Single Arm Pantograph Model: WBL22.03: Description Maintenance and Operating Manual

Schunk Metal & Carbon (India) Pvt. Ltd.
4 -14062-22.03 Page 1 von 71 Revision 2
Single Arm Pantograph

Model: WBL22.03
acc.Drg.No: 1-27410.14062
Description
Maintenance and
Operating Manual
Date: 10.08.13 Prepared: K.Seetharam Approved: Thomas Hentze

Copyright by Schunk Bahn- und Industrietechnik GmbH.

All rights reserved.
This publication may not be reproduced, stored in a retrieval system, translated into
another language, 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 Schunk Bahn- und Industrietechnik GmbH.
We are not responsible for the consequences of possible mistakes or errors in this
publication.
We reserve the right to make technical changes at any time, and without prior notice.
Schunk Bahn- und Industrietechnik GmbH

Aupoint 23
A-5101 Bergheim, Austria
Phone: +43 (0) 662 459200-0
Fax: +43 (0) 662 459200-1
e-mail: office@schunk-group.at
i-net: http://www.schunk-group.at
Rev.No. Revision Date Name

0 New Release 10.08.2013 Seetharam
1 Carbon strip wear limit modified and function principle 10.12.2013 Seetharam
of ADD and ORD added
2 Maintainance schedule added and carbon strip 26.10.2016 Seetharam
inspection details added

INDEX
1.0 Introduction………………………………………………………………………………………………………....6
2.0 Safety Instructions………………………………………………………………………………………..........7
2.1 General information…………………………………………………………………………………………..7
3.0 Technical Data……………………………………………………………………………………………..…….….8
4.0 Description of Pantograph Components…………………………………………......................10
4.1 General information…………………………………………………………………………………………10
4.2 Structural components…………………………………………………………………………………….11
4.2.1 Pantograph assembly………………………………………………………………………………….11
4.2.1.1 Base frame………………………………………………………………………………………..12
4.2.1.2 Lower frame……………………………………………………………………………...........12
4.2.1.3 Upper frame……………………………………………………………………………………..12
4.2.1.4 Air bellow……………………………………………………………………………..…………..13
4.2.1.5 Coupling rod……………………………………………………………………………………..13
4.2.1.6 Parallel guide bar………………………………………………………………………………13
4.2.1.7 Pan head…………………………………………………………………………………………..13
4.2.1.8 Damper……………………………………………………………………………………………..13
4.2.1.9 Shunt…………………………………………………………………………………………………13
4.2.1.10 Base and Upper bearing…………………………………………………………………...14
4.2.1.11 Valve unit ADD………………………………………………………………………………….14
4.2.1.12 Over Reach Detector………………………………………………………………….……..14
4.2.2 Pneumatic Control unit (Valve plate)……………………………………………………………14
4.2.3 Pneumatic Control unit………………………………………………………………………………..15
4.2.3.1 Pneumatic diagram……………………………………………………………………………..16
5.0 Packaging…………………………………………………………………………………………………………….17
5.1 Packaging for Transport…………………………………………………………………………............17
6.0 Storage………………………………………………………………………………………………………………..17
7.0 Cleaning………………………………………………………………………………………………………………17
8.0 Assembly……………………………………………………………………………………………………………..18
8.1 General information………………………………………………………………………………………….18
8.2 Transport and Storage………………………………………………………………………………………18
8.3 Attachment to the Vehicle…………………………………………………………………………………18
8.4 High Voltage Connection…………………………………………………………………………………..19
8.5 Mounting of Compressed Air Connection…………………………………………………………..19
9.0 Start Up ………………………………………………………………………………………………………………20
9.1 Check list…………………………………………………………………………………………………………20

10.0 Maintanance……………………………………………………………………………………………………….20
10.1 General Information……………………………………………………………………………………….20
10.1.1 Each Inspection (max.10,000kms)……………………………………………………………….21
10.1.2 Annual Inspection (AOH)……………………………………………………………………………..21
10.1.3 Intermediate Inspection (IOH)……………………………………………………………………..21
10.1.4 Periodic Overhauling (POH)………………………………………………………………………...22
10.2 Carbon Strip…………………………………………………………………………………………………...23
10.3 Bearings……………………………………………………………………………………………………….…23
10.3.1 Grooved ball bearings………………………………………………………………………………...23
10.3.2 Plane bearings……………………………………………………………………………………………23
10.4 Screw Joints…………………………………………………………………………………………………….23
10.4.1 Torque for Stainless steel connections…………………………………………………………24
10.4.2 Screw bonding and Srew sealing………………………………………………………………….24
10.5 Hydraulic oscillation Damper………………………………………………………………………….25
10.6 Insulators, Insulating tubes……………………………………………………………………………..25
10.7 Bellow drive…………………………………………………………………………………………………….25
10.8 Cable with terminals of raising mechanisam…………………………………………………..25
10.9 Shunt connections…………………………………………………………………………………………..25
10.10 Pan head Springs…………………………………………………………………………………………….25
10.11 Pneumatic control unit……………………………………………………………………………………25
10.12 Valve unit ADD………………………………………………………………………………………………..26
10.13 Over reach detector………………………………………………………………………………………..26
10.14 Auxilary Material…………………………………………………………………………………………….27
11.0 Trouble shooting – Trouble list…………………………………………………………………………….28
11.1 General Information………………………………………………………………………………………….28
11.2 Trouble List………………………………………………………………………………………………………..28
12.0 Repairs………………………………………………………………………………………………………………30
12.2 Dismounting of pantograph ……………………………………………………………………………..30
12.3 Complete dismounting of Pantograph……………………………………………………………….30
12.4 Repair of component…………………………………………………………………………………………31
12.4.1 Free bearing of base frame and upper frame……………………………………………..31
12.4.2 Fixed bearing of base frame,upper frame and Coupling rod……………………….32
12.4.3 Pan head Rocker box………………………………………………………………………………….32
12.4.4 Shunt…………………………………………………………………………………………………………33
12.4.5 Bellow drive……………………………………………………………………………………………….33
12.4.6 Other component parts………………………………………………………………………………34
12.4.7 Surface coating………………………………………………………………………………………….34

12.4.7.1 Pre treatment……………………………………………….…………………………………..34
12.4.7.2 Finishing paint………………………………………………………………………………… .34
12.4.7.3 Touch up paint……………………………………………………………………………….....35
12.5 Re-Assembly after complete Dis assembly…………………………………………………………35
13.0 Adjustment Procedures……………………………………………………………………………………..36
13.2 Adjustment Of Coupling Rod and Resting Position…………………………………………….37
13.3 Adjusting the Bellow Drive………………………………………………………………………………..38
13.4 Adjustment of Pneumatic Control……………………………………………………………………..39
13.4.1 Adjust safety valve…………………………………………………………………………………….40
13.4.2 Adjust Contact Pressure……………………………………………………………………………..40
13.4.3 Adjust Lowering Time…………………………………………………………………………………40
13.4.4 Adjust raising time…………………………………………………………………………………….41
13.5 Adjustment Curve of Contact Pressure………………………………………………………………42
13.6 Adjustment of pressure switch…………………………………………………………………………..43
13.7 Adjustment of Turning capacity of Pan Head…………………………………………………….44
14.0 Product Data Sheet……………………………………………………………………………………………45
14.1 Mosil Metaplast Compound………………………………………………………………………………45
14.2 Molygraf CC2…………………………………………………………………………………………………….46
14.3 Molygraf TC55…………………………………………………………………………………………………..48
14.4 High strength thread locker……………………………………………………………………………….49
14.5 Thread sealant…………………………………………………………………………………………………..50
15.0 Spare Parts ……………………………………………………………………………………………………….51

1.0 Introduction
The Single Arm Pantograph WBL 22.03 serves the Current Collection of electrically
operated Light Rail & Other Transist Vehicles.
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.

2.0 Safety Instructions
2.1 General information
Attention!!! Before starting any repair or maintenance work, always:

 Switch off the overhead wire current and ensure, that the current cannot
be inadvertently switched back on
 Lower the pantograph
Attention!!! No one is allowed underneath the pantograph while being transported by a
crane or other means.
Attention!!! After completion of every repair or maintenance:
 Please assure that no tools or other loose parts are left on top of the
vehicle roof.
Attention!!! The given internal safety regulations have to be kept.
Attention!!! Air Pressure for Continious Operation of pantograph smoothly without any
problems.
 Min.6bar of Dry and Oil free air, because of isolating characteristics.
 Chocking of Existing fine filters or damages on Valves can otherwise
happen
Compressed air quality according ISO 8573-1:
Solids
Class Particle Size Concentration Water Oil
(μm) (mg/m3)
1 0.1 0.1 -70 0.01
2 1 1 -40 0.1
3 5 5 -20 1
4 15 8 3 5
5 40 10 7 25
6 10

3.0 Technical Data

Standard ...................................................................................................... IEC 60494-1
Minimum height with insulators ................................................................. 585 ± 10 mm
Insulating distance ............................................................................................ ..250mm
Minimum working height over resting position................................................... 100mm
Maximum working height over resting position ...........................................min2290mm
Maimum Extension ……………………………………………………………………………….…min2400mm
Width of pan head .................................................................................... 1800 ± 10mm
Height of pan head ................................................................................... ... 310 ± 10mm
Total length in resting position ……………………………………………………………… 2335 ± 10 mm
Total weight without Insulators .............................................................. approx. 150 kg
Current collector strips - Length ....................................................................... 1030 mm
Current collector strips - spacing …………………………………………………………….. 390 ± 10 mm
Current collector strip – material ……………………………………………………. Metalised Carbon
Frame Insulators (4) …………………………………………………………………………………………… 25 kV
Height …………………………………………………………………………………………………………….320 mm
Nominal voltage ………………………………………………………………………………………………….25 kV
Nominal current …………………………………………………………………………………………60A at 25kV
Lateral deflection at max. working height & lateral force of 300N
acc.to IEC 60494-1………...……………………………………………………………………………Max.30mm
Static upward force of pantograph ……………………………………………………………… 70 N ± 5 N
Pan head ……………………… Individual suspension of carbon/steel strip, parallel mounted
Spring rate of pan suspension ................................................................8750 N/m ± 10%
Maximum speed under good overhead wire conditions …………………………max.160 km/h
Speed according specification ...................................................................max.120 km/h
Ambient temperature ………………………………………………………………………………-10 to +50°C
Propulsion system with air bellow

Air pressure supply from vehicle for raising of pantograph............................min.5,5 bar
Air pressure for continious operation
dry and oil-free air because of isolating characteristics ………………………………….min 6 bar
Raising time to maximum working height……………………………………………………………..≤10 s
Lowering time from maximum working height………………………………………………………≤10 s
Air-pressure connection.........................................High voltage insulating hose 1000mm

Forces applied to pantograph support insulators:

Conditions for calculation according UIC 566:
Acceleration longitudinal: ax=5g
Acceleration transversal: ay=1g
Acceleration vertical: az=3g
Fx (longitudinal direction)........................................................................... 2000N
Fy (transversal direction) ............................................................................ 400N
Fz (vertical direction) ................................................................................ 8600N

4.0 Description of Pantograph Components

4.1 General Information
Rail Vehicles, which are powered through an overhead wire system, can be equipped with
the Single Arm Pantograph WBL 22.03
Main features of the Single Arm Pantograph WBL22.03 are:
 Low weight
 Simple construction
 Minimum maintenance
 Excellent contact behavior, even under basic catenary conditions
 Maximum operating safety
This is mainly achieved through:
 Proven bearing techniques
 Patented hydraulic oscillation damping techniques
 Pan head with independent suspension of carbon strips

4.2 Structural Components

4.2.1 Pantograph Assembly
Shunt
Pan Head
Upper Frame
Upper Frame bearing
Parallel Guide Bar
Lower Frame
Base Bearing
Bellow Drive
Coupling Rod
Insulating Hose
Base Frame
Valve Unit ADD

Over Reach Detector


4.2.1.1 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
 Hydraulic damper
 Insulators
 High voltage hook-up
 Valve unit ADD
 Support spring
 Shunts
4.2.1.2 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 cables
 Parallel guide bar
 Hydraulic oscillation damper
 Shunts
4.2.1.3 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
 Shunts
4.2.1.4 Air Bellow
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
pneumatic control, and then continues via the solenoid valve on to the compressor. The
contact pressure is adjusted through the pneumatic control system.
4.2.1.5 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.
4.2.1.6 Parallel Guide Bar
The parallel guide bar prevents the pan head from distorting, while the pantograph is
raised or lowered.
4.2.1.7 Pan Head
The pan head is located at the crest of the upper frame and uses leaf springs for the
suspension of the carbon strips. They are affixed in the rocker box, and carry at each end
bearing supported mounts to which the carbon strips arethen attached. Parallel guiding
links assure that the carbon strips operate parallel to the catenary
4.2.1.8 Damper
The pantograph damping is attained through the oscillating damper between base frame
and lower frame. This guarantees a good contact between the carbon strips and the
overhead wire.
The dampers are suitable for temperatures ranging from -40 to +80 °C (approx. -40 to
+176 degrees Fahrenheit)
4.2.1.9 Shunt(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.

4.2.1.10 Base- and Upper frame bearing

The bearings of the pantograph are maintenancefree and greased for life. At each bearing
two, in a certain distance on an axle arranged, ball bearings are used.
To avoid condensation the gap between the ball bearings is filled with grease. The outside
of the bearings is protected with cover plates against mechanical damage.
4.2.1.11 Valve unit ADD (Auto Drop Device)
The pantograph is equipped with a pneumatic carbon monitoring system to minimize
damages of catenary and pantograph through worn or damaged carbon strips
(e.g.broken carbon pieces)
For this purpose, the pantograph is fitted with special suitable carbon strips, a valve unit is
fixed on to the base frame consisting of the rapid exhaust valve, cut off cock and an air
hose leading from the baseframe, lower frame and upper frame to the carbon strips.
4.2.1.12 Over Reach Detector (ORD)

The pantograph is equipped with a ORD system to avoid damages to pantograph when
pantograph reaches un wired section.
The overreach detection provides a pneumatic signal (pressure) to the vehicle in the case
that the pantograph reaches a certain height (preferred by Cust.)
The overreach detection mainly consists of a 3/2 way valve mounted on the base frame, a
clamp with a cam clamped to the lower frame and an insulating tube
4.2.2 Pneumatic Control (Valve plate)

The pneumatic control (Valve plate) consists mainly of a filter, 5/2-Way valve and Phoenix
connector.
The main part of the valve unit is the 5/2-Way valve, it is responsible for raising and
lowering control of pantograph
Phoenix connector is responsible to transfer electrical signal from the system to 5/2 way
valve.
4.2.3 Pneumatic Control

The pneumatic control consists mainly of a filter, two throttle valves, two safety valves, a
3/2-Way valve, pressure regulator, two pressure switches and Harting connector.

The main part of the valve unit is the pressure regulator, it is responsible for a constant
pressure for the air bellow during all service conditions.
The pressure regulator has a high sensitivity and is adjustable in a range of 1 to 8 bar.
Pressure switches mounted inside the pneumatic control box to monitor ADD and ORD
For the connection to the pneumatic system three connections available:
 One for the pressure supply of the air bellow
 One for the pressure supply to the Pressure switch from the ADD Valve
 One for the pressure supply to the Pressure switch from the ORD Valve
From ADD AIR IN
From ORD
To Air Bellow

4.2.3.1 Pneumatic diagram


5.0 Packaging
5.1 Packaging for Transport
The pantograph is mounted in an appropriate packaging (e.g.wood box) in lowered
position with pan head up.
Attention!!!!!! Always transport the pantograph with the proper side up,
the pan head must be upside.
6.0 Storage
For storage please get the pantograph in a roofed room. Make sure, that this place is well
ventilated, dry and the temperatures do not exceed the temperature limits according to
the technical data (see chapter #3.0). The pantograph can remain in the packaging for
storage.
Attention!!! Store the pantograph always with the proper side up, the pan
head must be upside.
Do not place other parts directly on the pantograph. If the pantograph is stored out of the
packing, take care, that the ground is flat, use spacers of a appropriate length under the
pantograph feet in order to avoid damages by the floor to low and moving parts (Air
bellow, Pneumatic control). If pantographs are stored one upon the other outside the
packing, use suitable frames. Take care, that exposed part (horns, etc.) will not be
damaged.
7.0 Cleaning
Use only acidless cleaning agents for cleaning!

8.0 Assembly
The pantograph is manufacturer-adjusted according to your system requirements.
8.2 Transport and Storage

For transportation and lifting purpose without packaging use ONLY the 4 transport hooks
provided in base frame.
Attention!!! No one is allowed underneath the pantograph while it is being transported!
8.3 Attachment to the Vehicle

The base frame has to be mounted tension free onto the vehicle roof. The base tube of the
lower frame has to be horizontal. If needed washers may be placed underneath the
insulators, to act as shims.
Base Mounting Hole
Base mounting hole

8.4 High Voltage Connection

The high voltage connection is to be fastened to the connection board (1,2), which is
attached to the base frame. Before establishing the connection please make sure that the
contact surface is cleaned and greased with contact grease
3
4
1 5
8.5 Mounting of Compressed Air Connection

The compressed air connection to lift the pantograph is made by the high voltage
insulating tube (white) at the position (3)
The air Connection to ADD signal to Pr. switch is made by the high voltage insulating tube
(Green) at the position (4)
The air Connection to ORD signal to Pr. switch is made by the high voltage insulating tube
(Blue) at the position (5)
The insulating tubes must be connected on the roof. After assembly the air connections
are to be checked for tightness.

9.0 Start Up
9.1 Check List
Before Start Up please check the following:
 Check insulating distances to vehicle according to the technical data
(see chapter #3).
 Assure that the screw connection of the high voltage connection is properly fastened
and well greased (see chapter #8.4).
 Check the contact pressure (see chapter #13.4.2) of the pantograph according
to the technical data (see chapter #3).
 Assure that the collector strips are seated friction free.
 Check that the pan head can turn freely from the horizontal position.
 Assure that the collector strips are parallel to the overhead wire.
 Assure that the raising and lowering times are in accordance with the technical data
(see chapter #3)
 Check the function of the overreach detection. (see chapter #13.8)
 Assure that the coupling rod rests on the resting bumper(see chapter #13.3)
Attention!!! No one is allowed underneath the pantograph while adjusting the overreach
detection on the train. The overreach detection is connected to a lowering function, the
pantograph will collapse if a certain height is detected.
10.0 Maintenance
The single arm pantograph requires a minimum of maintenance.
At the regular maintenance intervals of the vehicles, the following procedures are
recommended:
The required maintainance is influenced by the environmental and operational conditions,
so the operator has to adapt accordingly.

10.1.1 Every Inspection (max. 10.000 kms)

 Visual inspection of carbon strips for break and wear;
exchange carbon strips if necessary.
 Check upward force(contact force), Raising and Lowering time
(see chapter #13.4.2,#13.4.3 & #13.4.4)
Inspection Schedule as per RDSO SMI No. RDSO/PE/SMI/EMU/0037 Rev.’0’ amendment

No. 2 dated Dec. 2013:
Trip Inspection(TI) 10 Days

IA 45 days ± 03 Days
IC 180days ± 03 Days
POH 18 Months ± 05 Days
Sl Every Every Every Every
Description
No TI IA IC POH
1 Ensure tightness of fasteners Y Y Y Y
Visual inspection of carbon strips for break and
2 Y Y Y Y
wear; Exchange carbon strips if necessary.
3 Check Contact force according technical data (70N) Y Y Y Y
Check Raising and Lowering time, should be within
4 Y Y Y Y
6 to 10 Sec. Adjust if necessary
Inspection of the parallel guide bar for free
5 Y Y Y Y
movement of the pan head.
Visual inspection of Teflon insulating hose
6 Y Y Y Y
Exchange if necessary for any damages on surface
Visual inspection of Air hose
7 Y Y Y Y
Exchange if necessary for any damages on surface
Visual inspection of Cam & Cable with thread
fittings of raising mechanism for any damages.
Clean & apply Moly Graf CC2 Grease on Cable and
8 N Y Y Y
Cam groove.
Exchange Cable if more than ten single wires or one
single braid broken /damaged.
Visual inspection of damages/ cutting of shunt
strains.
*Change shunts in case more than 5% of wire strains
are broken.
9 N Y Y Y
Whenever shunts are required to replace,
Clean contact area and apply copper content contact
grease Molygraf TC-55

Sl Every Every Every Every

Description
No TI IA IC POH
Visual inspection of the pneumatic connectors for
10 N N Y Y
tightness of any air leakages.
Functional check of Pressure Regulator as described
11 N N Y Y
in manual
Functional check of safety valves as described in
12 N N Y Y
manual
Visual inspection of pan head leaf springs and
13 support spring of base frame for any bend, coating N N Y Y
peel off . Exchange if necessary for any damages
Remove diapharm of ADD Valve and Clean
14 After refitting carryout functional inspection of N N Y Y
ADD
Visual inspection of hydraulic dampers for any
leakage of fluid
Functional inspection of hydraulic dampers.
15 Fix damper at one end and hang 2kg weight at other N N Y Y
end and damper should open to max extension in
1min ±10secs
Exchange if necessary for any damages
Visual Inspection of Air bellows drive for any
16 leakages / damages / rubbing marks. N N Y Y
Exchange if necessary for any damages
Functional check of Air Filter
Replace the Element, O Rings when one of
17 followings occurs. N N Y Y
①Pressure drop reaches 0.1 MPa.
②Element operates for 1.5 years.
Check for friction of ball bearings of base frame,
18 upper frame and coupling rod. N N Y Y
Replace ball bearings if necessary
19 Ensure Pressure switch setting (Pmax & Pmin) N N N Y
10.2 Carbon Strip

Carbon strips need to be checked for damage & wear at every visual inspection.
Small outbreaks of carbon will not influence the function in service (….. can be
equilized by grinding with an engineers file or grinding paper)

Small breaks as shown in photo
Strips with bigger outbreaks have to be changed
A thin crack in the middle or horn area will not influence the
function of the strips. In case of more than 3 Cracks in the
carbon middle/ wear area, strips should be changed to avoid
a separation of the carbon material.
Carbon strips need to be checked for damage & wear at every visual inspection. As a guide
line to determine the intervals between visual inspections, please consider the following:
 Anticipated operating and wear life.
 Extreme weather conditions (ice, snow, rain, sleet, etc.)
The wear of both carbon strips should happen evenly , if not check the adjustment of the
parallel guide bar (see chapter # 13.7 ) or if parts of the pan head or the parallel guide bar
are damaged.
When the carbon strips wear down to the thickness indicated in the sketch below, they
must be replaced.
They always have to be replaced as a pair.
After the installation, the parallelism of the carbon strips and the contact pressure has to
be checked. (see chapter #13.4.2)

MUST CHANGE PARTS LIST

Every Every Every Every Every
SL Part No. /
Description MOH MOH MOH MOH MOH
No. Drawing No / Size
18months 36months 54months 72months 144 months
01 SM-Bumper 77010004000 Y Y Y Y Y
02 Filter Element AF30P-060S Y X Y X X
03 Bowl Packing C32FP-260S Y X Y X X
04 Shrink tube for Support 18/6
spring
Y X Y X X
05 Support spring with SB-024165

Shrink tube
X Y X Y Y
06 Cable with thread fitting 3-B14.4338 X Y X Y Y

07 Air bellow M31103 X Y X Y Y
08 Air hose 3-B04.6194 X Y X Y Y
09 Insulating Hose 4-B04.4724 X Y X Y Y
10 Air Filter I-AF30-F02 BD X Y X Y Y
11 Pressure Regulator I-IR3020 F02 X Y X Y Y
12 Throttle Valve (Raising) T1000C2800 X Y X Y Y
13 Throttle Valve (Lowering) T20C2800 X Y X Y Y
14 3/2 Way Valve V16B4D7A-X5090X
G1/4”
X Y X Y Y
15 Sealing Washer 4-V15.5090 Y Y Y Y Y

DIN 74324/ PA12W
16 Air pressure hose d 10/8
Black
Y Y Y Y Y
DIN 74324/ PA12W

17 Air pressure hose d 6/4
Black
Y Y Y Y Y
XG353A041V -
18 Quick Exhaust Valve ADD
TPL22383
X X X X Y

SL Description Part No. / Every Every Every Every Every

No. Drawing No / Size MOH MOH MOH MOH MOH
18months 36months 54months 72months 144 months
18-1 Spare kit for QEV (ADD) XC113443V-22383 Y Y Y Y X
19 3/2 way valve (ORD) CL-104A G1/8” X Y X Y Y
20 Bellow Best 1407 AW Best Nr. 1407AW Y Y Y Y Y
2539-324 7.5x180
21 Cable tie 7.5x180
PA 6.6(black)
Y Y Y Y Y
22 Leaf spring (25x2) 3-W08.12501 Y Y Y Y Y

23 Air pressure hose TFL 6x4 TFL 6X4 (PTFE) X Y X Y Y
CH-B7 127 043 010
24 Mounting clamp
- PA 12
Y Y Y Y Y
25 Shunt 240 4-S00.3579 X Y X Y Y

26 Shunt 250 4-S00.4999 X Y X Y Y
27 Shunt 270 4-12800.5848 X Y X Y Y
28 Base bearing floating 4-L01.9077 X X X Y Y
29 Base bearing fixed 4-L01.9078 X X X Y Y
30 Hydraulic Damper 3-7432 X X X Y Y
Diagonal rod incl heat
31 shrink tube & cable tie 3-17103.11748 X Y X Y Y
(1 set=2 no’s)
Upper frame bearing
32
floating
4-L03.9081 X X X Y Y
Upper frame bearing

33
fixed
4-L03.9080 X X X Y Y
34 Pan head bearing 4-L18.2697 X X X Y Y
10.3 Bearings
10.3.1 Grooved Ball Bearings
When the grooved ball bearings are to be changed, the space of the ball bearings needs
completely to be filled with grease in order to avoid condensation.
Grease bearing seats before mounting new bearings in order to prevent the parts from
corrosion.
10.3.2 Plane Bearings

All plane bearings of pantograph are maintenance free. The plane bearings are:
 Plastic bushings
If plane bearings are slow moving, determine and eliminate the cause of this slowness.
Damaged plane bearings need to be replaced. Dirty plane bearings require cleaning.
Grease bearing seats before mounting new bearings in order to prevent the parts from
corrosion.
10.4 Screw Joints
All mounting screws are to be checked for damage and tight fit, especially:
 Mounting screws for the collector strips.
 Pan Head connections.
 Shunts.
Attention!!! Hex head nuts according DIN 985 / EN ISO 10511 and lock washers
according BN 208010-8 must be replaced by new ones after dismounting!
10.4.1 Torque for Stainless Steel Screw Connections
The table below is valid for screw connections of strength class A2-70 with using an
assembly lubricant.
Thread Size [mm] Torque [Nm] Thread Size [mm] Torque [Nm]
M3 1,0 M10 30,0
M4 1,8 M12 50,0
M5 3,5 M14 80,0
M6 6,0 M16 120,0
M8 15,0 M20 250,0
10.4.2 Screw bonding and Screw sealing
Some screw connections have to be secured with a high strength thread locker or have to
be sealed with a thread sealant.
Please see in the illustrated spare parts catalogue (see chapter #15.0) for this connections.

10.5 Hydraulic Oscillation Damper

For operational test of hydraulic oscillation dampers, please disassemble.
No idle play is allowed between the draw- and the pressure stage.
No liquid withdrawal should be visible.
10.6 Insulators, Insulating Tubes

Dirty insulators and insulating tubes need to be cleaned.
Dirty insulators and insulating tubes needs to be cleaned with Securisol 29.
10.7 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 Moly graf CC2 of company Fortuna associates.
10.8 Cable with Terminals of Raising Mechanism
The cable with terminals of the raising mechanism needs to be checked for breaks of wires
and braids.
The cable needs to be changed if:
 more than 10 single wires or/and
 1 single braid
are broken.
For this examination the pantograph needs to be fully raised in order to do a visual
inspection of the whole cable.
Further the cable needs to be checked if it is well greased, if necessary grease the cable on
the contact surfaces to the cam.
10.9 Shunt Connections
The shunts need to be checked for breaks of the wires and braids.
The shunts need to be changed if:
 more than 5% of the wires are broken.
Before fixing new shunts the contact areas must be cleaned and greased with contact
grease.

10.10 Pan Head Springs

The pan head springs have to be checked for any deformation and corrosion.
Defective parts have to be changed.
10.11 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.
10.12 Valve Unit ADD (Auto Drop Device)
The Auto drop device (ADD) shall be checked every year for function.
Attention!!! No one is admitted underneath the pantograph, while testing the

Auto Drop Device.
Test procedure:
 Fix the pantograph in resting position.
 Give the raising signal.
 Open the pneumatic tube connection from the carbon strip.
 The rapid ventilation valve must react.
After the test fix the pneumatic tube to the carbon strip and check proper raising
10.13 Over Reach detector(ORD)

The over reach detector shall be checked During every year inspection
Test Procedure
 Fix the pantograph in resting position

 Give the raising signal
 Check the Overreach detection, means, the signal appears when the adjusted height
of the pantograph is exceeded
 Measure the height at air released, if necessary adjust the height.
 After completion of test, Check for raising and lowering

 Also check the wear of the 3/2 Way valve and the clamp part 1.
 If the wear of the roller ball is high and not able to turn easily / cam on clamp part 1
shows too much wear they have to be replace
10.14 Auxiliary Material

The following auxiliary material has to be used for maintenance and repairs:
Description Product Manufacturer Marking in
chapter. 13
Grease Moly Graf CC2 Fortuna associates.
Contact grease Mlygraf TC-55 Fortuna associates.
Assembly lubricant Mosil metplat Metallit GmbH
compound
High strength thread Weicon Lock AN Weicon Lock, 270
locker 306-38 oder Loctite
Loctite 270
Thread sealant Loctite 577 Loctite 577
Grease, contact grease and assembly lubricant are specified in Annex.

11.0 Trouble shooting – Trouble List

For adjustments: See also chapter Adjustment procedures.
11.2 Trouble List
Defect Reason(s) Correction
Pantograph does not Air bellow damaged. Check air bellow, exchange
Raise or Lower. broken air bellow. (also see
defect: Bellow drive defective).
Cable torn Replace cable. (also see defect:
Cable torn)
Pneumatic control unit Exchange pneumatic control.
defective.
Pneumatic tube defect. Replace pneumatic tube.
Shock absorber between Replace shock absorber.
base frame and lower
frame defect.
Inner friction of panto is Check pantograph for damages,
too high. and eliminate damages.
Replace defective bearings.
Auto drop device Check auto drop device, especially
activated carbon strips for air leakage or
damage. Change defective parts
Frequent interruption of Contact pressure is poorly Check contact pressure and
current transmittal adjusted. adjust. (see chapter #13.4.2)
(strong arcing).
Inner friction of panto is Check pantograph for damages,

too high. and eliminate damages.
Replace defect bearings.
Frequent interruption of Carbon strips show Replace carbon strips.
current transmittal strong breakage.
(strong arcing).

Pan head springs are Clean bearings, replace defect

slow motion.. bearings.
Carbon strip parallelism Adjust carbon strip to parallel to
is not correct adjusted. catenary.
Parallel guide bar is Adjust turning capacity of pan
poorly adjusted (pan head.
head doesn‘t turn freely
from horizontal position).
Uneven wear of corbon Parallel guide bar is Adjust turning capacity of pan
strips.. poorly adjusted. head.
Current flashover from Insulators between base Clean insulators between base
pantograph to vehicle frame and vehicle roof frame and vehicle.
roof. are dirty.
Cable torn. Cables are not greased Replace cable and grease in area
of cam disk with non-water-
soluble grease.
Bellow drive is improper Replace cable, adjust bellow to
adjusted; bellow does not achieve straight expanding line.
expand straight-lined. (see chapter #13.3)
Bellow drive defective. Screws are loose. Tighten screws.
Hose line leaking. Exchange leaking hose with new
hose line.
Bellow cylinder leaking. Exchange bellow cylinder; find
reason for leakage and check
bellow joints.
Excessive air leakage. Pressure-regulator Exchange pressure regulator.
defective (normal air
leakage of pressure
regulator = 0,5 l / min.).
Increase of contact Pressure regulator Exchange pressure regulator.
pressure without defective.
previous adjustment of
pressure regulator.

12.0 Repairs
Prior to disassembling the pantograph, please study the illustrated spare parts catalogue
(see chapter #15.0) be informed about the relationship of the individual component parts.
Deformed and defective component parts are to be changed.
Bearing alignment is only accurately measurable on a measuring table.
Schunk cann’t take responsibility for workmanship at repairs and maintenance carried out
by other companies.
12.2 Dismounting of Pantograph from Top of Vehicle Roof
 Lower pantograph into resting position.
Attention!!! Make sure that current in overhead is switched off and grounded!
 Detach electrical connections between pantograph and vehicle.
 Disassamble the high voltage insulating tubes between pantograph and vehicle.
 Secure pantograph at the transport hooks.
 Detach pantograph from insulators.
 Lift pantograph off vehicle roof only by using transport hooks.
12.3 Complete Disassembly of Pantograph

 Lower pantograph,place the pantograph on stand / work bench
Attention!!! Store the pantograph always with the proper side up, the pan head
must be upside.
Attention!!! Use spacers of a appropriate length under the pantograph feet in
order to avoid damages by the floor to low and moving parts (Air bellow, Pneumatic
control).
 Detach shunts from pan head
 Detach ADD connections and carbon strips from pan head
 Detach horn from pan head
 Detach rockerboxes from apex tube
 Detach parallel guide bar

 Detach apex tube from upper Frame

 Detach Pan head bearing from upper frame
Attention!!! Bearing house(PAS-Lx) to be detached only if it is damaged.
 Detach dampers from lower frame and base frame
 Detach shunts from coupling rod, upper frame and base 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
12.4 Repairs of Component Parts

12.4.1 Free Bearing of Base Frame and Upper Frame
Autol TopCC2
Moly Graf 2000
1
2
1 5
6 4
4 7
3
6 4-1490B.8216
Instructions:
 Remove both covers (1) (e.g. by using a screwdriver)
 Push bearing (2) out of bearing housing by means of a sleeve, which only rests on
the outer ring of the grooved ball bearing.
 Detach both external retaining rings (3) by using a retaining ring pliers.
 Detach both insulating rings (4)
 Push off the grooved ball bearings (7) from bearing shaft (5), and replace by new
ones if necessary.
 Replace the complete bearing shaft (5), including the insulating bushing (6)
 Assembly of the bearings in reversed order - pack space between grooved ball
bearings with grease.
12.4.2 Fixed Bearing of Base Frame, Coupling Rod and Upper
Frame
Autol
Moly Top
Graf 2000
CC2
1
2
4
3
5
2
1 5 6 4-1490B.8217
Instructions:
 Remove both covers (1) (e.g. by using a screwdriver).
 Detach both internal retaining rings (2) by using a retaining ring pliers.
 Push bearing (3) out of bearing housing by means of a sleeve, which only rests on
the outer ring of the grooved ball bearing.
 Push off the grooved ball bearings (6) from bearing shaft (4), and replace by new
ones if necessary.
 Replace the complete bearing shaft (4), including the insulating bushing (5).
 Assembly of the bearings in reversed order - pack space between grooved ball
bearings with grease.
12.4.3 Pan Head Rocker Boxes

 Detach collectorstrip supports from rocker boxes
 Detach rocker suspension, leaf springs and spring supports from rocker boxes.
 Check parts and replace defective ones.
 Assembly in reversed order.
12.4.4 Shunts
For the assembly of new shunts proceed according the following procedure:
 clean the contact areas,
 grease contact areas with contact grease,
 install shunts and
align them according to the following criteria:
 The shunts may neither contact each other, nor they may touch other components
of the pantograph.
 The shunts must hang loosely and are not allowed to be strained.
In order to achieve this, the shunts must be turned into the appropriate position, if
necessary also the cable sockets have to be bent.
To check the adjustment the pantograph must be lifted and lowered over the whole
working height, if necessary the shunts need to be readjusted.
12.4.5 Bellow Drive
4-B0B.6957

 Detach bellow drive, check parts and replace defective ones.

 Mount of bellow to pantograph.
Attention!!! Do not overtorque the cable, as it otherwise may jam the bellow.
 Tighten the rope (1) evenly and adjust bellow (see chapter #13.3)
12.4.6 Other Component Parts

If the pantograph is damaged, all components need to be checked very carefully and
replaced if needed.
 Parallel guide bar including ball joints.
 Upper frame including diagonal cables and bearings for pan head.
 Coupling rod.
 Lower frame including damper, bolt for parallel guide bar and cam.
 Base frame including support spring and rubber bumpers.
 Plane bearings and Screw connections.
12.4.7 Surface Coating

As a minimum standard for surface protection of coated parts we recommend powder
coating according the following procedure.
12.4.7.1 Pre-Treatment
Clean surface from oil, grease and other dirt. Sandblast steel parts according to ISO 8501-
1 grade SA 2 ½ in order to remove rust and foreign particles.
Afterwards the surface has to be cleaned from dust.
Roughen aluminium by grinding, then clean surface from dust.
12.4.7.2 Finishing Paint

Powder paint on polyester base:
Binder: Polyester
Pigment: Titanium dioxide, pigments giving colour
Hardener: Triglycidilisocyanurate (TGIC)
Total layer thickness: min. 80μm
Colour: RED (RAL 3020)
12.4.7.3 Touch Up Paint

To repair smaller damaged areas of powder coated surface we recommend the following
procedure:
 Clean parts from oil, grease and other dirt.
 Grind surfaces with sandpaper.
 Clean parts from dust.
 Paint with ground layer based on synthetic resin.
 After drying, paint with a finish coat based on synthetic resin, colour according your
requirements.
Attention!!! Current connections, bearing seats and threads MUST not be painted!
12.5 Re-Assembly after complete Disassembly

If the pantograph had been completely disassembled, the re-assembly is to be conducted
as follows:
 Mount free bearings and fixed bearings for lower frame as well as rubber bumper to
the base frame.
 Mount valve unit ADD and ORD valve to base frame
 Attach cam discs to lower frame.
 Mount lower frame to base frame.
 Attach bellow drive to base frame.
 Mount cable with terminals to lower frame and air bellow and secure with lock nuts.
 Assemble coupling rod and mount to base frame.
 Install bearings of upper frame.
 Mount upper frame to lower frame, and coupling rod to upper frame.
 Mount diagonal cables to upper frame and tighten (caution during tightening,
upper frame may not distort).
 Mount pan head bearing and apex tube to upper frame.
 Install spring support, leaf springs and rocker suspension into the rocker box.
 Install collector strip supports on to the rocker boxes.
 Attach rocker boxes to the apex tube.
 Attach collector strips and shunt assemblies.

 Assemble parallel guide bar.
 Attach parallel guide bar between lower frame and pan head mount.
 Attach air hose from Valve unit ADD to bellow.
 Intermediate Check - verify tightness of all screws.
 Adjust pantograph (see chapter #13.0).
 Attach Hydraulic damper between lower frame and base frame.
 Final inspection on pantograph.
 Mount pantograph to vehicle roof.
 Establish electrical connection between pantograph and vehicle.
 Connect high voltage insulation tube from base frame to the vehicle roof.
 Before operation follow instructions of checklist (see chapter #9.0)
13.0 Adjustment Procedures

Each pantograph had been calibrated by the manufacturer.
Adjustment works are to be carried out in the following order:
 Adjust coupling rod and resting position
 Adjust the air bellow drive
 Adjust pneumatic control
 Adjust curve of contact pressure
 Adjust parallelism of carbon mounted panto pans
 Adjust movebility of pantograph head

13.2 Adjustment of Coupling Rod and Resting Position

The resting position of the pantograph is adjusted through the coupling rod (1)
Upper Frame (3)
Lower Frame (2)

Coupling Rod (1)
Rod adjuster( 6 )
Bumper (4)
Lock nut (5)

Procedure:
 Loosen the lock nuts (5)
 Adjustments are made through the rod adjuster (6) on the coupling rod (1).
 After adjustments tighten lock nuts (5).
Inspection:
 Lower the Pantograph.
 Check the height in lowered position
 The Lower frame (2) and the upper frame (3) have to rest on rubber bumpers (4)
Attention!!! Through changing the length of the coupling rod the geometry of the
pantograph has changed. Therefore check the curve of the contact pressure
and adjust if necessary.

13.3 Adjusting the Bellow Drive
2 1 3
±5mm
4-B0B.6957
If fine tuning is required, proceed as follows:

 Lower pantograph. Bellow has to be completely without pressure.
 Loosen lock nuts (5) on both sides of the wire rope.
 Strain the wire rope (1) with the hex nuts (2) that bellow (3) moves up and down as
shown in the sketch.
Attention!!! If you strain the wire rope, you have to fix the terminals of the wire rope
means that the wire rope can not be pivoted ore turned off!
 Secure with lock nuts (5).
 Final inspection of the fine tuning through raising and lowering of the pantograph.
 Check the ±5mm motion of the cylinder support (4) again.

13.4 Adjustment of Pneumatic Control

The pneumatic control has to be connected to the air bellow on the pantograph and to air
supply of the vehicle or from workshop. The pantograph has to be mounted on the vehicle
or to appropriate mounting legs in the workshop.
If the pneumatic control has to be adjusted complete, the following things have to be
done before:
 Pressure regulation valve (1): Unscrew adjustment screw complete by turning
counter-clockwise.
 Throttle valve (2): Is for the adjustment of the raising time. Unscrew adjustment
screw complete by turning counter-clockwise.
 Safety valve (3): Screw in adjustment screw complete by turning clockwise.
 Throttle valve (4): Is for the adjustment of the lowering time. Screw in adjustment
screw complete by turning clockwise
 Safety Valve (5) : is for the adjustment of the quick lowering. Screw in adjustment
screw complete by turning clockwise
3
4
2
5
After each replacement of sliding strips the contact pressure needs to be verified. The
value of the static contact pressure can be taken from the technical data.
(see chapter #3.0).
13.4.1 Adjust Safety valve (3)

Switch on compressed air.
The adjustment screw of the pressure regulation valve (1) has to be screwed in
slowly (turning clockwise) until the static contact force is 25 N higher than indicated
in the technical data (see chapter #3.0). Check with a spring scale.
 Attention!!!: Don’t turn the adjustment screw of the pressuere
regulation valve too fast, otherwise the pantograph will raise too
fast and may be damaged.
Slowly unscrew (turning counter-clockwise) the adjustment screw of the safety valve
(3), until light air outlet occurs.
Increase the static contact pressure slowly and the safety valve (3) latest has to
open completely at static contact force plus 50 N.
13.4.2 Adjust Contact Pressure

The adjustment screw of the pressure regulation valve (1) has to be unscrewed
(turning counter-clockwise), until the contact pressure agrees with the value in the
technical data (see chapter #3.0). Check contact pressure with a spring scale.
Measurement of contact pressure with spring scale
Value 1: Measuring of contact pressure from highest working position with slow
descending motion into resting position.
Value 2: Measuring of contact pressure from resting position with slow
ascending motion into the highest working position.
Results: (Value 1 + Value 2)/2 = Average Value = Contact Pressure
Friction: Difference of contact pressure between Value # 1 and Value # 2 (ideal
value lower than 20 N)
If the difference of the contact pressure is greater than 40 N, determine the reason
(e.g. defective component part, dirt in the bearings, etc.) and have it corrected.
 Attention!!!: If this step has to be repeated and the pantograph needs to be

raised again, the raising time (see chapter #13.4.3) has to be adjusted first.

13.4.3 Adjust Raising time

Screw in (turning clockwise) complete Adjustment screw of throttle valve (2).
Unscrew (turning counter-clockwise) Adjustment screw of throttle valve (2) slowly,
until the raising time agrees with the value in the technical data (see chapter #3.0).
 Attention!!!: Don’t turn the adjustment screw of the throttle valve too fast,
otherwise the pantograph will raise too fast and may be damaged.
13.4.4 Adjust Lowering time

 Attention!!!: Make sure that nobody is below the pantograph.
Switch off compressed air.
The adjustment screw of the throttle valve (4) has to be unscrewed slowely (turning
counter-clockwise) so the pantograph lowers and touches down easily to the
support springs on the base frame.
 Attention!!!: Don’t turn the adjustment screw of the throttle valve too fast,
otherwise the pantograph will lower too fast and may be damaged.
The lowering time has to be in accordiance with the upper limit mentioned in the
technical data (see chapter #3.0).
Check that pantograph raises in the time which agrees with the value in the
technical data (see chapter #3.0).
Switch off compressed air.
Under repeated raising and lowering of the pantograph gradually unscrew (turning
counter-clockwise) the adjustment screw of the safety valve (5) until Safety valve
(5) responds short after switching off compressed air.
The Safety valve (5) should respond so that pantograph lowers quick for a distance
of the insulation distance shown in the technical data (see chapter #3.0). Raise
and lower the pantograph more times.
The total lowering time now should lie in the lower range of the value in the
technical data (see chapter #3.0) and touch down on the support bumpers on the
base frame should happen as soft as possible.

Attention!!!: Don’t turn the adjustment screw of the Quick exhaust valve too fast,
otherwise the pantograph will lower too fast and may be damaged.
After Adjustment, tighten all counter nuts of pressure regulation valve (1) and throttle
valve (2). Also lock adjustment screws of safety valve (3) and Quick exhaust valve (5) with
thread sealant.
13.5 Adjustment Curve of Contact Pressure
The contact pressure should be nearly constant over the entire working range.
4
1
3
Instructions: 4-B0B.6957
Loosen the four screw connections (3).

Calibration is done by means of adjustment screw (1) on the cam disc (4) of the
lower frame.
Adjustment through:
 Turns clockwise = contact pressure increases in the lower working range
 Turns counter clockwise = contact pressure decreases in the lower working range
Adjustment is required until curve of contact pressure is nearly constant over the entire
working range. Verification with spring balance or with the SCHUNK pantograph contact
pressure measuring gauge KM 11.
Then tighten lock nuts (2) and screw connections (3)

13.6 Adjustment of pressure switch

Following steps to be followed for Adjusting Pressure Switch
 Remove the top cover of the pressure switch

 Remove the threaded pin (1) from the knob using screw driver
 Rotate the knob clock wise/anti clock wise to set P max as shown
 Press the knob down & rotate clock wise/anti clock wise to set P min as shown
Attention!!!: Hex.Screw (2) should not rotate while setting p min
 Fix the threaded pin to knob using screw driver

 Fix the top cover of the pressure switch
1.Removal of Threaded Pin 2.Setting of Pressure P Max
3.Setting of Pressure P Min 4.Assembly of Threaded Pin

13.7 Adjustment of Turning Capacity of Pan Head

The pan head has to be able to move from its horizontal position in either direction over
the entire length of its working height range. The turning scope of the pan head in the
median working height should be the same in both directions.
The adjustment is made by adjusting the length of the parallel guide bar.
3
4
Instructions:
Remove the parallel guide bar from lower frame.
Loosen lock nut (2).
Adjustment is accomplished through screwing in or screwing out of the parallel
guide bar at the rod end (1).
After adjustment tighten lock nut (2) and re-check adjustment.
Fix bellow (4) again with cable tie (3)

14.0 Product Data Sheet

14.1 MOSIL METAPLAT COMPOUND
What it is :
It is an antiseize rust preventive compound consisting of homogeneously dispersed organometallic
complex of lead,copper and other solids to form a non -melting lubricating compound. It is further
fortified with highly effective oxidation and corrosion inhibitors to combat environmental severities.
Temperature range : -18°C to +1100°C
How it is applied:
It can be applied by Hand, or grease gun or can be lightly smeared on sliding surfaces.
How does it work?

It forms a tough plating over bearing surface by filling the surface irregularities \vith copper- lead matrix.
This matrix does not melt or harden even under extremes of environmental conditions. It also holds well
to threaded connections subjected to continious vibrations.
MOSIL METAPLAT
(Copper Based Antiseize Compound)
An organometallic complex of copper, lead and other solids to form a non-melting antiseize
lubricatingcompound. It ~s fhrther:-fortified with highly effective oxidation and corrosion inhibi tors to
combatenvironmental severities. It forms a protective film on the metal surfaces which ensures trouble
freeprotection against seizure, corrosion pitting and galling of metal surface. It is a lubricant with
unusualantiseize quality and rust preventive properties. It is ideal for preventing seizures under rusting
and corrosion environments.

Mosil Metaplast : Copper Based Antiseize Compound

Characteristics Typical Value
Appearance Grease (paste)
Base In Organic
Colour Copper Red
Specific gravity 1.2 – 1.5
Drop Point None
Worked Penetration 280 - 320
Water Resistance Excellent
Carbon stip Corrosion Negative
Additives Anti Oxidant, Anti corrosion
Thermal Stability L’pto 1100°C
Covering Power 100 SqCm/gm. Approx.
Opearting temperature range -18°C to +1100°C
AREA OF APPLICATION
Threaded connections, Nuts and Bolts of Steam / Gas / Chemical pipelines, Assembly compound for
Cylinder heads, Press fits. Slipper pads, Propeller shafts, Heavy duty marine and oil rig machines. As
lubricant for slow speed heavily loaded swivel and journal bearings,Large gears and Rotary klins.
BENEFITS
Prevents seizure against corrosion and temperature.Works very effective in humid and corrosive
environments.Reduces maintenance down time.Chemically inert and sea water resistant
14.2 Moly Synthetic Silicone Graphite (Molygraf CC2) Grease

Description:
Molygraf CC2 Super Longtime Grease complex grease specifically developed for serve operating
conditions , where moisture and steam play truant. The selective base oil and additive package helps in
optimum performance in serve applications in plain and roller bearings with excellent water resistance,
working stability,EP and AW properties.
Molygraf CC2 Super Longtime Grease prevents extraordinary wear-out even under extreme loads, as
found with unalloyed greases.

Advantages:
High drop point helps in higher operating parameters
Excellent EP and AW properties

High water resistance
Beter stability in mild acidic and alkaline condition
Excellent working stability and corrosion protection
Specification:
Moly Synthetic Silicone Graphite Grease (Molygraf CC2)

Base oil High grade mineral oil
Soap(Thickener) Calcium complex
Worked penetration (At
265 to 295
25ºC worked 60 strokes)
Drop point >260°C
Timken O.K. load 38
Oil separation
0.6%
(At 100°C for 3 hours)
Carbon strip corrosion Passes
Water washout <1%
Opearting temperature -2°C to +200°C
14.3 Copper based greasy Paste(Molygraf TC-55)

Description
Copper based greasy Paste with high Melting Point.

Molygraf TC-55 is a viscous copper based grease ensuring perfect current flow through current-carrying
connections of all kinds.
The paste exhibits outstanding adherence at high ambient temperatures and retains its consistency
when temperature varies.
It protects contact surfaces from soiling, incrustations and harmful mechanical stress.
It is chemically neutral towards engineering materials.

Application
To permanently ensure perfect current flow through current-carrying connections of all kinds.Particularly
suitable for use on contact surfaces subjected to high temperatures.Also reliable to prevent corrosion,
incrustations and soiling on any contact metals.
Technical Data
Colour Pink-metallic
Density 0,95g/cm³
Flashpoint +230°C
Dropping Point +48°C
Insulation Resistance 5,5x1012Ωcm
Conductivity 0,18x10-12 1/Ωcm
Temperature Range -40 to +300°C

14.4 High strength thread locker

14.5 Thread Sealant

15.0 Spare Parts
In case of an order, indicate:

Description and drawing No of the part.
Spare part ordering number
Requested quantity of spare parts

SL. Part Description Dwg.No Part No Qty / UOM Ordering

NO assly number
1 Pantograph Assembly 1-27410.15983 10608263 01 No 7001598301
2 Base Frame Complete 1-G01.15058 10598908 01 No 7011505800
3 Base bearing insl. complete 3-L01.4206 10482227 01 No 7134206000
4 Support Spring complete 3-G01.14894 10560941 04 Nos 7011489400
5 Support bumper M10 Form 25.481 10467249 03 Nos 7010004002
6 Lower Frame 1-UN02.6422 10602975 01 No 7022975004
7 Cam 2-UN12.4288 10512091 02 No 7024288003
8 Cable with threat fitting 3-B14.4338 10513756 01 No 7174338000
9 Hydraulic Damper 3-7432 10514084 02 No 7097432000
10 Upper Frame 1-3913.5326 10512576 01 No 7032576005
11 Upper frame bearing compl. 3-L03.4211 10467307 01 No 7144211000
12 Diagonal Cable (incl.Heat 3-17103.11748 10509942 01 Set 7109942001
Shrink tube & Cable Tie)
(1set =2nos.)
13 Pan head Bearing 4-L18.2697 10516016 02 No 7112697000
14 Air Bellow drive 1-B04.15759 10599740 01 No 7041575900
15 Air Hose 3-B04.4940 10510114 01 No 7204940000
16 Coupling Rod 2-K16.4276 10512015 01 No 7062015003
17 Coupling rod bearing insulated 4-L06.9621 10512061 02 No 7069621000
18 Parallel Gude bar 2-P07.5333 10512730 01 No 7072742002
19 Bellow Best Nr.1407AW 10448626 01 No 7070005000
20 Ball joint (Rod End) KA 10 DNJRO / 10467224 01 No 7070007000
GARSW 10 R.C3
21 Pan head 1-W08.15566 10599345 01 No 7081556602
22 Apex Tube 1-W08.12490 10513425 01 No 7083425000
23 Rocker box 2-W08.12507 10515943 02 Nos 7081250700
24 Leaf spring compl. 3-W08.12502 10510496 04 Nos 7081250200
25 Horn SB-029093 10780474 04 Nos 7082909300
26 Shunt 4-S00.3579 10514464 04 Nos 7083579000
27 Carbon Sliding strip (SK85Cu) SK 1590 10591398 02 Nos 7081590000


NO assly number
28 Valve Unit ADD 2-V15.16191 10611489 01 No 7151619100
29 Quick Exhaust Valve XG353A041V- 10467259 01 No 7157259000
TPL22383
30 Ball Valve L009.0100 R1/4” i 10511968 01 No 7151968000
31 Over Reach Detection 2-V15.15775 10600396 01 No 7151577500
32 3/2 Way Valve CL-104A G1/8” 10508598 01 No 7158598000
33 Clamp part 1 2-V05.12168 10511769 01 No 7151216800
34 Shunt 4-S00.4999 10514453 04 Nos 7154999000
35 Shunt 4-12800.5848 10467358 10 Nos 7205848000
36 Insulating hose(White) 4-B09.4724 10511644 01 No 7194724000
37 Insulating hose(Green) 4-B09.4724 10511644 01 No 7194724100
38 Insulating hose(Blue) 4-B09.4724 10511644 01 No 7194724200
39 Pneumatic Control Unit 1-V15.15750 10601221 01 No 7151575003
(Valve Plate assly)
40 5/2 Way Valve (incl. socket) 3-V15.15796 10552766 01 No 7151579600
41 Filter AF30-F02 BD 10510098 01 No 7059728021
42 Phoenix Connector Set 01 No
44 Pr.Regulation Valve IR3020-X3N277 10510138 01 No 7059728031
(F02)
45 Filter AF30-F02 BD 10510098 01 No 7059728021
46 Safety valve 3-V05.13667 10513904 02 Nos 7051366700
47 Throttle Valve T1000C2800 10510081 01 No 7059728050
48 3/2 Way Valve V61B4D7A-X5090 10508591 01 No
50 Pressure Safeguard MCS11-SOND 910 10510146 02 Nos 7150146000
G R1/4” 15bar
51 Insulator Complete 2-G01.15986 10608332 04 Nos 7011598600


NO assly number
1 Pantograph Assembly 1-27410.15983 10608263 01 No 7001598301

SL.NO Part Description Dwg.No Part No Qty / UOM Ordering

assly number
01 Base Frame Complete 1-G01.15058 10598908 01 No 7011505800
02 Base bearing insl. complete 3-L01.4206 10482227 01 No 7134206000
03 Support Spring complete 3-G01.14894 10560941 04 Nos 7011489400
04 Support bumper M10 Form 25.481 10467249 03 Nos 7010004002
Base Frame Complete Support spring Complete
Base bearing insl. complete Support Bumper


assly number
01 Lower Frame 1-UN02.6422 10602975 01 No 7022975004
02 Cam 2-UN12.4288 10512091 02 Nos 7024288003
03 Cable with threat fitting 3-B14.4338 10513756 01 No 7174338000
04 Hydraulic Damper 3-7432 10514084 02 Nos 7097432000
Lower Frame Hydraulic Damper
Cam Cable with threat fitting


assly number
01 Upper Frame 1-3913.5326 10512576 01 No 7032576005
02 Upper frame bearing 3-L03.4211 10467307 01 No 7144211000

compl.
03 Diagonal Cable (incl.Heat 3-17103.11748 10509942 01 Set 7109942001
Shrink tube & Cable Tie)
(1set =2nos.)
04 Pan head Bearing 4-L18.2697 10516016 02 No 7112697000
Upper Frame
Diagonal Cable (incl.Heat Shrink tube & Cable Tie)
Pan head bearing Upper bearing compl.


assly number
01 Air Bellow drive 1-B04.15759 10599740 01 No 7041575900
02 Air Hose 3-B04.4940 10510114 01 No 7204940000

assly number
01 Coupling Rod 2-K16.4276 10512015 01 No 7062015003
02 Coupling rod bearing insul. 4-L06.9621 10512061 02 No 7069621000
Coupling Rod
Coupling rod bearing insul.


assly number
01 Parallel Gude bar 2-P07.5333 10512730 01 No 7072742002
02 Bellow Best Nr.1407AW 10448626 01 No 7070005000
03 Ball joint (Rod End) KA 10 DNJRO / 10467224 01 No 7070007000
GARSW 10 R.C3
Parallel Gude bar Ball joint (Rod End)
Bellow

NO assly number
01 Pan head 1-W08.15566 10599345 01 No 7081556602
02 Apex Tube 1-W08.12490 10513425 01 No 7083425000
03 Rocker box 2-W08.12507 10515943 02 Nos 7081250700
04 Leaf spring compl. 3-W08.12502 10510496 04 Nos 7081250200
05 Horn compl. SB-029093 10780474 04 Nos 7082909300
06 Shunt 4-S00.3579 10514464 04 Nos 7083579000
07 Carbon Sliding strip (SK85Cu) SK 1590 10591398 02 Nos 7081590000

Pan head
Rocker box Apex Tube
Carbon Sliding strip (SK85Cu) Leaf spring compl.
Horn Compl. Shunt


assly number
01 Over Reach Detection 2-V15.15775 10600396 01 No 7151577500
02 3/2 Way Valve CL-104A G1/8” 10508598 01 No 7158598000
03 Clamp part 1 2-V05.12168 10511769 01 No 7151216800
Over Reach detector
Clamp part 1 3/2 Way Valve


assly number
01 Valve Unit ADD 2-V15.16191 10611489 01 No 7151619100
02 Quick Exhaust Valve XG353A041V- 10467259 01 No 7157259000
TPL22383
03 Ball Valve L009.0100 R1/4” 10511968 01 No 7151968000
i
Valve Unit ADD
Quick exhaust Valve Ball Valve


assly number
1 Shunt 4-S00.4999 10514453 04 Nos 7154999000
2 Shunt 4-12800.5848 10467358 10 Nos 7205848000
3 Insulating hose(White) 4-B09.4724 10511644 01 No 7194724000
4 Insulating hose(Green) 4-B09.4724 10511644 01 No 7194724100
5 Insulating hose(Blue) 4-B09.4724 10511644 01 No 7194724200
Shunt
Insulating hose


NO assly number
2 Pr.Regulation Valve IR3020-X3N277(F02) 10510138 01 No 7059728031
3 Filter AF30-F02 BD 10510098 01 No 7059728021
4 Safety valve 3-V05.13667 10513904 02 Nos 7051366700
6 3/2 Way Valve V61B4D7A-X5090 10508591 01 No 7059728060
8 Pressure Safeguard MCS11-SOND 910 G 10510146 02 Nos 7150146000
R1/4” 15bar
PneumaticControl Unit 1-V15.16074

Filter Pr.Regulation Valve Safety Valve 3/2 Way Valve
Throttle Valve Throttle Valve Pressure Safeguard


NO assly number
(Valve Plate assly)
2 5/2 Way Valve (incl. socket) 3-V15.15796 10552766 01 No 7151579600
3 Filter AF30-F02 BD 10510098 01 No 7059728021
4 Phoenix Connector Set 01 No
Pneumatic Control Unit (Valve plate)
5/2 Way Valve (incl. socket) Phoenix Connector Set


NO assly number
1 Insulator Complete 2-G01.15986 10608332 04 Nos 7011598600

Single Arm Pantograph Model: WBL22.03: Description Maintenance and Operating Manual

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Single Arm Pantograph Model: WBL22.03: Description Maintenance and Operating Manual

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Schunk Metal & Carbon (India) Pvt. Ltd.

4 -14062-22.03 Page 1 von 71 Revision 2

Single Arm Pantograph

Date: 10.08.13 Prepared: K.Seetharam Approved: Thomas Hentze

4 -14062-22.03 Page 2 von 71 Revision 2

Copyright by Schunk Bahn- und Industrietechnik GmbH.

Schunk Bahn- und Industrietechnik GmbH

Rev.No. Revision Date Name

Date: 10.08.13 Prepared: K.Seetharam Approved: Thomas Hentze

4 -14062-22.03 Page 3 von 71 Revision 2

4 -14062-22.03 Page 4 von 71 Revision 2

9.1 Check list…………………………………………………………………………………………………………20

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12.4.7 Surface coating………………………………………………………………………………………….34

Date: 10.08.13 Prepared: K.Seetharam Approved: Thomas Hentze

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Date: 10.08.13 Prepared: K.Seetharam Approved: Thomas Hentze

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2.0 Safety Instructions

2.1 General information

Attention!!! Before starting any repair or maintenance work, always:

Class Particle Size Concentration Water Oil

Date: 10.08.13 Prepared: K.Seetharam Approved: Thomas Hentze

4 -14062-22.03 Page 8 von 71 Revision 2

3.0 Technical Data

Propulsion system with air bellow

Date: 10.08.13 Prepared: K.Seetharam Approved: Thomas Hentze

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Forces applied to pantograph support insulators:

Date: 10.08.13 Prepared: K.Seetharam Approved: Thomas Hentze

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4.0 Description of Pantograph Components

Date: 10.08.13 Prepared: K.Seetharam Approved: Thomas Hentze

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4.2 Structural Components

Upper Frame bearing

Parallel Guide Bar

Valve Unit ADD

Date: 10.08.13 Prepared: K.Seetharam Approved: Thomas Hentze

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4.2.1.1 Base Frame

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4.2.1.5 Coupling Rod

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4.2.1.10 Base- and Upper frame bearing

4.2.1.12 Over Reach Detector (ORD)

4.2.2 Pneumatic Control (Valve plate)

4.2.3 Pneumatic Control

Date: 10.08.13 Prepared: K.Seetharam Approved: Thomas Hentze

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From ADD AIR IN

Date: 10.08.13 Prepared: K.Seetharam Approved: Thomas Hentze

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4.2.3.1 Pneumatic diagram

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4 -14062-22.03 Page 19 von 71 Revision 2

Date: 10.08.13 Prepared: K.Seetharam Approved: Thomas Hentze