JAKARTA MRT PROJECT CP-107 Metro One Consortium

Technical Specification for SIG- Mechanical Point Machine 7/SIG/SPC/0015

Mechanical Point Machine (Hereafter, point lever)

1. Mechanical Point Machine with electric locking and detector 1 set (Hereafter, point lever with electric lock)
2. Mechanical Point Machine 3 sets (Hereafter, point lever without electric lock)

Index

1. Introduction･･･････････････････････････････････････････････････････････ 3
2. Type ････････････････････････････････････････････････････････････････ 3
3. Inspection for processed goods ･･･････････････････････････････････････････ 3
4. Structure ････････････････････････････････････････････････････････････ 4
5. Characteristics ････････････････････････････････････････････････････････ 4
6. Shape and dimensions ･･････････････････････････････････････････････････ 5
7. Assembly ････････････････････････････････････････････････････････････ 5
8. Appearance and coating ･････････････････････････････････････････････････5
9. Test methods ･････････････････････････････････････････････････････････ 6
10. Outline drawing ･･･････････････････････････････････････････････････････ 7
11. Assembled drawing ････････････････････････････････････････････････････ 8
12. Wiring diagrams ･･････････････････････････････････････････････････････ 9
13. Electric lock ･･････････････････････････････････････････････････････････ 11
14. Detail of each part ･････････････････････････････････････････････････････ 13

Appendix 1. Stroke of Point Lever (type C) and Turnout ･･･････････････････････････････ 14

Appendix 2. Strength Test of Point Lever (type C) ････････････････････････････････････ 16
Appendix 3. Installation Concept Drawing ･･･････････････････････････････････････････ 19

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JAKARTA MRT PROJECT CP-107 Metro One Consortium
Technical Specification for SIG- Mechanical Point Machine 7/SIG/SPC/0015

1. Introduction
Recently, more flexible switches are used to improve passing speed on turnouts and to reduce maintenance work. The
flexible switch is thrown with its longer length and its elasticity, so bigger power is necessary compared with articulated
switch, which has pivot, and it is difficult to be operated manually on site.
To solve above problems, point lever (type C) is effective. Point lever (type C) is able to throw flexible switch with
small power by handle operation. Characteristics of point lever (type C) are as follows;

(1) Handle operation

Switches are set from normal position (reverse position) to reverse position (normal position) by handle operation.
Handle has an arrow plate to indicate the direction of rotation.

(2) Electric lock

Point lever is equipped with electric lock to simplify the structure. Also, reliable micro switches are used for contact.

(3) Water and dust proof

Housing (upper) is water-proof and dust-proof structure, and terminal box can be injected resin to prevent corrosion
and loosening of cables. Also, cable lead-in part of terminal box has a water-proof connector.

2. Type
Type of this point lever is as Table 1.

Table 1. Type of point lever

Weight
Type Quantity Division Use
(main body)
Without electric
3 Handle operation for 160kg
Handle lock Rotation of
C 15 switches which needs
operation With electric handle
1 higher setting force 163kg
lock
* Details of electric lock is described in chapter 13.

3. Inspection for processed goods

Inspection of major parts is as table 2.

Table 2. Major parts

Name JIS Tolerance
JIS B 1180 (Hexagon head bolts and hexagon head 6g(bolt with metric screw, screw and tap-end
Bolts
screws) bolt)
Round head
JIS B 1182 (Square head bolts)
screws
JIS B 1176 (Hexagon socket head cap screws)
Nuts JIS B 1181 (Hexagon nuts and hexagon thin nuts) 6H(nut with metric screw)
JIS B 0401-2(ISO system of limits and fits−Part 2 :Tables
H9(Hole drilling)
Each part of standard tolerance grades and limit deviations for holes
f7(axis)
and shafts)
* Material of each part is shown in figure 2.

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JAKARTA MRT PROJECT CP-107 Metro One Consortium
Technical Specification for SIG- Mechanical Point Machine 7/SIG/SPC/0015

4. Structure
(1) Switching reverse to normal or normal to reverse position, rotate handle by 15 times.
(2) Torque coupler shall keep rated joint power of 392 to 441N (operating power 40 to 45kgf) in handle
operation, and if handle is overloaded, clutch is securely released and handle runs at idle.
If handle clutch is released, handle runs at idle only one rotation, and securely comes back.
(3) Circular sector crank shall rotate vertically against clamp face, and work left and right evenly.
(4) Electric lock shall be securely done by locking crank fits notch of locking bar by 7mm, and shall be securely
unlocked by electromagnetic attraction of locking crank.
(5) When unlocking lever is raised by the position of “stop”, locking bar is raised from notch of circular sector
crank and unlocked. Standard clearance between bottom of locking bar and sliding surface of circular sector
crank is 2mm.
(6) When rotation of handle ends, locking bar shall be set to notch of circular sector crank by 15mm or more
and locked.
(7) Essential parts of rotation shall be lubrication free structure.
(8) Housing shall be rain proof and dust proof, and be able to padlocked.
(9) Exposed parts of conductors shall be away from other metal parts by 10mm or more.
(10) Terminal box shall be able to be injected resin, and clearance among terminals shall be 25mm or more.
(11) N/R of points can be output by signal from micro switches. (wiring diagram is as figure 3)
(12) Sign board type indicator, it is shown as item 3 in Table 7 and Figure 7, can show two direction
normal/reverse in accordance with Japanese style. It is replaceable to the board with Indonesian style in
site.
(13) The main cover as well as the unlocking lever of the mechanical point machine is lockable by a padlock.

5. Characteristics
Characteristics are as Table 3.

Table 3. Characteristics
Items Characteristics
By usual operation, each part securely works without any abnormality, and switching stroke shall be 215
(-0/+2) mm.
Operating
Also, round nut and fastening nut (as figure 7) of switch adjuster shall be adjusted properly so that the
characteristics
stroke of point lever (type C) is converted to the stroke of the point (155mm).
(Details are as appendix 1, Stroke of point lever (type C) and turnout.)
To rotate handle gradually at the position where circular sector crank is vertical (see figure 4), and joint
Strength characteristics
pin between crank and rod endures 29.42kN (approx. 30tonf) or more
Water proof Each part indicates no abnormalities in use in rainy weather.
Insulation resistance 10MΩ or more (DC 500V)
Voltage endurance AC 1500V, 1 minute (50/60Hz）
Shall securely work when locking bar and circular sector crank move to their
Operation
given positions
Characteristics of micro Maximum switching Shall be able to continuously switch at inductive load of DC24V, 5A and
switch capacity of contactors AC105V, 20A.
Contact resistance of Contact resistance shall be 0.05itch at inductive load of DC24V, 5A and
contactors times, the resistance shall be 0.1Ω or less.
Characteristics of torque
Controlling force of handle shall be 390 to 440N(40 to 45kgf), and it securely
coupler Operation
works.
switch

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JAKARTA MRT PROJECT CP-107 Metro One Consortium
Technical Specification for SIG- Mechanical Point Machine 7/SIG/SPC/0015

6. Shape and dimensions

Shape and dimensions shall be accordance with figure 1 and 2.

7. Assembly
(1) Screws shall be accordance with JIS B 0205 (ISO general purpose metric screw threads)
(2) Tolerances of screws shall be accordance with JIS B 0209 (ISO general purpose metric screw threads
−Tolerances−)
(3) Fits shall be shall be accordance with JIS B 0401(ISO system of limits and fits−)
(4) Surface roughness shall be accordance with JIS B 0601(Geometrical Product Specifications (GPS)-Surface
texture: Profile method-Terms, definitions and surface texture parameters) and JIS B 0031(Geometrical
Product Specifications(GPS)−Indication of surface texture in technical product specification)
(5) Bolts shall be accordance with JIS B 1180(Hexagon head bolts and hexagon head screws), 6g in JIS B
1182(Square head bolts), and JIS B 1176(Hexagon socket head cap screws)
(6) Nuts shall be accordance with 6H in JIS B 1181(Hexagon nuts and hexagon thin nuts)
(7) Spring washers shall be accordance with JIS B 1251(Spring lock washers)
(8) Split pins shall be accordance with JIS B 1351(Split pins)
(9) Taper pins shall be accordance with JIS B 1352(Taper Pins)
(10) Forged materials shall not be welded including forge welding
(11) Sliding surface and screw parts shall be lubricated by soft-coated solvent cutback type rust preventive oil
(12) Metal parts which may easily rust shall be done corrosion-resistant treatment including rust plating
(13) Bolts and nuts which may be easily loosened shall be done loosening prevention.
(14) Wiring diagram shall be accordance with figure 3

8. Appearance and coating

(1) Appearance
i. Surface of forged materials shall be smooth and free from burr or crack
ii. Surface of casted materials shall be smooth and free from burr, torsion, harmful cavity, or crack
(2) Coating
Coating
Final coat: Black Munsell # N1.5
Rust-proof: Ocher Munsell # 10YR6/10
Process: Final coating with spray coating gun for once, and rust-proof for once
Finishing: Cover the ground and surface becomes glossy

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JAKARTA MRT PROJECT CP-107 Metro One Consortium
Technical Specification for SIG- Mechanical Point Machine 7/SIG/SPC/0015

9. Test methods
Test methods are as Table 4

Table 4. Test methods

Items Methods
To operate by usual way and diagnose any abnormality. After
Operating characteristics
operation, measure switching stroke.
Either by compression or tensile test, gradually give load up to
29.42kN, and confirm there is no deformation or
Strength characteristics destruction.( Test method is as appendix 2 , Strength test of point
lever (type C).
The tests shall be done when torque coupler does not work.
Accordance with R2 water resistance test of JIS E 3017 (Parts for
Water proof
railway signaling -Waterproof test methods)
Accordance with R10 of insulation resistance test of JIS E
Insulation resistance 3021(Insulation resistance and withstand voltage testing methods
of parts for railway signaling)
Voltage endurance Accordance with 1500V of voltage endurance test of JIS E 3021.
To confirm locking bar and circular sector crank move to their
Operation
given position by operation.
Characteristics of Maximum switching To confirm there are no abnormality by continuous switching
micro switch capacity of contactors operation at inductive load DC24V, 5A and AC105V, 20A.
Contact resistance of To measure resistance at DC1A.
contactors

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Technical Specification for SIG- Mechanical Point Machine 7/SIG/SPC/0015

10. Outline drawing

Figure 1. Outline drawing

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Technical Specification for SIG- Mechanical Point Machine 7/SIG/SPC/0015

11. Assembled drawing

Figure 2. Assembled drawing

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JAKARTA MRT PROJECT CP-107 Metro One Consortium
Technical Specification for SIG- Mechanical Point Machine 7/SIG/SPC/0015

12. Wiring diagrams

Figure 3.Wiring diagrams

Table 5. Legend
N,R Micro switch
A Breaker switch
SW Unlocking switch
L Locking switch
KR Reversal relay

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Technical Specification for SIG- Mechanical Point Machine 7/SIG/SPC/0015

[Without electric lock]

With positive power supply of DC24 to terminal 5, terminal 5 is connected to terminal 4 when point is set to
normal position, and is connected to terminal 8 when point is set to reverse position, hence the position of
point can be detected.

[With electric lock]

With positive power supply of DC24 to terminal 5 and negative to terminal 6, terminal 5 is connected to 9
and terminal 6 is connected to 10 when point is set to normal position. When reverse position, terminal 5 is
connected to 10 and terminal 6 is connected to 9. Hence the position of point can be detected.

To make use of the above functions, external power supply of DC24 is necessary.
Breaker switch becomes ON when point lever (type C) is locked completely. Therefore, there is no electric
output from terminal 4/8 or 9/10 during handle operation.

Default N/R of point lever (type C) are as Table 6. If N/R are different from those of points on site, N/R
indication label of micro switch and wiring diagram inside the point lever shall be replaced. Also, electric
current from terminal 9 and 10 shall be reverse, so the controlling circuit needs to be designed accordingly.

Table 6. Default N/R of Point Lever (Type C)

Installation of Point Lever Direction of
N/R indication
(Type C) contacted point
Left contacted R
Right side of the point
Right contacted N
Left contacted R
Left side of the point
Right contacted N

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JAKARTA MRT PROJECT CP-107 Metro One Consortium
Technical Specification for SIG- Mechanical Point Machine 7/SIG/SPC/0015

13. Electric lock

(1) With no electric supply
When electric power is not supplied to terminal 1 and 2, locking crank gets into the notch of locking bar
(figure 4) and unlocking lever, which is connected to locking bar, cannot be lifted over the horizontal
position. It is necessary to lift unlocking lever up to the position of “STOP” to operate handle, therefore
handle cannot be operated in this case.

Unlocking lever

External Power supply

Locking crank
gets into the
notch of locking
bar

SW

Locking crank

Internal wiring

SW

Electromagnet

Locking bar

Figure 4. When power is not supplied

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 JAKARTA MRT PROJECT CP-107 Metro One Consortium
Technical Specification for SIG- Mechanical Point Machine 7/SIG/SPC/0015

(2) With electric supply

When electric power is supplied to terminal 1 and 2, if unlocking lever is lifted up to the horizontal
position (figure 5), unlocking cam turns on unlocking switch and locking crank rotates to the direction of the
arrow on figure 5, and then locking crank leaves from the notch of locking bar (electronic unlock). If
unlocking lever is lifted up to the position of "STOP" following the operation above (figure 6), point lever
(type C) is unlocked also mechanically, and handle becomes operable.

Electromagnet
External Power supply
Unlocking Switch
SW

Locking cam

Internal wiring
Locking crank rotates

and leaves from notch

SW If unlocking lever is lifted up to the horizontal

position, unlocking cam turns on unlocking
switch and AC100V is supplied to
Electromagnet electromagnet, therefore locking crank rotates.

Figure 5. When power is supplied

Lift up to the
position of “Stop”

External Power Supply

SW

Internal wiring

SW

Electromagne

Figure 6. When unlocking lever is lifted up

To make use of the above functions, external power supply of AC100V is necessary.
To control this electric lock function, control system is necessary according to the purpose of use.

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JAKARTA MRT PROJECT CP-107 Metro One Consortium
Technical Specification for SIG- Mechanical Point Machine 7/SIG/SPC/0015

14. Detail of each part

Detail of each part is as table 7.

Table 7. Detail of each part

① Point lever (type C)
② Escapement crank
③ Point indicator
④ Switch adjuster
⑤ Offset linkage
⑥ Lock rod
⑦ Drive rod
Device to set point.
Device to change the direction of setting force of point lever
Device to indicate route of turnout
Device to transfer setting force from escapement crank to drive rod
Device to transfer setting force from point lever to escapement crank
Device to transfer stroke of drive rod to crank of point indicator
Device to transfer setting force from switch adjuster to each tongue rail

The installation concept drawing is shown in Appendix 3.

Standard Installation Detail is described in “7/AZN/SIG/3454”

② ③

⑦ ⑥

Round nut,
④
fastening

Figure 7. Installation of each part

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JAKARTA MRT PROJECT CP-107 Metro One Consortium
Technical Specification for SIG- Mechanical Point Machine 7/SIG/SPC/0015

APPENDIX 1
Stroke of Point Lever(type C) and Turnout

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Technical Specification for SIG- Mechanical Point Machine 7/SIG/SPC/0015

Stroke of Point Lever (type C) and Turnout.

Switch adjuster is connected to point lever (type C) through offset linkage and escapement crank, so
stroke of point is the same value as that of point lever (type C).
Inside of arm plate, which is mounted on drive rod, is cylindrical, and rod of switch adjuster runs
through the cylinder. Therefore, drive rod does not work immediately when switch adjuster starts to
move. Until round nut and fastening nut, which are fixed on switch adjuster, come into contact with
arm plate, only switch adjuster moves and drive rod still remains in original position. After round nut
and fastening nut touch arm plate, arm plate, drive rod and tongue rails move together with switch
adjuster until point lever (type C) finishes its operation.

Round nut and Switch adjuster

fastening nut
Arm plate

Figure. Switch adjuster and Drive rod

Therefore, the following formula is established among stroke of point lever (type C, value c), gap
between arm plate and round nut/fastening nut (value a), and stroke of turnout (value b).

c=a+b

The stroke of point lever (type C, value c) is 215mm and the stroke of turnout (value b) is 155mm,
so the gap between arm plate and round nut/fastening nut (value a) shall be 215 – 155 = 60mm. In
the above figure, when point lever (type C) is operated, switch adjuster moves alone to the right
direction by 60mm, and then drive rod and tongue rail move together with switch adjuster by the rest
155mm after round nut/fastening nut come into contact with arm plate.

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JAKARTA MRT PROJECT CP-107 Metro One Consortium
Technical Specification for SIG- Mechanical Point Machine 7/SIG/SPC/0015

APPENDIX 2
Strength Test of Point Lever (type C)

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Technical Specification for SIG- Mechanical Point Machine 7/SIG/SPC/0015

Strength Test of Point Lever (type C)

1. Overview
The strength of point lever (type C) is tested by either of compression test or tensile test.

2-1. Compression test

Point lever (Type C)

Test stand

Circular sector crank Rod supporter Load cell

Joint pin Measuring rod

Figure 1. Compression test

【Test process】
(1) Fix point lever (type C) on the test stand
(2) Fix load cell and rod supporter on the test stand
(3) Rotate handle and set the circular sector crank at the middle position (the position where a hole
for joint pin at the circular sector crank comes to the centre of the point lever)
(4) Mount measuring rod on the circular sector crank and adjust the height of rod supporter until
measuring rod becomes vertical to the load cell
(5) Start the test by rotating handle
(6) After measuring, visually inspect that there is no deformation or destruction at holes for joint
pin or at inner gear
(7) Record the result of the test

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Technical Specification for SIG- Mechanical Point Machine 7/SIG/SPC/0015

2-2. Tensile test

Point lever (type C)

Circular sector crank Tension and compression

load cell

Joint pin Measuring rod

Bearing is built in

Chart 2 Tensile test

【Test process】
(1) Fix point lever (type C) on the test stand
(2) Fix tension and compression load cell and on the test stand (rod supporter is not necessary)
(3) Rotate handle and set the circular sector crank at the middle position (the position where a hole
for joint pin at the circular sector crank comes to the centre of the point lever)
(4) Start the test by rotating handle
(5) After measuring, visually inspect that there is no deformation or destruction at holes for joint
pin or at inner gear
(6) Record the result of the test

Note:
It is not necessary to check the vertical position of tension and compression load cell because this
load cell has built-in bearing.

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JAKARTA MRT PROJECT CP-107 Metro One Consortium
Technical Specification for SIG- Mechanical Point Machine 7/SIG/SPC/0015

APPENDIX 3
Installation Concept Drawing

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