Instruction Sheet

C622 12–2001

Instructions for Spacer Replacement in Contact Blocks Used On

40/70/125 Amp OT III and OTPC Transfer Switches (Kit 541–0766)
GENERAL INFORMATION
The following parts are included in this kit.
• Spacers (2)
Read these installation instructions completely and
become familiar with safety warnings, cautions, and
the installation procedure before starting.
WARNING Incorrect installation, service, or
parts replacement can result in severe personal
injury, death, and/or equipment damage. Service
personnel must be trained and experienced to
perform electrical and mechanical component
installations.
(962–0512) or the OTPC Service Manual
(962–0516) and remove the two contact block
and cross-bar assemblies. Be sure to follow all
safety warnings and cautions in the manual. A
picture of a contact block and cross-bar assem-
bly is shown in Figure 1.
PHASE
BARRIERS
RETAINER
BARRIER

DISCONNECT AC POWER
Before beginning any service procedure:

• If a generator set provides Source 2 (Emer-

gency) power, turn the operation selector
switch to Stop. (The selector switch is located
on the generator set control panel.) FIGURE 1. BLOCK AND CROSS-BAR ASSEMBLY

• Disconnect all sources of AC power to the
transfer switch.
• If there is an external battery charger, discon-
nect it from its AC power source. Then discon-
nect the set starting battery negative [–] cable.
2. Place the contacts in the open position. Re-
move the two screws securing the left and right
phase barriers. Remove the phase barriers
and the retainer barrier (see Figure 2).

WARNING The transfer switch presents a

shock hazard that can cause severe personal
injury or death unless all AC power is removed. PHASE
BARRIER
Disconnect all sources of AC power to the
transfer switch before servicing. Be sure to set
the generator set operation selector switch to
Stop, disconnect the battery charger from its
AC power source, and disconnect the starting
PHASE
battery negative [–] cable. BARRIER

SPACER REPLACEMENT RETAINER

BARRIER
1. Follow the instructions for 40 to 125 amp trans-
fer switches in the OT III Service Manual FIGURE 2. PHASE BARRIER REMOVAL

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 3. Locate the two cross-bar barriers on either side CROSS-BAR CROSS-BAR
of the handle (see Figure 3). Notice they have a ASSEMBLY BARRIER
small dab of hot melt to hold them in place. Use
a screwdriver to gently pry the hot melt up and
away so the barriers can be removed.

CROSS-BAR
BARRIER

FIGURE 5. CROSS-BAR ASSEMBLY REMOVAL

HOT 6. Remove the spacer from the contact block (see

MELT Figure 6). The spacer is down in the molded
block where the cross-bar was mounted.
FIGURE 3. CROSS-BAR BARRIER REMOVAL

4. Turn the contact block assembly over. Locate

the two screws that hold the cross-bar in the
block (see Figure 4). Remove the two screws
(#6–32 x 5/8”) and flat washers.
SPACER

FIGURE 6. SPACER REMOVAL

7. Install a new spacer in the contact block. Figure

7 illustrates the difference between the two
spacers.
SCREWS

FIGURE 4. CROSS-BAR RETAINING SCREWS

5. After removing the two screws and flat wash-

ers, gently pull the cross-bar assembly from the
molded block. You can pull on the handle but be
careful with the cross-bar assembly so it
NEW SPACER OLD SPACER
doesn’t fall apart; there’s not much holding it to-
gether at this point. It shouldn’t just fall apart but
it could if it gets twisted or pulled on hard. Fig- FIGURE 7. NEW AND OLD SPACERS
ure 5 shows the cross-bar assembly removed.

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 8. Carefully reinstall the cross-bar assembly. Se-
cure it to the contact block with the two #6–32 x
5/8” screws and washers. Torque the screws to
14–18 in-lbs (1.6–2.0 NSm).
9. Install the two cross-bar barriers. Use a small
amount of silicone to hold the cross-bar barri-
ers in place instead of the hot melt.
10. Install the retainer barrier and the two phase
barriers. Secure the barriers to the contact
block with the two screws.
11. Repeat steps 2 through 10 to replace the
spacer in the second contact block and cross-
bar assembly.
12. Follow the instructions in the OT III or OTPC
Service Manual to reinstall the two contact
block and cross-bar assemblies.
RECONNECTING AC POWER
(WHEN FINISHED)
After all service procedures are completed:
• If Source 2 (Emergency) is a generator, con-
nect the negative (–) battery cable to the
starting battery. If applicable, connect the bat-
tery charger to its AC power source.
• Reconnect Source 1 (Normal) Source 2
(Emergency).
• Set the operation selector switch on the gen-
set to the Remote position.
WARNING AC power within the cabinet and the
rear side of the cabinet door presents a shock
hazard that can cause severe personal injury or
death. Use extreme caution to avoid touching
electrical contacts whenever the cabinet door is
open.
C622
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