Operating andService Manual

C20

Kubota D1105 PoweredCompressor

GB 100006734/00 – DC042AA – 9/2004

CALIFORNIAProposition 65 Warning

Diesel engine exhaust and some ofits constituents are known to theState of California to cause cancer,birth defects, and other reproductiveharm.

Operating andService Manual

C20

Kubota D1105 PoweredCompressor

GB 100006734/00 – DC042AA – 9/2004

DC036AA4

DC036AA 5

Consumer protection act 1987 EECdirective covering product liability

EEC Council Directive No.85/374/EEC has been adopted byHM Government and becomes effective in the UnitedKingdom from March 1988.

Not withstanding other and various legally bindingrequirements, the Directive specifically requiresmanufacturers of products to provide instructions for thesafe use of such products.

CompAir support all new products being supplied to theircustomers with a comprehensive Operator Manual whichclearly defines mandatory instructions for the operation,safe use and maintenance of the product.

It is the responsibility of the owner or hirer of such productsto ensure that operators are provided with the manual andare suitably instructed regarding the purpose of the Manualand its safety instructions. In addition operators should besuitably and adequately trained in the use of the product.

This is an important notification and in their owninterest owners and hirers must comply.

Foreword

In the design of CompAir Products every effort is made tomake operation, maintenance and overhaul as simple aspossible. To obtain reliable service from the machinecorrect and regular maintenance is essential.

This manual has been prepared to assist the user in caringfor this machine and every effort has been made to providesufficiently detailed information for a competent person tobe able to do this properly. Provided the instructions areread carefully and followed by suitable trained persons theequipment will give long and trouble free service. Similarly,if the instructions are followed, we cannot foreseecircumstances in which this equipment will present ahealth or safety hazard.

It is expected that users will observe normal safe practiceswhen operating or working on the equipment such as thesafe handling of compressed air, engine exhaust, fuels,oils, cleaning fluids, lifting and moving the machine,working inside it and security of the machine if workingunderneath. Take care of your machine, keep it clean andin good mechanical condition.

The standard build of all CompAir Ltd. products are notintended for use in either Explosive or Potentially ExplosiveAtmospheres as defined in Directive 94/9/EC.

An Explosive atmosphere is a mixture with air, underatmospheric conditions, of flammable gases, vapours,hazes or dust in which, after ignition has occurred,combustion propagates to the entire unburned mixture andmay cause a hazard.

A potentially Explosive atmosphere is an atmospherewhich could become explosive due to local conditions.

Refer to the appropriate manufacturer’s publications foroperating, maintenance and servicing instructions forengine or other major factored equipment fitted to thismachine

Where references are made in this book, the towbar end ofthe plant is the front, and left and right are as viewed fromthe rear.As far as possible the information contained in thisbook was correct at the date of publication. Themanufacturers reserve the right to modify specifications inaccordance with new or improved designs.

Whilst every effort is made to maintain accuracy in thedata given all figures must be taken as typical and in noway binding.

If assistance is required contact your nearest CompAirRegional Company or Distributor or, if this is notpracticable, contact directly CompAir Ltd, CompAirDistribution Centre, Claybrook Drive, Washford industrialEstate, Redditch, Worcestershire B98 0DS, UK.

Control of Substances hazardous to Health Regulations (COSHH) (United Kingdom)YOUR ATTENTION IS DRAWN TO THE FOLLOWINGLISTS OF LIQUIDS AND SUBSTANCES USED IN OURPRODUCTS WHICH MAY EXPOSE PERSONNEL TORISK IF SWALLOWED OR IF SKIN OR FACIALCONTACT IS ALLOWED.

1. Portable Air CompressorsDiesel fuel oil.Compressor and engine lubricating oils and greases.Anti-freeze agents and mixes (liquid cooled engines).Corrosion inhibitors and conditioners (some cooling systems).Battery acid.

2. Pneumatic Tools and Rock DrillsLubricating oils and greases.Anti-freeze agents.

Note:Comprehensive maintenance instructions are contained inour operator manuals. In the interest of safety these shouldbe strictly observed at all times.

Product liability

The Company reserves the right to change product details without obligation

6 DC036AA

Contents

Section Subject Page

1. Safety1.1 Operation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.2 The use of compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.3 Towing the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.4 Before starting the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.5 During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.6 After stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.7 Maintenance and overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.8 When working on the plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.9 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.10 Signs and symbols used on your compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Plant information2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.2 Torque figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.3 Recommended lubricant for compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.4 Recommended engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.4 Tool Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.5 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.6 Recommended Lubricants for the undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3. Plant description3.1 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163.2 Oil separation and recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163.3 Unloading and speed control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183.4 Blowdown valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.5 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.6 Electrical system / control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213.7 Protection equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4. Operating instructions4.1 Initial preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224.2 Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224.3 To start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244.4 During operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254.5 To stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5. Routine maintenance5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265.2 Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265.3 First 50 hours running only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265.4 Every 125 hours running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265.5 Every 250 hours running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265.6 Every 1000 hours / 6 months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285.7 Every 12 months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295.8 Silencing foam cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6. Planned servicing schedule 30

7. Fault finding chart 31

8. Adjustments8.1 Off-load air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328.2 Engine speed range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

9. Detailed servicing9.1 Checking / replacing the air / oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339.2 Cleaning the radiator and oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339.3 Servicing the air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

DC036AA 7

Contents / Illustrations

Diagram Description Page

Fig. 1 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Fig. 2 Oil separation and recovery . . . . . . . . . . . . . . . . . . . . . . .17

Fig. 3 Unloading and speed control system . . . . . . . . . . . . . . . .19

Fig. 4 Blowdown valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Fig. 5 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Fig. 6 Operating and maintenance locations . . . . . . . . . . . . .23, 27

Fig. 7 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Fig. 8 Lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Fig. 9 Pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Fig. 10 Speed control linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Fig. 11 Air / oil separator assembly . . . . . . . . . . . . . . . . . . . . . . . .33

Fig. 12 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Fig. 13 KNOTT Overrun Brake . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Fig. 14 KNOTT Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Figs. 15 & 16 KNOTT transmission system for single-axle chassis. . . . . .38

Section Subject Page

10 Undercarriage10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3510.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3510.3 KHV7.5 height-adjustable Towing System, model B2.5.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3510.4 Braking System - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3610.5 Overrun Hitches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3610.6 Braking System Adjustment - Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3610.7 Braking System Adjustment - Preliminary Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3710.8 Adjusting the brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3710.9 Adjusting the brake compensating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3810.10 Adjusting the brake linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3810.11 Readjusting the brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3910.12 Maintenance and care KNOTT overrun systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

11 Undercarriage fault finding 41

8 DC036AA

1.1 Operation & maintenance

1.1.1 This machine is designed to compress air forpowering tools and equipment mainly in theconstruction, mining and quarrying industries.Do not attempt to use it for compressing anyother gas.

1.1.2 It is expected that users will employ safeworking practices and will observe anyrelated legal requirements when operating oroverhauling this machine.

1.1.3 The following notes augment instructionsgiven elsewhere in this publication and theyare intended as a guide to the safe use of thismachine and its associated compressed airsupply under normal working conditions.

1.1.4 In the United Kingdom, your attention isdrawn to the “Health and Safety at Work Act”and to relevant codes of practice.

1.2 The use of compressed air

Compressed air can be dangerous

1.2.1 Use only certified pressure vessels ofadequate working pressure. OTHERS COULD EXPLODE.

1.2.2 Fit a non-return valve or a shut-off valve in thedelivery line if the compressor is to be coupledin parallel with another compressor orconnected to an air supply system.

1.2.3 Distribution pipework and hoses must be thecorrect size and suitable for the workingpressure involved. If working pressures areabove 7 bar (100 lbf/in2) it is recommendedthat hoses incorporating safety wires areused.

1.2.4 Do not use frayed, damaged or deterioratedhoses. Always store hoses properly and awayfrom heat sources or direct sunlight. A HOSEFAILURE CAN CAUSE INJURY.

1.2.5 Use only the correct type and size of hose endfittings and connections. Use clamps of robustconstruction especially made for compressedair.

1.2.6 If using compressed air for cleaning downequipment, do so with extreme caution. Takecare not to blow debris at yourself or otherpersons or into machinery. Use eyeprotection.

1.2.7 When blowing through a hose or air line,ensure that the open end is held securely.

A free end will whip and can cause injury.

Open the supply air cock carefully and ensurethat any ejected particles will be restrained.

A blocked hose can become acompressed air gun.

1.2.8 Never apply compressed air to your skin ordirect it at another person. Never usecompressed air to blow dust and debris fromyour clothing.

1.2.9 Do not use air directly from a compressor forbreathing purposes, e.g. charging aircylinders, unless the compressor isspecifically designed or equipped for thispurpose.

1.2.10 Never operate a compressed air system, forexample compressor pipework or pneumaticappliance, at a higher pressure than that forwhich it has been designed or rated.

1.2.11 Shut off the air cock at the compressor andrelease air pressure before disconnecting ahose or line unless there is an automaticvalve to give protection at the upstream jointbeing separated.

1.3 Towing the compressor

1.3.1 Check the towbar, braking system andcoupling. Check that wheels are secure andthat tyres are in good condition and inflatedcorrectly.

1.3.2 Connect lighting cable to towing vehicle ifapplicable. Check correct operation of alllights.

1.3.3 On two wheel plant raise propstand/jockeywheel fully and lock.

1.3.4 Ensure breakaway cable is secured to towingvehicle (where fitted).

1 Safety

9DC036AA

1.3.5 On four-wheel plant, ensure the reversingbrake stop on towing eye shank isdisengaged. Engage it again when reversing.

1.3.6 Release the handbrake (where fitted).

1.4 Before starting the compressor

ensure:1.4.1 Plant is level and secure with brakes applied

and, wherever possible, is sited with exhaustpointing down wind.

1.4.2 Plant is clean internally.

1.4.3 All air pressure is released from machine.

1.4.4 All hoses and tubing in good condition,secure and not rubbing.

1.4.5 No fluid leaks.

1.4.6 All fasteners tight.

1.4.7 Fluid levels correct. Top up only with specifiedoils/coolants. Filler caps must be tight.

1.4.8 All electrical leads secure and in good order.

1.4.9 Fan belt tension correct.

1.4.10 All guards in place and secure.

1.4.11 Engine exhaust system in good condition andno combustible material lying on or against it.

1.4.12 Start and stop procedures are clearlyunderstood. Before starting close airdischarge cocks. Refer to the operatinginstructions.

1.5 During operation

1.5.1 Keep enclosure doors shut.

1.5.2 Check all pressures and temperatures arecorrect. Refer to the operating instructions.

1.5.3 Stop the plant if warning lights show or ifgauges register outside normal limits.Untrained personnel must not attemptadjustments. Call in a Plant Fitter toinvestigate.

1.5.4 Do not refill with fuel while the plant isrunning. Keep fuel away from hot pipes.

1.5.5 Ensure that the engine exhaust is freelyvented to the atmosphere.

1.5.6 Do not remove the oil filler cap.

1.5.7 Do not remove the radiator cap. (Liquid-cooled engines).

1.5.8 Do not carry out adjustments inside thecanopy when the machine is running, otherthan where specifically instructed.

1.5.9 Do not disconnect the battery.

1.5.10 Do not remove guards.

1.5.11 Do not use the machine in a fire hazard areaunless it is suitably equipped. Do not operatein the presence of toxic fumes.

1.5.12 Be aware that communication with peoplenearby will be impaired.

1.6 After stopping

1.6.1 Ensure that the automatic blowdown valvehas operated to release all air pressure fromthe system.

1.6.2 Allow radiator to cool before removing fillercap. Allow engine to cool before addingcoolant (liquid-cooled engines).

1.6.3 Remove starting key if fitted.

1.6.4 Secure and lock all doors at the end of eachworking shift.

1.7 Maintenance and overhaul

Before starting any work on the plant:1.7.1 Ensure the appropriate “Maintenance Work in

Progress” sign is prominently displayed on ornear the machine.

1.7.2 Disconnect battery to ensure that machinecannot be started inadvertently.

1.7.3 Ensure that all air pressure is completelyreleased from the system.

1.7.4 Stand the plant on level ground.

10 DC036AA

1.7.5 Apply the brakes if fitted. Securely fix thepropstand/jockey wheel on two-wheeledplant.

1.7.6 Chock wheel or wheels securely if jacking-upor if working on the brakes. Support towbaron two-wheeled plant.

1.7.7 Support axle(s) securely if workingunderneath or removing a wheel. DO NOTRELY ON JACKS. Support towbar as 6.

1.7.8 Ensure that any door that opens upwards issecurely fastened when open and that nodoor can slam shut and trap you.

1.8 When working on the plant:

1.8.1 Use proper lifting gear of adequate capacity.

1.8.2 Examine condition of lifting bale before liftingplant by it.

1.8.3 Use the correct tools for the job.

1.8.4 When using a chemical or solvent cleaner,follow the manufacturer’s instructions.

1.8.5 Do not weld or perform any operationinvolving heat near the fuel or oil systems.Fuel and oil tanks must be completelypurged, e.g. by steam cleaning, before suchoperations.

1.8.6 Do not weld or in any way modify anypressure vessel.

1.8.7 Before clearing the machine for use, checktest that operating pressures, temperatures,and speed are correct and that the controlsand shut-down devices work correctly.

1.8.8 Finally - remember that using any other thangenuine CompAir UK replacement parts willinvalidate your guarantee.

1.9 Disposal

When items of CompAir constructionequipment or tools are to be taken out ofservice for disposal it is recommended thatthe following instructions are adhered to:

1.9.1 In order to prohibit ‘the bringing back in toservice’ of such equipment or tools bypersons unknown, they should be renderedunusable in order to avoid improper re-use.

1.9.2 Alternatively all such items of equipment ortools should be stripped into their componentform for ‘material composition disposal’ e.g.base metals, plastics, fabrics, glass etc andbe subject to normal industrial waste re-cycling process.

1.9.3 Bio-degradeable items should be subject tonormal industrial waste disposal processes.Ensure that no plastic, rubber or compositematerials are disposed of by incineration.

1.9.4 Ensure that all fluid waste e.g. diesel fuel,lubricating oils and greases, anti-freezeagents or mixes, refrigerant fluids, corrosiveinhibitors and conditioners, any acids oralkalies should be kept separated anddisposed of by authorised salvage disposal orre-cycling systems ensuring that none ispermitted to enter either the industrial ordomestic waste water system.

DC036AA 11

1400-17240DO NOT START OR CARRY OUT ANY MAINTENANCEUNTIL YOU HAVE READ THE OPERATOR MANUAL

1400-14550LASHING POINT

1400-12720HOOK

1400-17230ENSURE ALL GUARDS IN PLACE - WARNING:- PRESSURISED COMPONENT - WARNING:- HOT SURFACES - WARNING:- DIESEL ENGINE EXHAUSTDO NOT BREATHE AIR FROM THIS MACHINE. DO NOT STAND ON AIR TAPS - DO NOT REMOVE USER HANDBOOK FROM MACHINEDO NOT OPEN CANOPY WHILE MACHINE IS RUNNING.

1400-11745FUEL FILLER

1400-13460PRESSURE VESSEL. RELIEVE ALL PRESSURE BEFORE TOPPING UP WITH OIL. REFER TO OPERATOR MANUAL

A93634740SOUND POWER LEVEL

IT IS RECOMMENDED THAT IN THE INTEREST OF SAFETY:

ALL MISSING OR DAMAGED WARNINGVINYLS SHOULD BE REPLACED AS PART

OF A REGULAR SERVICE.

1400-13010OIL DRAIN

1.10 Signs and symbols used on your compressor

12

2.2 Torque figuresNm lbf/ft

Wheel Nuts 88 65Towbar to Axle Fixing Brackets:- Setscrews 70 52Towbar Clamping Plate to Base Nuts/Screws 95 70Axle Mounting Pads to Base Nuts/Screws 95 70Coupling Body to Towbar Nuts/Bolts 115 85Propstand Clamp Attachment Nuts/Bolts 100 74Towing Eye to Coupling Body Nuts/Bolts 70 52

DC036AA

2.1 Technical data

2 Plant information

33.6 lt/sec (2.0 m3/min, 71 ft3/min)

On Load Off Load6 bar (85 lbf/in2) 7 bar (100 lbf/in2)7 bar (100 lbf/in2) 8 bar (116 lbf/in2)2800 rev/min 2000 rev/min115° C

50° C100 dB(A) LWA 84 dB(A) LPA

1 x dry type disposable

1 x 3/4 in. BSP cocksSpeed control and inlet throttlingSingle spin-on canister typeOil fed to bearings and rotorsby air at working pressureair blast (aluminium)see para 2.3

Kubota D 1105 - 3 cylinderliquid cooled diesel12 v negative earth1 x two-stage dry type with safety elementSee Engine ManualSee Engine Manual

6.5 lt (1.42 U.K. gal)5 lt (1.1 U.K. gal)34 lt (7.5 U.K. gal)

1320 mm (4 ft 4 in)2695 mm (8 ft 10 in)1068 mm (3 ft 6 in)1160 mm (3 ft 91/2 in)145 mm (53/4 in)340 mm (1 ft 13/8 in)145 - R10 or 145 - R132.4 bar (35 lbf/in2)10° continuous, 15° intermittent

540 kg (1190 lb)

PerformanceFree Air Delivered at 7 bar and max. rev/min to ISO 1217.1996(T1 measured at compressor inlet filter for application consistency) . . . . . . . . . . . . . . . . . . . . . .

Normal working pressure range (factory set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maximum working pressure range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine speed range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maximum compressor air/oil discharge temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(Temperature at manifold is approx. 10° lower)Maximum permissible ambient temperature at 7 bar continuous full load . . . . . . . . . . . . . . . . . .Maximum sound power level to 2000/14/EC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maximum sound pressure level at Operator Position to PNEUROP PN8NTC2.2 @ 7m . . . . . . .

CompressorAir inlet filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air delivery outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Load control method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Method of lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Approved lubricating oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EngineType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air inlet filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Approved lubricating oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Approved coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluid CapacitiesCompressor oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine oil system (with filter renewal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GeneralWidth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Length, including towbar (straight) to C/L of 2 in towing eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wheel track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ground clearance, minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Towing eye height (towbar horizontal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tyre size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tyre pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tilt from horizontal, maximum permissible any direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight (approx.)Compressor complete, wet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C20

13

2.3 Recommended lubricant for compressor

Note In these screw compressors, circulating oilhas not only a lubricating function, but inparticular it also has cooling and sealingfunctions. It is therefore exposed to moredifficult conditions. In particular thetemperature conditions at the installation siteand the consistency of the air (dust, dirt, andhumidity content, as well as chemicalinfluences) must be taken into account whenselecting a suitable lubricant.

CautionDo not mix oils of different specifications.

The maintenance intervals and themaximum and minimum operatingtemperatures given in this operatingmanual only apply when high-qualitymulti-grade oils are used.

Use of the wrong oil leads to impairmentof function.

Change the compressor oil morefrequently than specified if the equipmentis operated under abnormal conditions,i.e. at a high ambient temperature, high airhumidity or in a dusty environment. Ifnecessary, analyse the oil.

2.3.1 Out of consideration for the high loadsimposed on the lubricant in screwcompressors with oil injection cooling, werecommend the use of suitable, non ageing,non foaming, corrosion-protective oils. Theymust meet the following requirements forhydraulic fluids: H-LP 32 and H-LP 46 inaccordance with DIN 51524, Part 2, June1985.

2.3.2 The viscosity of the lubricants should complywith viscosity class ISO VG 32 DIN 51519,July 1976, with 28 - 35 mm2/s(cSt) / 40 ºC, orif the ambient temperature is constantlyabove 25 ºC, with viscosity class ISO VG 46DIN 51519, July 1976, with 41 - 50mm2/s(cSt)/40 ºC.

CautionConventional engine oils marked HD mustnot be used.

2.3.3 When using oils with the “Brief DescriptionHYD 10/HYD 20” in accordance with the‘Standard Lubricants for Building Machineryand Vehicles’ published by the ‘Hauptverbandder Deutschen Bauindustrie e.V.’ (PrincipalAssociation of the German Building Industry),only the given hydraulic fluids may be used inaccordance with ISO VG 32 and ISO VG 46.

2.3.4 If other lubricants are to be used, pleasecontact:

CompAir Drucklufttechnik GmbH ArgenthalerStraße 11 D-55469 Simmern/HunsrückTelephone 06761 / 832-339 Telefax 06761 /832-421

or your authorized dealer or your localbranch.

DC036AA

14

2.4 Recommended engine oil

2.4.1 Lubricant specifications for the driving enginecan be found in the enclosed engineoperating manual.

2.5 Tool lubricants

CautionDo not run the machine with an emptyoiler tank. The tank must always contain aminimum of 0.2 l of tool oil.

The wrong tool lubricants lead to depositsthat cause malfunctions in the appliancesconnected.

2.5.1 For the perfect lubrication of concretebreakers and pneumatic spades, werecommend the use of CompAir oilers orautomatic pipe oilers, using the specialsynthetic CompAir oil AES 82.

The special advantages of CompAir oil are asfollows:

a) Biodegradable,

b) Ice guard down to -50 ºC, for use with soundabsorbers,

c) Very good lubricity, thus wear-reducing,

d) No irritating exhaust gases, work in enclosedrooms possible,

e) Good cleaning effect, no residue formation

f) Excellent preservation properties, protectsfrom corrosion.

2.5.2 When using compressed air appliances madeby other manufacturers, their regulations mustbe observed.

2.6 Diesel fuel

2.6.1 Use common diesel fuel with a sulfur contentof less than 0.5 %. If the sulfur content ishigher, oil has to be changed at shorterintervals.

2.6.2 The following fuel specifications areapplicable:

a) DIN 51 601

b) Nato Codes F 54, F 75, and F 76

c) BS 2869: A1 and A2 (observe sulfur content with A2)

d) ASTM D 975-81 : 1-D and 2-D

e) VV-F-800a : DF-A, DF-1, and DF-2.

Note See engine instruction manual.

2.6.3 At low temperatures, paraffin precipitation cancause blocks in the fuel system anddisruptions in operation. Below outsidetemperatures of 0 ºC use winter diesel fuel (to-15 ºC). (This is usually available at gasstations in good time before the winterseason begins.) Diesel fuel with additives isfrequently offered for use at temperatures aslow as -20 ºC (“Superdiesel”).

Note Only mix in the tank. First put in the requiredquantity of petroleum, then fill up.

See engine instruction manual.

2.6.4 Below -15 ºC or -20 ºC, petroleum must beadded.

2.6.5 If it is necessary to use summer diesel fuelbelow 0 ºC, petroleum can also be added upto 60 %.

2.6.6 In most cases, adequate resistance to lowtemperatures can be achieved by adding aproduct to improve flow properties (fueladditive). Consult your engine service station.

Attention The compressor must not be fuelled withbio-diesel (DIN 51606) or vegetable oil.

DC036AA

DC036AA 15

2.7 Recommended lubricants for the undercarriage

2.7.1 For relubrication use only lithium saponifiedgrease which fulfils the followingspecifications:

a) consistency groups (NLGI) 2 DIN 51818

b) worked penetration 265-295 DIN ISO 2137

c) dripping point > 180 ºC DIN ISO 2176

d) operational temperature - 40 ºC ... +140 ºC

This corresponds to a DIN 51502 lubricationgrease, designation KP2N-4U.

Greases with different thickeners (soap base)must not be mixed.

Recommended grease: Fuchs Renolit LZR 2.

DC036AA16

3.1 Lubrication system (Fig. 1)

3.1.1 When the compressor is running, the entiresystem is pressurised and oil is forced fromthe pressure vessel (1) to the oil cooler (6).The cooled oil then passes through a filter (4)before being injected onto the rotors where itmixes with the air at the commencement ofcompression.

3.1.2 The oil cools the air being compressed, sealsbetween the rotors and lubricates the driveshaft and rotor bearings. Oil from thebearings is returned via internal porting to themain oil flow by differential pressure.

3.2 Oil separation and recovery (Fig. 2)

3.2.1 The pressure vessel is mounted at the frontright-hand side of the plant. Its purpose is toseparate the oil from the air/oil mixture aftercompression has taken place, and to act asan oil reservoir.

3.2.2 The vessel consists of a vertical steel casingconstructed in accordance with theappropriate Standards for fusion-weldedpressure vessels. Mounted on top of thecasing is a spin-on type fine separatorelement.

3.2.3 The air/oil mixture from the compressorenters the vessel through a tangentialconnection which causes most of the oil to becentrifuged out to run down the walls of thecasing where it re-joins the main oil flow andis re-circulated. The air which now holds onlya small amount of fine oil mist, then flowsthrough the fine separator where the mist isremoved. From there, the collected oil isreturned via the oil scavenge tube (2) andstrainer to the rotor casing by differentialpressure. Its rate of return is controlled by arestrictor in the scavenge tube connectionelbow at the compressor.

3 Plant description

DC036AA 17

Fig. 1 Lubrication system

1. Pressure vessel2. Separator scavenge oil return3. Oil from cooler4. Oil filter5. Compressor unit6. Oil cooler7. Hot oil to cooler8. Air/Oil mixture from compressor

Fig. 2 Oil separation and recovery

1. Air to delivery manifold2. Separator scavenge oil return3. Cover4. Air/oil mixture

from compressor5. Separator6. Drain point7. Oil feed to cooler8. Pressure vessel casing

View A

A

PU 6794

1

6

7

8

4

32

5

8

2

1

3

4

5

6

7

PU 6795

DC036AA18

3.3 Unloading and speedcontrol system (Fig. 3)

3.3.1 Compressor air output is controlled byunloader valve (15) which regulates theamount of air admitted to the compressorunit, together with variation of engine speedvia control cylinder (12).

3.3.2 When the compressor is started, the vacuumcreated within the unloader body causes thevalve (15) to move down over guide post (14)against plunger (16) and spring (18). Air isthus admitted to the compressor to build uppressure in pressure vessel (11). Vesselpressure is piped to the integrated pressureregulator (5) and START/RUN valve (9).

3.3.3 On starting up, pressure (10) by-passes thepressure regulator via the START/RUN valveand acts directly on unloader piston (13) andspeed control cylinder. When vessel pressurereaches approx. 2.75 bar (40 lbf/in2), it movespiston and unloader valve upward over theguide post to close off the air intake. At thesame time it acts on the speed controlcylinder to reduce engine speed to idlingwhile the machine warms up.

3.3.4 When machine has reached operatingtemperature, the START/RUN valve ispressed. This brings the pressure regulatorinto circuit. Spring (17) will then move pistonand valve downward to admit more air to thecompressor, and the engine will speed up. Airpressure will therefore increase in thepressure vessel and manifold until itovercomes the pressure regulator spring. Theattached needle valve (3) will then lift from itsseat and allow air (7) to act on unloaderpiston and speed control cylinder to off-loadthe machine at 7 bar (100 lbf/in2) and reduceengine speed.

3.3.5 As the demand for air from the machinevaries, regulator (5) will adjust pressure inchamber (20) in response, and unloadervalve and speed control cylinder will moveuntil air demand is exactly matched.

3.3.6 When the compressor is shut down correctly(i.e. delivery cocks are first closed) themachine will be off-load with the unloadervalve held firmly on its seat. As the rotorsstop turning, pressure in the vessel isprevented from getting back to the inletpipework by the closed unloader valve whichnow acts as a non-return valve.

3.3.7 The resulting pressure build up within theunloader body is utilised to operate blowdownvalve (2).

3.3.8 As pressure in chamber (20) dissipates, spring(17) moves piston downwards, while theunloader valve remains on its seat, assisted byspring (18). The system is then ready for thenext start-up.

Fig. 3 Unloading and speed control system

1. Air to delivery manifold2. Blowdown valve3. Needle valve4. Atmospheric vents5. Pressure regulator6. Diaphragm7. Control air to unloader and

speed control cylinder8. Unloading system bleed9. Start / run valve10. Air supply to pressure regulator and

unloading system11. Pressure vessel12. Speed control cylinder13. Piston14. Guide post15. Unloader valve16. Plunger17. Spring18. Plunger spring19. Seal20. Chamber

A. StationaryB. Off-loadC. Full-load

19DC036AA

8

6

5

7

3

4

2

1

9

11

124

10

PU 6782/1

15

14

16

17

13

1819

A

B

C

20

DC036AA20

3.4 Blow down valve (Fig. 4)

3.4.1 This valve is situated on the pressure vessel.It operates automatically to release all airpressure within the system on shut-down,thus ensuring that the plant is not startedagainst delivery pressure.

3.4.2 The valve consists of a body (5) whichcontains a fluted valve guide (7), valve (4)and valve seating washer (3). The valvecomponents are attached to a diaphragm (2),and the whole is enclosed by a cap (1) at oneend and a screwed cover (6) at the other.

3.4.3 When the plant is running, a depression iscreated within the unloader body which isapplied to the top of the diaphragm via anylon pipe. Vessel air pressure (10) actssimultaneously against the underside of thevalve (4) and washer (3). The washer istherefore retained firmly on its seat thuspreventing the escape of vessel pressurethrough ports (8) in the upper portion of thevalve body.

3.4.4 On shut-down the residual pressure in thevessel builds up within the unloader body (theunloader valve now acting as a non-returnvalve as previously described) and acts onthe top of diaphragm (2).

3.4.5 This pressure on the large area of diaphragm(2) is sufficient to overcome the similarpressure acting on the smaller area of valve(4), therefore the washer (3) is lifted from itsseat so allowing the pressure still in thevessel to escape to atmosphere through ports(8).

3.5 Cooling system

3.5.1 Heat is continuously extracted from the airbeing compressed by the injection of acontrolled flow of cool oil into the compressorunit rotor casing. This contributes to efficientcompression and results in acceptably low airdelivery temperatures without the need forother intercoolers or aftercoolers.

3.5.2 The oil itself is cooled in an air blast cooler,the necessary air flow being provided by apusher fan which is mounted on the enginewater pump pulley.

3.5.3 The plant must be run with the canopy doorsclosed to obtain the most efficient cooling.Always select the coolest place possible forthe plant to operate in; refer to Technical Datafor maximum permissible operating ambienttemperatures.

Fig. 4 Blowdown valve

1. Cap2. Diaphragm3. Valve seating washer4. Valve5. Body6. Screwed cover7. Valve guide8. Port9. To unloader body10. Vessel air pressure

PU 6845

7

6

10

5

4

3

8

2

1

9

DC036AA 21

3.6 Electrical system / control panel (Fig. 5)

3.6.1 The electrical system is a 12 volt DC negativeearth system, incorporating a maintenance-free battery and electric starting. When theengine is running, a belt-driven alternatorcharges the battery and supplies power to thevarious operating and protection circuits.

3.6.2 The control panel incorporates an airpressure gauge (1A) and electrically drivenhourmeter (1B) A 4-position rotary switch(1G) controls starting and stopping. Noignition key is required. The panel also carriesthe START/RUN valve (1H) and four indicatorlights; one for battery charge (1C) one for lowfuel (1F) one for engine oil pressure, enginecoolant temperature and air deliverytemperature (1D) and one Heater PlugIndicator (1E).

3.6.3 Behind and below the control panel is thecircuit protection fuse-holder which carriesblade type fuses. Each of these will illuminateto indicate that it has blown.

3.6.4 The front of the control panel also carries agraphical operating instruction vinyl.

3.7 Protection equipment

3.7.1 Your machine will shut down automatically ifany one of the following occurs:-

a) Low engine oil pressure :- 1.0 bar (14.5 lbf/in2)

b) High engine coolant temperature:-115ºC (239ºF).

c) High air delivery temperature:-120ºC (248ºF).

d) Low fuel level.

3.7.2 Should a fault occur, the switch concernedwill cut the power to the engine fuel solenoidand stop the machine.

3.7.3 A pressure relief valve is also fitted in thepressure vessel to protect the system againstan undue rise in air pressure.

Fig. 5 Control panel

1A. Air delivery pressure gauge1B. Hourmeter1C. Battery charge warning light1D. Shut-down warning light1E. Heater plug indicator light1F. Low fuel light1G. Four position rotary switch1H. Start / run valve

DC036AA22

4.1 Initial preparation

4.1.1 On receipt, check the plant for possible loss of,or damage to, parts. Report any such problemto your nearest CompAir authorised dealer.

4.1.2 Refer to Technical Data or Engine Manual forfuel and oil capacities and specifications, andfor any fuel system alterations required for highaltitude operation.

4.1.3 Plants are despatched from the factory filledwith oil and coolant and fitted with amaintenance-free battery. Ensure the batteryconnections are tight and engine andcompressor oil and coolant levels are correct.(See para 4.2.4).

Caution:Some lubricating oils may not becompatible with others, and mixing themcan result in the formation of lacquer-typedeposits or sludges. Avoid mixing oils ofdiffering brands, grades or types.

4.1.4 Refer to Engine Manual for all additionalinformation.

4.2 Before starting (Fig. 6)

Warning:Engine exhaust extension pipes are a firehazard and must not be fitted to themachine.

4.2.1 Ensure plant is standing level with handbrake(25) fully applied (vertical).

4.2.2 Check gauge (1A) to ensure no air pressurewithin the plant.

4.2.3 Check the following are closed or tight asapplicable:

a) Pressure vessel oil drain (6).

b) Fuel tank drain (19).

4.2.4 Check oil level in pressure vessel.

a) Remove combined filler plug/dipstick (8).

b) If necessary top up with approved oil to the top mark on the dipstick.

c) Replace and secure filler cap.

4.2.5 Check level in fuel tank; ensure there issufficient for the task in hand. The tank ismanufactured from polyethylene and level canbe checked visually. Top up if necessary withfuel of the required specification (see enginemanual).

4.2.6 Check engine oil level as detailed in enginemanual. Top up if necessary.

4.2.7 Check the coolant level in the radiator

a) Remove the radiator filler cap (24)

b) Check the coolant level and if necessary topup to within 25 - 40 mm of bottom of fillerneck with a suitable anti-freeze mixture, asdetailed in the engine manufacturer’shandbook.

4.2.8 Close air delivery cocks (2).

4.2.9 Shut enclosure and open control panel door.

4 Operating instructions

DC036AA 23

Fig. 6 Operating / maintenance locations

1. Control panel1A. Air pressure gauge1B. Hourmeter1C. Battery charge warning light1D. Shut down warning light1E. Heater indicator light1F. Low fuel light1G. Rotary switch1H. Start / run valve2. Air delivery cock3. Air pressure regulator4. Blow down valve5. Pressure relief valve6. Pressure vessel oil drain7. Air / oil separator8. Pressure vessel oil filler plug/dipstick9. Fuel filter10. Fuel water separator

11. Separator oil scavenge restrictor and strainer.

12. Compressor oil filter13. Air filter (compressor)14. Air filter service indicator15. Air filter (engine)16. Fuel tank filler17. Fuel tank drain18. Engine air filter dust valve19. Battery20. Engine speed control cylinder21. Fuel lift pump22. Engine oil filter23. Engine coolant drain24. Engine coolant filler25. Handbrake

DC036AA24

4.3 To start (Fig.7)

Warning:Do not use hand-held ether sprays in anattempt to improve cold starting. Theresulting high energy burn or explosioncould be disastrous.

Fig. 7 Control panel

1A. Air delivery pressure gauge1B. Hourmeter1C. Battery charge warning light1D. Shut-down warning light1E. Heater plug indicator light1F. Low fuel light1G. Four position rotary switch1H. Start / run valve

4.3.1a) Turn rotary switch (1G) 1 position clockwise

(aux). Control panel lights (1C, 1D) shouldcome on. If the low fuel light (1F) illuminatesalso then there is insufficient fuel in the tankand the engine cannot be started until morefuel has been added.

b) If pre-heat is required (refer to table below),turn rotary switch 1 position further clockwise(heater indicator light (1E) illuminates) andhold for the required length of time, then turnswitch fully clockwise to start. If pre-heat isnot required, turn switch fully clockwisewithout pausing in pre-heat position. Releasestarter switch when engine has started.Ensure all panel lights have gone out. If anyshow, stop the plant immediately and callplant fitter to investigate.

Ambient Temperature Preheat DurationAbove 10ºC (50ºF) No Need10ºC (50ºF) to -5ºC (23ºF) Approx 5 SecondsBelow -5ºC (23ºF) Approx 10 SecondsMaximum permissible pre-heat duration is 20 Seconds

c) If engine fails to start within five to ten seconds,return rotary switch (1G) to the ‘OFF’ positionand repeat starting sequence after allowingmoving parts to stop and all air has beenexhausted.

4.3.2 Plant will run at idling speed with air pressureregistering about 2.7 bar (40 lbf/in2).

4.3.3 With cold engine, allow machine to warm up fortwo minutes then press START/RUN button(1H). If engine is warm, button can be pressedimmediately. Air pressure will then increase to 7 bar (100 lbf/in2)

4.3.4 Plant is now ready for use. Check tools / hosesare connected correctly and open required airdelivery cocks.

DC036AA 25

4.4 During operation

Refer to Fault Finding Chart to aid faultanalysis.Refer to engine manual for engineinformation.

Caution:Do not disconnect wiring from battery oralternator while engine is running.

4.4.1 Check hourmeter (1B) is recording.

4.4.2 If oil mist is discharged from the air cocks oroil consumption is excessive, stop plant andrefer to Fault Finding Chart.

4.4.3 Check battery charge warning light (1C) isextinguished. If it glows, stop plant and referto Fault Finding Chart.

4.4.4 Check the air pressure (1A) is beingmaintained between 5.9 and 6.9 bar (85 to100 lbf/in2) depending on air demand.

4.4.5 Check air filter service indicator (17) is clear.

4.4.6 If the plant stops, check as follows beforeswitching off isolating switch (1G):-

a) Check control panel lights. If low fuel light(1F) is lit, switch off isolating switch and re-fillthe fuel tank, then re-start the plant in thenormal way.

b) If the shut-down and charge warning lights are lit, remove the electrical connectionfrom the engine oil pressure switchimmediately following shut-down and leave itoff.

c) If the shut-down warning light (1D) goes off, itindicates that low engine oil pressure or afaulty engine has caused the shut-down.Refer to engine manual for problem solving.

d) If the light stays on, it indicates that highengine temperature or high air deliverytemperature has caused to shut-down. To identify the source of the fault exactly,remove the electrical connection from theengine coolant temperature switch, leavingthe oil pressure switch disconnected. If thelight goes out it indicates a coolanttemperature problem.

e) If the light stays on, the fault lies elsewhere.Replace the coolant temperature switchconnection then check the pressure vesseltemperature switch in the same way. Checkall electrical connections are back in placeafter the fault has been traced to ensurecorrect operation of the protection equipment.Finally, replace the engine oil pressure switchconnection.

f) Return the isolating switch anti-clockwise to‘OFF’ position on completion.

Note:It is imperative that these checks are carriedout immediately the plant shuts down, as theprotection circuits will reset themselves as theplant cools.

4.5 To stop

4.5.1 Close air delivery cocks and allow plant toidle for 3 minutes. This is especiallyimportant if plant has been working at fullload for some time prior to shut-down.

4.5.2 Return isolating switch (1G) to the ‘OFF’position.

Note:This switch is also considered to be theemergency stop. No other means of stoppingis fitted.

4.5.3 When engine stops, automatic blowdownvalve will release all air from plant.

DC036AA26

5.1 General

This section of the Manual should be used inconjunction with the Planned ServicingSchedule, Detailed Servicing Section and theengine manual.Maintenance periods listed should be carriedout according to hours registered on thehourmeter. We recommend that aMaintenance Record Log be kept to assist inan accurate control of maintenance. Ensurethat all compressed air has been releasedbefore working on the plant. Unless carryingout performance tests and runningadjustments the engine must be stopped.Prior to undertaking work on any electricalequipment or associated circuits the batterymust be disconnected. If repairs require theuse of an electric welding set it is essentialthat the earth terminal of the set is connecteddirectly to the part to be welded to preventdamage to the alternator.

5.2 Daily

5.2.1 Check levels in fuel tank, pressure vessel,engine sump and radiator; refer to paras 4.2.4, 4.2.5, 4.2.6, 4.2.7 and engine manual.

5.2.2 Check engine air filter service indicator (Fig.6 (14)). A red signal sleeve becomesprogressively more visible with increasingfilter restriction. If the sleeve is locked in fullview, service the filter; refer to DetailedServicing. On completion, reset the indicatorby pressing its reset button.

5.2.3 Examine the plant for fluid leaks, and thecanopy and undercarriage for damage.

5.3 First 50 hours only

5.3.1 Change compressor oil filter element. Referto 5.6.2 (c) and (d).

5.3.2 Refer to Maintenance Schedule (enginemanual).

5.4 Every 125 hours running

5.4.1 Inspect silencing foam for contamination ordamage (where fitted). Refer to para 5.8.

5.4.2 Check condition of canopy, control panel doorand all hinges; oil all hinges, refer to Fig. 7.

5.4.3 Check operation of unloading and speedcontrol system. (see ‘Adjustments’)

5.4.4 Check tyre pressures; refer to Technical Data.

5.4.5 Check pressure relief valve is free to operateby turning its knurled top cover anti-clockwiseuntil air is discharged from the ports in thebase of the valve (Fig. 6 (5)). Screw the coverdown again on completion.

5.4.6 Refer to Maintenance Schedule (enginemanual).

5.5 Every 250 hours running

5.5.1 Carry out 125 hours service.

5.5.2 Torque tighten the bolts attaching towbar toaxle and axle to chassis; refer to TechnicalData.

5.5.3 Check condition of compressor unit air filter(Fig. 6 (13)) and renew if necessary. Refer to detailed servicing.

5.5.4 Refer to Maintenance Schedule (Engine Manual)

5 Routine maintenance

27DC036AA

Fig. 6 Operating / maintenance locations

1. Control panel1A. Air pressure gauge1B. Hourmeter1C. Battery charge warning light1D. Shut down warning light1E. Heater indicator light1F. Low fuel light1G. Rotary switch1H. Start / run valve2. Air delivery cock3. Air pressure regulator4. Blow down valve5. Pressure relief valve6. Pressure vessel oil drain7. Air / oil separator8. Pressure vessel oil filler plug/dipstick9. Fuel filter10. Fuel water separator11. Separator oil scavenge restrictor and

strainer.12. Compressor oil filter13. Air filter (compressor)14. Air filter service indicator15. Air filter (engine)16. Fuel tank filler17. Fuel tank drain18. Engine air filter dust valve19. Battery20. Engine speed control cylinder21. Fuel lift pump22. Engine oil filter23. Engine coolant drain24. Engine coolant filler25. Handbrake

Fig. 8 LUBRICATION POINTS

A - GREASEB - OIL

B

A

A

A

A

PU 6779

B

DC036AA28

5.6 Every 1000 hours running or 6 months, whichever occurs first

5.6.1 Carry out 250 hours service.

5.6.2 Carry out a compressor system oil change asfollows:

a) Remove pressure vessel filler plug/dipstick.

b) Place a 25 litre (5 gallon) container underpressure vessel and remove oil drain plug(Fig 6 (6)).

c) Remove compressor oil filter element. Thefilter has a ‘spin-on’ element and this is bestremoved using a strap wrench. Position acontainer to collect any possible spillage.

d) Fit a new spin-on element, following themanufacturer’s instructions.

e) Replace pressure vessel oil drain plug.

f) Fill vessel to top mark on dipstick using anapproved grade of oil (refer to TechnicalData). Replace and tighten the filler plug /dipstick.

g) Run plant for ten minutes then shut down.ENSURE ALL AIR PRESSURE HAS BEENRELEASED FROM THE VESSEL. Wait threeminutes for lubricating oil to settle, then topup again to top mark on dipstick.

5.6.3 Clean the radiator / oil cooler fins and checkfor leaks or damage. Refer to DetailedServicing Section for approved cleaning andservicing procedures.

5.6.4 Clean battery top and terminals. Coatterminals with petroleum jelly. The batterysupplied with your machine is a maintenancefree type and should require only infrequentattention.

5.6.5 Thoroughly examine and lubricate theundercarriage. Refer to Detailed Servicingand Fig. 7.

5.6.6 Check that the plant protection circuits arefunctioning correctly as follows:-

a) With the plant running, remove the electricalconnection from the engine oil pressureswitch and touch it onto a goodelectrical earth. The plant should shut down.The shut-down warning light should alsoremain on with the connection still earthed.

b) With the oil pressure switch still disconnected,re-start the plant and repeat the above withthe temperature switches protecting thepressure vessel and engine. With these,however, replace each individual connectionbefore re-starting and proceeding to the nextswitch. Ensure all terminals are re-connectedon completion.

c) Replace the engine oil pressure switchconnection.

d) Re-start the machine and, using a length ofclean dowel rod or similar into the fuel tank,gently press down the float on the low fuelswitch. After a slight delay the machineshould shut down with just the low fuel light(and battery charge warning light) on thecontrol panel illuminated. Return the rotaryswitch to 'OFF'.

5.6.7 Check run the plant.

5.6.8 Refer to Maintenance Schedule (enginemanual).

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5.7 Every 12 months

5.7.1 Carry out 6 Months Service.

5.7.2 Check / renew air/oil separator. See Detailed servicing.

5.7.3 Remove and clean the oil cooler, internallyand externally. Refer to Detailed Servicing forthe approved cleaning procedures.

5.7.4 Remove and clean internally, all flexible oilpipes between the oil cooler, compressor andpressure vessel.

5.7.5 Steam clean (or similar) the plant.

5.7.6 Check settings of protection equipmenttemperature switches.

Warning:High temperatures.

a) Remove engine coolant temperature switchand put a 12 Volt supply and max. 12W bulbin series with it. Immerse switch in acontainer of oil and raise temperature. Bulbshould illuminate at 100oC ± 3o (212oF ± 5o). Ifsatisfactory, replace switch, otherwise renewit.

b) Repeat the above with air end temperatureswitch. In this case, bulb should illuminate at120oC ± 3o (248oF ± 5o).

5.7.7 Refer to Maintenance Schedule (enginemanual).

5.8 Silencing foam cleaning, if fitted (frequency as required)

5.8.1 Silencing foam is self extinguishing whenexposed to fire in an uncontaminatedcondition but it can be a fire hazard if it iseither damaged or becomes heavilycontaminated with oil, fuel, soot or dust. Inthe interests of safety the foam should bewashed with a detergent regularly andrenewed if necessary. Use material toBS4735 specification when renewing thefoam and, when using an adhesive, ensurethat the surface is dry and dust free. Use anapproved adhesive such as 3M IndustrialAdhesive type Scotch-Grip 847, obtainablefrom your nearest 3M stockists.

30

6.1.1 The servicing task is shown in the left handcolumn and the next column shows wherefurther information on the indicated taskscan be found. The next five columns indicatethe frequency with which each task is to becarried out.

6.1.2 Reading down the columns will indicate whichtasks are to be carried out during thatMaintenance period.

6.1.3 You will note that the servicing frequencyextends over a 12 month period, after whichthe cycle is repeated.

6.1.4 Refer to the engine manufacturer’s handbookfor details of the servicing tasks to be carriedout on the engine.

6 Planned servicing schedule

DC036AA

Warning! !The use of parts or lubricating oil not supplied orapproved by CompAir, or failure to observe themaintenance instructions, may have serious Safetyand/or Warranty implications.

CompAir accept no responsibility for damage orinjury caused by use of non-approved parts or failure to comply with maintenance instructions.

Every

Servicing task

Para Day

125Hours

Running

250Hours

Running

12Months

1000 HoursRunning or6 Months

WhicheverOccurs First

Check fuel level in tank 4.2.5 • • • • •Check engine oil level in sump 4.2.6 • • • • •Check oil level in pressure vessel 4.2.4 • • • • •Check air filter service indicator 5.2.2 • • • • •Visually check plant for leaks and damage 5.2.3 • • • • •Inspect silencing foam where fitted 5.8 • • • •Check condition of doors and hinges 5.4.2 • • • •Check operation of speed control and unloading system 8. • • • •Check tyre pressures 2.1 • • • •Check safety valve free to operate 5.4.5 • • • •Torque tighten towbar bolts & axle securing bolts 9.5/9.6 • • •Check / renew compressor air filter element 5.5.3 • • •Change compressor system oil and filter 5.6.2 • •Clean and inspect radiator & oil cooler fins 9.2 • •Check battery 5.6.4 • •Thoroughly examine and lubricate undercarriage 9.4 • •Test protection circuits 5.6.6 • •Check run the plant 5.6.7 • •Clean oil cooler externally and internally 9.2 •Clean all flexible oil pipes 5.7.4 •Steam clean the plant 5.7.5 •Test temperature switches 5.7.6 •Check brake adjustment + 9.7Change engine air filter elements ++ 9.3

+ Every 5000 km (3000 miles)++ Every year if not changed previously.

DC036AA 31

NOTE:The instructions in the Remedy column are abbreviated.Refer to Detailed Servicing if more information is required.

7 Fault finding

Battery charge warning (a) Faulty alternator Refer to engine manuallight on. Engine running (b) Wiring fault Check circuit

Shut-down due to low (a) Low oil pressure Refer to engine manualengine oil pressure (b) Faulty pressure switch or circuit Change switch or check circuit

Plant fails to start (a) Flat battery, faulty starter, loose or dirty Recharge or replace battery, overhaul starter, tightenconnections, blown fuse or clean connections, diagnose fault and replace fuse.

(b) Fuel tank empty or air or water/ dirt in the Fill fuel tank or clear fuel system and prime using handfuel system priming pump

(c) Pressure in the pressure vessel Overhaul or renew blow down valve

(d) Faulty engine Refer to engine manual

Plant starts and stops (a) Bleed hole in fuel filler cap blocked Clear bleed hole

(b) Faulty engine Refer to engine manual

Compressor fails to build (a) Choked air intake filter Replace air intake filter elementup to working pressure (b) Suction unloader valve stuck on seat Inspect and release valve through unloader air intake

(c) Faulty blow down valve Overhaul or renew blow down valve

(d) Faulty gauge Renew or overhaul gauge

(e) Faulty START/RUN valve Renew valve

Compressor fails to (a) Suction unloader valve stuck open Inspect and release valve through unloader air intakeoff-load (b) Suction unloader/compressor joint leak Tighten nuts or renew joint(safety valve blowing)

(c) Punctured diaphragm on pressure Inspect and renewregulator

(d) Pressure relief valve faulty Inspect and rectify

(e) Air/oil separator clogged Renew separator

Plant not operating at (a) Speed control linkage out of adjustment Reset speed control linkagecorrect minimum or (b) Engine air intake filter choked Replace air intake filter elementmaximum speed

(c) Punctured diaphragm in speed control Inspect and renewcylinder. NOTE: Air issuing from vent incylinder will indicate punctured diaphragm

(d) Engine faulty Refer to engine manual

Excessive compressor (a) Separator scavenge oil restrictor / Clean oil restrictor / straineroil consumption strainer choked *

(b) Air/oil separator faulty Renew element

(c) Incorrect grade of oil Drain, refill with correct grade of oil

Shut down due to high (a) Plant not standing level or sited badly Stand plant level or resite for maximum air flowair delivery temperature (b) Pressure vessel oil level low Top up

(c) Incorrect grade of compressor oil Drain, refill with correct grade of oil

(d) Air/oil separator clogged Clean or renew element

(e) External surface of oil cooler clogged Clean

(f) Clogging of compressor oil circulating Drain, flush and refill circulating systemsystem

(g) Faulty vessel temperature switch or circuit. Change switch/s or check circuit

Shut-down due to high (a) Radiator fins clogged Steam clean finsengine coolant (b) Engine overheating Refer to engine manualtemperature (c) Faulty temperature switch or circuit Change switch or check circuit

* Fitted in oil scavenge line on compressor unit

FAULT POSSIBLE CAUSE REMEDY

DC036AA32

8.1 Off-load air pressure (Fig. 9)

8.1.1 The pressure control system fitted to thesemachines operates progressively over arange of approx 1 bar (15 lbf/in2), so that theoff-load air pressure (suction regulator valveshut, engine idling) is approx 1 bar higherthan the full-load pressure (suction regulatorvalve wide open, engine at maximum speed).

8.1.2 The normal off-load pressure is 7 bar (100 lbf/in2) and machines leaving the factoryare set at this figure. However, the systemcan be adjusted to give off-load pressuresbetween 5.2 bar (75 lbf/in2) and 8 bar (115lbf/in2) via the pressure regulator. Release thelocknut (2) and turn the adjusting screw (1)anti-clockwise to lower the off-load pressure,or clockwise to raise it to the required figure.

8.2 Engine speed range (Fig. 10)

8.2.1 Engine speeds are checked using astroboscopic rev. counter on the enginecrankshaft pulley. Check air delivery cocksare closed, start engine and allow to warmup. Press START/RUN valve.

8.2.2 If necessary, adjust off-load air pressure tothe required figure - normally 7 bar (100lbf/in2) - as described in paragraph 8.1.2

8.2.3 Fit a silencer to an air cock. Gradually openthe air cock and lower the delivery airpressure to the required full load figure -normally 6 bar (85 lbf/in2) The engine speedwill increase.

8.2.4 Check that the engine is running at its correctmaximum speed (see Technical Data). If not,adjust the length of the speed control linkageby releasing locknut (2) and turning ballcoupling (1). Keep checking the air pressureas the engine speed is adjusted, and ensurethat it stays at the required full-load pressure.Finally, tighten the locknut.

Caution:Do not rotate the piston rod itself duringthis operation, otherwise the operatingdiaphragm within the speed controlcylinder will be damaged and renderedunfit for further use.

8.2.5 Close the air delivery cock and, again using astrobe, check the engine minimum speed iscorrect (see Technical Data). If not, releaselocknut (4) on the speed control cylinder andturn adjusting screw (3) until the correctminimum speed is obtained. Tighten thelocknut.

8.2.6 Stop the machine.

Fig. 9 Pressure regulator

1. Adjusting screw2. Locknut

Fig. 10 Speed control linkage

1. Ball coupling2. Locknut3. Adjusting screw4. Locknut5. Speed control cylinder

PU 6797

1

2

3

4

5

PU 6796

2

1

8 Adjustments

DC036AA 33

9.1 Checking / replacing the air/oil separator (Fig. 11)

9.1.1 Replace the air/oil separator at least once peryear or measure the differential pressure asfollows:

9.1.2 Ensure the engine is stopped and there is nopressure in the compressor system. Unscrewthe dipstick from the pressure vessel.

9.1.3 Screw a pressure gauge into the vacateddipstick/filler hole and start the compressor.

9.1.4 The difference in pressure between thepressure gauge on the pressure vessel andthe pressure gauge on the instrument panelmust not exceed 1 bar.

9.1.5 If the differential pressure exceeds 1 bar,renew the air/oil separator. Replace thedipstick.

9.1.6 Unscrew air/oil separator using a strapwrench and discard according to the localregulations.

9.1.7 Clean separator mounting and install thereplacement in accordance with themanufacturer's instructions.

9.1.8 Check for leaks.

9.2 Cleaning the radiator and oil cooler

Caution:Cleaning these items is a specialisedfunction and should be entrusted toqualified contractors. The followinginstructions are a general guide only.

9.2.1 ExternalClean the radiator and cooler fins using acompressed air or water jet parallel to thefins. If using cleaning additives with the waterensure they are compatible with aluminium.

9.2.2. InternalDue to the nature of the materials necessaryto clean the tanks and tubes successfully,CompAir UK recommend internal cleaning beentrusted to qualified contractors.

Fig. 11 Air/oil separator assembly

1. Air/oil separator2. Pressure vessel

PU 6798

1

2

9 Detailed servicing

DC036AA34

9.3. Servicing the air filters (Fig. 12)

9.3.1 Engine

a) Air filter elements need only be checkedwhen the red field in the service indicatorremains locked in view with plant stopped.

b) The filter contains a large main element and asmaller safety element. The safety elementshould not be cleaned, but should berenewed after 3 service cycles of the mainelement. The main element should berenewed after 6 cleanings or after 1 year.

c) Check that replacement elements are in goodcondition and free from storage or transitdamage. Do not fit an imperfect element; thiscould result in costly engine damage.

d) To clean the elements:-

Caution:Do not wash or brush out main filterelement. The only approved method ofcleaning is as follows:

i) Release the securing clips and removedust box. Withdraw main element.

ii) Empty any dust collected in the box and wipeclean. Ensure the rubber dust valve iscorrectly fitted and in good working order;replace it if worn or damaged.

iii) Service element by directing a jet of drycompressed air through pleats from inside tooutside. Rotate element while moving jetslowly up and down inside.

Caution:Air pressure must not exceed 5 bar (70 lbf/in2) or damage will result. Aftercleaning, inspect condition of elementrubber seals and check paper pleats fordamage by placing a bright light inside.Thin spots, pin holes or the slightestbreak will make the element unfit forfurther use.

iv) Wipe out the inside of the filter casing andcheck for cracks or other damage.

v) Re-assemble the element and replace dustbox. Secure the clips.

vi) Reset the service indicator.

9.3.2 Compressor

Note:The compressor air filter element must bechanged annually, or every 250 runninghours, whichever is soonest. Thecompressor air filter element is adisposable item. Do not attempt to cleanor reuse.

To change the air filter element:

a) Unscrew the air filter cover and remove the old element.

b) Wipe out the inside of the casing and check for cracks or other damage.

c) Insert the new air filter element and replace the air filter cover.

Fig. 12 Typical engine air filter

DC036AA 35

10.1 Introduction

WarningThe user forfeits all rights to claim if partsother than those of the manufacturer areused.

10.1.1 We reserve the right to modify design andperformance without prior notice. Pleasequote axle number, model and article numberwhen contacting us with queries or orderingspare parts.

10.2 Safety

10.2.1 It is most important that the wheel and thehub are compatible dimensionally. Thismeans that the P.C.D., wheel bolts and insetmust all be compatible both with the hub andthe rim. Particular attention must be paid tothe recommended torque figures for thewheel bolts.

10.2.2 No welding is permitted on the axle.

10.2.3 Please note the swing arm movement. (Seeassembly instructions).

10.2.4 The wheel brakes are matched to the overrundevices. Before using an overrun fromanother manufacturer, please check thecompatibility with our Technical Department.

CautionModel details must not be obscured bypaint now concealed by components.

10.3 KHV7.5 height-adjustable towing system, model B 2.5.7

10.3.1 The adjustable joint between the drawbar andintermediate arm, and between the overrunsystem and intermediate arm, consists oftoothed heads or retainers with Hirth-type orradial serrations.

10.3.2 The radial serrations are secured withfastening screws. The fastening nut must betightened to the specified torque in order toestablish a no-play, torque transmittingconnection. The tightening torque depends onthe permitted gross weight of the trailer andthe length of intermediate (swivelling) arm.

10.3.3 Adjusting procedure

a) After the spring-loaded plugs have beenreleased from the fastening nuts, the nuts canbe loosened until the teeth are exposed. Theangle of the intermediate arm can then beadjusted.

WarningCare must be taken without fail to ensurethat the overrun or towing system isalways aligned parallel with the drawbar.

The vehicle must not be driven unless theoverrun system is parallel with thedrawbar

b) After the coupling has been adjusted forheight, the serrations should be lockedtogether with the clamping nuts and securedagainst working loose by means of the spring-loaded plugs.

c) The radial serrations of the intermediary pieceand the drawbar are joined by union bolts,tightened to a torque of 250Nm

d) The radial serrations of the intermediary pieceand the run-up assembly are joined by unionbolts, tightened to a torque of 100Nm

10 Undercarriage

DC036AA36

10.4 Braking system - Introduction

10.4.1 KNOTT over-run brake systems consist ofover-run hitches and wheel brakes used incombination with KNOTT torsional thrustspring axles. They are approved in allcountries of the EC and in Switzerland.

10.4.2 With the KNOTT autoreverse system there isno problem changing the direction of travelfrom forward to reverse. The braking systemis ready for immediate operation again whenchanging from reverse to forward travel.

10.4.3 KNOTT torsional thrust spring axles as wellas rubber spring axles have superb springingand excellent dampening characteristics. Withthe torsional thrust spring axles the springelements with their vulcanized rubber arepretensioned before being pressed into theaxle tubes. There is no squashing of therubber during spring action. Instead therubber is stretched in accordance with itscharacteristics. With the rubber spring axlesthe axle tube bears the axle by pretensionedrubber strings. The results of the stretchingare exceptionally long life and zeromaintenance.

Caution

i) Use the jack only under the fixing brackets or at the chassis, never in thecentre.

ii) Towing eye and ball coupling may only bechanged by specialists.

iii) Use a new safety nut every time one of these items is changed.

iv) Use specified torque setting:

Ball couplingM12 8.8: T = 87 Nm

Towing eyesM12 8.8 T = 87 Nm

v) When using the ball coupling, pleasefollow the instructions given.

10.5 Over-run hitches

10.5.1 KNOTT over-run hitches are available forboth hydraulic and mechanical brakes.Handbrake lever with power reservoir, code“KH”

10.5.2 With the type “KH” the spring reservoir isunder torsion at the centre point. If thehandbrake is applied, then it worksautomatically and requires almost no force.

10.5.3 The system is designed so that when thehandbrake is applied, sufficient energy isstored within the spring. When transmittedthrough the brake rods this prevents thebrake shoes from slipping away from thebrake drum.

10.6 Braking System Adjustment -Preparations (Fig. 13)

10.6.1 Jack up the trailer

10.6.2 Release the handbrake

10.6.3 Pull out the drawbar [5] of the overrun system as far as it will go

Fig. 13 KNOTT overrun brake

1 Contact-breaking cable2 Trailer coupling ring (varies by type)3 Handbrake lever4 Transmission lever5 Drawbar and bellows

15 Security bolt16 Warning plate

WarningWhen any disconnection of the brakingsystem takes place, secure handbrakelever by reinserting the security bolt [15](see warning plate [16]).

DC036AA 37

10.7 Braking System Adjustment -Preliminary requirements (Figs. 13 & 15)

10.7.1 When carrying out adjustments, always startwith the wheel brakes.

10.7.2 When carrying out adjustments, turn thewheel only in the direction of forward travel.

10.73.3 Insert the security bolt [15] (see warningplate [16]).

10.7.4 Do not pre-tension the expanding lockingmechanism in the brake. If necessary, loosenthe brake linkage [6] at the brakecompensator (See Fig. 15).

10.7.5 Check the expanding locking mechanism andcontrol cable [11] for ease of movement.

Notes

i) The compression spring [7] may only belightly pre-tensioned and must not becomefully compressed when activated.

ii) Bowden cable [14] must not activate brake.

iii) Never readjust the braking system or brakesby the brake linkage [6] or turnbuckles (iffitted) in the linkage.

10.8 Adjusting the brake shoes (Figs. 14 & 15)

Fig. 14 KNOTT wheel brake

12 Adjusting screw13 Cable entry

10.8.1 Tighten the adjusting screw [12] (on theoutside of the brake plate, opposite the cableentry [13]), turning clockwise until the wheelcan only be turned with difficulty or not at all.

10.8.2 Wrench size for adjusting screws [12] - SW17

10.8.3 Ease off the adjusting screw [12] in theanticlockwise direction (approx. 1/2 turn) untilthe wheel turns freely. Slight rubbing noises,which do not affect the free turning of thewheel, are permitted.

10.8.4 When the brake is correctly adjusted, theactuating travel of the control cable [11] willbe 5-8 mm.

10.8.5 Carry out the adjustment procedure, asdescribed, on all the wheel brakes insuccession.

38

10.9 Adjusting the brake compensating system (Figs. 15 & 16)

Fig. 15 KNOTT transmission system forsingle-axle chassis.

6 Brake linkage7 Compression spring8 -9 -10 Compensating balance (single axle)11 Control cable

Fig. 16 KNOTT transmission system forsingle-axle chassis.

14 Bowden cable for handbrake15 Security bolt16 Warning plate

10.9.1 Insert the security bolt [15] (see warning plate[16] )

10.9.2 Remove the bowden cable [14].

10.9.3 Preadjust the length of the brake linkage [6](slight play permitted).

10.9.4 Insert the bowden cable [14].

10.9.5 Remove the security bolt [15].

10.9.6 Operate the handbrake lever [3] and checkthe position of the compensating balance[10]. It should be at right angles to thedirection of towing.

10.9.7 If necessary, adjust the position of thebalance [10] and control cables [11] on thelinkage [6].

10.9.8 The compression spring [7] may only belightly pre-tensioned and must not becomefully compressed when activated

10.10 Adjusting the brake linkage [6](Figs. 13, 15 & 16)

10.10.1 Firstly, adjust the brake linkage [6] so that it isfree of play longitudinally, without initialtension (reversing lever [4] free of play).

10.10.2 Readjustment

a) Operate the handbrake lever [3] vigourouslyseveral times in order to settle the brakingsystem.

b) Check the position of the brake compensatingbalance [10] which should be at right anglesto the direction of towing.

c) Check the play in the linkage [6]; if necessary,adjust the linkage [6] again so that it is free ofplay, but without initial tension. Slight play inthe bowden cable [14] must persist.

d) Check the position of the handbrake lever [3];when checking the dead centre of the lever,resistance starts 10-15 mm above deadcentre.

e) Check that the wheels rotate freely with thebrake released.

DC036AA

39

10.10.3 Final check

a) Check fastenings for security (secure thehexagon locking nuts of the screw fasteningsfor the transmission system, control cables,brake compensators, turnbuckle, linkage,etc.).

b) Check the bowden cable for slight play [14]; ifneccessary, adjust the cable.

c) Check the compression spring [7] for initialtension.

10.10.4 Test run

a) If necessary, carry out 2-3 brake tests

10.10.5 Brake test

a) Recheck the play in the brake linkage [6] and,if necessary, readjust the linkage [6] for lengthfree of play ( during operating braking withempty trailer should be used maximally 1/2 ofthe overrun travel )

10.11 Readjusting the braking system.

10.11.1 In general, readjusting the brake shoescorrectly serves to readjust the brakingsystem, i.e. to compensate for brake liningwear.

10.11.2 To readjust the brake shoes, proceed asdescribed in para 10.8 ‘Adjusting the brakeshoes’.

10.11.3 Check the play in the linkage [6] and readjustif necessary.

Caution

i Check the expanding locking mechanismand control cable [11]

ii The expanding lock compensator must notbe pre-tensioned in the brake.

iii Do not attempt to compensate for ease ofmovement caused by brake lining wear byreadjusting (shortening) the brake linkage[6], e.g. by way of the linkage screwfastenings.

10.11.2 Readjustment

a) Operate the handbrake lever [3] vigourouslyseveral times in order to settle the brakingsystem

b) Check the position of the brake compensatingbalance [10] (which should be at right anglesto the direction of towing).

c) Recheck the play in the linkage [6]; ifnecessary, adjust the linkage [6] again so thatit is free of play, but without initial tension.

d) Check the positions of the handbrake lever [3], the play in the bowden cable andcompression spring [7] (only light initialtension).

e) When checking the dead centre of the lever,resistance starts 10-15 mm above deadcentre.

10.11.3 Final check

a) Check the screw fastenings for thetransmission system (control cables, brakecompensators, linkage, etc.).

b) During operating braking with empty trailershould be used maximally 1/2 of the overruntravel

c) Check the bowden cable for slight play [14]; ifneccessary, adjust the cable.

d) Check the tension of the compression spring[7]

DC036AA

40

10.12 Maintenance and care KNOTT - overrun systems

10.12.1 The overrun system must be lubricated withlithium-soap grease by way of the greasenipples and at all the moving parts.a) every 5000 km (3000 miles)b) or every 6 monthsc) or if they become stiff

10.12.2 Inspect the bellows for damage, replace ifnecessary

10.12.3 Replace the overrun shock absorber every20,000 km (12,500 miles) or every 3 years atthe latest.

10.12.4 Check the play at the coupling point every20,000 km (12,500 miles). If the play exceeds3 mm, replace the guide bearing or drawbar.

10.12.5 Check the tightening torques of the fasteningscrews at the guide bearing every 5000 km(3000 miles);

Screws with grease nipple 50-55 Nm Screws without grease nipple 80-85 Nm

10.12.6 Check the tightening torques at the clampingblock of the drawbar and clamping socket(drawbar tube - axle joint) every 5000 km(3000 miles);

M12 screws 80-85 NmM14 screws 90-100 Nm

10.12.7 Check that the braking system is correctlyadjusted every 5000 km (3000 miles).

10.12.8 Vertically adjustable drawbarsClean the faces of the tooth systems free offretting rust or other contamination at leastonce a year in order to maintain a good fit.Lubricate the threaded bolts and joints once ayear or at any time if they become stiff.

CautionDo not grease the tooth system

10.12.9 If desired, a lifting and adjusting system canbe installed between the drawbar and theoverrun system. The control arms of theadjusting system permit swivelling about anangle of -10º to +49º in six positions. In everycase, the overrun system or drawgear alwaysremains horizontal.

10.12.10 An integral gas-filled strut automaticallygenerates lifting force which reduces theforce required by the user. If the strutbecomes damaged or develops a leak, itmust be replaced.

10.12.11 Information regarding dual-row angular ballbearings:

a) These bearings are maintenance-free, havebeen provided with a lifetime lubrication. andhave an extremely high running performance.

b) The bearings have been fixed in their correctposition using a safety flanged nut. Thisflanged nut must be tightened with a torque of280 +/- 10 Nm.

c) It is recommended to check this tighteningtorque in the course of service works.

d) The flanged nut can only be unscrewed andre-used once. Afterwards. a new nut must beused. When releasing or tightening theflanged nut, grease the threads slightly, so asto avoid damage to the fine thread.

e) Due to the high durability and themaintenance-free design of these dualrowangular ball bearings, there will be nodamage at the bearings under normalconditions.

f) If, due to exceptional circumstances,problems were to occur with these bearings,completely new brake drums with pressed-inbearings, circlips and new locking nuts shouldbe installed in principle.

g) Due to the design characteristics of thebearings, the brake drums and the wheelsmay have a slight axial and tilting play;however, this is insignificant.

DC036AA

41DC036AA

Fault

Insufficient braking effect

Brakes snatch when braking

Trailer is braked unevenly

Trailer is already braked when theaccelerator pedal is released.

Reverse driving hard to accomplish, oreven impossible.

Braking action of hand brake insufficient

Wheel brakes get hot

Cause

a) Excessive backlash in brake system

b) Brake linings not ‘run in’

c) Brake linings glazed, oily or damaged

d) Overrunning hitch hard to operate

e) Brake linkage is jammed or deformed

f) Brake Bowden cables rusty or kinked

a) Excessive backlash in brake system

b) Shock absorber of overrunning hitchdefective.

c) Auto-reverse brake shoe is jammed inthe brake shoe holder.

a) Wheel brakes operate unevenly

b) Causes: possibility specified under“Insufficient braking effect”.

a) Shock absorber of overrunning hitchdefective.

a) Brake system adjusted too tightly

b) Bowden cables pre-loaded

c) Auto-reverse brake shoe is jammed inthe brake shoe holder.

a) Incorrect setting

b) Causes: possibly specified under“Insufficient braking effect”

c) Auto-Reverse brake shoe is jammedin the brake shoe holder

a) Brake system incorrectly set

b) Causes: possibly specified under“Insufficient braking effect”

c) Auto-Reverse brake shoe is jammedin the brake shoe holder

d) Wheel brakes dirty

e) Reversing lever of overrunning hitch isjammed

f) Handbrake lever not or only partiallyreleased.

Remedy

a) Re-adjust brake system

b) Actuate hand brake lever slightly;driive 2-3 kilometers

c) Replace brake shoes completely;clean braking areas in the brakedrums

d) Grease overrunning hitch

e) Eliminate cause

f) Replace Bowden cables

a) Re-adjust brake system

b) Replace shock absorber

c) Replace compl, brake shoe with brakeshoe holders

a) Re-adjust brake system

b) see above

a) Replace shock absorber

a) Re-adjust brake system

b) Re-adjust brake system

c) Replace compl, brake shoe with brakeshoe holders

a) Re-adjust brake system then actuatehand-brake lever as far as possible

b) see above

c) Replace compl, brake shoe with brakeshoe holders

a) Readjust brake system

b) See above

c) Replace complete brake shoes andbrake shoe holders

d) Clean

e) Remove reversing lever, clean it andgrease it with Molykote

f) Fully release handbrake

11 Undercarriage Fault Finding

42 DC036AA

Fault

Ball coupling does not rest on ball

Cause

a) Coupling dirty on the inside

b) Ball of towing vehicle too big

Remedy

a) Clean and grease thoroughly

b) Check ball diameter:According to DIN 74058, the ball onthe car must not exceed 50mm indiameter when new. If the balldiameter decreases to less than49.5mm, the ball has to be replaced.The ball must be perfectly spherical.

Warning

i) Work on the brake system may only be carriedout in specialised workshops.

ii) When replacing brake shoes, make sure that allbrake shoes of the axle are replaced.

iii) When working on the wheel brakes, make surethat the springs, the brake shoes and thespreading lever are correctly installed; observethe correct direction of rotation.

iv) When adjusting the wheel brakes, turn wheelsin forward direction.

v) After completing any work on the brakingsystem, the system should be readjusted asdetailed in Sections 10.8 to 10.11