Operating and

Service Manual

C20

Kubota D1105 Powered

Compressor

GB 100006734/00 – DC042AA – 9/2004

Operating and
Service Manual

C20
CALIFORNIA
Proposition 65 Warning
Kubota D1105 Powered
Compressor Diesel engine exhaust and some of
its constituents are known to the
State of California to cause cancer,
birth defects, and other reproductive
harm.

GB 100006734/00 – DC042AA – 9/2004

4 DC036AA
Product liability
Consumer protection act 1987 EEC
directive covering product liability
EEC Council Directive No.85/374/EEC has been adopted by
HM Government and becomes effective in the United
Kingdom from March 1988.
Not withstanding other and various legally binding
requirements, the Directive specifically requires
manufacturers of products to provide instructions for the
safe use of such products.
CompAir support all new products being supplied to their
customers with a comprehensive Operator Manual which
clearly defines mandatory instructions for the operation,
safe use and maintenance of the product.
It is the responsibility of the owner or hirer of such products
to ensure that operators are provided with the manual and
are suitably instructed regarding the purpose of the Manual
and its safety instructions. In addition operators should be
suitably and adequately trained in the use of the product.
This is an important notification and in their own
interest owners and hirers must comply.
Foreword
In the design of CompAir Products every effort is made to
make operation, maintenance and overhaul as simple as
possible. To obtain reliable service from the machine
correct and regular maintenance is essential.
This manual has been prepared to assist the user in caring
for this machine and every effort has been made to provide
sufficiently detailed information for a competent person to
be able to do this properly. Provided the instructions are
read carefully and followed by suitable trained persons the
equipment will give long and trouble free service. Similarly,
if the instructions are followed, we cannot foresee
circumstances in which this equipment will present a
health or safety hazard.
It is expected that users will observe normal safe practices
when operating or working on the equipment such as the
safe handling of compressed air, engine exhaust, fuels,
oils, cleaning fluids, lifting and moving the machine,
working inside it and security of the machine if working
underneath. Take care of your machine, keep it clean and
in good mechanical condition.
The standard build of all CompAir Ltd. products are not
intended for use in either Explosive or Potentially Explosive
Atmospheres as defined in Directive 94/9/EC.
The Company reserves the right to change product details without obligation
DC036AA
An Explosive atmosphere is a mixture with air, under
atmospheric conditions, of flammable gases, vapours,
hazes or dust in which, after ignition has occurred,
combustion propagates to the entire unburned mixture and
may cause a hazard.
A potentially Explosive atmosphere is an atmosphere
which could become explosive due to local conditions.
Refer to the appropriate manufacturer’s publications for
operating, maintenance and servicing instructions for
engine or other major factored equipment fitted to this
machine
Where references are made in this book, the towbar end of
the plant is the front, and left and right are as viewed from
the rear.As far as possible the information contained in this
book was correct at the date of publication. The
manufacturers reserve the right to modify specifications in
accordance with new or improved designs.
Whilst every effort is made to maintain accuracy in the
data given all figures must be taken as typical and in no
way binding.
If assistance is required contact your nearest CompAir
Regional Company or Distributor or, if this is not
practicable, contact directly CompAir Ltd, CompAir
Distribution Centre, Claybrook Drive, Washford industrial
Estate, Redditch, Worcestershire B98 0DS, UK.
Control of Substances hazardous to
Health Regulations (COSHH) (United Kingdom)
YOUR ATTENTION IS DRAWN TO THE FOLLOWING
LISTS OF LIQUIDS AND SUBSTANCES USED IN OUR
PRODUCTS WHICH MAY EXPOSE PERSONNEL TO
RISK IF SWALLOWED OR IF SKIN OR FACIAL
CONTACT IS ALLOWED.
1. Portable Air Compressors
Diesel fuel oil.
Compressor and engine lubricating oils and
greases.
Anti-freeze agents and mixes (liquid cooled
engines).
Corrosion inhibitors and conditioners (some
cooling systems).
Battery acid.
2. Pneumatic Tools and Rock Drills
Lubricating oils and greases.
Anti-freeze agents.
Note:
Comprehensive maintenance instructions are contained in
our operator manuals. In the interest of safety these should
be strictly observed at all times.
5
Contents
Section Subject Page
1. Safety
1.1 Operation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 The use of compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Towing the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Before starting the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6 After stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.7 Maintenance and overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.8 When working on the plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.9 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.10 Signs and symbols used on your compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2. Plant information
2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Torque figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 Recommended lubricant for compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Recommended engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 Tool Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6 Recommended Lubricants for the undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3. Plant description
3.1 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Oil separation and recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 Unloading and speed control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4 Blowdown valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.6 Electrical system / control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.7 Protection equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4. Operating instructions
4.1 Initial preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . . . . . . . . . . . 22
4.2 Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . . . . . . . . . . . 22
4.3 To start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . . . . . . . . . . . 24
4.4 During operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . . . . . . . . . . . 25
4.5 To stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . . . . . . . . . . . 25
5. Routine maintenance
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2 Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.3 First 50 hours running only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4 Every 125 hours running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.5 Every 250 hours running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.6 Every 1000 hours / 6 months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.7 Every 12 months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.8 Silencing foam cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6. Planned servicing schedule 30
7. Fault finding chart 31
8. Adjustments
8.1 Off-load air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.2 Engine speed range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9. Detailed servicing
9.1 Checking / replacing the air / oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.2 Cleaning the radiator and oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.3 Servicing the air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

6 DC036AA
Contents / Illustrations

Section Subject Page

10 Undercarriage
10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.3 KHV7.5 height-adjustable Towing System, model B2.5.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.4 Braking System - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10.5 Overrun Hitches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10.6 Braking System Adjustment - Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10.7 Braking System Adjustment - Preliminary Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10.8 Adjusting the brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10.9 Adjusting the brake compensating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.10 Adjusting the brake linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.11 Readjusting the brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10.12 Maintenance and care KNOTT overrun systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11 Undercarriage fault finding 41

Diagram Description Page

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

DC036AA
7
1 Safety
1.1 Operation & maintenance
1.1.1 This machine is designed to compress air for
powering tools and equipment mainly in the
construction, mining and quarrying industries.
Do not attempt to use it for compressing any
other gas.
1.1.2 It is expected that users will employ safe
working practices and will observe any
related legal requirements when operating or
overhauling this machine.
1.1.3 The following notes augment instructions
given elsewhere in this publication and they
are intended as a guide to the safe use of this
machine and its associated compressed air
supply under normal working conditions.
1.1.4 In the United Kingdom, your attention is
drawn to the “Health and Safety at Work Act”
and to relevant codes of practice.
1.2 The use of compressed air
Compressed air can be dangerous
1.2.1 Use only certified pressure vessels of
adequate working pressure.
OTHERS COULD EXPLODE.
1.2.2 Fit a non-return valve or a shut-off valve in the
delivery line if the compressor is to be coupled
in parallel with another compressor or
connected to an air supply system.
1.2.3 Distribution pipework and hoses must be the
correct size and suitable for the working
pressure involved. If working pressures are
above 7 bar (100 lbf/in2) it is recommended
that hoses incorporating safety wires are
used.
1.2.4 Do not use frayed, damaged or deteriorated
hoses. Always store hoses properly and away
from heat sources or direct sunlight. A HOSE
FAILURE CAN CAUSE INJURY.
1.2.5 Use only the correct type and size of hose end
fittings and connections. Use clamps of robust
construction especially made for compressed
air.
8 DC036AA
1.2.6 If using compressed air for cleaning down
equipment, do so with extreme caution. Take
care not to blow debris at yourself or other
persons or into machinery. Use eye
protection.
1.2.7 When blowing through a hose or air line,
ensure that the open end is held securely.
A free end will whip and can cause injury.
Open the supply air cock carefully and ensure
that any ejected particles will be restrained.
A blocked hose can become a
compressed air gun.
1.2.8 Never apply compressed air to your skin or
direct it at another person. Never use
compressed air to blow dust and debris from
your clothing.
1.2.9 Do not use air directly from a compressor for
breathing purposes, e.g. charging air
cylinders, unless the compressor is
specifically designed or equipped for this
purpose.
1.2.10 Never operate a compressed air system, for
example compressor pipework or pneumatic
appliance, at a higher pressure than that for
which it has been designed or rated.
1.2.11 Shut off the air cock at the compressor and
release air pressure before disconnecting a
hose or line unless there is an automatic
valve to give protection at the upstream joint
being separated.
1.3 Towing the compressor
1.3.1 Check the towbar, braking system and
coupling. Check that wheels are secure and
that tyres are in good condition and inflated
correctly.
1.3.2 Connect lighting cable to towing vehicle if
applicable. Check correct operation of all
lights.
1.3.3 On two wheel plant raise propstand/jockey
wheel fully and lock.
1.3.4 Ensure breakaway cable is secured to towing
vehicle (where fitted).
1.3.5 On four-wheel plant, ensure the reversing 1.5.4 Do not refill with fuel while the plant is
brake stop on towing eye shank is running. Keep fuel away from hot pipes.
disengaged. Engage it again when reversing.
1.5.5 Ensure that the engine exhaust is freely
1.3.6 Release the handbrake (where fitted). vented to the atmosphere.

1.4 Before starting the compressor 1.5.6 Do not remove the oil filler cap.

1.5.7 Do not remove the radiator cap. (Liquid-

ensure: cooled engines).
1.4.1 Plant is level and secure with brakes applied
and, wherever possible, is sited with exhaust 1.5.8 Do not carry out adjustments inside the
pointing down wind. canopy when the machine is running, other
than where specifically instructed.
1.4.2 Plant is clean internally.
1.5.9 Do not disconnect the battery.
1.4.3 All air pressure is released from machine.
1.5.10 Do not remove guards.
1.4.4 All hoses and tubing in good condition,
secure and not rubbing. 1.5.11 Do not use the machine in a fire hazard area
unless it is suitably equipped. Do not operate
1.4.5 No fluid leaks. in the presence of toxic fumes.
1.4.6 All fasteners tight. 1.5.12 Be aware that communication with people
nearby will be impaired.
1.4.7 Fluid levels correct. Top up only with specified
oils/coolants. Filler caps must be tight.
1.6 After stopping
1.4.8 All electrical leads secure and in good order.
1.6.1 Ensure that the automatic blowdown valve
1.4.9 Fan belt tension correct. has operated to release all air pressure from
the system.
1.4.10 All guards in place and secure.
1.6.2 Allow radiator to cool before removing filler
1.4.11 Engine exhaust system in good condition and cap. Allow engine to cool before adding
no combustible material lying on or against it. coolant (liquid-cooled engines).

1.4.12 Start and stop procedures are clearly 1.6.3 Remove starting key if fitted.
understood. Before starting close air
discharge cocks. Refer to the operating 1.6.4 Secure and lock all doors at the end of each
instructions. working shift.

1.5 During operation 1.7 Maintenance and overhaul

Before starting any work on the plant:

1.5.1 Keep enclosure doors shut.
1.5.2 Check all pressures and temperatures are
correct. Refer to the operating instructions.
1.5.3 Stop the plant if warning lights show or if
gauges register outside normal limits.
Untrained personnel must not attempt
adjustments. Call in a Plant Fitter to
investigate.
1.7.1 Ensure the appropriate “Maintenance Work in
Progress” sign is prominently displayed on or
near the machine.
1.7.2 Disconnect battery to ensure that machine
cannot be started inadvertently.
1.7.3 Ensure that all air pressure is completely
released from the system.
1.7.4 Stand the plant on level ground.

DC036AA
9
1.7.5 Apply the brakes if fitted. Securely fix the
propstand/jockey wheel on two-wheeled
plant.
1.7.6 Chock wheel or wheels securely if jacking-up
or if working on the brakes. Support towbar
on two-wheeled plant.
1.7.7 Support axle(s) securely if working
underneath or removing a wheel. DO NOT
RELY ON JACKS. Support towbar as 6.
1.7.8 Ensure that any door that opens upwards is
securely fastened when open and that no
door can slam shut and trap you.
1.8 When working on the plant:
1.8.1 Use proper lifting gear of adequate capacity.
1.8.2 Examine condition of lifting bale before lifting
plant by it.
1.8.3 Use the correct tools for the job.
1.8.4 When using a chemical or solvent cleaner,
follow the manufacturer’s instructions.
1.8.5 Do not weld or perform any operation
involving heat near the fuel or oil systems.
Fuel and oil tanks must be completely
purged, e.g. by steam cleaning, before such
operations.
1.8.6 Do not weld or in any way modify any
pressure vessel.
1.8.7 Before clearing the machine for use, check
test that operating pressures, temperatures,
and speed are correct and that the controls
and shut-down devices work correctly.
1.8.8 Finally - remember that using any other than
genuine CompAir UK replacement parts will
invalidate your guarantee.
10
1.9 Disposal
When items of CompAir construction
equipment or tools are to be taken out of
service for disposal it is recommended that
the following instructions are adhered to:
1.9.1 In order to prohibit ‘the bringing back in to
service’ of such equipment or tools by
persons unknown, they should be rendered
unusable in order to avoid improper re-use.
1.9.2 Alternatively all such items of equipment or
tools should be stripped into their component
form for ‘material composition disposal’ e.g.
base metals, plastics, fabrics, glass etc and
be subject to normal industrial waste re-
cycling process.
1.9.3 Bio-degradeable items should be subject to
normal industrial waste disposal processes.
Ensure that no plastic, rubber or composite
materials are disposed of by incineration.
1.9.4 Ensure that all fluid waste e.g. diesel fuel,
lubricating oils and greases, anti-freeze
agents or mixes, refrigerant fluids, corrosive
inhibitors and conditioners, any acids or
alkalies should be kept separated and
disposed of by authorised salvage disposal or
re-cycling systems ensuring that none is
permitted to enter either the industrial or
domestic waste water system.
DC036AA
1.10 Signs and symbols used on your
compressor

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

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

1400-11745 1400-12720 1400-14550

FUEL FILLER HOOK LASHING POINT

1400-13460 1400-13010
PRESSURE VESSEL. RELIEVE OIL DRAIN
ALL PRESSURE BEFORE TOPPING
UP WITH OIL. REFER TO OPERATOR MANUAL

A93634740
SOUND POWER LEVEL

IT IS RECOMMENDED THAT IN THE

INTEREST OF SAFETY:

ALL MISSING OR DAMAGED WARNING

VINYLS SHOULD BE REPLACED AS PART
OF A REGULAR SERVICE.

DC036AA
11
2 Plant information

2.1 Technical data

C20
Performance
Free Air Delivered at 7 bar and max. rev/min to ISO 1217.1996
(T1 measured at compressor inlet filter for application consistency) . . . . . . . . . . . . . . . . . . . . . . 33.6 lt/sec (2.0 m3/min, 71 ft3/min)

On Load Off Load

Normal working pressure range (factory set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 6 bar (85 lbf/in2) 7 bar (100 lbf/in2)
Maximum working pressure range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 7 bar (100 lbf/in2) 8 bar (116 lbf/in2)
Engine speed range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 2800 rev/min 2000 rev/min
Maximum compressor air/oil discharge temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 115° C
(Temperature at manifold is approx. 10° lower)
Maximum permissible ambient temperature at 7 bar continuous full load . . . . . . . . . . . ....... 50° C
Maximum sound power level to 2000/14/EC Directive . . . . . . . . . . . . . . . . . . . . . . . . . ....... 100 dB(A) LWA
Maximum sound pressure level at Operator Position to PNEUROP PN8NTC2.2 @ 7m ....... 84 dB(A) LPA
Compressor
Air inlet filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... . 1 x dry type disposable
................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... .
Air delivery outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... . 1 x 3/4 in. BSP cocks
Load control method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... . Speed control and inlet throttling
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... . Single spin-on canister type
Method of lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... . Oil fed to bearings and rotors
................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... . by air at working pressure
Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... . air blast (aluminium)
Approved lubricating oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... . see para 2.3
Engine
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kubota D 1105 - 3 cylinder
liquid cooled diesel
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . 12 v negative earth
Air inlet filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . 1 x two-stage dry type with safety element
Approved lubricating oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . See Engine Manual
Approved coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . See Engine Manual
Fluid Capacities
Compressor oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 lt (1.42 U.K. gal)
Engine oil system (with filter renewal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 lt (1.1 U.K. gal)
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 lt (7.5 U.K. gal)
General
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1320 mm (4 ft 4 in)
Length, including towbar (straight) to C/L of 2 in towing eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2695 mm (8 ft 10 in)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1068 mm (3 ft 6 in)
Wheel track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1160 mm (3 ft 91/2 in)
Ground clearance, minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 mm (53/4 in)
Towing eye height (towbar horizontal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 mm (1 ft 13/8 in)
Tyre size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 - R10 or 145 - R13
Tyre pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 bar (35 lbf/in2)
Tilt from horizontal, maximum permissible any direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10° continuous, 15° intermittent

Weight (approx.)
Compressor complete, wet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540 kg (1190 lb)

2.2 Torque figures

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

12 DC036AA
2.3 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
temperature 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.
Caution
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.
2.3.3 When using oils with the “Brief Description
HYD 10/HYD 20” in accordance with the
‘Standard Lubricants for Building Machinery
and Vehicles’ published by the ‘Hauptverband
der Deutschen Bauindustrie e.V.’ (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.
2.3.4 If other lubricants are to be used, please
contact:
CompAir Drucklufttechnik GmbH Argenthaler
Straße 11 D-55469 Simmern/Hunsrück
Telephone 06761 / 832-339 Telefax 06761 /
832-421
or your authorized dealer or your local
branch.

Use of the wrong oil leads to impairment

of function.

Change the compressor oil more

frequently than specified if the equipment
is operated under abnormal conditions,
i.e. at a high ambient temperature, high air
humidity or in a dusty environment. If
necessary, analyse the oil.

2.3.1 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.

2.3.2 The viscosity of the lubricants should comply

with viscosity class ISO VG 32 DIN 51519,
July 1976, with 28 - 35 mm2/s(cSt) / 40 ºC, or
if the ambient temperature is constantly
above 25 ºC, with viscosity class ISO VG 46
DIN 51519, July 1976, with 41 - 50
mm2/s(cSt)/40 ºC.

Caution
Conventional engine oils marked HD must
not be used.

DC036AA
13
2.4 Recommended engine oil 2.6 Diesel fuel

2.4.1 Lubricant specifications for the driving engine 2.6.1 Use common diesel fuel with a sulfur content
can be found in the enclosed engine of less than 0.5 %. If the sulfur content is
operating manual. higher, oil has to be changed at shorter
intervals.
2.5 Tool lubricants
2.6.2 The following fuel specifications are
Caution applicable:
Do not run the machine with an empty
oiler tank. The tank must always contain a a) DIN 51 601
minimum of 0.2 l of tool oil.
b) Nato Codes F 54, F 75, and F 76
The wrong tool lubricants lead to deposits
that cause malfunctions in the appliances c) BS 2869: A1 and A2
connected. (observe sulfur content with A2)

2.5.1 For the perfect lubrication of concrete d) ASTM D 975-81 : 1-D and 2-D
breakers and pneumatic spades, we
recommend the use of CompAir oilers or e) VV-F-800a : DF-A, DF-1, and DF-2.
automatic pipe oilers, using the special
synthetic CompAir oil AES 82. Note
See engine instruction manual.
The special advantages of CompAir oil are as
follows: 2.6.3 At low temperatures, paraffin precipitation can
cause blocks in the fuel system and
a) Biodegradable, disruptions in operation. Below outside
temperatures of 0 ºC use winter diesel fuel (to
b) Ice guard down to -50 ºC, for use with sound -15 ºC). (This is usually available at gas
absorbers, stations in good time before the winter
season begins.) Diesel fuel with additives is
c) Very good lubricity, thus wear-reducing, frequently offered for use at temperatures as
low as -20 ºC (“Superdiesel”).
d) No irritating exhaust gases, work in enclosed
rooms possible, Note
Only mix in the tank. First put in the required
e) Good cleaning effect, no residue formation quantity of petroleum, then fill up.

f) Excellent preservation properties, protects See engine instruction manual.

from corrosion.
2.6.4 Below -15 ºC or -20 ºC, petroleum must be
2.5.2 When using compressed air appliances made added.
by other manufacturers, their regulations must
be observed. 2.6.5 If it is necessary to use summer diesel fuel
below 0 ºC, petroleum can also be added up
to 60 %.

2.6.6 In most cases, adequate resistance to low

temperatures can be achieved by adding a
product to improve flow properties (fuel
additive). Consult your engine service station.

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

14 DC036AA
2.7 Recommended lubricants for
the undercarriage

2.7.1 For relubrication use only lithium saponified

grease which fulfils the following
specifications:

a) consistency groups (NLGI) 2 DIN 51818

b) worked penetration 265-295 DIN ISO 2137

c) dripping point > 180 ºC DIN ISO 2176

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

This corresponds to a DIN 51502 lubrication

grease, designation KP2N-4U.

Greases with different thickeners (soap base)

must not be mixed.

Recommended grease: Fuchs Renolit LZR 2.

DC036AA
15
3 Plant description

3.1 Lubrication system (Fig. 1)

3.1.1 When the compressor is running, the entire

system is pressurised and oil is forced from
the pressure vessel (1) to the oil cooler (6).
The cooled oil then passes through a filter (4)
before being injected onto the rotors where it
mixes with the air at the commencement of
compression.

3.1.2 The oil cools the air being compressed, seals

between the rotors and lubricates the drive
shaft and rotor bearings. Oil from the
bearings is returned via internal porting to the
main oil flow by differential pressure.

3.2 Oil separation and recovery (Fig. 2)

3.2.1 The pressure vessel is mounted at the front

right-hand side of the plant. Its purpose is to
separate the oil from the air/oil mixture after
compression has taken place, and to act as
an oil reservoir.

3.2.2 The vessel consists of a vertical steel casing

constructed in accordance with the
appropriate Standards for fusion-welded
pressure vessels. Mounted on top of the
casing is a spin-on type fine separator
element.

3.2.3 The air/oil mixture from the compressor

enters the vessel through a tangential
connection which causes most of the oil to be
centrifuged out to run down the walls of the
casing where it re-joins the main oil flow and
is re-circulated. The air which now holds only
a small amount of fine oil mist, then flows
through the fine separator where the mist is
removed. From there, the collected oil is
returned via the oil scavenge tube (2) and
strainer to the rotor casing by differential
pressure. Its rate of return is controlled by a
restrictor in the scavenge tube connection
elbow at the compressor.

16 DC036AA
 Fig. 1 Lubrication system

1. Pressure vessel
2. Separator scavenge oil return
3. Oil from cooler
4. Oil filter
5. Compressor unit 6
6. Oil cooler
7. Hot oil to cooler 3
8. Air/Oil mixture from compressor

5 2 7

1
8

4
PU 6795

Fig. 2 Oil separation and recovery View A

1. Air to delivery manifold

2. Separator scavenge oil return 5
A
3. Cover
4. Air/oil mixture
from compressor 1
5. Separator 7
6. Drain point
7. Oil feed to cooler 4
8. Pressure vessel casing 2 3
8

PU 6794

DC036AA
17
3.3 Unloading and speed 3.3.6 When the compressor is shut down correctly
control system (Fig. 3) (i.e. delivery cocks are first closed) the
machine will be off-load with the unloader
3.3.1 Compressor air output is controlled by valve held firmly on its seat. As the rotors
unloader valve (15) which regulates the stop turning, pressure in the vessel is
amount of air admitted to the compressor prevented from getting back to the inlet
unit, together with variation of engine speed pipework by the closed unloader valve which
via control cylinder (12). now acts as a non-return valve.

3.3.2 When the compressor is started, the vacuum 3.3.7 The resulting pressure build up within the
created within the unloader body causes the unloader body is utilised to operate blowdown
valve (15) to move down over guide post (14) valve (2).
against plunger (16) and spring (18). Air is
thus admitted to the compressor to build up 3.3.8 As pressure in chamber (20) dissipates, spring
pressure in pressure vessel (11). Vessel (17) moves piston downwards, while the
pressure is piped to the integrated pressure unloader valve remains on its seat, assisted by
regulator (5) and START/RUN valve (9). spring (18). The system is then ready for the
next start-up.
3.3.3 On starting up, pressure (10) by-passes the
pressure regulator via the START/RUN valve
and acts directly on unloader piston (13) and
speed control cylinder. When vessel pressure
reaches approx. 2.75 bar (40 lbf/in2), it moves
piston and unloader valve upward over the Fig. 3 Unloading and speed control
guide post to close off the air intake. At the system
same time it acts on the speed control
cylinder to reduce engine speed to idling 1. Air to delivery manifold
while the machine warms up. 2. Blowdown valve
3. Needle valve
3.3.4 When machine has reached operating 4. Atmospheric vents
temperature, the START/RUN valve is 5. Pressure regulator
pressed. This brings the pressure regulator 6. Diaphragm
into circuit. Spring (17) will then move piston 7. Control air to unloader and
and valve downward to admit more air to the speed control cylinder
compressor, and the engine will speed up. Air 8. Unloading system bleed
pressure will therefore increase in the 9. Start / run valve
pressure vessel and manifold until it 10. Air supply to pressure regulator and
overcomes the pressure regulator spring. The unloading system
attached needle valve (3) will then lift from its 11. Pressure vessel
seat and allow air (7) to act on unloader 12. Speed control cylinder
piston and speed control cylinder to off-load 13. Piston
the machine at 7 bar (100 lbf/in2) and reduce 14. Guide post
engine speed. 15. Unloader valve
16. Plunger
3.3.5 As the demand for air from the machine 17. Spring
varies, regulator (5) will adjust pressure in 18. Plunger spring
chamber (20) in response, and unloader 19. Seal
valve and speed control cylinder will move 20. Chamber
until air demand is exactly matched.
A. Stationary
B. Off-load
C. Full-load

18 DC036AA
 5
4

6 3
10

9 7

8 A

15
B
16
11
14
17
2
13
19
1 18
20
4 12

PU 6782/1

DC036AA
19
3.4 Blow down valve (Fig. 4)
3.4.1 This valve is situated on the pressure vessel.
It operates automatically to release all air
pressure within the system on shut-down,
thus ensuring that the plant is not started
against delivery pressure.
3.5.3 The plant must be run with the canopy doors
closed to obtain the most efficient cooling.
Always select the coolest place possible for
the plant to operate in; refer to Technical Data
for maximum permissible operating ambient
temperatures.

3.4.2 The valve consists of a body (5) which PU 6845

9
contains a fluted valve guide (7), valve (4)
and valve seating washer (3). The valve 1
components are attached to a diaphragm (2),
and the whole is enclosed by a cap (1) at one
end and a screwed cover (6) at the other.
2
3.4.3 When the plant is running, a depression is
created within the unloader body which is
applied to the top of the diaphragm via a 8
7
nylon pipe. Vessel air pressure (10) acts
simultaneously against the underside of the 3
valve (4) and washer (3). The washer is
4
therefore retained firmly on its seat thus
preventing the escape of vessel pressure
through ports (8) in the upper portion of the
valve body. 6 5
10
3.4.4 On shut-down the residual pressure in the
vessel builds up within the unloader body (the
unloader valve now acting as a non-return Fig. 4 Blowdown valve
valve as previously described) and acts on
the top of diaphragm (2). 1. Cap
2. Diaphragm
3.4.5 This pressure on the large area of diaphragm 3. Valve seating washer
(2) is sufficient to overcome the similar 4. Valve
pressure acting on the smaller area of valve 5. Body
(4), therefore the washer (3) is lifted from its 6. Screwed cover
seat so allowing the pressure still in the 7. Valve guide
vessel to escape to atmosphere through ports 8. Port
(8). 9. To unloader body
10. Vessel air pressure
3.5 Cooling system

3.5.1 Heat is continuously extracted from the air

being compressed by the injection of a
controlled flow of cool oil into the compressor
unit rotor casing. This contributes to efficient
compression and results in acceptably low air
delivery temperatures without the need for
other intercoolers or aftercoolers.

3.5.2 The oil itself is cooled in an air blast cooler,

the necessary air flow being provided by a
pusher fan which is mounted on the engine
water pump pulley.

20 DC036AA
3.6 Electrical system / control panel
(Fig. 5)

3.6.1 The electrical system is a 12 volt DC negative

earth system, incorporating a maintenance-
free battery and electric starting. When the
engine is running, a belt-driven alternator
charges the battery and supplies power to the
various operating and protection circuits.

3.6.2 The control panel incorporates an air

pressure gauge (1A) and electrically driven
hourmeter (1B) A 4-position rotary switch
(1G) controls starting and stopping. No
ignition key is required. The panel also carries
the START/RUN valve (1H) and four indicator
lights; one for battery charge (1C) one for low
fuel (1F) one for engine oil pressure, engine
coolant temperature and air delivery
temperature (1D) and one Heater Plug
Indicator (1E).
Fig. 5 Control panel
3.6.3 Behind and below the control panel is the
circuit protection fuse-holder which carries 1A. Air delivery pressure gauge
blade type fuses. Each of these will illuminate 1B. Hourmeter
to indicate that it has blown. 1C. Battery charge warning light
1D. Shut-down warning light
3.6.4 The front of the control panel also carries a 1E. Heater plug indicator light
graphical operating instruction vinyl. 1F. Low fuel light
1G. Four position rotary switch
3.7 Protection equipment 1H. Start / run valve

3.7.1 Your machine will shut down automatically if

any one of the following occurs:-

a) Low engine oil pressure :-

1.0 bar (14.5 lbf/in2)

b) High engine coolant temperature:-

115ºC (239ºF).

c) High air delivery temperature:-

120ºC (248ºF).

d) Low fuel level.

3.7.2 Should a fault occur, the switch concerned

will cut the power to the engine fuel solenoid
and stop the machine.

3.7.3 A pressure relief valve is also fitted in the

pressure vessel to protect the system against
an undue rise in air pressure.

DC036AA
21
4 Operating instructions

4.1 Initial preparation
4.1.1 On receipt, check the plant for possible loss of,
or damage to, parts. Report any such problem
to your nearest CompAir authorised dealer.
4.1.2 Refer to Technical Data or Engine Manual for
fuel and oil capacities and specifications, and
for any fuel system alterations required for high
altitude operation.
4.1.3 Plants are despatched from the factory filled
with oil and coolant and fitted with a
maintenance-free battery. Ensure the battery
connections are tight and engine and
compressor oil and coolant levels are correct.
(See para 4.2.4).
Caution:
Some lubricating oils may not be
compatible with others, and mixing them
can result in the formation of lacquer-type
deposits or sludges. Avoid mixing oils of
differing brands, grades or types.
4.2.5 Check level in fuel tank; ensure there is
sufficient for the task in hand. The tank is
manufactured from polyethylene and level can
be checked visually. Top up if necessary with
fuel of the required specification (see engine
manual).
4.2.6 Check engine oil level as detailed in engine
manual. Top up if necessary.
4.2.7 Check the coolant level in the radiator
a) Remove the radiator filler cap (24)
b) Check the coolant level and if necessary top
up to within 25 - 40 mm of bottom of filler
neck with a suitable anti-freeze mixture, as
detailed in the engine manufacturer’s
handbook.
4.2.8 Close air delivery cocks (2).
4.2.9 Shut enclosure and open control panel door.

4.1.4 Refer to Engine Manual for all additional

information.

4.2 Before starting (Fig. 6)

Warning:
Engine exhaust extension pipes are a fire
hazard and must not be fitted to the
machine.

4.2.1 Ensure plant is standing level with handbrake

(25) fully applied (vertical).

4.2.2 Check gauge (1A) to ensure no air pressure

within the plant.

4.2.3 Check the following are closed or tight as

applicable:

a) Pressure vessel oil drain (6).

b) Fuel tank drain (19).

4.2.4 Check oil level in pressure vessel.

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

b) If necessary top up with approved oil to

the top mark on the dipstick.

c) Replace and secure filler cap.

22 DC036AA
 Fig. 6 Operating / maintenance locations

1. Control panel 11. Separator oil scavenge restrictor and

1A. Air pressure gauge strainer.
1B. Hourmeter 12. Compressor oil filter
1C. Battery charge warning light 13. Air filter (compressor)
1D. Shut down warning light 14. Air filter service indicator
1E. Heater indicator light 15. Air filter (engine)
1F. Low fuel light 16. Fuel tank filler
1G. Rotary switch 17. Fuel tank drain
1H. Start / run valve 18. Engine air filter dust valve
2. Air delivery cock 19. Battery
3. Air pressure regulator 20. Engine speed control cylinder
4. Blow down valve 21. Fuel lift pump
5. Pressure relief valve 22. Engine oil filter
6. Pressure vessel oil drain 23. Engine coolant drain
7. Air / oil separator 24. Engine coolant filler
8. Pressure vessel oil filler plug/dipstick 25. Handbrake
9. Fuel filter
10. Fuel water separator

DC036AA
23
4.3 To start (Fig.7) 4.3.1
a) Turn rotary switch (1G) 1 position clockwise
Warning: (aux). Control panel lights (1C, 1D) should
Do not use hand-held ether sprays in an come on. If the low fuel light (1F) illuminates
attempt to improve cold starting. The also then there is insufficient fuel in the tank
resulting high energy burn or explosion and the engine cannot be started until more
could be disastrous. fuel has been added.

b) If pre-heat is required (refer to table below),

turn rotary switch 1 position further clockwise
(heater indicator light (1E) illuminates) and
hold for the required length of time, then turn
switch fully clockwise to start. If pre-heat is
not required, turn switch fully clockwise
without pausing in pre-heat position. Release
starter switch when engine has started.
Ensure all panel lights have gone out. If any
show, stop the plant immediately and call
plant fitter to investigate.

Ambient Temperature Preheat Duration

Above 10ºC (50ºF) No Need
Fig. 7 Control panel 10ºC (50ºF) to -5ºC (23ºF) Approx 5 Seconds
Below -5ºC (23ºF) Approx 10 Seconds
Maximum permissible pre-heat duration is 20 Seconds
1A. Air delivery pressure gauge
1B. Hourmeter
1C. Battery charge warning light c) If engine fails to start within five to ten seconds,
1D. Shut-down warning light return rotary switch (1G) to the ‘OFF’ position
1E. Heater plug indicator light and repeat starting sequence after allowing
1F. Low fuel light moving parts to stop and all air has been
1G. Four position rotary switch exhausted.
1H. Start / run valve
4.3.2 Plant will run at idling speed with air pressure
registering about 2.7 bar (40 lbf/in2).

4.3.3 With cold engine, allow machine to warm up for

two minutes then press START/RUN button
(1H). If engine is warm, button can be pressed
immediately. Air pressure will then increase to
7 bar (100 lbf/in2)

4.3.4 Plant is now ready for use. Check tools / hoses

are connected correctly and open required air
delivery cocks.

24 DC036AA
4.4 During operation e) If the light stays on, the fault lies elsewhere.
Replace the coolant temperature switch
Refer to Fault Finding Chart to aid fault connection then check the pressure vessel
analysis. temperature switch in the same way. Check
Refer to engine manual for engine all electrical connections are back in place
information. after the fault has been traced to ensure
correct operation of the protection equipment.
Caution: Finally, replace the engine oil pressure switch
Do not disconnect wiring from battery or connection.
alternator while engine is running.
f) Return the isolating switch anti-clockwise to
4.4.1 Check hourmeter (1B) is recording. ‘OFF’ position on completion.

4.4.2 If oil mist is discharged from the air cocks or Note:

oil consumption is excessive, stop plant and
refer to Fault Finding Chart.
4.4.3 Check battery charge warning light (1C) is
extinguished. If it glows, stop plant and refer
to Fault Finding Chart.
4.4.4 Check the air pressure (1A) is being
maintained between 5.9 and 6.9 bar (85 to
100 lbf/in2) depending on air demand.
4.4.5 Check air filter service indicator (17) is clear.
4.4.6 If the plant stops, check as follows before
switching off isolating switch (1G):-
a) Check control panel lights. If low fuel light
(1F) is lit, switch off isolating switch and re-fill
the fuel tank, then re-start the plant in the
normal way.
b) If the shut-down and charge warning
lights are lit, remove the electrical connection
from the engine oil pressure switch
immediately following shut-down and leave it
off.
It is imperative that these checks are carried
out immediately the plant shuts down, as the
protection circuits will reset themselves as the
plant cools.
4.5 To stop
4.5.1 Close air delivery cocks and allow plant to
idle for 3 minutes. This is especially
important if plant has been working at full
load for some time prior to shut-down.
4.5.2 Return isolating switch (1G) to the ‘OFF’
position.
Note:
This switch is also considered to be the
emergency stop. No other means of stopping
is fitted.
4.5.3 When engine stops, automatic blowdown
valve will release all air from plant.

c) If the shut-down warning light (1D) goes off, it

indicates that low engine oil pressure or a
faulty engine has caused the shut-down.
Refer to engine manual for problem solving.

d) If the light stays on, it indicates that high

engine temperature or high air delivery
temperature has caused to shut-down.
To identify the source of the fault exactly,
remove the electrical connection from the
engine coolant temperature switch, leaving
the oil pressure switch disconnected. If the
light goes out it indicates a coolant
temperature problem.

DC036AA
25
5 Routine maintenance

5.1 General 5.4 Every 125 hours running

This section of the Manual should be used in
conjunction with the Planned Servicing
Schedule, Detailed Servicing Section and the
engine manual.
Maintenance periods listed should be carried
out according to hours registered on the
hourmeter. We recommend that a
Maintenance Record Log be kept to assist in
an accurate control of maintenance. Ensure
that all compressed air has been released
before working on the plant. Unless carrying
out performance tests and running
adjustments the engine must be stopped.
Prior to undertaking work on any electrical
equipment or associated circuits the battery
must be disconnected. If repairs require the
use of an electric welding set it is essential
that the earth terminal of the set is connected
directly to the part to be welded to prevent
damage to the alternator.
5.2 Daily
5.2.1 Check levels in fuel tank, pressure vessel,
engine sump and radiator; refer to paras
4.2.4, 4.2.5, 4.2.6, 4.2.7 and engine manual.
5.2.2 Check engine air filter service indicator
(Fig.6 (14)). A red signal sleeve becomes
progressively more visible with increasing
filter restriction. If the sleeve is locked in full
view, service the filter; refer to Detailed
Servicing. On completion, reset the indicator
by pressing its reset button.
5.2.3 Examine the plant for fluid leaks, and the
canopy and undercarriage for damage.
5.4.1 Inspect silencing foam for contamination or
damage (where fitted). Refer to para 5.8.
5.4.2 Check condition of canopy, control panel door
and all hinges; oil all hinges, refer to Fig. 7.
5.4.3 Check operation of unloading and speed
control system. (see ‘Adjustments’)
5.4.4 Check tyre pressures; refer to Technical Data.
5.4.5 Check pressure relief valve is free to operate
by turning its knurled top cover anti-clockwise
until air is discharged from the ports in the
base of the valve (Fig. 6 (5)). Screw the cover
down again on completion.
5.4.6 Refer to Maintenance Schedule (engine
manual).
5.5 Every 250 hours running
5.5.1 Carry out 125 hours service.
5.5.2 Torque tighten the bolts attaching towbar to
axle and axle to chassis; refer to Technical
Data.
5.5.3 Check condition of compressor unit air filter
(Fig. 6 (13)) and renew if necessary.
Refer to detailed servicing.
5.5.4 Refer to Maintenance Schedule
(Engine Manual)

5.3 First 50 hours only

5.3.1 Change compressor oil filter element. Refer

to 5.6.2 (c) and (d).

5.3.2 Refer to Maintenance Schedule (engine

manual).

26 DC036AA
 Fig. 6 Operating / maintenance locations

1. Control panel
1A. Air pressure gauge
1B. Hourmeter A
1C. Battery charge warning light
A
1D. Shut down warning light
1E. Heater indicator light B B
1F. Low fuel light
1G. Rotary switch
1H. Start / run valve
2. Air delivery cock
3. Air pressure regulator
4. Blow down valve
5. Pressure relief valve A
6. Pressure vessel oil drain
7. Air / oil separator
8. Pressure vessel oil filler plug/dipstick
9. Fuel filter
10. Fuel water separator
11. Separator oil scavenge restrictor and
strainer.
12. Compressor oil filter
13. Air filter (compressor) A
14. Air filter service indicator
15. Air filter (engine)
16. Fuel tank filler
17. Fuel tank drain
18. Engine air filter dust valve
PU 6779
19. Battery
20. Engine speed control cylinder Fig. 8 LUBRICATION POINTS
21. Fuel lift pump
22. Engine oil filter A - GREASE
23. Engine coolant drain B - OIL
24. Engine coolant filler
25. Handbrake

DC036AA
27
5.6 Every 1000 hours running or
6 months, whichever occurs first
5.6.1 Carry out 250 hours service.
5.6.2 Carry out a compressor system oil change as
follows:
a) Remove pressure vessel filler plug/dipstick.
b) Place a 25 litre (5 gallon) container under
pressure vessel and remove oil drain plug
(Fig 6 (6)).
c) Remove compressor oil filter element. The
filter has a ‘spin-on’ element and this is best
removed using a strap wrench. Position a
container to collect any possible spillage.
d) Fit a new spin-on element, following the
manufacturer’s instructions.
e) Replace pressure vessel oil drain plug.
f) Fill vessel to top mark on dipstick using an
approved grade of oil (refer to Technical
Data). Replace and tighten the filler plug /
dipstick.
g) Run plant for ten minutes then shut down.
ENSURE ALL AIR PRESSURE HAS BEEN
RELEASED FROM THE VESSEL. Wait three
minutes for lubricating oil to settle, then top
up again to top mark on dipstick.
5.6.3 Clean the radiator / oil cooler fins and check
for leaks or damage. Refer to Detailed
Servicing Section for approved cleaning and
servicing procedures.
5.6.4 Clean battery top and terminals. Coat
terminals with petroleum jelly. The battery
supplied with your machine is a maintenance
free type and should require only infrequent
attention.
28
5.6.5 Thoroughly examine and lubricate the
undercarriage. Refer to Detailed Servicing
and Fig. 7.
5.6.6 Check that the plant protection circuits are
functioning correctly as follows:-
a) With the plant running, remove the electrical
connection from the engine oil pressure
switch and touch it onto a good
electrical earth. The plant should shut down.
The shut-down warning light should also
remain on with the connection still earthed.
b) With the oil pressure switch still disconnected,
re-start the plant and repeat the above with
the temperature switches protecting the
pressure vessel and engine. With these,
however, replace each individual connection
before re-starting and proceeding to the next
switch. Ensure all terminals are re-connected
on completion.
c) Replace the engine oil pressure switch
connection.
d) Re-start the machine and, using a length of
clean dowel rod or similar into the fuel tank,
gently press down the float on the low fuel
switch. After a slight delay the machine
should shut down with just the low fuel light
(and battery charge warning light) on the
control panel illuminated. Return the rotary
switch to 'OFF'.
5.6.7 Check run the plant.
5.6.8 Refer to Maintenance Schedule (engine
manual).
DC036AA
5.7 Every 12 months 5.8 Silencing foam cleaning, if fitted
(frequency as required)
5.7.1 Carry out 6 Months Service.
5.8.1 Silencing foam is self extinguishing when
5.7.2 Check / renew air/oil separator. exposed to fire in an uncontaminated
See Detailed servicing. condition but it can be a fire hazard if it is
either damaged or becomes heavily
5.7.3 Remove and clean the oil cooler, internally contaminated with oil, fuel, soot or dust. In
and externally. Refer to Detailed Servicing for the interests of safety the foam should be
the approved cleaning procedures. washed with a detergent regularly and
renewed if necessary. Use material to
5.7.4 Remove and clean internally, all flexible oil BS4735 specification when renewing the
pipes between the oil cooler, compressor and foam and, when using an adhesive, ensure
pressure vessel. that the surface is dry and dust free. Use an
approved adhesive such as 3M Industrial
5.7.5 Steam clean (or similar) the plant. Adhesive type Scotch-Grip 847, obtainable
from your nearest 3M stockists.

5.7.6 Check settings of protection equipment

temperature switches.

Warning:
High temperatures.

a) Remove engine coolant temperature switch

and put a 12 Volt supply and max. 12W bulb
in series with it. Immerse switch in a
container of oil and raise temperature. Bulb
should illuminate at 100oC ± 3o (212oF ± 5o). If
satisfactory, replace switch, otherwise renew
it.

b) Repeat the above with air end temperature

switch. In this case, bulb should illuminate at
120oC ± 3o (248oF ± 5o).

5.7.7 Refer to Maintenance Schedule (engine

manual).

DC036AA
29
6 Planned servicing schedule

6.1.1 The servicing task is shown in the left hand

column and the next column shows where
further information on the indicated tasks
can be found. The next five columns indicate
the frequency with which each task is to be
carried out.
6.1.2 Reading down the columns will indicate which
tasks are to be carried out during that
Maintenance period.
! Warning
!
The use of parts or lubricating oil not supplied or
approved by CompAir, or failure to observe the
maintenance instructions, may have serious Safety
and/or Warranty implications.

6.1.3 You will note that the servicing frequency CompAir accept no responsibility for damage or
injury caused by use of non-approved parts or
extends over a 12 month period, after which failure to comply with maintenance instructions.
the cycle is repeated.

6.1.4 Refer to the engine manufacturer’s handbook

for details of the servicing tasks to be carried
out on the engine.

Every
1000 Hours
Servicing task 125 250 Running or
Hours Hours 6 Months 12
Para Day
Running Running Whichever Months
Occurs First

Check fuel level in tank 4.2.5 • • • • •

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

+ Every 5000 km (3000 miles)

++ Every year if not changed previously.

30 DC036AA
7 Fault finding

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

FAULT POSSIBLE CAUSE REMEDY

Plant fails to start (a) Flat battery, faulty starter, loose or dirty Recharge or replace battery, overhaul starter, tighten
connections, blown fuse or clean connections, diagnose fault and replace fuse.
(b) Fuel tank empty or air or water/ dirt in the Fill fuel tank or clear fuel system and prime using hand
fuel system priming pump
(c) Pressure in the pressure vessel Overhaul or renew blow down valve
(d) Faulty engine Refer to engine manual

Plant starts and stops (a) Bleed hole in fuel filler cap blocked Clear bleed hole
(b) Faulty engine Refer to engine manual

Compressor fails to build (a) Choked air intake filter
up to working pressure (b) Suction unloader valve stuck on seat
(c) Faulty blow down valve
(d) Faulty gauge
(e) Faulty START/RUN valve
Replace air intake filter element
Inspect and release valve through unloader air intake
Overhaul or renew blow down valve
Renew or overhaul gauge
Renew valve

Compressor fails to (a) Suction unloader valve stuck open Inspect and release valve through unloader air intake
off-load (b) Suction unloader/compressor joint leak Tighten nuts or renew joint
(safety valve blowing)
(c) Punctured diaphragm on pressure Inspect and renew
regulator
(d) Pressure relief valve faulty Inspect and rectify
(e) Air/oil separator clogged Renew separator

Plant not operating at (a) Speed control linkage out of adjustment
correct minimum or (b) Engine air intake filter choked
maximum speed
(c) Punctured diaphragm in speed control
cylinder. NOTE: Air issuing from vent in
cylinder will indicate punctured diaphragm
(d) Engine faulty
Excessive compressor (a) Separator scavenge oil restrictor /
oil consumption strainer choked *
(b) Air/oil separator faulty
(c) Incorrect grade of oil
Shut down due to high (a) Plant not standing level or sited badly
air delivery temperature (b) Pressure vessel oil level low
(c) Incorrect grade of compressor oil
(d) Air/oil separator clogged
(e) External surface of oil cooler clogged
(f) Clogging of compressor oil circulating
system
(g) Faulty vessel temperature switch or circuit.
Reset speed control linkage
Replace air intake filter element
Inspect and renew
Refer to engine manual
Clean oil restrictor / strainer
Renew element
Drain, refill with correct grade of oil
Stand plant level or resite for maximum air flow
Top up
Drain, refill with correct grade of oil
Clean or renew element
Clean
Drain, flush and refill circulating system
Change switch/s or check circuit

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

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

Battery charge warning (a) Faulty alternator Refer to engine manual

light on. Engine running (b) Wiring fault Check circuit

* Fitted in oil scavenge line on compressor unit

DC036AA
31
8 Adjustments

8.1 Off-load air pressure (Fig. 9)
8.1.1 The pressure control system fitted to these
machines operates progressively over a
range of approx 1 bar (15 lbf/in2), so that the
off-load air pressure (suction regulator valve
shut, engine idling) is approx 1 bar higher
than the full-load pressure (suction regulator
valve wide open, engine at maximum speed).
8.2.5 Close the air delivery cock and, again using a
strobe, check the engine minimum speed is
correct (see Technical Data). If not, release
locknut (4) on the speed control cylinder and
turn adjusting screw (3) until the correct
minimum speed is obtained. Tighten the
locknut.
8.2.6 Stop the machine.

8.1.2 The normal off-load pressure is 7 bar

(100 lbf/in2) and machines leaving the factory
are set at this figure. However, the system 2
can be adjusted to give off-load pressures
1
between 5.2 bar (75 lbf/in2) and 8 bar (115
lbf/in2) via the pressure regulator. Release the
locknut (2) and turn the adjusting screw (1)
anti-clockwise to lower the off-load pressure,
or clockwise to raise it to the required figure.
PU 6796
8.2 Engine speed range (Fig. 10)
Fig. 9 Pressure regulator
8.2.1 Engine speeds are checked using a 1. Adjusting screw
stroboscopic rev. counter on the engine 2. Locknut
crankshaft pulley. Check air delivery cocks
are closed, start engine and allow to warm
up. Press START/RUN valve. 5

8.2.2 If necessary, adjust off-load air pressure to 4

the required figure - normally 7 bar (100 3
lbf/in2) - as described in paragraph 8.1.2
2
8.2.3 Fit a silencer to an air cock. Gradually open 1
the air cock and lower the delivery air
pressure to the required full load figure -
normally 6 bar (85 lbf/in2) The engine speed
will increase.
PU 6797

8.2.4 Check that the engine is running at its correct

maximum speed (see Technical Data). If not,
adjust the length of the speed control linkage
by releasing locknut (2) and turning ball Fig. 10 Speed control linkage
coupling (1). Keep checking the air pressure
as the engine speed is adjusted, and ensure 1. Ball coupling
that it stays at the required full-load pressure. 2. Locknut
Finally, tighten the locknut. 3. Adjusting screw
4. Locknut
Caution: 5. Speed control cylinder
Do not rotate the piston rod itself during
this operation, otherwise the operating
diaphragm within the speed control
cylinder will be damaged and rendered
unfit for further use.

32 DC036AA
9 Detailed servicing

9.1 Checking / replacing the air/oil

separator (Fig. 11)

9.1.1 Replace the air/oil separator at least once per

year or measure the differential pressure as
1
follows:

9.1.2 Ensure the engine is stopped and there is no

pressure in the compressor system. Unscrew
the dipstick from the pressure vessel.

9.1.3 Screw a pressure gauge into the vacated

dipstick/filler hole and start the compressor.

9.1.4 The difference in pressure between the

pressure gauge on the pressure vessel and
the pressure gauge on the instrument panel
must not exceed 1 bar.

9.1.5 If the differential pressure exceeds 1 bar,

renew the air/oil separator. Replace the
dipstick.
2
9.1.6 Unscrew air/oil separator using a strap
wrench and discard according to the local
regulations.

9.1.7 Clean separator mounting and install the

replacement in accordance with the
manufacturer's instructions.

9.1.8 Check for leaks.

PU 6798
9.2 Cleaning the radiator and oil cooler

Caution:
Cleaning these items is a specialised
function and should be entrusted to Fig. 11 Air/oil separator assembly
qualified contractors. The following
instructions are a general guide only. 1. Air/oil separator
2. Pressure vessel
9.2.1 External
Clean the radiator and cooler fins using a
compressed air or water jet parallel to the
fins. If using cleaning additives with the water
ensure they are compatible with aluminium.

9.2.2. Internal
Due to the nature of the materials necessary
to clean the tanks and tubes successfully,
CompAir UK recommend internal cleaning be
entrusted to qualified contractors.

DC036AA
33
9.3. Servicing the air filters (Fig. 12) vi) Reset the service indicator.

9.3.1 Engine 9.3.2 Compressor

a) Air filter elements need only be checked Note:

when the red field in the service indicator
remains locked in view with plant stopped.
b) The filter contains a large main element and a
smaller safety element. The safety element
should not be cleaned, but should be
renewed after 3 service cycles of the main
element. The main element should be
renewed after 6 cleanings or after 1 year.
c) Check that replacement elements are in good
condition and free from storage or transit
damage. Do not fit an imperfect element; this
could result in costly engine damage.
The compressor air filter element must be
changed annually, or every 250 running
hours, whichever is soonest. The
compressor air filter element is a
disposable item. Do not attempt to clean
or reuse.
To change the air filter element:
a) Unscrew the air filter cover and remove
the old element.
b) Wipe out the inside of the casing and
check for cracks or other damage.

d) To clean the elements:- c) Insert the new air filter element and
replace the air filter cover.
Caution:
Do not wash or brush out main filter
element. The only approved method of
cleaning is as follows:

i) Release the securing clips and remove

dust box. Withdraw main element.

ii) Empty any dust collected in the box and wipe

clean. Ensure the rubber dust valve is
correctly fitted and in good working order;
replace it if worn or damaged.

iii) Service element by directing a jet of dry Fig. 12 Typical engine air filter
compressed air through pleats from inside to
outside. Rotate element while moving jet
slowly up and down inside.

Caution:
Air pressure must not exceed 5 bar
(70 lbf/in2) or damage will result. After
cleaning, inspect condition of element
rubber seals and check paper pleats for
damage by placing a bright light inside.
Thin spots, pin holes or the slightest
break will make the element unfit for
further use.

iv) Wipe out the inside of the filter casing and

check for cracks or other damage.

v) Re-assemble the element and replace dust

box. Secure the clips.

34 DC036AA
10 Undercarriage
10.1 Introduction
Warning
The user forfeits all rights to claim if parts
other than those of the manufacturer are
used.
10.1.1 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.
10.2 Safety
10.2.1 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.
10.2.2 No welding is permitted on the axle.
10.2.3 Please note the swing arm movement. (See
assembly instructions).
10.2.4 The wheel brakes are matched to the overrun
devices. Before using an overrun from
another manufacturer, please check the
compatibility with our Technical Department.
Caution
Model details must not be obscured by
paint now concealed by components.
DC036AA
10.3 KHV7.5 height-adjustable towing
system, model B 2.5.7
10.3.1 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.
10.3.2 The radial serrations are secured with
fastening screws. The fastening nut must be
tightened to the specified torque in order to
establish a no-play, torque transmitting
connection. The tightening torque depends on
the permitted gross weight of the trailer and
the length of intermediate (swivelling) arm.
10.3.3 Adjusting procedure
a) After the spring-loaded plugs have been
released from the fastening nuts, the nuts can
be loosened until the teeth are exposed. The
angle of the intermediate arm can then be
adjusted.
Warning
Care must be taken without fail to ensure
that the overrun or towing system is
always aligned parallel with the drawbar.
The vehicle must not be driven unless the
overrun system is parallel with the
drawbar
b) After the coupling has been adjusted for
height, the serrations should be locked
together with the clamping nuts and secured
against working loose by means of the spring-
loaded plugs.
c) The radial serrations of the intermediary piece
and the drawbar are joined by union bolts,
tightened to a torque of 250Nm
d) The radial serrations of the intermediary piece
and the run-up assembly are joined by union
bolts, tightened to a torque of 100Nm
35
10.4 Braking system - Introduction
10.4.1 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.
10.4.2 With the KNOTT autoreverse system 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.
10.4.3 KNOTT torsional thrust spring axles as well
as rubber spring axles have superb springing
and excellent dampening characteristics. With
the torsional thrust spring axles the spring
elements with their vulcanized rubber are
pretensioned before being pressed into the
axle tubes. There is no squashing of the
rubber during spring action. Instead the
rubber is stretched in accordance with its
characteristics. With the rubber spring axles
the axle tube bears the axle by pretensioned
rubber strings. The results of the stretching
are exceptionally long life and zero
maintenance.
Caution
i) Use the jack only under the fixing
brackets or at the chassis, never in the
centre.
ii) Towing eye and ball coupling may only be
changed by specialists.
iii) Use a new safety nut every time
one of these items is changed.
iv) Use specified torque setting:
Ball coupling
M12 8.8: T = 87 Nm
Towing eyes
M12 8.8 T = 87 Nm
v) When using the ball coupling, please
follow the instructions given.
36
10.5 Over-run hitches
10.5.1 KNOTT over-run hitches are available for
both hydraulic and mechanical brakes.
Handbrake lever with power reservoir, code
“KH”
10.5.2 With the type “KH” the spring reservoir is
under torsion at the centre point. If the
handbrake is applied, then it works
automatically and requires almost no force.
10.5.3 The system is designed so that when the
handbrake is applied, sufficient energy is
stored within the spring. When transmitted
through the brake rods this prevents the
brake shoes from slipping away from the
brake drum.
10.6 Braking System Adjustment -
Preparations (Fig. 13)
10.6.1 Jack up the trailer
10.6.2 Release the handbrake
10.6.3 Pull out the drawbar [5] of the
overrun system as far as it will go
Fig. 13 KNOTT overrun brake
1 Contact-breaking cable
2 Trailer coupling ring (varies by type)
3 Handbrake lever
4 Transmission lever
5 Drawbar and bellows
15 Security bolt
16 Warning plate
Warning
When any disconnection of the braking
system takes place, secure handbrake
lever by reinserting the security bolt [15]
(see warning plate [16]).
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10.7 Braking System Adjustment - 10.8 Adjusting the brake shoes
Preliminary requirements (Figs. 14 & 15)
(Figs. 13 & 15)

10.7.1 When carrying out adjustments, always start

with the wheel brakes.

10.7.2 When carrying out adjustments, turn the

wheel only in the direction of forward travel.

10.73.3 Insert the security bolt [15] (see warning

plate [16]).

10.7.4 Do not pre-tension the expanding locking

mechanism in the brake. If necessary, loosen
the brake linkage [6] at the brake
compensator (See Fig. 15).
Fig. 14 KNOTT wheel brake
10.7.5 Check the expanding locking mechanism and
12 Adjusting screw
control cable [11] for ease of movement.
13 Cable entry

10.8.1 Tighten the adjusting screw [12] (on the

Notes
outside of the brake plate, opposite the cable
entry [13]), turning clockwise until the wheel
i) The compression spring [7] may only be
can only be turned with difficulty or not at all.
lightly pre-tensioned and must not become
fully compressed when activated.
10.8.2 Wrench size for adjusting screws [12] - SW17
ii) Bowden cable [14] must not activate brake.
10.8.3 Ease off the adjusting screw [12] in the
anticlockwise direction (approx. 1/2 turn) until
iii) Never readjust the braking system or brakes
the wheel turns freely. Slight rubbing noises,
by the brake linkage [6] or turnbuckles (if
which do not affect the free turning of the
fitted) in the linkage.
wheel, are permitted.

10.8.4 When the brake is correctly adjusted, the

actuating travel of the control cable [11] will
be 5-8 mm.

10.8.5 Carry out the adjustment procedure, as

described, on all the wheel brakes in
succession.

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37
10.9 Adjusting the brake 10.9.1 Insert the security bolt [15] (see warning plate
compensating system [16] )
(Figs. 15 & 16) 10.9.2 Remove the bowden cable [14].

10.9.3 Preadjust the length of the brake linkage [6]

(slight play permitted).

10.9.4 Insert the bowden cable [14].

10.9.5 Remove the security bolt [15].

10.9.6 Operate the handbrake lever [3] and check

the position of the compensating balance
[10]. It should be at right angles to the
direction of towing.

10.9.7 If necessary, adjust the position of the

balance [10] and control cables [11] on the
linkage [6].

10.9.8 The compression spring [7] may only be

Fig. 15 KNOTT transmission system for lightly pre-tensioned and must not become
single-axle chassis. fully compressed when activated

6 Brake linkage
10.10 Adjusting the brake linkage [6]
7 Compression spring
8 - (Figs. 13, 15 & 16)
9 -
10 Compensating balance (single axle) 10.10.1 Firstly, adjust the brake linkage [6] so that it is
11 Control cable free of play longitudinally, without initial
tension (reversing lever [4] free of play).

10.10.2 Readjustment

a) Operate the handbrake lever [3] vigourously

several times in order to settle the braking
system.

b) Check the position of the brake compensating

balance [10] which should be at right angles
to the direction of towing.

c) Check the play in the linkage [6]; if necessary,

adjust the linkage [6] again so that it is free of
play, but without initial tension. Slight play in
Fig. 16 KNOTT transmission system for the bowden cable [14] must persist.
single-axle chassis.
d) Check the position of the handbrake lever [3];
14 Bowden cable for handbrake when checking the dead centre of the lever,
15 Security bolt resistance starts 10-15 mm above dead
16 Warning plate centre.

e) Check that the wheels rotate freely with the

brake released.

38 DC036AA
10.10.3 Final check
a) Check fastenings for security (secure the
hexagon locking nuts of the screw fastenings
for the transmission system, control cables,
brake compensators, turnbuckle, linkage,
etc.).
b) Check the bowden cable for slight play [14]; if
neccessary, adjust the cable.
c) Check the compression spring [7] for initial
tension.
10.10.4 Test run
a) If necessary, carry out 2-3 brake tests
10.10.5 Brake test
a) Recheck the play in the brake linkage [6] and,
if necessary, readjust the linkage [6] for length
free of play ( during operating braking with
empty trailer should be used maximally 1/2 of
the overrun travel )
10.11 Readjusting the braking system.
10.11.1 In general, readjusting the brake shoes
correctly serves to readjust the braking
system, i.e. to compensate for brake lining
wear.
10.11.2 To readjust the brake shoes, proceed as
described in para 10.8 ‘Adjusting the brake
shoes’.
10.11.3 Check the play in the linkage [6] and readjust
if necessary.
Caution
i Check the expanding locking mechanism
and control cable [11]
ii The expanding lock compensator must not
be pre-tensioned in the brake.
iii Do not attempt to compensate for ease of
movement caused by brake lining wear by
readjusting (shortening) the brake linkage
[6], e.g. by way of the linkage screw
fastenings.
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10.11.2 Readjustment
a) Operate the handbrake lever [3] vigourously
several times in order to settle the braking
system
b) Check the position of the brake compensating
balance [10] (which should be at right angles
to the direction of towing).
c) Recheck the play in the linkage [6]; if
necessary, adjust the linkage [6] again so that
it is free of play, but without initial tension.
d) Check the positions of the handbrake lever
[3], the play in the bowden cable and
compression spring [7] (only light initial
tension).
e) When checking the dead centre of the lever,
resistance starts 10-15 mm above dead
centre.
10.11.3 Final check
a) Check the screw fastenings for the
transmission system (control cables, brake
compensators, linkage, etc.).
b) During operating braking with empty trailer
should be used maximally 1/2 of the overrun
travel
c) Check the bowden cable for slight play [14]; if
neccessary, adjust the cable.
d) Check the tension of the compression spring
[7]
39
10.12 Maintenance and care
KNOTT - overrun systems
10.12.1 The overrun system must be lubricated with
lithium-soap grease by way of the grease
nipples and at all the moving parts.
a) every 5000 km (3000 miles)
b) or every 6 months
c) or if they become stiff
10.12.2 Inspect the bellows for damage, replace if
necessary
10.12.3 Replace the overrun shock absorber every
20,000 km (12,500 miles) or every 3 years at
the latest.
10.12.4 Check the play at the coupling point every
20,000 km (12,500 miles). If the play exceeds
3 mm, replace the guide bearing or drawbar.
10.12.5 Check the tightening torques of the fastening
screws at the guide bearing every 5000 km
(3000 miles);
Screws with grease nipple 50-55 Nm
Screws without grease nipple 80-85 Nm
10.12.6 Check the tightening torques at the clamping
block of the drawbar and clamping socket
(drawbar tube - axle joint) every 5000 km
(3000 miles);
M12 screws 80-85 Nm
M14 screws 90-100 Nm
10.12.7 Check that the braking system is correctly
adjusted every 5000 km (3000 miles).
10.12.8 Vertically adjustable drawbars
Clean the faces of the tooth systems free of
fretting rust or other contamination at least
once a year in order to maintain a good fit.
Lubricate the threaded bolts and joints once a
year or at any time if they become stiff.
Caution
Do not grease the tooth system
10.12.9 If desired, a lifting and adjusting system can
be installed between the drawbar and the
overrun system. The control arms of the
adjusting system permit swivelling about an
angle of -10º to +49º in six positions. In every
case, the overrun system or drawgear always
remains horizontal.
40
10.12.10 An integral gas-filled strut automatically
generates lifting force which reduces the
force required by the user. If the strut
becomes damaged or develops a leak, it
must be replaced.
10.12.11 Information regarding dual-row angular ball
bearings:
a) These bearings are maintenance-free, have
been provided with a lifetime lubrication. and
have an extremely high running performance.
b) The bearings have been fixed in their correct
position using a safety flanged nut. This
flanged nut must be tightened with a torque of
280 +/- 10 Nm.
c) It is recommended to check this tightening
torque in the course of service works.
d) The flanged nut can only be unscrewed and
re-used once. Afterwards. a new nut must be
used. When releasing or tightening the
flanged nut, grease the threads slightly, so as
to avoid damage to the fine thread.
e) Due to the high durability and the
maintenance-free design of these dualrow
angular ball bearings, there will be no
damage at the bearings under normal
conditions.
f) If, due to exceptional circumstances,
problems were to occur with these bearings,
completely new brake drums with pressed-in
bearings, circlips and new locking nuts should
be installed in principle.
g) Due to the design characteristics of the
bearings, the brake drums and the wheels
may have a slight axial and tilting play;
however, this is insignificant.
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11 Undercarriage Fault Finding

Fault Cause Remedy

Insufficient braking effect a) Excessive backlash in brake system a) Re-adjust brake system

b) Brake linings not ‘run in’ b) Actuate hand brake lever slightly;
driive 2-3 kilometers

c) Brake linings glazed, oily or damaged c) Replace brake shoes completely;

clean braking areas in the brake
drums

d) Overrunning hitch hard to operate d) Grease overrunning hitch

e) Brake linkage is jammed or deformed e) Eliminate cause

f) Brake Bowden cables rusty or kinked f) Replace Bowden cables

Brakes snatch when braking a) Excessive backlash in brake system a) Re-adjust brake system

b) Shock absorber of overrunning hitch b) Replace shock absorber

defective.

c) Auto-reverse brake shoe is jammed in c) Replace compl, brake shoe with brake
the brake shoe holder. shoe holders

Trailer is braked unevenly a) Wheel brakes operate unevenly a) Re-adjust brake system

b) Causes: possibility specified under b) see above

“Insufficient braking effect”.

Trailer is already braked when the a) Shock absorber of overrunning hitch a) Replace shock absorber
accelerator pedal is released. defective.

Reverse driving hard to accomplish, or a) Brake system adjusted too tightly a) Re-adjust brake system
even impossible.
b) Bowden cables pre-loaded b) Re-adjust brake system

c) Auto-reverse brake shoe is jammed in c) Replace compl, brake shoe with brake
the brake shoe holder. shoe holders

Braking action of hand brake insufficient a) Incorrect setting a) Re-adjust brake system then actuate
hand-brake lever as far as possible

b) Causes: possibly specified under b) see above

“Insufficient braking effect”

c) Auto-Reverse brake shoe is jammed c) Replace compl, brake shoe with brake
in the brake shoe holder shoe holders

Wheel brakes get hot a) Brake system incorrectly set a) Readjust brake system

b) Causes: possibly specified under b) See above

“Insufficient braking effect”

c) Auto-Reverse brake shoe is jammed c) Replace complete brake shoes and

in the brake shoe holder brake shoe holders

d) Wheel brakes dirty d) Clean

e) Reversing lever of overrunning hitch is e) Remove reversing lever, clean it and

jammed grease it with Molykote

f) Handbrake lever not or only partially f) Fully release handbrake

released.

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41
Fault Cause Remedy

Ball coupling does not rest on ball a) Coupling dirty on the inside a) Clean and grease thoroughly

b) Ball of towing vehicle too big b) Check ball diameter:

According to DIN 74058, the ball on
the car must not exceed 50mm in
diameter when new. If the ball
diameter decreases to less than
49.5mm, the ball has to be replaced.
The ball must be perfectly spherical.

Warning

i) Work on the brake system may only be carried

out in specialised workshops.

ii) When replacing brake shoes, make sure that all

brake shoes of the axle are replaced.

iii) When working on the wheel brakes, make sure

that the springs, the brake shoes and the
spreading lever are correctly installed; observe
the correct direction of rotation.

iv) When adjusting the wheel brakes, turn wheels

in forward direction.

v) After completing any work on the braking

system, the system should be readjusted as
detailed in Sections 10.8 to 10.11

42 DC036AA