SCHUNK WBL 85 Balfour Beatty Operating and maintenance manual

Single Arm Pantograph
Model: WBL 85 - Balfour Beatty
Permaquip, SRS
Issue: 1/00 Made available: 25/05/00 Description no.: 4-991B.5111
Designed: Techdok Zauner GmbH Checked/approved: Santner
Description
Maintenance- and
Operating Manual

Contents Single Arm Pantograph WBL 85 Balfour Beatty
Contents
Page 2 WBL 85-15kV
1. Introduction ........................................................................................ 4
2. Safety Instructions ............................................................................. 5
2.1 General ...................................................................................... 5
2.2 Carrying Out Earth ..................................................................... 5
2.2.1 Safety Device ............................................................... 5
2.2.2 Safety Check ................................................................ 5
2.2.3 Repair and Maintenance Work ..................................... 6
2.2.4 Transport ...................................................................... 6
3. Technical Data .....................................................................................7
4. Description of Pantograph Components ................................ 8 to 11
4.1 General Information ................................................................... 8
4.2 Structural Components ...................................................... 9 to 11
4.2.1 Base Frame .................................................................. 9
4.2.2. Lower Frame ................................................................ 9
4.2.3 Upper Frame ................................................................ 9
4.2.4 Coupling Rod ................................................................ 9
4.2.5 Pan Head ................................................................ 9, 10
4.2.6 Parallel Guide Bar ...................................................... 10
4.2.7 Air Bellow Drive .......................................................... 10
4.2.8 Electrical Equipment ................................................... 10
4.2.9 Pneumatic Control Unit ............................................... 10
4.2.10 Compressed Air Chamber .......................................... 11
4.2.11 Compresse Air Signal Horn ........................................ 11
4.2.12 Ltach ........................................................................... 11
5. Assembly ................................................................................. 12 to 13
5.1 General Information ................................................................. 12
5.2 Transport .................................................................................. 12
5.3 Mounting ................................................................................. 12
5.4 Installation of Electrical Equipment ......................................... 13
5.4.1 High Voltage Connection ............................................ 13
5.5 Mounting of Pneumatic Air Connection ................................... 13
6. Start - Up ........................................................................................... 14
6.1 Checklist (also see # 10. “Adjustment“) .................................. 14
7. Maintenance ............................................................................ 15 to 17
7.1 General Information ................................................................. 15
7.2 Carbon Current Collector Strip ................................................. 16

Contents
Single Arm Pantograph WBL 85 Balfour Beatty
7.3 Bearings ................................................................................... 16
7.3.1 Grooved Ball Bearing, Ball Bearing Guide,
Ball Bushing ................................................................ 16
7.3.2 Plain Bearing .............................................................. 16
7.4 Screw connections ................................................................... 17
7.4.1 Fastening Moment for Screw Connections ................. 17
7.5 Bellow Drive ............................................................................. 17
7.6 Pneumatic Control Unit ............................................................ 17
8. Troubleshooting ...................................................................... 18 to 19
8.1 General Information ................................................................. 18
8.2 Trouble Table ................................................................... 18 to 19
9. Repairs ..................................................................................... 20 to 24
9.1 General Information ................................................................. 20
9.2 Dismounting of Pantograph from Top of Vehicle Roof ............. 20
9.3 Complete Disassembly of Pantograph ..................................... 20
9.4 Repairs of component parts ............................................ 21 to 23
9.4.1 Free Bearing of Base Frame and Upper Frame ......... 21
9.4.2 Fixed Bearing of Base Frame, Coupling Rod and
Upper Frame .............................................................. 22
9.4.3 Pan Head .................................................................... 22
9.4.4 Bellow Drive ................................................................ 23
9.4.5 Other Component Parts .............................................. 23
9.5 Re-assembly after Complete Disassembly ........................ 23, 24
10. Adjustment Work .................................................................... 24 to 30
10.1 General Information ................................................................. 24
10.2 Adjustment of Coupling Rod and Resting Position .................. 25
10.3 Adjusting the Bellow Drive ....................................................... 26
10.4 Adjustment of Contact Pressure .............................................. 27
10.5 Adjustment of Raising- and Lowering Time .............................. 28
10.6 Adjustment Curve of Contact Pressure .................................... 29
10.7 Adjust Turning of Pan Head ..................................................... 30
10.8 Adjustment of Pan .................................................................... 31
10.9 Adjustment of Contact Force Monitoring System ..................... 32
11. Spare Parts .............................................................................. 33 to 53
12. Annex
Page 3WBL 85-15kV

Introduction Single Arm Pantograph WBL 85 Balfour Beatty
1. Introduction
The single arm pantograph WBL 85 Balfour Beatty has been developed as an
earthing pantograph which allows for a mobile electrical earthing of the catenary.
Please note that the earthing pantograph should only be used as an additional
earthing between two stationary earthing poles.
Our objective was to design and manufacture a simple, light weight, and easy to
maintain, Pantograph. We further wanted to achieve an optimum in catenary contact
behavior, even under the most basic overhead wire conditions, and combine with it a
maximum of operating safety.
The last chapter contains the spare parts drawings. We kindly request you to
describe the needed parts as accurate as possible and in accordance with this
catalogue to assure a problem free order processing, and subsequent delivery.
Page 4 WBL 85-15kV
Copyright by Schunk Bahntechnik Ges.mbH
All rights reserved.
This publication may not be reproduced, stored in a retrieval system, or transmitted in whole or in part,
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without
the prior written permission of the Copy Right Owner.
No liability for amy errors in this document.
We reserved the right to make any technical modifications.
Schunk Bahntechnik Ges.mbH
Aupoint 23
A-5101 Bergheim, AUSTRIA
phone: [phone]
fax: [phone]
email: [email protected]

Safety Instructions
Single Arm Pantograph WBL 85 Balfour Beatty
2. Safety Instructions
2.1 General
Warning:
Earthing with the aid of the WBL 85 earthing pantograph may only
be carried out by authorsied personnel. For this reason the
pantograph can only be activated by a key-switch, which is
provided inside the car.
2.2 Carrying Out Earthing
- Check the overhead wire with a voltage indicator pole.
- Set up fixed earthing points at the ends of the working area in front of and
behind the vehicle (distance of 5-6 km).
- Check again the overhead wire with a voltage indicator pole for correct earthing.
- If the overhead wire is voltage free, raise the pantograph up to the catenary
2.2.1 Safety Device
During raising and lowering of the pantograph, a signal horn sounds. As soon as the
pantograph has reached the desired contact pressure for the appropriate earthing
function, the acoustic signal ceases.
If the contact pressure falls below the preset level, then the signal sounds indicating
that the earthing function of the pantograph has ceased.
2.2.2 Safety Check
(has be to made everytime from outhorised personnel when panto gets raised):
- Raise pantograph: check that horn sounds
- When carbonstrip contacts the catenary, check that the signal ends
- Wait about 10-15 sec
- Lower pantograph: check that horn sounds
- Raise panto into working position.
Page 5WBL 85-15kV

^130 N
Technical Data Single Arm Pantograph WBL 85 Balfour Beatty
Page 6 WBL 85-15kV
2.2.3 Repair and Maintenance Work
Before carrying out any repair and maintenance work ensure that:
- the power to the catenary is switched off
- the pantograph is lowered.
After competing any repair and maintenance work ensure that:
- no tools or other loose parts have been left on the vehicle roof.
2.2.4 Transport
Attention
Persons are not allowed to stay underneath the pantograph during
lifting and transportation.

Technical Data
Single Arm Pantograph WBL 85 Balfour Beatty
Page 7WBL 85-15kV
3. Technical Data
Height in resting position............................................................................454 ±10 mm
Fixation distance - crossways .......................................................................950 ±1 mm
Fixation distance longitudinal ........................................................................800 ±1 mm
Min. working height over resting position ...........................................................100 mm
Max. working height over resting position ........................................................2250 mm
Max. raising height over resting position...................................................2460 ±50 mm
Total length................................................................................................2484 ±10 mm
Lateral deflection at max. working height
and a lateral force of 300 N, according to IEC 494 ..............................................30 mm
Weight ................................................................................................................~120 kg
Contact strip length ............................................................................................920 mm
Pan width ..................................................................................................1600 ±10 mm
Pan height .....................................................................................................300 ±5 mm
Contact strip width................................................................................................35 mm
Contact strip material ..............................................................................Graphit-carbon
Rated voltage .........................................................................................................25 kV
Static contact force...................................................................120 N ±10 N(adjustable)
Rising time to max. working height .............................................................max. 10 sec.
Lowering time from max. working height .....................................................max. 10 sec
Supply pressure from vehicle ..........................................................................min. 5 bar
Electrical resistance of pantograph........................................................................5 mW
Max. speed for earthing function ........................................................................10 km/h
Contact force monitoring:..........................................................................by signal horn
Raising and lowering
controlled by ..............................key-switch inside vehicle (provided by vehicle supplier

Description Single Arm Pantograph WBL 85 Balfour Beatty
Page 8 WBL 85-15kV
4. Description of Pantograph Components
4.1 General Information
Main features of the Single Arm Pantograph WBL 85 are:
- Low weight
- Simple construction
- Minimum maintenance
- Excellent contact behavior, even under basic catenary conditions
- Maximum operating safety
4.2 Structural Components
Bellow Drive
Lower Frame
Upper Frame
Coupling Rod
Pneumatic
Control Unit
Pan Head
Parallel Guide Bar
Latch
Compressed
Air Chamber
Base Frame Signal Horn

Description
Single Arm Pantograph WBL 85 Balfour Beatty
Page 9WBL 85-15kV
4.2.1 Base Frame
The base is a welded structure of closed rectangular hollow steel profiles.
The following component parts are located on the base frame:
- Basic bearings for the lower frame
- Resting buffer for upper and lower frame
- Mounting fixtures for:
- Air bellow
- Coupling rod
- High voltage hook-up
- Pneumatic control unit
- Signal horn
4.2.2. Lower Frame
The lower frame is a welded structure. Its seating is located on the base frame.
The following component parts are mounted to the lower frame:
- Cam disks with suspension fixture for the bellow-drive ropes
- Parallel guide bar
4.2.3 Upper Frame
The upper frame is a welded structure made of seamless tubes. Necessary lateral
stability is achieved through a cross wire-rope construction.
Attached to the upper frame are the following component parts:
- Pan head
- Coupling rod
- Lower frame
- Bearing blocks for the knuckle joint bearings
4.2.4 Coupling Rod
The coupling rod consists of two individually welded round-tubes. Both tubes are
then connected through a control element. Through this control element the
geometry of the pantograph will be adjusted and fine tuned.
4.2.5 Pan Head
The pan is fixed to the upperframe of the pantograph by means of a pantube. Fitted to
the pan tube are two levers which at the other ends take up the carbon strip via a
collectorstrip support. These levers guide the collectorstrip when moving vertically.

WBL 85-15kV
Description Single Arm Pantograph WBL 85 Balfour Beatty
Page 10
The collectorstrip is raised up against weight and contact pressure by means of leaf
springs. As the carbon strip presses against the catenary with increasing force, it
tensions up until the spring system is arrested by an adjustable stopper.
On the pan, a monitoring valve is located which applies pressure to a pneumatic
signalhorn (located on the baseframe) – as long as the correct contact force between
carbonstrip and catenary is not reached. When the pre-set contact pressure is
achieved, the carbon strip tensions against the stopper, the monitoring valve switches
over, the horn is no longer pressured, and the signal ceases.
In addition, the following parts are located on the pan:
- Shunts for the connection between contact strip and upperframe
- 3/2 way monitoring valve
4.2.6 Parallel Guide Bar
The parallel guide bar prevents the pan head from rotating,. It holds the collector strip
in a horizontal position.
4.2.7 Air Bellow-Drive
The pneumatic bellow drive allows the pantograph to rise. It is mounted between the
base frame and the lower frame. A pneumatic line connects the bellow drive with the
valve control unit. The contact pressure as well as the raising and lowering time is
adjusted through the valve control system unit.
4.2.8 Electrical Equipment
All bearing locations are by-passed by shunt connectors. These prevent the current
from flowing through the bearings. The shunts are consisting of flexible copper cables
with clamped end pieces. The current connectors are greased with copper grease to
archieve good conducting properties between the shunts and the frame parts.
4.2.9 Pneumatic Control Unit
The pneumatic control unit is fitted inside a switching box which is fixed on the
baseframe.
The pneumatic control unit ensures pneumatic adjustment of the pantograph like
contactforce and raising- and loweringtime.

The main components of the valve control unit are:
- Airfilter with condensate seperator
- Pressure regulation valve
- Throttle valve
- Security valve
There is also a pneumatic conduction for the latch, which is leading through the
switchingbox.
4.2.11 Compressed Air Chamber
A compressed air chamber is integrated into the pneumatic feed to the signalhorn,
forming a pressure air reservoir, ensuring that – in the event of a fall in air pressure in
the feed to the signal horn (when the pantograph is lowered or when a loss of air
pressure occurs in the feed as a result of a fault) – sufficient air volume is still
available to enable the signal horn to sound for the appropriate duration.
4.2.12 Compressed Air Signal Horn
A signal horn is attached to the baseframe. The horn sounds during the raising and
lowering operations and when there is too little contact pressure onto the catenary. As
soon as the pantograph has reached the required contact pressure for correct
earthing function, the acoustic signal ends. A monitoring valve on the pan controls the
signal horn operation.
4.2.13 Latch
The latch ensures, that the pantograph is secured in restingposition, when it is out of
service. The pneumatic circuit inside the vehicle is layed out in a way, that the latch
opens before the the airbellow get under pneumatic-pressure for raising the
pantograph.
WBL 85-15kV
Description
Single Arm Pantograph WBL 85 Balfour Beatty
Page 11

WBL 85-15kV
Assembly Single Arm Pantograph WBL 85 Balfour Beatty
Page 12
5. Assembly
5.1 General Information
The Single Arm Pantograph is manufacturer-adjusted according to your system‘s
requirements.
5.2 Transport
For transportation and lifting purposes fix panto only on fixing points (1, 2, 3, 4) of the
base frame.
Attention:
No one admitted underneath the pantograph during lifting and
transportation !
Caution: Do not damage coating during transportation !
5.3 Mounting
The base frame has to be mounted tension free onto the vehicle roof. The base pipe of
the lower frame has to be horizontal. If needed washers may be installed underneath
the fixing lappets.
12
3
4

5.4 Installation of Electrical Equipment
5.4.1 High Voltage Connection
The high voltage earthing has to be made on the connecting strap (1) connection. The
connecting spot needs to be well greased with conducting grease.
WBL 85-15kV
Assembly
Single Arm Pantograph WBL 85 Balfour Beatty
Page 13
5.5 Mounting of Pneumatic Air Connection
The pneumatic connection between vehicle and pantograph has to be accomplished
on the connections (1) and (2). Both connection have a 1/4" inside thread.
Connection (1): Connection for pantograph-airbellowdrive
Connection (2): Connection for latch
21
1

WBL 85-15kV
Start - Up Single Arm Pantograph WBL 85 Balfour Beatty
Page 14
6. Start - Up
6.1 Checklist (also see # 10. “Adjustment“)
Check before start-up :
❍Screw connections of high voltage hook-up, and verify that they are well
greased
❍Contact pressure of pantograph ( 120N, ± 10N )
❍Raising and Lowering time to be in according with technical data
❍Check signal horn for proper function (see 2.2)

7. Maintenance
7.1 General Information
The Single Arm Pantograph WBL 85 requires less maintenance. At the regular
maintenance intervals of the vehicles, the following procedures are recommended:
During each inspection (max. 10000 km):
❍Inspection of carbon strips (breaks, wear).
❍Inspction of horns.
❍Check proper function of signalhorn and contact force monitoring system.
Every year:
❍Visual inspection of screws and shunts.
❍Visual inspection of cable of raising mechanism, if needed, grease with
TOP 2000 of company AGIP Schmiertechnik.
❍Inspection upward force, adjust, if necessary.
❍Inspection easy motion of bearings, pan head springs, etc.
❍Pneumatic equipment for leakages.
After max. 3 years:
❍Grease the ends of the tow-rope with TOP 2000 of AGIP Schmiertechnik.
❍Replace shunts.
After every 8 to 10 years and on any main inspection
(max. after 2000000 km / 1250000 miles):
❍Change all ball bearing.
❍Inspect for corrosion, if necessary replace coaling.
❍Change rubber bumpers on base frame.
❍Change leaf springs of pan head.
❍Change cable of raising mechanism.
❍Inspect/change of valve control unit.
❍Change plain bearings.
❍Replace all air tubes.
❍Inspect/replace air bellow drive.
❍Replace 3/2-way monitoring valve on pan head.
WBL 85-15kV
Maintenance
Single Arm Pantograph WBL 85 Balfour Beatty
Page 15

Maintenance Single Arm Pantograph WBL 85 Balfour Beatty
Page 16 WBL 85-15kV
Latest with a remaining carbon height of 2 mm the carbon strips should be replaced.
7.3 Bearings
7.3.1 Grooved Ball Bearing, Ball Bearing Guide, Ball Bushing
The grooved ball bearings are to be cleaned and greased during every main inspection,
and tested for flexibility of motion and bearing play. If motion of bearings is slow,
determine the reasons (e.g. misalignment, bent component part, locked up stress,
etc.). Damaged grooved ball bearings are to be exchanged. The space of the ball
bearings needs to be filled completely with
grease TOP 2000 of AGIP Schmiertechnik
in order to avoid condensation.
7.3.2 Plain Bearing
All plain bearings of pantograph WBL 85 are maintenance free. The plain bearings
are either:
- Teflon-coated bronze bushings or
- Plastic bushings
If plain bearings are slow, reason of slowness has to be determined and eliminated.
Damaged plain bearings need to be exchanged. Dirty plain bearings have to be
cleaned. We recommend to grease bearings with
grease TOP 2000 of AGIP Schmiertechnik.
min. 2 mm
7.2 Carbon Current Collector Strip
The carbon strip need to be checked for damage and wear at every visual inspection.
As a guide line to determine the intervals between visual inspections, please
consider:
- Anticipated operating and wear life.
- Extreme weather conditions (ice, snow, rain, etc).

Maintenance
Single Arm Pantograph WBL 85 Balfour Beatty
Page 17WBL 85-15kV
7.4 Screw Connections
All mounting screws are to be checked for damage and tight fit, especially:
- Mounting screws for carbon strips.
- Pan Head connections.
Hex nuts according DIN 985 must be replaced by new ones after dismounting !
7.4.1 Fastening Moment for Screw Connections
7.5 Bellow Drive
The bellow drive is maintenance free.
Check bellow drive for operation during each main inspection by lifting and lowering
the pantograph. If needed, replace damaged or bent parts.
The cables are to be greased with TOP 2000 of AGIP Schmiertechnik, if necessary.
7.6 Pneumatic Control Unit
During each main inspection the safety valve needs to be tested by increasing the
pressure through the pressure regulator.
After completed test, adjust contact pressure to required level.
Thread Fastening
Moment
M3 1,1 Nm
M4 2,6 Nm
M5 5,1 Nm
M6 8,8 Nm
Thread Fastening
Moment
M8 21,4 Nm
M10 44,0 Nm
M12 74,0 Nm
M14 119,0 Nm
Thread Fastening
Moment
M16 183,0 Nm
M20 370,0 Nm

Troubleshooting Single Arm Pantograph WBL 85 Balfour Beatty
Page 18 WBL 85-15kV
8. Troubleshooting
8.1 General Information
Adjustment works are referred to in the “Adjustment Work“ chapter.
8.2 Trouble Table
Check air bellow,
exchange broken air
bellow. (also see defect: Bellow
drive defective)
Replace cables. (also see
defect: Cable torn)
Exchange valve unit.
Replace pneumatic tube.
Check pantograph for
damages, and eliminate
damages.
Replace defective bearings.
Adjust turning capacity of
pan head. (also see # 10.7, adjust
turning capacity of pantograph head)
Replace cables, adjust
bellow to achieve straight
expanding line. (also see
# 10.3, adjusting the bellow drive)
Replace cables and
grease in area of cam disk
with non-water-soluble
grease.
Tighten screws.
Exchange leaking hose
with new hose line.
Air bellow damaged.
Cable torn.
Pneumatic control unit
defective.
Pneumatic tube defect.
Inner friction of panto is
too high.
Parallel guide bar is poorly
adjusted.
Bellow drive is improper
adjusted; bellow does not
expand straight-lined.
Cables are not greased
Screws are loose.
Hose line leaking.
Pantograph does not
rise or lower.
Uneven wear of carbon
strip.
Cable torn.
Bellow drive defective.
Defect Reason(s) Correction

Exchange bellow cylinder;
find reason for leakage and
check bellow joints.
Exchange pressure regulator.
Exchange pressure
regulator.
Replace valve
Replace restrictoror
Replace air hose
Replace signal horn
Check contact force and
re-adjust setting
Adjust setting of valve
Re-adjust setting
Find cause of excessive
friction and replace
defective component
Replace bearings. Check
pan levers for deformation
and replace if necessary.
Bellow cylinder leaking.
Pressure-regulator defective
(normal air leakage of pressure
regulator = 0,5 l / min.).
Pressure regulator
defective.
Monitoring valve on pan
defective
Restrictor in compressed
air line defective
Compressed air line
defective
Signal horn defective
Contact force incorrectly
set.
Monitoring valve on pan
poorly set
Pan head spring stop
incorrectly set
Excessive inner friction of
pantograph
Pan lever bearings are
stiff.
Excessive air leakage.
Increase of contact
pressure without previous
adjustment of pressure
regulator.
Signal horn for contact
force monitoring does not
sound during raising or
lowering.
Signal horn sounds while
pantograph in operation
(on catenary)
Defect Reason(s) Correction
Troubleshooting
Single Arm Pantograph WBL 85 Balfour Beatty
Page 19WBL 85-15kV

9. Repairs
9.1 General Information
Prior to disassembling the pantograph, please make familiar with the relationship of
the individual component parts by studying the drawings (chapter #11).
Deformed component parts are to be disassembled before adjusting.
The alignment of the bearings is only accurately measurable on a measuring table.
9.2 Dismounting of Pantograph from Top of Vehicle Roof
❑Lower pantograph into lowest resting position.
❑Make sure that current in catenary is switched off.
❑Detach electrical connection between pantograph and vehicle.
❑Unscrew pneumatic connections to vehicle.
❑Secure upper frame to base frame (e.g. with a rope)
❑Secure pantograph at the transport fixing points. (see # 5.2 Transport Chapter).
❑Detach pantograph from fixing-supports on vehicle.
❑Lift pantograph off vehicle roof.
Attention: No persons is allowed to be underneath the transported
pantograph.
9.3 Complete Disassembly of Pantograph
❑Mount pantograph on suitable resting feets to protect air bellow and signal horn.
❑Lower pantograph into lowest resting position.
❑Detouch signal horn from base frame.
❑Detach air conditions.
❑Detach shunts and carbon strips.
❑Detach parallel guide bar.
❑Detach pan head from upper frame..
❑Detach coupling rod from upper frame and base frame.
❑Detach upper frame from lower frame.
❑Detach air bellow drive.
❑Detach lower frame from base frame.
❑Detach latch from base frame.
❑Detach pneumatic control unit from base frame and compressed air chamber.
Repairs Single Arm Pantograph WBL 85 Balfour Beatty
Page 20 WBL 85-15kV