same or Opposite Hand a) Clean any dirt and paint from the surface of the bearing housing mount and

dowels in the case (opposite side housing mount and dowels if changing hand).

b) Fit the yoke mounting and switch plate and slip the yoke loosely around the shaft. Note that the yoke must be fitted with the letters “LH” or “RH” upwards depending on the hand of machine being assembled.

c) Fit the bearing housing onto the dowels but only screw down finger tight. Ensure that the previously marked teeth on the gears are aligned.

d) Fit the selector bearing and slide the yoke onto the selector.

e) Fit the yoke pin and top plate and secure.

f) Temporarily fit the hand throw lever (lever should be fitted vertical at mid stroke).

g) With the selector in the hand position (clutch engaged), operate the machine and ensure that the stroke is even both sides of mid point. At each ‘end of stroke’ position there should be between 10 mm and 15 mm from the end of the rack to the side of the case.

h) If this needs adjustment, remove the screws from the bearing housing and carefully lift the housing until the bevel gear teeth disengage. Ensure that the selector bearing remains in the yoke. Turn the bevel pinion one tooth in the required direction and refit the bearing housing.

i) Check that throw is now even. If so tighten down the bearing housing.

j) Refit the hand throw bearing plate and hand throw lever.

k) Refit the interlocking plate and ball (ball position will depend on hand and lay of points). Ensure that the countersunk screw is placed in the unused ball recess in the hand throw lever.

l) Refit the selector lever.

m) Refit the lever supports and blanking plates.

n) Reverse the labels on the hand throw and selector levers where necessary.

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Fig 3.8 Hand throw mechanism right hand

5 Detector Slide Bearing Renewal (*)4 Refer to WSA Manual TTTO_84M.


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6 Throw Bar Bearing Renewal (#) Refer to WSA Manual TTTO_84M.

7 Upgrading a D84M Mk 1 to a D84M Mk 3 Point Machine The following are instructions for upgrading a D84M Mk 1 point machine to a D84M Mk 3 point machine. Refer to the 84M series point machines workshop manual for detailed assembly instructions and illustrations.

Note: The sequence of operation is important and should be followed in the order given.

7.1 Disassembly a) Electrically isolate the point machine to prevent unexpected operation.

b) Place point machine selector lever in “HAND” then bring it back sufficient to clear the lever stand.

c) For point machines fitted with a Fortress lock remove lock (4 off M6 then lock bracket).

d) Remove selector lever, being careful not to lose the key and interlock ball (interlock ball is not fitted to point machines fitted with a Fortress lock).

e) Remove interlock plate; note the position of the cut outs so it may be refitted the same way.

f) Centre rack by moving the hand throw lever to its vertical position.

g) Pull hand-throw lever part of the way off the shaft to enable the two remaining bearing casting screws to be undone.

h) Remove the two bevel gear bearing block hold down screws.

i) Lift the complete hand throw assembly up and clear of the machine; if bearing housing is stuck to the case with sealant it can be carefully prized away with a chisel or similar tool; do not attempt to hammer it off as it may crack the casing.

j) Note whether selector yoke has “RH” or “LH” stamped on its top face as it must be assembled the same way up: if there are no letters then it can be reassembled either way.

k) Remove selector yoke pivot plate, pivot shaft and finally the yoke.

l) Disconnect motor plug.

m) Undo two hold down screws and remove motor by sliding it back and then lifting away.

n) Remove three terminal assembly hold down screws and lift it clear of the main bearing housing with care to avoid damaging the incoming wires.

o) Undo six motor control switch assembly hold down screws and carefully lift both assemblies clear of the main bearing housing.

p) Remove seven gearbox hold-down screws and lift gearbox out of the point machine; the gear box is located on dowels and may need to be hit on the side with a soft faced mallet to free it. W

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7.2 Reassembly a) Clear away any debris or rust particles from the pads in the point machine

housing; if necessary remove rust build up on the pads or dowels and apply a light coat of grease or oil to facilitate reassembly.

b) Drop new gearbox in position and ensure that it is located on the dowels and is sitting fully down on the pads; redo seven hold-down screws and tighten to 50 Nm.

c) Refit selector yoke, ensuring that it is the correct way around, and fit pin and support plate; redo screws.

d) Engage hand throw clutch by rotating bevel pinion until clutch faces align and moving the yoke to the drive end of the machine.

e) With the rack in approximately mid position refit hand throw assembly with the lever vertical.

f) Ensure the selector crank sliding block engages the slot in the selector yoke and the crank moves freely when the yoke is rotated on its pivot.

g) If there are alignment marks on the bevel gears ensure that these are aligned.

h) Hand tighten bevel gear support bearing block hold-down screws and the two shorter bearing housing hold-down screws.

i) Apply a light film of oil on the shaft and push the hand throw lever fully back against the bearing housing.

j) Throw the point machine in both directions to ensure the rack travel is centralised in the housing.

k) If the rack stops more than 4mm closer to the housing at one end the larger bevel gear must be moved forward by one tooth at a time relative the bevel pinion until the distances are the same within 4 mm.

l) Tighten the four screws to 50 Nm.

m) Refit indexing plate and ball if one was originally fitted.

n) Insert woodruff key and push selector lever onto the shaft; operate lever to check correct operation of the hand throw clutch; refit washer and nut.

o) Replace motor control assemblies; redo six screws.

p) Replace terminal assembly; redo three screws.

q) Refit motor; redo two screws and reconnect motor leads.

r) Place point machine in “HAND” and throw points to check that it works correctly.

s) Remove power isolation and place in “MOTOR”; call points to check motor operation.

t) Replace point machine in “HAND” to confirm the clutch re-engages.

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8 Spare Parts 84M Series Machines

8.1 8 4M Series Of Mechanisms – Common Parts Part Part NumberCase 0335305901Detector bar (top) 2335201303 Detector bar (bottom) 2335201304 Detector Switch Unit 3335203801 Cut off switch complete LH 3335201002 Cut off switch complete RH 3335201001 Throw bar 3335305001 Rack – drive 2335304901 Cover complete 3335201501 Bearing – detector slide 3335301901 Motor 110/120 V 50 Hz 1520100204 Capacitor 50 mfd 250 V 3166/26

8.1.1 84M Non Trailable, Non Dual Control Machine Part Part NumberGearbox complete 1335202801 (Mk1 model) Capacitor Unit 3335204102 Hand Crank Switch 3335200701 Wiring Harness 3340304401 Plug complete – hand crank aperture 4335201201

8.1.2 T84M Trailable, non dual control machine Part Part NumberGearbox complete 1335202703 Capacitor Unit 3335204102 Hand Crank Switch 3335200701 Wiring Harness 3335200401 Plug complete – hand crank aperture 4335201201 Clutch Spring 4177300901

8.1.3 D84M Non Trailable, dual control machine Part Part NumberGearbox complete 1335208801 (Mk 3 model) Capacitor Unit 2520200402 Hand Throw Switch 3335202501 Wiring Harness 3335205101 Lever, Selector (hand/power) 2335321501 Lever, Hand Throw 2335321401 Electric Brake With

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© RailCorIssued Fe

age 40 of 42 1.1Version

p bruary 2012 UNCONTROLLED WHEN PRINTED

P

8.1.4 TD84M Trailable, Dual Control Machine Part Part NumberGearbox Complete 1335202703 Capacitor Unit 2520200402 Hand Throw Switch 3335202501 Wiring Harness 3335205101 Clutch Spring 4177300901 Lever, Selector (hand/power) 2335321501 Lever, Hand Throw 2335321401

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ering Manual — Signals — Maintenance achine - Westinghouse 84M Mechanism TMG E1580

© Rai Page 41 of 42 Issue Version 1.1

lCorp d February 2012 UNCONTROLLED WHEN PRINTED

9 Appendix A – Lubrication Alternatives for Claw Locks and 84M Series Switch Machines Manufacturer Product Comment Applications Shell Retinax HDX2 Heavy duty EP grease, contains MoS2, suitable for Claw Lock components

heavy duty applications with shock loading in hostile environments

Caltex Molygrease Heavy Heavy duty EP grease, contains MoS2, high water and corrosion resistance, high load carrying capacity

Claw Lock components

Rocol Tufgear 90 ** Heavy duty grease, contains MoS2, high corrosion resistance, high load capacity

Claw Lock components, gears in 84M machines

Mobil Mobilgrease Special Heavy duty EP grease, contains MoS2, high corrosion resistance, high resistance to water washout

Claw Lock components

Caltex Texclad 2 ** Heavy duty grease, contains MoS2 and graphite, is high Claw Lock components, gears in 84M adhesive, highly resistant to water wash out, resists machines flaking at low temperatures

Shell Malleus GL500 ** Premium EP grease, contains MoS2, inhibits corrosion, Claw Lock components, gears in 84M resists drying out and ‘squeeze out’, reduced dirt and machines dust retention.

Note: All of the above greases can be used on the gears within 84M series machines. However the greases marked ** are open gear greases which will resist “fling off”.

RailCorp EngineElectric Points M

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10 Appendix B – Detection Gauge – Westinghouse Detectors 1.06

2.06

150

40 5

4 dia

30

Silver solder

Material: 316 or 304 Stainless Steel

10°

40

Detection Gauge for Westinghouse 84M Machines and HM2 / HM3 / HMX Detectors


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technical note - tn 041: 2016 · pdf filethis is the base model point machine which is...

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