Series 300

J300, J4ATS, J7ATS Transfer Switches 4000 & 7000 Series

260, 400, and 600 amp sizes Service Bulletin

Figure 1. 260 and 400 amp Transfer Switches Figure 2. 600 amp. Transfer Switches.
J4ATS and J7ATS 3 pole with switched neutral shown. Series 300, 3 pole, customer terminal block shown;
260 and 400 amp. has single–barrel terminal lugs. 600 amp. has two–barrel terminal lugs, extended
front barrier, rear barriers, and side mounting rails.
This service bulletin explains how to replace the
solenoid coil and coil control contacts in 260, 400, and Tools Needed
600 amp ASCO Series 300, 4000 Series, and 7000
◆ safety glasses (for eye protection)
Series J–design Automatic Transfer Switches.
◆ 1/4–3/8” straight blade 6” screwdriver
Contents ◆ short handle blade screwdriver
page
◆ 3/8” ratchet drive, 6”& 12” extensions
Tools Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ◆ 3/8” socket
Maintenance Handle . . . . . . . . . . . . . . . . . . . . . 2 ◆ 3/8” open–end or box wrench
Solenoid Coil Replacement . . . . . . . . . . . . . . . 3 ◆ 3/8” nutdriver
Control Contact Replacement . . . . . . . . . . . . . 6
◆ torque wrench 0 to 20 ft.–lbs (240 in–lb)
◆ needlenose & regular pliers
◆ wire labels

To prevent the possibility of fatal electrical shocks

and burns, deenergize the transfer switch before
working on it. Open both Normal and Emergency
circuit breakers and padlock them.

ASCO POWER TECHNOLOGIES L.P. 50 Hanover Road, Florham Park, New Jersey 07932 USA www.ascopower.com 381339–277 A
 Maintenance Handle
A detachable maintenance handle is provided on the left side of
transfer switch
frame of the Transfer Switch for maintenance purposes
only. After the Transfer Switch is completely deener-
gized this handle can be used to change the position of
the contacts and operator mechanism. The windows in
the right side of the Transfer Switch frame indicate
which contacts are open and closed.
maintenance
! handle
Do not manually operate the transfer switch until
both power sources are disconnected: open both
normal and emergency source circuit breakers.
storage clip
1. Deenergize the transfer switch. After deenergiz-
ing both power sources, open the enclosure door.
Use a voltmeter to verify that no electrical power
is present at the transfer switch terminals.
2. Install the maintenance handle. Locate and re-
move the maintenance handle from clips on the
left side of the transfer switch frame. Insert the
handle into the molded hub on the left side of the
operator. See Figures 3 and 4 and Table A.
3. Use the maintenance handle (if necessary). Move
the maintenance handle up or down as shown to
manually operate the transfer switch to the opposite
position.
Figure 3. Maintenance handle and its storage clips.
Note: If Normal and Emergency connections are
reversed this operation is also reversed. Table A. Maintenance handle positions.
ATS Position Handle Indicators
4. Return the transfer switch to the Normal position.
Observe that the window indicators (right side) E up E=O
show the top shaft O (open) and the bottom shaft C Normal
upper contacts open

(closed). N=C
N lower contacts closed
5. Remove the maintenance handle and store it on the
frame (left side) in the clips provided. E E=C
upper contacts closed
Emergency
N=O
N down lower contacts open

Emergency
UP closes the contacts
handle Normal source
contacts (lower) window
indicators contact position
hub DOWN closes the O is open indicators (right side)
Emergency source C is closed
contacts (upper)
Normal
frame contacts
Figure 4. Maintenance handle operation and contact position indicators.

2 ASCO POWER TECHNOLOGIES L.P. 50 Hanover Road, Florham Park, New Jersey 07932 USA www.ascopower.com
 Solenoid Coil Replacement
Solenoid Coil Replacement
solenoid
Solenoid coil kits include only the coil (see below for frame
appropriate voltage).
solenoid
Replacement Solenoid Coil Kit coil
(includes coil only, see voltages below)
Solenoid Coil Kit rectifier
cover

solenoid
Transfer Switch Solenoid Coil weight
Service Voltage Kit Number (not shown)
110 / 120 V K734768–001
190 / 240 V K734768–002
380 / 415 V K734768–003
440 / 480 V K734768–004 left side of
550 / 600 V K734768–005 transfer switch

How to Replace the Solenoid Coil

1. Remove rectifier cover and disconnect coil leads.
Use a blade screwdriver (ccw) to loosen one screw
(do not remove it), then remove the rectifier Figure 5. Solenoid operator assembly.
cover. Disconnect the two coil leads from the
rectifier. See Figures 5 and 6. ✓ included
in kit
2. Remove solenoid retaining bracket and coil. four
SEMS retaining
Use a 3/8” socket, open–end, or box wrench to screws bracket
remove (ccw) four SEMS screws from the
solenoid retaining bracket. Then remove the
bracket from the top of the solenoid. Remove the
solenoid coil by pulling it upward (off the core flange
tube) and out of the frame. See Figure 6. on coil

3. Install the new solenoid coil.

Position the new replacement coil so that the
flange end is on top and the coil leads are on the solenoid
coil ✓
left side. Install the coil (in this position) into the
frame by pushing it downward (onto the core tube)
and into the frame. Secure the coil by reinstalling
rectifer
the solenoid retaining bracket. Use a 3/8” socket, cover
open–end, or box wrench to install (cw) four core
SEMS screws. Tighten the screws to 5.5 ft.–lbs. tube
(66 in.–lbs.) torque. See Figure 5. rectifier
4. Connect the new coil and reinstall rectifier cover.
Install the quick–connect coil leads onto the
rectifier terminals (DC). Then install the rectifier solenoid
cover onto the top of the solenoid frame. Use a frame
blade screwdriver (cw) to tighten the screw. See
Figures 5 and 6. Figure 6. Solenoid coil. loosen screw

ASCO POWER TECHNOLOGIES L.P. 50 Hanover Road, Florham Park, New Jersey 07932 USA www.ascopower.com 3
 Solenoid Coil and Solenoid Assembly Replacement continued
Solenoid Assembly Replacement
Solenoid assemblies include entire solenoid with bearing
frame, coil, core tube, core spring, and core and link. plate

Replacement Solenoid Assembly with core & link

(includes rectifier & cover, locking pin)
locking pin
Solenoid Assembly
hub

weight not shown

(behind the plate)
Figure 7. Weight locking pin.

screw weight slot

auxilary contact
Transfer Switch Solenoid Assembly assembly
Service Voltage Number
110 / 120 V K753882–001
190 / 240 V K753882–002
380 / 415 V K753882–003 tabs
440 / 480 V K753882–004
550 / 600 V K753882–005
screw
How to Replace the Solenoid Assembly
Figure 8. Auxiliary contact assembly removal.
1. Put the transfer switch in the Emergency position.
The upper contacts must be closed to replace the retaining
solenoid assembly. If necessary, use the screw link pin
maintenance handle to operate the transfer switch
to the Emergency position. See page 2.
2. Remove rectifier cover and disconnect two wires.
Use a blade screwdriver (ccw) to loosen one
screw, then remove the rectifier cover. Then
disconnect the two wires wires coming into the
solenoid assembly from the harness. See Figure 6.
weight
3. Insert the weight locking pin.
To prevent the operator from moving during Figure 9. Link pin retaining screw.
disassembly insert the locking pin through the hub
and into the bearing plate. See Figure 7. core link
clevis pin
4. Remove auxiliary contact assembly from weight. weight
Use a 3/8” open–end or box wrench (ccw) to
remove two SEMS screws then remove the
auxiliary contact assembly so that you can gain
access to the weight. See Figure 8.
5. Remove link pin from weight to release core link.
Use a 5/16” nutdriver to remove CCW the link pin
retaining screw from the weight left cavity. Insert
a screwdriver into the weight right cavity and push
clevis pin to the left into left cavity. This operation
releases the core link from the weight. Then
remove clevis pin from weight. See Figures 9 & 10. Figure 10. Link connection.

4 ASCO POWER TECHNOLOGIES L.P. 50 Hanover Road, Florham Park, New Jersey 07932 USA ww.ascopower.com
 Solenoid Coil and Solenoid Assembly Replacement continued
!
6. Remove the solenoid assembly.
Use a 3/8” open–end or box wrench (ccw) to
To prevent personal injury do not attempt to remove four SEMS screws (two at the top, one on
remove the clevis pin until the weight is locked either side). See Figure 10.
in the emergency position (step 3, figure 7).
6. Transfer the labels from old solenoid to new one.
! Carefully remove the nameplate, WCR label, and
DANGER label from the old solenoid. Then
To prevent shortened equipment life or apply them onto the new solenoid.
malfunction, do not damage the clevis pin when
removing it. 7. Install the new solenoid assembly.
Position the new solenoid assembly onto the
mounting rail so that the two protrusions align
solenoid with the holes in the solenoid assembly. The core
assembly link should be in the slot in the weight. Use a 3/8”
open–end or box wrench to install four new 1/4–20
x 3/4” long SEMS screws (two at the top, one on
either side. See Figure 10.
2 screws
8. Install new rectifier cover and connect two wires.
Connect two wires from the harness (previously
disconnected) to the rectifier terminals (AC).
Then install the new rectifier cover onto the
solenoid assembly. See Figure 15 on page 9.
9. Reinstall link pin into weight.
Install the link pin into the left side of the weight
(through the core link from the solenoid
assembly). Apply Loctite 242 sealant onto the
threads of the 1/4–20 link retaining screw. Then
install it through the control contact link and link
pin into the left side of the weight. Use a 7/16”
2 screws open– end or box wrench to tighten (cw) the
retaining screw. There should be some play to
allow movement of the control contact link. See
Figure 18 above.
10. Remove the weight locking pin.
To unlock the weight from the bearing plate,
remove the clevis pin from the hub. This is very
important! Otherwise severe damage will occur
when transfer switch is reenergized! See Figure 17
on page 10.

Figure 10. Solenoid assembly removal. !

To prevent severe damage to the solenoid

assembly, remove the clevis pin from the hub on
the left side. This action will unlock the weight and
allow free movement of the operator when it is
reenergized.

11. Manually operate the transfer switch.

Use the maintenance handle (page 2) to operate
the transfer switch several times. It should operate
smoothly; if not, recheck the solenoid assembly
installation.

ASCO POWER TECHNOLOGIES L.P. 50 Hanover Road, Florham Park, New Jersey 07932 USA www.ascopower.com 5
 Control Contact Replacement
Control Contact Assembly Replacement
The coil control contact assembly (two pushbutton
switches) is located below the solenoid operator on
the left side of the transfer switch. See Figure 11.

Coil Control Contact Kit left side of

(with mounting hardware) transfer switch

control
contact
K791176 assembly

How to Replace the Control Contacts

1. Label eight wires connected to control contacts.
Carefully label all wires that are connected to the
control contacts. Then use a narrow blade
screwdriver (ccw) to disconnect the eight wires.
2. Remove the control contact assembly.
Remove (ccw) two SEMS screws then remove the
control contact assembly. See Figure 12. Figure 11. Location of control contacts.
3. Install the new control contact assembly.
Position the new control contact assebly with its
pushbuttons against the cams on the weight.
Install (cw) two #10–32 SEMS screws with
washers and tighten. See Figure 12.
!

Note proper positioning of pushbuttons on control

cam surfaces prior to tightening screws. contact
assembly
4. Connect eight labeled wires to control contacts.
Carefully reconnect the wires (disconnected in
step 1) to the new control contact assembly.
screw washer
5. Manually operate the transfer switch.
Use the maintenance handle (page 2) to operate When installed these two indicators
the transfer switch several times. You should see show one closed and the other open.
the two indicators change alternately from open to Figure 12. Control contact assembly removal.
closed. If not, recheck the installation. See Fig. 12.

6 ASCO POWER TECHNOLOGIES L.P. 50 Hanover Road, Florham Park, New Jersey 07932 USA ww.ascopower.com