Fastrack Remote Switch Left Hand 060 # 6-16828 lock up problem

I recently bought a new 0-36 switch (6-81946).  I noticed after the train passes through the switch a few times the lever would no longer change the switch.  I can manually move the switch rail and the lever will start working again.  I can also duplicate by pushing the lever the same direction multiple times.  Does this sound like the same issue?

Here's a video showing the issue: https://youtu.be/2g5_diMVydQ

It acts like one of the microswitches at the stop is not being contacted or not working electrically. The segment gear(pie shaped thingy) moves to the stop position on either side and bumps the arm of the microswitch to signal the board of the position of the swivel rails. When the switch does not do this, the motor rotation will not change. The gear motor will hold the switch.

One other thought is the lantern arm binding or the screws that hold it are too tight causing the binding.

You'll need to bench test it with power and the bottom cover removed. Just use some small wires to touch thru and out to ground and some alligator jumpers to the rail pins from a transformer.

Then, observe what's going on under power and if the segment gear is pushing the switch arm enough.

One question, are you powering the switch via track power or separate power?

You can get the small switch from Lionel Parts.

Also, the bench testing with wires to control the switch will eliminate the controller lever device as a possible problem or identify it as the problem.

I will pull the cover off and test.  I'm using track power.  These are brand new switches.  The first one bought about a month ago.  The dealer ordered two more switches (one left and one right) from a different source to eliminate a bad lot.  I got them last Friday and they have the same issue.  

I also noted that removing track power doesn't reset the switch which to me points to something mechanical.

Can you give me more info on the lantern arm and screws?  That sounds possible since the issue happens from either direction.  The arm would fit.

Thanks for your reply.

The problem is that the motor pinion gear rides under a tooth on the rack that it moves, preventing the rack or pinion from moving. It might be that the position of the end of the rack movement can be adjusted to prevent this...activate the microswitch a bit sooner, etc.

I have had several switches lock up this way. The first 060 switch that locked up a couple years ago, I used to rap with a screwdriver handle to free it until I got inside it and determined what the cause was. On that switch I replaced the motor and pinion just to see if a variation in parts would solve the issue and it did. The second one that locked up, I messed with the stopping position of the rack/microswitch and solved the issue for that one.

The bottom line is that there is a small variation in parts/position/sloppiness of the pinion and rack that can cause this lock up in a small percentage of these switches. I would call that a design flaw even though the chances of it happening are small. 

While I still can't explain it, after bench testing and verifying the limit switches are working and the gear moves without a noticeable resistance I loosened the screws holding the motor.  One of two switches now works without issue.  The second switch still locks up but not as much as before.  I need to take it apart and perform more testing but wanted to reply back with what I found out so far.

Thanks Moonman and CJack

That is a good solution for tuning the switches. Too much pressure by the motor pinion gear on the segment gear can hamper movement. Good find!

I forgot about that. I think Mike (Lionel) had video about that adjustment. One of mine needed it. it was used.

Now that you know the switch, just "tune" the problematic ones and you'll have trouble free operation. Just imagine someone screwing down as many motors as they can in a day. A few can get a little too tight or loose.

I think it has more to do with when the rack stops and the motor still continues to run. Loosening the screws probably allows the motor pinion to ride up over the rack without being stuck on top of a tooth. That is a solution.