Step Switch Base Replacement Instructions 3-Pole, 60 AMP, Fusible, Heavy Duty Safety Switches Work Description All work should be performed in accordance with NFPA 70E. Tools Required: Personal Protective Equipment (Gloves and Eye Protection) Properly rated voltage sensing device. 1/4" Torque Controlled Driver with magnetic socket. 5/16" Torque Controlled Driver with magnetic socket. Small work table and screw bin. Reference Pictures & Comments 1 Turn OFF and lock out all power supplying this switch before installing base kit. 2 Turn switch to "OFF" position. 3 Verify there is NO voltage present at the line and load terminals using a properly rated voltage sensing device. 1 of 9
4 Remove fuses. 5 Remove clear line shield using a 1/4" driver. (1 screw) Keep parts for reinstallation on new base. 6 Remove red arc shield using a 1/4" driver. (1 screw) 7 For fusible switches remove middle load side fuse clip connector screw with 1/4" driver. Keep screw for reinstallation. 2 of 9
8 Remove insulator screw with 1/4" driver and remove insulator. Keep parts for reinstallation. Insulator used only on 60 amp and 30 amp Canadian models. 9 On fusible switches it is helpful to remove two screws with 5/16" driver from the lower fuse base and lower it out of the way. Keep screws for reinstallation. x2 10 If equipped with a neutral or control pole, loosen mounting screw with 5/16" driver and slide to the left. Screw is captivated by plastic base and does not need removed. 11 Mark the line side lugs before removing so they can be reinstalled back in their original phase locations. 3 of 9
12 Remove screws from line side lugs using 5/16" driver. Move wires to the side for base removal. Keep screws for reinstallation on new base. x3 13 Remove switch base with 5/16 driver. (3 screws, 2 on bottom, 1 on top) Keep screws for reinstallation on new base. 14 Slide base to left to disengage shaft from mechanism. Remove insulator. Keep insulator if present for reinstallation on new base. Insulator used only on 60 amp models. 15 Verify there is no foreign material left in the mechanism shaft coupling. This could cause misalignment and premature failure of the new base. 16 Remove three fuse clips with 5/16" driver and keep for reinstallation. x3 4 of 9
17 Remove three fuse puller straps with 1/4" driver and keep for reinstallation. 18 Remove universal base and hardware from box verifying the following contents. 1-Universal Base 3-Lug Stops - *Not used for fusible devices. 3-Lug Stop Screws - *Not used for fusible devices. 19 Reinstall three fuse puller straps from original base with 1/4" driver on new base assembly. Torque to 15-25 in-lbs. 20 Reinstall three fuse clips from original base with 5/16" driver on new base assembly. Make sure retainer tang is up as shown in picture. Torque to 20-30 in-lbs. x3 5 of 9
21 Rotate switch base shaft counter-clockwise to put switch blades in open/off position. Place insulator on mechanism. *Insulators used only on 60 amp models. 22 Align base mounting holes and install 3 screws with 5/16" driver. (1 on top, 2 on bottom) Torque to 20 to 25 in-lbs. 23 Align fuse base and install 2 mounting screws with 5/16" driver. Torque to 20 to 25 in-lbs. x2 24 For fusible switches reinstall insulator and and retainer screw with 1/4" driver. The right side of the insulator wraps around the switch base wall as shown. Torque to 20 to 30 in-lbs. Insulator used only on 60 amp and 30 amp Canadian models. 6 of 9
25 For fusible switches position load side fuse clip connector onto the locator tabs and fasten with screw using 1/4" driver. Torque to 20-30 in-lb. LOCATORS 26 Remove arc shield mounting screw with 1/4" driver. Remove arc shield. Keep screw and arc shield for reinstallation. x1 27 Reattach line side lugs using 5/16" driver. Torque to 20-30 in-lbs. x3 NIB 28 If device has a neutral or control pole, reinstall. Note : Two nibs on the side fit into notches on the side of the base. Tighten mounting screw to 20 to 25 in-lbs. NIB 7 of 9
29 Reattach arc shield. Torque to 20-30 in-lbs. x1 30 Install line shield. Torque to 20-30 in-lbs. x1 31 Install fuses. 32 Verify all parts are in place and screws torqued to specification. 8 of 9
33 Hold in mechanism-defeat lever and actuate switch 3-4 times verifying switch blades are opening and closing properly. 34 Prior to energization remove any loose materials or tools from the switch enclosure. Close cover before turning power on ahead of switch. 9 of 9