WCH 3590
WCH 3590
WCH 3590
Equipped With
3590 Series
Gate Mechanism
WESTERN-CULLEN-HAYES, Inc.
2700 West 36th Place • Chicago, Illinois 60632
Telephone: (773)254-9600 • Fax: (773)254-1110
Web Site: www.wch.com
TABLE OF CONTENTS
Introduction................................................................................................................. 1
10/2017
INTRODUCTION
Western-Cullen-Hayes, Inc. and it’s predecessor companies, have been serving the
railroad industry with crossing warning equipment for over 100 years. Among many “firsts”, we pro-
vided the first automatically actuated crossing gate signal installed in
North America in 1936.
This manual is designed to provide instructions on the installation and use of all
Model 10 Signals with 3590 Series Gate Mechanisms.
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SECTION 1
11-11/16" Sq.
Roadside
Figure 2A
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2. Remove the junction box cover to access the conduit adapter and hardware kit.
Attach the conduit adapter to the top of the base. Loosen the base clamp bolts
and install the lower pipe shield in the bottom of the base. Insert the signal mast
into the base and tighten the base clamp bolts. Place the base and mast assembly
on the foundation with the junction box cover facing on-coming traffic as shown in figure 3.
Secure the assembly to the foundation anchoring bolts.
Figure 3
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3. Secure the mechanism support assembly to the mast 48 inches above the top of the
foundation in a position as shown in figure 4 or 4A, depending on the style of support ordered.
4. Install 4 square head bolts into the slots in the rear of the mechanism case.
Set the mechanism onto the support assembly. Install saddle clamps and nuts.
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5. Remove hole plugs from mechanism case. Install conduit fittings, adapters,
cable grip and ventilator. Install the 1-1/2" sealtite from the base to the
mechanism. Be sure enough slack is available to allow rotation of the mechanism.
6. Remove nuts, washers and spline protectors from the ends of the mechanism
main shaft.
7. Make sure the main shaft is in the position it assumes when the gate arm is
down (horizontal). This condition exists when segment gear (A) is resting on
the horizontal stop pin (B) at point (C) as shown in figure 5.
Ref. No Description
A Segment Gear
C Contact Point
Horizontal
D Horizontal Stop Spring Housing
Stop Detail
Figure 5
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8. Refer to figure 6. Apply gate and counterweight support arms (B) to the
mechanism main shaft (A). Keeping the gate end of the supports in the down
(horizontal) position, install washers and hand tighten nuts on the main shaft.
If the mechanism is supplied with a sidewalk arm shaft (C), install the sidewalk
arm adapter to the shaft at this time. Do not install the sidewalk arm.
11. Assemble the arm by sliding sections together to achieve desired length. In some cases, it may be
necessary to drill holes in the inserted arm section. Secure
sections with provided hardware.
Ref. No Description
Gate and Counterweight
Support Installation
A Main Shaft
Figure 6
B Gate and Counterweight Support Arms
D Conversion Bracket
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PIVOT TYPE BREAKAWAY ADAPTER
Referring to figure 6, page 6, insert the cast breakaway adapter (E) into the gate arm
end section (F) and secure with provided hardware. Position the gate arm with adapter
attached 90 degrees from the mechanism assembly. Slip adapter onto mounting pin. Rotate arm 90
degrees, arm will lock in place.
12 3
Figure 7
Install brass shear bolts in holes as instructed below. Gate arm length is measured
from the centerline of the signal mast.
Install adapter to channel with provided hardware, then slide adapter sleeve into the mounting channel.
Install shear pin and cotter pin per figure 7A . Insert gate arm onto adapter sleeve and secure with
hardware provided.
Adapter Sleeve
Cotter Pin
Figure 7A
Insert shear pin; #3575-170-1 for 0-28' gate arms or #3575-201-1 for gate arms over 28'.
Adjust and loosely tighten 5 locking bolts to align and secure gate arm. Once aligned,
securely tighten the 5 locking bolt jam nuts.
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After securing gate arm to breakaway adapter, install gate lamps. See paragraph
14 and figure 11, page 12, for gate lamp installation.
Attach the pre-assembled gate arm to the gate arm support. Insert bolts, apply washer plates
on the inner side of the side boards. Secure with provided hardware. Remove tip section.
Re-insert section at desired length. In some cases, it may be necessary to drill holes in this
section. Secure the section with provided hardware. Install this gate arm and support
assembly to the counterweight support arms and secure with hardware provided.
See paragraph 14 and figure 11, page 12, for gate lamp installation.
A. Square single slot counterweights on cast iron counterweight arms with counterweight
support assembly
Maintain and secure the gate in the horizontal position. For arms longer than 32 feet, install
the counterweight extension arms to the counterweight arms. Install the clamp washers
to the extension arm bolts and insert the bolts through the slot from the inside of the counterweight
arm. Install the extension arms onto the bolts. Install flat washers and nuts, position the arms near
the center of the slot and tighten the nuts. Be sure that the teeth in the clamp washers are seated
into the teeth on the inside of the counterweight arm. Slide the counterweight support assembly
onto the extension arm and loosely tighten the three support assembly set screws. Install the
counterweight bolt from the inside of the extension arm. Install the counterweights by placing
each weight onto the support and sliding the slot over the counterweight bolt. Distribute the
weights evenly on the two arms. After all weights are installed, install the flat washer and nut
onto the counterweight bolt and tighten.
Slide the counterweight support assembly onto the counterweight arm. Position
the assembly near the center of the slot in the arm and loosely tighten the three
support assembly set screws. Install the clamp washer onto the counterweight
bolt and insert the bolt through the slot from the inside of the counterweight arm.
Install the counterweights by placing each weight onto the support and sliding
the slot over the counterweight bolt. If two counterweight arms are supplied,
distribute the weights evenly on the two arms. After all weights are installed,
install the flat washer and nut onto the counterweight bolt and tighten. Be sure
that the teeth in the clamp washer are seated into the teeth on the inside of the
counterweight arm.
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Extension Arm Bolt, Washer and Nut - 2
Extension Arm
Clamp Washers - 2
Figure 8
Counterweight Bolt,
Washer, and Nut
Clamp Washer
Strap
Figure 8A
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B. Square double slot counterweights on aluminum counterweight arms
Refer to figure 9.
Install the counterweight support plate to the counterweight arm by inserting the clamp washer
(short) studs through the slot from the outside of the arm. Install the clamp washers, flat washers
and nuts to the studs. Locate the support plate near
the center of the slot and tighten the clamp washer nuts. Be sure that the teeth in the clamp wash-
ers are seated into the teeth on the inside of the counterweight arm.
Raise and secure the gate arm in the up (vertical) position. Install the counterweights to the
counterweight (long) studs. Install the flat washers and nuts to these studs and hand tighten
the nuts. If two counterweight arms are supplied, distribute the weights evenly on the two arms.
Now position the weights near the middle of the slot in the weights and securely tighten the
counterweight nuts. Lower the gate arm to the horizontal position.
Counterweights
Support Plate
Counterweight
Clamp Washer Nut and Washer
Counterweight Arm
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C. Oblong counterweights on cast iron or aluminum counterweight arms
Raise and secure the gate arm in the up (vertical) position. Install the
counterweights to the counterweight (long) studs. Install the flat washers and
nuts to these studs and hand tighten the nuts. If two counterweight arms are
supplied, distribute the weights evenly on the two arms. Align the weights and i
nsert the alignment bolt into the holes at the bottom of the weights. Install
washers and nut onto the alignment bolt and securely tighten. Now position
the weights near the middle of the slot in the weights and securely tighten the
counterweight nuts. Lower the gate arm to the horizontal position.
Counterweights
Support Plate
Clamp Washer Counterweight
Nut and Washer
Counterweight Arm
Alignment Bolt
Inside View, Arm Horizontal Outside view, Arm Vertical
Figure 10
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14. Install gate arm lights using provided hardware. Attach cable to the arm using eyelets provided.
Leave slack in the cable between eyelets to provide drip points. Route cable through cable grip
installed in the mechanism and terminate wires at required binding posts. Refer to figure 11 for
proper lamp spacing.
15. Install signal light units, signs and bell or pinnacle as required.
16. Wire size for the motor circuit should be calculated so that the wire selected has
no more than 0.1 ohm resistance between the battery and the mechanism terminals.
Wire should be soft drawn copper.
2-Way Length of Run Wire Size Refer to AAR and FRA specifications
0 - 60 ft. #6AWG for battery stand-by power as
60 - 120 ft. 2-#6AWG or determined by the calculated
1-#4AWG mechanism and lamp load per the
Over 120 ft 3-#6AWG or crossing application.
1-#2AWG
Figure 11
17. Complete field electrical wiring of mechanism, signal lights, and bell as required.
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18. Horizontal Torque Adjustment
Open mechanism cover and place gate in horizontal position. Gently push
down on the counterweights to raise the gate arm about 2 feet from
horizontal.
Attach the 7/8" socket attached to the torque wrench onto the hex surface
on the motor pinion gear.
Slowly release the counterweight arm and allow the wrench to rotate and
rest against the housing. Note the scale reading.
The reading should be between 50 and 100 pounds regardless of the length
of the gate arm.
If adjustment is required, loosen the counterweight bolt nut and the lower
two counterweight support assembly set screws to allow the weights to be
moved.
If the reading is more than specified, move the counterweights away from
the mechanism.
If the reading is less than specified, move the counterweights toward the
mechanism.
When weights are installed on two counterweight arms, move the weights
on each arm proportionally.
After the proper scale reading is achieved, tighten the counterweight nut
just enough so that the weights do not move and the clamp washer teeth
are securely seated into the teeth in the counterweight arm.
Attach the 50 pound spring scale to the gate arm at a point located 10 feet
from the center of the mechanism main shaft.
Lift the gate by the scale and note the scale reading. The scale reading
should be 5 to 10 pounds regardless of the length of the gate arm. See
figure 12, page 14.
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If adjustment is required, loosen the counterweight bolt nut and the lower two
counterweight support assembly set screws to allow the weights to be moved.
If the reading is more than specified, move the counterweights away from the
mechanism.
If the reading is less than specified, move the counterweights toward the
mechanism.
When weights are installed on two counterweight arms, move the weights on
each arm proportionally.
After the proper scale reading is achieved, tighten the counterweight nut just
enough so that the weights do not move and the clamp washer teeth are securely
seated into the teeth in the counterweight arm.
For gate arms longer than 32 feet using counterweight extension arms, adjust
the horizontal torque by moving the extension arms within the slot in the
counterweight arm per the procedure outlined above.
10 Feet
Figure 12
Gently push down on the counterweights to raise the gate arm about 2 feet
from horizontal.
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Attach the 7/8" socket attached to the torque wrench onto the hex surface on
the motor pinion gear.
Slowly release the counterweight arm and allow the wrench to rotate and rest
against the housing. Note the scale reading.
The reading should be between 50 and 100 pounds regardless of the length of the
gate arm.
If adjustment is required, loosen the clamp washer nuts to allow the weights to
be moved.
If the reading is more than specified, move the counterweights away from the
mechanism.
If the reading is less than specified, move the counterweights toward the
mechanism.
When weights are installed on two counterweight arms, move the weights on
each arm proportionally.
After the proper scale reading is achieved, tighten the clamp washer nuts
securely. Be sure the teeth on the clamp washers are securely seated into
the teeth in the counterweight arm.
Attach the 50 pound spring scale to the gate arm at a point located 10 feet from
the center of the mechanism main shaft.
Lift the gate by the scale and note the scale reading. The scale reading should be
5 to 10 pounds regardless of the length of the gate arm. See figure 13, page 16.
If adjustment is required, loosen the clamp washer nuts to allow the weights to be
moved.
If the reading is more than specified, move the counterweights away from the
mechanism.
If the reading is less than specified, move the counterweights toward the
mechanism.
When weights are installed on two counterweight arms, move the weights on
each arm proportionally.
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After the proper scale reading is achieved, tighten the clamp washer nuts
securely. Be sure the teeth on the clamp washers are securely seated into the
teeth in the counterweight arm.
Scale Reading
5-10 Pounds
10 Feet
A. Square single slot counterweights on cast iron counterweight arms with counterweight
support assembly
Attach the 7/8" socket attached to the torque wrench onto the hex surface
on the motor pinion gear.
With the wrench held securely, open the manual test switch (gold nut).
The arm will begin to descend. Slowly allow the wrench to rotate until the
wrench rests against the housing. Note the scale reading. Compare the
scale read ing with the torque specification for the applied length of gate
arm as listed in tables 2 and 3, pages 21-25, per your *counterweight
configuration. Manually assist the gate back to the vertical position. Remove
the torque wrench and close the test switch.
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CAUTION: Do not loosen the counterweight bolt nut too much as the
counterweights may slip in the counterweight slot and may
cause injury or the necessity to re-set the horizontal torque.
If the reading is more than specified, move the counterweights away from the
roadway.
If the reading is less than specified, move the counterweights toward the
roadway.
Repeat procedure as required until the scale reading is within the listed
specification.
When complete, securely tighten the counterweight bolt nut, the three set
screws and the set screw jam nuts. Remove the insulating material from the
motor down contact.
Place insulating material in the motor down contact. Refer to table 1, page
20, to determine location of the motor down contact.
Attach the 50 pound spring scale between the gate arm and the mast, on a
horizontal plane, at "X" distance from the center of the mechanism main shaft.
Refer to tables 2 or 3, pages 21-25, to determine "X" distance for the length of
applied gate arm per your *counterweight configuration. See figure 14, page 18.
Open the manual test switch (gold nut) to allow the gate arm to descend
approximately 5 degrees. Note the scale reading and compare with the specifi-
cation in tables 2 or 3, pages 21-25.
If the reading is more than specified, move the counterweights away from the
roadway.
If the reading is less than specified, move the counterweights toward the
roadway.
Manually assist the gate back to the vertical position, close the test switch,
remove the insulating material from the motor down contact and remove the
spring scale.
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When complete, securely tighten the counterweight bolt nut, the three set
screws and the set screw jam nuts.
Scale Reading
See Table 2 or 3
Page 21-25
Figure 14
Attach the 7/8" socket attached to the torque wrench onto the hex
surface on the motor pinion gear.
With the wrench held securely, open the manual test switch (gold nut).
The arm will begin to descend, slowly allow the wrench to rotate until the
wrench rests against the housing. Note the scale reading. Compare the
scale reading with the torque specification for the applied length of gate
arm as listed in tables 2 and 3, pages 21-25, per your *counterweight
configuration. Manually assist the gate back to the vertical position,
remove the torque wrench and close the test switch.
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If the reading is more than specified, move the counterweights away from
the roadway.
If the reading is less than specified, move the counterweights toward the
roadway.
Repeat procedure as required until the scale reading is within the listed
specification.
When complete, securely tighten the counterweight stud nuts and remove
the insulating material from the motor down contact.
Attach the 50 lb spring scale between the gate arm and the mast, on a
horizontal plane, at "X" distance from the center of the mechanism main
shaft. Refer to tables 2 or 3, pages 21-25, to determine "X" distance for the
length of applied gate arm per your *counterweight configuration.
Open the manual test switch (gold nut) to allow the gate arm to descend
approximately 5 degrees. Note the scale reading and compare with the
specification in tables 2 or 3, pages 21-25.
If the reading is more than specified, move the counterweights away from
the roadway.
If the reading is less than specified, move the counterweights toward the
roadway.
Manually assist the gate back to the vertical position, close the test switch,
remove the insulating material from the motor down contact and remove the
spring scale.
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Scale Reading
See Table 2 or 3
Page 21-25
Distance "X"
See Table 2 or 3
Page 21-25
Figure 15
Table 1
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Table 2A
Torque Spring
Gate Arm Counterweight Counterweights
Counterweight Wrench Scale Distance
Length in Supplied in ......Supplied
Arms Reading Reading "X" in Feet
Feet Pounds 25lb 50lb
(ft.lbs) (lbs)
18 1 175 1 3 200 36 5
19-20 1 300 2 5 200 38-40 5
21 1 300 2 5 210 42 5
22 1 300 2 5 220 42 5
23 1 300 2 5 230 42 5
24 1 300 2 5 240 48 5
25 2 350 2 6 250 50 5
26 2 350 2 6 260 26 10
27 2 350 2 6 270 27 10
28 2 350 2 6 280 28 10
29 2 400 4 6 290 29 10
30 2 400 4 6 300 30 10
31 2 400 4 6 310 31 10
32 2 400 4 6 320 32 10
33 2+ Extension 400 4 6 330 33 10
34 2+ Extension 400 4 6 340 34 10
35 2+ Extension 400 4 6 350 35 10
36 2+ Extension 400 4 6 360 36 10
37 2+ Extension 400 4 6 370 37 10
38 2+ Extension 400 4 6 380 38 10
39 2+ Extension 400 4 6 390 39 10
40 2+ Extension 400 4 6 400 40 10
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Table 2B
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Table 2C
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Table 2D
Torque Spring
Gate Arm Counterweight Counterweights Distance
Counterweight Wrench Scale
Length in Supplied in .......Supplied ......"X"
Arms Reading ..Reading
Feet Pounds 25lb 50lb in Feet
(ft.lbs) (lbs)
18 2 250 2 4 200 36 5
19 2 350 2 6 200 38 5
20 2 350 2 6 200 40 5
21 2 350 2 6 210 42 5
22 2 350 2 6 220 44 5
23 2 350 2 6 230 46 5
24 2 350 2 6 240 48 5
25 2 450 2 8 250 50 5
26 2 450 2 8 260 26 10
27 2 450 2 8 270 27 10
28 2 450 2 8 280 28 10
29 2 500 4 8 290 29 10
30 2 500 4 8 300 30 10
31 2 500 4 8 310 31 10
32 2 500 4 8 320 32 10
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Table 3
Torque Spring
Gate Arm Counterweights Distance
Counterweight Wrench Scale
Length in Supplied in ......."X"
Arms Reading Reading
Feet Pounds in Feet
(ft.lbs) (lbs)
14 1 175 175 35 5
15 1 175 175 35 5
16 1 175 175 35 5
17 1 225 175 35 5
18 1 225 180 36 5
19 1 275 190 38 5
20 1 275 200 40 5
21 1 275 210 42 5
22 1 275 220 44 5
23 1 300 230 46 5
24 1 350 240 48 5
25 2 375 250 50 5
26 2 400 260 26 10
27 2 425 270 27 10
28 2 475 280 28 10
29 2 525 290 29 10
30 2 600 300 30 10
31 2+ Extension 400 310 31 10
32 2+ Extension 425 320 32 10
33 2+ Extension 450 330 33 10
34 2+ Extension 475 340 34 10
35 2+ Extension (1 500 350 35 10
36 2+ Extension (1 525 360 36 10
37 2+ Extension (1 550 370 37 10
38 2+ Extension (1 575 380 38 10
39 2+ Extension (1 600 390 39 10
40 2+ Extension (1 625 400 40 10
41 2+ Extnesion (1 650 410 41 10
42 2+ Extension (1 675 420 42 10
43 2+ Extension (1 700 430 43 10
44 2+ Extension (1 725 440 44 10
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SECTION 2
INTERNAL ADJUSTMENT
The horizontal and vertical stops are set at the factory. If it is necessary to
adjust the stops in the field, follow these directions and refer to figure 5, page 5.
a. Lower the gate to horizontal position. The segment gear (A) should be
resting on the horizontal stop pin (B) at point (C). The clearance between
the segment gear and the stop pin is 0.0 inch.
c. Attach the angle finder, PN: 3590-1014 to the main shaft and position
the angle finder so that a reading of 0 degrees is shown.
d. To adjust the horizontal gate position, loosen the stop pin lock nut then
turn the spring housing in or out until the arm is parallel with the roadway.
e. Note the reading on the angle finder. If the arm has been adjusted more
than 5 degrees either side of 0 degrees, it will be necessary to adjust some
of the contact cams, especially the snub contact cam. Refer to section 2.3,
page 27, for contact cam adjustment instructions.
If your requirements are such that the gate must rest at more or less than
the 86 degrees vertical factory setting, the motor up contact cam will have
to be adjusted to stop the gate arm at the desired vertical position.
a. Place the gate in the horizontal position by loosening the gold test nut.
Attach the angle finder, PN: 3590-1014 to the main shaft and position
the angle finder so that a reading of 0 degrees is shown.
b. Loosen the motor up contact cam and rotate the cam downward until the
contact is open and the cam has cleared the contact.
d. Apply finger pressure on the motor up contact to close the contact, the gate
will begin to rise. Remove finger pressure when the gate is near the desired
vertical position. Apply pressure again if necessary to jog the gate to the
final desired position.
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f. Holding the metal frame of the cam, rotate the cam upward until the cam
surface is approximately 1/16-1/8 inch above the contact cam follower. Be
certain that the sliding portion of the cam is fully downward within the cam
frame. Tighten the contact cam. Refer to section 2.3 below for specifications
on the contact and cam clearances.
g. When complete, cycle the gate. Note the reading on the angle finder. If the
reading is between 84 and 90 degrees, adjust the vertical stop pin. Refer to
instruction below. If the reading is less than 86 degrees, it will be necessary
to adjust the gate clear cam. A minimum differential of 4 degrees between
the closing of the gate clear contact and the opening of the power up contact
must be maintained. Refer to section 2.3 below for contact cam adjusments.
h. To adjust the vertical stop pin (E), remove the stop pin cover (K).
Turn the stop pin nut (F) counterclockwise until the stop pin just contacts
the segment gear (A) at (G). Then turn the nut clockwise until a minimum
clearance of 3/32 inch is achieved between the stop pin (E) and the segment
gear (A) at point (G). Check this with a 3/32 inch wire gauge, PN:3590-1013.
Re-install and tighten the cover. NOTE: After cycling of a pedestrian
mechanism, (3595, 3596), this clearance is no longer required. The segment
gear will rest against the vertical stop pin in normal operation.
WARNING: Do not place hands into the gear area when checking
this clearance.
Cams and contacts are factory set at the positions shown on the wiring diagram.
Be sure that the slots in the power up cam (G) are kept free of foreign material
at all times, and cam follower surfaces are clean.
a. Beginning with the gate in the horizontal position, attach the angle finder,
PN: 3590-1013 to the main shaft and position it so that a reading of 0 degrees
is shown.
b. Move the gate to the position required. Refer to the mechanism wiring
diagram for the normal operational positions.
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c. Loosen one allen head cap screw (A) or (L), rotate the cam to a position
where the contact cam follower (B) just touches the end of the cam surface
(E) or (H).
EXAMPLE: If adjusting the motor down cam, position and hold the gate
at 45 degrees, position the cam so that the motor down contact
is open and the cam follower (B) is touching the end of the cam
surface (E).
d. After adjustment, be certain to tighten the allen head cap screw securely.
Caution needs to be taken when tightening the cap screws referred
to below.
Referring to figure 16B, the motor up cam has a slotted insert (G) which
allows for 3/16 inch radial travel. Refer to table 4, page 30, for motor up
cam and contact position. When cam insert (H) is rotated to the closest
point toward cap screw (L), a gap of 1/16 inch must be maintained between
the cap screw and the cam insert at location (J).
Referring to figure 16A, for all other cams, a gap of 1/16 inch must be
maintained between cam insert (E) and cap screw (A) at position (K).
To adjust a contact, it will be necessary to bend the contact spring to achieve the
following specifications by using the contact adjusting tool, PN: ES-6104-2.
When adjusting contacts, gently bend the contact spring by applying several
gentle upward or downward forces against the contact spring. Recheck the gap
or pressure after each operation. Repeat this procedure until specification is
achieved. Overbending may damage the contact and make it impossible to
achieve proper contact spring pressure. Always apply the adjusting tool at the
top of the contact directly beneath the circuit controller board. Never bend the
contact body or at the bend near the contacting surface. Do not twist the contact
while bending. Minimum contacting area must be 1/4 inch.
Using an insulated 1/16 inch gauge, PN: 3590-1010, adjust contacts in the
following order. Refer to figure 16A.
a. With the contact in the fully open position, the clearance between the cam
follower (B) and the metal frame of the cam (C) must be a minimum of 1/16
inch. To adjust, bend the back contact until specification is achieved.
b. With the contact in the fully open position, the clearance between the
contacting surfaces (D and F) must be a minimum of 1/16 inch. To adjust,
bend the front contact until specification is achieved.
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Using an ounce spring scale, PN: 3565-211, and contact adjusting tool,
PN: ES-6104-2, adjust contact spring pressure as follows. Refer to figure 16A.
Position the gate so that the contact cam follower (B), is well upon the cam
surface (E) or (H) and the contact is fully closed. Hook the end of the scale
to the front contact at the bend (F), near the contacting surface and lift
gently until the contact opens. The reading should fall between 18 to 28
ounces on the motor up contact and between 16 to 24 ounces for all other
contacts. To adjust, bend the front contact while the contact is closed.
To reduce pressure, bend the contact away from the cam. To increase
pressure, bend the contact toward the cam.
Figure 16 A Figure 16 B
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Motor up Contact Cam Location
Table 4
5. Hold Clear Device
The armature support assembly should have appreciable end play on its pivot
and should not be restricted in any manner by friction or any tendency to bind.
Engagement between the ratchet wheel, (1, figure 18, page 43), and the pawl,
(2, figure 19, page 44), is controlled by the position of the hold-clear device on the
motor face. With the hold clear coils energized and the armature, (10, figure 19,
page 44), against the pole faces, the tip of the pawl should just touch the bottom
or root of the space between the ratchet wheel teeth. This adjustment is set at the
factory. If field adjustment becomes necessary, loosen the three hex head cap
screws holding the hold-clear to the motor and move the entire hold-clear assembly
to the proper position. Retighten mounting screws.
In the de-energized position, the pawl should clear the ratchet wheel teeth by
a minimum of .020 inch. This clearance is controlled by stop screw and attendant
lock nut. This adjustment should be maintained in service and the lock nut kept
tight to prevent movement of the stop screw.
The pawl is double-sided. When the tip becomes worn to the point where it will
not properly engage the ratchet wheel, it may be taken off the hold-clear device,
turned around and re-attached. When both tips are worn, the pawl and pawl
screw should be replaced.
The armature support bracket springs, (6, figure 19, page 44), are adjusted as
follows; with the hold-clear coil energized and the armature held against the pole
faces, the nuts are tightened until the coils of the springs are compressed together
lightly, then each nut is backed off one-half turn and locked in place with the
cotter pin.
The parallelism between the hold-clear armature, (10, figure 19, page 44), and its
pole pieces, (15, figure 19, page 44), at time of latching is controlled by set screw
and attendant lock nut. The lock nut should be kept tight to prevent movement
of the set screw. If field adjustment is required, this measure should be under
taken when hold-clear device is de-energized. If the parallelism adjustment is
changed, it will be necessary to re-adjust the pawl to ratchet clearance and the
stop springs per the above instructions.
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6. Motor Down Contact Adjustment on Hold Clear 38-0045-340
Disconnect one wire from the terminal block (10). Apply hand pressure to the
armature plate, (10, figure 19, page 44), to hold the armature in the closed,
(energized) position. Check the gap between the contacts (8 and 9). The gap
should be set at 0.032 inch. Check with gauge, PN: 3590-1011. To adjust the gap,
insert contact adjusting tool, PN: ES-6104-2 onto the lower contact (9), near the
mounting block spacer (4). To increase the gap, apply several forward forces on
the tool to bend the contact. To decrease the gap, apply several rearward forces to
bend the contact.
Release the armature. Check the contact spring pressure. Place the straight end
of the ounce spring scale, PN: 3565-211, on the upper side of the lower contact (9)
near the bend in the contact. Press downward on the contact until the contact just
opens. The reading should be no less than 4 ounces. If it is necessary to adjust the
contact spring pressure, insert contact adjusting tool, PN: ES-6104-2 onto the lower
contact (9), near the mounting block (4). With a finger on the top of the upper
contact (8), securely hold the contacts against the contact operating cam, (8, figure
19, page 44). To increase the pressure, apply several rearward forces on the tool to
bend the contact.
7. Ratchet Wheel
The ratchet wheel includes a press-fit, pre-lubricated and shielded one-way clutch.
No maintenance of this unit is required. When the ratchet wheel becomes worn so
as to interfere with proper latching or if the internal clutch becomes inoperative, it
should be replaced.
A snap ring, (5) and the key hold the ratchet wheel in place on the motor shaft.
If the ratchet wheel is removed for any reason, the snap ring should be replaced.
When remounting the snap ring, care should be taken to insure that the
rounded edges of the snap ring face into the ratchet wheel, thereby reducing the
wear of the ratchet wheel cover plate. When positioned properly, the snap ring
should be no closer to the ratchet wheel cover plate than 0.010 inch. A light coat
of multipurpose oil should be maintained between the two parts to reduce wear.
8. Wiring Diagram
10/2017 31
Wiring Diagram Reference
Table 5
10/2017 32
10/2017 33
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10/2017 42
SECTION 3
GENERAL MAINTENANCE
1. Operational Tests.
All mechanisms are given a final inspection and are properly lubricated and
adjusted before shipment from the factory.
To increase speed, move slide on the limit resistor upward; to reduce move
downward. The limit resistor is mounted to the left of the snub resistor.
10/2017 43
Gravity Descending Adjustment
To increase speed, move slide on the snubbing resistor downward; to reduce move
upward. The snub resistor is mounted to the right of the limit resistor.
Care should be taken to be sure that the resistor slide contact is bearing on the
windings with firm pressure and that the slide screw and locknut are securely
tightened.
Depending on gate arm length and voltage supplied, the arm should raise to the
clear position between 6 to 10 seconds.
Relay Specifications
Maximum
Minimum
Coil Required
Mechanism Relay Drop
Resistance Voltage To
Voltage
Pick
3590, 3593, 3593I, 3595, 3596 38-0050-200 1000 ohm 5.96 2.14
10/2017 44
SETUP CHECKLIST
6. Check and adjust descending time. Resistor screws tight. _____ seconds
15. 3/32" clearance between segment gear and vertical stop. _____
16. Contact cams adjusted if gate stop positions have been altered.
10/2017 45
2. Lubrication.
The mechanism gear train, main shaft and motor bearings are
pre-lubricated and sealed. No periodic lubrication is required for
these bearings.
The gear teeth are to be lubricated periodically with, PN: 3590-1733 Areoshell 33
all-temperature lubricating grease.
3. Motor Service.
The motor has a totally enclosed, non-ventilated housing and has pre-
lubricated sealed bearings.
The motor brushes should be periodically inspected for wear. Replace brushes
and springs, (11 and 12) when carbon portion has worn to 5/8 inch length or
less.
NOTE: Motor brush caps (13) screw on. Remove caps by turning
counter-clockwise. Hand tighten only when replacing caps.
Always remove motor brushes (11) when gate arm is in the
horizontal position. No dynamic braking is provided with a
brush removed. Note: brushes are spring-loaded (12) in
holder (10), care should be taken during disassembly.
The optional arc suppressor, (Item 9, figure 21, page 47) is a fused, passive
electronic network encapsulated in a throw-away cartridge. A defective
arc suppressor can be detected by removing the unit from the circuit
controller and testing it with an analog ohmmeter. After shorting the
two arc suppressor mounting lugs together to discharge any stored energy,
set the meter on the highest resistance scale and touch each probe to one
of the arc suppressor mounting lugs. If the unit is functioning properly,
a noticeable kick will be observed on the meter, followed by a gradual
return to full scale as the capacitor charges. If the unit is bad, the meter
will show an open circuit.
10/2017 46
SECTION 4
OPTIONAL EQUIPMENT
1. Sidewalk Arm Kit, (figure 22, page 50), permits the addition of a sidewalk
arm to the mechanism in service as operator of roadway arm. The kit
includes necessary bearings, gears, keys, shafts and instructions. Does not
include sidewalk arm bracket or sidewalk arm.
2. Heater, (figure 23, page 51), may be attached to the mechanism for
prevention of frost formation on controller contacts.
4. Set-up and adjustment tools are listed on the last page of the mechanism
parts section.
10/2017 47
3590 SERIES
CROSSING GATE MECHANISMS
Internal View
Contents Page
10/2017 48
Basic Gate Mechanism
Single End
2 Wire 3 Wire Vital Non-Vital Standard
Features Contacts Mainshaft
Control Control Relay Relay Mainshaft
(RH)
3590 X X 7 X
3590B X X 5 X
3593 X X 7 X
3593B X X 5 X
3593C X X 5 X
3593E X X 6 X
3593F X X 6 X
3593I X X 7 X
3593NJ X X 7 X
3595 X X 7 X
3596 X X 7 X
3596B X X 5 X
3596NJ X X 7 X
Note:
Add Suffix - 132 for sidewalk kit. Specify field or track side sidewalk arm.
10/2017 49
CROSSING GATE ASSEMBLY
Figure 17
4 C 30 27
54* 35 39 19
D 26 31
36 8 18
3
45
44
15, 22, 38
50 20
46 51
1, 25, 29, 34
52 1, 25, 29, 34
53
16, 48
16, 48
11
32
19-A
55
37, 43
B 14 58
57 A 47
42 43 13
40
12
38
10
9
17
38
10
21
2
33
5 28 23
24 41
10/2017 50
3590 SERIES
CROSSING GATE ASSEMBLY
REPLACEMEENT PARTS
10/2017 51
REPLACEMENT PARTS
10/2017 52
MOTOR AND RATCHET WHEEL
REF. A
Figure 18
10/2017 53
HOLD CLEAR ASSEMBLY
REF. B, B1
Figure 19
16 23
26
2, 9
20 1, 1A
Reference B
25 22 21
17
19
11, 12, 28, 29, 30
7
14
3
4
5
13 15 10 6
16 18
23 Reference B
26
24
20
27 8
17
Reference B1
10/2017 54
HOLD CLEAR ASSEMBLY
Rev. 1/97
10/2017 55
MOTOR DOWN CONTACT BLOCK
38-0045-410
Figure 20
11, 12
10
1
14
13 16
15
7 3
2
5
8
4 9
6
10/2017 56
CIRCUIT CONTROLLER ASSEMBLY
REF. C
Figure 21
12 13 7* 1 10
11
8*
14
6 15
4 5
3
9*
10 Connector 1705-4
13 Washer 10708
10/2017 57
Circuit Controller
3590 X
3590B X
3593 X
3593B X
3593C X
3593E X
3593F X
3593I X
3593NJ X
3595 X
3596 X
3596B X
3596NJ X
Contact s 7 5 7 5 5 6
10/2017 58
MECHANISM RELAYS
REF. D REF. D1
10/2017 59
SIDEWALK KIT
Figure 22
3 10
6
8, 9 5 1 5 4, 9
2
E Sidewalk Arm Shaft Kit (for Right or Left Hand use) 3590-295
REPLACEMENT PARTS
2 Gear Segment w/clamp and Assembly Bolts, for Sidewalk Shaft. 3590-224
3 Gear Segment w/clamp and Assembly Bolts, for Main Shaft. 3590-225
4 Collar 3590-227
5 Bearing 3590-248
8 Cap 3580-226-M
10/2017 60
CONTACT HEATER ASSEMBLY
Figure 23
10/2017 61
SET-UP AND ADJUSTMENT TOOLS
10/2017 62
Page left blank intentionally.
10/2017 63
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