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Well it had to happen I guess. After 22 years of faithful service with only a few minor issues, one of my old bullet proof 022 switches suffered a fatal flaw. It quit switching into the turnout position and one controller bulb was dead. This usually means either a wiring issue, controller issue, or an electrical issue within the switch machine. A quick test involving shorting each outer electrical post to the center one confirmed my worst fears; an internal machine issue. Yikes! This means removal of the switch from the layout, with tearing up of track, moving a ton of stuff, the works! Ugh!

From this picture you can see why I was not enthusiastic about the prospect.

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After feeling sorry for myself for a while and mulling over options, I decided to try something I've never done before; an in situ repair. If you are able to remove the two screws holding the switch machine to the bottom of the switch you can easily remove the machine. The trouble is the screws are only accessible from the underside! So I decided to tackle the repair from beneath the layout.

First it took about 1/2 hour just to move stuff from under the layout to get to the right area. This was not a bad thing because there were several long-lost treasures found along the way. Then I made a template of the baseplate from a spare that was on hand. I used this to mark the location of the screws and used a 1" hole saw to cut access holes, per below. Luckily the screws were right where they ought to be! The hole sawing was pretty straightforward, there being only 1/2" of homosote topped with 3/16" of cork roadbed.

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After removing the screws all I had to do was loosen the adjoining switches and tracks, and lift the switch up slightly about 1/4" and slide the switch machine out. I replaced it with my ready to go spare, and bingo, all was well and good in trainland once again. Took maybe 2 hours total, and I got to unearth some cool treasures in the process!

Below are the sliding contacts within the base of these switches. As luck would have it when I connected power to the failed switch machine on the workbench, it worked flawlessly in both directions! What?? How can this be? Undaunted I cleaned the contact points up nice and shiny anyway per below and oiled it up sparingly. Now it will be the new "spare" for the next switch failure.

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So in summary, this unorthadox repair saved me a lot of back-breaking work leaning over the edge of the layout pulling up track and switches. I got lucky because it so happened that both screws were accessible from below, and not obstructed by framework members. I am sure not all would be this easy to get to. But it's good to know that this may be an option for the future.

Rod

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Many would advise to remove the screws holding the switch machine cover down and install the switch with the cover held in place by gravity. This way, the machine an be serviced from above easily. This does not help with motor replacement though as the motor would still be attached and secured by screws. I like how you overcame that obstacle!

Creative solution, glad I use Ross switches and I can take the DZ-2500 switch machine off with two easily accessible screws.

Yeah John the newer stuff is way nicer I guess. When I built this layout there was no Fastrack, no Atlas. Gargraves has been around for decades of course, but not sure if RCS switches were out by then. These old 022's date back to the 1950's, and the design must be about 80 years old by now. Wow

@rtr12 posted:

That was a good idea for the fix!  Nice shot hitting both screws with only one hole per screw!  I would have had a 'swiss cheese' down there by the time I got to both screws.

Tom I was really happy and kind of surprised when both screws turned up right where they should have been! Went and bought a lottery ticket.

Rod

Last edited by Rod Stewart
@Rod Stewart posted:

Yeah John the newer stuff is way nicer I guess. When I built this layout there was no Fastrack, no Atlas. Gargraves has been around for decades of course, but not sure if RCS switches were out by then. These old 022's date back to the 1950's, and the design must be about 80 years old by now. Wow

Trust me, I know all about O22 switches!  I had a bunch of them at one time, I actually got pretty good at rebuilding them.  I went from tubular track to Fastrack, and finally my current layout is my first go with Gargraves/Ross.  We use Atlas on our modular club modules.

Yes it was nice to get this bottleneck out of the picture for sure. You really don't realize how much you rely on fully operational switches until you have one that fails. On the plus side though, in 23 years this is the first out of 28 total 022 switches on the layout that has had the sliding contact switch fail. Not too bad really I guess.

Going forward it's nice to know that this type of in place repair is an option, as long as you can get to the two underside screws that is!

Rod

Last edited by Rod Stewart

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