Installation Instructions - Model 10 Signal

INTRODUCTION
Western-Cullen-Hayes, Inc. and its predecessor companies, have been serving the
railroad industry with crossing warning equipment for over 100 years. Among many firsts, we provided 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.
Rev. 5/98
SECTION 1
INSTALLATION INSTRUCTIONS - MODEL 10 SIGNAL
1.
Install foundation in proper location per the requirements of the installation.

Refer to figures 1 and 2 for typical foundation details.
Suggested Concrete Foundation

for Model 10 Gate Signal Using
2149 Junction Box Base
Galvanized Steel Foundation

No. 1181-9
Figure 1
Figure 2
11-11/16" Sq.
Wire Entrance - 3-3/4" sq.

Track Side
17" Sq.
Field Side
Roadside
Plan View of Type 2149
Junction Box Base
Figure 2A
2
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.
Typical Model 10 Signal
Figure 3
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.
Cast Mechanism Support Installation
Figure 4
Clamp Type Mechanism Support Installation
Figure 4A
Rev. 11/95
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
Segment Gear
Horizontal Stop Pin
Contact Point
Horizontal Stop Spring Housing
Vertical Stop Pin
Vertical Stop Pin Nut
Clearance Gap 3/32" Minimum
Horizontal Stop Pin Locknut
Horizontal Stop Pin Cover
Vertical Stop Pin Cover
Horizontal
Vertical 3/32"
Stop Detail
Figure 5
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.
CAUTION:
9.
10.
Do not apply counterweight before the roadway gate arm

is installed.
Install conversion bracket or breakaway adapter channel (D) to the counterweight

support arms (B). Secure with provided hardware. The square head bolts fit into
the recess on the support arm with the threads facing up.
Tighten the main shaft nuts (A).
Installation of fiberglass or aluminum/fiberglass gate arms
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.
Gate and Counterweight

Support Installation
Ref. No
Description
Main Shaft
Gate and Counterweight Support Arms
Sidewalk Arm Adapter
Conversion Bracket
Cast Breakaway Adapter
Gate Arm Section
Figure 6
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.
Top View of Conversion
Bracket Assembly
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.
0-18' Gate Arms - Holes 2 and 3
19'-28' Gate Arms - Holes 1 and 2
Over 29' Gate Arms - Holes 1, 2 and 3
CHANNEL TYPE BREAKAWAY ADAPTER

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.
Shear Pin
Locking Bolt
Jam Nut
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.
Rev. 8/96
After securing gate arm to breakaway adapter, install gate lamps. See paragraph
14 and figure 11, page 12, for gate lamp installation.
12.
Installation of Wooden Gate Arms

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.
13.
Installation of Counterweights
A.
Square single slot counterweights on cast iron counterweight arms with counterweight
support assembly
Refer to figure 8, page 9.
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.
Refer to figure 8A, page 9.
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.
Extension Arm Bolt, Washer and Nut - 2
Extension Arm
Clamp Washers - 2
Single Slot Counterweight Assembly with Extension Arm
Figure 8
Counterweight Support Assy.
Counterweights
Counterweight Bolt,
Washer, and Nut
Clamp Washer
Strap
Set Screw and Lock Nut
Single Slot Counterweight Assembly
Figure 8A
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 washers 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
Nut and Washer
Clamp Washer
Clamp Washer Stud

Clamp Washer Nut and Washer
Counterweight Stud
Counterweight Arm
Outside view, Arm Vertical
Inside View, Arm Horizontal
Double Slot Counterweight Assembly
Figure 9
10
C.
Oblong counterweights on cast iron or aluminum counterweight arms

Refer to figure 10.
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 washers 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. 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
Clamp Washer Stud

Clamp Washer Nut and Washer
Counterweight Stud
Counterweight Arm
Alignment Bolt
Inside View, Arm Horizontal
Outside view, Arm Vertical
Oblong Counterweight Assembly
Figure 10
11
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.

Minimum recommended battery and wire requirements
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.
Minimum Wire Recommendation:
(Battery to mechanism terminals)
Battery Recommendation:
2-Way Length of Run

0 - 60 ft.
60 - 120 ft.
Refer to AAR and FRA specifications

for battery stand-by power as
determined by the calculated
mechanism and lamp load per the
crossing application.
Over 120 ft
Wire Size
#6AWG
2-#6AWG or
1-#4AWG
3-#6AWG or
1-#2AWG
Specified
length of
gate arm
14 Ft.
15 Ft.
16-17 Ft.
18-19 Ft.
20-23 Ft.
24-28 Ft.
29-31 Ft.
32-34 Ft.
35-37 Ft.
38 Ft. & Over
Dimension
"A"
Dimension
"B"
Dimension
"C"
6"
18"
24"
28"
28"
28"
36"
36"
36"
36"
36"
36"
36"
41"
4'-0"
5'-0"
6'-0"
7'-6"
9'-0"
10'-0"
5'-0"
5'-0"
5'-0"
5'-0"
5'-0"
5''-1"
6'-0"
7'-6"
9'-0"
10'-0"
Suggested Roadway Gate Arm Light Spacing
Figure 11
17.
Complete field electrical wiring of mechanism, signal lights, and bell as required.
12
18.
Horizontal Torque Adjustment
A.
Square single slot counterweights on cast iron counterweight arms

with counterweight support assembly
NOTE: If sidewalk arm is being used, all torque adjustments must
be made with the sidewalk arm support installed and the
sidewalk gate arm not installed.
1. Using torque wrench PN: 3590-K9
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.
2. Using spring scale PN: 3562-210
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.
13
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.
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.
Extension Arm
Scale Reading
5-10 Pounds
Increase
Adjust
Decrease
10 Feet
Shown with Square Counterweights
Figure 12
B.
Square double slot counterweights on aluminum counterweight arms

or oblong counterweights on cast iron or aluminum counterweight arms
NOTE: If sidewalk arm is being used, all torque adjustments must be
made with the sidewalk arm support installed and the sidewalk
gate arm not installed.
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.
14
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.
mechanism.
mechanism.
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.
mechanism.
mechanism.
15
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
Increase
Adjust
Decrease
10 Feet

Shown with Oblong Counterweights
Figure 13
19.
Vertical Torque Adjustment
A.
Square single slot counterweights on cast iron counterweight arms with counterweight
support assembly
Refer to figure 14, page 18
1.
Using torque wrench PN: 3590-K9

Place the gate in the vertical position.
Place insulating material in the motor down contact. Refer to table 1,
page 20, to determine location of the motor down contact.
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.
NOTE:
Do not attempt to obtain readings with a foot pound

torque wrench.
If adjustment is required, loosen the counterweight bolt nut just enough to

allow the weights to be moved when the counterweight support assembly set
screws are turned. To adjust, move the set screws with a wrench as follows.
16
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.
roadway.
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 specification in tables 2 or 3, pages 21-25.
If adjustment is required, loosen the counterweight bolt nut just enough to
allow the weights to be moved when the counterweight support assembly set
screws are turned. To adjust, move the set screws with a wrench as follows.
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.
roadway.
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.
17
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
Extension Arm
Distance "X"
See Table 2 or 3
Page 21-25
Increase
Adjust

Shown with Square Counterweights
Figure 14
B.
Square double slot counterweights on aluminum counterweight

arms or oblong counterweights on cast iron or aluminum
counterweight arms
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.
NOTE:
Do not attempt to obtain readings with a foot pound

torque wrench.
If adjustment is required, loosen the counterweight stud nuts just enough to

allow the weights to slide in the weight slots.
18
Decrease
the roadway.
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 adjustment is required, loosen the counterweight stud nuts just enough to
allow the weights to slide in the weight slot.
the roadway.
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.
When complete, securely tighten the counterweight stud nuts.
19
Scale Reading
See Table 2 or 3
Page 21-25
Distance "X"
See Table 2 or 3
Page 21-25
Increase
Adjust
Decrease

Shown with Oblong Counterweighs
Figure 15
Motor
Down Contact
Mechanism
Location
Contact Location
3590, 3590B, 3593, 3593I, 3593NJ, 3595, 3596, 3596NJ.
3593B, 3593C, 3593E, 3593F, 3596B.
3
Table 1
20
Table 2A
TABLE OF WEIGHT AND VERTICAL TORQUE VALUES FOR

FIBERGLASS AND ALUMINUM/FIBERGLASS GATE ARMS.
*SQUARE SINGLE SLOT COUNTERWEIGHTS WITH CAST IRON COUNTERWEIGHT ARMS
Spring
Scale
Reading
(lbs)
Counterweight
Arms
18
175
200
36
19-20
300
200
38-40
21
300
210
42
22
300
220
42
23
300
230
42
24
300
240
48
25
350
250
50
26
350
260
26
10
27
350
270
27
10
28
350
280
28
10
29
400
290
29
10
30
400
300
30
10
31
400
310
31
10
32
400
320
32
10
33
2+ Extension
400
330
33
10
34
2+ Extension
400
340
34
10
35
2+ Extension
400
350
35
10
36
2+ Extension
400
360
36
10
37
2+ Extension
400
370
37
10
38
2+ Extension
400
380
38
10
39
2+ Extension
400
390
39
10
40
2+ Extension
400
400
40
10
Rev. 11/95
Counterweight Counterweights
Supplied in
......Supplied
Pounds
25lb
50lb
Torque
Wrench
Reading
(ft.lbs)
Gate Arm
Length in
Feet
21
Distance
"X" in Feet
Table 2B

*OBLONG COUNTERWEIGHTS WITH CAST IRON COUNTERWEIGHT ARMS.
Gate Arm
Length in
Feet
Counterweight Counterweight
Arms
Supplied in
Pounds
Counterweights
Supplied
47lb.
Torque
Wrench
Reading
(ft.lbs)
Spring Scale
Reading
(lbs)
Distance
"X"
in Feet
18
188
200
36
19
235
200
38
20
235
200
40
21
235
210
42
22
235
220
44
23
235
230
46
24
235
240
48
25
329
250
50
26
329
260
26
10
27
329
270
27
10
28
329
280
28
10
29
376
290
29
10
30
376
300
30
10
31
376
310
31
10
32
376
320
32
10
33
564
12
330
33
10
34
564
12
340
34
10
35
564
12
350
35
10
36
564
12
360
36
10
37
564
12
370
37
10
38
564
12
380
38
10
39
564
12
390
39
10
40
564
12
400
40
10
22
Rev. 11/95
Table 2C

*OBLONG COUNTERWEIGHTS WITH ALUMINUM COUNTERWEIGHT ARMS.
Gate Arm
Length in
Feet
Counterweight Counterweight Counterweights

Arms
Supplied in
Supplied
Pounds
47lb.
Torque
Wrench
Reading
(ft.lbs)
Spring
Scale
Reading
(lbs)
Distance
"X"
in Feet
18
188
200
36
19
235
200
38
20
235
200
40
21
235
210
42
22
235
220
44
23
235
230
46
24
235
240
48
25
329
250
50
26
329
260
26
10
27
329
270
27
10
28
329
280
28
10
29
376
290
29
10
30
376
300
30
10
31
376
310
31
10
32
376
320
32
10
33
470
10
330
33
10
34
470
10
340
34
10
35
470
10
350
35
10
36
470
10
360
36
10
37
470
10
370
37
10
38
470
10
380
38
10
39
470
10
390
39
10
40
470
10
400
40
10
Rev. 11/95
23
Table 2D

*SQUARE DOUBLE SLOT COUNTERWEIGHTS WITH ALUMINUM COUNTERWEIGHT ARMS.

32 FOOT GATE MAXIMUM ALLOWED WITH THIS COUNTERWEIGHT SETUP.
Torque
Gate Arm
Counterweight Counterweights
Counterweight
Wrench
Length in
Supplied in
.......Supplied
Arms
Reading
Feet
Pounds
25lb
50lb
(ft.lbs)
Spring
Scale
..Reading
(lbs)
Distance
......"X"
in Feet
18
250
200
36
19
350
200
38
20
350
200
40
21
350
210
42
22
350
220
44
23
350
230
46
24
350
240
48
25
450
250
50
26
450
260
26
10
27
450
270
27
10
28
450
280
28
10
29
500
290
29
10
30
500
300
30
10
31
500
310
31
10
32
500
320
32
10
24
Rev. 11/95
Table 3

WOODEN GATE ARMS.
*SQUARE SINGLE SLOT COUNTERWEIGHTS WITH CAST IRON COUNTERWEIGHT ARMS
Counterweight
Arms
Counterweights
Supplied in
Pounds
Torque
Wrench
Reading
(ft.lbs)
14
175
175
35
15
175
175
35
16
175
175
35
17
225
175
35
18
225
180
36
19
275
190
38
20
275
200
40
21
275
210
42
22
275
220
44
23
300
230
46
24
350
240
48
25
375
250
50
26
400
260
26
10
27
425
270
27
10
28
475
280
28
10
29
525
290
29
10
30
600
300
30
10
Gate Arm
Length in
Feet
Spring
Scale
Reading
(lbs)
Distance
......."X"
in Feet
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
(1) Counterweights Inverted

Rev. 11/95
25
SECTION 2
INTERNAL ADJUSTMENT
1.
Horizontal Gate Position and Stop 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.
b.
Remove the horizontal stop cover (J).
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.
f.
2.
Tighten the stop pin locknut and re-install the cover.
Vertical Gate Position. Motor up Cam and Vertical Stop Adjustment

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.
c.
Tighten the gold test nut.
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.
e.
Note and record the angle finder reading.

26
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.
If the reading is less than 84 degrees, do not adjust the vertical
stop pin.
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:
3.
Do not place hands into the gear area when checking

this clearance.
Contact Cam Adjustments

Refer to figures 16A and 16B, page 29.
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, that cam and cam follower surfaces are clean and a light coating
of Bison all-temperature lubricating grease, PN: 3590-1650, or semaphore oil,
is present on the cam surface (E) and (H).
CAUTION: Do not use any other type of lubricant on the cam
surface. Do not lubricate the sides of the cam or the
cam frame.
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.
27
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).
4.
Circuit Controller Contact Adjustment

Bending adjustment of contacts is not normally required unless the
contact has been replaced.
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.
28
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.
CAUTION: Do not overbend the contact. Overbending may damage
the contact and make it impossible to achieve the correct
gap or contact spring pressure.
Cam and Contact Detail
Sliding Cam Detail
Figure 16 A
Figure 16 B
Ref. No
Description
Ref. No
Cap Screws
Attach Spring Scale

18-28 oz. Motor Up Contact
16-24 oz. All other Contacts
Cam Follower
Cam Slot
Cam Frame
Cam Insert Surface
Minimum Gap 1/16"
Minimum Gap 1/16"
Cap Screw
D
E
Description
Minimum Gap 1/16"

Cam Insert Surface
29
Motor up Contact Cam Location

Mechanism
Contact/Cam Location
3590, 3590B, 3593, 3593I, 3593NJ, 3595, 3596, 3596NJ
3593B, 3593C, 3593E, 3593F, 3596B
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.
Refer to figures 18, 19 and 20, pages 43, 44 and 46.
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.
Rev. 11/95
30
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.
CAUTION: Do not overbend the contact. Overbending may damage the
contact and make it impossible to achieve the correct gap or
contact spring pressure.
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
The following wiring diagrams illustrate the arrangement of mechanism wiring
and operating circuits for all 3590 series crossing gate mechanisms. The same
diagrams show the standard adjustment of all circuit controller contacts as set
at the factory.
31
Wiring Diagram Reference

Mechanism Model
Wiring Diagram
Page
3590, 3595
38-0045-321
32A
3590B
38-0045-320
32B
3593, 3593NJ, 3596, 3596NJ
38-0045-330
32C
3593B
38-0045-400
32D
3593C
38-0045-470
32E
3593E, 3593-J
38-0045-461
32F
3593F
38-0045-463
32G
3593I
38-0045-330-1
32H
3596B
38-0045-450
32I
3596-C
38-0045-469
32J
Table 5
32
Rev. 2/99
33
34
35
36
37
38
39
40
41
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.
Before placing any mechanism in service:
a.
Inspection should be made to insure that there is no oil, grease or dirt

on the armature or pole faces of the hold-clear magnet. These surfaces
should be kept clean at all times.
b.
Supply voltage should be maintained between 11 and 16 volts DC.

Observing polarity, check supply voltage at the motor supply terminal
points. Refer to proper wiring diagram for terminal points.
c.
Operate the mechanism through an up-down cycle and note operating

voltage readings. As the gate goes up, voltage should not drop below
11 volts and current should range from 6 to 20 amps. As the gate descends,
voltage should not drop below 11 volts and current should range from 6 to
15 amps. Readings will vary depending on the length of gate arm. If voltage
drops below 10 volts, check motor supply wiring between the battery and the
mechanism terminal points for proper wire sizing and voltage drop. Correct
wiring where necessary.
d.
Perform a gravity down test. Place a piece of insulating material, (business

card, credit card, etc.), between the motor up contacts. ( Refer to table 4,
page 30). Open the test switch. The gate should descend freely to the
horizontal position. When complete, remove the insulating material from
the contacts and close the test switch.
CAUTION: Before returning mechanism to service, be sure to
remove insulating material.
e.
Normal field descending time should be between 10 and 15 seconds

depending on gate arm length and local requirements. Long gate arms
should usually operate slower than shorter arms. Arms of unequal length
at the crossing should be adjusted to descend at equal times.
Powered descending speed, 90 to 45 degrees, is adjusted at the limit resistor.

Gravity descending speed from 45 to 5 degrees, is adjusted at the snubbing resistor.
Powered Descending Adjustment
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.
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.
f.
Check the clearing time:
Depending on gate arm length and voltage supplied, the arm should raise to the
clear position between 6 to 10 seconds.
g.
Check for grounds in the battery and control circuit wiring.
h.
Check hold-clear release voltage. Hold-clear should release at not

less than 2.5 volts DC, and hold-clear should energize between 7.5
and 10 volts DC.
Replace any hold-clear that does not energize by 10 volts.
i.
No field adjustments are recommended to the motor control relay.

Field tests suggested are:
1.
2.
Verify pick and drop values as listed in table 6.

Visually inspect contacts for arcing or burning.
Relay Specifications
Relay
Coil
Resistance
Maximum
Required
Voltage To
Pick
Minimum
Drop
Voltage
3590, 3593, 3593I, 3595, 3596
38-0050-200
1000 ohm
5.96
2.14
3593NJ, 3596NJ
38-0050-300
160 ohm
5.32
2.89
Relay
Coil
Resistance
Nominal
Pick
Nominal
Drop
3590B
91254-10
32.3 ohm
6.54
.72
3593B, 3593C, 3593E, 3593F,

3596B
91254-11
32.3 ohm
6.54
.72
Mechanism
Mechanism
NOTE: Replace any 91254 relay that fails to pick by 9 VDC.
44
SETUP CHECKLIST
Location: _______________________________
In Service Date: ______________
1.
Hold clear armature and pole faces clean.
_____
2.
Supply voltage between 11 and 16 volts DC.
_____ volts
3.
Voltage during gate up cycle.
_____ volts
4.
Amperage during gate up cycle.
_____ amps
5.
Gravity down test.
_____
6.
Check and adjust descending time. Resistor screws tight.
_____ seconds
7.
Check clearing time.
_____ seconds
8.
Check for grounds in wiring.
_____
9.
Check hold clear release voltage.
_____ volts
10.
Check relay pick voltage.
_____ volts
11.
Check relay drop voltage.
_____ volts
12.
Set horizontal gate arm torque.
_____ ft. lbs.
13.
Set vertical gate arm torque.
_____ ft. lbs.
14.
Gate parallel to roadway surface.
_____
15.
3/32" clearance between segment gear and vertical stop.
_____
16.
Contact cams adjusted if gate stop positions have been altered.

Motor up cam.
_____
Snub cam closed at 10 degrees.
_____
Installed by: _______________________________________________________

Checked by: _________________________________________________________
Rev. 5/98
45
2.
Lubrication.
Time interval for periodic lubrication will be governed by usage.
This interval, therefore, should be determined by the user.
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: 3590-1650
Bison all-temperature lubricating grease. Contact cams to be lubricated
as specified in section 2, paragraph 3, page 27.
3.
Motor Service.
The motor has a totally enclosed, non-ventilated housing and has prelubricated 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:
4.
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.
Optional Arc Suppressor Testing

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.
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.
3.
Counter kit, PN: 38-0045-192, consists of an electro-mechanical counter

and mounting bracket. (Not shown).
4.
Set-up and adjustment tools are listed on the last page of the mechanism
parts section.
47
3590 SERIES
CROSSING GATE MECHANISMS
Internal View
Contents
Page
Gate Mechanism Complete

Gate Mechanism Detail
Motor and Ratchet Wheel
Hold-Clear Assembly
Circuit Controller Assembly
Mechanism Relays
Sidewalk Kit
Contact Heater Assembly
Maintenance Aids
39
40
43
44
47
49
50
51
52
48
Basic Gate Mechanism

3 Wire
Control
Vital
Relay
3590
3590B
Features
2 Wire
Control
Non-Vital
Relay
Single End
Mainshaft
(RH)
3593
3593B
3593C
3593E
3593F
3593I
3593NJ
3595
Contacts
Standard
Mainshaft
3596
3596B
3596NJ
X
X
Note:
Add Suffix - 132 for sidewalk kit.
Specify field or track side sidewalk arm.
49
CROSSING
GATE ASSEMBLY
Figure 17
C
54*
35 39
36
30
8
19
27
26
18
31
3
45
44
15, 22, 38
50
51
52
53
46
16, 48
20
1, 25, 29, 34
1, 25, 29, 34
16, 48
11
32
19-A
55
37, 43
B
57
14 58
A
42
47
43
13
40
12
38
10
9
17
38
10
21
2
33
7
24
28
41
50
23
3590 SERIES
CROSSING GATE ASSEMBLY
REPLACEMEENT PARTS
Refer to Figure 17, Page 40
Ref. No.
Description
Part No.
Bearing Cover
38-0045-30
Spring, Vertical Stop
38-0045-38
Spacer Tube
38-0045-42
Cam Assembly
38-0045-55
Wiring Diagram (Consult W-C-H)
Slide Cam Assembly
38-0045-92
3/8"-16 Square Nut
JJ-11-JJ-3
Gear Shaft for Intermediate Gears
38-0045-267
Horizontal Stop Pin Assembly
38-0045-305
10
Stop Pin Cover
38-0045-329-M
11
Adjustable Resistance Unit
1110-1
12
Staple
1265-4
13
Ventilator Screen
1265-6-B
14
Hasp Assembly*
1265-40-1*
15
Main Shaft Bearing
3580-166
16
End Cap
3580-291
17
Neoprene Gasket
3580-281
18
Gear Segment
3590-219-F
19
Gear Cluster
3590-220-F
Gear Cluster With Hole
3590-220-G
Main Shaft
3590-222
20-A
Single End (Right) Main Shaft (Not Shown)
3590-226
21
Nut, Nylon Insert, for Vertical Stop Assembly
3590-231
22
Main Shaft Cap
3590-232
Main Shaft Cap Without Hole (Not Shown)
3590-232-1
23
Case
3590-234-2-M
24
Cover*
3590-240-2-M*
25
Bearing
3590-249
26
Set Screw
3590-251
27
Woodruff Key
3590-254
28
Cover Gasket*
3590-258-2*
29
3/8" Lockwasher
RR-00-AM-3
19-A
20
22-A
51
REPLACEMENT PARTS
Refer to Figure 17, Page 40
Ref. No.
Description
Part No.
30
Spacer
3590-277
31
Spacer
3590-278
32
Spacer
3590-279
33
Vertical Stop Pin Assembly
3590-293
34
#8-32 x 3/8" Button Head Socket Cap Screw
BB-32-BB-3-0037
35
#10-24 x 1-1/4 Round Head Machine Screw
AA-10-CC-3-0125
36
#10 Split Lock Washer
RR-00-AH-3
37
3/8" Hex Nylok Nut
AL-12-JJ-3
38
1/4"-20 x 3/4" Hex Head Socket Cap Screw
BB-23-EE-3-0075
39
1/4"-20 x 1-1/4" Hex Head Socket Cap Screw
BB-23-EE-3-0125
40
Eyebolt
3590-381
41
3/8"-16 x 3/4" Socket Cap Screw
BB-59-JJ-3-0075
42
5/26"-18 x 2 1/4" Hex Head Bolt
CC-12-GG-3-0225
43
3/8"-16 Hex Nut
HH-12-JJ-3
44
1-1/4"-7 Hex Nut
JJ-12-AD-3
45
1-1/4" ID Flat Washer
3570-114
46
10-24 x 1-3/4" Round Head Machine Screw
AA-10-CC-3-0175
47
1/4" Plain Washer
PP-00-AJ-3
48
1/4"-20 x 3/8" Hex Socket Cap Screw
BB-23-EE-3-0037
50
Mtg. Brkt. for Non-Vital Relay
38-0045-190-1
Mtg. Brkt. & Spring Base Assembly for Vital Relay (Not Shown)
38-0045-225
51
5/16"-18 Hex Nylok
AL-12-GG-3
52
Installation Manual
54
Arc Suppressor (Optional) Not Shown
38-0045-293
55
Pinion Gear
3590-218
56
Mounting Kit for 5" Mast (Not Shown)
3590-294
57
Cap Screw
38-0045-282
58
Spacer for Bearing Cap
3590-275
59
10-32 x 2 Round Head Machine Screw Steel
AA-10-DD-3-02
60
#10 Plain Steel Washer
PP-00-AH-3
61
Torsion Spring-Formed
3590-382
62
10-32 Nylon -Lok Hex Nut
AL-12-DD-3
50-A
52
Rev. 1/97
MOTOR AND RATCHET WHEEL

REF. A
Figure 18
Ref. No
A
Description
Motor Assembly Complete
Part No.
38-0045-82X
REPLACEMENT PARTS
1
RatchetWheel Assembly
38-0045-262
Motor Pinion Woodruff Key
38-0045-86
Washer
38-0045-182
Ratchet Wheel Key
3580-270
Snap Ring
3580-271
Motor
3590-217X
Motor Pinion Gear
3590-218
8
9
Round Head Nylok Machine Screw 8/32 x 1/2

Washer
BJ-10-BB-3-005
38-0045-241
10
Brush Holder
38-0045-117
11
Motor Brush
38--0045-118
12
Cap Spring
38-0045-137
13
Brush Cap
38-0045-268
Rev. 1/97
53
HOLD CLEAR ASSEMBLY

REF. B, B1
Figure 19
16
23
26
2, 9
11, 12, 28, 29, 30
24
1, 1A
20
Reference B
17
25 22 21
19
11, 12, 28, 29, 30
7
14
3
4
5
16
13 15 10 6
18
Reference B
23
26
24
20
27
8
17
Reference B1
54
HOLD CLEAR ASSEMBLY

Refer to figure 19, Page 44
Ref. No.
Description
Part No.
Hold-Clear Assembly
38-0045-254
B1
Hold-Clear Assembly with Motor Down Contact

Armature and Support Bracket Assembly, Consists of
Ref: 2,3,4,5,6,7,9,10,11,12,28,29 and 30
38-0045-340
1
1A
Armature & Support Bracket Assembly for Hold Clear With Motor
Down Contact, Consists of Ref: 2,3,4,5,6,7,8,9,10,11,12,28,29 and 30
38-0045-159
38-0045-159-1
Pawl
38-0045-7
Cotter Pin
38-0045-139
Castle Nut
38-0045-140
Cup Washer
38-0045-220
Compression Spring
38-0045-223
Armature Support Bracket
38-0045-246
Cam
38-0045-390
Pawl Mounting Screw
38-0045-261
10
Armature Sub-Assembly
38-0045-265
11
1/4-20 Hex Jam Nut
KK-12-EE-8
12
Set Screw
38-0045-266
13
Coil Spacer
38-0045-147
14
Magnet Yoke
38-0045-148
15
Magnet Pole and Core Sub-Assembly
38-0045-151
16
Hold Coil, 340 Ohms
38-0045-158
17
18
Pick Coil, 32 Ohms

Mounting Screw, Pole/Core Sub Assy to Hold -Clear Base
38-0045-162
38-0045-260
19
Hold-Clear Base
38-0045-248
Hold-Clear Base For Contact Plate
38-0045-322
20
Mounting Screw, Magnet Yoke to Pole/Core Sub-Assembly
38-0045-264
21
Hinge Pin Stop
38-0045-152
22
Bolt/Screw Keeper
38-0045-153
23
Set Screw, Nickel Plated Brass
38-0045-157
24
Hinge Pin
38-0045-160
25
Hex Bolt, Nickel Plated Brass
38-0045-279
26
Hex Head Cap Screw, Grade 8
38-0045-282
27
Motor Down Contact Block (Ref. Page 46 )
38-0045-410
28
Plain Washer 1/4 ID-7/16 OD x 1/32
AH-00-AJ-8
29
Nylok Nut 1/4 x 20
AL-00-EE-3
30
External Lock Washer
TT-00-AJ-3
19A
Rev. 1/97
55
MOTOR DOWN CONTACT BLOCK

38-0045-410
Figure 20
11, 12
10
1
14
16
13
15
2
5
9
6
Ref. No
Description
Part No.
Mounting Bracket
38-0045-375
Washer Plate
38-0045-376
Keeper
38-0045-380
Mounting Block Spacer
38-0045-381
Spacer
38-0045-382
Insulator
38-0045-383
Screw
38-0045-384
Upper Contact Spring Assembly
38-0045-387
Lower Contact Spring Assembly
38-0045-388
10
Terminal Block
2506-2
11
#10-32 x 1/2 Round Head Machine Screw
AA-10-DD-8-005
12
#10 Lockwasher External
TT-00-AH-3
13
Clamp Nut
10707
14
Washer
10708
15
Guard
38-0045-386
16
#8-32 x 1/4 Round Head Machine Screw
AA-10-BB-8-0025
56
Rev. 5/98
CIRCUIT CONTROLLER ASSEMBLY

REF. C
Figure 21
12 13
7*
11
10
8*
14
15
5
3
9*
Ref. No.
Description
Part No.
Circuit Controller Assembly Complete Listed on Page 48
Terminal Board
38-0045-21
Back Contact Spring Assembly
38-0045-27
Front Contact Spring Assembly
38-0045-28
Insulator Sleeve
38-0045-29-A
Insulator Washer
38-0045-29-B
Binding Post Seat
38-0045-77
7*
Test Terminal (Location will vary)
38-0045-89-R
8*
Gold Nut (Location will vary)
38-0045-290
9*
Arc Suppressor (Optional)
38-0045-293
10
Connector
1705-4
11
Binding Nut
10706
12
Clamp Nut
10707
13
Washer
10708
14
Binding Post 1-7/8 Lg.
10709-2
15
Binding Post 2-1/4 Lg.
10709-3
Rev. 1/97
57
Circuit Controller
Mechanism
38-0045-20
3590
38-0045-20-1
38-0045-235
38-0045-235-1 38-0045-235-2
38-0045-423
3590B
3593
3593B
3593C
3593E
3593F
3593I
3593NJ
3595
X
X
3596
3596B
3596NJ
Contact s
58
MECHANISM RELAYS
REF.
Ref. No.
D
D1
Rev. 8/95
REF. D1
Description
Part No.
1000 OHM Vital Relay (Shown)
38-0050-200
160 OHM Vital Relay (Not Shown)
38-0050-300
Non-Vital Relay for 3590B mechanism with

mounting plate (Not shown)
38-0045-188-1
Non-Vital Relay for all other mechanisms with

mounting plate (Shown)
38-0045-188-2
Non-Vital Relay only for 3590B mechanism
91254-10
Non-Vital Relay only for all other mechanisms
91254-11
Cover for Non-Vital Relay (Not Shown)
91254-1
59
SIDEWALK KIT
Figure 22
10
6
3
8, 9
5 4, 9
2
7
Ref. No.
E
Description
Sidewalk Arm Shaft Kit (for Right or Left Hand use)
Part No.
3590-295
REPLACEMENT PARTS
1
Sidewalk Arm Shaft
3590-223
Gear Segment w/clamp and Assembly Bolts, for Sidewalk Shaft.
3590-224
Gear Segment w/clamp and Assembly Bolts, for Main Shaft.
3590-225
Collar
3590-227
Bearing
3590-248
Woodruff Key, for Main Shaft
3590-254
Key, for Sidewalk Shaft
3590-255
Cap
3580-226-M
1/4-20 x 3/4 Machine Socket Screw
AA-15-EE-3-0075
10
Sidewalk Arm Adaptor (not included in kit)
3565-111
60
CONTACT HEATER ASSEMBLY

Figure 23
Ref. No.
Description
Part No.
Contact Heater Assembly Complete, 115VAC, 50 Watt
38-0045-287
F1
Contact Heater Assembly Complete, 230VAC, 50 Watt
38-0045-318
61
SET-UP AND ADJUSTMENT TOOLS

Spring Scale, PN: 3562-210
Used for measuring gate arm torque.
Torque wrench with socket, PN: 3590-K-9.
Used for measuring gate arm torque.
Snap ring pliers, PN: 3590-1007
Used for ratchet wheel removal.
.020 gauge, PN: 3590-1012
Used to adjust ratchet wheel to hold clear pawl clearance.
.032 gauge, PN: 3590-1011
Used to adjust gap on hold clear mounted power down contact.
Ounce spring scale, PN: 3565-211
Used to measure contact spring pressure.
1/16" insulated gauge , PN: 3590-1010
Contact bending tool for contacts without stiffeners, PN: ES-6104-2
Contact bending tool for contacts with stiffeners, PN: ES-6104-1
Used to adjust circuit board contact.
Angle finder, PN: 3590-1014
Used to set contact cam operating position.
3/32" wire gauge, PN: 3590-1013
Used to check vertical stop to segment gear clearance.
Tool kit, PN: 3590-K-11
Includes snap ring pliers, 3/32", 3/16" and 7/32" T handle allen wrenches, 7/16"
combination wrench and canvas pouch.
Bison all temperature lubricating grease, PN: 3590-1650
For lubrication of gears and contact cams, 1 quart can.
62
Page left blank intentionally.
63

Installation Instructions - Model 10 Signal

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Installation Instructions - Model 10 Signal

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INTRODUCTION

Install foundation in proper location per the requirements of the installation.

Suggested Concrete Foundation

Galvanized Steel Foundation

Wire Entrance - 3-3/4" sq.

Cast Mechanism Support Installation

Clamp Type Mechanism Support Installation

Horizontal Stop Pin

Horizontal Stop Spring Housing

Vertical Stop Pin

Vertical Stop Pin Nut

Clearance Gap 3/32" Minimum

Horizontal Stop Pin Locknut

Horizontal Stop Pin Cover

Vertical Stop Pin Cover

Do not apply counterweight before the roadway gate arm

Install conversion bracket or breakaway adapter channel (D) to the counterweight

Gate and Counterweight

Gate and Counterweight Support Arms

Sidewalk Arm Adapter

Cast Breakaway Adapter

Gate Arm Section

PIVOT TYPE BREAKAWAY ADAPTER

CHANNEL TYPE BREAKAWAY ADAPTER

Installation of Wooden Gate Arms

Extension Arm Bolt, Washer and Nut - 2

Single Slot Counterweight Assembly with Extension Arm

Counterweight Support Assy.

Single Slot Counterweight Assembly

Square double slot counterweights on aluminum counterweight arms

Clamp Washer Stud

Outside view, Arm Vertical

Inside View, Arm Horizontal

Double Slot Counterweight Assembly

Oblong counterweights on cast iron or aluminum counterweight arms

Clamp Washer Stud

Outside view, Arm Vertical

Oblong Counterweight Assembly

Install signal light units, signs and bell or pinnacle as required.

2-Way Length of Run

Refer to AAR and FRA specifications

Suggested Roadway Gate Arm Light Spacing

Horizontal Torque Adjustment

Square single slot counterweights on cast iron counterweight arms

Square double slot counterweights on aluminum counterweight arms

Horizontal Torque Adjustment

Vertical Torque Adjustment

Using torque wrench PN: 3590-K9

Do not attempt to obtain readings with a foot pound

If adjustment is required, loosen the counterweight bolt nut just enough to

Vertical Torque Adjustment

Square double slot counterweights on aluminum counterweight

Do not attempt to obtain readings with a foot pound

If adjustment is required, loosen the counterweight stud nuts just enough to

Vertical Torque Adjustment

3590, 3590B, 3593, 3593I, 3593NJ, 3595, 3596, 3596NJ.

3593B, 3593C, 3593E, 3593F, 3596B.

TABLE OF WEIGHT AND VERTICAL TORQUE VALUES FOR