J300, J4ATS, J7ATS Transfer Switches Series 300

4000 & 7000 Series

260, 400, and 600 amp sizes
Service Bulletin

Figure 1. 260 and 400 amp Transfer Switches

J4ATS and J7ATS 3 pole with switched neutral Figure 2. 600 amp. Transfer Switches.
shown.260 and 400 amp. has single–barrel Series 300, 3 pole, customer terminal block
terminal lugs. shown;600 amp. has two–barrel terminal lugs,
extended front barrier, rear barriers, and side
This service bulletin explains how to replace the mounting rails.
solenoid coil and coil control contacts in 260,
400, and 600 amp ASCO Series 300, 4000 Tools Needed
Series, and 7000 Series J–design Automatic
 safety glasses (for eye protection)
Transfer Switches.
 1/4–3/8” straight blade 6” screwdriver
 short handle blade screwdriver
Contents
 3/8” ratchet drive, 6”& 12” extensions
page
 3/8” socket
Tools Needed ............................................ 1  5/16” and 3/8” open–end or box wrench
Maintenance Handle ................................. 2  5/16” and 3/8” nutdriver
Solenoid Coil Replacement ....................... 3  torque wrench 0 to 20 ft.–lbs (240 in–lb)
Control Contact Replacement ................... 6  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.

381339-277 C
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 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 deenergized 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: storage clip
open both normal and emergency source circuit
breakers.

1. Deenergize the transfer switch.

After deenergizing 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
remove 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 Figure 3. Maintenance handle and its storage clips.
to manually operate the transfer switch to the
opposite position. Table A. Maintenance handle positions.
ATS Position Handle Indicators
Note: If Normal and Emergency connections Normal up E=O
E
are reversed this operation is also reversed. upper contacts open
N=C
4. Return the transfer switch to the Normal position. N
lower contacts closed

Observe that the window indicators (right side) show

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

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
Figure 3. Maintenance handle operation and contact position indicators.
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 Solenoid Coil Replacement
Solenoid Coil Replacement
solenoid
Solenoid coil kits include only the coil (see below for frame
appropriate voltage).
Replacement Solenoid Coil Kit solenoid
coil
(includes coil only, see voltages below)
Solenoid Coil Kit rectifier
cover

Transfer Switch Solenoid Coil solenoid

Service Voltage Kit Number weight
(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
transfer switch
550 / 600 V K734768–005

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 cover. Figure 5. Solenoid operator assembly.

Disconnect the two coil leads from the rectifier. See  included
Figures 5 and 6. in kit
four
2. Remove solenoid retaining bracket and coil. retaining
SEMS
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 tube) and out of the flange
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 left side. solenoid
Install the coil (in this position) into the frame by coil 
pushing it downward (onto the core tube) and into the
frame. Secure the coil by reinstalling the solenoid
rectifer
retaining bracket. Use a 3/8” socket, open–end, or box
cover
wrench to install (cw) four SEMS screws. Tighten the core
screws to 5.5 ft.–lbs. (66 in.–lbs.) torque. See tube
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 cover onto
solenoid
the top of the solenoid frame. Use a blade screwdriver frame
(cw) to tighten the screw. See Figures 5 and 6.
Figure 6. Solenoid coil. loosen screw

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 Solenoid Coil and Solenoid Assembly Replacement continued
Solenoid Assembly Replacement
Solenoid assemblies include entire solenoid with frame, bearing
plate
coil, core tube, core spring, and core and link.
Replacement Solenoid Assembly with core & link
(includes rectifier & cover, locking pin)
Solenoid Assembly locking pin

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 maintenance screw link pin
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 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.
clevis pin core link
4. Remove auxiliary contact assembly from weight.
Use a 5/16” open–end or box wrench (ccw) to remove weight
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.

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 Solenoid Coil and Solenoid Assembly Replacement continued
6. Remove the solenoid assembly.
Use a 3/8” open–end or box wrench (ccw) to
remove four SEMS screws (two at the top, one on
To prevent personal injury do not attempt to
remove the clevis pin until the weight is locked in either side). See Figure 10.
the emergency position (step 3, figure 7). 7. Transfer the labels from old solenoid to new one.
Carefully remove the nameplate, WCR label, and
DANGER label from the old solenoid. Then apply
them onto the new solenoid.
To prevent shortened equipment life or 8. Install the new solenoid assembly.
malfunction, do not damage the clevis pin Position the new solenoid assembly onto the
when removing it. mounting rail so that the two protrusions align with
the holes in the solenoid assembly. The core link
should be in the slot in the weight. Use a 3/8”
solenoid open–end or box wrench to install four new 1/4–20
assembly
x 3/4” long SEMS screws (two at the top, one on
either side). See Figure 10.
9. Install new rectifier cover and connect two wires.
2 screws 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 6 on page 3.
10 .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” 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 10.
2 screws
11. 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 7
on page 4.

To prevent severe damage to the solenoid

assembly, remove the clevis pin from the hub on
Figure 10. Solenoid assembly removal. the left side. This action will unlock the weight and
allow free movement of the operator when it is
reenergized.

12. 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.

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 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.
3. Install the new control contact assembly.
Figure 11. Location of control contacts.
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 cam

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

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