Original operating and service manual

DLT2702 HP
C230TS-17, C210TS-21, C200TS-24
Gardner Denver GD-M1
Powered Compressor

●
GB Id. no. ZS1109282 / 01 - September 2014
 CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
and other reproductive harm.
Maintenance and Inspection
Manual for CompAir Compressors

This Maintenance and Inspection

Manual is intended only as a supplement
to the operating instructions and parts list
for your CompAir compressor.
It does not replace these technical
documents.
This Maintenance and Inspection
Manual is intended for you, the machine
attendant. It is provided to facilitate the
required maintenance and inspection work
and allow this work to be reviewed at any
time. When this Maintenance and
Inspection Manual is kept carefully it can
contribute to reduction of the maintenance
costs and increasing the operating
reliability and service life of your
compressor.

Attention
When starting up your compressor for
the first time, observe the operating
instructions under all circumstances.
Proper operation, care and continuous
supervision of the compressor system are
decisive for the operating reliability,
performance and service life.
We cannot assume any liability for
damage resulting from failure to observe
the operating instructions, improper
repairs or use of other than genuine parts.

Questions/Parts orders
Always indicate:
- Machine number (rating plate)
- Machine model.

We request you to present this

Maintenance and Inspection Manual to our
service personnel on request.
Thank you.

Danger

Please observe the maintenance

instructions (service intervals and
points) given in the operating
instructions.
Perform inspection, maintenance and
repair work only when the machine is
standing still, not under voltage and
not under pressure.
Operation of the system without
protective equipment (e.g. fan safety
grills) is not permitted.
Service Contact Partner, name: ______________________________________________________ ☎ _________________________________

Plant Maintenance Personnel, Name: _________________________________________________ ☎ _________________________________

Number of associated Parts List: __________________________________________________________________________________________

Machine model:________________________________________________________________________________________________________

Machine serial number: _________________________________________________________________________________________________

Year of production: _____________________________________________________________________________________________________

Data acc. to compressor rating plate: ______________________________________________________________________________________

_____________________________________________________________________________________________________________________

_____________________________________________________________________________________________________________________

_____________________________________________________________________________________________________________________

Operating pressure (≤ max. operating pressure): _____________________________________________________________________________

Remarks:

_____________________________________________________________________________________________________________________

_____________________________________________________________________________________________________________________

_____________________________________________________________________________________________________________________
 Total operating hours
Time required for service work

Date Maintenance – Inspection – Repair

Hours
Start

End
Oil change (date/hours)

Type of oil Cause of malfunction – Remarks

Temperature (°C) compressor

(outlet-pressure fitting oil inlet)

Mechanic's signature
Original operating and service manual

DLT2702 HP
C230TS-17, C210TS-21, C200TS-24
Gardner Denver GD-M1
Powered Compressor
 1. Index
1 Index

1 Index................................................................................................................................................................................................... 2
2 Foreword............................................................................................................................................................................................ 4
2.1 Information on the compressor ................................................................................................................................................... 4
2.2 Normal use ................................................................................................................................................................................. 4
2.3 Specifications ............................................................................................................................................................................. 5
2.4 Declaration of conformity ............................................................................................................................................................ 7
2.5 Maintenance and care ................................................................................................................................................................ 8
2.6 General information .................................................................................................................................................................... 8
3 Security Regulations......................................................................................................................................................................... 9
3.1 Identification of safety instructions .............................................................................................................................................. 9
3.2 General safety regulations .......................................................................................................................................................... 9
3.3 Particular dangers associated with compressed air .................................................................................................................. 10
3.4 Particular dangers associated with machines with combustion engines ................................................................................... 11
3.5 Dangers present when loading/moving machines..................................................................................................................... 12
3.6 Particular dangers associated with mobile machines................................................................................................................ 12
3.7 General workplace dangers ...................................................................................................................................................... 13
3.8 Dangers resulting from neglecting to perform maintenance...................................................................................................... 13
3.9 Dangers during maintenance and repairs ................................................................................................................................. 14
3.10 Dangers resulting from conversion work/modifications on the machine .................................................................................... 14
3.11 Symbols and definitions............................................................................................................................................................ 15
4 Construction and functional description....................................................................................................................................... 17
4.1 Construction ............................................................................................................................................................................. 17
4.2 Functional description............................................................................................................................................................... 18
4.3 SCRT® (exhaust after-treatment system) system description .................................................................................................. 19
4.4 System description ................................................................................................................................................................... 21
4.5 Wiring diagram ......................................................................................................................................................................... 22
4.6 Exhaust after-treatment system circuit diagram ........................................................................................................................ 23
4.7 Terminal Diagram DIN EN ISO 11446 ...................................................................................................................................... 26
5 Transport and installation on site .................................................................................................................................................. 27
5.1 Transport .................................................................................................................................................................................. 27
5.2 Attachment of the contact-breaker cable on braked chassis..................................................................................................... 27
5.3 Loading/Relocation................................................................................................................................................................... 28
5.4 Installation on site..................................................................................................................................................................... 28
6 Preparing the compressor for operation....................................................................................................................................... 30
6.1 Checking oil levels.................................................................................................................................................................... 30
6.1.1 Checking the oil level in the pressure tank.................................................................................................................... 30
6.1.2 Checking the oil level in the engine............................................................................................................................... 30
6.2 Battery...................................................................................................................................................................................... 30
6.3 Filling up the fuel tank............................................................................................................................................................... 31
6.3.1 Fill with diesel ............................................................................................................................................................... 31
6.3.2 Fill with AdBlue® .......................................................................................................................................................... 31
7 Putting the compressor into operation ......................................................................................................................................... 32
7.1 Initial operation ......................................................................................................................................................................... 32
7.2 Operating elements .................................................................................................................................................................. 32
7.3 Start-up..................................................................................................................................................................................... 32
7.4 Setting the operating pressure.................................................................................................................................................. 33
7.5 Monitoring / fault ....................................................................................................................................................................... 33
7.6 Operation.................................................................................................................................................................................. 33
7.7 Shutdown ................................................................................................................................................................................. 34
7.8 Decommissioning ..................................................................................................................................................................... 34
8 Fuels................................................................................................................................................................................................. 35
8.1 Recommended lubricant for compressor .................................................................................................................................. 35
8.2 Recommended engine oil ......................................................................................................................................................... 35
8.3 Diesel fuel................................................................................................................................................................................. 35
8.4 AdBlue® ................................................................................................................................................................................... 35
8.5 Coolant ..................................................................................................................................................................................... 35
8.6 Recommended lubricants for the bogies................................................................................................................................... 35

2
 1. Index

9 Maintenance .................................................................................................................................................................................... 36
9.1 General maintenance ............................................................................................................................................................... 36
9.2 Engine maintenance ................................................................................................................................................................. 36
9.3 Daily maintenance .................................................................................................................................................................... 36
9.4 Maintenance of chassis and brakes.......................................................................................................................................... 36
9.5 Maintenance and inspection schedule ...................................................................................................................................... 37
9.5.1 Oil filter replacement (compressor) ............................................................................................................................... 39
9.5.2 Oil change (compressor) .............................................................................................................................................. 39
9.5.3 Inspecting / Replacing the fine separator ...................................................................................................................... 39
9.5.4 Air filter replacement (compressor / engine) ................................................................................................................. 40
9.5.5 Checking the safety valve ............................................................................................................................................. 40
9.5.6 Control .......................................................................................................................................................................... 41
9.5.7 Battery maintenance..................................................................................................................................................... 41
9.5.8 SCRT® unit maintenance ............................................................................................................................................. 41
9.5.9 Torque specifications .................................................................................................................................................... 41
9.6 Spare parts for maintenance purposes ..................................................................................................................................... 42
9.7 Inspection intervals for pressure vessels and electrical installations......................................................................................... 42
10 Troubleshooting .............................................................................................................................................................................. 43
10.1 General fault rectification information........................................................................................................................................ 43
10.2 Warning lights........................................................................................................................................................................... 43
10.3 Fault elimination ....................................................................................................................................................................... 43
10.4 Faults, causes and remedy....................................................................................................................................................... 44
10.5 Troubleshooting........................................................................................................................................................................ 45
11 Electronic system ........................................................................................................................................................................... 51
11.1 Overview .................................................................................................................................................................................. 51
11.2 Operation.................................................................................................................................................................................. 51
11.3 Menu navigation ....................................................................................................................................................................... 51
12 Undercarriage .................................................................................................................................................................................. 52
12.1 Introduction............................................................................................................................................................................... 52
12.2 Safety ....................................................................................................................................................................................... 52
12.3 Height-adjustable towing system .............................................................................................................................................. 52
12.4 Braking system ......................................................................................................................................................................... 53
12.5 Adjusting the braking system.................................................................................................................................................... 53
12.5.1 Preparations ................................................................................................................................................................. 53
12.5.2 Preliminary requirements: ............................................................................................................................................. 54
12.5.3 Adjusting the brake ....................................................................................................................................................... 54
12.5.4 Adjusting the brake compensating system................................................................................................................... 54
12.5.5 Adjusting the brake linkage [6] ...................................................................................................................................... 54
12.6 Readjusting the braking system................................................................................................................................................ 55
12.7 Maintenance and care .............................................................................................................................................................. 55
12.8 Malfunctions and remedies ....................................................................................................................................................... 56

3
 2. Foreword
2 For ewor d

2.1 Information on the The compressor is designed for providing

compressor
CompAir screw compressors are the
product of many years' research and
development. These preconditions,
together with high quality standards,
guarantee the manufacture of screw
compressors with a long service life, a
high degree of reliability and cost-effective
operation. The strict environmental
protection standards have of course been
complied with.
compressed air:
* For operating compressed-air
appliances
* For conveying bulk material
* For the supply of floor pavement
* For sandblasting and paint-spraying
operations
* For cleaning machines and shuttering
material - do not direct towards
persons!
* For blow-cleaning drilled holes.

2.2 Normal use Any other use, or any additional use,

for example as respiratory air, is regarded
The compressors have been built using as not being for the originally intended
the latest techniques in design and in purpose. The manufacturer / supplier
accordance with recognized safety accepts no liability for any resulting
regulations. damage. The risk is assumed by the user
alone.
Nevertheless, the operator or third
parties may be exposed to risk to life and The compressor may only be used in
limb in the course of the use of the a technically perfect condition, for its
compressor (e.g. through flying pieces of intended purpose, with appropriate
building material, swirling particles of dirt awareness of safety regulations and
or dust, electrical current, thermal hazards, subject to compliance with the
vibrations, noise or mechanical hazards), operating manual. In particular, faults
and the machine or other tangible assets representing safety hazards are to be
may be impaired, for reasons that could corrected at once.
not have been avoided through preventive
constructional safety measures.
Hazards occur particularly when:
* The compressor is not used for its
intended purpose
* The compressor is not operated by
trained personnel
* Unauthorized changes or modifications
are carried out on the compressor
* You are not wearing the prescribed
protective clothing
* You do not comply with the safety
instructions
* You do not observe the information in
the operating manual
For this reason every person involved in
the operation, maintenance and repair of
the compressor must read and observe
the operation manual and the safety
regulations. This is to be confirmed by
signature as required.
Furthermore, the following naturally apply:
* The relevant accident prevention
regulations
* Generally recognized safety and traffic
regulations
* Particular national regulations

4
 *
Trade name Trade name

C 230TS-17
C 210TS-21
C 200TS-24

axle load
2. Foreword

3
Delivery volume

[kg]
Gross vehicle weight rating*

3500
3500
3500
C 200TS-24 20.00
[m /min]
2.3 Specifications

Operating weight Operating pressure

[barg]

24.0

[kg]

3490
3490
3490
standard model

Pressure range

[barg]

C 230TS-17 23.00 17.00 13-17

C 210TS-21 21.00 21.00 13-21
13-24
Length, max.

[mm]

5500
5500
5500
[°C]

-10
-10
-10
min.

Overall width

[mm]

1960
1960
1960
Ambient

[°C]

+50
+50
+50
max.
temperature

Height

[mm]

2568
2568
2568
max. installation height
3000
3000
3000
[m above
sea level]

Rim
[l]

55
55
55

Oil fill (compressor)

5,5 J x 14
5,5 J x 14
5,5 J x 14
Gardner
Denver Engine
GD-M1
Tyres
water Type of cooling

205 R 14 C
205 R 14 C
205 R 14 C
Engine rating
[kw]

228
228
228

[barg] Tyre pressure

3,75
3,75
3,75
[rpm]
min.

1000
1000
1000
speed
Engine

[rpm]

Compressed air
2400
2400
2400
max.

1 x 2”
connections
Volume of cooling water
[l]

60
60
60

filled into engine

max. permissible noise
100
100
100

level, acc. to 2000/14/EC

[dB/1pW]

Filling volume of
[l]

17
17
17

max. sound intensity acc. to engine oil

81
81
81

PN8NTC 2.2 at the operators

[dB(A)]
[l]

location,distance 1m Fuel tank capacity

350
350
350

max. sound intensity acc. to AdBlue®

72
72
72
[l]

38
38
38

[dB(A)]

PN8NTC 2.2, distance 7m tank content

5
 2. Foreword

Fig. 1

6
2. Foreword

2.4 Declaration of conformity

1. Declaration of conformity
in accordance with the EC Machinery Directive 2006/42/EC, Supplement II A

2. We, hereby declare Gardner Denver Deutschland GmbH

Argenthaler Str.11
D-55469 Simmern

that the product: Kompressor

type: DLT0206 ; DLT0408 ; DLT0704 ; DLT1303 ; DLT2701 ; DLT2702

trade mark: C20 ; C25 ; C25-10; C30 ; C35-10 ; C38 ; C42 ; C50 ; C55-14 ; C60-12 ; C65-10 ; C65HS ; C76 ;
C85-14 ; C95-12 ; C105-14 ; C110-9 ; C115-12 ; C125-7 ; C140-9 ; C200TS-14 ; C210TS-12 ;
C220TS-10 ; C230TS-9 ; C240TS-14 ; C250TS-12 ; C260TS-10 ; C270TS-9 ; C200TS-24 ;
C210TS-21 ; C203TS-17

manufacturer no.:

in the form as shipped by us complies with the following relevant provisions:

2006/ 42/ EG 2009/ 105/ EG 2004/ 108/ EG

2007/ 46/ EG 2006/ 95/ EG

This machine is exempt from 97/23/EC the Pressure Equipment Directive, reference Article 1
clauses 3.3 and 3.6

3. If the machine is modified in a way not agreed upon with us, this statement will be void.

4. Harmonized standards applied, particularly

EN 1012-1 EN ISO 12100 EN 61000-6-2

EN 29001 EN 60034-1 EN 60204-1 EN 61000-6-4

5. National engineering standards and specifications applied

AD-S1/2000 VDE 0100 DIN 3230

BetrSichV

6. Recording agency: CompAir Drucklufttechnik -

Zweigniederlassung der
Gardner Denver Deutschland GmbH

Simmern,
Date Signature

7
 2. Foreword

2.5 Maintenance and care
Care and maintenance are all-important
if the screw compressor is to meet the
demands placed upon it. Compliance with
the prescribed maintenance intervals and
careful execution of care and maintenance
work are therefore essential, especially
under difficult working conditions.
Service
2.6 General information
This operating manual is to help you to
get to know the compressor and to use it
for its intended applications. It contains
important information about how to
operate the compressor safely, cost-
effectively and with due care. Compliance
with the instructions in this manual will
help to avoid danger, reduce repair costs
and downtime, and increase the reliability
and service life of the compressor.
This fact results in the termination/
expiration of the guarantee and warranty
claims against the manufacturer.
Safety regulations
Danger
It is important that you follow the
safety regulations in Chapter 3 of the
operating manual.

In case of faults, or should you require This operating manual is to be

spare parts for the screw compressor,
please contact your local CompAir agent.
In case of damage, the trained technical
staff will guarantee a fast, expert repair
using CompAir spare parts. Original
CompAir spare parts are manufactured
according to the state of the art and
guarantee continued reliable operation.
If you have important questions,
supplemented by instructions concerning Technical modifications
current national regulations for accident
prevention and environmental protection. We reserve the right to undertake
It must always be available at the site of modifications without notice in the
the compressor. The operating manual is interests of technical progress.
to be read and used by all persons in
charge of work with the compressor, for
example operation, including setting up,
correcting faults during operation, disposal
of waste products from production, care,
disposal of process materials, upkeep
(maintenance, inspection, repair) and
transport.
Besides the operating instructions and
the current regulations applicable in the
user's country and at the sites of operation
concerning accident prevention, the
recognized technical rules for safe and
proper working are also to be complied
with.

Fig. 2
Please enter the data from the identifi-
cation plate for your compressor, in the
spaces above. In case of questions or
orders for spare parts, please give us the
compressor type, compressor number
and the year of construction as given on
the identification plate.
Warranty
Only use this compressor with accurate
knowledge of and in compliance with this
manual.
Gardner Denver do not accept
responsibility for safe functioning of the
compressor for actions that do not
correspond to normal use or for purposes
not mentioned in the manual.
Warranty claims cannot be entertained for:
* Operating errors
* Inadequate maintenance
* Incorrect fuels
* Damage caused by non-use of original
CompAir parts
* Modification of the system.

If you give us this data you can be sure
that you will be given the correct
information or sent the spare parts you
require.
The Guarantee and Liability terms of
Gardner Denver's General Terms and
Conditions are not extended through the
above instructions.
Any unauthorized modification of the
compressor system/station or the
installation of components (e.g. fine
separators) not released by the
manufacturer result in the loss of the
CE symbol.

8
 3. Security Regulations
3 Security Re gulati ons

3.1 Identification of safety If any of the regulations contained in Danger

instructions
Gardner Denver accepts no
responsibility for any damage or injury
caused by non-compliance with these
safety measures or non-observance of
normal care and caution during the
handling, operation, maintenance or repair
of this compressor, even if not expressly
stated in this operating manual.
this manual do not correspond to local
statutory provisions, particularly with
reference to safety, then the stricter of
the two applies.
These safety instructions are of a
general nature and are applicable to
various types of machine and equipment.
For this reason it is possible that some
information may not apply to the
aggregate(s) described in this manual.
Places thus marked refer to possible
dangers for persons.
Attention
Places thus marked refer to possible
dangers for machines or parts of
machines.
Note
Places thus marked give general and
technical information for optimum, cost-
effective machine use.

3.2 General safety regulations

Danger Safety measure required

Working with compressors involves
dangers that are not immediately
apparent.
Everyone working with the machine must have first read and understood the operating
manual. Donʼt leave this until you start work – itʼs too late.
Please keep this operating manual handy at all times on the site of the machine /
installation, in the bag provided.

Pay attention to all safety and danger warnings on the machine/ installation!

Deploy trained staff only. The responsibility of the personnel for operating, setting up and
maintaining the machine / installation must be clearly defined.

Make sure that only authorized personnel use the machine.

Define who is responsible for operating the machine, and authorize him to ignore
instructions from third parties if these instructions could compromise safety.

Symbols on the machine indicating Ensure that all safety and danger notices on the machine/system stay fully legible.
dangers may become dirty.

Faults and modifications to the machine In case of malfunction, shut down and secure the machine / installation immediately. Have
may jeopardise safety. malfunctions corrected immediately.

Check the machine / installation for external damage and faults at least once per shift.

Any changes noticed (including changes in operating performance) must be reported

immediately to the authority or person in charge. If necessary, shut down and secure the
machine immediately.

9
 3. Security Regulations

3.3 Particular dangers associated with compressed air

Danger Safety measure required

Compressed air is very powerful. It can be Never play about with compressed air.
used for example to break open concrete
but can also put lives at risk.

Small parts propelled at high speed by When using compressed air to clean equipment, work with extreme caution and always
compressed air can penetrate the skin or wear suitable eye protection.
destroy an eye.
Never direct compressed air onto the skin or towards another person.

Never use compressed air for cleaning clothing.

Compressed air connections may split and All connected components must be of the correct size and be suitable for the specified
put people at risk. operating pressure and temperature.

A hose connected to an air valve must be fitted with a safety wire for operating pressures
above 7 bars; it is in fact recommended that this safety device should be used for
pressures above 4 bars. The steel wire has a diameter of 8 mm and is firmly clamped to
the hose at least every 500 mm. Both ends are fitted with cable lugs.

Only use the correct type and size of hose coupling and connection.

The compressed air line connected at the air exit of the unit must not be under strain.

No force may be exerted on the discharge valves, for example by pulling the hoses or
fitting additional equipment (e.g. a water separator, compressed air oiler, etc.) directly to
the discharge valve.

Compressed air lines get hot and expand. Make sure that the compressed air line from the compressor to the air network can expand
as a result of heat and cannot come into contact with inflammable materials.

Pipes and other parts with a surface temperature of more than 80 °C must be suitably
secured against contact and suitably marked.

Loose hose ends may flog and result in Before blowing through a hose or air line, it is essential to hold the open end firmly.
injury.
Before connecting or disconnecting hoses, always close the compressor air outlet valves.
Before disconnecting a hose, always make sure that it is not under pressure.

Compression results in high temperatures. The system should be set up such that hazardous mixtures (inflammable solvent vapours
Risk of explosion from drawn in materials. etc. but also dusts and other dangerous or toxic materials) cannot be drawn in. The same
applies to flying sparks.

Never use the machine in environments where the possibility cannot be ruled out that
inflammable or toxic vapours may be taken in.

The installation is to be set up in such a way that it is adequately accessible and that the
necessary cooling is ensured. Never block the admission of air.

There is strong suction at the air inlet. The air intake is to be designed in such a way that no loose clothing can be drawn in.

There is a risk of injury, e.g. from getting The personnel must not have long, loose hair, or wear loose clothing or jewellery, including
stuck or being drawn in. rings, due to risk of injury through catching. Personal protective equipment should be worn
if necessary.

Connected compressed air tools may start Before switching on the machine / installation, or starting it up, make sure that nobody can
up unexpectedly when switching on. be injured by the machine / installation as it starts up.

Compressed air may contain oil and other The compressed air produced by these compressors must not be used as breathable air,
substances that may damage your health unless it has been processed specially for such an application in accordance with the
if inhaled. “Safety requirements for breathable air.”

When breathing apparatus with cartridges is used, make sure that the correct cartridge has
been inserted and that its service life has not expired.

10
 3. Security Regulations
Danger
As a rule:
3.4 Particular dangers associated with machines with combustion engines
Danger
The exhaust emissions of combustion
engines contain carbon monoxide - a
lethal gas.
Fuel can easily ignite.
Filling up at a pump can cause static
electricity and possibly sparks.
In water-cooled combustion engines,
water vapour is produced in the cooling
circuit under high pressure.
Sparks from the exhaust may cause fires
and explosions in environments with fire
hazards.
Noise, even when it is not very loud, can
make us nervous and irritated, and after a
longer period of time our nervous system
can suffer serious damage.
Safety measure required
If several compressors are arranged in a system, manually operated valves have to be
installed so that each machine may be shut off individually. For the purpose of shutting off
pressurized systems, you should never rely on the effectiveness of return valves alone.
All pressure tanks located outside the unit with an approved operating pressure higher than
atmospheric pressure and fitted with two or more pressure feed lines must be equipped
with an additional safety device to automatically prevent the approved operating pressure
from being exceeded by more than 10%.
Never operate the system at temperatures and/or pressures below or above the values
indicated in the technical data sheet.
Safety measure required
If a machine with such an engine has to work in an enclosed room, the exhaust gases must
therefore be conducted out of doors by means of a hose or pipe with an internal diameter of
at least 150 mm. The use of extraction systems is highly recommended in test rooms for
mobile machines.
Make sure that fuel does not come into contact with hot machine parts.
Do not smoke while filling up with fuel.
Never fill up with fuel while the engine is running.
In order to avoid this, a ground cable must be connected to the system while it is being
filled up.
The cap of the coolant recovery bottle must not be removed before the system has cooled
down to ambient temperature.
The operation of the compressor in areas where there is a risk of explosion is strictly
forbidden! (Exception: specially-made compressors with the necessary technical
modifications for use in such areas)
If a machine with a combustion engine has to work in a fire-risk environment, the unit must
be fitted with a spark catcher.
Make sure that the engine exhaust system is operationally safe and that no inflammable
material is in the vicinity.
Persons must be protected against any risks caused by noise in accordance with EC
Guideline 2003/10/EG. Wearing ear muffs may impair communication between persons.
Warnings may not be heard. Inform supervisor.
Shielding and doors must be closed during operation so that the flow of cool air within the
housing is not deflected and the efficiency of the sound insulating is not reduced.
11
 3. Security Regulations

3.5 Dangers present when loading/moving machines

Danger Safety measure required

Loose parts may fall off when lifting. All loose parts must first be removed or secured; parts fitted so that they can turn like
doors etc. must be secured and made immobile.

Parts to be removed for transport purposes must be carefully refitted and fixed again
before putting the machine / installation back into operation.

The compressor may fall if mistakes are Only use lifting tackle approved for the weight in question.
made when lifting.
Observe the operating manual for the lifting tackle.

When heavy loads are being conveyed by means of hoisting gear, it is imperative to keep
well clear of the load in order to avoid accidents.

Raise the compressor by its lifting lug only, using a hook or shackle that satisfies local
safety regulations. Cables, chains or ropes must never be fitted directly to or through
lifting lugs.

The compressor may be damaged if lifted Machines may only be hoisted correctly using hoisting gear in accordance with the
incorrectly. information in the operating manual (lifting spots for heavy-lift facilities etc.)

Never relocate the machine if external lines or hoses are connected to the discharge
valves, in order to avoid damage to the valves and/or collecting pipe and hoses.

3.6 Particular dangers associated with mobile machines

Danger Safety measure required

As a rule: Observe all the relevant traffic regulations and before starting to move, ensure that the
machine is in a suitable condition with regard to traffic laws.

Pressurised parts may be overloaded Switch off the compressor at least 10 min. before travel and allow the pressure in the lines
during travel. to drop by opening a pressure cock.

Wheels may come loose during travel. Make sure that the wheel nuts are properly tightened; never exceed the specified torque.

Machine may tip over if positioned at too Install the machine so that it is as horizontal as possible; a slight inclination is permissible
great an angle. (see information in Chapter 5.4 "Installation on site").

Always keep a safe distance from the edges of foundation ditches and embankments.

Do not travel across slopes transversely.

Unsecured machines may roll away. Before disconnecting the machine from the towing vehicle, apply the handbrake.
Disconnect the rapid-emergency brake cable and lighting cable, disconnect the lines of
the air brakes, use chocks to ensure that the machine does not roll away.

Ensure that the compressor system is stable before starting work and do not permit any
work that impairs this!

12
 3. Security Regulations

3.7 General workplace dangers

Danger Safety measure required

This manual only describes how to work Please note and pass on general statutory and other binding regulations that may
safely with the compressor itself. But other supplement the operating manual for the prevention of accidents and the protection of the
dangers will arise during work. environment. Such obligations may be for example the handling of hazardous materials, or
the provision and/or wearing of personal protective equipment, or traffic regulations.

Instructions, including supervisory responsibility and duty of notification for taking account
of special in-plant factors, for example regarding work organization, sequences of
operations, personnel assigned to certain tasks, are to be added to the operating manual.

Before starting work, make yourself familiar with the working environment at the installation
site. The working environment includes, for example, obstacles in the working and
transport areas, the carrying capacity of the ground, and any necessary cordoning off of the
building site from public traffic areas.

The location and operation of fire extinguishers must be made known. Observe the
instructions concerning fire alarm and fire fighting.

Set up the machine in such a way that no inlets, outlets or gates are blocked.

Keep an adequate distance between the machine/unit and overhead power lines! When
working near overhead power lines, equipment must not come near the power lines!
Danger! Find out about the safe distance to be observed!

When handling oils, greases and other chemical substances, observe the safety
regulations applicable for the product.

Caution when handling process materials (risk of burning / scalding).

3.8 Dangers resulting from neglecting to perform maintenance

Danger Safety measure required

Components of importance to safety wear Observe the setting, maintenance, and inspection work and intervals stipulated in the
over time. operating manual, including information about the replacement of parts / partial sections.
This work may only be carried out by specialists.

Observe the intervals stipulated or those given in the operating manual for routine checks
and inspections.

Verify regularly that safety valves and other pressure-relief devices are in perfect condition
and are not blocked, for example by dirt or paint

Lines perish. Replace hydraulic hose lines at the stated or at reasonable intervals even if no defects of
relevance to safety are apparent! (DIN 20066, part 5)

Spurting oil can result in injuries and fire. Check all lines, hoses, and bolted connections regularly for leaks and visible damage.
Repair damage immediately and always arrange for damaged parts to be replaced!

Risk of electric shock. Have the electrical equipment on a machine/system checked regularly. Have defects like
loose connections or charred cables rectified immediately.

13
 3. Security Regulations
3.9 Dangers during maintenance and repairs
Danger
During maintenance and repairs, parts
that may be pressurised must be
removed. If you maintain the compressor
and have not been trained by CompAir,
you will put yourself and others at risk.
Incorrectly configured spare parts may
jeopardise safety, e.g. tear when loaded.
Risk of electric shock.
Risk of injury from pressurised or moving
parts.
Modifications to the machine impair safety. After completing repair work, always check to see whether any tools, loose parts or cloths
3.10 Dangers resulting from conversion work/modifications on the machine
Danger
Genuine parts are designed especially for
the machine. Modifications may interfere
with safety equipment or give rise to new
dangers for which protection is not
provided.
If protective equipment is not functioning, Only operate the machine when all protective devices, shutdown devices, sound-insulating
operating the system may put lives at risk. equipment and extraction equipment are in place and working.
14
Safety measure required
The compressor can only be maintained by specially trained technicians. Contact your
CompAir agent.
Only persons with special knowledge and experience of hydraulics may work on system
elements, for example components under pressure.
Spare parts must meet the technical requirements laid down by the manufacturer. This is
always guaranteed when original spare parts are used.
Work on the electrical systems of the machine / installation may only be carried out by a
trained electrician in accordance with electrical regulations.
Only carry out inspection, maintenance, and repair work when the screw compressor
system is at a standstill and is not under pressure. Make sure that the system cannot be
switched on by accident.
have been left in or on the machine, driving engine or driving equipment.
After the work has been completed, replace any protective devices that have been
removed. Operation without protective devices is not permissible.
Safety measure required
No alterations, additions, or modifications to the machine may be carried out without the
approval of the manufacturer. Unauthorized modifications to the machine are prohibited for
reasons of safety.
Original parts are specially designed for our machines. We must explicitly point out that
parts and special accessories not supplied by us are not approved by us. Installing or using
such products may thus adversely affect active and/or passive safety.
The manufacturer accepts no liability whatsoever for damage resulting from the use of non-
original parts or special accessories.
This also applies to the installation and adjustment of safety devices and valves as well as
to welding on bearing and pressurized parts.
Safety devices, protective covers, or insulations mounted on the system must not be
removed or modified in any way.
Note
The General Type Approval becomes invalid in case of modifications or alterations which
change or infringe upon the external geometry as well as the gross axle weight rating.
3. Security Regulations

3.11 Symbols and definitions

Carefully read the Operating Manual Check cooling water level, engine oil Tie down point
before machine set-up and level and compressor oil level before
maintenance. starting up.

Never attempt to operate the machine Attention: Hot surfaces Attention: Hot and dangerous exhaust
without the safety device mounted. fumes

Do not inhale any compressed air from Attention: Pressurized part or system. Do not step/stand on maintenance
the system. valve or other parts of the pressurized
system.

3,75 BAR

Lifting spot Attention: Maintain specified tyre

Never attempt to operate the machine
pressure! (See Chapter
with open or loose shielding.
Foreword, specifications.)

15
 3. Security Regulations

Condensate discharge (oil/water) Emergency stop device

System radiator/coolant recovery

Attention: Do not use an ether aerosol
reservoir may be under pressure.

Do not remove the Operating and

Maintenance manual and manual
holder from this machine.

Attention: Prior to starting any

maintenance work consult
the operating and
maintenance instructions

100
Attention: Max. permissible noise level
(See Chapter Foreword,
specifications.)

16
 4. Construction and functional description
4 Constr uction and func tional desc riptio n

Fig. 3
1 Screw compressor 4.1 Construction Housing (casing)
2 Diesel engine
The body consists of a floor panel
3 turbo charger 1 for engine Compressor and engine
mounted on a base-frame. On this floor
4 turbo charger 2 for compressor
The machine owes the increase in panel, all body components are screwed
5 air filter (compressor and engine)
supplied air to the "TurboScrew" system. onto or screwed to one another in form of
6 pre-compressed air heat exchanger
Here a turbo charger driven by the individual panels. Large flaps on all four
7 water heat exchanger
exhaust of the engine supplies the oil- sides allow easy access for service and
8 oil heat exchanger
flooded CompAir screw compressor with maintenance work. Their opening action is
9 oil filter (compressor)
pre-compressed air. The machine effectively supported by gas springs. The
10 pressure reservoir
provides a two-step compression with eye for attaching lifting tackle can be
11 air outlet cock
intermediate cooling. This thermo- easily reached through a flap in the roof.
12 control panel
13 battery dynamically sensible compression
For convenient assembly, all individual
14 suspension principle allows a considerable increase in
parts of the body are bolted together using
15 vehicle identification number the effeciency. In conjunction with the
machine bolts. For effective corrosion
(type plate) CompAir screw shape this compression
prevention, the individual parts are zinc-
16 chassis system is at the latest state of technology.
phosphate coated, electrostatically
17 fuel tank The machine components and the powder coated, and stove-enamelled at
18 Exhaust after-treatment system pressure reservoir with the outlet element 220 °C.
19 Coolant compensating reservoir are held on insulating elements which
20 AdBlue® container All current noise regulations (15. Blm
prevent structure-born noise and dampen
21 LED warning light SchV, ISO, EC directives) are complied
down vibrations.
with. The sound absorbing mats are
The drive unit is a water cooled charged inserted and may be cleaned easily.
diesel engine with pre-compressed air
heat exchanger. It drives the compressor
screw rotor via an elastic flange coupling
and a set of spur gears. The sizes of the
gears are chosen depending on the
desired operating pressure of the
installation (17, 21 or 24 bar).

17
 4. Construction and functional description
Frame and chassis
The complete compressor unit is
mounted on an easily movable tandem
support. The chassis is equipped with
automatic overrun brakes and parking
brakes, as well as a jockey wheel
adjustable in height.
Air channelling
Fresh air is sucked in via a air inlet
cover at the rear end of the roof. The fresh
air is used for cooling the compressor and
engine pre-compressed air. Under this
cover the air supply for the engine is also
taken up. In addition, fresh air flows into
the engine chamber through exactly
matched inlet openings near the rear in
the side walls, and is mixed with the air
coming from the air inlet cover over the
engine unit. In the front part of the
machine, the complete air flow is
conducted through the engine cooling
water heat exchanger and the compressor
oil heat exchanger.
A bulkhead wall in the compressor
separates the cold and hot zones so that
a thermal short between the engine
compartment and the cooling air
discharge area is excluded.
18
4.2 Functional description circuit. The pressure sensor (12) only
allows the machine to be restarted when
(compare Fehler! Verweisquelle konnte the operating pressure has fallen below
nicht gefunden werden.) 1,5 bar.
Oil circuit Control
The oil needed for sealing and cooling A combined throttle / rotational speed
the rotor and for lubricating the roller control allows a continuous air quantity
bearings is injected from the pressure tank between 1 % and 100 % to be drawn.
(9) which is under system pressure into the
When started up the engine (27) initially
compressor (7). The pressure differential
runs at a low gentle speed. The suction
between the pressure tank and the oil
control valve (6) opens due to the intake
injection point is used to regulate oil
vacuum pressure created and the
volume. The oil passes through the oil filter
compressor begins to transport air. Once
(20), the oil temperature regulator (21),
a low operating pressure has been built
which depending on its temperature sends
up, the suction control (6) closes and the
the oil through the oil heat exchanger (22).
engine stays at the gentle rotating speed.
Downstream of the compressor a
After a warm-up phase of around 60 sec
temperature sensor (8) is located which
the compressor system automatically
switches off the machine in the event of
increases the pressure to achieve
excess temperature.
operating pressure. The warm-up phase
The oil collecting in the fine oil separator is automatically shortened to 20 sec if the
(10) is also transported back by the system has already reached operating
system pressure via an orifice plate (23). temperature. When the operating pressure
has been reached the suction control
The suction valve (6) is equipped with a valve (6) is loaded with control air by the
stop function which protects the air inlet electronic proportional controller (17) and
tubes from flooding when the machine is the engine regulated to idling speed by the
switched off. electronic control. This in turn regulates
the machine down depending on
Air circuit consumption until idling speed is reached
again. When the machine is switched off
Two turbo chargers (3 and 4) are the relief valve (14) opens and the
connected in series in the exhaust gas compressor is automatically bled.
flow of the diesel engine (27) which take in
fresh air via two air filters (1). The pre- System deactivation as a result of faults:
compressed air is than cooled down in the see section 10.
pre-compressed air heat exchanger (5)
and then entered into the diesel engine
(27) or the screw compressor (7). When
the suction regulator (6) is set to the
closed position the pre-compressed air
transported to it is blown out of the
machine in order to prevent damage to the
turbo charger (6). When the suction
regulator is open the pre-compressed air
passes into the screw compressor (7).
During the compression process oil is
injected here for lubricating, cooling and
sealing the screw rotor. The compressed
air / oil mixture flows into the pressure
tank (9). Here a preliminary centrifugal
separation of the oil is achieved when the
mixture enters the tank in a tangential
direction. The remaining oil is separated
from the air in the fine oil separator (10).
After this the nearly oil-free compressed air
reaches the compressed air outlet cocks
(15) via the pressure maintenance valve
(13) with integrated stop valve (13). The
pressure maintenance valve (13) reliably
prevents the system pressure from
dropping below the minimum operating
pressure required for the machine. The
differential pressure switch (2) for the air
filters, a temperature switch (24) for the
engine pre-compressed air, a temperature
switch (8) for the compressor oil, a system
pressure manometer (16) and a tempera-
ture sensor (12) are integrated into the air
 4. Construction and functional description
4.3 SCRT® (exhaust after-treatment system) system description
Fig. 4
1 No soot particles
2 No nitrogen oxide
SCRT® = Selective Catalytic Reduction
Technology
The SCRT® system has a modular
structure consisting of CRT and SCR
modules with the related components.
Soot particles are removed in the CRT
module; nitrogen oxide is reduced in the
SCR module.
The CRT module is comprised of an
oxidizing catalytic converter and an SMF®
(SMF® = Sintered Metal Filter). With the
SMF®, particles from the exhaust gas are
filtered and collected. The CRT effect
(Continuously Regenerating Trap) is used
for removing the soot collected in the
SMF®. To do this the upstream oxidizing
catalytic converter converts the nitrogen
monoxide (NO) present in the exhaust gas
into nitrogen dioxide (NO2). With the
nitrogen dioxide (NO2) the soot residue is
then burned (soot oxidation) constantly in
the SMF®.
In addition to the flammable soot, the
SMF® also collects ash, amongst other
things, from the burning of the motor oil.
The ash cannot be regenerated.
Therefore, when the SMF® is saturated
with ash, cleaning is required. With the aid
of permanent measurement, the increase
in exhaust gas back pressure is
monitored. Once the set threshold value is
exceeded, saturation is achieved and the
filter requires cleaning.
The downstream SCR system (SCR =
Selective Catalytic Reduction) comes into
effect to reduce the nitrogen oxide (NO2).
The additive carried along based on
carbamide (brand name AdBlue®) is
mixed into the exhaust gas behind the
CRT module.
Ammonia (NH3) is produced from this in Attention
the mixing path. Combined with the SCR
catalytic converter, it converts the nitrogen The SCRT® system and motor have
oxide (NOx) into harmless nitrogen (N2) been developed and constructed in
and water (H2O). The SCR unit thus accordance with statutory regulations
reduces nitrogen oxide emissions, which in relation to emissions standards. Any
are harmful to the environment and alteration or modification is forbidden
people's health. by law. In the event of non-compliance,
this may lead to fines, absorption of
Equipped with the SCRT® system, the
costs for reconditioning, forfeiting of
compressor fulfills all statutory limit values warranty claims, legal action being
of grade 4 in accordance with 97/68/EC.
taken, and the confiscation of the
compressor until it has been returned
The compressor is equipped with a
monitoring system which alerts operating to its original condition. Maintenance
personnel to system faults of the SCRT® and/or repair work on the motor and on
system. In such cases, the LED warning the SCRT® system may only be carried
light on the roof of the compressor flashes out by certified service personnel.
(see section 10.2).
SCRT® system disruptions are divided
into the following fault categories:
* Insufficient AdBlue® quality (faults due
to operation with insufficient or diluted
AdBlue®)
* AdBlue® feed interrupted
* Monitoring malfunction (fault on the, or
manipulation of the, SCRT® system;
e.g. electrical fault, missing or
deactivated sensors, etc.).
Each error category is assigned a meter
which limits prohibited operation of the
SCRT® system.
If a fault of the same error category
occurs three times within the space of 40
hours of compressor operation, start
approval is then only possible by the
authorized dealer.
If no further faults occur in one error
category within 40 hours of compressor
operation, the meter is reset to zero
(otherwise referred to as self-healing
diagnosis).
19
 4. Construction and functional description

Fig. 5

1. Exhaust gas entry 11. AdBlue® dosing unit (doser) 21. HJS ECU
2. Temperature sensor before CRT 12. AdBlue® suction pipe flow 22. ECU diagnostics connection
3. NOx sensor 13. AdBlue® pressure pipe flow 23. HJS ACU
4. CRT module 14. AdBlue® return pipe 24. ACU diagnostics connection
5. Differential pressure sensor 15. Coolant valve 25. Compressor cable harness connection
6. Pressure measuring point before CRT 16. Coolant flow 26. Compressor diagnostics connection
7. Pressure measuring point after CRT 17. Coolant return flow 27. Terminal 31 connection
8. Temperature sensor before SCR 18. SCR module 28. Terminal 30 connection
9. AdBlue® tank with TQL sensor 19. Temperature sensor after SCR
10. AdBlue® dosing unit (pump) 20. Exhaust air discharge

20
 4. Construction and functional description

4.4 System description

Fig. 6 A13578574
1 air filter 12 Pressure sensor 24 non-return valve
2 differential pressure switch 13 pressure maintenance valve 25 Pressure sensor
3 exhaust turbo charger for engine 14 relief valve 26 –
4 exhaust turbo charger for compressor 15 air outlet cocks 27 diesel engine
5 pre-compressed air heat exchanger 16 Pressure limiter 28 non-return valve
for compressor and engine 17 Electronic proportional regulator 29 compensation tank with level switch
6 suction control valve 18 non-return valve 30 water heat exchanger
7 compressor 19 Quick-acting valve 31 Diesel tank with level gauge
8 temperature switch 20 oil filter 32 Relay valve
9 pressure tank 21 oil temperature regulator 33 nozzle for venting mechanism
10 fine oil separator 22 oil heat exchanger 34 aperture for venting mechanism
11 safety valve 23 orifice plate in suction pipe 35 venting mechanism
36 bypass valve
37 Pressure sensor

21
 4. Construction and functional description

4.5 Wiring diagram

Fig. 7 A13534874 / 01
T1. Tank pressure T7. Supply voltage T13. Relay for starter
T2. Control pressure T8. Shielding T14. Solenoid valve for volume flow
T3. Compressor load pressure T9. Key switch T15. Solenoid valve pressure relief
T4. Cooling water level T10. Starter T16. Option
T5. Pressure gland temperature T11. Generator T17. Solenoid valve emergency tripping
T6. Fuel level low T12. Relay for voltage supply T18. Alarm

22
 4. Construction and functional description

4.6 Exhaust after-treatment system circuit diagram

Fig. 8

23
 4. Construction and functional description

Fig. 9

24
 4. Construction and functional description

Fig. 10

25
 4. Construction and functional description

4.7 Terminal Diagram DIN EN ISO 11446

Fig. 11 A13533874
The terminal diagram is designed for a voltage of 12 Volts!

1. Indicator left 11. Not assigned R. Brake light right

2. Fog tail lamp 12. Not assigned Brake light left
3. Mass for contacts 1- 8 13. Mass for contacts 9 - 12 S. Number plate light
4. Indicator right GE. Indicator left Tail light left
5. Tail light right BL. Fog tail lamp Outline and/or side lights
6. Brake lights W. Mass for contacts 1- 8 G. Reversing light
7. Tail light left GN. Indicator right X. Socket on the vehicle
8. Reversing light B. Outline and/or side lights Y. Plugs on the attachment
9. Permanent positive Tail light right
10. Charging + for battery Number plate light

26
 5. Transport and installation on site
5 Tra nspo rt a nd ins tallatio n o n site
5.1 Transport
Fig. 12
Fig. 13
Danger
Make sure to check the torque after
50 kilometers following wheel
mounting and at regular intervals.
Tighten wheel nuts or screws evenly
in a diagonal sequence to the specified
torque using a torque wrench.
Replacing the trailer coupling ring
The coupling arrangements which can
be used:
* Trailer coupling ring DIA 40 in
accordance with DIN 74054 - 40A
* ball coupling Ø 50
* coupling ring DIA 76.2 VG 74059
A different coupling unit in the form of a
complete kit may be ordered, if necessary.
Replacing the trailer coupling ring is
permitted only if proper fitting is carried out
by an inspectorate for the sector covered
by the Regulations Authorizing the Use of
Vehicles for Road Traffic (e.G. the TÜV -
Technical Inspectorate, DEKRA - German
Motor Vehicle Monitoring Association,
etc.). The inspection station provides a
fitting certificate to be kept with the vehicle
documents.
Danger Attention
The screw compressor may only Always keep a safe distance from the
be transported on public roads if edges of foundation ditches and
embankments! Do not travel across
* The machine group (engine) is slopes transversely.
not running,
* The pressure tank is not under
pressure,
* The shielding is closed, 5.2 Attachment of the contact-
* The blocks are firmly hooked in breaker cable on braked
place, chassis
* Hoisted and secured tail wheel,
If the towing connection becomes
* The tyres and brakes are uncoupled, the trailer is braked by the
operationally safe and roadworthy, breakaway cable. Put the breakaway
cable in the eye provided or wind it
* The lighting is fully functional.
around the towing collar and hitch it up
Never exceed the maximum towing to the cable with the snap link.
speed! Danger! Observe national
The breakaway cable must be attached
regulations!
in a way that ensures that even on
Please also observe the safety extremely sharp bends there is no danger
instructions in Chapter 3 on the of activating the locking brake.
subject of transporting.
Before transporting the compressor,
check to make sure that the draw gear of
the towing vehicle and the drawbar eye
or trailer hitch ball connection are aligned
exactly to each other.
When transporting the screw compressor
with a vehicle, the following points must
be observed:
* The shielding is closed.
* The blocks are firmly hooked in place. Fig. 14
* The support(s) is(are) retracted and
locked in position (jockey wheel).
* Drawbar is connected to the towing
vehicle.
* The drawbar is adjusted to the height
of the towing vehicle (option).
* The contact-breaking cable is
connected to the towing vehicle. Safety
chains are attached on towing vehicle.
* The electrical cable (option) is
connected to the vehicle and to the
screw compressor.
* Check the lights (tail lights, brake
lights, indicator lights, and rear fog
lamp) (option).
* Check to make sure that the wheels
are properly tightened, the tyres are
in a roadworthy condition and the tyre
pressure is correct (danger of
accidents).
* When parking the compressor prior to
uncoupling from the towing vehicle
actuate the handbrake, detach the
contact-breaker cable and the lighting
cable, and secure the compressor
against rolling using chocks. Then
adjust to the horizontal position by
means of a support or support wheel.
27
 5. Transport and installation on site
5.3 Loading/Relocation
Fig. 15
Danger
Only use hoisting gear (e.g. crane) with
appropriate lifting capacity for the
loads occurring!
Only use the correct suspension gear!
Keep clear of the swiveling range of the
hoisting gear!
Keep clear of suspended loads!
Lifting when the compressor is running
is prohibited!
All loose parts that could fall down
during hoisting must first be removed
or secured; pivoting parts, like doors,
towbars, etc. must be secured in such
a way that they cannot move.
Never leave the load suspended on the
hoisting gear. Acceleration or braking
of the means of transport must remain
within the approved limits.
Please also observe the safety
instructions in Chapter 3 on the subject
of loading.
Attention
Do not attempt to use a crane hook or
similar load suspension devices direct
on the lifting device to avoid damages
to the lifting device!
Use proper hoisting gears only such as
hoisting straps in compliance with DIN
standard 61360 with proper lifting ca-
pacity for connecting the load
suspension device (e.g. crane) and the
lifting device.
Only deploy load bearing equipment
which corresponds to the safety
instructions for lifting gear.
Transportation by helicopter is
prohibited.
Never lift up or lash down the unit
using the shielding!
Never relocate the machine if external
lines or hoses are connected to the
discharge valves, in order to avoid
damage to the valves and/or collecting
pipe and hoses.
28
When loading, the following points must
be observed:
* Secure the load suspension device or
the hoisting gear in the lifting device of
the screw compressor.
* When hoisting the compressor, set up
the hoisting gear in such a way that the
compressor, which must be set up
horizontally, is lifted vertically.
* Only relocate the compressor by itself.
* Raise and lower the compressor
carefully.
* After relocating, remove the load
suspension device or the hoisting gear
from the lifting device.
* Tie down the compressor on the cargo
area of the means of transport.
* Only tie to the pull tube or to the wheel
axles, or use the openings provided in
the frame
* When the chassis is being dismantled,
the shielding with machine group may
only be supported under the base
frame.
5.4 Installation on site
A = 1m
B = 1m
Fig. 16
Danger
The air intake must be positioned in
such a way that loose personal
clothing cannot be drawn in.
Make sure that the pressure pipe from
the compressor to the aftercooler or
the air system can expand as a result
of heat, and that it does not come into
contact with inflammable materials.
The air intake is to be designed in such
a way that no dangerous admixtures
(inflammable solvent vapours etc.,
but also other dangerous or toxic
substances) can be taken in. This also
applies to flying sparks.
Pipes and other parts with a surface
temperature of more than 80 °C must
be suitably secured against contact
and suitably marked.
The operation of the compressor in
areas where there is a risk of explosion
is strictly forbidden! (Exception:
specially-made compressors with the
necessary technical modifications for
use in such areas)
Please also note the safety instructions
in Chapter 3 on the subject of
installation on site.
Location
The complete system is to be set up in
such a way that it is easily accessible and
that the required cooling is guaranteed.
Never block the air intake. Ensure that the
entering of moisture and dirt together with
the intake air is kept to a minimum.
The compressor is to be set up away
from walls.
 5. Transport and installation on site

Attention
The screw compressor is to be set up
in such a way that no air reflection can
take place, i.e. neither waste air nor
exhaust emissions may be drawn in;
the same applies to dangerous
admixtures to the air. Drawing this
waste air in could lead to overheating
and a loss of power.
The compressor must be set up in as
horizontal a position as possible.
Maximum permissible inclination during
operation:
* In direction of pull: 15 degrees
* Backwards: 15 degrees
* To the right and to the left: 15 degrees
Attention
No force may be exerted on the dis-
charge valves, for example by pulling
the hoses or fitting additional
equipment (e.g. a water separator,
compressed air oiler, etc.) directly at
the discharge valve.
Temperatures/air humidity
Install the compressor in a location with
maximum possible frost protection. The
suction air temperature must be within the
range specified on the data
Note
Particularly in case of installation out of
doors and at night, observe fuel tempera-
ture. At temperatures below 0 °C, summer
diesel fuel tends to precipitate and block
the fuel filter. In this case use winter diesel
fuel.

15° 15°

15° 15°

Fig. 17

Attention

Greater inclinations endanger the

operating reliability of the screw
compressor.
When setting up the unit on ground that
is not horizontal, or with a variable angle
(see operating instructions) please consult
CompAir.
Set up the machine in such a way that
no inlets, outlets or gates are blocked,
even when the doors are open. Prior to
uncoupling from the tow vehicle, apply the
handbrake. Disconnect contact-breaking
cable and lighting cable, uncouple air
brake lines. Secure wheels with chocks.

Note
In dusty environments, set up the machine
in such a way that the wind does not blow
the dust in the direction of the machine.
During operation in clean environments,
the intervals for cleaning the air intake
filter and the cooler elements are much
longer.

29
 6. Preparing the compressor for operation
6 Prepari ng t he c omp ress or f or o per ation

6.1 Checking oil levels 6.1.2 Checking the oil level in 6.2 Battery
the engine
6.1.1 Checking the oil level in
the pressure tank

Fig. 20
Fig. 19
Danger
Fig. 18 Danger
When working with battery acid
Danger Only check the oil level when the (electrolyte), wear acid-resistant
compressor engine is at a standstill. goggles, gloves and apron.
Only check the oil level when the Spill no oil! The oil may be hot. Risk
of scalding! The gases released by the battery are
engine is at a standstill and the
explosive. Avoid sparks and open fires
compressor is not under pressure. Check for leaks. in the vicinity of the battery.
The pressure tank may be under Proceed as follows: Do not allow acids to come into contact
pressure and the oil may be hot.
* Ensure that the screw compressor is with skin or clothing. Wear safety
Risk of scalding! Spill no oil! standing horizontally. goggles.
Check for leaks. * Ensure that the screw compressor has Place no tools on the battery.
Proceed as follows: been out of operation for some time. The battery is filled and charged in
* Unscrew dipstick. accordance with DIN 43539. The battery is
* Before checking the oil level in the fastened with clamping strips.
engine and in the compressor ensure * The oil level should be as near as
that the vehicle is standing horizontally. possible to the upper dipstick mark. The batteries used are ready to be
installed and ready for service. Replace-
* Ensure that the screw compressor has * Correct as required. ment batteries should be of the same type
been out of operation for some time.
* Screw in dipstick. as the batteries installed (low gassing).
* Unscrew dipstick. The replacement battery should be unfilled
* Close oil filler. and only be preloaded so that it has to be
* The oil level should be within the marks
* For oil specifications, see “Engine filled with battery acid. The battery and the
on the dipstick.
Operating Manual”. acid should have a temperature of at least
* Correct as required. +10 °C.
* Check the seal on the dipstick and Attention Proceed as follows:
replace if required. After a short test run, the oil level * Fill up with battery acid as far as the
* Screw in dipstick and tighten firmly. should be between the markings on base of the control insert
the dip stick.
Attention * Leave the battery to stand for some
For oil specifications, see engine time
After a short test run, the oil level instruction manual.
* Then shake it gently
should be between the markings on
the dip stick. For oil specifications, see * If required, top up with acid
recommended lubricants, Chapter 8.1.
* Tighten sealing caps
With a system which has been out of
operation for some time, run the * Leave for 1 hour
machine for an approx. 1 minute warm- * The battery is ready for use
up period and then check the oil level.

30
 6. Preparing the compressor for operation

6.3 Filling up the fuel tank 6.3.2 Fill with AdBlue®

Danger

Only fill up when the screw

Fig. 21
6.3.1 Fill with diesel
Danger
Only fill up with fuel when the screw
compressor is at a standstill.
Cleanliness is essential! Spill no fuel!
Filling up at a pump can cause static
electricity and possibly sparks.
Proceed as follows:
* Open tank lid
* Fill up tank with diesel fuel, using a
sieve (use summer or winter diesel fuel
depending on outside temperatures)
* Close tank tight with tank lid
* Close the covering.
compressor is at a standstill! Ensure
cleanliness! Do not spill AdBlue®!
Static electricity can occur when filling
up at a pump and possibly
cause sparks.
Proceed as follows:
* Open tank lid
* Fill the tank with customary AdBlue®
* Close tank tight with tank lid
* Close the covering.
The system monitors that the AdBlue®
system is not run completely empty. If air
gets into the system due to an error, the
system is stopped and the fault is
displayed.
Attention
If air gets into the AdBlue® system, it
must be carefully ventilated by
specialist personnel.

Note

The fuel tank should always be filled up in

good time. The fuel gauge displays the
fuel level.
For outside temperatures below 0 °C, use
only winter diesel fuel.
For outside temperatures below 0 °C,
observe the operating manual of the
engine manufacturer for winter operation.
You can reduce the occurrence of
condensation in the fuel tank considerably
by filling it up in good time. This also
prevents downtimes and starting problems
that can occur when the fuel tank is run
dry.

31
 7. Putting the compressor into operation
7 Putting t he co mp resso r int o op era tion
7.1 Initial operation
Transport inspection
Every CompAir screw compressor
has already run in the factory and has
already undergone a thorough test before
shipment. This test ensures that the
compressor complies with the given data
and works perfectly. Independent of
the care taken in the factory, it is still
possible for the compressor to be
damaged during transport. For this reason
it is recommended that the unit should be
examined for possible damage during
transport.
Remove any transport seals (dummy
flange, plugs, etc.) and dehydrating
agents before start-up. Distribution tubes
and connection lines must have the
specified dimensions and must be suitable
for use with the max. operating pressure
and the media to be taken up.
During the first hours of operation, the
compressor should be observed in order
to be able to ascertain any possible
malfunctions.
7.2 Operating elements
Operating panel:
Fig. 22
1 Operating pressure in bar and psi
2 Individual fault type
1 = Engine oil pressure
2 = Cooling water temperature +
cooling water level
3 = Intercooler temperature
4 = Airend temperature
5+10 = AdBlue® fill level
6 = Water in fuel + fuel level
7 = Battery voltage
8 = Cable break, Start against pressure
9 = Other errors from CAN-Bus (engine)
+ fault from exhaust after-treatment
system (SCRT® system)
3 Engine speed, operating hours
4 LED green (ok)
5 LED red (fault)
6 Start button
7 Ignition key, Stop (shut down
compressor)
8 Reset button, Enter
9 Choice of menu
32
10 Decrease working pressure Starting up the compressor:
11 Increase working pressure
* Perform maintenance on the system
once daily prior to commissioning in
accordance with section 9.3.
7.3 Start-up * Close air tapping cocks.
Danger * Turn ignition key to position "I" (on).
Symbols 1 and 7 light up.
Before starting up, make sure that no
* Press start button
one is in the danger area of the engine /
screw compressor. * The system starts for 15 seconds.
Compressors may not be operated in * After starting the engine runs in idle
hazardous environments unless they and the compressor at reduced
have been specially designed for this pressure.
purpose (e.g. exhaust protected
against emission of flying sparks etc.). * A warm-up period of the motor follows.
* The system is now ready for operation.
Never, under any circumstances, use
Check that the hoses / tools are
"Startpilot" (Spray-can starting aid),
correctly connected and open the
ether or other starting aids - Danger of
requisite air bleed cocks.
explosion!
After service work has been Note
completed: Make sure that all
If the unit does not start following the start
protective devices have been refitted
attempt, wait until the tank pressure has
and that all tools have been removed.
dropped. The symbol "8" (see Fig. 22)
The exhaust from the system contains shows when the tank pressure has
carbon monoxide, a lethal gas. dropped enough to permit a start release.
The exhaust must be routed to the
Note
outside via a pipe or a hose with an
internal diameter of not less than Starting after a shutdown due to faults
150 mm if the compressor is used with turbochargers (fault entry: ATL 1 or
indoors. ATL 2) is only possible with the reset
button also pressed.
Adequate ventilation must be assured.
The use of an exhauster system is
urgently recommended. Start-up using jumper cables /
auxiliary batteries
Only operate the compressor with the
hood closed. The hood may only be
opened briefly for minor adjustments
while the compressor is running.
Skilled personnel only are authorized
to work with the hood open.
When working with the screw
compressor in operation and with the
shielding/hood open, wear ear
protection.
Caution: this may impair
communication between persons.
Warnings may not be heard. Inform Fig. 23
supervisor.
Danger
Attention
Longer operation with an auxiliary
Opening the covering interferes with
battery or jumper cables connected
the flow of cool air in the compressor
can lead to sudden emissions of gas.
section. For this reason, the machine
An inflammable air / gas mixture is
will switch off after a short time.
formed. Explosion hazard!
Full sound-insulating is only achieved
when the covering is closed. Attention
Check the oil levels in the pressure Serious damage can be caused to the
tank and in the engine of the electrical system if wrongly connected.
compressor each time before start-up.
Do not start the compressor unless the
air tapping cocks are closed.
 7. Putting the compressor into operation
* Ignition key in position “0” (Off-Aus)
* First connect positive terminals then
negative terminals (ground).
* Start as described in section “Starting
up the compressor.”
Note
After the engine has started, first
disconnect the negative cables (ground)
and then the positive cables.
Follow the instructions for operating the
compressor at an ambient temperature of
less than 0 °C, in Chapter 5, Transport
and Installation on Site, in this operating
manual.
7.4 Setting the operating pressure
Danger
The setting of the operating pressure
may only be carried out by a specialist.
The operating pressure is set via the
operating panel (see Fig. 22).
* pressing the arrow button obtains the
menu to set the operating pressure
* set the requisite operating pressure
using the arrow buttons
* confirm the new operating pressure
with the reset button
Note
The operating pressure can be set in the
range of 13.0 bar to a max. operating
pressure (depending on the system
version). The maximum admissible
operating pressure is noted on the type
plate!
7.5 Monitoring / fault
Danger
Interference with the automatic
monitoring system is not permitted.
When the “Fault” indicator lamp lights up,
the screw compressor is automatically
shut down when the following faults occur:
* engine oil pressure too low
* cooling water temperature too high
* charge air temperature too high
* engine oil temperature too high
* cooling water level too low
* Water present in fuel pre-filter
* charge control (e.g. V-belt tear,
defective generator, ...)
* hardware fault (e.g. cable break)
* AdBlue® fill level < 2%
* Motor charging pressure too low
* Screw compressor entry charging
pressure too low
* Exhaust after-treatment system fault
* Other faults with the compressor
electrics
* other fault in the engine electronics
Following a malfunction of this type,
the compressor may only be restarted
once the cause of the shut down has
been eliminated and the error has been
confirmed using reset button "8" (see Fig.
22).
All other operating states are
represented using the system electronics
menu.
Attention
Disconnect the battery or generator
only when the engine is not running.
Switch the system off if an oil mist is
entrained in the compressed air or if
excessive oil consumption is apparent
(see "Trouble-shooting")
7.6 Operation
Danger
Only operate the compressor at the
permissible operating pressure and at
the permissible temperature.
Only use the compressor for its
intended purpose (see Chapter 2.2 of
this operating manual) in order to avoid
residual risk for persons and assets.
Only operate the compressor in a safe,
functioning condition.
All components, hoses etc. fitted must
be of the correct size and designed for
the specified operating pressure and
temperature.
When working with compressed air,
wear suitable protective clothing (e.g.
protective suit, safety goggles, etc.).
Wearing ear muffs may impair
communication between persons.
Warnings may not be heard. Inform
supervisor.
Check the compressor regularly. Check
the machine / installation for external
damage and faults at least once per
shift. Any changes noticed (including
changes in operating performance)
must be reported immediately to the
authority or person in charge. If
necessary, shut down and secure the
machine immediately.
Leaking condensation contains a
proportion of oil and must be collected
and disposed of under safe conditions.
Condensation must not enter the
soil or the rivers. Major quantities of
condensation accumulate particularly
in versions with aftercoolers for
processing compressed air. Provide a
collecting basin.
33
 7. Putting the compressor into operation

7.7 Shutdown 7.8 Decommissioning

In order to shut down the compressor:
* Close air discharge valves. The screw
compressor reduces the speed of the
engine back to idling speed after the
preset final pressure has been
reached.
* Allow the screw compressor to idle for
a few minutes.
* Turn ignition key to position "0" (off).
The system switches off after a defined
overtravel time.
* Withdraw the ignition key. Fig. 24

The screw compressor is automatically If the system is to be closed down for a

depressurized to atmospheric pressure.
A re-start is only then possible once the
container pressure has fallen below
1.5 bar.
Note
In the case of emergency (!) the system
can be closed down via an emergency-
stop switch. The system comes to an
immediate standstill. This type of
shutdown is stored in the electronics.
Attention
The pressure line between the
pressure tank and the outlet valves will
remain pressurised because of the
pressure maintenance valve with its
non-return function. In order to allow
the remaining pressure to be released
open an outlet valve while outlet pipes
are connected.
longer period of time (approx. 3 months
or longer) the following preservation
measures must be taken:
* Engine preservation (see separate
engine operating manual).
* Disconnect battery cables.
* No special measures are required at
the compressor.
* Relieve the strain on tyres by jacking
up the vehicle.
* Check tyre pressure every 2 months.
* Release the handbrake.
Attention
When putting back into operation,
carry out the maintenance work
in accordance with Chapter 9
“Maintenance.”

Danger

It is important that you ensure that the

pressure is completely blown off via
the blow-off valve.
Should this not be the case, open the
air outlet valves, identify the fault and
correct it.

34
 8. Fuels
8 Fuels
8.1 Recommended lubricant for
compressor
Note
In these screw compressors, circulating oil
has not only a lubricating function, but in
particular it also has cooling and sealing
functions. It is therefore exposed to more
difficult conditions. In particular the tempe-
rature conditions at the installation site and
the consistency of the air (dust, dirt, and
humidity content, as well as chemical
influences) must be taken into account
when selecting a suitable lubricant.
Attention
Do not mix oils of different
specifications.
The maintenance intervals and the
maximum and minimum operating
temperatures given in this operating
manual only apply when high-quality
multi-grade oils are used.
Use of the wrong oil leads to
impairment of function.
Out of consideration for the high loads
imposed on the lubricant in screw
compressors with oil injection cooling, we
recommend the use of suitable, non
ageing, non foaming, corrosion-protective
oils. They must meet the following
requirements for hydraulic fluids:
H-LP 32 and H-LP 46 in accordance with
DIN 51524, Part 2, June 1985.
The viscosity of the lubricants should
comply with viscosity class ISO VG 32
DIN 51519, July 1976, with 28 - 35
mm2/s(cSt) / 40 °C, or if the ambient
temperature is constantly above 25 °C,
with viscosity class ISO VG 46 DIN 51519,
July 1976, with 41 - 50 mm2/s(cSt)/40 °C.
Attention
Conventional engine oils marked HD
must not be used.
When using oils with the “Brief De-
scription HYD 10/HYD 20" in accordance
with the ʻStandard Lubricants for Building
Machinery and Vehiclesʼ published by the
ʻHauptverband der Deutschen Bauindustrie
e.V.ʼ (Principal Association of the German
Building Industry), only the given hydraulic
fluids may be used in accordance with
ISO VG 32 and ISO VG 46.
If other lubricants are to be used, please
contact:
Gardner Denver Deutschland GmbH
Argenthaler Straße 11
D-55469 Simmern/Hunsrück
Telephone 06761 / 832-339
Telefax 06761 / 832-421
or your authorized dealer or your local
branch.
8.2 Recommended engine oil 8.6 Recommended lubricants for
the bogies
Lubricant specifications for the driving
engine can be found in the enclosed For relubrication use only lithium
engine operating manual. saponified grease which fulfils the
following specifications:
* consistency groups (NLGI) 2
DIN 51818
8.3 Diesel fuel * worked penetration 265-295
DIN ISO 2137
Use common diesel fuel (EN590).
* dripping point > 180 °C
Attention DIN ISO 2176
See engine instruction manual. * operational temperature
– 40 °C … +140 °C
Attention
This corresponds to a DIN 51502
The compressor must not be fuelled lubrication grease, designation KP2N-4U.
with bio-diesel (DIN 51606) or
vegetable oil. Greases with different thickeners
(soap base) must not be mixed.
Recommended grease: Fuchs Renolit
LZR 2.
8.4 AdBlue®
Use AdBlue® in accordance with
DIN 70070 / ISO 22241-1.
Note
AdBlue® starts to freeze from –7°C.
The mixing or use of other substances
leads to system shutdown.
8.5 Coolant
Attention
Only operate the engine with coolant!
Pure water may cause damage to the
engine and to connected components.
The coolant consists of 50% water and
50% corrosion protection/antifreeze
fluid. Use soft water only; drinking
water usually meets this requirement.
Do not use sea, brackish, industrial,
rain or distilled water.
Use released corrosion protection/
antifreeze fluid only. The use of anti-
corrosion oil as cooling-system anti-
freeze is not permitted.
Products of differing product groups
must not be mixed!
Note
Please observe the engine manufacturer's
operating instructions and fuel
specifications.
35
 9. Maintenance
9 Mainte nan ce
9.1 General maintenance
Danger
Install a "Caution maintenance work"
warning sign and cordon off a wide
area around the workplace before
starting any work.
During inspection, adjustment, or
maintenance work, remember that the
surfaces of machine parts can be hot,
particularly the exhaust system (risk
of burning) and that the control device
may move during operation (risk of
crushing).
Clean the screw compressor at regular,
not too long intervals:
* Blow-clean all valves, controllers,
fittings, pressure tank, oil cooler,
radiator, screw compressor, and
engine with compressed air or a steam
jet appliance.
* Inspect the cooling ribs of the radiator
to make sure that air can pass through.
* Clean the body at regular intervals.
Then grease or oil the hinges of the
body hood with multi-purpose grease.
If sound-absorbing matting has to be
replaced, remove the retaining brackets,
replace the old sound-absorbing matting
with new matting, replace the retaining
brackets.
9.2 Engine maintenance
The maintenance of the engine is to be
carried out in accordance with the engine
operating manual.
Attention
Full load speed is factory-set by the
manufacturer and must not be
modified.
The idling speed must not be changed
either, as this might cause serious
damage to the screw compressor,
e.g. damage to the coupling!
36
Advance fuel filter
Fig. 25
1 Conveying pump
2 Vent plug
3 Filter element
4 Water sensor
5 Water drain
Danger
Change filters only with the engine off
and in cool condition.
Do not spill fuel.
Attention
Frequency of water draining or element
replacement is determined by the
contamination levels present in diesel
fuel.
Note
Ensure the system is free from leakage.
Check the hoses for cracks and replace
if necessary.
Dispose of contaminated filters in
accordance with the regulations.
Changing the filter element
The intervals for changing the filter
element will depend on the quality of the
fuel. A clogged filter will lead to a reduced
fuel supply and to a loss of performance
and start difficulties. The filter element
must be replaced if the performance drops
noticeably.
* Drain off a little fuel. To do this open
the water drain (5).
* Unscrew the filter element (3) from the
filter head. Remove the filter element
and clean the sealing surfaces.
* Coat the filter seal with fresh fuel or a
little grease. Tightly screw on the new
filter element to the filter head. Do not
use tools to tighten!
* Actuate the fuel conveying pump with
open bleed screw until fuel exits from
the bleed screw. Close the bleed
screw, start the engine and observe
leakages. Make any necessary
corrections with machine switched off.
9.3 Daily maintenance
Drain water out of upstream fuel filter
Danger
Drain water only with the engine off.
Water is heavier than diesel fuel. It
separates out on the floor of the fuel pre-
filter. The water must be emptied on a
daily basis (via water drain, fig. 25,
pos. 5). The water sensor monitors the
water content in the fuel and switches off
the system if the water content is too high.
Checking oil levels
Check the oil levels as described in
chapter 6.1 on p. 30.
Check the AdBlue® fill level
The fill level of the AdBlue® tank is
shown in the display on the right. Average
AdBlue® consumption is around 3–5%
from fuel consumption.
If the fill level is less than 10%, AdBlue®
must be refilled urgently.
If the fill level is less than 2.5% or if the
AdBlue® quality is inadequate, the system
automatically switches itself off and must
be restored by certified service staff.
The display "---%" indicates that the
sensor is frozen or soiled. In such cases,
have the system defrosted or cleaned.
9.4 Maintenance of chassis
and brakes
The maintenance of the chassis and the
brakes must be carried out in accordance
with the chassis instruction manual.
Work on the brakes may only be carried
out by trained technical staff or by
specialist brake services!
Danger
During inspection, adjustment, or
maintenance work, remember that the
surfaces of machine parts can be hot,
particularly the exhaust system (risk
of burning) and that the control device
may move during operation (risk of
crushing).
 9. Maintenance

9.5 Maintenance and inspection schedule

60 h
250 h
500 h
750 h
1,000 h
1,250 h
1,500 h
1,750 h
2,000 h
2,250 h
2,500 h
2,750 h
3,000 h
3,250 h
3,500 h
3,750 h
4,000 h
4,250 h
4,500 h
4,750 h
5,000 h
5,250 h
5,500 h
5,750 h
6,000 h
Due at x hours run

At the latest after x years 1 yr 2 yrs 3 yrs 4 yrs 5 yrs 6 yrs

Daily:
Visual checking for external damage, defects and leaks
Check the oil level in the diesel engine
Check the coolant level
Check the oil level in the compressor
(drain off any condensate from the oil tank)
Check the AdBlue® fill level
Drain off water in the fuel pre-filter
Clean air filter (screw compressor/engine) between times
or renew if the red field appears
Engine maintenance
Maintenance every 250 h; although at least every 3 months:
Visual inspection of the exhaust gas preparation system ■■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■
Condensation drainage of the exhaust gas preparation system ■■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■
Maintenance every 500 h, although at least every 6 months
Check tyre pressure and wheel nuts, retighten if necessary ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Adjust brake system (option) or have checked ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Lubricate chassis / draw gear ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Inspect safety valve ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Lubricate hood hinges ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Clean cooler (more frequently if used in a dusty environment) ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Maintenance every 1,000 h, although at least each year
Change both air filters (screw compressor/engine) ■ ■ ■ ■ ■ ■
Change oil filter of the screw compressor ■ ■ ■ ■ ■ ■
Oil change (screw compressor) ■ ■ ■ ■ ■ ■
Inspect automatic operational monitoring ■ ■ ■ ■ ■ ■
Change fine separator every year or if differential pressure > 1bar ■ ■ ■ ■ ■ ■
Clean screen of the suction-off line ■ ■ ■ ■ ■ ■
Inspect control (adjustment/function) ■ ■ ■ ■ ■ ■
Inspect solenoid valves ■ ■ ■ ■ ■ ■
Check the battery acid level ■ ■ ■ ■ ■ ■
Check clamping bolts and nuts and retighten, if necessary
■ ■ ■ ■ ■ ■
(chassis, frame and bodywork)
Check suspension components ■ ■ ■ ■ ■ ■
Maintenance every 2,000 h; although at least every 2 years:
Inspection and AdBlue® pump filter change ■ ■ ■
Inspection every 4 years:
Inspection of the electrical installation by a qualified electrician ■
Inspection every 5 years:
Internal inspection of the pressure vessel by a qualified person ■
Inspection every 10 years:
Strength test of the pressure vessel by the appointed body
■
X For your own benefit, put a cross on the servicing schedule against maintenance work when performed.

37
9. Maintenance

6,750 h

10,000 h
10,250 h
10,500 h
10,750 h
11,000 h
11,250 h
11,500 h
11,750 h
12,000 h
12,250 h
12,500 h
12,750 h
13,000 h
13,250 h
13,500 h
13,750 h
14,000 h
14,250 h
14,500 h
14,750 h
15,000 h
15,250 h
15,500 h
15,750 h
16,000 h
16,250 h
16,500 h
16,750 h
17,000 h
17,250 h
17,500 h
17,750 h
18,000 h
18,250 h
18,500 h
18,750 h
19,000 h
19,250 h
19,500 h
19,750 h
20,000 h
6,250 h
6,500 h

7,000 h
7,250 h
7,500 h
7,750 h
8,000 h
8,250 h
8,500 h
8,750 h
9,000 h
9,250 h
9,500 h
9,750 h
7 yrs 8 yrs 9 yrs 10 yrs 11 yrs 12 yrs 13 yrs 14 yrs 15 yrs 16 yrs 17 yrs 18 yrs 19 yrs 20 yrs

■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■
■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■

■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

■ ■ ■ ■ ■ ■ ■

■ ■ ■ ■

■ ■ ■

■ ■

38
 9. Maintenance
9.5.1 Oil filter replacement
(compressor)
Fig. 26
Danger
Only replace the oil filter cartridge
when the engine is at a standstill and
the screw compressor is not under
pressure.
Caution with hot oil: risk of scalding!
Spill no oil!
Attention
Change the oil filter every 1,000 oper-
ating hours, but at least once per year.
Note
Dispose of oil filter cartridge in accordance
with the relevant regulations - hazardous
waste!
Check for leaks.
Changing the oil filter:
* Unscrew the oil filter cartridge using
appropriate tools
* Dispose of oil filter cartridge
* Apply a thin coat of oil to the seal of the
new oil filter cartridge
* Screw on and tighten the new oil filter
cartridge (follow the instructions on the
oil filter cartridge)
* Check for leaks
* Check oil level, add oil if necessary
9.5.2 Oil change (compressor)
Fig. 27
Danger
Only change the oil when the engine is
at a standstill and the system is not
under pressure.
Caution when draining off hot oil:
risk of scalding! Spill no oil!
Attention
Change the oil filter every 1,000 oper-
ating hours, but at least once per year.
The screw compressor must not be
under pressure during oil change.
Drain the oil at operating temperature.
Do not mix oils of different
specifications.
Note
Collect used oil, do not allow it to enter the
soil. Dispose of oil in accordance with the
relevant regulations - hazardous waste!
Spill no oil! Check for leaks.
Changing the oil:
* Unscrew dipstick
* Place oil drain pan under oil drain valve
* Unscrew the sealing cap of the
pressure vessel
* Collect used oil in the oil drain pan
* When the used oil has been drained
completely, use a new sealing ring on
the sealing screw of the pressure
vessel, position and tighten screw or
close the oil drain valve
* Fill up with new oil (see section
"Specifications" in chapter 2.3 for initial
oil capacity; use a little less oil when
performing an oil change).
* For lubricants see “Lubricant Table”
* Check sealing ring on dipstick, replace
if necessary
* Screw in and tighten dipstick
* Start screw compressor; allow to rise to
operating temperature (compressed air
temperature > 70°C); check for leaks
* Switch off screw compressor
* Check oil level, add oil if necessary
9.5.3 Inspecting / Replacing the
fine separator
Fig. 28
Danger
Pressure tank is under pressure. Only
work when the motor is at a standstill
and the screw compressor is not under
pressure.
Caution with hot oil: risk of scalding!
Spill no oil!
Note
Dispose of fine separator in accordance
with the relevant regulations - hazardous
waste!
Check for leaks.
Replace the fine separator at least once
per year or measure the differential
pressure as follows:
* When the engine is at a standstill and
the screw compressor is not under
pressure, unscrew the dipstick from the
pressure tank.
* Screw in the reducing adapter.
* Screw the pressure gauge into the
reducing adapter.
* Start the screw compressor and let it
run at full operating pressure with the
maximum air flow.
* The difference in pressure between
the pressure gauge on the pressure
tank and the pressure gauge on the
instrument panel must not exceed
1 bar.
39
 9. Maintenance
If the differential pressure is > 1 bar, the
fine separator cartridge must be replaced.
* Disconnect all lines from the tank
cover.
* Remove all hexagon screws around the
circumference of the lid.
* Remove the lid and the old fine
separator.
* Remove the used seals from the
pressure tank, clean the sealing
surface and insert new seals.
* Insert a new fine separator into the
pressure vessel and fit new seals.
* Fit the lid. Insert the hexagon screws
and tighten them across the diagonal
(tightening torque see Chapter 9.5.9
"Torque specifications").
* Reconnect all lines to the tank cover.
* Check for leakage.
* Dispose of the old fine separator
cartridge in the specified manner.
9.5.4 Air filter replacement
(compressor / engine)
Danger
All inspections and servicing work
must be carried out when the engine is
at a standstill and the screw
compressor is not under pressure.
Fig. 29
Note
The air filter elements must be replaced at
least once a year. Do not clean and reuse
the air filter elements.
Replacement of air filter elements:
* open the clamps on the air filter cover
* pull the old air filter element out from
the casing
* insert the new air filter element
* reattach air filter cover as shown in
Fig. 29
40
Note
The air filters should be checked weekly
for dust contamination.
The maintenance interval of the air
filter depends on the dustiness of the
environment.
Replacing the safety cartridge
(at the latest with every third replacement
of the air filter element):
* Open the clamps on the air filter cover
* Pull the air filter element out from the
casing
* pull the safety cartridge out from the
casing
* insert the new safety cartridge
* push on air filter element
* reattach air filter cover as shown in
Fig. 29
Attention
The air filter cartridges are never
cleaned!
* clean the sealing area in the casing
* Insert filter cartridge and ensure that
the seal is in the correct position
* push on the lid with the air filter and
click into the clamps
9.5.5 Checking the safety valve
Fig. 30
Check the operation of the safety valve
at least twice a year. The check is carried
out with the system pressurised. Carefully
turn the knob anti-clockwise, until the
internal pressure lifts the valve cone,
releasing a mixture of oil and air. Then
turn the knob fully clockwise again.
In accordance with national standards,
but at least once a year, carry out a
suitable test to check whether the valve
blows down at the correct pressure.
If the valve is not working properly,
replace it immediately with a new one
designed for the system. This type of
operation may only be carried out by
trained personnel.
Danger
The screw compressor must not be
operated with a faulty safety valve!
A mixture of oil and air will escape
when the valve is checked/tested.
 9. Maintenance

9.5.6 Control Attention A condensation drain hole is located on

Check the acid level after a maximum
of 1,000 operating hours, or after
24 months, whichever occurs first, and
fill up with distilled water if necessary.
For battery maintenance please also
refer to the manufacturerʼs instructions
and the engine operating manual.
9.5.8 SCRT® unit maintenance
Fig. 31 Attention
The control system takes the form of a Your authorized dealer should be
stepless speed/volumetric flow regulation contacted for the AdBlue® pump filter
system. It consists of: change.
* The intake control valve on the air
intake
* Pressure transducer
* Proportional valve
* Electronic unit
the underside of the exhaust gas outlet
pipe. Check that this is free flowing
regularly. When so doing, proceed as
follows:
* Open the front housing flap.
* Place the collecting vessel below the
condensation drain.
* Open the rain flaps and fill the exhaust
gas outlet tube with approx. 100 ml of
water.
* Check whether the water quantity
poured in has flown into the collecting
vessel.
* Remove the collecting vessel and close
the housing flap.
* If the water does not flow through, or
does so only very slowly, clean the
condensation outlet with appropriate
tools.
9.5.9 Torque specifications

The intake regulation valve contains a The following tightening torques apply to
cone, which changes the volume of the air screwed connections:
intake and which has a non-return
Wheel screws 90 Nm
function, in order to prevent the intake
regulation valve and the air filter from Pressure vessel cover 100 Nm
being flooded with oil when the screw
Safety valve 80 Nm
compressor is turned off.
Engine bearing
on engine 169 Nm
on spring element 180 Nm

9.5.7 Battery maintenance Fig. 33 Compressor bearing

on compressor 90 Nm
Visual inspection of the SCRT® unit:
on spring element 180 Nm
* Check the entire system for visible
Chassis mounting screw 180 Nm
damage (coolant hoses, AdBlue®
pipes, electrical pipes, flexible tubes). Suspension device 180 Nm
* Check the entire system for leaks
(AdBlue®, coolant, exhaust gas).
* Check that hose connections, electrical
plug connections, and screw joints are
tightly connected.

Check condensation drainage

Fig. 32

Danger

The gases released by the battery are

explosive.
Avoid sparks and open fires in the
vicinity of the battery.
Do not allow acids to come into contact
with skin or clothing. Wear safety
goggles.
Place no tools on the battery.
The battery is maintenance-free in
accordance with DIN.

Fig. 34

41
 9. Maintenance

9.6 Spare parts for maintenance 9.7 Inspection intervals for

purposes pressure vessels and
electrical installations
Designation Identification No.
Pressure vessels
Service package 1000 Bh A19053374
As per the requirements of the 97/23/EC
Service package A19008874
Pressure Equipment Directive, a qualified
(fine separator)
person must inspect the pressure vessel
Spare parts list ZS1058479 from inside every five years.
As per the requirements of the 97/23/EC
Service parts Pressure Equipment Directive, an
appointed body must perform a strength
Air filter element A13368674 test on the pressure vessel after ten
Air filter safety element A13368774 years.

Fuel filter set 100011182

Oil filter cartridge (engine)
Advance fuel filter (engine)
Oil filter cartridges
(compressor)
Electrical installation
100011183
The electrical installation must be
100011184 inspected by a qualified electrician after
100015389 four years and also each time work has
been performed on it.

Air-oil separator element 100003725 Should stricter inspection intervals apply

in your country, these must be observed.
Seal for air-oil separator A00652974
element

42
 10. Troubleshooting
10 Tro ublesh ootin g

10.1 General fault rectification 1 11 10 9 10.3 Fault elimination

information
A fault leads either to a warning or the
system shutting down.
Danger

The ʻWarning, maintenance work Warning

underwayʼ sign must be put up before
the following work is undertaken. If there is a warning, the yellow light on
Cordon off the area around the the roof (fig. 35) and the red warning light
workplace as required. (Fig. 37, item 5) on the control panel.
When performing monitoring, 2 3 4 5 6 8 7 The compressor can continue to be
adjustment, or maintenance work, operated. However, the reason for the
Fig. 37
watch out for hot surfaces of machine fault must be eliminated.
parts – especially the exhaust system OK Fault Description
(risk of burns) – and the control
equipment that moves during operation Shutdown
Engine oil pressure
(risk of crushing). During shutdown, the yellow light on the
Pay attention to the safety regulations Engine water temperature * roof flashes and the red warning light (Fig.
in section 3; especially "Hazards 37, item 5) lights up permanently.
Engine water level *
during maintenance and repairs" in The compressor is shut down. A repair /
section 3.9. system check is mandatory; e.g. filling up
Intercooler temperature
Whenever you encounter problems for of AdBlue®.
which no remedy is provided in this Airend temperature
manual, contact your CompAir agent.
Otherwise you will put yourself and Fuel level *
Please proceed as follows:
safe compressor operations at risk.
Water in fuel * * Switch off the ignition.
Attention
D+, Battery voltage, * Eliminate the source of the fault as per
Repair work on the motor and on the generator section 10.4 and 10.5.
SCRT® system may only be carried out
Hardware, Cable break, * Switch the ignition back on again.
by certified service personnel. Refer to
Start against pressure **
your authorized dealer. After some disruptions starting the
Other errors from CAN-Bus compressor is not immediately
(engine) * possible. Press the reset button
Exhaust after-treatment (Fig. 37, item 8), if the icon (fig. 36,
10.2 Warning lights
system (SCRT® system) item 2) appears in the display.
fault *
If the fault has been resolved all the
warning lights go out. Start the
AdBlue® fill level in % compressor.
If the fault is not resolved, or there is
Press the reset button once another fault, the compressor cannot
fault is eliminated be started and additional repairs are
necessary.
* Double assignment of fields for single Also, if the same fault on the SCRT®
fault alerts system has been reset with the reset
** Flashing 50 hours before maintenance button three times within 40 operating
interval: Notice of next maintenance. hours, the compressor can no longer
Fig. 35
Permanent lights OK; provided be started. In this case, the icon
1 2 maintenance interval (every 250 hours) and the symbol SCR appears on a
has lapsed completely.. black background. Refer to your
authorized dealer.
If the and SCR icons flash at the
same time, the same fault has occurred on
the SCRT® system three times within 40
operating hours. The system can only be
restored by authorized service personnel.
The yellow light on the roof (fig. 35)
flashes in the event of errors.
You can find the source of the fault
using the error message in the display
Fig. 36 (numerical combination SPN/FMI Figure
23) in section 10.5.

43
 10. Troubleshooting

10.4 Faults, causes and remedy

Further information on faults is provided in the section on the electronics system (see chapter 10.5).

Problem Possible cause(s) Correction

Insufficient or no air supply Clogged air filter Clean air filter
Clogged oil fine separator filter cartridge Replace compressor oil, oil filter and oil
fine separator filter cartridge
Coupling defective Replace
Wrong setting at controller To be adjusted by a specialist
Plunger inside the intake control valve is not Clean, replace parts if necessary, readjust
fully opened
Insufficient pressure Pressure control valve defective Repair or replace
Control line defective Repair or replace
Piston ring or spring in engine control Repair or replace
cylinder or controller defective
Compressor becomes excessively hot Wrong oil Replace
(automatic shutdown)
Compressor oil level too low Fill up with oil
Fan broken Replace
Oil cooler dirty (outside) Clean
Oil filter clogged Replace
Leak in oil line Repair or replace
Air short circuit Repair
Screw compressor will not start No fuel Fill up with fuel
Fuel filter clogged Replace fuel filter cartridge
Fuel line loose, broken, or jammed Repair line
Operating voltage low Charge battery or replace
Electrical connection loose, corroded, Replace
or broken
Air in system Vent fuel system
Lifter magnet not working Replace
Relay defective Replace
Starter defective Replace
Other engine problems See engine operating manual
Fuse defective Replace
Ignition switch defective Replace
Oil in air line Orifice in oil return line clogged Repair / clean
Oil fine separator defective Replace
Too much oil in pressure tank Correct
Safety valve blows off Controller set too high To be adjusted by a specialist
Pressure control valve defective Replace or repair
Intake control valve, control cylinder, Replace
engine, or connected control lines defective
Safety valve defective Replace
Oil comes out of the air filter of the Intake control valve defective Check and repair
compressor after the screw compressor
has been shut down
Engine starts but switches off again Refer to instrument panel for cause of fault Check and repair
immediately, or the system switches off (refer also to Chapter 11. Electronic
while running system)

44
 10. Troubleshooting

10.5 Troubleshooting
Error information according to CAN-bus, J1939:

SPN = Suspect Parameter Number

FMI = Failure Mode Identifier

Fault information according to CAN bus, J1939:

SPN FMI Problem Possible cause(s) Correction

97 0/15 Water in fuel Water content too high in fuel Check, drain off water from fuel pre-filter,
improve fuel quality
100 1/18 Engine oil level too low Wrong oil level, incorrect grade of oil Check, fill up oil
Defective switch / cable harness Check, replace
105 0 Intercooler temperature Loss of pressure charge air cooler Check, clean
too high too high
Outlet temperature turbocharger too high Check, correct
Operation with open doors (TS...) Check, correct
110 0 Engine water temperature Radiator dirty Check, clean
too high
Cooling air intake blocked Check, correct
Ventilator defective Check, replace
157 1/18 Pressure fuel pump too low Suction resistance too high Check, correct
Air content in fuel too high Examine fuel system for leakages
Clogged fuel filter/prefilter Check, replace filter
No fuel (with external fuelling) Check, fill up
Defective fuel hand pump Check, replace
G1 overvoltage (loose cable) Check, correct
Defective engine cable harness Check, replace
Contact engine manufacturer
Defective sensor Check, replace
Contact engine manufacturer
627 0 Battery supply interrupted System stopped via EMERGENCY STOP Engine electronics system could not shut
F1 failed in operation down properly
Restart system and switch off correctly,
acknowledge error
627 33 Battery supply interrupted Pressing EMERGENCY STOP following SCRT system power supply should be
motor stop maintained for 120 sec.

45
10. Troubleshooting

Further error information according to CompAir:

SPN FMI Problem Possible cause(s) Correction

0 0 Interruption to K1 or F2 defective Check, replace
engine electronics Loose cable on K1, F2, G1, X3, ... Check, correct
Broken belt drive systems (G1) Check, replace
Battery voltage too low Check, correct
1 3 Pressure transducer (DMU1) Defective / wrong pressure transducer Check, replace
(pressure tank)
outside measurement range
< 3 mA
1 21 Pressure transducer (DMU1) Defective / wrong transducer Check, replace
(pressure tank)
outside measurement range > 21
mA
2 0 Operating pressure constantly Intake regulator not closing Check, correct, replace
increasing (during standard Control air to DMU2 interrupted
operation)
Pressure regulator or Y1 defective
2 2 Pressure transducer (DMU2) Defective / wrong transducer Check, replace
(suction controller)
outside measurement range
< 2 mA
2 21 Pressure transducer (DMU2) Defective / wrong transducer Check, replace
(suction controller)
outside measurement range > 21
mA
2 24 ATL 2: Fault on exhaust gas Suction controller defective Check, correct
turbocharger 2 (Suction controller Discharge cylinder defective Check, correct
remains closed) – Caution: Start
Control pipes frozen Check, correct
only possible with additionally
pressed reset button!
5 5 Operating pressure constantly Intake regulator not closing Check, correct, replace
increasing (during warm-up Control air to DMU2 interrupted
phase)
Pressure regulator or Y1 (Y3) defective
102 1 ATL 1: Fault on exhaust gas Exhaust gas turbocharger 1 defective Check, correct
turbocharger 1 (Charge pressure Charge air pipe defective or incorrectly Check, correct
beyond permitted range) – attached
Caution: Start only possible with
Fault on exhaust gas turbocharger 2 Check, correct
additionally pressed reset button!
102 2 ATL 1: Fault on exhaust gas Voltage supply to motor electronics Check, correct
turbocharger 1 (No data reception interrupted
on CAN bus) – Caution: Start only K1 or K2 defective Check, replace
possible with additionally pressed
reset button! Loose cables on K1, F2, G1, X3, etc. Check, correct
Driving belt (G1) ripped Check, replace
Battery voltage too low Check, correct
Charge pressure sensor defective Check, replace
333 3 HJS SCRT = exhaust after- All faults have been reset by certified Caution: Any manipulation of the SCRT®
treatment system fault (following a service personnel. system is forbidden by law.
fault, start approval was forced
multiple times within 40 hours by
pressing the reset button)
522 0 Torque required outside Coupling defective Check, replace
normal range Operating pressure too low Check, correct
Intake controller remains closed Check, correct

46
10. Troubleshooting
SPN FMI Problem
522 1 Resonance
1128 1 ATL 2: Fault on exhaust gas
turbocharger 2 (Charge pressure
beyond permitted range) –
Caution: Start only possible with
additionally pressed reset button!
1128 2 ATL 2: Fault on exhaust gas
turbocharger 2 (Pressure
transducer DMU3 beyond
measuring range < 2 mA) –
Caution: Start only possible with
additionally pressed reset button!
1128 21 ATL 2: Fault on exhaust gas
turbocharger 2 (Pressure
transducer DMU3 beyond
measuring range >21 mA) –
Caution: Start only possible with
additionally pressed reset button!
3368 19 HJS SCRT = exhaust after-
treatment system fault (ECU not
responding
3442 19 HJS SCRT = exhaust after-
treatment system fault (ACU not
responding
3611 Fault on the diesel particle filter
Possible cause(s) Correction
Starter defective / no activation Check, correct
Drag load too high Check, correct
- Intake regulator remains open
- Oil level compressor too low
- Incorrect hydraulic oil
Problems with fuel system Check, correct
- Filter contaminated, frozen, ...
- Air in system
- Defective speed sensor
Contact engine manufacturer
Exhaust gas turbocharger 2 defective Check, replace
Charge air pipe defective or incorrectly Check, correct
attached
Defective or incorrect DMU3 Check, replace
Defective or incorrect DMU3 Check, replace
Defective or incorrect DMU3 Check, replace
Defective cable harness, other connection Check, correct
problems
Defective cable harness, other connection Check, correct
problems
Diesel particle filter soiled or defective Have the diesel particle filter cleaned or
repaired by a specialist dealer
Attention
Continued operation without repair /
cleaning may lead to the filter setting
on fire!
47
10. Troubleshooting

Exhaust gas after-treatment system fault information:

SPN FMI Problem Possible cause(s) Correction

108 3 Ambient pressure sensor fault ACU defective Replace ACU
Open line
108 4 Ambient pressure sensor fault ACU defective Replace ACU
Short-circuit in supply line
168 14 Voltage supply fault Vehicle voltage too low See compressor fault resolution
Vehicle voltage too high See compressor fault resolution
Voltage supply feed faulty Check, repair
639 12 CAN after-treatment fault Supply line / plug connection between ACU Check, repair
and compressor diagnostics defective
Engine control device communication Check, repair
defective
1235 12 CAN engine fault NOx sensor defective Replace sensor
Tank sensor defective Replace sensor
Supply line / plug connection between Check, repair
sensor and ACU defective
1646 12 Internal ACU fault Temporary miscalculation ACU restart
ACU defective Replace ACU
1761 1 AdBlue® fill level too low AdBlue® fill level too low Fill up AdBlue®
1761 12 TQL sensor fault Tank is empty Fill up AdBlue®
AdBlue® fill level Tank is frozen: Tank temperature sensor Replace tank temperature sensor
defective Clean tank and TQL sensor
TQL sensor soiled Replace TQL sensor
TQL sensor defective
2802 12 Internal ACU fault ACU defective Replace ACU
3031 12 AdBlue® temperature sensor TQL Sensor defective Replace TQL sensor
tank unit fault
3216 3 Internal NOx sensor fault NOx sensor defective Replace sensor
3216 5 Internal NOx sensor fault NOx sensor defective Replace sensor
3216 10 Internal NOx sensor fault NOx sensor defective Replace sensor
Plausibility
3217 3 Internal NOx sensor fault NOx sensor defective Replace sensor
3217 5 Internal NOx sensor fault NOx sensor defective Replace sensor
3275 3 Temperature before CRT fault Supply line / plug connection defective Check, repair
Open line Sensor defective Check, replace sensor
3275 4 Temperature before CRT fault Supply line / plug connection defective Check, repair
Short-circuit in supply line Sensor defective Check, replace sensor
3275 16 Temperature after filter too high Filter temperature too high Factory service necessary, perform filter
service, check exhaust has turbocharger
and replace if necessary, check SCR
catalytic converter and replace if
necessary
3275 18 CRT temperature profile Operation with too little load Increase load
3361 3 AdBlue® dosing unit fault Dosing unit defective Check, replace
Short-circuit in battery Supply line / plug connection defective Check, repair
3361 4 AdBlue® dosing unit fault Dosing unit defective Check, replace
Ground short-circuit Supply line / plug connection defective Check, repair
3361 5 AdBlue® dosing unit fault Dosing unit defective Check, replace
Open line Supply line / plug connection defective Check, repair

48
10. Troubleshooting

SPN FMI Problem Possible cause(s) Correction

3363 3 Coolant valve fault Coolant valve defective Check, replace
Short-circuit in supply line Supply line / plug connection defective Check, repair
3363 4 Coolant valve fault Coolant valve defective Check, replace
Ground short-circuit Supply line / plug connection defective Check, repair
3363 5 Coolant valve fault Coolant valve defective Check, replace
Open line Supply line / plug connection defective Check, repair
3509 3 5V - sensor supply Sensor defective Check, replace
Short-circuit in battery supply Supply line / plug connection defective Check, repair
ACU defective Replace ACU
3509 4 5V - sensor supply Sensor defective Check, replace
Ground short-circuit Supply line / plug connection defective Check, repair
3516 12 TQL sensor fault Tank is empty Fill up AdBlue®
AdBlue® quality TQL sensor soiled Clean TQL sensor
TQL sensor defective Replace TQL sensor
Tank is frozen: Tank temperature sensor Replace TQL sensor
defective
3597 3 ACU 24V voltage output fault Supply line / plug connection defective Check, repair
Short-circuit in supply ACU defective Check, replace sensor
3597 4 ACU 24V voltage output fault Supply line / plug connection defective Check, repair
Ground short-circuit ACU defective Check, replace sensor
3598 14 Internal ACU fault ACU defective Replace ACU
3611 3 Pressure sensor fault Supply line / plug connection defective Check, repair
Open line Pressure sensor defective Check, replace sensor
3611 4 Pressure sensor fault Supply line / plug connection defective Check, repair
Ground short-circuit Pressure sensor defective Check, replace sensor
3611 13 Pressure sensor fault Pressure sensor defective Check, replace sensor
3611 15 Differential pressure filter high Filter load limit almost reached Perform filter service during next motor
servicing
3611 16 Differential pressure filter too high Filter load limit reached Perform filter service
3611 18 Differential pressure filter too low Differential pressure sensor hose lines Check, repair
incorrectly connected or defective
Filter defective Replace filter
4129 0 AdBlue® quality fault AdBlue® does not meet specifications Empty AdBlue® tank, rinse with distilled
water, and fill with suitable AdBlue®
4129 1 AdBlue® tank empty AdBlue® fill level too low Fill up AdBlue®
4304 14 Internal ACU fault ACU defective Replace ACU
4334 3 Dosing unit pressure sensor Dosing unit defective Check, replace
Open line Supply line / plug connection defective Check, repair
4334 4 Dosing unit pressure sensor Dosing unit defective Check, replace
Ground short-circuit Supply line / plug connection defective Check, repair
4334 10 Dosing unit pressure sensor Dosing unit defective Check, replace
Plausibility AdBlue® circuit blocked Check, repair
4340 3 AdBlue® line heating 1 Heated line defective Check, replace
Short-circuit in supply Supply line / plug connection defective Check, repair
4340 4 AdBlue® line heating 1 Heated line defective Check, replace
Ground short-circuit Supply line / plug connection defective Check, repair
4340 5 AdBlue® line heating 1 Heated line defective Check, replace
Open line Supply line / plug connection defective Check, repair

49
10. Troubleshooting

SPN FMI Problem Possible cause(s) Correction

4342 3 AdBlue® line heating 2 Heated line defective Check, replace
Short-circuit in supply Supply line / plug connection defective Check, repair
4342 4 AdBlue® line heating 2 Heated line defective Check, replace
Ground short-circuit Supply line / plug connection defective Check, repair
4342 5 AdBlue® line heating 2 Heated line defective Check, replace
Open line Supply line / plug connection defective Check, repair
4344 3 Dosing unit heating Dosing unit internal heating defective Check, replace
Short-circuit in supply Supply line / plug connection defective Check, repair
4344 4 Dosing unit heating Dosing unit internal heating defective Check, replace
Ground short-circuit Supply line / plug connection defective Check, repair
4344 5 Dosing unit heating Dosing unit internal heating defective Check, replace
Open line Supply line / plug connection defective Check, repair
4360 3 Temperature before SCR fault Sensor defective Check, replace
Open line Supply line / plug connection defective Check, repair
4360 4 Temperature before SCR fault Sensor defective Check, replace
Ground short-circuit Supply line / plug connection defective Check, repair
4360 10 Temperature before SCR fault Sensor defective Check, replace
Plausibility
4363 3 Temperature after SCR fault Sensor defective Check, replace
Open line Supply line / plug connection defective Check, repair
4363 4 Temperature after SCR fault Sensor defective Check, replace
Ground short-circuit Supply line / plug connection defective Check, repair
4363 10 Temperature after SCR fault Sensor defective Check, replace
Plausibility
4364 10 AdBlue® system pressure build- Ventilation malfunction Remove AdBlue® lines, empty
up faulty completely, check for consistency, install
AdBlue® line leaking Check, replace
AdBlue® pump defective Check, replace
4374 3 AdBlue® supply unit speed fault Sensor / supply unit defective Check, replace
Open line / short-circuit in supply Supply line / plug connection defective Check, repair
line
4374 4 AdBlue® pump speed fault Sensor / supply unit defective Check, replace
Ground short-circuit Supply line / plug connection defective Check, repair
4375 3 AdBlue® pump control fault Supply unit defective Check, replace
Short-circuit in supply Supply line / plug connection defective Check, repair
4375 4 AdBlue® supply unit control fault Supply unit defective Check, replace
Ground short-circuit Supply line / plug connection defective Check, repair
4375 10 AdBlue® supply unit speed fault Pump motor defective Replace pump
5024 3 Internal NOx sensor fault NOx sensor defective Replace NOx sensor
5024 5 Internal NOx sensor fault NOx sensor defective Replace NOx sensor
5024 10 NOx sensor heating fault Sensor heating defective Replace NOx sensor
Supply line / plug connection defective Check, repair

50
 11. Electronic system
11 Electronic syste m

11.1 Overview Set display contrast (bright), display Individual error display under menu
lighting (on / off) and language: option 3:
1 11 10 9 * select with arrow button (10, 11) E 1 (= continuous Error number)
* move to entry field with reset button (8) Error .... at .... h
-------------------------------------
* change value with arrow button (10, 11) Date :
Time :
* actuate with reset button (8). Eng. Oil Press. : bar
Eng. Water Temp. : C
Intercooler Temp : C
Airend Temp. : C
Menu 2: Operating data of the Working Pressure : bar
compressor Actual Eng. Speed : RPM
2 3 4 5 6 8 7 AirCtrl. Pressure : bar
______- 2 -______________________ Ambient Temp. : C
Fig. 38 Compressor Operating Data SPN / FMI :
1) Rated Eng. Speed : RPM Start OK / K.O. : /
1= Operating pressure in bar and psi 2) Actual Eng. Speed : RPM
2= Individual fault type 3) Load @ Act. Speed : %
3= Engine speed (min-1) and working 4) Fuel Consumption : L/h
5) Engine Oil Press. : bar
SPN and FMI are error codes according to
hours (h) J1939 which are sent by the engine
6) Engine Water Temp. : C
4 = LED green (ok) 7) dp DPF : mbar electronic system.
5 = LED red (fault) 8) Intercooler Temp : C
6 = Start button 9) Charge Air Press : bar Return to menu option 3 with button 9.
7 = Ignition key, Stop (shut down 10) Battery Voltage : V Pressing button 9 again returns the
compressor) 11) Airend Temp. : C display to the original state (see Fig. 38).
8 = Reset button, Enter 12) Control pressure : bar
9 = Choice of menu
10 = Decrease working pressure
11 = Increase working pressure Menu 3: Errors with detailed
information

____________- 3 -____________________
11.2 Operation Qty: No: Error
-------------------------------------
1. Starting the compressor 0 01 Engine Oil Pressure
0 02 Engine Water Temp.
see chapter 7.3
0 03 Intercooler Temp.
2. Changing the operating pressure 0 04 Airend Temperature
see chapter 7.4 0 05 Engine Water Level
0 06 Fuel Level
3. Troubleshooting 0 07 Water in Fuel
see chapter 7.5 0 08 Alternator Voltage
0 09 Hardware
4. Switching off the compressor 0 10 CAN-SPN
see chapter 7.7 0 11 Emergency Stop
0 12 HJS SCRT®

11.3 Menu navigation Qty. = Number of errors, i.e. how often

has this error occurred
Fig. 38 is the main window and shows the
current operating status of the system. No. = Error number
Additional information can be displayed by Error = Error name
pressing button 9.
The number of the menu window appears Using this menu point additional
in the top line. information on the individual errors can be
viewed with the arrow buttons (10, 11).
Menu 1: General information and The individual error display provides
settings operating data of an error. The last error is
displayed. Previous errors can be selected
- 1 -________________________________ with the arrow button 11. This function is
Date : 01.03.07 only available when the unit is at a
Time : 15:00:00 standstill.
Version : V******
Compressor type : DLT2702
WCA-No. : (17 characters)
Engine-No. : (8 characters)
Next service : h

Display Contrast : 140 (preset)

Display Lighting : On/Off (preset)
Language : English (preset)

51
 12. Undercarriage
12 Underc ar riage
12.1 Introduction
Danger
The user forfeits all rights to claim if
parts other than those of the
manufacturer are used.
We reserve the right to modify design
and performance without prior notice.
Please quote axle number, model and
article number when contacting us with
queries or ordering spare parts.
12.2 Safety
* It is most important that the wheel and
the hub are compatible dimensionally.
This means that the P.C.D., wheel
bolts and inset must all be compatible
both with the hub and the rim.
Particular attention must be paid to the
recommended torque figures for the
wheel bolts.
* Use torque wrench!
* No welding is permitted on the rubber
suspension axle.
* Please note the swing arm movement.
(See assembly instructions).
* The wheel brakes are matched to the
overrun devices. Before using an
overrun from another manufacturer,
please check the compatibility with our
Technical Department.
Attention
Model details must not be obscured by
paint now concealed by components.
52
12.3 Height-adjustable towing
system
The adjustable joint between the
drawbar and intermediate arm, and
between the overrun system and
intermediate arm, consists of toothed
heads or retainers with Hirth-type or radial
serrations.
To allow transmission of the towing
torque without any backlash, the nut must
be tightened to the specified torque
setting.
The teeth of the swivel arm (Fig. 39,
pos. 1) and the drawbar are clamped
together with an M36x1.5 bolt. The towing
torque then depends on the permissible
gross weight of the trailer, and the length
of the swivel arm.
Torque setting = 650 Nm
The teeth of the swivel arm and the
overrun device are clamped (Fig. 39,
pos. 2) together with an M28x1.5 bolt.
The nut must be tightened to a torque
setting of T = 400 Nm.
After the teeth have been clamped,
to prevent it working loose the nut must
secured to the bolt with the cotter pin.
The cotter pin is attached to the drawbar
with a chain.
 12. Undercarriage

12.4 Braking system

Before connection or disconnection of

braking system insert security bolt M10.
6

Fig. 39
Deviations from drawing possible
Danger

The handbrake lever is preloaded.

Remove the red security bolt only after
complete assembly of the braking
system including the connection of
the brake rod to the hitch. When any
servicing or disconnection of the
braking system takes place, reinsert
the security bolt. If attention to these
points is ignored, then the handbrake
lever can fly off, due the mechanics
of the preloaded system.
Fig. 40
Attention
Use the jack only under the fixing
brackets or at the chassis, never in the
centre.
Introduction
* KNOTT over-run brake systems consist
of over-run hitches and wheel brakes
used in combination with KNOTT
torsional thrust spring axles. They are
approved in all countries of the EC and
in Switzerland.
8 7 8 3 5 3 4
Fig. 41 Over-run hitches
* Both the KNOTT torsional thrust spring The KNOTT overrun systems are
axles and the KNOTT rubber spring mechancal overrun systems with a
axles have superb springing and hydraulic shock absorber.
excellent dampening characteristics.
The torsional thrust spring elements
with their vulcanized rubber are 12.5 Adjusting the braking system
pretensioned before being pressed into
the axle tubes. There is no squashing 12.5.1 Preparations
of the rubber during spring action.
Instead the rubber is stretched in * Jack up the trailer
accordance with its characteristics. * Release the handbrake
The results of this combination of
pretensioning and stretching are * Pull out the drawbar [5] of the overrun-
exceptionally long life and zero system as far as it will go
maintenance.
3 4 5 2 1
Attention
* Towing eye and ball coupling may
only be changed by specialists.
* Use a new safety nut every time one
of these items is changed.
* Use specified torque setting:
Towing eyes: M14 10.9: T = 180 Nm
Ball coupling: M14 10.9: T = 125 Nm

* With the KNOTT autoreverse system
ʻBackmatʼ there is no problem changing
the direction of travel from forward to
reverse. The braking system is ready for
immediate operation again when
changing from reverse to forward travel.
* When using the ball coupling,
please follow the instructions given.
Fig. 42 KNOTT overrun brake
1 Contact-breaking cable
2 Trailer coupling ring (varies by type)
3 Handbrake lever
4 Transmission lever
5 Drawbar and bellows

53
 12. Undercarriage
Danger
Always secure the handbrake lever
using the lockscrew before
dismounting the brake linkage.
12.5.2 Preliminary requirements:
* When carrying out adjustments, always
start with the wheel brakes.
* When carrying out adjustments, turn
the wheel only in the direction of
forward travel.
* Always make sure that the lockscrew
has been mounted.
* Do not pre-tension the expanding
locking mechanism in the brake. If
necessary, loosen the brake linkage [6]
at the brake compensator [8].
* Check the expanding locking
mechanism and control cable [11]
for ease of movement.
Attention
* The compression spring [7] may
only be lightly pre-tensioned and
must not become fully compressed
when activated!
* Never readjust the braking system
or brakes by the brake linkage [6] or
turnbuckles (if fitted) in the linkage!
12.5.3 Adjusting the brake
Wrench sizes for adjusting screws [12]
Brake size Wrench size
160x35 / 200x50 SW 17
250x40 SW 19
300x60 SW 22
Fig. 43 KNOTT wheel brake
12 Adjusting screw
13 Cable entry
Tighten the adjusting screw [12] (on the
outside of the brake plate, opposite the
cable entry [13]), turning clockwise until
the wheel can only be turned with difficulty
or not at all.
54
Ease off the adjusting screw [12] in the 12.5.5 Adjusting the brake linkage [6]
anticlockwise direction (approx. 1/2 turn)
until the wheel turns freely. Slight rubbing Adjust the brake linkage [6] so that it is
noises, which do not effect the free turning free of play longitudinally, without initial
of the wheel, are permitted. tension.
When the brake is correctly adjusted, Readjustment
the actuating travel of the control cable * Operate the handbrake lever [3]
[11] will be 5-8 mm. powerfully several times in order to
settle the braking system.
Carry out the adjustment procedure,
as described, on all the wheel brakes * Check the position of the brake
in succession. compensating balances [9 and 10]
which should be at right angles to the
12.5.4 Adjusting the brake direction of towing
compensating system * Check the play in the linkage [6]
* Check that the wheels rotate freely with
the brake released.
Final check
* Check fastenings for security (secure
the hexagon locking nuts of the screw
fastenings for the transmission system,
control cables, brake compensators,
turnbuckle, linkage, etc.).
Fig. 44 KNOTT transmission system for * Check the compression spring [7] for
tandem axle chassis.
initial tension.
Test run
* If necessary, carry out 2-3 brake tests
Brake test
* Recheck the play in the brake linkage
[6] and, if necessary, readjust the
linkage [6] for length free of play
Fig. 45 KNOTT transmission system for
single axle chassis.
6 Brake linkage
7 Compression spring
8 Compensating balance assembly
9 Compensating balance (tandem) or
master compensator
10 Compensating balance (single axle)
11 Control cable
* Always make sure that the lockscrew
has been mounted.
* Preadjust the length of the brake
linkage [6] (slight play permitted).
* Remove lockscrew.
* Operate the handbrake lever [3] and
check the position of the compensating
balances [9 and 10]. They should be at
right angles to the direction of towing.
* If necessary, adjust the position of the
balance [10] and control cables [11]; in
the case of tandem trailers, also adjust
the master compensator [9] on the
linkage [6].
* The compression spring [7] may only be
lightly pre-tensioned and must not
become fully compressed when
activated!
 12. Undercarriage

12.6 Readjusting the braking 12.7 Maintenance and care Split lock Split lever always acts
system on the one-piece
Danger primary shoe
In general, readjusting the wheel brakes Check for smooth
adequately serves to readjust the braking These works may only be effected in operation
system, i.e. to compensate for brake lining specialized workshops.
wear. To readjust the wheel brakes, Replace corroded parts
proceed as described under 'Adjusting the
The split lever must
braking system'. Check the play in the Overrun hitches operate smoothly –
linkage [6] and readjust if necessary.
* After approximately 5000 km at least otherwise the brakes
Attention once a year the system should be may overheat
greased. The split lever must not
* Check the expanding locking
* Reaction test. Pull the handbrake lever be preloaded
mechanism and control cable [11]
as far as possible. Push the ball An important check
* The expanding lock compensator coupling as far back into the overrun- when servicing the
must not be pre-tensioned in the ning hitch as it will go. It should then braking system
brake. push itself out with a gas filled shock
absorber. Tension springs Replace corroded or
* Do not attempt to compensate for
over-stretched springs
ease of movement caused by brake * Grease the ball coupling.
lining wear by readjusting (shorten- Note installation position
ing) the brake linkage [6], e.g. by
way of the linkage screw fastenings Only attach springs on
Testing the brakes the tightening on the
* With the handbrake on, a braking effect brake shoe shield in the
of at least 18% of the permissible gross plate facing the brake
Readjustment
weight must be achieved. shield (tilting moment of
* Operate the handbrake lever [3] the backmat shoe to the
powerfully several times in order to * With the KH power lever, this braking brake shield)
settle the braking system effect must be achieved almost
immediately the slack has been taken Tightening Wedge tightening -
* Check the position of the brake up. comprising:
compensating balances [9 and 10] 1 tightening wedge
(which should be at right angles to the 2 tightening bolts
direction of towing). Toothing of height-adjustable drawbar 1 tightening screw
SW 19 brake 250x40
* Recheck the play in the linkage [6]; * To ensure they continue to engage with KHV35
if necessary, adjust the linkage [6] properly, clean rust and other dirt off SW 17 brake 200x50
again so that it is free of play, but the profiles of the toothed connections with KHV30
without initial tension. at least once a year.
Replace the coated
* Check the positions of the handbrake tightening screw (safety
lever [3], the play in the bowden cable Ball coupling effect) with a new one if
and compression spring [7] (only light * Follow the manufacturer (KNOTT) the safety effect is
initial tension) maintenance instructions. insufficient
General brake shoes
Final check
Wheel brake Check for wear:
* Check the screw fastenings for the every 5000 km, and at
transmission system (control cables, Brake hub Rusty, scored brake least once a year
brake compensators, linkage, etc.) surface – replace the
brake hub check permitted coating
* Check the tension of the compression thickness of 1.5 to 2 mm
spring [7] Do not unscrew or re-
turn the braking surface Coating wear: always
greater on the primary
Whenever possible (one-piece) brake shoe
replace the brake hubs
on both sides of the axle Brake coating surface:
to ensure equal braking 80% contact pattern
Friction carbon provides
Brake Versions mechanically optimum operating
activated split lever friction factor
Simplex brake with
automatic return New state: coatings
when new without
friction carbon: up to
30% less braking power
Pollution: brake
coatings polluted with oil
or grease – shoes must
be replaced

55
 12. Undercarriage

Backmat shoe Components: Brake Brake balancing Ensure right-angled 12.8 Malfunctions and remedies
shoe shield, curve shoe position– Adjust using
and tension springs the hexagonal nuts on Danger
the cables
Smooth operation of the
curve shoe – clean Brake linkage Suspension of the Works on the brake system may only
sliding curves if linkage be carried out in specialized
necessary and lightly workshops.
Counter the screw
grease them with high- The brakes, transmission system,
connections
temperature grease stopping system and cable shaft are
Functional check: checked and approved to meet the
Smooth operation latest EU guidelines. Only components
Wheel bearings
and parts checked to this level may be
Cable holder Single parts: 2 half- General notes used.
liners, one loose
Attention Braking systems require regular
Installation: maintenance by accredited garages to
Attach and detach the Retighten wheel screws or nuts with maintain operational safety. When
cable from outside the specified torque after first loaded replacing braking shoes, make sure
journey or after 50 kilometres which- that all brake shoes of the axle are
Security: Secure the
ever occurs first. Retighten again after replaced.
half-liners by inserting
160 kilometres. In addition, check
cable grommets When working at the wheel brakes,
wheel bearing play. Wheel nuts should
make sure that the springs, the brake
Coupling ring Installation position: be tightened depending on conditions
shoes and the spreading lever are
oval opening facing of use, but at least once every six
correctly installed; observe the correct
outwards months.
sense of rotation.
Assembly Ensure correct
When adjusting the wheel brakes, turn
installation of the brake
Information regarding dual-row angular wheels in forward direction!
shoes – one-piece
bail bearings:
primary shoe must run Basically, a readjustment must be
in the forward drum * These bearings are maintenance-free, effected whenever works are carried
direction onto the shoe have been provided with a lifetime out at the brake system.
support (tightening lubrication. and have an extremely high
device) or rest on it If the wheel brakes or the brake drum
running performance.
have got very hot, continue to drive
Before inserting the * The bearings have been fixed in their carefully on, if possible, until they have
brake hub check again correct position using a safety flanged somewhat cooled down.
for completeness, nut. This flanged nut must be tightened
installation position and Use only genuine replacement parts so
with a torque of 280 +/- 10 Nm.
position of the parts that
* It is recommended to check this
* proper operation and safety is
tightening torque in the course of
ensured
service works.
Transmission system
* operating permission in national
* The flanged nut can only be unscrewed
Cable KNOTT patent – cable and international law is maintained
and re-used once. Afterwards. a new
can be attached and
nut must be used. When releasing or * guarantees remain valid.
detached from outside
tightening the flanged nut, grease the
Detaching: threads slightly, so as to avoid damage
Release cable to the fine thread.
connection
* Due to the high durability and the
Remove cable grommet
maintenance-free design of these dual-
from cable holder
row angular ball bearings, there will be
Fold out and remove the
no damage at the bearings under
outer liner
normal conditions.
Detach the nipple from
the coupling ring * If. due to exceptional circumstances.
problems were to occur with these
Attaching:
bearings, completely new brake drums
The same procedure in
with pressed-in bearings, circlips and
reverse
new locking nuts should be installed in
Smooth operation: principle.
The cable must operate
* Due to the design characteristics of the
smoothly – check on
bearings, the brake drums and the
every service
wheels may have a slight axial and
Replace cables which
tilting play; however, this is
do not operate smoothly
insignificant.
– they can cause the
brakes to overheat * Tighten wheel nuts at the
Cable - check corresponding tightening torque.
suspension

56
 12. Undercarriage
Malfunction
Insufficient braking effect
Brake reacts by jerks
Trailer is braked unilaterally
Trailer is already braked when the
accelerator pedal is released
Reverse driving had to accomplish,
or even impossible
Braking action of hand-brake
insufficient
Wheel brakes get hot
Ball coupling does not rest on ball
Cause
Excessive backlash in brake system
Brake linings not "run in"
Brake linings glazed, oily or damaged
Overrunning hitch hard to operate
Brake linkage is jammed or deformed
Brake Bowden cables rusty or kinked
Excessive backlash in brake system
Shock absorber of overrunning hitch
defective
Backmat brake shoe is jammed in the
brake shoe holder
Wheel brakes are actuated unilaterally
Backmat brake shoe is jammed in the
brake shoe holder
Causes: possibly specified under
"Insufficient braking effect"
Shock absorber of overrunning hitch
defective
Brake system adjusted too tightly
Bowden cables pre-loaded
Backmat brake shoe is jammed in the
brake shoe holder
Incorrect setting
Hand brake not pulled tightly
Causes: possibly specified under
"Insufficient braking effect"
Backmat brake shoe is jammed in the
brake shoe holder
Brake system incorrectly set
Causes: possibly specified under
"Insufficient braking effect"
Backmat brake shoe is jammed in the
brake shoe holder
Wheel brakes dirty
Reversing lever of overrunning hitch is
jammed
Handbrake lever not or only partially
released
Coupling dirty on the inside
Ball of towing vehicle too big
Remedy
Re-adjust brake system
Actuate hand-brake lever slightly; drive 2-3
kilometers
Replace brake shoes completely; clean
braking areas in the brake drums
Grease overrunning hitch
Eliminate cause
Replace Bowden cables
Re-adjust brake system
Replace shock absorber
Replace compl. brake shoes with brake shoe
holders
Re-adjust brake system
Replace compl. brake shoes with brake shoe
holders
see above
Replace shock absorber
Re-adjust brake system
Re-adjust brake system
Replace compl. brake shoes with brake shoe
holders
Re-adjust brake system
Actuate hand-brake lever as far as possible
idem
Replace compl. brake shoes with brake shoe
holders
Re-adjust brake system
idem
Replace compl. brake shoes with brake shoe
holders
Clean
Remove reversing lever, clean it and grease it
with Molykote
Set handbrake lever into zero- position
Clean and grease thoroughly
Check ball diameter: According to DIN 74058,
the ball on the car must not exceed 50 mm in
diameter when new. If the ball diameter
decreases to less than 49.5 mm, the ball has
to be replaced.
The ball must be perfectly spherical
57
Gardner Denver Deutschland GmbH
Argenthaler Str. 11
55469 Simmern
Deutschland

Tel. ++49 (0)6761 832-0

www.compair.com
e-mail: sales@compair.com