EMS switch: setting switch shoes, pins and end positions correctly

By Tobias Schott  ·  Reading time approx. 23 minutes  ·  Updated: November 2026

Dismantling and adjustment of an overhead conveyor switch by our installation team
Below the hall ceiling, in the weekend window: a switch is dismantled, fitted with new switch shoes and pins and readjusted in its end positions.

An EMS switch decides whether a vehicle turns off cleanly or stops. Every vehicle runs over it, and its end position must sit precisely with every switching action. Worn switch shoes, worn-out pins and a wandering end position show up as a knock, a stop or a data error. Anyone who knows the mechanics of the switch finds the cause – and knows where the qualified electrician takes over.

The EMS switch is the moving heart of an electrified monorail. It changes the route many times in every shift, often for long periods without a break. If it fails, not one vehicle stops but a whole line. And because it hangs below the hall ceiling, hardly anyone sees how it slowly wears.

This guide goes into depth on one component: the switch. It explains structure, damage patterns, inspection, adjustment and replacement – and how a misadjusted switch puts strain on rollers, collectors and data bus. The overview of all assemblies is given in our guide to Overhead conveyor maintenance. How the system runs as a whole is explained in our knowledge article on the electrified monorail.

We are a maintenance contractor from Rodgau near Frankfurt. We dismantle switches, replace switch shoes and pins, set end positions mechanically and align transitions. Limit switches and switch motors are connected by our own qualified electricians; controls and parameters stay with the manufacturer. We say so in every chapter.

Key points at a glance

What is an EMS switch – and how is it built?

Explanatory graphic: structure of an EMS switch – moving rail section, switch drive, switch shoes and pins, and end position with locking and end position sensing, each with check points and responsibility
Moving rail section, drive, switch shoes and pins, end position with locking and sensing: every component has its own check points – the installation contractor checks the mechanics, the qualified electrician the sensors. Graphic: Omega Mounting

An EMS switch is a moving section of the track that diverts the vehicles of an electrified monorail from one route to another. A drive moves it into the end position, a locking device holds it there, and sensors report to the controls that the switch is in a safe position.

The electrified monorail is a discontinuous conveyor. Each vehicle runs individually and is sent on its way via switches. Only the switches turn a line into a network of lines, branches and buffer sections.

Designs: sliding switch and turntable switch

The design depends on the manufacturer and the age of the system. In a sliding switch, the drive moves a frame with several rail sections across the direction of travel. It stops as soon as the right section is in front of the fixed track. In a turntable switch, a rail section turns about a pivot and thus connects the routes. For maintenance, the same applies to every design: what moves, what guides, what fixes the end position?

The components of a switch

The mechanics extend to the sensor bracket. The sensor itself, its wiring and its switching point are electrics.

Why is the switch the weak point of every electrified monorail?

Technical drawing of an EMS switch in plan view: sliding switch with approach, straight and branch exits, sliding frame in both end positions, switch shoes, drive, stop with locking and limit switch
On a sliding switch, one side of the separation joint moves with every switching action at entry and exit – whether it lines up depends solely on the end position. Graphic: Omega Mounting

The switch is the weak point of every electrified monorail because movement, impact and precision meet there: every vehicle runs over it, every switching action moves drive, shoes and pins, and even a small offset in the end position becomes a knock at every pass.

Every vehicle runs over it

If the whole fleet runs through a branch, this section sees more passes than almost any other point of the system. Add to that lateral forces when the vehicle enters the curve. The guide rollers then press against the moving part and try to push it out of position.

Transitions that move

The switch has a transition to the fixed track at entry and at exit. There is a separation joint there over which rollers and current collectors roll. On the fixed track, a rail joint is aligned and stays that way. At the switch, one side of the joint moves with every switching action. How well the transition lines up therefore depends solely on how precisely the end position sits.

The end position must be exact

A fixed rail joint changes slowly. An end position, on the other hand, is approached anew with every switching action. If shoes, pins or stops wear, it wanders. At first the offset is barely visible. Then you hear it as a knock at every pass. Finally the end position sensing no longer reports reliably, and the vehicle stops in front of the switch.

Then there is age: for older switches the manufacturer does not always still supply parts. Then people improvise, and some switches are eventually locked.

Close-up of a steel running rail with dirt and wear marks
Abrasion and wear tracks on the rail reveal where rollers knock – around the switch, this is often the first visible sign.

What damage does a worn EMS switch show?

A worn EMS switch shows worn switch shoes, worn-out pins and bushes, a wandering end position or one that is no longer reported, knocking transitions with wear marks, loose stops, damaged brackets and, in the extreme case, a switch that has been mechanically decommissioned.

Worn switch shoes

The shoes guide the moving part with every switching action. Over time they wear away. Then the moving part has play. It no longer sits precisely in the end position but slightly askew or too low. Typical signs are shiny wear tracks, abrasion below the switch and audible rattling when switching.

Worn-out pins

Pins in drive and levers run in bushes that are often barely lubricated. Both wear, the joint gets play, and the play of all joints adds up. In the end the drive covers its travel correctly, but the moving part no longer arrives precisely where it should.

Wandering end position

A wandering end position is usually a consequence, not a cause. Shoes, pins or stops have given way, or someone has adjusted a stop to bridge a fault. The results are offset, knocks and sensor reporting errors.

Knocking transitions

A knocking transition is the damage pattern operators hear first. The rollers run over an edge instead of rolling over a smooth joint. Over time they knock wear marks into the running surface there. Around the switch you see this in scored running surfaces, abrasion and broken rollers.

Brackets, suspension and stops

Knocks and vibrations are transmitted to the brackets below the building structure. Typical are loose bolts, cracks at welds and torn-off brackets. Whether the building structure can carry the loads is assessed by a structural engineer.

Mechanically decommissioned switches

The last damage pattern is an emergency solution: a switch that was locked in one end position after damage. The system keeps running, but one route is missing.

Mechanics or electrics: who is responsible for what at the switch?

Explanatory graphic: EMS switch – comparison of the mechanical work of the installation contractor and the electrical work on limit switches, sensors and switch motor by the qualified electrician, ours on request
At the switch, mechanics and electrics meet more closely than anywhere else on the electrified monorail – the end position is only right when both sides are adjusted. Graphic: Omega Mounting

At the switch, the installation contractor takes on the mechanics: switch drive mechanically, switch shoes, pins, stops, locking, alignment of the transitions and brackets. Limit switches, proximity sensors, switch motor and conductor rail are handled at our company by our own qualified electricians, controls and parameters by the manufacturer.

Switches are the assembly where mechanics and electrics come closest together. That is why a clear boundary is particularly important here.

What is mechanical

What is electrics, sensors and controls

Limit switches, proximity sensors, switch motor and measurements on the conductor rail are handled by our own qualified electricians. Controls, data bus and parameters stay with the manufacturer or controls engineer. Isolation and securing follow your procedure before we touch the switch. How the procedure is set up is described in our guide to lockout tagout in maintenance.

Where both work together

The end position has a mechanical and an electrical side. We set the stop so that the switch lines up precisely. The qualified electrician then sets the switching point of the end position sensing to it. If only one side is adjusted, the switch is not right. It lines up but does not report. Or it reports but does not line up – and that is the more dangerous case.

How do you inspect a switch mechanically?

Technical drawing of the mechanical inspection of an EMS switch: side view with checks of play, joints and brackets from the working platform, detail of the straightedge at the offset edge of the transition
First listen and look in operation, then feel for play by hand when isolated – finally the straightedge at the transition shows whether there is an edge in each end position. Graphic: Omega Mounting

You inspect a switch mechanically in a fixed sequence: first in operation with ears and eyes from the hall floor, then isolated by hand at drive, shoes, pins and stops, finally with the straightedge at the transition – tolerances as per manufacturer's data.

In operation: listen and look

Watch several switching actions from the hall floor. Does the switch rattle, does it jerk? Is there a knock when a vehicle runs over the transition? Is there abrasion below the switch – plastic from rollers, black dust from carbon brushes, metal chips? Note which switch stands out and in which switching direction.

Isolated: touch

Once the line is isolated and secured, check from the working platform. Move the moving part in the end position by hand. Noticeable play in height or side points to shoes or pins. Check the joints individually, the stops for seating and the welds on brackets for cracks.

At the transition: line up

Place a rule or straightedge over the transition between fixed track and moving part. Check the running surface and the guide surface. You see immediately whether there is an edge or everything lines up. Check each end position, because often only one switching direction lines up. How much deviation is permissible is set by the manufacturer.

What the controls reveal

The fault memory shows at which switch end position signals are missing or vehicles stop. Have it read out by the qualified electrician or controls engineer – the list is the best starting point for the mechanical inspection. How to get from the fault message to the cause is shown in our guide to troubleshooting on conveyor systems.

Documenting

Record the findings per switch with photos. This list determines the order of the repair. Check points for the whole system are in our overhead conveyor maintenance checklist.

Positioning strip and read head at the switch. On many systems the barcode strip also runs over the moving section. Check whether it continues at both transitions without gap or edge. If the moving part is only slightly offset in the end position, the read head briefly loses the track. The vehicle then stops in front of or in the switch, even though it has switched mechanically. Anyone who only checks the controls here is looking in the wrong place.

Adjusting an EMS switch: setting end positions, lining up the transition, testing

Explanatory graphic: adjusting an EMS switch – sequence from isolation and findings via replacing switch shoes and pins, setting end positions and lining up the transition to end position sensing, test runs and release
First isolate and record findings, then replace wearing parts, set end positions and line up – the qualified electrician sets the end position sensing before test runs and release follow. Graphic: Omega Mounting

Adjusting an EMS switch means: having the line isolated, recording findings, replacing worn switch shoes and pins, setting the end positions mechanically, lining up the transitions and checking with test runs – the end position sensing is set by the qualified electrician.

Isolating and securing

Before the first touch, the line is isolated according to your procedure – by our or your qualified electrician – and secured against being switched back on. The area below the switch is cordoned off and nearby vehicles are secured.

Wearing parts first, then adjustment

Adjusting an end position on worn shoes does not last. The play carries the adjustment away again in a short time. That is why new switch shoes and pins come first. Adjustment follows.

Setting end positions mechanically

The moving part moves into one end position. We set the stop so that the running surfaces line up in height and side. The locking must engage securely without jamming. Then the remaining end positions follow, on sliding switches with several positions each one individually. Each end position is set and checked on its own.

Lining up the transition

Every transition is checked with the straightedge: running surface, guide surface and, where the design allows, the conductor rail chamber. Where the fixed track before the switch is itself worn, the best switch adjustment does not help. Then the rail section in front of the switch is aligned or shifted slightly so that the end position sits on less worn rail.

End position sensing by the qualified electrician

Once the mechanics are set, the qualified electrician sets the switching point of the limit switches or proximity sensors. They check the signal to the controls. Only then is the line switched back on.

Test runs

The switch switches several times into each end position. Then vehicles run over it in each direction, first empty, then with load. We watch for knocks at the transition, smooth running of the rollers, clearance of the guide rollers and a current collector that glides smoothly over the joint.

Release after the repair

After work that can affect safety, the operator determines whether and how inspection takes place. The basis is their risk assessment under the German Ordinance on Industrial Safety and Health (BetrSichV). The inspection is carried out by a person qualified to inspect. We hand over findings, photos and a list of replaced parts. This section is a practical classification, not legal advice.

Switch shoes and pins: repair or replace?

Technical drawing of an EMS switch in section: worn and new switch shoe on the guide, and worn-out and new pin joint with bush and locking
Switch shoes, pins and bushes are wearing parts and are replaced – guide, bearing point and brackets are cleaned, checked and repaired. Graphic: Omega Mounting

Switch shoes and pins are usually replaced because they are wearing parts. The parts around them are repaired: mountings, brackets, stops and bearing points. If the manufacturer no longer supplies, parts are re-made to measurement, manufacturer's documents or operator approval.

Replacing switch shoes

The old shoes are removed and compared with a new part. This shows how much has worn away and whether the guide has suffered too. New shoes go into a cleaned guide. Lubrication only if the manufacturer specifies it, because grease binds dust.

Pins and bushes as a pair

A new pin in a worn-out bush soon has play again. Pin and bush are therefore checked together and usually replaced together. The bearing point is cleaned and checked for out-of-roundness. After fitting, the pin is secured. Why pairs wear together is explained in our guide on Wear on the electrified monorail.

When force becomes necessary

A pin that can only be loosened with a hammer, a switch part that jams, a drive that catches: that is a finding, not a work step. Anyone who carries on with force hides the cause. It may be a distorted bracket, a bent guide or a wrongly made seat. We measure before we hit again.

Re-making in the workshop

Older switches often have parts that nobody supplies any more. Then we re-make switch shoes, pins, bushes or brackets in our workshop in Rodgau. The basis is a survey, a manufacturer's drawing or the operator's approval. Materials and characteristic values for load-bearing parts are set by the manufacturer or operator, not by the installation contractor. How to deal with missing parts is described in our guide to spare parts that are no longer available.

Brackets and drive

Torn-off brackets are repositioned and welded if the operator approves. The structural analysis of the suspension is assessed by a structural engineer. On the drive we replace mechanical parts such as coupling and lever. Connecting the motor electrically is done by the qualified electrician.

How a misadjusted switch strains rollers, collectors and data bus

Technical drawing: plan view of the transition of an EMS switch with offset between fixed rail and moving part – roller knocks, collector jumps, read head loses the positioning strip
A small offset in the end position hits roller, collector and read head at once – the controls then report a data error. Graphic: Omega Mounting

A misadjusted switch strains the whole system: every offset at the transition knocks on running and guide rollers, on current collectors and carbon brushes. Current collection becomes unsteady, and communication faults occur that look like electronics but have a mechanical cause.

The chain of consequential damage

What this means for troubleshooting

Do not only look for the fault where it is reported. If data errors accumulate at one spot, check the switch there mechanically. The electrical measurement is done by the qualified electrician. Only both together show the cause of an EMS switch fault. Conversely, a worn track in front of the switch makes even the best switch knock. Switch and track are therefore always assessed together.

Maintained current collectors on the drive of the electrified monorail
After cleaning comes maintenance: current collectors, carbons and contacts – and the switches whose transitions knock on the collectors.
Repair work on an overhead conveyor in Frankfurt during a planned shutdown
In the planned shutdown the system gets back what it was missing: switches that had been locked for a long time run again after repair and a function test.

Putting decommissioned switches back into service

Technical drawing: five steps to put a decommissioned EMS switch back into service – free, clean and lubricate, adjust end position, test electrics, empty test run
Free, clean, adjust – then the qualified electrician tests, then the first vehicle runs empty. Graphic: Omega Mounting

A mechanically decommissioned switch can often be put back into service. Findings are recorded, the cause of the decommissioning is eliminated, wearing parts are replaced, end positions set and transitions lined up. Then the qualified electrician tests the electrics and the operator releases the switch.

Why switches are decommissioned

It usually starts with damage: a broken part or an end position that no longer reports. There is no time or no part for the repair. What was meant as a temporary solution often stays that way for a long time.

What decommissioning costs

Vehicles take detours, buffer sections fill up. If a switch fails elsewhere, there is no alternative route. Availability drops even though everything seems to be running.

The way back

It starts with the question of why the switch was decommissioned and which parts are missing. If they are no longer available, they are re-made to measurement and approval. Then repair, adjustment and function test follow as for any other switch. Important: a switch that has been locked for a long time is often blocked or bypassed in the controls. Whether it goes back into operation is decided by the operator and controls engineer. That belongs in the planning, not at the end of the window.

Many switches in the weekend window: how to plan the work

Explanatory graphic: EMS switch – sequence when many switches are repaired in one weekend window: preparation, isolation, switch by switch, inspection and handover
Many switches in one window only succeed with preparation, fixed procedures per switch and a clear handover at the end. Graphic: Omega Mounting

Many switches in one weekend window succeed if every switch has been assessed and prioritised beforehand, spare parts are ready per area, workplaces at height are prepared, teams work in parallel and the end consists of function test, documentation and release.

Findings and sequence

Before the first window, every switch is documented and assessed. The sequence results from this. Switches that can stop the material flow and badly damaged switches come first. Decommissioned switches follow once the running ones are safe.

Spare parts are ready per area, re-made parts are finished before the window.

Access at height

Switches hang below the ceiling, often above production areas. Work is done from mobile working scaffolds or the mobile elevating work platform, with additional lighting and a cordoned-off area below. Tools are secured against falling. What applies when working from the platform is described in our guide to installation work with a MEWP.

Working in parallel

Several technicians work at different switches at the same time, each group in its isolated area. A qualified electrician – from our team or yours – is scheduled for isolating, end position sensing and switching back on.

Fallback and completion

For every switch it is decided in advance what happens if it is not finished by restart. Usually it is locked in a safe end position and completed in the next window. What is possible during operation and what needs a real shutdown window is separated in our guide to Maintenance during live operations. Every window ends with a function test, photos, a record and a list of open points.

Two fitters on mobile access towers at the overhead conveyor
Working in parallel, each group in its isolated area: this is how many switches fit into a tight window between the end of production and restart.

Symptom, cause, next inspector: the EMS switch overview

Overview: faults on the EMS switch – symptoms, possible mechanical causes and who checks next, from the installation contractor via the qualified electrician to the structural engineer
Rattling, knocking, missing end position signal, data error: behind almost every symptom at the switch there is a mechanical cause – and for each there is a next inspector. Graphic: Omega Mounting

The overview assigns possible mechanical causes to each symptom at the EMS switch and names who checks next: the installation contractor the mechanics, the qualified electrician sensors and electrics, manufacturer or controls engineer controls and data.

SymptomPossible mechanical causeWho checks next
Rattling when switchingWorn switch shoes, play in pins and levers.Installation contractor
Knock at every passOffset at the transition, wandered end position, worn rail.Installation contractor
Switch does not reach the end positionJamming guide, bent part, stiff drive.Installation contractor, motor electrically by the qualified electrician.
End position is not reportedEnd position mechanically misadjusted, sensor bracket loose.Installation contractor, switching point by the qualified electrician.
Vehicle stops in front of the switchMissing end position signal, locking does not engage.Qualified electrician and installation contractor together.
Data error at the switchOffset of the conductor rail at the transition, jumping current collector.Installation contractor, measurement by the qualified electrician.
Abrasion below the switchRollers knock at the transition, shoes wear away.Installation contractor
Crack in the bracketKnocks, vibration, overload.Installation contractor, structural analysis by the structural engineer.
Switch mechanically lockedBroken part, missing spare part.Installation contractor, controls by the manufacturer.

The table does not replace findings on site. But it shows where to start.

Typical mistakes on the EMS switch

The typical mistakes on the EMS switch are: adjusting on worn parts, replacing pins without bushes, checking only one end position, readjusting the limit switch instead of the mechanics, forgetting the rail in front of the switch and decommissioning switches instead of eliminating the cause.

Almost all mistakes have the same root: the switch is seen as a single part. In fact it is a chain of drive, joints, shoes, stops, transitions and sensors. Anyone who fixes only one link shifts the problem to the next.

Overhead conveyor maintenance in Frankfurt
From Rodgau in Frankfurt: maintenance on switches, rails and trolleys – the electrics are handled by a qualified electrician, ours on request.

Switch maintenance in the Rhine-Main region: how we work

For us, EMS maintenance in the Rhine-Main region means for switches: recording findings mechanically, repairing and adjusting – in Frankfurt, Offenbach, Hanau, Darmstadt and Aschaffenburg and beyond, at weekends and in shutdown windows.

Our core is the mechanics; disconnecting and reconnecting are handled on request by our own qualified electricians. We dismantle switches, replace switch shoes, pins, bushes and rollers, set end positions and align transitions. We weld brackets after approval and re-make missing parts in our own workshop. We bring scaffolding and lighting.

Isolation, limit switches and electrical measurements are handled by our own qualified electricians by arrangement. Controls and parameters stay with the manufacturer or controls engineer. Short distances from Rodgau help with walk-throughs before the window and when a shutdown is postponed. Our scope of services is described on the page Maintenance and servicing.

Project examples

The following jobs show what matters with switches: record findings before the window starts, repair the mechanics completely and always see switches together with rail and conductor rail.

Frankfurt: many switches in weekend shutdowns

With the maintenance of an overhead monorail system in Frankfurt we found a very old system at a manufacturing company in Hesse. It had many switches in several operating areas. We found worn and broken running and guide rollers, scored running surfaces, offset rail transitions and damaged brackets. Some switches had been mechanically decommissioned after parts had broken off.

First every switch was documented and assessed and the sequence agreed with the customer. Work was done at weekends in a tight time window between the end of production and restart, in parallel from mobile towers and mobile platforms.

Rollers were replaced, internal ones partly with complete dismantling of the switch. Switch shoes and pins were replaced and adjusted, transitions aligned, end positions set. Torn-off brackets were welded. Worn rail sections were shifted slightly so that the end positions sit on less worn rail. The decommissioned switches went back into operation.

For your system this means: an old switch does not necessarily need replacing. It needs findings, the right parts and a prepared window.

Beverage plant: switches adjusted after cleaning

In a beverage plant an electrified monorail had constant dropouts and faults in the data bus. Sugary, humid air had covered rails and conductor rail with a sticky deposit. We cleaned the very long track section by section from the mobile tower – every switch and every transition included. The subsequent maintenance showed: switches and transitions were partly not set correctly and caused additional communication faults. Poorly aligned transitions are mechanical poison for the collectors. We adjusted them and serviced current collectors, carbons and contacts. The electrical tests were carried out by the qualified electrician.

For your system this means: anyone who only cleans fixes part of the faults. The switches belong in the same maintenance.

Are switches knocking, jamming or standing still at your plant?

Then get in touch with us. Send us a list of the noticeable switches, photos and, if available, extracts from the fault memory. We will tell you what we take on mechanically and electrically and where the handover point to your electricians lies.

Cleaning the EMS rail from a mobile tower in the production hall
Section by section from the mobile tower: first clean rail and conductor rail, then check and adjust every switch and every transition.

What this means for your role

For buyers: Separate the findings per switch from the repair in the quotation. Require the supplier to name the interface to the qualified electrician.

For designers: Switch position and accessibility decide how much effort every later maintenance takes. Plan space for mobile scaffolds and record the design of every switch in the documents.

For project managers and site managers: Plan the switches as a sequence of windows with findings before and release after. On site you coordinate isolation, scaffolding, cordoning off and the qualified electrician.

For maintenance managers: Your fault memory is the best switch list. Have the most noticeable switches checked mechanically first, before one has to be decommissioned.

For operations and plant managers: Every decommissioned switch costs availability, even if the system is running. Release the windows needed for a complete repair.

EMS switch check sheet: template on request

The EMS switch check sheet is a one-page working document per switch. It guides you through identification and location, observation in operation, mechanics in the isolated state, transitions per end position, responsibility and measure. Each point has fields for “finding”, “responsible” and “done” or “open”. There are deliberately no number fields or tolerances – the manufacturer supplies those. Request the template via our contact form – keyword “EMS switch check sheet”.

Why Omega Mounting?

We are based in Rodgau near Frankfurt, can be reached around the clock and work with our own fitters, our own equipment for work at height and our own workshop. The linked job in Frankfurt shows how we work on switches: every switch assessed, switch shoes and pins replaced, end positions set, decommissioned switches brought back into operation. We say beforehand where our service ends: the electrics at the switch are done by our own qualified electricians, controls and parameters by the manufacturer. What this means for you: a single point of contact for the mechanics and electrics of your switches, who defines the handover point to your electricians in advance.

Conclusion

An EMS switch is the component where an electrified monorail stumbles most often. Worn shoes, pins and end positions cause knocks, stops and data errors. The solution is a fixed sequence: record findings, replace wearing parts, set end positions mechanically, line up transitions, test. The end position sensing is set by the qualified electrician, release is given by the operator. Decommissioned switches can often be brought back. If your switches knock or stand still, send us your switch list and photos – we will get back to you with an honest assessment.

Planning a move-in, installation or maintenance in the Rhine-Main region?

Tell us briefly what you need – we'll come back with an honest assessment.

Free, no-obligation callback

Tobias Schott, managing director of Omega Mounting GmbH, on a construction site in front of scaffolding

About the author

Tobias Schott

Managing director of Omega Mounting GmbH, Rodgau · more than 20 years of hands-on experience in installation and maintenance

A trained mechatronics technician, working in maintenance, servicing and industrial installation since 2004 – first alongside his father, and with Omega Mounting since 2012: from overhead conveyors in Frankfurt to the crane system in a new-build hall. He plans and leads lifting operations as an appointed person (AP) in data centers and on industrial sites in the Rhine-Main region, trains and examines operators of cranes, mobile elevating work platforms and telehandlers, and is a qualified occupational safety specialist. On jobs abroad he is known as the “German Troubleshooter” – the person you call when a site gets stuck. He learned what quality means from his father, not from a manual: Made in Germany as a standard for his own work, not a label. That is why quality comes first at Omega Mounting – ahead of speed and price. He writes these guides from that practice: what works on our sites is in them – what exists only on paper is not.

Frequently asked questions

Usually because of wear on the mechanics: worn switch shoes and worn-out pins create play, the end position wanders, and the end position sensing no longer reports reliably. Add to that jamming guides, bent parts and loose stops. Less often the electrics themselves are the cause – that is checked by the qualified electrician.

In a sliding switch, the drive moves a frame with several rail sections across the direction of travel. In a turntable switch, a rail section turns about a pivot. In both, guides, pins and stops determine the end position.

By rattling when switching, abrasion below the switch and play of the moving part in the end position. In the isolated state the play can be felt by hand. Comparing a removed shoe with a new part shows how much has worn away.

The installation contractor sets the mechanical end position: they set the stops so that the transitions line up. The qualified electrician then sets the switching point of the limit switches or proximity sensors. Only when both sides are right is the end position correctly set.

Yes, if the manufacturer no longer supplies them. The basis is a survey, a manufacturer's drawing or the operator's approval. Materials for load-bearing parts are set by the manufacturer or operator.

Often yes. It is repaired and adjusted, and the qualified electrician tests the electrics. The operator and controls engineer take it back into operation, and the operator releases it.

Because the conductor rail runs through the switch. If it does not line up at the transition, the current collector jumps and the contact briefly breaks. The controls report a communication error – the cause is mechanical.

Whether and how is determined by the operator in their risk assessment. After work that can affect safety, a person qualified to inspect carries out the inspection. For this we hand over findings, photos and the list of replaced parts.

Send us a list of the noticeable switches, photos, the location and, if available, extracts from the fault memory. We will then look at the switches on site and tell you in writing what we take on mechanically and electrically and where the handover point to your electricians lies. Your contact is Tobias Schott – reachable via our contact form.

EnglishEnglish