SM 6495
1000 Technology Drive, Pittsburgh, PA 15219
645 Russell Street, Batesburg, SC 29006
MODEL 95
Highway Crossing Gate Mechanism
12-Volt Systems
24-Volt Systems
Highway Crossings
Pedestrian Crossings
Sidewalk Crossings
♦ Installation
♦ Maintenance
Copyright © 2008
Union Switch & Signal Inc.
Downloaded from www.Manualslib.com manuals search engine
December 2008
Rev. 7
Downloaded from www.Manualslib.com manuals search engine
Notices
Proprietary Notice
This document and its contents are the property of Union Switch & Signal Inc. (hereinafter US&S).
This document has been furnished to you on the following conditions: no right or license under any
patents or any other proprietary right in respect of this document or its content is given or waived in
supplying this document. This document or its content are not to be used or treated in any manner
inconsistent with the rights of US&S, or to its detriment, and are not to be copied, reproduced,
disclosed to others, or disposed of except with the prior written consent of US&S.
IMPORTANT NOTICE
This document and its contents are the property of Union Switch & Signal Inc. (hereinafter US&S).
This document has been furnished to you on the following conditions: no right or license under any
patents or any other proprietary right in respect of this document or its content is given or waived in
supplying this document. This document or its content is not to be used or treated in any manner
inconsistent with the rights of US&S, or to its detriment, and are not to be copied, reproduced,
disclosed to others, or transferred without the prior written consent of US&S.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
i
Revision History
Revision History
Rev.
Date
Nature of Revision
Original
September 1996
Original Issue
1
March 1999
2
March 2003
3
September 2003
4
March 2005
Added new cam clamp in the parts list and updated the parts lists and
figures in general. Added Pedestrian Gate Arm Shield information.
Incorporated terminal block changes. Modified the Test Check List (Table
2-4). Miscellaneous format and editorial changes.
Incorporated ECO EM-2035. Incorporated information on the redesigned
Power Down Module into the manual and added a new section on its
installation.
Incorporated ECO EM-2006. Added information on the torque readings for
the counterweight installation to include readings with the new torque
wrench being supplied as part of the Torque Wrench Kit (PN 467000-03).
Miscellaneous format and editorial changes.
Incorporated ECO EM-2177 – Corrected part numbers. Corrected the
motor part number in the parts list. Removed the lists of X-bills from
manual and put the individual parts in the parts lists.
Incorporated ECO EM-2178 – Revised Figures A-4, A-5, A-6, and A-7 to
include the new snub diode. Added specific part numbers to the parts lists.
Items 300, 305, 310, 315 and 320 were added to the parts list for
N46782101 and N46782001.
Incorporated ECO EM-2215A – Removed the stiffener from the parts list
and revised Figures A-4, A-5, A-6, and A-7 to reflect the absence of the
stiffener.
In addition, modified the Warning at the beginning of Section 3 to account
for other mechanisms at a crossing.
Included maintenance switch installation in the manual.
Incorporated ECO EM-2221 – Changed part number X46703701 to
X46703702.
Incorporated ECO EM-2232 - Modified wiring diagrams.
5
July 2005
Incorporated CRS-01341 – Added Safety Consideration in Section 3.1 to
prevent backfeed of other gate mechanisms at a crossing when performing
maintenance on one gate mechanism.
Miscellaneous format and editorial changes.
Incorporated ECO EM-2283 - Added new version of Figure 2- 5.
Corrected identification of Item 320 in Tables 5-2, 5-3, and 5–4.
ii
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Revision History
Rev.
Date
Nature of Revision
6
June 2006
Incorporated ECO EM-1890 – Corrected the description for Part No.
J0523620003 in Tables 5-2, 5-3, and 5-4.
Incorporated ECO EM-2177 – Changed part number J0702051208 for gear
motor to N46703602 in Table 5-2.
Incorporated ECO-EM-2277A – Added new part number PN46716401 and
the description for the relay in Table 5-6.
Incorporated ECO EM-2308 – Changed the part number and name of
N46709102, Toggle Switch Assembly Retrofit to N46790104, Toggle
Switch Assembly Wires in Table 5-10.
Incorporated ECO EM-2352 – Added information on the additional
Pedestrian Mechanism relay. Added new Section 5.8, revised Table 5-9,
and revised Figure 5-14.
Incorporated ECO EM-2356B – Added Warning Label, PN M46717401 to
Table 5-11.
Incorporated ECO EM-2387 – Added parts list for the Snub Components
Upgrade kit to the manual as Table 5-16.
Incorporated ECO EM-2515A – Figure 2-6 was revised to include the latest
revision of Drawing 467173.
Incorporated ECO EM-2564, added new Section 4.3 on “severe weather
shocks” and added part number 46701402 to Tables 5-2, 5-3, and 5-4.
Added new part number N46780202 (24-Volt Vital Mechanism).
Replaced Section 3.2.10 with new procedure requiring disassembly of the
gear motor to eliminate grounds in the motor rather than just blowing the
motor out through the brush access ports.
7
December 2008
Incorporated ECO EM-3028 – Added part number N156683 to Table 5-5,
Item Number 40.
Incorporated ECO EM-2712 – Revised Tables 5-5 and 5-7. Revised
Figures 5-10 and 5-12. Electrical assemblies changed.
Incorporated ECO EM-2709 – Revised Tables 5-6, 5-8, and 5-9. Revised
Figures 5-11, 5-13, and 5-14. Gate mechanism non-vital relay cover
eliminated.
Incorporated ECO EM-2660 – Revised Table 5-17. Conversion bracket
assembly part number changed.
Incorporated ECO EM-2647 – Revised Tables 5-7 and 5-8. Resistor part
number changed.
Incorporated ECO EM-2684 – Revised Table 5-10 and Figure 5-16.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
iii
Revision History
iv
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Table of Contents
Table of Contents
1.
2.
3.
INTRODUCTION................................................................................................................................1-1
1.1. Description and General Operation ..........................................................................................1-1
1.2. Reference Documents ..............................................................................................................1-3
1.3. Parts List Ordering References.................................................................................................1-3
1.4. Major Installation Parts .............................................................................................................1-4
INSTALLATION .................................................................................................................................2-1
2.1. Introduction ...............................................................................................................................2-1
2.1.1. Required Tools..............................................................................................................2-1
2.1.2. Foundations ..................................................................................................................2-1
2.2. Mast Mounting ..........................................................................................................................2-1
2.2.1. Mast Mounting for Sidewalk Gate Mechanisms............................................................2-2
2.2.2. Pedestrian Gate Shield Installation...............................................................................2-4
2.3. Power and Control Wiring .........................................................................................................2-5
2.3.1. Power Supply Filtering and Regulation Test for Non-Battery Operation for
12 and 24 VDC Systems...............................................................................................2-6
2.3.2. Wiring Diagram for 12-Volt Systems.............................................................................2-7
2.3.3. Wiring Diagram for 24-Volt Systems.............................................................................2-7
2.3.4. Wiring Diagram for 3-Wire Control 12-Volt Systems ....................................................2-7
2.3.5. Wiring Diagram for Pedestrian Mechanism 12-Volt Systems.......................................2-8
2.4. Spring Buffer Adjustment ........................................................................................................2-15
2.4.1. Horizontal (Down) Buffer Adjustment ........................................................................ 2-15
2.4.2. Vertical (Up) Buffer Adjustment ................................................................................. 2-15
2.5. Torque Testing and Adjustments............................................................................................2-15
2.5.1. Torque Testing (Not required for Sidewalk Gate Mechanisms)................................. 2-15
2.5.2. Horizontal Adjustment................................................................................................ 2-16
2.5.3. Vertical Adjustment .................................................................................................... 2-17
2.6. Cam Adjustment .....................................................................................................................2-17
2.7. Gate Arm Ascent and Descent Time Test (12-Volt Systems) ................................................2-18
2.7.1. Gate Arm Ascent and Descent Time Test (24-Volt Systems) ................................... 2-19
2.7.2. Circuit Breaker ........................................................................................................... 2-19
2.8. Test Checklist..........................................................................................................................2-20
GENERAL MAINTENANCE AND TROUBLESHOOTING ...............................................................3-1
3.1. Safety Considerations at Multiple Gate Locations ....................................................................3-1
3.2. General Maintenance................................................................................................................3-2
3.2.1. Periodic Maintenance ...................................................................................................3-2
3.2.2. Control Relays...............................................................................................................3-2
3.2.3. Contact Adjustments.....................................................................................................3-2
3.2.4. Electrical Assembly.......................................................................................................3-3
3.2.5. Hold Clear Device (Brake) Removal/Replacement and Testing Procedure.................3-4
3.2.6. Gearmotor .....................................................................................................................3-7
3.2.7. Idler Gear Assembly .....................................................................................................3-8
3.2.8. Main Shaft and Segment Gear .....................................................................................3-8
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
v
Table of Contents
4.
5.
6.
7.
3.2.9. Power Down of the Gate Arm .......................................................................................3-9
3.2.10. Eliminating Brush Dust Related System Grounds in the Gearmotor ......................... 3-11
3.2.11. Installing the Power Down Module Upgrade Kit ........................................................ 3-12
3.3. Troubleshooting (General) ......................................................................................................3-15
3.3.1. Testing and Troubleshooting the Power Down Module for 12-Volt Systems ............ 3-15
3.3.2. Testing and Troubleshooting the Power Down Module for 24-Volt Systems ............ 3-16
3.3.3. Verification of Maintenance Switch Operation ........................................................... 3-16
OPTIONAL EQUIPMENT ..................................................................................................................4-1
4.1. Heater (Defroster) .....................................................................................................................4-1
4.1.1. Installation Instructions for Model 95 Gate Mechanism Heater Kit...............................4-1
4.2. Maintenance Switch..................................................................................................................4-1
4.3. Severe Weather Shock Option .................................................................................................4-1
PARTS LISTS AND EQUIPMENT DIAGRAMS................................................................................5-1
5.1. Model 95 Gate Mechanism – Mechanical Assembly Parts List
(12- and 24-Volt Systems)........................................................................................................5-2
5.2. Model 95 Pedestrian Gate Mechanism - Mechanical Assembly Parts List ..............................5-6
5.3. Model 95 Sidewalk Gate Mechanism - Mechanical Assembly Parts List ...............................5-12
5.4. Model 95 Gate Mechanism Electrical Assembly with PN-150 Relay
(12-Volt Systems) (N46782101).............................................................................................5-17
5.5. Non-Vital Relay Electrical Assembly for 12-Volt Systems (N46782001) ................................5-20
5.6. PN-150 Electrical Assembly for 24-Volt Systems (N46782102).............................................5-23
5.7. Non-Vital Relay Electrical Assembly for 24-volt Systems (N46782002).................................5-26
5.8. Non-Vital Pedestrian Mechanism Relays Electrical Assembly for
12-Volt Systems (N46782201, N46782202) ..........................................................................5-29
5.9. Model 95 Maintenance Switch ................................................................................................5-31
5.10. Tool Kit (N46707001).............................................................................................................5-33
5.11. Recommended Model 95 Non-Vital Gate Mech Spare Parts Kit (X46700016)......................5-34
5.11.1. Recommended Spare Parts Not Contained in the Spare Parts Kit ........................... 5-34
5.12. Model 95 Gate Mech Torque Wrench Kit (X46700003) .........................................................5-34
5.13. Power Down Module Upgrade Kit (X46700031).....................................................................5-35
5.14. Snub Component Upgrade Kit ................................................................................................5-35
5.15. Accessories for the Model 95 Gate Mechanism .....................................................................5-35
5.16. Gate Arm Light Fuse Retrofit Kit .............................................................................................5-37
GATE ARM CLEARING GRAPHS....................................................................................................6-1
TECHNICAL SUPPORT ....................................................................................................................7-1
vi
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Table of Contents
List of Figures
Figure 1-1 - Model 95 Gate Mechanism Basic Configurations ................................................................1-2
Figure 1-2 - Original and Redesigned Power Down Modules..................................................................1-4
Figure 1-3 - Model 95 Gate Mechanism Major Installation Parts.............................................................1-5
Figure 2-1 - Completed Pedestrian Crossing Gate Arm Shield Installation.............................................2-5
Figure 2-2 - Wiring Diagram for 12-Volt Systems – with Maintenance Switch ........................................2-9
Figure 2-3 - Wiring Diagram for 12-Volt Systems – without Maintenance Switch .................................2-10
Figure 2-4 - Wiring Diagram for 24-Volt Systems ..................................................................................2-11
Figure 2-5 - Wiring Diagram for 3-Wire Control 12-Volt Systems ..........................................................2-12
Figure 2-6 - Wiring Diagram for Pedestrian Mechanism 12-Volt Systems with
Maintenance Switch ..........................................................................................................2-13
Figure 2-7 - Wiring Diagram for Pedestrian Mechanism 12-Volt Systems without
Maintenance Switch ..........................................................................................................2-14
Figure 2-8 - Torque Increase/Decrease Diagram ..................................................................................2-16
Figure 2-9 - Number 1 Contact...............................................................................................................2-18
Figure 3-1 - Hold Clear Device.................................................................................................................3-5
Figure 3-2 - Installation Close-up ...........................................................................................................3-10
Figure 3-3 - Location of the Power Down Module (Units Manufactured
Before September 1, 2003) ...............................................................................................3-13
Figure 3-4 - Proper Hardware Configuration on Terminal Posts 1C, 2C, and 3C..................................3-14
Figure 3-5 - Location of Redesigned Power Down Module on Terminal Posts 1C, 2C, and 3C ..........3-14
Figure 5-1 - Model 95 Gate Mechanism – Mechanical Assembly (Sheet 1 of 2)....................................5-4
Figure 5-2 - Model 95 Gate Mechanism – Mechanical Assembly (Sheet 2 of 2)....................................5-5
Figure 5-3 - Model 95 Pedestrian Gate Mechanism – Mechanical Assembly (Sheet 1 of 4) .................5-8
Figure 5-4 - Model 95 Pedestrian Gate Mechanism – Mechanical Assembly (Sheet 2 of 4) .................5-9
Figure 5-5 - Model 95 Pedestrian Gate Mechanism – Mechanical Assembly (Sheet 3 of 4) ................5-10
Figure 5-6 - Model 95 Pedestrian Gate Mechanism – Mechanical Assembly (Sheet 4 of 4) ...............5-11
Figure 5-7 - Model 95 Sidewalk Gate Mechanism – Mechanical Assembly (Sheet 1 of 3)
(RH Shown – LH Available)...............................................................................................5-14
Figure 5-8 - Model 95 Sidewalk Gate Mechanism – Mechanical Assembly (Sheet 2 of 3)
(RH Shown – LH Available)...............................................................................................5-15
Figure 5-9 - Model 95 Sidewalk Gate Mechanism – Mechanical Assembly (Sheet 3 of 3)
(RH Shown – LH Available)...............................................................................................5-16
Figure 5-10 - Model 95 Gate Mechanism Electrical Assembly with PN-150 Relay
(12-Volt Systems) ..............................................................................................................5-19
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
vii
Table of Contents
Figure 5-11 - Model 95 Gate Mechanism Electrical Assembly with Non-Vital Relay
(12-Volt Systems) ..............................................................................................................5-22
Figure 5-12 - Model 95 Gate Mechanism Electrical Assembly with PN-150 Relay
(24-Volt Systems) ..............................................................................................................5-25
Figure 5-13 - Model 95 Gate Mechanism Electrical Assembly with Non-Vital Relay
(24-Volt Systems) ..............................................................................................................5-28
Figure 5-14 - Non-Vital Pedestrian Mechanism Relay, Electrical Assembly ..........................................5-30
Figure 5-15 - Maintenance Switch Retrofit Assembly (N46709202) ......................................................5-31
Figure 5-16 - Maintenance Switch Installation .......................................................................................5-32
Figure 5-17 - Tool Kit (N46707001) .......................................................................................................5-33
Figure 5-18 - Gate Arm Light Fuse Retrofit Kit.......................................................................................5-38
Figure 6-1 - Ten-Second Gate Arm Clearing Graph ................................................................................6-1
Figure 6-2 - Fifteen-Second Gate Arm Clearing Graph ...........................................................................6-2
Figure 6-3 - Twenty-Second Gate Arm Clearing Graph...........................................................................6-3
viii
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Table of Contents
List of Tables
Table 2-1 - Model 95 Gate Mechanism Counterweight Table .................................................................2-3
Table 2-2 - Battery and Wire Requirements.............................................................................................2-5
Table 2-3 - Cam Adjustment ..................................................................................................................2-17
Table 2-4 - Test Checklist ......................................................................................................................2-20
Table 3-1 - Troubleshooting Table for Model 95 Gate Mechanism .......................................................3-15
Table 4-1 - Model 95 Heater Kit Ordering Information.............................................................................4-1
Table 5-1 - Model 95 Gate Mechanism Configurations ...........................................................................5-1
Table 5-2 - Model 95 Gate Mechanism – Mechanical Assembly Parts List for 12- and
24-Volt Systems ..................................................................................................................5-2
Table 5-3 - Model 95 Pedestrian Gate Mechanism - Mechanical Assembly Parts List ...........................5-6
Table 5-4 - Model 95 Sidewalk Gate Mechanism - Mechanical Assembly Parts List ............................5-12
Table 5-5 - Parts List for the 12-Volt Electrical Assembly with PN-150 Relay.......................................5-17
Table 5-6 - Parts List for the 12-Volt Electrical Assembly with Non-Vital Relay ....................................5-20
Table 5-7 - Parts List for the 24-Volt Electrical Assembly with the PN-150 Relay.................................5-23
Table 5-8 - Parts List for the 24-Volt Electrical Assembly with non-Vital Relay.....................................5-26
Table 5-9 - Parts List for the 12-Volt Electrical Assembly for Non-Vital Pedestrian Mechanisms .........5-29
Table 5-10 - Model 95 Maintenance Switch Retrofit Assembly (Refer to Figure 5-15
and Figure 5-16) ................................................................................................................5-31
Table 5-11 - Parts List for Tool Kit (N46707001) ...................................................................................5-33
Table 5-12 - Parts List for Spare Parts Kit (N46700016) .......................................................................5-34
Table 5-13 - Other Recommended Spare Parts ....................................................................................5-34
Table 5-14 - Torque Wrench Kit (X46700003) .......................................................................................5-34
Table 5-15 - Power Down Module Kit (X46700031) ..............................................................................5-35
Table 5-16 - Snub Component Upgrade Kit (X46700038).....................................................................5-35
Table 5-17 - Accessories for the Model 95 Gate Mechanism ................................................................5-35
Table 5-18 - Parts List for the Gate Arm Light Fuse Retrofit Kit (X46700039) ......................................5-36
Table 5-19 - Parts List for the Fuse Holder Assembly (N46719101) (Figure 5-18) ...............................5-37
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
ix
Table of Contents
x
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Introduction
1.
INTRODUCTION
1.1. Description and General Operation
The Model 95 Gate Mechanism represents a leap into the use of modern techniques and materials.
Its modular design yields an uncluttered mechanism with fewer parts to stock and a simpler unit to
service and maintain.
Each unit can be removed and replaced with minimal effort.
Each piece of the subassembly is designed to be replaced in the field should the need arise.
The unit can be mounted on 4-inch or 5-inch diameter masts with standard hardware.
The hold clear device, located on the gearmotor, uses 150 to 160 milliamps on 12 VDC systems and
185 milliamps on 24 VDC systems. The brake disengages and allows the arm to lower when a train
approaches the gate mechanism.
The motor is controlled through the Motor Control Relay (MCR) contacts. The MCR is de-energized
when the gate is clear, therefore none of the circuit controller contacts carry motor current.
The electrical assembly is plate-mounted so that all of the electrical components can be easily removed
and replaced.
The unique snap-action motor contact extends contact life, while helping to operate the mechanism
more smoothly.
There are three basic versions of the Model 95 Gate Mechanism: the Pedestrian Gate, the Highway
Crossing Gate, and the Sidewalk Gate (Figure 1-1). The Model 95 Pedestrian Gate Mechanism
includes crossing gates for both highway crossings and sidewalk crossings on the same mast. The
Model 95 Highway Gate Mechanism includes only the highway crossing gate, and the Model 95
Sidewalk Gate Mechanism includes only the sidewalk crossing gate.
All gate mechanisms are inspected prior to shipment to ensure that all parts and modules are present,
undamaged, and appropriately packaged. If any equipment is missing or damaged, contact the Union
Switch and Signal Service Shop for replacement items at:
Union Switch and Signal
645 Russell Street
Batesburg, SC 29006
Attn: Customer Service
1-800-652-7276
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
1-1
Introduction
SIDEWALK GATE
HIGHWAY CROSSING GATE
NOTE:
PEDESTRIAN GATE
THE GATE MECHANISMS ARE SHOWN
WITH VARIOUS OPTIONAL EQUIPMENT
INSTALLED. THE FINAL CONFIGURATION
OF EACH BASIC GATE DEPENDS ON THE
CUSTOMER’S SPECIFIC REQUIREMENTS.
Figure 1-1 - Model 95 Gate Mechanism Basic Configurations
1-2
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Introduction
1.2. Reference Documents
The following manuals are part of the family of gate mechanism manuals.
SM 6495 - Model 95 Highway Gate Crossing Mechanism
SM 6495A - Model 95 Gate Mechanism Pedestrian Arm Upgrade Option
SM 6495B - Model 95 Highway Crossing Exit Gate Mechanism for Quad Gate Application
SM 6495C - Model 95 Maintenance Switch Retrofit Kit Installation\Operation
SM 6495D - Model 95 Power-Down Module Installation Kit
SM 6495E - Model 95 Gate Arm Light Fuse Retrofit Kit – Installation Instructions
1.3. Parts List Ordering References
This section presents the Assembly Part Order Number along with a breakdown of the specific item
part numbers that constitute that Order Number.
In addition to the order numbers listed below special tools and kits are available as follows:
Tool Kit – P\N N46707001 – Included with all new Model 95 Gate Mechanisms – See Section 5.10 for
the components in this kit.
Spare Parts Kit, Non-Vital – P\N X46700016 – See Section 5.11 for a list of the components in this kit.
Torque Wrench Kit – P\N X46700003 – See Section 5.12 for a list of the components in this kit.
Power Down Module Upgrade Kit – P\N X46700031 – See Section 0 for a list of the components in
this kit.
Maintenance Switch Retrofit Assembly – P\N N46709202 – See Section 5.9 for a list of the
components in this kit.
Gate Arm Light Fuse Retrofit Kit – P\N X46700039 – See Section 5.16 for a list of the components in
this kit.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
1-3
Introduction
NOTE
Highway crossing gate mechanisms manufactured on September 1,
2003 and later are equipped with a redesigned power down module
(Figure 1-2). Gate mechanisms manufactured before this date that need
a replacement power down module will require the new Power Down
Module Upgrade Kit, X46700031. The old and new modules are
functionally identical; power down modules that are operating properly
do not need to be replaced.
Original Design
Redesigned Module
Figure 1-2 - Original and Redesigned Power Down Modules
1.4. Major Installation Parts
The major installation parts are P\N shown in Figure 1-3.
1-4
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Introduction
Figure 1-3 - Model 95 Gate Mechanism Major Installation Parts
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
1-5
Introduction
1-6
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
General Maintenance and Troubleshooting
2.
INSTALLATION
WARNING
To avoid possible injury to personnel or local traffic, ensure that
Railroad Standard Operating Procedures are followed during installation
of the gate mechanism and the gate arm.
2.1. Introduction
When installing the Model 95 Gate Mechanism, follow your railroad’s standard operating procedures.
2.1.1. Required Tools
The Model 95 Gate Mechanism is designed to be installed with standard tools. All gate mechanisms
are shipped with a tool kit (N46707001). This kit includes Allen wrenches for buffer and cam
adjustments, other various wrenches, and a hold down pin.
A torque wrench, or a spring scale, or both will be needed to set the counterweights. Union Switch &
Signal offers an optional torque wrench kit (X46700003) that includes a torque wrench and a socket.
2.1.2. Foundations
Standard pre-cast or poured concrete may be used as a foundation for the Model 95 Gate Mechanism.
Examples are given in the AAR Manual, Part 14. Bolt spacing is a standard four-bolt pattern spaced
11-11/16” on center for 5” junction box.
2.2. Mast Mounting
See Section 2.2.1 for Mounting Sidewalk Gate Mechanisms.
To mount the mast, follow the steps below.
1. Erect mast with junction box.
2. Mount pivot clamp (X46705402). Position top of clamp 42-3/4” above top of the foundation. (The
exact height may need to be adjusted slightly in order to meet the required height of the gate arm
above the roadway.)
3. Install T-bolts (X46705401), included with mechanism) in back of gate mechanism with threaded
portion toward the mast. Place the gate mechanism on top of support clamp. Fasten to mast with
clamps and supplied hardware.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
2-1
General Maintenance and Troubleshooting
4. Thread 1-1/2” flexible conduit and 90° elbow coupling (X46700002) to gate mechanism and
junction box.
5. Install cable grip conduit for gate arm lights cable, included with gate mechanism.
6. Apply a light coating of grease to the main shaft ends. Install gate arm supports (hubs premounted) to keyed main output shaft (Taping the keys to the shaft may assist with installation of
the gate arm supports). Place washers and nut on the end of shaft and tighten.
7. Install conversion bracket assembly (J7051915806) to gate arm supports.
8. Install gate arm (rotate gate mechanism so that gate arm will extend parallel to roadway, so traffic
is not blocked during installation).
9. Install counterweights as follows:
a. Install stud plate assemblies (X46700001) on support arms.
b. Slide on the proper number and type of counterweights. Refer to the Counterweight Table
(Table 2-1).
c. Secure with the proper hardware.
The number of counterweights required depends on the type and length of the gate arm. The fiberglass
and aluminum arms are equal in weight, so they require the same counterweight arrangements. If
extension arms are not used for longer arms, additional weights must be used to compensate and obtain
a proper torque value.
10. Rotate the mechanism on the mast so the gate arm is positioned over the roadway before raising the
arm when the highway is clear.
2.2.1. Mast Mounting for Sidewalk Gate Mechanisms
1. Erect mast with junction box.
2. Position mechanism approximately 42-3/4” above top of the foundation. (The exact height may
need to be adjusted slightly in order to meet the required height of the gate arm above the
sidewalk.)
3. Install T-bolts (X46705401), included with mechanism) in back of gate mechanism with threaded
portion toward the mast. Sit gate mechanism on top of support clamp. Fasten to mast with clamps
and supplied hardware.
4. Thread 1-1/2” flexible conduit and 90° elbow coupling (X46700002) to gate mechanism and
junction box.
2-2
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
90-130
90-130
90-130
90-130
90-130
90-130
90-130
90-130
16-18
19-21
22-23
24-26
27-29
30-32
33-36
37-40
17 – 24
17 – 24
17 – 24
17 – 24
17 – 24
17 – 24
17 – 24
17 – 24
17 - 24
(in-oz)
1.1 - 1.5
1.1 - 1.5
1.1 - 1.5
1.1 - 1.5
1.1 - 1.5
1.1 - 1.5
1.1 - 1.5
1.1 - 1.5
1.1 - 1.5
(in-lbs)
At Motor Shaft
398
382
395
381
370
347
339
254
228
At Main
Shaft (ftlbs)
4.5
4.4
4.6
4.4
4.3
4
3.9
3
2.7
(in-lbs)
8
8
8
8
8
7
7
6
5
Distance
“X”(ft)
49
48
49
47
46
50
48
42
45
Scale
Reading
(lbs)
Clear Position Scale
Reading
Bold columns indicate inch-ounce or inch-pound torque wrench (X46700003) settings
72
71
74
71
69
64
63
47
42
(in-oz)
At Motor Shaft
Clear Position Torque
* With Extension Arms (Part Number N451484-2403
90-130
12-15
(ft-lbs)
At
Main Shaft
Gate Arm Horizontal Position Torque
Length
12*
11*
16
14
13
11
10
6
4
Quantity
X46740159
X46740158
X46740157
X46740156
X46740155
X46740154
X46740153
X46740152
X46740151
Kit Number
Square Weights
10
7
6
5
3
Quantity
X46740169
X46740167
X46740166
X46740165
X16740163
Kit Number
Oblong Weights
Counterweight Information
Table 2-1 - Model 95 Gate Mechanism Counterweight Table
General Maintenance and Troubleshooting
2-3
General Maintenance and Troubleshooting
5. Install cable grip conduit for gate arm lights cable, included with gate mechanism.
6. Install pedestrian gate arm adapter (P/N M46705801) on shaft, insert key into key way, and tighten
set screw in adapter.
7. Install 3’ aluminum sleeve, weight, and gate arm.
2.2.2. Pedestrian Gate Shield Installation
NOTE
Highway Crossing Gate Mechanisms manufactured after April 1, 2003,
are supplied with the pedestrian gate shield. For models manufactured
before this date, a shield kit (Part Number X46712202) can be ordered
from US&S to add to existing pedestrian gate mechanisms. The kit
includes the shield and necessary mounting hardware.
1. Lower the pedestrian gate arm to its horizontal position.
2. Disconnect electrical power from the gate mechanism and comply with all railroad/transit authority
procedures for maintenance lock out/tag out safety instructions. (See Section 3 for additional
details.)
3. Remove the four screws, washers, and nuts securing the pedestrian gate arm to the cast aluminum
adapter arm.
4. Position the shield on the side of the pedestrian gate arm opposite the gate mechanism. Insert four
(4) 3/8 x 3” screws (P/N J5073490148) and four lock washers (P/N J4751210113) provided with
the shield through the gate arm/adapter arm holes with the screw head towards the counterweight
arm. Install the flat washers (P/N J4751200114) and nuts (P/N J480218) on the screws.
5. Align the bottom of the shield with the bottom of the pedestrian gate arm and finger tighten the
fasteners.
6. Using the two holes on the far right of the shield as a guide, locate the corresponding holes in the
pedestrian gate arm and punch through the gate arm tape to open the holes.
7. Install two (2) screws, lock washers, flat washers, and nuts through these holes.
8. Tighten all screws.
9. The completed installation will be as shown in Figure 2-1. Return the gate mechanism into service.
2-4
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
General Maintenance and Troubleshooting
COUNTERWEIGHTS
GATE ARM
SUPPORT
CONVERSION
BRACKET
ASSEMBLY
PEDESTRIAN
GATE ARM
SHIELD
PEDESTRIAN
CROSSING
GATE ARM
5A1.0011.00
HIGHWAY
CROSSING
GATE ARM
Figure 2-1 - Completed Pedestrian Crossing Gate Arm Shield Installation
2.3. Power and Control Wiring
A maximum of 0.1 ohm resistance is allowed between the battery and the mechanism terminals. The
wiring requirements are given in Table 2-2:
Table 2-2 - Battery and Wire Requirements
Distance from Battery to Mechanism
Cable Conductor Size
Up to 60 feet
60 to 120 feet
120 to 250 feet
No. 9 AWG
No. 6 AWG
No. 4 AWG (or 2 #6 AWG)
Number of Cells (12-Volt System)
Gate Arm Length
Up to 24 feet
25 to 42 feet
Lead
6
7
Gate Arm Length
Up to 24 feet
25 to 42 feet
Lead
12
14
Nickel-Iron
9
11
Nickel-Cadmium
9
11
Number of Cells (24-Volt System)
Nickel-Iron
18
22
Nickel-Cadmium
18
22
For more detailed information, refer to Section 6. These three curves are based on the maximum gate
arm clearing times of 10, 15, and 20 seconds. These times are relative to the minimum voltage for
various cell quantities of lead acid batteries and nickel iron or nickel cadmium batteries. The curves
represent maximum gate arm clearing times relative to minimum battery cell voltages. Fully charged
batteries will decrease the time it takes for the gate arm to clear.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
2-5
General Maintenance and Troubleshooting
CAUTION
12 VDC Systems
The specified operating voltage for the Model 95 is 11 to 16 volts direct
current. This applies to both the motor supply (B12) and the Up Control.
Generally, this power will be supplied from batteries; however, it is
possible to use a power supply without batteries. (This can be done only
if battery backup is not required in the event of a power failure.) If used,
this power supply must be properly filtered and regulated. Otherwise,
equipment damage may occur. To check this, perform the test in Section
2.3.1.
CAUTION
24 VDC Systems
The specified operating voltage for the Model 95 is 21 to 28 volts direct
current. This applies to both the motor supply (B24) and the Up Control.
Generally, this power will be supplied from batteries; however, it is
possible to use a power supply without batteries. (This can be done only
if battery backup is not required in the event of a power failure.) If used,
this power supply must be properly filtered and regulated. Otherwise,
equipment damage may occur. To check this, perform the test in Section
2.3.1.
2.3.1. Power Supply Filtering and Regulation Test for Non-Battery Operation for
12 and 24 VDC Systems
1. Set a voltmeter on the VDC scale.
2. Place the voltmeter negative (black) lead on terminal 6B of the gate mechanism.
3. Place the voltmeter positive (red) lead on terminal 2C of the gate mechanism.
4. The voltage should read no more than 16 VDC on 12-volt systems and 28 VDC on 24-volt
systems.
5. Move the positive (red) lead of the voltmeter to terminal 1C.
6. The voltage should read no more than 16VDC on 12-volt systems and 28 VDC on 24-volt systems.
2-6
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
General Maintenance and Troubleshooting
7. With the crossing operating and the gate arm going up, make certain that the voltage does not fall
below 11VDC on 12-volt systems and 21 VDC on 24-volt systems.
8. Place the voltmeter on the AC scale. The voltmeter must block the DC voltage. For some
voltmeters, such as most analogs, it may be necessary to place a 0.1μF to 1μF capacitor in series
with the meter. An oscilloscope can be used as an alternative.
9. Again, with the crossing operating and the gate arm going up, check that the voltmeter does not
read more than 3 VAC (this is checking the AC).
2.3.2. Wiring Diagram for 12-Volt Systems
Connect the wires to the Terminal Board as shown in Figure 2-2 or Figure 2-3 for 12-volt systems.
NOTE
The wiring diagrams in Figure 2-2 and Figure 2-3, have the spare,
unused terminals on the lower terminal block. Gate mechanisms
produced prior to July 5, 2004, have wiring arrangements that had the
spare/unused terminals on the upper block.
2.3.3. Wiring Diagram for 24-Volt Systems
Connect the wires to the Terminal Board as shown in Figure 2-4 for 24-volt systems.
NOTE
The wiring diagram in Figure 2-4 has the spare, unused terminals on the
lower terminal block. Gate mechanisms produced prior to July 5, 2004,
have wiring arrangements that had the spare/unused terminals on the
upper block.
2.3.4. Wiring Diagram for 3-Wire Control 12-Volt Systems
Connect the wires to the Terminal Board as shown in Figure 2-5 for 3-wire control 12-volt systems
NOTE
The wiring diagram in Figure 2-5 has the spare, unused terminals on the
lower terminal block. Gate mechanisms produced prior to July 5, 2004,
have wiring arrangements that had the spare/unused terminals on the
upper block.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
2-7
General Maintenance and Troubleshooting
2.3.5. Wiring Diagram for Pedestrian Mechanism 12-Volt Systems
Connect the wires to the Terminal Board as shown in Figure 2-6 and Figure 2-7 for 12-volt systems
NOTE
The wiring diagrams in Figure 2-6 and Figure 2-7 have the spare,
unused terminals on the lower terminal block. Gate mechanisms
produced prior to July 5, 2004, have wiring arrangements that had the
spare/unused terminals on the upper block.
2-8
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
(H3)
(H2)
-
C11/
A11 (H4)
B11
C8/
A8
SEE NOTE 4.
MOTOR
HC
(BRAKE)
MCR
C12/
A12
C10/
A10
B12
C9/
A9
C7/
A7
+
(B4)
(F4)
(B3)
(B2)
(F2)
A1
+
C1
-
3C
3B
3A
T4
T3 T2 T1
T5
T6
T7
SNUB
DIODE
BREAKER
BAT CIRCUIT AUX
2C
2B
2A
GATE ARM
LIGHT TERMS
1C
1B
1A
UNION SWITCH & SIGNAL
4C
4B
4A
SNUB
RES
R1
6C
6B
6A
POWER
DOWN
MODULE
5C
R2
5B
5A
R4
LIM
RES
R3
XRP
(SEE NOTE 2)
INDICATION
(SEE NOTE 1)
GATE DOWN
OPTIONAL
HEATER
7
6
5
4
NOTE: T6 AND T7
ONLY APPLY TO
RETROFIT KIT
N46709202
POLARITY
REVERSING
SWITCH
(IS)
12 9
11 8
10
UP
CONTROL
B12
N12
TEST LINK BETWEEN 5B & 6B
OPENS WITH GOLD NUT LOOSEN ED.
}
MODEL 95 GATE MECHANISM
MOMENTARY
SWITCH
2S-1
2S-2
46 - 93 DEG
5 - 93 DEG
0 - 5 DEG
83 - 90 DEG
1 FRONT
2
3
4
5
6
CLOSED
0 - 89 DEG
CONTACT
VACANT SLOT
MOTOR DN
BELL
GATE DN IND
FLASH'G LIGHT
MOTOR UP
FUNCTION
WIRING DIAGRAM FOR STD UNITS WITH MAIN T. SWITCH
LABEL PART NO. M46709001 / US&S DWG. C467090 REV.5
3
2
1
NOTE 4:
RELAY TERMINATIONS AS SHOWN
ARE FOR PN-150HD.
LETTERS IN PARENTHESIS ARE
FOR NON-VITAL RELAY.
NOTE 3:
DASHED WIRES INDICATE USER
WIRING.
NOTE 2:
ADD JUMPER 2C-6C FOR POS.
XRP OR 4B-6C FOR NEG. XRP.
NOTE 1:
ADD JUMPER 2C-5C FOR GATE
DOW N IND.
General Maintenance and Troubleshooting
C467090
Figure 2-2 - Wiring Diagram for 12-Volt Systems – with Maintenance Switch
2-9
2-10
Downloaded from www.Manualslib.com manuals search engine
_
C1
_
(H4)
(H3)
B11
C11/
A11
+
M OTOR
+
C12/
A12
(B4)
C10/
A10
B12
C9/
A9
C7/
A7
(F4)
(B3)
(B2)
(F2)
A1
(BRAKE)
HC
MCR
(H2)
C8/
A8
SEE NOTE 4.
UG0106.0028.00
1C
1B
1A
3C
3B
3A
T4
T2
T1
SPARES
(MAY BE USED
FOR ARM LIGHTS)
T3
T5
T6
T7
BREAKER
4A
SNUB
DIODE
4C
4B
BAT CIRCUIT AUX
2C
2B
2A
R1
SNUB
RES
R2
5C
5B
5A
R4
LIM
RES
R3
POWER
DOWN
MODULE
6C
6B
6A
NOTE 3:
DASHED WIRES INDICATE USER
WIRING.
NOTE 2:
ADD JUMPER 2C-6C FOR POS.
XRP OR 4B-6C FOR NEG. XRP.
NOTE 1:
ADD JUMPER 2C-5C FOR GATE
DOWN IND.
4
5
6
2
3
1 FRONT
FUNCTION
GATE DN IND
FLASHING LIGHT
0 - 5 DEG
83 - 90 DEG
5 - 93 DEG
MOTOR DN
BELL
VACANT SLOT
MOTOR UP
46 - 93 DEG
0 - 89 DEG
CONTACT CLOSED
UNION SWITCH & SIGNAL
645 RUSSELL ST.
BATESBURG, SC. 29006
LABEL PART NO. M46705201 / US&S DWG. B467052 REV. 6
MODEL 95 GATE MECHANISM WIRING DIAGRAM
FOR STD. UNITS WITHOUT MAINT. SWITCH
UP
CONTROL
N12
NOTE 4:
RELAY TERMINATIONS AS SHOWN
TEST LINK BETWEEN 5B & 6B
OPENS WITH GOLD NUT LOOSENED. ARE FOR PN-150HD.
LETTERS IN PARENTHESIS ARE
FOR NON-VITAL RELAY.
B12
XRP
(SEE NOTE 2)
INDICATION
(SEE NOTE 1)
GATE DOWN
OPTIONAL
HEATER
General Maintenance and Troubleshooting
Figure 2-3 - Wiring Diagram for 12-Volt Systems – without Maintenance Switch
SM 6495, Rev. 7, December 2008
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
C1
(-)
_
HC
MOTOR
+
C12/
A12
B12
(B3)
C10/
A10
(F4)
INTERNAL
OVERLOAD
(BRAKE)
C11/
A11
(H4)
(H3)
B11
C9/
A9
(B2)
C7/
A7
(F2)
A1
(+)
(B4)
MCR
C8/
A8
(H2)
SEE NOTE 4.
UG0106.0029.00
3C
3B
3A
4C
4B
4A
T4
T3 T2 T1
T5
T6
T7
BREAKER
BAT CIRCUIT AUX
2C
2B
RESISTOR
2A
9
8
7
6C
R1
LIMIT
DIODE
R4
LIM
RES
R3
B POWER 3
2
A RELAY 1
6B
6A
SNUB
RES
R2
5C
5B
5A
SNUB
DIODE
SPARE TERM'S
(MAY BE USED FOR ARM LIGHTS)
NOT USED
AT THIS TIME
1C
1B
1A
6
5
4
OPTIONAL
HEATER
NOTE 3:
DASHED WIRES INDICATE USER
WIRING.
NOTE 2:
ADD JUMPER 2C-6C FOR POS.
XRP OR 4B-6C FOR NE G. XRP.
NOTE 1:
ADD JUMPER 2C-5C FOR GATE
DOWN IND.
1
2
3
4
5
6
CONTACT
46 - 93 DEG
5 - 93 DEG
0 - 5 DEG
83 - 90 DEG
0 - 89 DEG
CLOSED
MOTOR UP
VACANT SLOT
MOTOR DN
BELL
GATE DN IND
FLASH'G LIGHT
FUNCTION
NOTE 4:
RELAY TERMINATIONS AS SHOWN
ARE FOR PN-150HD.
LETTERS IN PARENTHESIS ARE
FOR NON-VITAL RELAY.
UNION SWITCH & SIGNAL
645 RUSSELL ST.
BATESBURG, SC 29066
UNION SWITCH & SIGNAL
MODEL 95 GATE MECHANISM,
24 VDC WIRING DIAGRAM
LABEL PART NO. M46707101 / B467071 REV. 7
UP
CONTROL
B24
TEST LINK BETWEEN 5B & 6B
OPENS WITH GOLD NUT LOOSENED.
N24
XRP
(SEE NOTE 2)
GATE DOWN
INDICATION
(SEE NOTE 1)
}
General Maintenance and Troubleshooting
Figure 2-4 - Wiring Diagram for 24-Volt Systems
2-11
2-12
Downloaded from www.Manualslib.com manuals search engine
-
(H3)
(H2)
-
MOTOR
(BRAKE)
HC
MCR
C11/
A11 (H4)
B11
C8/
A8
SEE NOTE 3.
.
C1
(B4)
(F4)
(B3)
(B2)
(F2)
A1
+
UG0106.0030.00
C12/
A12
C10/
A10
B12
C9/
A9
C7/
A7
3C
3B
3A
T4
T3 T2 T1
T5
T6
T7
4A
SNUB
DIODE
4C
4B
BAT CIRCUIT AUX
BREAKER
2C
2B
2A
SPARE TERM'S
(MAY BE USED FOR ARM LIGHTS)
1C
1B
1A
R2
R1
SNUB
RES
5C
5B
5A
6C
6B
6A
R4
LIM
RES
R3
N12
XRP
INDICATION
(SEE NOTE 1)
GATE DOWN
OPTIONAL
HEATER
2
3
4
5
6
1 FRONT
CONTACT
FUNCTION
46 - 93 DEG
5 - 93 DEG
0 - 5 DEG
83 - 90 DEG
VACANT SLOT
MOTOR DN
BELL
GATE DN IND
FLASH'G LIGHT
0 - 89 DEG MOTOR UP
CLOSED
NOTE 3:
RELAY TERMINATIONS AS SHOWN
ARE FOR PN-150HD.
LETTERS IN PARENTHESIS ARE
FOR NON-VITAL RELAY.
NOTE 2:
DASHED WIRES INDICATE USER
WIRING.
NOTE 1:
ADD JUMPER 2C-5C FOR GATE
DOWN IND.
UNION SWITCH & SIGNAL
645 RUSSELL ST.
BATESBURG, SC 29066
UNION SWITCH & SIGNAL
MODEL 95 GATE MECHANISM
WIRING DIAGRAM / 3 WIRE CONTROL
LABEL PART NO. M46708001 / B467080 REV. 4
DOWN
CONTROL
UP
CONTROL
TEST LINK BETWEEN 5B & 6B
OPENS WITH GOLD NUT LOOSENED.
}
General Maintenance and Troubleshooting
+
Figure 2-5 - Wiring Diagram for 3-Wire Control 12-Volt Systems
SM 6495, Rev. 7, December 2008
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
(RED)
C1
-
-
C11/
A11 (H3/H4)
MOTOR
(BRAKE)
HC
MCR
(H1/H2)
C8/
A8
SEE NOTE 4.
(BLK)
+
(B4)
C12/
A12
C10/
A10
(F3/F4)
(B2)
C9/
A9
C7/
A7
(F1/F2)
A1
+
(BLU)
BOSCH
(WHT)
T3
3C
3B
3A
4C
4B
4A
T4
T2 T1
T5
T6
T7
SNUB
DIODE
BREAKER
BAT CIRCUIT AUX
2C
2B
2A
GATE ARM
LIGHT TERMS
1C
1B
1A
UNION SWITCH & SIGNAL
SNUB
RES
R1
6C
6B
6A
POWER
DOWN
MODULE
5C
R2
5B
5A
R4
LIM
RES
R3
7
(IS)
9
POLARITY
REVERSING
SWITCH
12
11 8
10
UP
CONTROL
B12
N12
TEST LINK
BETWEEN 5B & 6B
OPENS WITH GOLD
NUT LOOSEN ED.
XRP
(SEE NOTE 2)
INDICATION
(SEE NOTE 1)
GATE DOWN
NOTE: T6 AND T7
ONLY APPLY TO
RETROFIT KIT
N46709202
}
OPTIONAL
HEATER
6
5
4
3
2
1
CLOSED
5 - 93 DEG
0 - 5 DEG
83 - 90 DEG
46 - 93 DEG
0 - 89 DEG
FUNCTION
MOMENTARY
SWITCH
2S-1
2S-2
BELL
GATE DN IND
FLASH'G LIGHT
VACANT SLOT
MOTOR DN
MOTOR UP
WIRING DIAGRAM FOR NON-VITAL PED MECH
UNITS WITH MAINT. SWITCH & HEATER
LABEL PART NO. M46717301 /
US&S DWG. C467173 REV.1
MODEL 95 GATE MECHANISM
NOTE 4:
RELAY TERMINATIONS AS SHOWN
ARE FOR PN-150HD.
LETTERS IN PARENTHESIS ARE
FOR NON-VITAL RELAY.
4
5
6
2
3
1 FRONT
CONTACT
NOTE 3:
DASHED WIRES INDICATE
USER WIRING.
NOTE 2:
ADD JUMPER 2C-6C FOR POS.
XRP OR 4B-6C FOR NEG. XRP.
NOTE 1:
ADD JUMPER 2C-5C
FOR GATE DOWN IND.
General Maintenance and Troubleshooting
C467173 R1
Figure 2-6 - Wiring Diagram for Pedestrian Mechanism 12-Volt Systems with
Maintenance Switch
2-13
2-14
Downloaded from www.Manualslib.com manuals search engine
(RED)
C1
C11/
A11
MOTOR
HC
(BRAKE)
MCR
(H3/H4)
C8/
A8
(H1/H2)
SEE NOTE 4.
(BLK)
(B4)
C12/
A12
C10/
A10
(F3/F4)
3C
3B
3A
T4
T3 T2 T1
T5
T6
T7
4A
SNUB
DIODE
4C
4B
BAT CIRCUIT AUX
BREAKER
2C
2B
2A
R2
5C
R1
6C
6B
6A
R4
LIM
RES
R3
POWER
DOWN
MODULE
SNUB
RES
5B
5A
SPARE TERM'S
(MAY BE USED FOR ARM LIGHTS)
1C
C9/
A9
(B2)
1B
1A
C7/
A7
(F1/F2)
A1
+
(BLU)
BOSCH
(WHT)
OPTIONAL
HEATER
NOTE 1:
ADD JUMPER 2C-5C FOR GATE
DOWN IND.
46 - 93 DEG
5 - 93 DEG
0 - 5 DEG
83 - 90 DEG
0 - 89 DEG
VACANT SLOT
MOTOR DN
BELL
GATE DN IND
FLASH'G LIGHT
MOTOR UP
MODEL 95 GATE MECHANISM WIRING DIAGRAM
FOR STD. UNITS WITHOUT MAINT. SWITCH
LABEL PART NO. M46705201 /
US&S DWG. B467172 REV. 0
2
3
4
5
6
1 FRONT
FUNCTION
NOTE 4:
RELAY TERMINATIONS AS SHOWN
ARE FOR PN-150HD.
LETTERS IN PARENTHESIS ARE
FOR NON-VITAL RELAY.
UP
CONTACT CLOSED
CONTROL
B12
TEST LINK BETWEEN 5B & 6B
OPENS WITH GOLD NUT LOOSENED.
N12
XRP
NOTE 3:
(SEE NOTE 2) DASHED WIRES INDICATE USER
WIRING.
INDICATION
NOTE 2:
(SEE NOTE 1) ADD JUMPER 2C-6C FOR POS.
GATE DOWN XRP OR 4B-6C FOR NE G. XRP.
}
General Maintenance and Troubleshooting
+
467172, R0
Figure 2-7 - Wiring Diagram for Pedestrian Mechanism 12-Volt Systems without
Maintenance Switch
SM 6495, Rev. 7, December 2008
UG0106.0031.00
General Maintenance and Troubleshooting
2.4. Spring Buffer Adjustment
The Model 95 Gate mechanism is equipped with adjustable spring buffers to control the horizontal and
vertical rest positions of the gate.
2.4.1. Horizontal (Down) Buffer Adjustment
10. Remove the aluminum buffer cap located on the top of the mechanism with the Allen wrench
supplied in the Model 95 tool kit (N46707001).
11. Loosen the lock nut of the buffer nearest the mechanism door (furthest from the road) and turn the
threaded sleeve.
CAUTION
If the spring buffer is adjusted down too far, it can hit the segment gear
and cause damage to the buffer.
12. Adjust until arm is properly leveled.
13. Tighten the lock nut and replace gasket and cap.
2.4.2. Vertical (Up) Buffer Adjustment
1. Remove the aluminum buffer cap located on the top of the mechanism.
2. Loosen the lock nut of the buffer furthest away from the mechanism door (nearest the road) and
turn the threaded sleeve.
3. Screw the buffer to just touch the segment gear. Then back off three turns. This will give
approximately a 1/16” to 1/8” gap between the buffer stop and the segment gear.
4. Tighten the lock nut and replace gasket and cap.
2.5. Torque Testing and Adjustments
2.5.1. Torque Testing (Not required for Sidewalk Gate Mechanisms)
For the Gate Mechanism to operate properly, you must test the torque values of the gate arm. The
torque must be calibrated properly to reduce mechanical stress that could reduce the effective lifetime
of the mechanism. Follow the torque values as shown in Table 2-1. Refer to Sections 2.5.2 and 2.5.3
for details on horizontal and vertical position torque testing. Figure 2-8 should be used to decide which
way to move the counterweights for the torque adjustments.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
2-15
General Maintenance and Troubleshooting
Figure 2-8 - Torque Increase/Decrease Diagram
2.5.2. Horizontal Adjustment
2.5.2.1. Horizontal Adjustment Using Spring Scale
Lower arm to the horizontal position. At 10 feet from the mechanism output shaft, a spring scale
should read 9-13 pounds when the gate arm is near the 5° position (a 5° rise of the gate arm is
equivalent to 10.5 inches at 10 feet). To adjust, loosen hardware and slide counterweights in or out.
2.5.2.2. Horizontal Adjustment Using Torque Wrench
Lift the arm or hand turn the brake armature until the arm is near the 5° position. Apply an appropriate
torque wrench (J039000-0115 supplied in optional torque wrench kit X467000-03) to the motor shaft
located in the lower-left corner of the inside housing. The torque should read between 17 to 24 in.-oz
(for the torque wrench with the 0-80 scale) or 1.1 to 1.5 in.-lbs (for the torque wrench with the 0-6
scale). If the proper torque wrench is not available, use the spring scale method above. To adjust,
loosen hardware and slide counterweights in or out.
2-16
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
General Maintenance and Troubleshooting
2.5.3. Vertical Adjustment
2.5.3.1. Vertical Adjustment Using Spring Scales
Raise the gate to the vertical position. Attach the spring scale at the specified distance (x) according to
Table 2-1. This distance is measured from the mechanical output shaft and up the arm to where the
spring scale is to be attached. Once scale is in place, release arm by loosening the gold nut on the
terminal board. To adjust, loosen hardware and slide counterweights back and forth (this would be up
and down if the arm were down).
2.5.3.2. Vertical Adjustment Using Torque Wrench
Apply an appropriate torque wrench (J039000-0115 supplied in optional torque wrench kit X46700003) to the motor shaft located in the lower-left corner of inside housing. Release arm by loosening the
gold nut on the terminal board. To adjust, loosen hardware and slide counterweights back and forth
(this would be up and down if the arm were down). Refer to Table 2-1 for appropriate measurements.
2.6. Cam Adjustment
The cams should be rotated so that the appropriate contacts are closed as indicated in Table 2-3. Use a
3/16” T-handle Allen wrench provided with the gate mechanism to loosen one of the two cam screws
to be adjusted.
Table 2-3 - Cam Adjustment
Contact No.
1
2
3**
4
5
6
*
Closed (Degrees)*
Function
0-89
Not used for contact set.
46-93
5-93
0-5
83-90
Motor Control Relay
Motor Down
Bell
Gate Down Indicator
Flashing light
Ninety degrees-gate in vertical position.
** When adjusting cams for the Sidewalk Gate Mechanism, it may be necessary to adjust the #3 cam in order
to properly drive the gate arm down.
In a typical installation, the No. 1 cam will have to be rotated to determine precisely where the arm
rests in the vertical position. Ensure that the side-to side cam adjustment is centered with the contact
assembly so that the contact assembly side walls do not touch the cams. Refer to Figure 2-9.
After the cams are properly positioned, begin tightening the clamping screws until each cam begins to
fit securely to the shaft. Turn the screw approximately 1-1/2 more turns to obtain torque. The Heel
Spring force on the cams is 1-1/2 to 4 pounds on No. 1 spring, and 1/2 to 3 pounds on springs 3-6. Do
not allow gaps between each cam half.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
2-17
General Maintenance and Troubleshooting
Figure 2-9 - Number 1 Contact
2.7. Gate Arm Ascent and Descent Time Test (12-Volt Systems)
This unit is equipped with a Power Down Module (PDM). The PDM is used in the power down
portion of operation (90° - 45°).
1. Apply 12 VDC to the control line of the gate mechanism. This will raise the arm automatically to
the clear position.
2. Measure the ascent time required to raise the arm from 0 to 90 degrees (horizontal to vertical
position). The ascent time is normally between 8 to 12 seconds.
3. With the arm in the vertical position, check that the gap between the buffer and segment gear is
about 1/8”.
4. Verify that the brake holds the arm in the up position.
5. Remove the control voltage (set DC voltage to 0). Removing the voltage will force the brake to
disengage and allow the arm to descend.
6. Measure the descent-time. The descent time should be adjusted to railroad specification, (generally
9 to 20 seconds). If necessary, adjust the snub resistor slide (refer to Figure 5-10 and Figure 5-11,
Item 40) and retest the descent time. The fixed limit resistor (refer to Figure 5-10 and Figure 5-11,
Item 42) on the right side of electrical assembly limits the current to the motor during the first 45°
of the power down cycle.
2-18
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
General Maintenance and Troubleshooting
2.7.1. Gate Arm Ascent and Descent Time Test (24-Volt Systems)
This unit is equipped with a Power Down Relay. The Power Down Relay is used in the power down
portion of operation (90° - 45°).
1. Apply 24 VDC to the control line of the gate mechanism. This will raise the arm automatically to
the clear position.
2. Measure the ascent time required to raise the arm from 0 to 90 degrees (horizontal to vertical
position). The ascent time is normally between 8 to 12 seconds.
3. With the arm in the vertical position, check that the gap between the buffer and segment gear is
about 1/8”.
4. Verify that the brake holds the arm in the up position.
5. Remove the control voltage (set 0 VDC). Removing the voltage will force the brake to disengage
and allow the arm to descend.
6. Measure the descent-time. The descent time should be adjusted to railroad specification, (generally
9 to 20 seconds). If necessary, adjust the snub resistor slide (refer to Figure 5-12 and Figure 5-13,
Item 40) and retest the descent time. The fixed limit resistor (refer to Figure 5-12 and Figure 5-13,
Item 42) on the right side of electrical assembly limits the current to the motor during the first 45°
of the power down cycle.
2.7.2. Circuit Breaker
The Model 95 is equipped with a self-restoring circuit breaker for the protection of the mechanism,
batteries, etc., in the case of excessive current draw during ascent of the gate arm due to an obstruction.
The circuit breaker is mounted on the electrical assembly, Figure 5-10, Item 35.
The circuit breaker is rated at 20 amps on a 12VDC system and 10 amps on a 24VDC system. The
circuit breaker is designed to carry 100% of the rating for approximately one-hour. At 125% of rated
current, the unit opens within an hour, and at 200% of rated current, the unit opens within a minute.
The circuit breaker on the pedestrian gate mechanisms is rated at 10 amps on a 12-volt system (see
Figure 5-14).
The unit normally resets itself within a minute, and in most field applications, the unit opens within a
few minutes.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
2-19
General Maintenance and Troubleshooting
2.8. Test Checklist
Table 2-4 lists 10 items that should be tested and recorded after installation.
Table 2-4 - Test Checklist
Item
Result
Torque Set Correctly
Ascent Time @ 12 or 24VDC Nom. (System Voltage)
(Maximum: 15 seconds)
*Ascent Current @ 12VDC Nom. (System Voltage)
(Maximum: 15 Amps)
*Ascent Current @ 24VDC Nom. (System Voltage)
(Maximum: 8 Amps)
Descent Time @ 12 or 24VDC Nom. (System Voltage)
(Maximum 12 seconds)
Cams Adjusted
#1 cam centered on roller cage. (Figure 2-9)
Contacts Adjusted (Section 3.2.3)
Down (Front) Buffer
Up (Rear) Buffer With 1/8” Gap
Hold Clear Device (Brake) Operational (Section 3.2.5.3)
*Connect ammeter between 4B and 6B. Open gold nut on 5B to measure ascent current.
2-20
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
General Maintenance and Troubleshooting
3.
GENERAL MAINTENANCE AND TROUBLESHOOTING
WARNING
To avoid bodily injury when performing any maintenance on the Model
95 Gate Mechanism, the following steps MUST be taken:
Position the gate arm of the Mechanism being serviced in the desired position (See
Section 3.2.9),
Electrically disconnect the Mechanism being serviced by loosening the gold nut on
Terminal 5B, and
Remove and insulate the B12 (or B24) supply wire from Terminal 2C.
3.1. Safety Considerations at Multiple Gate Locations
When performing maintenance on a Model 95 Gate Mechanism with the gold nut (5B) open (Figure
3-2) and pinning the gate in the UP position, it is possible to back-feed an adjacent Model 95
Mechanism with enough energy to prevent its Hold Clear (brake) coil from de-energizing when the
crossing is activated. As a consequence, the gate arm of the adjacent mechanism may not descend
when required. This is only possible if multiple Gate Mechanisms at a given location share a common
UP Control input. This is not a problem if each mechanism has its UP Control input derived via
separate contacts of the Crossing Control Relay (XR or XPR).
Therefore, the best practice is to provide the UP Control input to each mechanism at a multiple-gate
location through a separate contact of the Crossing Control Relay (XR or XPR). If a solid-state
controller provides the Crossing Control output, this output should drive the XR, instead of using it to
control multiple mechanisms through diode-OR’d circuits.
If the above recommended best practice is not feasible for whatever reason, one of the following
actions, in addition to opening the gold nut (5B), shall be taken for the gate that is being taken out of
service and locked in the up position:
1. Place insulation between the power down contact 3A-3C (Figure 2-2, Figure 2-3, Figure 2-4, or
Figure 2-5), or
2. Disconnect the Gate Control (GC) wire at terminal 1C.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
3-1
General Maintenance and Troubleshooting
3.2. General Maintenance
3.2.1. Periodic Maintenance
The unit should be checked periodically to see if it is working and within the required guidelines.
While being inspected, the exposed gear teeth and cover hinge pins should be lubricated with white
lithium grease. Units in heavier traffic areas should be inspected and tested more frequently.
Generally, the frequency of maintenance should be determined by the customer, but should not exceed
six months.
If system grounds are detected at the gearmotor, the gearmotor may need to be opened and the dust
removed (Section 3.2.10).
3.2.2. Control Relays
The Model 95 can accommodate both non-vital relays and Vital Plug-In Relay US&S PN-150HD. The
motor control relays should be serviced per the requirements of the particular relay and the
requirements as set forth in AREMA, FRA, and other applicable publications.
3.2.3. Contact Adjustments
Contacts 3 through 6 have a simple contact arrangement; closed when on top of the cam and open
when on the lower portion of the cam. The No. 1 contact has a snap action which controls the motor
control relay when on top of the cam and energizes the relay. The No. 2 position is not used for a
contact set.
CONTACT 1
1. Adjust the contact tip so that it rests flat against the heel contact.
2. The No. 1 contact should have a minimum 0.050” total air gap between the heel contact.
3. The contact pressure should be measured close to the contact tip. The pressure of contact No. 1
should be 1-1/2 to 4 lbs. Heel preloading (heel spring pressure is 1-3 lbs. against the lower portion
of the cam) is necessary for the snap action roller to operate efficiently.
4. Make sure the resistance of each contact does not exceed 0.03 ohms (30 mohms) when closed. If
needed, burnish the contacts with 600 grit sandpaper.
CONTACTS 3 - 6
1. Adjust the contact tip so that it rests flat against the heel contact.
2. Each contact pair is set to a minimum of 0.050” gap when fully open.
3-2
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
General Maintenance and Troubleshooting
3. The contact pressure should be measured close to the contact tip. The pressure of these contacts
should be 1/2 to 3 lbs. Heel preloading is allowed (heel spring pressure is allowed against the
lower portion of the cam and should always remain in contact with the cam).
4. Make sure the resistance of each contact does not exceed 0.03 ohms (30 mohms) when closed. If
needed, burnish the contacts with 600 grit sandpaper.
3.2.4. Electrical Assembly
To remove the electrical assembly (Figure 5-10, Figure 5-11, Figure 5-12, or Figure 5-13), follow
these steps.
WARNING
To avoid bodily injury when performing any maintenance on the Model
95 Gate Mechanism, the following steps MUST be taken:
1. Position the gate arm of the Mechanism being serviced in the
desired position (See Section 3.2.9),
2. Electrically disconnect the Mechanism being serviced by
loosening the gold nut on Terminal 5B, and
3. Remove and insulate the B12 (or B24) supply wire from
Terminal 2C.
Removing power from the gate will cause the gate arm to drop. The
lights will also flash if power has not been removed from them. When
power is restored, the gate arm and lights will return to normal
operation.
1. Ensure external power is off. Remove external power and control wires.
2. Remove (white) brake wires from 1B and 4B on 12-volt systems and 2B and 4B on 24-volt
systems. Remove (red and black) power wires from T4 and T5.
3. Loosen and slide No. 1 cam and No. 6 cam inward for access to two top mounting bolts.
4. Remove the seven 7/16” head bolts and one screw that attach the electrical assembly to the
housing.
The electrical assembly is replaced by reversing the above steps.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
3-3
General Maintenance and Troubleshooting
3.2.5. Hold Clear Device (Brake) Removal/Replacement and Testing Procedure
WARNING
To avoid bodily injury, remove power from gate mechanism before
attempting to remove the hold clear device. The following steps MUST
be taken:
1. Position the gate arm of the Mechanism being serviced in the
desired position (See Section 3.2.9),
2. Electrically disconnect the Mechanism being serviced by
loosening the gold nut on Terminal 5B, and
3. Remove and insulate the B12 (or B24) supply wire from Terminal
2C.
3.2.5.1. Removal of Hold Clear Device
The hold clear device (J0702050438), is mounted on the left end of the gear motor (See Figure 3-1) in
the lower left corner of the gate mechanism. Before removing the hold clear device, secure the gate
arm and remove power from the gate mechanism. To remove the hold clear device, follow these steps.
1. Remove (white) brake wires 1B and 4B on circuit controller on 12-volt systems and 2B and 4B on
24-volt systems.
2. Loosen two (2) Allen head screws on the armature. Slide the armature off output shaft of gear
motor. Keep key in place. Remove spacers (one M46710601 and one M46710602).
3. Remove four (4) Allen head screws securing the hold clear device to the gearmotor.
3.2.5.2. Replacement of the Hold Clear Device
To replace the hold clear device, perform the removal procedure in reverse order. The air gap should
be measured and adjusted (if necessary) according to the following procedure.
3-4
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
General Maintenance and Troubleshooting
HOLD CLEAR DEVICE
UNION SWITCH & SIGNAL
133-500-9255
24 VDC
XXXX
UNION SWITCH & SIGNAL
MODEL
HP
VOLTS
011-500-9355-1/6
12
D.C.GEARMOTOR
REV.
INT. DUTY
AMPS
15.0
RPM
30
55:1
RATIO
290 IN LBS
TORQUE
SUPPLIER SEQ.NO.
MADE IN USA DATE MFG.
5A1.0014.00
MOTOR# 32-999-2500-N09 (BISON ELEC. P/N)
(BISON GEAR P/N)
CUST# 150-203-1509B
AMBIENT TEMP.
° C (MAX
09272 INS# F3 AMB 25
WITH CONT. RUNNING)
Figure 3-1 - Hold Clear Device
1. Loosen the two (2) armature Allen head screws, using the Allen wrench (J0529800014) included in
the Model 95 Tool Kit (N46707001), so that the armature slides freely on the motor shaft (taking
care not to bend the armature springs when sliding).
2. Insert a 0.020” feeler gauge between armature and coil unit (preferably use two gauges and insert
one on each side of the shaft to assure that the armature does not cock sideways).
3. Tighten the two (2) Allen head screws.
4. Ensure the brake is operational.
3.2.5.3. Operational Test of Hold Clear Device (Factory/Shop Test)
WARNING
Remove power from gate mechanism before attempting to remove hold
clear device. Otherwise, bodily injury could result.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
3-5
General Maintenance and Troubleshooting
The hold clear device (J070205-0438) is mounted on the left end of the gear motor (See Figure 3-1) in
the lower left corner of the gate mechanism. Before removing the hold clear device, secure the gate
arm and remove power from the gate mechanism. To remove the hold clear device, follow these steps.
1. Remove the white brake wires from terminals 1B and 4B on the circuit controller on 12-volt
systems and from terminals 2B and 4B on 24-volt systems.
2. Loosen two (2) Allen head screws on the armature. Slide the armature off of the output shaft of the
gear motor. Keep the key in place.
3. Remove four (4) Allen head screws securing the hold clear device to the gearmotor.
To replace the hold clear device, perform the removal procedure in reverse order. The air gap should
be measured and adjusted (if necessary) according to the following procedure.
1. Loosen the two (2) armature Allen head screws, using the Allen wrench (J052980-0014) included
in the Model 95 Tool Kit, so that the armature slides freely on the motor shaft (taking care not to
bend the armature springs when sliding).
2. Insert a 0.020” feeler gauge between the armature and the coil unit (preferably use two gauges and
insert one on each side of the shaft to assure that the armature does not cock sideways).
3. Tighten the two (2) Allen head screws.
4. Ensure the brake is operational.
The electrical test is as follows:
1. Open the gold nut on terminal 5B to lower gate arm.
2. Remove the white wire from terminal 1B on the 12-volt system and 2B on the 24-volt system.
3. Add a positive system voltage to this white wire from terminal 1B for 12-volt systems or from
terminal 2B for 24-volt systems.
4. Add a negative system voltage to terminal 4B.
5. Energize the brake armature with 12 Volts DC.
6. Reduce the voltage until 3 volts is reached. Continue reducing the voltage slowly until the brake
releases. Any partial disengagement of the brake is considered the release voltage (the motor shaft
must turn freely by hand for the brake to be released, the minimum release voltage is 1 VDC).
7. Reduce the voltage to 0 VDC. Open the circuit for 1 second. Gradually increase the voltage until
the armature picks up (armature must be fully engaged). The maximum pick-up voltage is 9 VDC.
8. Reconnect the brake wire to its terminal and tighten the gold nut.
3-6
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
General Maintenance and Troubleshooting
If necessary, the air gap may be adjusted as low as 0.015” and as high as 0.025” to obtain the proper
pick-up and drop-away values.
3.2.6. Gearmotor
The gearmotor (see Figure 5-1, Figure 5-3, or Figure 5-7, Item 40) is a contained unit with a special gel
lubricant sealed in the gearbox. Should the gearmotor become faulty, it is recommended that the entire
unit be replaced. The hold clear device is attached to the gearmotor at the bottom of the gate
mechanism.
1. Disconnect (white) brake wires from contacts labeled 1B and 4B on 12-volt systems and 2B and
4B on 24-volt systems.
WARNING
To avoid bodily injury, remove power from the gate mechanism before
attempting to remove or replace the gearmotor. The following steps
MUST be taken:
1. Position the gate arm of the Mechanism being serviced in the
desired position (See Section 3.2.9),
2. Electrically disconnect the Mechanism being serviced by
loosening the gold nut on Terminal 5B, and
3. Remove and insulate the B12 (or B24) supply wire from
Terminal 2C.
2. Disconnect (red and black) power wires from contacts labeled T4 and T5. (For models with
maintenance switch, contacts are labeled T6 and T7.)
3. Remove screws from the limit resistor. Temporarily move limit resistor to the side to clear
gearmotor when removing.
4. Remove pinion gear on output shaft of gearmotor.
NOTE
Place your hand under the gearmotor to secure it before removing the
last bolt.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
3-7
General Maintenance and Troubleshooting
5. Remove five (5) bolts from (bottom to top) the gear drive on the side of the pinion gear. When
replacing the gearmotor use Loctite 242 (Blue) on the mounting screws, tighten to a torque of 110140 in-lb.
6. Install the gearmotor output shaft gear. Align with the mating idler gear and tighten the gearmotor
set screws to 40-45 in-lb. Assure that set screws are seated in recessed area of motor output shaft.
Use Loctite 242 (Blue) on both set screws.
7. Lubricate pinion gear with a light coat of lubricant.
3.2.7. Idler Gear Assembly
To remove the idler gear assembly (see Figure 5-1, Figure 5-3, or Figure 5-7, Items 50 and 55), follow
these steps.
1. Remove the left-idler shaft-snap ring and the right bearing retaining ring.
2. Drive the shaft from the left side. The small idler gear will force the right bearing out the right
side. Allow the small idler gear to pass through the right side wall.
3. Hold the large idler gear in place while removing the shaft and small idler gear.
4. Remove the key.
To replace the Idler Gear Assembly, perform the removal procedures in reverse order. After replacing
idler gear assembly, ensure the idler gear assembly and the segment gear turn freely. Lubricate gear
teeth with a light grease. Sealed bearings should be replaced when replacing the idler gear assembly.
3.2.8. Main Shaft and Segment Gear
WARNING
To avoid bodily injury, use care when inserting hold down pin
[M46706901 in Model 95 Tool Kit (N46707001)] into gear.
To remove the main shaft (see Figure 5-1, Figure 5-3, or Figure 5-7), follow these steps.
1. Remove circuit controller cams.
2. Remove left snap ring. (Refer to Figure 5-2, Figure 5-4, or Figure 5-8, Item 70.)
3. Remove the segment gear set screw. (Refer to Figure 5-1, Figure 5-3, or Figure 5-7, Item 160.)
4. Drive main shaft from right side forcing left bearing out the left side. Hold segment gear. Ensure
main shaft is allowed to slide freely through segment gear. Keep segment gear key in place.
3-8
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
General Maintenance and Troubleshooting
To replace the main shaft and segment gear, perform the removal procedures in reverse order. Use
Loctite 242 (Blue) on segment gear set screw and torque to 48 ft-lbs. Lubricate gear teeth with a light
grease. Sealed bearings should be replaced when main shaft is replaced.
3.2.9. Power Down of the Gate Arm
There are two procedures to power down the gate arm. If the maintenance switch (Figure 3-2) is
installed, use the procedure in Section 3.2.9.1; if the maintenance switch is not installed use the
procedure in Section 3.2.9.2.
US&S has been installing the maintenance switch as part of the standard gate mechanism. If your gate
mechanism does not have one installed, a Maintenance Switch Upgrade kit is available for installation
from US&S as part number N461092-02.
3.2.9.1. With the Maintenance Switch Installed
If it becomes necessary to replace the gate arm on the mechanism, use the following procedure. Note
that due to long cable lengths from the batteries and/or weak batteries, it may be necessary to remove
some of the counterweights so that the mechanism will drive completely to the gate down position.
1. Loosen the gold nut on terminal 5B (refer to Figure 3-2 for terminal location).
WARNING
Keep fingers and hands clear of gears and electrical connections when
inserting hold down pin (M46706901 in Model 95 Tool Kit) into gear,
otherwise personal injury may result.
2. Toggle the maintenance switch to the MAINTENANCE position. Press and hold the push button
switch to drive the gate mechanism to the down position. Immediately insert the hold down pin
(M46706901 in tool kit N46707001 furnished with each mechanism) into an appropriate opening
in the large idler gear as the gate mechanism approaches the down position. If the hold down pin is
not inserted into the idler gear prior to the segment gear contacting the gear shock assembly, jog
the push button switch to allow insertion of the pin.
CAUTION
Do not hold the Maintenance Switch down longer than 60 seconds if the
hold down pin is not inserted prior to the segment gear contacting the
gear shock assembly; otherwise motor damage may occur.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
3-9
General Maintenance and Troubleshooting
LEAD 2C
TERMINATES
HERE
TERMINAL 5B
TWO LEADS 6B
TERMINATE HERE
MAINTENANCE
SWITCH
Figure 3-2 - Installation Close-up
3. After hold down pin in inserted into idler gear, release the push button switch.
4. Replace the gate arm.
5. Remove the hold down pin. If the pin is locked in place, momentarily press the push button switch
to jog the motor and free the pin.
3-10
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
General Maintenance and Troubleshooting
6. Toggle the maintenance switch to the NORMAL position.
7. Tighten the gold nut on Terminal 5B.
3.2.9.2. Maintenance Switch Not Installed
If it becomes necessary to replace the gate arm on the mechanism, the following procedures may be
used. (For models with maintenance switch, see Section 3.2.9.1).
1. Remove red motor lead from terminal T4.
2. Loosen the gold nut on terminal 5B (refer to Figure 2-2, Figure 2-3, Figure 2-4, and Figure 2-5 for
terminal locations).
3. Temporarily connect a jumper from terminal 6B on the terminal board to red motor lead.
4. Connect another jumper from terminal 2C on the terminal board to T5 of the terminal strip (T5
usually has a black wire connected to it).
5. Allow the support arm to drive down. Immediately insert the provided hold down pin into an
appropriate opening in the large idler gear.
CAUTION
Remove jumpers quickly after pinning the gear. With the jumpers
installed the motor will be in a stalled condition which may potentially
cause damage to the motor.
6. Remove the jumper wires connected to terminal 2C and 6B on the terminal board.
7. Replace the gate arm.
8. Remove hold down pin.
9. Reconnect red motor lead to terminal T4 and tighten gold nut on 5B.
3.2.10.
Eliminating Brush Dust Related System Grounds in the Gearmotor
"Dust and dirt may collect in the gearmotor and create a ground on the system. These grounds can be
removed as follows:
1. Remove the gearmotor from the gate mechanism per Section 3.2.6.
2. Disassemble the gearmotor completely, clean the gearmotor thoroughly per standard motor
cleaning processes, and reassemble the gearmotor.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
3-11
General Maintenance and Troubleshooting
3. Re-install the gearmotor per Section 3.2.6.
As a preventive maintenance measure, it is recommended that this procedure be followed every
200,000 gate mechanism cycles.
3.2.11.
Installing the Power Down Module Upgrade Kit
WARNING
This procedure removes the crossing gate from service. Follow all of the
local and FRA regulations and safety requirements for temporarily
removing a crossing gate from service. (See Section 3 for additional
details.)
NOTE
Wiring diagrams for the 12-volt and 24-volt systems are presented in
Figure 2-2 through Figure 2-5.
1. Remove the gate mechanism from service and render it in a safe condition for maintenance.
2. Remove the spiral wrap and the wire ties from the wiring harness.
3. Remove the field wires from terminals 1C and 2C. Save the attaching hardware for later use.
4. Remove the four wires from the old power down module from terminal 1C, 2C, 3C, and 5B. Do
not reinstall the nuts and washers yet. The old module need not be removed, however, US&S
recommends that it be removed when a new power down module is installed. If the old module is
left in, the module wires should be cut as close to the module as possible and removed. The
location of the old power down module is shown in Figure 3-3.
5. Remove the remaining wires and hardware from terminal C1. Remove the terminal post from the
terminal block by removing the half nut and washer holding the post to the underside of the block.
6. Remove the terminal post from the terminal block and replace it with the longer terminal post from
the Power Down Upgrade Kit. Ensure that the head on the new longer terminal post is firmly
seated in the bottom of the terminal block. Secure the terminal post to the terminal block in the
same manner that the shorter post was secured.
7. Repeat Steps 5 and 6 for terminal post 2C.
8. Place new wire ties on the wire harness and reattach the spiral wrap removed in Step 2.
3-12
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
General Maintenance and Troubleshooting
Figure 3-3 - Location of the Power Down Module
(Units Manufactured Before September 1, 2003)
NOTE
The wire harness must be positioned so that it is below the Power Down
Module after the module is mounted on the terminals.
9. Install the wires, new power down module, and hardware on terminal posts 1C, 2C, and 3C per
Figure 3-4. If the hardware is not installed properly the power down module will not sit level on
terminal posts 1C, 2C, and 3C. The redesigned Power Down Module is shown in its proper
location in Figure 3-5.
10. Attach the single wire on the power down module to terminal post 5B and secure it in place using
the washer and nuts removed in Step 4.
11. Reattach the field wires on terminals 1C and 2C using the hardware removed in Step 3.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
3-13
General Maintenance and Troubleshooting
WASHER, LOCKING (STAR)
NUT, FULL
WASHER, FLAT
AMP CONNECTOR
NUT, HALF
POWER DOWN
MODULE
TERMINAL POST
TERMINAL BLOCK
Figure 3-4 - Proper Hardware Configuration on Terminal Posts 1C, 2C, and 3C
Figure 3-5 - Location of Redesigned Power Down Module on
Terminal Posts 1C, 2C, and 3C
3-14
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
General Maintenance and Troubleshooting
3.3. Troubleshooting (General)
Table 3-1 presents a list of troubleshooting concerns and their solutions.
Table 3-1 - Troubleshooting Table for Model 95 Gate Mechanism
CONDITION
1. Gate arm remains in a horizontal position when
track is unoccupied.
2. Gate arm descent too fast or too slow.
3. The gate arm drops below the horizontal position.
4. Motor does not drive gate arm through powerdown portion of descent.
5. Grounds in the Gearmotor.
SOLUTION
a. Ensure gate mechanism is receiving correct
supply voltage. Ensure #1 contact is closed.
b. Ensure relay is operational, energized.
c. Ensure gold nut on test link is closed.
d. Ensure circuit breaker is closed.
a. Adjust snub resistor on electrical assembly.
b. Ensure counterweights are set properly.
a. Adjust the horizontal buffer spring.
b. Ensure torque is set correctly on gate
mechanism.
a. Check No. 3 contact on circuit controller, make
sure it is closed 46-93°.
b. Check power down module on 12-volt systems
(Refer to Section 3.3.1) or power down relay on
24-volt systems (Refer to Section 3.3.2).
Blow the brush dust out of the gearmotor (Refer to
Section 3.2.10).
3.3.1. Testing and Troubleshooting the Power Down Module for 12-Volt Systems
The following procedure describes the steps taken to test the power down module (Figure 5-10 or
Figure 5-11, Item 275).
1. With arm in the clear position, place voltmeter on terminals 6B(-) and 3A(+). The meter should
read approximately 0 volts (refer to 5B (refer to Figure 2-2, Figure 2-3, and Figure 2-5 for terminal
locations for terminal locations).
2. With arm descending, meter should read 12VDC nom. (system voltage).
3. When arm reaches the 45° point (halfway down), the meter should return to 0 volts.
If this test resulted in incorrect readings, check the following:
1. Check the No. 3 contact for proper adjustment.
2. Check the limit resistor to ensure it is not open.
3. Check for proper wiring (refer to Figure 2-2, Figure 2-3, and Figure 2-5).
4. If no problems are found with items one through three above, then replace the Power Down
Module.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
3-15
General Maintenance and Troubleshooting
3.3.2. Testing and Troubleshooting the Power Down Module for 24-Volt Systems
The following procedure describes the steps taken to test the power down module (Figure 5-12 or
Figure 5-13, Item 275).
1. With arm in the clear position, place voltmeter on terminals 6B(-) and 3C(+). The meter should
read approximately 0 volts (refer to Figure 2-4 for terminal locations).
2. With arm descending, place voltmeter on 6B(-) and 3C(+). The meter should read 24 VDC.
3. There will also be 24 VDC between 6B(-) and 3A(+) until the arm reaches the 45° point (halfway
down or at point No. 3 contact opens). The meter should read 0 volts on 3A at this point.
If this test resulted in incorrect readings, check the following:
1. Check the No. 3 contact for proper adjustment.
2. Check the limit resistor to ensure it is not open.
3. Check for proper wiring (refer to Figure 2-4).
4. If no problems are found with items one through three above, then replace the Power Down Relay.
3.3.3. Verification of Maintenance Switch Operation
Note that the function of the maintenance switch is to drive the mechanism to the down position
without the arm installed. The following procedure is recommended instead of a functional test.
1. Loosen the gold nut on Terminal 5B and reconnect power to the gate mechanism (refer to Figure
3-2 for terminal location).
2. Connect a voltage meter to the gate mechanism, with the positive meter lead on motor Terminal T6
and the negative meter lead on Terminal T7.
3. With the arm in the up position, operate the toggle switch on the maintenance switch to the
MAINTENANCE position and momentarily push the PUSH AND HOLD button. The arm should
power down, giving a positive reading on the voltage meter. The positive meter reading verifies
proper wiring terminations.
4. Return the toggle switch to the NORMAL position and power arm to up position by resecuring the
gold nut on Terminal 5B.
3-16
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Optional Equipment
4.
OPTIONAL EQUIPMENT
4.1. Heater (Defroster)
Each heater kit (optional) uses a 25-watt resistive element. Refer to Table 4-1 for the appropriate heater
for your unit.
Table 4-1 - Model 95 Heater Kit Ordering Information
Heater Model
Number
N467048-01
N467048-02
N467048-03
Description
Model 95 Heater Kit
Model 95 Heater Kit
Model 95 Heater Kit
Voltage
120 V
24 V
240 V
4.1.1. Installation Instructions for Model 95 Gate Mechanism Heater Kit
Use two each 4 - 40 screws, nuts and washers to mount resistor unit to left inside panel of the electrical
module bracket, just under the terminal board using two holes provided. (Some units may have the two
mounting holes on the right side of the electrical module bracket.)
Connect leads to terminal posts 2A and 3B on top of the terminal board (polarity is unimportant). If
heater kit is for a voltage of 50 volts or more, use the two insulator sleeves provided to cover the two
terminal posts together with the two insulator caps. It may be necessary to trim the length of the
insulator sleeves in order to accommodate the post lengths.
Connect two voltage supply leads (user provided) to 2A and 3B.
4.2. Maintenance Switch
The Maintenance Switch (Figure 5-15) was developed to make replacing a gate arm easier and safer.
The switch allows the gate to be driven down without the weight of the gate arm to assist. Use of the
switch eliminates the need to connect jumpers inside the mechanism to drive the gate down.
If not installed, the maintenance switch may be ordered as part number N46709202
4.3. Severe Weather Shock Option
Gear Shock Assembly 1400 (PN N46701402) is a direct replacement for the standard gear shock
assembly used to maintain the gate mechanism’s gate arm position in the horizontal position.
This shock option offers a stiffer shock than standard. Its greater resistance minimizes the gate arm
dropping below horizontal due to increased weight from ice and snow sometimes encountered in
severe weather conditions.
After removal of the standard horizontal spring buffer shock, the severe weather shock is installed and
adjusted identical to the spring buffer as described in Section 2.4.1.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
4-1
Optional Equipment
4-2
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Parts List
5.
PARTS LISTS AND EQUIPMENT DIAGRAMS
Table 5-1 is a list of the Model Numbers for the various Model 95 Gate Mechanism configurations.
The list of configurations is dynamic – if you are interested in a configuration that is not listed, please
contact the support team (Section 7).
Table 5-1 - Model 95 Gate Mechanism Configurations
Model Number
N46780101
N46780102
N46780103
N46780104
N46780105
N46780106
N46780107
N46780108
N46780109
N46780110
N46780111
N46780112
N46780201
N46780202
N46780204
N46780205
N46780206
N46780207
N46780208
N46780209
N46780210
N46780301
N46780302
N46780304
N46780305
N46780401
N46780402
N46780403
N46780405
N46710401
N46710402
N46710406
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
Description
Non-Vital Mechanism
Non-Vital Mechanism, 24-Volt
Non-Vital Sidewalk Mechanism, RH
Non-Vital Sidewalk Mechanism, LH
Non-Vital Mechanism with 120 VAC Heater
Non-Vital Mechanism with 120 VAC Heater and Maintenance Switch
Vital Sidewalk Mechanism, 3-wire control
Non-Vital Mechanism with Maintenance Switch
Non-Vital Sidewalk Mechanism, RH, with 120 VAC Heater
Non-Vital Sidewalk Mechanism, LH, with 120 VAC Heater
Non-Vital Sidewalk Mechanism, RH, with 120 VAC Heater and
Maintenance Switch
Non-Vital Sidewalk Mechanism, LH, with 120 VAC Heater and
Maintenance Switch
Vital Mechanism
Vital Gate Mechanism, 24 VDC
Vital Gate Mechanism, 3-Wire Control
Vital Sidewalk Mechanism, RH, 3-Wire Control
Vital Gate Mechanism with Maintenance Switch
Vital Sidewalk Mechanism, RH
Vital Sidewalk Mechanism, LH
Vital Sidewalk Mechanism, RH, with 120VAC Heater and Maintenance
Switch
Vital Sidewalk Mechanism, LH, with 120VAC Heater and Maintenance
Switch
Non-Vital Pedestrian Mechanism
Non-Vital Pedestrian Mechanism with 120 VAC Heater
Non-Vital Pedestrian Mechanism with Upgrade Option
Non-Vital Pedestrian Mechanism with 120 VAC Heater and
Maintenance Switch
Vital Pedestrian Mechanism
Vital Pedestrian Mechanism with 120 VAC Heater
Vital Pedestrian Mechanism with Upgrade Option
Vital Pedestrian Mechanism with 120 VAC Heater and Maintenance
Switch
Non-Vital Fail–Up (Exit) Model 95 (Service Manual SM 6495B)
Vital Fail-Up (Exit) Model 95 (Service Manual SM 6495B)
Non-Vital Fail–Up (Exit) Model 95 (Service Manual SM 6495B)
5-1
Parts List
5.1. Model 95 Gate Mechanism – Mechanical Assembly Parts List
(12- and 24-Volt Systems)
Table 5-2, Figure 5-1, and Figure 5-2 list the parts for the 12- and 24-volt Model 95 Gate Mechanism
mechanical assemblies.
Table 5-2 - Model 95 Gate Mechanism – Mechanical Assembly Parts List for
12- and 24-Volt Systems
Item
Number
05
07
10
12
15
20
21
25*
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145*
150
155
157
160
162
165
180
185
Part Number
M46700101
J47599990005
N46700401
J4802110108
Q46702101
M46710202
M46710201
J0680140006
M46707401
M46700601
N46703602
N46703604
M46700701
M46700801
M46700802
M46700901
J7256450012
J7120580006
M46700803
M46700804
J7256450011
J7120580004
N46701401
N46701402
M46701101
J6909510007
J0523620003
M46700805
J7120580005
J7762830001
J5001010105
J4751210113
J5000970116
J041245
J6909510008
J0504980002
J4750780002
J0504980003
J0480750004
J048417
J0487220007
J0680140008
5-2
Downloaded from www.Manualslib.com manuals search engine
Part Description
Mechanical Gearbox
U-Bolt Assembly, 1/4” – 20 Hasp
Cover with Hasp
Nut, 1/4” – 20, SS Hex (Included in Item 7)
Casting, Cover Latch
Threaded Rod, 3/8” – 24 x 4”
Cover Latch Hook
Spring – Pin ¼ Dia SS
Groove Pin – 3/8 x 2-1/2 SS (with hole for Bridge Pin, Item 180)
Shaft, Mod 95 Main
Gearmotor – 1/6 HP (12 VDC)
Gearmotor – 1/6 HP (24 VDC)
Gearmotor Drive
Gear, Large Idler
Gear, Small Idler
Gear, Segment Drive
Bearing-Roller 209PP
Ring - #209 INT Snap
Shaft, Idler Gear
Key, Idler Gear Shaft
Bearing – Roller 205PP
Ring - #205 External Snap
Gear Shock Assembly
Optional Severe Weather Shock
Cover, Gear Shock
Gasket - Model 95 Shock
Screw, 3/8-16 x 1-1/4 Hex Socket
Key, Segment Gear
Ring - #205 Internal Snap
Cam – Model 95 Circuit Cont
Screw - 1/4 - 20 x 5/8 Hex Cap SS
Washer – SS Lock 3/8”
Screw, 1/4 –20 x 1 Hex SS
Threadlocker – 242
Gasket – EPMD Sponge, Black
Set Screw 1/4 - 20 x 5/16
Washer - 15/16 ID 3” OD
Set Screw 1/2 - 13 x 1/2
Nut - 7/8” - 9 Lock
Nut, 1-1/2 Cndt Lock
Pin – Bridge - 3/8”
Spring – Pin 1/4” Diameter, SS
SM 6495, Rev. 7, December 2008
Parts List
Item
Number
190
195
200
205
210
220
305
310
315
320
505
510
Part Number
M46700806
J4751200112
J4751210111
J056448003
J4803170110
J480217
M46710204
00205112
J4751200114
M46703901
X46703702
M46705201
M46707101
M46708001
M46709001
Part Description
Hub Key
Washer, SS Plate, No. 1/4
Washer, SS Lock No. 1/4
Eye Bolt, 1/2” – 13, SS
Nut , 1/2” – 13, Heavy Jam, SS
Nut, 1/2” – 13, Elastic Stop
Hold, Threaded
Hex Nut, 18 – 8, 3/8” - 24
Washer, SS Plate, 3/8”
Cam Clamp
T-Bolt Kit
Wiring Label (12 VDC)
Wiring Label (24 VDC)
Wiring Label (3-Wire Control 12VDC)
Wiring Label (NV with Maintenance Switch)
* Part not shown in Figure 5-1 or Figure 5-2.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
5-3
Parts List
505
5
110 135
35
157
(2 per side)
162
10
310
315
135
305
185
105 100
20
21
95 165
15
200 195 12
25
7
115
160 60
55
140
50
155 45
195
200
5A1.0001.00
40
Figure 5-1 - Model 95 Gate Mechanism – Mechanical Assembly (Sheet 1 of 2)
5-4
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Parts List
205 210
150
5
220
125 130 320
65 70
190
115
35
120
85 90
75 80
180
10
30
5A1.0002.00
510
Figure 5-2 - Model 95 Gate Mechanism – Mechanical Assembly (Sheet 2 of 2)
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
5-5
Parts List
5.2. Model 95 Pedestrian Gate Mechanism - Mechanical Assembly Parts List
Table 5-3 and Figure 5-3 through Figure 5-6 list the parts for the Model 95 Pedestrian Gate
Mechanism mechanical assemblies.
Table 5-3 - Model 95 Pedestrian Gate Mechanism - Mechanical Assembly Parts List
Item
Number
05
07
10
15
20
25
30
31
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145*
150
155
157
160
162
165
180
185
195
200
210*
215
220
Part Number
M46700102
J47599990005
N46700402
Q46702101
N46710203
J0680140006
M46707401
J703394003
M46700601
N46703602
M46700701
M46700801
M46700802
M46700901
J7256450012
J7120580006
M46700803
M46700804
J7256450011
J7120580004
N46701401
N46701402
M46701101
J6909510007
J0523620003
M46700805
J7120580005
J7762830001
J5001010105
J4751210113
J5000970116
J041245
J6909510008
J0504980002
J4750780002
J0504980003
J0480750004
J048417
J0487220007
J0680140008
J4751200112
J4751210111
J0480750004
J5001240096
J4751210115
5-6
Downloaded from www.Manualslib.com manuals search engine
Part Description
Mechanical Gearbox
U-Bolt Assembly
Cover With Hasp
Casting, Cover Latch
Cover Latch Assembly
Spring - Pin 1/4 Dia SS
Groove Pin - 3/8 x 2-1/2 SS (with hole for Bridge Pin, Item 180)
Groove Pin - 3/8 x 2-1/2 SS
Shaft, Mod 95 Main
Gearmotor - 1/6 HP with Brake Assembly
Gearmotor Drive
Gear, Large Idler
Gear, Small Idler
Gear, Segment Drive
Bearing – Roller 209PP
Ring - #209 Internal Snap
Shaft, Idler Gear
Key, Idler Gear Shaft
Bearing – Roller 205PP
Ring - #205 External Snap
Gear Shock Assembly
Optional Severe Weather Shock
Cover, Gear Shock
Gasket - Model 95 Shock
Screw, 3/8-16 x 1-1/4 Hex Socket
Key, Segment Gear
Ring - #205 Internal Snap
Cam - Model 95 Circuit Cont
Screw - 1/4 – 20 x 5/8 Hex Cap SS
Washer, SS Lock 3/8”
Screw, 1/2 - 20 x 1, Hex, SS
Threadlocker – 242
Gasket – Silicone
Set Screw 1/4 - 20 x 5/16
Washer – 15/16 ID 3” OD
Set Screw 1/2 - 13 x 1/2
Nut, 7/8” – 9, Lock
Nut, 1-1/2 Cndt Lock
Pin – Bridge - 3/8”
Spring - Pin 1/4 Dia SS
Washer, SS Plate No1/4
Washer, SS Lock No1/4
Nut, 7/8” - 9 Lock
Screw, ½ - 20 x 2-1/2 Socket Head
Washer, SS Lock No 1/2
SM 6495, Rev. 7, December 2008
Parts List
Item
Number
225
230
235
240
245
250
255
260
265
270
275
280*
285*
290
295
300
305
310
315
320
Part Number
J4751200116
J0504980007
J050657
J4751210113
M46700807
M46706101
M46706201
M46705901
PN46706004
J056448003
J4803170110
J480217
J0504980011
M46705801
J0504980011
M46700808
M46710204
00205112
J4751200114
M46703901
Part Description
Washer, 1/2” Plain Flat
Screw, 3/8 - 16 x 2-1/4 Hex SS
Screw, 3/8 - 16 x .500”
Washer - SS Lock, 3/8”
Key, Pedestrian, Gate Arm Gear
Gear, Pedestrian, Gate Arm
Gear Clamp, Pedestrian, Gate Arm
Shaft, Pedestrian, Gate Arm
Bearing Support, Pedestrian, Gate Arm
Bolt - Eye 1/2 – 13 SS
Nut, 1/2 - 13 SS Hex
Nut, 1/2” Elastic Stop
Screw, Set 3/8” - 16 x 3/4” Cup Point
Pedestrian Adapter Arm
Adapter Arm Set Screw
Adapter Arm Key 1.5”
Screw, 1/2 - 20 x 2-1/2
Hex Nut, 18 – 8, 3/8 – 14
Washer, SS Plate, 3/8”
Cam Clamp
* Part not shown in Figure 5-3 through Figure 5-6.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
5-7
Parts List
110 135
35
157
16 2
310
315
135
25
30 5
185
10 5 10 0
20
95 16 5
15
25
3 2
7
125 320
3
16 0 6 0
55
50
140
195
155 45
20 0
40
Figure 5-3 - Model 95 Pedestrian Gate Mechanism – Mechanical Assembly
(Sheet 1 of 4)
5-8
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Parts List
270 275
15 0
125 130 320
5
65 70
N46781001
115
26 0
120
265
85 90
75 80
225 220 215
180
31
10
30
Figure 5-4 - Model 95 Pedestrian Gate Mechanism – Mechanical Assembly
(Sheet 2 of 4)
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
5-9
Parts List
255
245
235
250
35
IMPORTANT: GEAR
TOOTH ENGAGEMENT
MUST BE SHOWN
3 2
3
260
250
235
245
255
VIEW “A”
230
240
ASSEMBLE GEARS WITH
MECH. IN UP POSITION
AS SHOWN IN THIS VIEW
Figure 5-5 - Model 95 Pedestrian Gate Mechanism – Mechanical Assembly
(Sheet 3 of 4)
5-10
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Parts List
Figure 5-6 - Model 95 Pedestrian Gate Mechanism – Mechanical Assembly
(Sheet 4 of 4)
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
5-11
Parts List
5.3. Model 95 Sidewalk Gate Mechanism - Mechanical Assembly Parts List
Table 5-4 and Figure 5-7 through Figure 5-9 list the parts for the Model 95 Sidewalk Gate Mechanism
mechanical assemblies.
Table 5-4 - Model 95 Sidewalk Gate Mechanism - Mechanical Assembly Parts List
Item
Number
Part Number
03*
05
07
10
12*
15
20
25
30
M46700101
M46700102
J47599990005
N46700402
J4802110108
Q46702101
N46710203
J0680140006
M46707401
31
35
J703394003
M46707301
M46707302
N46703602
M46700701
M46700801
M46700802
M46700901
J7256450012
J7120580006
M46700803
M46700804
J7256450011
J7120580004
N46701401
N46701402
M46701101
J6909510007
J0523620003
M46700805
J7120580005
J7762830001
J5001010105
J4751210113
J5000970116
J041245
J6909510008
J0504980002
J0504980003
J048417
J0487220007
J0680140008
J4751200112
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125*
130
135
140
145*
150
155
160
165
180
185
195
5-12
Downloaded from www.Manualslib.com manuals search engine
Part Description
Mechanical Gearbox (Includes Items 5 and 10)
Mechanical Gearbox (Included in Item 3)
U-Bolt Assembly
Cover with Hasp (Included in Item 3)
Nut, 1/4 - 20 SS Hex (Included in Item 7)
Casting, Cover Latch
Cover Latch Assembly
Spring - Pin 1/4 Dia SS
Groove Pin - 3/8 x 2-1/2 SS (with hole for Bridge Pin, Item
180)
Groove Pin - 3/8 x 2-1/2 SS
Shaft, Mod 95 Main R.H.
Shaft, Mod 95 Main L.H.
Gearmotor - 1/6 HP with Brake Assembly
Gearmotor Drive
Gear, Large Idler
Gear, Small Idler
Gear, Segment Drive
Bearing – Roller 209PP
Ring - #209 Internal Snap
Shaft, Idler Gear
Key, Idler Gear Shaft
Bearing – Roller 205PP
Ring - #205 External Snap
Gear Shock Assembly
Optional Severe Weather Shock
Cover, Gear Shock
Gasket - Model 95 Shock
Screw, 3/8-16 x 1-1/4 Hex Socket
Key, Segment Gear
Ring - #205 Internal Snap
Cam - Model 95 Circuit Cont
Screw - 1/4 - 20 x 5/8 Hex Cap SS
Washer - SS Lock, 3/8”
Screw, 1/4 –20 x 1 Hex SS
Threadlocker – 242
Gasket – Silicone
Set Screw 1/4 – 20 x 5/16
Set Screw 1/2 - 13 x 1/2
Nut, 1-1/2 Cndt Lock
Pin - Bridge - 3/8”
Spring - Pin 1/4 Dia SS
Washer, SS Plate No 1/4
SM 6495, Rev. 7, December 2008
Parts List
Item
Number
Part Number
Part Description
200
205
210
220*
230
235
240
305
J4751210111
J056448003
J4803170110
J480217
M46705801
J0504980011
M46700805
M46710204
Washer, SS Lock No 1/4
Eye Bolt, 1/2 - 13 SS
Nut, 1/2 - 13
Nut, 1/2 - 13 Elastic Stop
Pedestrian Adapter Arm
Adapter Arm Set Screw
Adapter Arm Key 1.5”
Hold Threaded
310
315
320
005112
J4751200114
M46703901
Hex Nut – 18 - 8, 3/8 - 24
Washer, SS Plate, 3/8”
Cam Clamp
* Part not referenced in Figure 5-7 through Figure 5-9.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
5-13
Parts List
5
110 135
35
10
310
315
135
305
185
105 100
20
95 165
15
25
7
115
160 60
55
50
140
195
155 45
200
5A1.0008.00
40
Figure 5-7 - Model 95 Sidewalk Gate Mechanism – Mechanical Assembly
(Sheet 1 of 3) (RH Shown – LH Available)
5-14
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Parts List
205 210
150
5
125 130 320
65 70
115
120
85 90
75 80
180
31
30
5A1.0013.00
10
Figure 5-8 - Model 95 Sidewalk Gate Mechanism – Mechanical Assembly
(Sheet 2 of 3) (RH Shown – LH Available)
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
5-15
Parts List
Figure 5-9 - Model 95 Sidewalk Gate Mechanism – Mechanical Assembly
(Sheet 3 of 3) (RH Shown – LH Available)
5-16
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Parts List
5.4. Model 95 Gate Mechanism Electrical Assembly with PN-150 Relay
(12-Volt Systems) (N46782101)
Table 5-5 and Figure 5-10 list the parts for the 12-volt Model 95 gate mechanism electrical assembly
with PN-150 Relay).
Table 5-5 - Parts List for the 12-Volt Electrical Assembly with PN-150 Relay
Item
Number
05
10
15
20
25
30
35
40
42
45
50
60
65
70
75
80*
85*
90*
110*
112*
115*
120
125
130
135*
140*
145*
150
155
160*
165
170
175
191
200
205
265
275
280
285
300
305
Part Number
N46701801
N4513760301
J5001360114
J4751210111
M038448
J7257150018
J7256940169
N156682
N156683
N156682001
M107471
N322505702
M015577
J4751210108
J5001390114
J5001320128
N46704205
N46704302
N46704403
M130200
M118271
M4510113501
J047818
J480300
J480301
M4510113402
J071626
M047290
N46706702
J047521
J075483
J4802110108
J048145
00305047
J5000970112
X46700038
J4751820013
J7915970003
N46712401
J507218
J4751210111
N46705602
J7355190364
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
Part Description
Relay Mounting Bracket
PN-150 Mounting Base
Screw - SS 1/4 - 20 x 7/8 RD
Washer, SS Lock No 1/4
Washer
Block - Terminal Board Black
Circuit Breaker - 12V 20A Reset
Resistor, Comp for N46782101 only
Resistor, Comp for N46782104 only
Resistor, Comp
Block, 4-Way Terminal
Relay, PN-150HD
Washer
Washer - SS Lock No 8
Screw - SS 1/4-20 x 7/8
Screw - 8 - 32 x 1-3/4 SS
#1 Contact Assembly
Heel Contact Assembly
Front Contact Assembly
Terminal Post, AAR
Term Post, AAR
Lock Washer
Washer, 17/64 x 9/16 COP, AAR
Nut, 14 - 24 Hex Brass NP, AAR
Nut, 14 - 24 Hex Brass, AAR
Washer, Insulating
Link, Test
Connector, #18 x 1/2”
Harness, PN-150
Washer, high collar lock, 1/4”
Grommet, Rbr Atl. 1919
Nut, 1/4 - 20 SS Hex
Nut, 10 - 32 Hex Steel
Washer, #10 Flat
Screw, 1/4 – 20 x 3/4 Hex HD SS
Diode Assembly, Snub Mod. 95
Washer, #8 Flat Nylon
Screw, 8 - 32 x 3/4 Nylon RH
Power Down Module
Screw, 1/4 - 20 x 5/8 SS
Washer, 1/4 SS Lock
Diode Assembly, Limit
Resistor, 50 Ohm, 5 Watt
5-17
Parts List
Item
Number
310
325
330
Part Number
J730041
M109154
J5000970114
Part Description
Term - Pre-Insul Diagr
Terminal Block, 3 Way
Screw, 1/4 - 20 x 7/8 Hex
* Part not shown in Figure 5-10.
** For mounting electrical assembly to housing. Not shown in Figure 5-10.
5-18
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Parts List
125
120
25
20
15
130
5
FOR REF. ONLY
HEATER KIT
TO BE ORDERED
SEPARATELY
25 20 15 10
10
35 265 65 205
SEE
SECTION
"A-A"
SECTION "B-B"
SCALE: 2:1
SECTION "A-A"
130
200
120
280 285 65
130
125
50
175 170 150
120
125
125
191120 155 165
330 120 155 165
120
SECTION C-C
30
FOR REF. ONLY
HEATER KIT
TO BE ORDERED
SEPARATELY
310 305 300
"A"
"A"
275
B
B
C
C
5A1.0003.00
42 75 205 60 65
155 70 45
200
40 75 205 60 65
MAKE CERTAIN RESISTOR END WITH
INSULATED TERMINAL POST IS
ORIENTED DOWNWARD.
155 70 325
467821
Figure 5-10 - Model 95 Gate Mechanism Electrical Assembly with PN-150 Relay
(12-Volt Systems)
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
5-19
Parts List
5.5. Non-Vital Relay Electrical Assembly for 12-Volt Systems (N46782001)
Table 5-6 and Figure 5-11 list the parts for the 12-volt Model 95 gate mechanism electrical assembly
with non-vital relay).
Table 5-6 - Parts List for the 12-Volt Electrical Assembly with Non-Vital Relay
Item
Number
05
10
30
35
40
42
45
55
60
65
70
75
80*
85*
90*
110*
112*
115*
120
125
130
135*
140*
145*
150
155
165
170
175
190
191
200
205
265
270
275
280
285
290
300
305
310
325
330
335*
Part Number
N46708702
PN46716401
J7257150018
J7256940169
N156682
N156682001
M107471
J5001320108
J4751200109
J4751210108
J5001390114
J5001320128
N46704205
N46704302
N46704403
M130200
M118271
M4510113501
J047818
J480300
J480301
M4510113402
J071626
M047290
N46706602
J047521
J4802110108
J048145
00305047
J703310
J5000970112
X46700038
J4751820013
J7915970003
M437500
N46712401
J507218
J4751210111
J5001390116
N46705602
J7355190364
J730041
M109154
J5000970114
J4751210124
5-20
Downloaded from www.Manualslib.com manuals search engine
Part Description
Relay Mounting Bracket
MCR NV Relay w/Ties and Label
Block - Terminal Board Black
Circuit Breaker – 12V 20A Reset
Resistor, Comp
Resistor, Comp
Block, 4-Way Terminal
Screw, SS, 8 - 32 x 1/2 RD
Washer, SS Plate No 8
Washer, SS Lock No 8
Screw, SS 1/4 - 20 x 7/8
Screw, SS 8 - 32 x 1-3/4
#1 Contact Assembly
Heel Contact Assembly
Front Contact Assembly
Terminal Post, AAR
Term Post, AAR
Lock Washer
Washer, 17/64 x 9/16 COP, AAR
Nut, 14 - 24 Hex Brass NP, AAR
Nut, 14 - 24 Hex Brass, AAR
Washer, Insulating
Link, Test
Connector, #18 x 1/2”
Harness, PB
Washer, high collar lock, ¼”
Nut, ¼ - 20 SS Hex
Nut, 10 - 32 Hex Steel
Washer, #10 Flat
Cable, Tie Self Lkg
Screw, 1/4 - 20 x 3/4 Hex HD SS
Diode Assembly, Snub Mod. 95
Washer - #8 Flat Nylon
Screw, 8-32 x 3/4 Nylon RH
Spacer
Power Down Module
Screw, 1/4 – 20 x 5/8 SS
Washer, 1/4 SS Lock
Screw, SS, 1/4 – 20 x 1 FIL
Diode Assembly. Limit
Resistor, 50 ohm, 5 Watt
Terminal, pre-insulated, diamond grip
Terminal Block, 3-Way
Screw, 1/4 - 20 x 7/8 Hex
Washer, 1/4 SS Lock
SM 6495, Rev. 7, December 2008
Parts List
Item
Number
340*
Part Number
N46716501
Part Description
Snub Support Lead
* Part not shown in Figure 5-11.
** For mounting electrical assembly to housing. Not shown in Figure 5-11.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
5-21
Parts List
55 60 65
55
5
130
5
200
120
125 130
125
120
10
10
OR
290
290
OR
125
280 285
205 265
35
150 170 175
SECTION C-C
190
330 120 155 165
165 155 120 191
30
DETAIL "B"
130
125
120
SECTION "A-A"
SCALE: 2:1
FOR REF. ONLY
HEATER KIT
TO BE ORDERED
SEPARATELY
310 305 300
275
A
A
C
C
42 75 205
5A1.0004.00
155 70 45
200
MAKE CERTAIN RESISTOR END WITH
INSULATED TERMINAL POST IS
ORIENTED DOWNWARD.
40 75 205
155 70 325
467820
Figure 5-11 - Model 95 Gate Mechanism Electrical Assembly with Non-Vital Relay
(12-Volt Systems)
5-22
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Parts List
5.6. PN-150 Electrical Assembly for 24-Volt Systems (N46782102)
Table 5-7 and Figure 5-12 list the parts for the 24-volt Model 95 gate mechanism electrical assembly
with the PN-150 Relay).
Table 5-7 - Parts List for the 24-Volt Electrical Assembly with the PN-150 Relay
Item
Number
05
10
15
20
25
30
35
40
42
45
50
55*
60
65
70
75
80*
85*
90*
110*
112*
115*
120
125
130
135*
140*
145*
150
155
160*
165
170
175
191
200
205
265
275
280
285
295**
300
305
Part Number
N46701801
N4513760301
J5001360114
J4751210111
M038448
J7257150018
J7256940228
N214995
N156683001
M107471
N322505702
J5001320108
J4751200109
J4751210108
J5001390114
J5001320128
N46704205
N46704302
N46704403
M130200
M118271
M4510113501
J047818
J480300
J480301
M4510113402
J071626
M047290
N46706702
J047521
J075483
J4802110108
J048145
00305047
J5000970112
X46700038
J4751820013
J7915970003
N46712401
J507218
J4751210111
J047521
N46705602
J7355190364
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
Part Description
Relay Mounting Bracket
PN-150 Mounting Base
Screw, SS, 1/4 - 20 x 7/8 RD
Washer, SS, Lock No 1/4
Washer
Block - Terminal Board Black
Circuit Breaker, 24V 10A Reset
Resistor, Comp
Resistor, Comp
Block, 4-Way Terminal
Relay, PN-150HD
Washer, High Collar, Lock,1/4"
Washer, SS, Plate No 8
Washer, SS, Lock No 8
Screw, SS, 1/4 - 20 x 7/8
Screw, 8 - 32 x 1-3/4 SS
#1 Contact Assembly
Heel Contact Assembly
Front Contact Assembly
Terminal Post, AAR
Terminal Post, AAR
Lock Washer
Washer, 17/64 x 9/16 Cop, AAR
Nut, 14 - 24 Hex Brass NP, AAR
Nut, 14 - 24 Hex Brass, AAR
Washer, Insulating
Link, Test
Connector, #18 x 1/2”
Harness, PN-150
Washer, high collar, lock, 1/4”.
Grommet, Rbr Atl. 1919
Nut, 1/4 - 20 SS Hex
Nut, 10 - 32 Hex Steel
Washer, #10 Flat
Screw, 1/4 – 20 x 3/4 Hex HD SS
Diode Assembly, Snub Mod. 95
Washer, 8 Flat Nylon
Screw, 8 - 32 x 3/4 Nylon RH
Power Down Module
Screw, 1/4 – 20 x 5/8 SS
Washer, 1/4 SS Lock
Washer, ¼ Lock
Diode Assembly, Limit
Resistor, 50 Ohm, 5 Watt
5-23
Parts List
Item
Number
320
325
330
Part Number
J5001320110
M109154
J5000970114
Part Description
Screw, SS, 8 - 32 x 5/8 RD
Terminal Block, 3-Way
Screw, 1/4 - 20 x 7/8 Hex
* Part not shown in Figure 5-12.
** For mounting electrical assembly to housing. Not shown in Figure 5-12.
5-24
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Parts List
125
120
25
20
15
130
5
FOR REF. ONLY
HEATER KIT
TO BE ORDERED
SEPARATELY
25 20 15 10
10
35 265 65 205
SEE
SECTION
"A-A"
SECTION "B-B"
SCALE: 2:1
SECTION "A-A"
130
200
120
280 285 65
130
125
50
175 170 150
120
125
125
191 120 155 165
330 120 155 165
120
SECTION C-C
30
FOR REF. ONLY
HEATER KIT
TO BE ORDERED
SEPARATELY
305 300
"A"
"A"
275
B
B
C
C
5A1.0003.00
42 75 205 60 65
155 70 45
200
40 75 205 60 65
MAKE CERTAIN RESISTOR END WITH
INSULATED TERMINAL POST IS
ORIENTED DOWNWARD.
155 70 325
467821
Figure 5-12 - Model 95 Gate Mechanism Electrical Assembly with PN-150 Relay
(24-Volt Systems)
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
5-25
Parts List
5.7. Non-Vital Relay Electrical Assembly for 24-volt Systems (N46782002)
Table 5-8 and Figure 5-13 list the parts for the 24-volt Model 95 gate mechanism electrical assembly
with a non-vital relay).
Table 5-8 - Parts List for the 24-Volt Electrical Assembly with non-Vital Relay
Item
Number
05
10
30
35
40
42
45
55
60
65
70
75
80*
85*
90*
110*
112*
115*
120
125
130
135*
140*
145*
150
155
165
170*
175*
190
191
200
205
260*
265*
270*
280
285
290
295**
300
305
310
325
Part Number
N46708702
J7261530267
J7257150018
J7256940228
N214995
N156683001
M107471
J5001320108
J4751200109
J4751210108
J5001390114
J5001320128
N46704205
N46704302
N46704403
M130200
M118271
M4510113501
J047818
J480300
J480301
M4510113402
J071626
M047290
N46706602
J047521
J4802110108
J048145
00305047
J703310
J5000970112
X46700038
J4751820013
A774241
J7915970003
M437500
J507218
J4751210111
J5001390116
J047521
N46705602
J7355190364
J730041
M109154
5-26
Downloaded from www.Manualslib.com manuals search engine
Part Description
Relay Mounting Bracket
24 VDC PM 17DY24
Block – Terminal Board Black
Circuit Breaker, 24V 10A Reset
Resistor, Comp
Resistor, Comp
Block, 4-Way Terminal
Screw, SS, 8 – 32 x 1/2 RD
Washer, SS Plate No 8
Washer, SS Lock No 8
Screw, SS 1/4 - 20 x 7/8
Screw, 8 - 32 x 1-3/4 SS
#1 Contact Assembly
Heel Contact Assembly
Front Contact Assembly
Terminal Post, AAR
Terminal Post, AAR
Lock Washer
Washer, 17/64 x 9/16 Cop, AAR
Nut, 14 - 24 Hex Brass NP, AAR
Nut, 14 - 24 Hex Brass, AAR
Washer, Insulated
Link, Test
Connector, #18 x 1/2”
Harness, PB
Washer, high collar, lock, 1/4”.
Nut, 1/4 - 20 SS Hex
Nut, 10 - 32 Hex Steel
Washer, #10 Flat
Cable, Tie Self Locking
Screw, 1/4 - 20 x 3/4 Hex HD
Diode Assembly, Snub Mod. 95
Washer - #8 Flat Nylon
Tubing, Sprl Wrp 1/4” PE
Screw, 8 - 32 x 3/4 Nylon RH
Spacer
Screw, 1/4 – 20 x 5/8 SS
Washer, 1/4 SS Lock
Screw, SS, 1/4 - 20 x 1 Fil
Washer, 1/4 Lock
Diode Assembly. Limit
Resistor, 50 ohm, 5 Watt
Term - Pre – Insul Diagr
Terminal Block, 3-Way
SM 6495, Rev. 7, December 2008
Parts List
Item
Number
330
340*
Part Number
J5000970114
N46716501
Part Description
Screw, 1/4 - 20 x 7/8 Hex
Snub Support Lead
* Part not shown in Figure 5-13.
** For mounting electrical assembly to housing. Not shown in Figure 5-13.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
5-27
Parts List
55
55 60 65
5
130
5
200
120
125 130
125
120
10
OR
10
OR
290
290
125
280 285
205 265
35
150 170 175
SECTION C-C
190
330 120 155 165
165 155 120 191
30
DETAIL "B"
130
125
120
SECTION "A-A"
SCALE: 2:1
FOR REF. ONLY
HEATER KIT
TO BE ORDERED
SEPARATELY
310 305 300
275
A
A
C
C
42 75 205
5A1.0005.00
155 70 45
200
MAKE CERTAIN RESISTOR END WITH
INSULATED TERMINAL POST IS
ORIENTED DOWNWARD.
40 75 205
155 70 325
467820
Figure 5-13 - Model 95 Gate Mechanism Electrical Assembly with Non-Vital Relay
(24-Volt Systems)
5-28
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Parts List
5.8. Non-Vital Pedestrian Mechanism Relays Electrical Assembly for 12-Volt Systems
(N46782201, N46782202)
Table 5-9 and Figure 5-14 list the parts for the 12-volt Model 95 gate mechanism electrical assembly
with the PN-150 Relay).
Table 5-9 - Parts List for the 12-Volt Electrical Assembly for Non-Vital Pedestrian
Mechanisms
Item
Number
05
10
30
35
40
42
45
55
60
65
70
75
80*
85*
90*
110*
112*
115*
120
125
130
135*
140*
145*
150
155
165
170
175
190
191
200
210
205
265
275
325
330
335
340
Part Number
N46708702
N46716401
J7257150018
J7256940403
N156682
N156682001
M107471
J5001240242
J4751200109
J4751210108
J5001390114
J5001320128
N46704205
N46704302
N46704403
M130200
M118271
M4510113501
J047818
J480300
J480301
M4510113402
J071626
M047290
N46706603
J047521
J4802110108
J048145
O0305047
J703310
J5000970112
X46700038
N46707702
J4751820013
J7915970003
N46712401
M109154
J5000970114
J4751210124
N46717101
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
Part Description
Relay Mounting Bracket
MCR NV Relay w/Ties and Label
Terminal Board Block, Black
Circuit Breaker, 10 Amps, 12 VDC
Resistor
Resistor
Terminal board
Screw, 8 - 32 x 1/2, w Lock Washer
Washer, No. 8 Plate, SS
Washer, No. 8 Lock, SS
Screw, 1/4 - 20 x 7/8, SS
Screw, 8-32 x 1-3/4, SS
No. 1 Contact Assembly
Heel Contact Assembly
Front Contact Assembly
Terminal Post
Terminal Post
Washer, Lock
Washer, 17/64 x 9/16 Cop
Nut, 14-24 Brass, Hex Head, NP
Nut, 14-24 Brass, Hex Head
Washer, Insulated
Link, Test
Connector, No. 18 x 1/2
Harness Assembly, Pedestrian PB
Washer, High Collar Lock, 1/4”
Nut, 1/4 - 20, Hex Head, SS
Nut, 10 - 32 Hex Head, Steel
Washer, No. 10 Flat
Cable, Tie Self Locking
Screw, 1/4 - 20 x 3/4 Hex Head, SS (N46782201 Only)
Model 95 Snub Diode Assembly
Assembly, Resistor Bracket
Washer, No. 8, Flat Nylon
Screw, 8 - 32 x 3/4, Nylon RH
Model 95 PCB
Terminal Block
Screw, 1/4 - 20 x 7/8 Hex Head, SS
Washer, lock, 1/4”, SS
Relay Brake Assembly
5-29
Parts List
130
55
55 60 65
200
120
130
5
125
5
120
120
125
120
125
10
10
SECTION C-C
35
150 170 175
190
210
330 120 155 165
165 155 120 191
130
30
125
DETAIL "B"
120
REF REF. ONLY
HEATER KIT
TO BE ORDERED
SEPERATELY
SECTION "A-A"
SCALE: 2:1
275
C
C
155 70 45
5A1.0006.00
42 75 205
55 340
200
40 75 205
MAKE CERTIAN RESISTOR END WITH
INSULATED POST IS
ORIENTED DOWNWARD.
Figure 5-14 - Non-Vital Pedestrian Mechanism Relay, Electrical Assembly
5-30
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Parts List
5.9. Model 95 Maintenance Switch
Table 5-10 presents the parts list for the Maintenance switch. Figure 5-15 and Figure 5-16 illustrate
the maintenance switch and its installation.
Table 5-10 - Model 95 Maintenance Switch Retrofit Assembly
(Refer to Figure 5-15 and Figure 5-16)
Item
Number
1**
2**
3**
4**
5**
6
7
8
9
10
11
12
13
14*
15*
16*
17*
18*
20*
21*
Part Number
M46708801
PN46709102
M46708901
J7257070650
J5000970114
J4751200112
J047521
J4802110108
J055643
M109154
J480300
J480301
J047818
J5072770010
M46709001
J703302
A043013
J055639
J047709
J5072950106
Description
Maintenance Label
Toggle Switch Assemblyy, Retrofit
Bracket, Maintenance
Switch-Momentary Pushbutton
Screw,1/4-20-X7/8 Ss Hex head
Washer, Sst Plate No1/4
Washer-High Collar Lock,1/4"
Nut,1/4-20 Sst Hex
Bag, Ziplock 5 X 7
Block, Terminal
Nut,14-24 Hex Brass Np
Nut,14-24 Hex Brass
Washer,17/64x9/16 Cop
Screw-1/4-20"X1" Fili Head
Wiring Label
Cable Tie,3.62",Nylon,Natural
Wire-Seal #22 Awg, 2 Ply
Bag-Ziplock 8 X 10
Washer, Int. Lock, #8
Screw, Sst 8-32x3/8 Pan
* Part not shown in Figure 5-16
** These parts are pre-assembled.
Figure 5-15 - Maintenance Switch Retrofit Assembly (N46709202)
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
5-31
Parts List
NUT
KEYED WASHER
LOCK WASHER
25-1
25-2
20
21
NUT
SWITCH, MOMENTARY
(MOUNTING AND WIRE TERMINATION)
SWITCH, TOGGLE
(MOUNTING OF PRE-WIRED SWITCH.
HARDWARE PROVIDED WITH SWITCH.)
#6-32 TERMINAL
SCREWS WITH
INTERNAL TOOTH
LOCK WASHER
10
4 7
1
11
2
5
3
8
6 9
12
REAR VIEW OF TOGGLE SWITCH
LOOKING IN DIRECTION
OF ARROW
FOR REF. ONLY
HEATER KIT
TO BE ORDERED
SEPARATELY
5
A
OPEN GOLD NUT on terminal 5B prior to
switching to the MAINTENANCE position
6
7
8
3
NORMAL
4
MAINTENANCE
PUSH AND HOLD
1
WARNING:
Maintenance switch for intermittent
use only! engage lock pin into idler gear to secure
counter weight arms in up position. Consult Service
Manual for details on the Maintenance Switch function.
2
5A1.0007.00
10
14
11 12 13
Figure 5-16 - Maintenance Switch Installation
5-32
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Parts List
5.10. Tool Kit (N46707001)
Table 5-11 lists the parts in the tool kit (N46707001 and Figure 5-17 identifies the parts in the tool kit.
Table 5-11 - Parts List for Tool Kit (N46707001)
Item Number
05
10
15
20
25
30
35
40*
45*
Part Number
J0390000119
M46706901
J0390000116
J0529800014
J0529800015
J0529800016
J0529800017
A7737150007
M46717401
Part Description
Tool Bag - #166 Zip Vinyl
Pin, Hold Down
Hex Key, 3/16" Ball Point (Cams)
Hex Key, 5/64" Short Series (Brake)
Hex Key, 1/8" Short Series (Pinion)
Hex Key, 9/64" Short Series (Brake)
Hex Key, 5/16" Short Series (Buffers)
Velcro, 3/4”, Hook/Loop, Black
Warning Label
* Part Not shown in Figure 5-17
Figure 5-17 - Tool Kit (N46707001)
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
5-33
Parts List
5.11. Recommended Model 95 Non-Vital Gate Mech Spare Parts Kit (X46700016)
Table 5-12 lists the parts in the Model 95 Spare Parts Kit (N46700016).
Table 5-12 - Parts List for Spare Parts Kit (N46700016)
Part Number
N46703602
N46716401
N46704205
N46704302
N46704403
J7256940169
X46700038
X46700031
N156682001
N156682
J0702050438
5.11.1.
Part Description
Gearmotor - 1/6 HP
MCR NV Relay w/Ties and Label
# 1 Contactor Assembly
Heel Contact Assembly
Front Contact Assembly
Circuit Breaker, 12V, 20A, Reset
Snub Diode Assembly
Power Down Module
Limit Resistor
Snub Resistor
Electric Brake Assembly (Hold Clear Device)
Recommended Spare Parts Not Contained in the Spare Parts Kit
Table 5-13 lists other recommended spare parts that are not included in the spare parts kit (Table 5-12).
Table 5-13 - Other Recommended Spare Parts
Part Number
J0702050635
Part Description
Replacement Motor Brushes (2 per motor required)
5.12. Model 95 Gate Mech Torque Wrench Kit (X46700003)
Table 5-14 lists the parts in the torque wrench kit (X46700003).
Table 5-14 - Torque Wrench Kit (X46700003)
Part Number
J0390000115
J0390000117
5-34
Downloaded from www.Manualslib.com manuals search engine
Part Description
Torque Wrench
Socket, 7/16" 12 Point, 1/4" Sq Drive
SM 6495, Rev. 7, December 2008
Parts List
5.13. Power Down Module Upgrade Kit (X46700031)
Table 5-15 lists the part included in the power down module kit (X46700031).
Table 5-15 - Power Down Module Kit (X46700031)
Part Number
N46712401
J4751210124
M118271
J047818
J480301
J480300
S006495D
Part Description
Model 95 PCB
Washer, 1/4” Lock, SS
Terminal Post
Washer, 17/64 x 9/16 Cop
Nut, 14-24 Brass Hex Head
Nut, 14-24 Brass NP, Hex Head
Service Manual
5.14. Snub Component Upgrade Kit
Table 5-16 lists the parts included in the snub component upgrade kit (X46700038).
Table 5-16 - Snub Component Upgrade Kit (X46700038)
Part Number
J078399
J047818
J480300
N46705601
N46716501
Part Description
Plastic Bag, #60F-0406
Washer, 17/64 x 9/16
Nut, 14 – 24 Hex Head Bracket
Diode Assembly, Snub Mode
Snub support Lead
5.15. Accessories for the Model 95 Gate Mechanism
Table 5-17 lists the accessories for the Model 95 Gate Mechanism.
Table 5-17 - Accessories for the Model 95 Gate Mechanism
Part Number
J7051915806
J026111
J0702050860
N7050490804
M4511953602
M4513944001
N46730103
N46730201
X438002003
X46700001 (2)
X46700002
X46705402
X46740157
X46740155
M4514843116(14)
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
Part Description
Conversion Bracket Assembly
Pinnacle, 4” or 5”
Erico Ground Stud
5” Junction Box
Rodent Cover
Mast 15’-3” x 5”
LH Gate Arm with Hub & Key
RH Gate Arm with Hub & Key
X-Sign, Hi-Intensity with Ext.
Universal Stud Plate for Counterweights
Conduit Kit
Pivot Clamp
Weight Kit 30-32’
24-26’ Counterweight Kit
36-lb Counterweight
5-35
Parts List
Part Number
J7051911010
J7051916141
N46707802
M46705002 (4)
M46705101 (2)
J4751200120 (8)
J4751210119 (8)
J4802120116 (8)
M46707901
M46708101
M451484- (3)
X4515060308
X392931008
X392929002
X4515060318
X46740152
J7051915822
J7916150007
M4513943902
J0702051394
M4513944010
M397808
J4751200118
J4802120114
N4514150804
N4514150702
J7051910083
Q4514842402 (4)
R4514843503
J071463
J705173
J7051915820
M4513944201
J47512101419 (16)
5-36
Downloaded from www.Manualslib.com manuals search engine
Part Description
10’ Gate Arm Section
4” Gate Arm Light
Sleeve, Weight Gate Arm
Studs for Counterweights
Exit Gate Stud Plate
3/4” SS Plate Washer
3/4” SS Lock Washer
3/4” Hex Nut
Label “Exit Gate”
Label “Wiring Diagram”
29-lb Counterweights
Signal Light, 4 Unit
X-Buck, Hi-Intensity
Track Sign 5”
4 Unit 120B LED
Weight Kit 16-18’
High Wind Bracket Flex
2-Track Sign
Mast 13’-6” x 5”
ST 90 Degree Offset Arm
Mast
U” Bolt 5” SS
Washer, 5/8 FT SS
Nut, 5/8 Hex SS
Jct. Box/XARM4-Unit/No Heads
Jct. Box/XARM4-Unit/No Heads
4” Tip Light with Cable & Bulb
Serrated Washer
Plate Adapter
Lamp, 10V, 18W
Bell
High Wind Bracket, Rigid
6’-9’Mast
3/4” SS Lock Washer
SM 6495, Rev. 7, December 2008
Parts List
5.16. Gate Arm Light Fuse Retrofit Kit
Table 5-18 lists the parts included in the gate arm light fuse retrofit kit (X46700039).
Table 5-19 lists the parts included in the fuse holder assembly (N46719101).
Table 5-18 - Parts List for the Gate Arm Light Fuse Retrofit Kit (X46700039)
Item
Number
Description
Part Number
Quantity
1
2
3
Fuse Holder Assembly
Screw, 1/4 x 20 x 7/8”
Installation Manual
N46719101
J5001240181
S006495E
1
2
1
Table 5-19 - Parts List for the Fuse Holder Assembly (N46719101) (Figure 5-18)
Item
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Description
Part Number
Quantity
Mounting Bracket
Fuse Box, 4 Gang ATC No. HL62935
Fuse, Automotive 10A, 32V, Red
Terminal Block
Screw, 8 – 32 x 5/8 Hex Head, SS
Nut, 8 - 32 Elastic Stop
Washer, No. 8 Plate SS
Screw, 1/4 – 20 x 7/8 Fil Head SS
Nut, 1/4 - 20 Elastic Stop
Washer, 1/4 Plate SS
Washer, 17/64 x 9/16 Cop
Nut, 14 - 24 Hex Brass NP
Nut, 14 - 24 Hex Brass
Wire, w 14PVC Black M258 M258-30
Terminal, Pre-insulated Dia.G, No.
321045
Terminal, Faston No. 16-14 No.
640905-1
Label, Vinyl Cloth
Label Fuse Holder Assembly
M46718901
J7100380196
J7100380131
M108571
J5072950120
J048080
J4751200109
J5001390114
J480260
J4751200112
J047818
J480300
J480301
A0455190001
1
1
4
1
2
2
6
1
1
1
12
4
4
3
J730044
4
J7091460520
4
J0759550002
M46719001
8
1
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
5-37
Parts List
Figure 5-18 - Gate Arm Light Fuse Retrofit Kit
5-38
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Gate Arm Clearing Graphs
6.
GATE ARM CLEARING GRAPHS
Figure 6-1 - Ten-Second Gate Arm Clearing Graph
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
6-1
Gate Arm Clearing Graphs
Figure 6-2 - Fifteen-Second Gate Arm Clearing Graph
6-2
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Gate Arm Clearing Graphs
Figure 6-3 - Twenty-Second Gate Arm Clearing Graph
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
6-3
Gate Arm Clearing Graphs
6-4
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008
Technical Support
7.
TECHNICAL SUPPORT
The Rapid Action Information Link (RAIL) Team is comprised of a group of experienced product and
application engineers ready to assist and resolve any technical issues concerning any US&S product.
Any questions regarding the contents of this Service Manual can be answered by contacting the RAIL
Team toll free at 800-652-7276 or via Internet e-mail: railteam@switch.com.
SM 6495, Rev. 7, December 2008
Downloaded from www.Manualslib.com manuals search engine
7-1
Technical Support
7-2
Downloaded from www.Manualslib.com manuals search engine
SM 6495, Rev. 7, December 2008