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Description B-MA20.21-en 06/2007 Rev.01 Dual-chamber air dryer units LTZ 011, LTZ011-H LTZ012, LTZ012-H
Transcript
Page 1: B-ma20.21 Air Dryer Unit Rev.1

Description B-MA20.21-en06/2007 Rev.01

Dual-chamber air dryer unitsLTZ 011, LTZ011-H

LTZ012, LTZ012-H

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1 General information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Copyright 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Technical changes 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Target group for this document 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 Notes and warning messages 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Introduction 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Related documents 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Basic safety information 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Validity 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Authorized use of the product 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Operator’s commitment to due care 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1 Assignment of personnel 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.2 Availability of the document 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.3 Amendments to the document 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.4 Spares and wearing parts 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Technical description 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Technical features 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Construction 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Working principle 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Removal and installation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Installation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.1 Requirements 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.2 Procedure 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.3 Leakage testing 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.4 Function testing 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Removal 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.1 Requirements 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.2 Procedure 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Maintenance 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Inspection 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.1 Interval 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.2 Special tools 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.3 Procedure 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Servicing 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.1 Interval 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.2 Special tools 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.3 Procedure 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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6.3 Repair 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.1 Auxiliary products and working materials 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.2 Special tool for dual-chamber air dryer units LTZ012, LTZ012-H 30. . . . . . . . . . . .

6.3.3 Procedure 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 Overhaul 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4.1 Interval 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Troubleshooting 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 Special tools 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 Procedure 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 General information

DANGER

Please read this document carefully from start to finish to ensure safety of

operation and to avoid personal injuries and damage to equipment.

1.1 Copyright

KNORR-BREMSE Systeme für Schienenfahrzeuge GmbH

Moosacher Str. 80, 80809 München, Germany

Department: Technical Documentation

Phone: +49 (89) 3547-0

Fax: +49 (89) 3547-2767

All data is protected by copyright. All rights are reserved. The CD containing cus-

tomer documents from KNORR-BREMSE Systeme für Schienenfahrzeuge GmbH

− called �KB SfS" in the following − may be installed and used on a computer

and a connected printer. A copy of the CD may be made provided it is used for

backup only. Any such copy must bear copyright notes (and trade marks).

A hardcopy of the customer documents may be used in-house if it is marked

�confidential". No part of the customer documents may be transmitted to others in

any form whatever.

Any exception to these rules requires the express, written approval of KB SfS.

1.2 Technical changes

KB SfS reserves the right to change the unit or this document at any time without

giving special notice.

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1.3 Target group for this document

This document is intended for use by KB SfS-trained service technicians who

� have the skill, experience, safety awareness and professional ability

− to remove and install the unit,

− to inspect, service and debug the unit,

� have read and understood this document from start to finish and

� are familiar with the safety codes and accident prevention regulations for

these activities.

NOTE

This document will be useful to other target groups as well, e.g. project

engineers.

However, it does not claim to provide complete information for such target

groups.

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1.4 Notes and warning messages

Warning messages are subdivided into the following hazard levels in this docu-

ment:

DANGER

Failure to comply with these instructions will lead to irreversible personal injuries

which may have fatal consequences.

WARNING

Failure to comply with these instructions may lead to irreversible physical injuries

which may have fatal consequences.

CAUTION

Failure to comply with these instructions may lead to personal injuries and/or to

damage to the unit or the environment.

Safety notes have a specific structure which is explained here for DANGER:

DANGER (= word of alert)

Source of the danger

Consequence of the danger

Remedial measures

Notes do not contain any messages relevant to safety and are intended merely to

complete the reader’s information.

NOTE

Notes contain useful hints and additional information about the unit.

Warning messages in other parts of this Description draw your attention to the

individual risks concerning your use of the product. Warning messages and notes

generally precede the descriptions of the relevant applications.

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2 Introduction

This Description contains particulars specific to the unit and discusses operation,

installation, removal, function testing and maintenance of the unit on board.

2.1 Related documents

The related installation drawing specific to each item number must be consulted.

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3 Basic safety information

3.1 Validity

WARNING

Validity note (item number or type designation) ignored!

The consequences may be personal injuries and damage to the unit.

The validity notes in the document must always be taken into account. The item

number or type designation is stated on the name plate and must agree with the

validity note stated in this document.

This document is valid for units with type designations

LTZ011LTZ011-H

LTZ012LTZ012-H

NOTE

Please contact a KB SfS Service Center if the unit cannot be uniquely identified,

e.g. because the name plate is illegible or missing.

3.2 Authorized use of the product

The unit named in Section 3.1 shall be used only in the system that has been de-

signed and engineered by KB SfS for the accompanying vehicle.

Other applications and assignments, as well as changes, attachments and modifi-

cations may jeopardize the safety, reliability and functionality of the system. They

invalidate any warranty on the part of KB SfS and transfer the liability to the oper-

ator.

KB SfS must always be consulted before any other application or assignment is

implemented.

3.3 Operator’s commitment to due care

3.3.1 Assignment of personnel

The operator shall ensure that the personnel assigned to the specified activities

possesses the qualifications defined for the given target group.

3.3.2 Availability of the document

The operator shall ensure that the present document is always available to the rel-

evant personnel in a complete, up-to-date and readable form.

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3.3.3 Amendments to the document

The operator shall ensure that, at the place of use, the present document is reg-

ularly amended by, or replaced with, instructions based on:

� statutory accident prevention regulations

� statutory accident protection regulations

� trade association regulations

3.3.4 Spares and wearing parts

The operator shall ensure that none other than genuine KB SfS parts or KB SfS-

approved spares or wearing parts are used.

The installation of spares other than approved may impair the safety and reliability

of the given unit and overall system and invalidates any warranty on the part of

KB SfS.

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4 Technical description

The model LTZ011, LTZ011-H, LTZ012 and LTZ012-H dual-chamber air dryer units

dry the compressed air to an insignificant residual level and largely prevent mois-

ture from getting inside compressed air systems and causing pneumatic equip-

ment to malfunction and wear prematurely as a result of corrosion and potential

freezing.

4.1 Technical features

See Fig. 1

The unit performs the following main function:

� Reducing the humidity level of the compressed air to an insignificant residual

amount.

Moisture in the compressed air of pneumatic systems may cause the pneumatic

equipment to malfunction and wear prematurely as a result of corrosion and po-

tential freezing.

Atmospheric air always contains water vapour. As long as the moisture stays in

the form of vapour, it is bound inside the air. Only when the saturation limit is ex-

ceeded (= 100% relative humidity), is the water precipitated in the form of

droplets, fog or snow.

Fig. 1 shows how the saturation limit varies with temperature, and how the air is

able to absorb more moisture with rising temperature. This explains why water

cannot be precipitated as the temperature of the air in the compressor rises dur-

ing compression. Precipitation only takes place when the air from the compressor

is cooled down again in the aftercooler.

Let us now illustrate this process in a simple arithmetic example.

At an ambient temperature of +30°C and relative humidity of 80%, one cubic

metre of aspirated air contains 24.5 g water in the form of water vapour.

Hence, one cubic metre of compressed air at 10 bar gauge contains

11 × 24.5 g = 269.5 g water. The temperature of the air rises with increasing com-

pression. After being cooled down to 50°C, however, the air in its saturated state

can hold only 83 g/m3 water vapour, which means that 269.5−83 = 186.5 g/m3

water are precipitated.

This example demonstrates quite clearly that the air in pneumatic systems is al-

ways saturated after being cooled down.

Consequently, any further temperature drop due to natural cooling will cause

precipitation, leading in turn to commonly known problems such as corrosion and

freezing.

Let us now continue our example to illustrate the matter still further.

As the compressed air cools down from 50°C to 20°C it deposits a further quan-

tity of 66 g/m3 water, while cooling to 10°C will produce as much as 74 g/m3.

This arithmetic example shows what a considerable amount of water is still left in

the pneumatic system in the form of vapour, even after the air has been well

cooled in the compressor and the precipitate removed.

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However, a pneumatic system can only work reliably and efficiently if the air in the

system is dried so well that the relative humidity always stays below 35%. Atmos-

pheric corrosion does not take place below this �critical moisture" level, even

when the air contains so-called corrosion stimulators such as acids.

The air dryer units named above work on the heatless regenerative adsorption

principle. This method has proved reliable in rail vehicles in particular, and is the

most efficient arrangement known for this application.

This principle is based on the following physical process.

Humid compressed air flows through a desiccant (adsorbent) of crystalline metal

aluminosilicates which by virtue of their molecular structure have extraordinarily

large, specific inner surfaces and thus withdraw water vapour from the passing air.

Compared with other desiccants, they have the decisive advantage that they are

largely unaffected by oil. The silicate has very regular pore openings sized just to

allow the water molecules to be adsorbed, while the larger oil molecules cannot

be coadsorbed.

Fig. 1 Absolute water content as a function of air temperature

X 100% relative humidity

Y Air temperature (°C)

Z Absolute water content (g/m3)

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4.2 Construction

See Fig. 4 and 5

NOTE

The schematic in Fig. 5 shows a representative construction of a model LTZ012

dual-chamber air dryer unit. The construction of the air dryer units discussed in

the present document differs only in minor details from this representation.

The part numbers used in the following text relate to the dual-chamber air dryer

unit LTZ012 shown in Fig. 4 and 5.

The dual-chamber air dryer units LTZ011, LTZ011-H, LTZ012 and LTZ012-H de-

scribed here consist essentially of the following:

� Two desiccant towers (1), each with an integrated oil separator, and consisting

of bowl (1.10) full of Raschig rings (1.9); versions LTZ011 and LTZ011-H have

two filter cartridges (see Fig. 2)

� Bracket (21) with regeneration choke (61) and the following valves:

− two check valves (26) for the towers,

− a precontrol valve (39) for the control air,

� Duplex piston valve (14)

� Silencer (17) to discharge the regeneration air and to drain the unit

� Valve magnet (27)

� Electronic circuit board (28) for cycle timing

Dual-chamber air dryer units LTZ011 and LTZ012 designated additionally by �-H"

are equipped with a thermostat-controlled cartridge heater as well.

The model LTZ011, LTZ011-H dual-chamber air dryer units have fully exchange-

able filter cartridges (1, Fig. 2) instead of the towers (1).

The model LTZ012, LTZ012-H dual-chamber air dryer units can be equipped with

a slide-in frame (see Fig. 3).

All versions come in variants differing according to the diameter of the regener-

ation choke, the electric connection and the length of the working cycle.

The units can therefore be matched very widely to all possible working conditions.

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Fig. 2 Dual-chamber air dryer unit LTZ011-H (example)

1 Filter cartridge

2 Bracket

17 Duplex piston valve

20 Silencer

26 Valve magnet

57 Housing

A1 Air inlet

A2 Air outlet (optionally us-

able)

E1 Opening for electric con-

nection

K3 Regeneration air outlet

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Fig. 3 Dual-chamber air dryer unit LTZ012-H with a frame (example)

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Fig. 3 (continued) Dual-chamber air dryer unit LTZ012-H with a frame (example)

1 Air dryer unit

2 Frame

3 Deep-groove ball bearing

4 Retaining ring

5 Swivel fitting

6 Pipe

7 Machine screw

8 Lock washer

9 Extension

10 O-ring

11 Thrust screw

12 Thrust ring

13 Sealing ring

14 Pipe

15 Screw plug

16 Sealing ring

17 Thrust screw

18 Sealing ring

19 Thrust ring

20 Extension

21 O-ring

22 Rubber-jacketed cable

23 Connecting case

24 Connector

25 Socket case

30 Rivet

31 Name plate

32 Female connector

34 Sleeve insert

A1 Air inlet

A2 Air outlet

E1 Electric connection

K3 Regeneration air outlet

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Fig. 4 Dual-chamber air dryer unit LTZ012-H (example)

1 Tower

1.5 Bolt

1.10 Bowl

14 Duplex piston valve

17 Silencer

21 Bracket

27 Valve magnet

28 Circuit board

57 Housing

A1 Air inlet

A2 Air outlet

E1 Opening for electric con-

nection

K3 Regeneration air outlet

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Fig. 5 Dual-chamber air dryer unit LTZ012 (schematic)

1.. Tower

1.5 Bolt

1.6 Desiccant

1.9 Raschig rings

1.10 Bowl

14 Duplex piston valve

14.4 Piston

14.5 KNORR K-ring

14.8 KNORR K-ring

14.10 Piston

17 Silencer

21 Bracket

26.. Valve head, check valve

27 Valve magnet

38 KNORR K-ring

39 Piston, precontrol valve

A1 Air inlet

A2 Air outlet

O.. Exhaust port

K3 Regeneration air outlet

V.. Valve seat

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Fig. 6 Pneumatic diagram LTZ012

1 Tower

14 Duplex piston valve

17 Silencer

21 Bracket

26 Check valve

27 Valve magnet

39 Precontrol valve

61 Choke

A1 Air inlet

A2 Air outlet

K3 Regeneration air

outlet

4.3 Working principle

See Fig. 4 to 7

Functional characteristics

A heatless regenerative adsorption dryer of the dual-chamber type operates simul-

taneously in two phases, i.e. drying and regeneration run in parallel. While the

main airstream is being dried in one of the towers, the desiccant is being regener-

ated in the other.

Functional description

Fig. 5 shows the air dryer unit in the operating state in which the tower (1a) is dry-

ing and the tower (1b) is regenerating.

The valve magnet (27) is energized by the electric input signal coming from the

cycle timer; the valve seat V3 is open. The compressed air drawn off the air pipe

to the port A2 flows through the open valve seats V2 and V3 to the duplex piston

valve (14).

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NOTE

The precontrol valve (39) is designed to prevent the duplex piston valve (14) from

assuming an intermediate position. It opens only after the necessary shuttling

pressure has been reached.

The shuttling pressure pushes the pistons (14.4) and (14.10) to the top and bot-

tom positions against the acting spring forces, and thereby opens the valve

seats V5 and V8.

Having been cooled down and predrained, the compressed air delivered by the

compressor flows through the port A1 and the open valve seat V5 to the

tower (1a), passes through this tower from bottom to top and is subsequently redi-

rected down through the central tube and the check valve (26a) to the port A2.

Before the air can enter the desiccant (1.6), it is first carried through the Raschig

ring filling (1.9) in the oil separator (bowl 1.10). Being repeatedly deflected, swirled

and impacted, the minute droplets of oil and water that are still suspended in the

compressed air are precipitated on the relatively large surfaces of the Raschig

rings. They gather to form larger drops which then fall under gravity into the col-

lecting chamber.

As the air passes subsequently through the desiccant it gives off so much of its

water content that the relative humidity of the compressed air leaving the

tower (1a) is less than 35%.

Some of the air thus dried is drawn off, expanded through the regeneration

choke (61) and conveyed through the desiccant in the tower (1b) in the opposite

direction. This expanded air, which is also known as regeneration air, extracts the

moisture from the desiccant that is to be regenerated, and escapes to atmosphere

through the open valve seat V8 and the silencer (17).

Shortly before the desiccant reaches its saturation limit, the unit is shuttled by the

electric cycle timer at T/2 (see Fig. 7), i.e. the valve magnet (27) is deenergized.

The valve seat V3 is closed and the valve seat V4 opened. The control line to the

duplex piston valve�(14) is vented.

As a result, the spring forces push the pistons to the top and bottom positions,

respectively. This action closes the valve seats V5 and V8 and opens the valve

seats V6 and V7.

In this condition, the main airstream (A1 −> A2) is dried in the tower (1b) and the

desiccant is regenerated in the tower (1a). Fig. 7 shows the cycle timing and the

various working phases.

To work correctly, the unit requires a certain shuttling pressure at which the pre-

control valve (39) opens and the duplex piston valve (14) can shuttle.

The two check valves (26) prevent the main reservoir and the onboard pipes from

being vented while the compressor is idle.

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Fig. 7 Diagram of one working cycle

1) Regeneration phase

2) Drying phase

1.. Desiccant tower

T Working cycle

Cycle timing

The cycle timer is switched on together with the compressor. It controls the ON

and OFF times of the valve magnet (27) according to a fixed program.

When the compressor is off or idling, the cycle timer remembers the actual state

and continues the count when the compressor is switched on again. This arrange-

ment ensures that the desiccant to be regenerated is dried entirely and will not get

oversaturated in case the working cycle is displaced.

The air dryer unit is controlled in such a way that compressed air can always con-

tinue flowing through one of the desiccant towers, even if the shuttling facility

works irregularly.

Rating

See Fig. 8

The desiccant towers and the regeneration air choke orifice must be sized to en-

sure that − above a certain ambient temperature limit − the relative humidity of

the dried air is always below 35%.

The performance of an air dryer unit depends on the amount of desiccant used

and on the regeneration air consumption. It is described by the following para-

meters:

� Compressor’s volumetric intake

� Working pressure

� Air inlet temperature

� Ambient temperature limit

� Working cycle

The ratio of desiccant quantity to regeneration air consumption is optimized for

the conditions under which the air dryer units are required to operate in rail ve-

hicles.

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Please observe the following notes on the ambient temperature limit.

It is not advisable to rate an air dryer unit for ambient temperatures below −30°C

if such values occur just rarely within the vehicle’s range of operation. KB SfS

dual-chamber air dryer units are engineered to yield a pressure dew point reduc-

tion of at least 10°C relative to ambient temperature (see Fig. 8). At ambient tem-

peratures below -30°C there is very little risk of corrosion due to elevated humid-

ity; this means the air dryer units can be operated at levels as low as -40°C

without any thought of danger.

The duplex piston valve in the model LTZ�011-H and LTZ012-H air dryer units is

heated by a thermostat-controlled cartridge heater to prevent it from freezing. The

condensate can therefore be discharged reliably to the drainage outlet under all

conditions.

To keep the air dryer units performing at their most efficient level, you should en-

sure that their air inlet temperature is not much above ambient temperature and

never exceeds 60°C.

Fig. 8 Relationship between pressure dew point, ambient temperatureand relative humidity

X Ambient temperature

(°C)

Y Pressure dew point

(°C)

ϕ Relative humidity (%)

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5 Removal and installation

DANGER

Beware of a moving vehicle!

A vehicle allowed to move inadvertently will cause personal injury.

It is vital to observe the working rules for arresting a vehicle.

5.1 Installation

CAUTION

Beware of contaminating the pneumatic system!

Device and/or system functions will fail.

Keep out dirt during installation. If necessary, blow out the pipes of the

pneumatic system.

CAUTION

Beware of disregarding the installation instructions!

Safety will be diminished and functions restricted.

Installation instructions and installation drawings must be taken into account.

CAUTION

Beware of installing untested units!

Safety will be diminished and functions restricted.

Make sure that units are always tested before they are installed.

The system must have been tested and found to be in order before the vehicle is

cleared for service.

NOTE

It is vital to observe the maker’s safety instructions and directions for the use of

cleaning substances, sealants, adhesives, auxiliary products, working

substances, etc.

5.1.1 Requirements

See Fig. 9

The unit can be installed with standard tools.

The unit is designed for installation anywhere in the sprung part of a vehicle, pro-

vided it is protected from wet and dirt. The place of installation must be defined

accordingly when the vehicle is being engineered.

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To keep the air dryer units performing at their most efficient level, you should en-

sure that their air inlet temperature (A1) is not much above ambient temperature.

On no account may the air dryer unit be installed in the immediate vicinity of

sources of heat that might additionally elevate the desiccant temperature.

A good aftercooler (N) downstream of the compressor (K) lowers the air inlet tem-

perature and, hence, the temperature of the desiccant as well. However, the desic-

cant should not fall below a temperature of +10°C.

Fig. 9 shows how an effective aftercooler influences the temperature and water

content of the air prior to entering the air dryer unit. At +50°C inlet temperature,

the air still contains 83 g/m3 water, but only 23 g/m3 at +25°C.

Fig. 9 Construction of an air supply system (schematic)

a Poor aftercooler

b Good aftercooler

T Temperature (°C)

W Water content (g/m3)

K Compressor

N Aftercooler

LTZ Air dryer unit

HL Pipe to main reservoir

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The supply line from the compressor to the air dryer unit must be rustproof steel.

Before attaching any piping to an air dryer unit, take care to remove all traces of

dirt, scale and chippings from inside this piping.

The installation drawing of the unit contains mandatory notes on the mounting

position and necessary clearances.

The vehicle builder’s documents on installation − especially the data on fastening

screws and tightening torques − must also be observed.

5.1.2 Procedure

See Fig. 4

WARNING

Beware of electric shock!

Danger of physical injuries that may have fatal consequences.

Before starting work, switch off the power supply to the electric connection and

prevent it from being restored without due authorization.

� Prior to installing the dual-chamber air dryer unit, thoroughly clean the sealing

surfaces and threads.

� Carefully blow off and blow out the pipes with compressed air to remove and

expel any trace of dirt.

� Locate the air dryer unit on the onboard rack and attach by its fastening

screws.

� Connect the pipes for compressed air inlet and compressed air outlet to the

air dryer unit.

NOTE

Connect the electric circuits correctly. Refer to the applicable vehicle documents,

the circuit diagram of the unit, and the circuit diagrams valid for each of the

component assemblies.

� Connect the ground circuit between the air dryer unit (see ground tag) and

vehicle rack.

� Detach housing (57), run the onboard connecting cable through the bracket

and connect as shown in the circuit diagram.

� Re-attach housing (57).

� Version with a connector: Plug in the connector.

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5.1.3 Leakage testing

WARNING

Beware of electric shock!

Danger of physical injuries that may have fatal consequences.

The work of testing a unit equipped with electric components must always be left

to specially trained and authorized personnel.

Never allow a leakage testing substance to get into contact with electrically live

components.

Carry out the leakage test by applying a leakage testing substance. The test may

be performed alternatively with a soap solution if no such special products are

available.

� Test the pipe connections for leakage at the maximum acceptable working

pressure. Air bubbling is unacceptable.

� Leakage testing substances and all traces of soap must be removed immedi-

ately after the test.

5.1.4 Function testing

The unit is an integral part of a system and must be tested for correct interaction

with this system in the manner instructed by the railway administration / vehicle

builder.

5.2 Removal

WARNING

Pneumatic system is under high pressure!

Particles flung outwards will, for instance, cause severe eye injuries.

Observe the safety regulations for pneumatic systems.

Prior to removal, unload the pressure from the (sub-)system.

CAUTION

Beware of contaminating the pneumatic system!

Device and/or system functions will fail.

Keep out dirt after removal, such as by masking the ports.

5.2.1 Requirements

The unit can be removed with standard tools.

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5.2.2 Procedure

See Fig. 4

WARNING

Beware of electric shock!

Danger of physical injuries that may have fatal consequences.

Before starting work, switch off the power supply to the electric connection and

prevent it from being restored without due authorization.

� Turn off the supply of compressed air and entirely vent all the air pipes con-

nected to the unit.

� Switch off the power supply and prevent it from being restored. Do not allow

electric power to reach the air dryer unit any longer.

� Unplug the connector from the mating socket.

� If your version does not have a connector, detach housing (57) from the air

dryer unit, disconnect the onboard connecting cable and then re-attach hous-

ing (57).

� Disconnect the pipes for compressed air inlet and compressed air outlet from

the air dryer unit.

� Disconnect the ground circuit between the air dryer unit and vehicle frame.

� Remove the fastening screws and lift the air dryer unit off the onboard rack.

� Cover up the ports of the air dryer unit.

� Cover up the onboard air pipes unless a replacement air dryer unit is going to

be fitted immediately after removal.

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6 Maintenance

Maintenance at KB SfS is basically subdivided into:

� Inspection � Servicing � Repair � Overhaul

The maintenance intervals required for the activities described below must be

timed according to the statutory operating requirements, the service conditions

under which the unit is used, and the environmental influences in the area where

the vehicles are run. An interval stated generally for all projects will therefore be of

only limited validity.

KB SfS has the capacity to test the state of its products regularly during their life-

time. The aim of this service is to find jointly with the customer the best mainten-

ance interval for each individual project. The interval applicable to a specific pro-

ject can be derived from the targets named in the table. The first target is always

more significant than the successively lesser targets.

The following tables contain an overview of the necessary maintenance activities.

6.1 Inspection

The unit must be checked for good external condition and correct operation at

regular intervals as specified by the vehicle operator.

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6.1.1 Interval

Activity Interval Valid for

Function test-

ing (the cycle

timer must be

inspected and

the main reser-

voir checked

for water)

1. According to vehicle operator’s project-spe-

cific experience

For all item

numbers cov-

ered by the

validity

2. In accordance with project-specific main-

tenance schedule, if any (*)

Making sure

that the si-

lencer’s regen-

eration air

outlet K3 is

clear

3. According to vehicle operator’s project-spe-

cific experience

4. In accordance with project-specific main-

tenance schedule, if any (*)

Function test-

ing with a pres-

sure dew point

meter**

5. Once a year before winter starts

* If a project-specific maintenance schedule is drawn up, it must be worked out jointly by the cus-

tomer and KB SfS.

** Activity is recommended (see Fig. 10)

6.1.2 Special tools

Item number Name

II 51382 Pressure dew point meter

6.1.3 Procedure

See vehicle operator’s instructions

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Fig. 10 Measuring the pressure dew point

B Main reservoir

DM Pressure dew point

meter

F Micromesh oil filter

K Compressor plus af-

tercooler

L Air dryer unit

S Safety valve

The air dryer unit can be monitored accurately for correct operation using a pres-

sure dew point meter (see Fig. 10). The dew point reading must be below the

boundary curve of 35% relative humidity at the prevailing ambient temperature.

6.2 Servicing

Servicing the air dryer units named in the present Description is confined to

changing the filter cartridges (1, Fig. 2) in units LTZ011 and LTZ011-H.

6.2.1 Interval

Activity Interval Valid for

Changing the

filter cartridges

1 year

LTZ011,

LTZ011-H1. In accordance with project-specific main-

tenance schedule, if any (*)

* If a project-specific maintenance schedule is drawn up, it must be worked out jointly by the cus-

tomer and KB SfS.

6.2.2 Special tools

Strap wrench to release filter cartridges (1, Fig. 2)

6.2.3 Procedure

Change the filter cartridges in accordance with Section 6.3.

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6.3 Repair

Please contact a KB SfS Service Center if the unit develops a malfunction that

cannot be corrected by the measures described in Section 7.2.

Notes on repair, exchanging the desiccant

The desiccant will not need exchanging if it gets oversaturated as a result of a

malfunction in the air dryer unit, e.g. a cycle timing failure. The desiccant is regen-

erated automatically as soon as the unit starts to work normally again. Depending

on the degree of oversaturation, the unit may take several hours of compressor air

delivery until it has fully recovered.

The main reservoir will have to be well drained if large amounts of water have col-

lected there after an air dryer failure.

The life of the desiccant is virtually unlimited under good service conditions. As a

rule, it will be sufficient to exchange the desiccant of units LTZ012 and LTZ012-H

at the time of the main vehicle inspection. However, the desiccant may have to be

exchanged prematurely if it is severely contaminated by dirt and oil.

6.3.1 Auxiliary products and working materials

The following auxiliary products and working materials are needed; they can be

purchased from KB SfS by their order numbers (where stated):

� Chemical cleaning spirit for aluminium alloys, eroding less than 420 mg/(m2 h)

� Grease (order number: ID No. 502647)

� for LTZ012, LTZ012-H: Desiccant (order number: ID No. 503328 or ID No.

503329), see related parts list

� for LTZ011, LTZ011-H: Filter cartridge (item number II17793)

6.3.2 Special tool for dual-chamber air dryer units LTZ012, LTZ012-H

� Special tool according to Fig. 11

Special tools can be purchased from KB SfS by their order numbers (where

stated). Special tools without an order number must be made to the specifications

in the figures. The dimensions specified in the figures are mandatory values. Un-

specified dimensions are left to the toolmaker’s discretion.

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Fig. 11 Thrust member (D)

C11220/3

6.3.3 Procedure

The towers (1) or filter cartridges (1) must be removed before the desiccant can

be exchanged. If lack of space makes this impossible while the air dryer unit is

still on board, the air dryer unit will have to be removed in accordance with Sec-

tion 5.2.

DANGER

Beware of a moving vehicle!

A vehicle allowed to move inadvertently will cause personal injury.

It is vital to observe the working rules for arresting a vehicle.

WARNING

Pneumatic system is under high pressure!

Particles flung outwards will, for instance, cause severe eye injuries.

Prior to removal, unload the pressure from the (sub-)system and observe the

safety regulations for pneumatic systems.

CAUTION

Beware of contaminating the pneumatic system!

Device and/or system functions will fail.

Keep out dirt after removal, such as by masking the ports.

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WARNING

Pretensioned spring (spring force up to about 400 N)!

Pretensioned springs may jump abruptly out of the housing and cause, say,

severe eye injuries.

Perform all the working steps in the specified sequence and use no tools other

than named.

CAUTION

Undue disposal of substances harmful to the environment!

This would mean unnecessary and legally punishable harm to the environment.

Observe the officially applicable waste disposal regulations.

CAUTION

Beware of incorrect handling!

Malfunctions and/or leakage due to damaged sealing surfaces.

Take care not to damage the sealing surfaces in the course of dismantling,

assembling and cleaning the unit.

Exchanging filter cartridge (1) (LTZ011, LTZ011-H)

� Turn off the supply of compressed air and entirely vent all the air pipes con-

nected to the unit.

� Switch off the power supply and prevent it from being restored. Do not allow

electric power to reach the air dryer unit any longer.

� Exchange the filter cartridges. Use a strap wrench to release the filter car-

tridge.

Dismantling the towers (LTZ012, LTZ012-H)

See Fig. 4, 11, 12, 13 and 14

� Turn off the supply of compressed air and entirely vent all the air pipes con-

nected to the unit.

� Switch off the power supply and prevent it from being restored. Do not allow

electric power to reach the air dryer unit any longer.

� Release bolt (1.5), and remove tower (1) from the bracket.

� Turn over the tower (1) and put down on the press bed.

� Apply thrust member (D) to spring retainer (1.12).

� Lower the press punch onto thrust member (D), and adjust the press force to

480 N.

� Unscrew the unloaded nut (1.13).

� Slowly draw back the press punch and remove the unloaded compression

spring (1.11).

� Dismantle the tower (1) (see Fig. 14).

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Fig. 12 Removing and installing the compression spring

1.1 Tower

1.11 Compression spring

1.12 Spring retainer

1.13 Nut

D Thrust member

CAUTION

Undue disposal of substances harmful to the environment!

This would mean unnecessary and legally punishable harm to the environment.

Observe the officially applicable waste disposal regulations.

� Tip out and discard the desiccant (1.6).

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Cleaning the component parts

WARNING

Beware of using auxiliary products and working materials incorrectly!

The skin or respiratory tracts may be harmed or inflamed.

It is vital to observe the maker’s safety codes and directions for use.

NOTE

Prior to putting components in a bath for cleaning, check them for compatibility

with the chemical cleaning spirit. Any component suspected of attack by the

chemical cleaning spirit must be handled and cleaned like a non-metallic part.

� Clean all metal parts with chemical cleaning spirit in a bath at 70°C to 80°C

and then blow dry with compressed air. Read the notes and details on clean-

ing substances in Section 6.3.1.

� Clean all non-metallic parts with a cold cleaning substance and wipe dry with

a cloth.

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Fig. 13 Removing and installing the tower (1)

1 Tower

(1) Filter cartridge

2 O-ring

3 O-ring

4 Ring

5 O-ring

21 Bracket

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Fig. 14 Tower (1)

1.1 Tower

1.2 Washer

1.3 O-ring

1.4 Strainer

1.5 Bolt

1.6 Desiccant

1.7 Retaining ring

1.8 Strainer

1.9 Raschig rings

1.10 Bowl

1.11 Compression spring

1.12 Spring retainer

1.13 Nut

1.14 Sign

Filling up with desiccant

� Put strainer (1.4) in tower (1.1).

� Close the pipe opening (see Fig. 15) and fill up with desiccant.

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� Compact the desiccant by tapping the tower wall gently with a rubber-headed

hammer while simultaneously turning the tower to and fro.

CAUTION

Beware of assembling the unit incorrectly!

The unit might malfunction or its performance be impaired.

To operate the air dryer unit correctly, fill the towers with enough desiccant to

locate the bottom of bowl (1.10) 37mm below the tower rim (see Fig. 15).

Fig. 15 Filling up with desiccant

C11220/2

* Close the tube opening

Assembling the tower (1)

See Fig. 4, 11, 12, 13 and 14

� Assemble the tower (1) in the reverse sequence to disassembly.

� Lubricate O-rings (2) and (3) and O-ring (5) with a thin film of grease.

� Insert a new greased O-ring (1.3) and washer (1.2), and attach tower (1) to

bracket (21) by bolt (1.5); tightening torque 200 Nm.

NOTE

Drain and dry the main reservoir after the desiccant has been exchanged, yet

before the air dryer unit is returned to service.

� Carry out the leakage test in accordance with Section 5.1.3.

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6.4 Overhaul

KB SfS gives top priority to safety and quality.

To guarantee this claim, KB SfS offers to overhaul its own products. KB SfS per-

forms overhauls in its capacity as the original equipment manufacturer, while ac-

counting for the safety aspects of the production processes.

The KB SfS Service Centers have the experience and technical equipment needed

for performing professional overhauls.

6.4.1 Interval

To judge when overhauls are required under the actual service conditions, you are

urged to inspect a few randomly selected units for functionality and condition after

a sufficient period of operation, and dismantle them to check for wear.

Activity Interval

Overhaul

1. According to vehicle operator’s project-specific experience

2. In accordance with project-specific maintenance schedule, if

any (*)

* If a project-specific maintenance schedule is drawn up, it must be worked out jointly by the cus-

tomer and KB SfS.

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7 Troubleshooting

If the unit starts to malfunction, trace possible problems on board. Causes of

trouble can be corrected with the help of the directions proposed for debugging.

7.1 Special tools

Not required

7.2 Procedure

Problem Cause Remedy

Air dryer unit inoperat-

ive

Unit not being acti-

vated pneumatically

Test the unit for correct pneumatic

control.

Unit not being acti-

vated electrically

Test the unit for correct electric

control.

Air discharging con-

stantly from the air pipe

connections

Air pipe connec-

tions leaking

Tighten the air pipe connections

and test for leakage in accord-

ance with Section 5.1.3.

White coating forming

at regeneration air

outlet K3

Desiccant is no

longer good

Exchange the desiccant as de-

scribed in Section 6.3.

Only for LTZ011-H,

LTZ012-H: MR pressure

not rising, although

compressor is running

Air dryer frozen be-

cause heater has

failed

Thaw out the duplex piston valve.

Remove the unit as described in

Section 5.2 and ship to a KB SfS

Service Center for repair.Regeneration air not

discharging from the si-

lencer’s regeneration air

outlet K3 while the com-

pressor is delivering air

Unit defective

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Problem RemedyCause

Strong stream of air

from the silencer’s re-

generation air outlet K3

(provided the air dryer

unit is working correctly,

regeneration air must

be discharged as usual

while the compressor is

delivering air)

Unit defective Remove the unit as described in

Section 5.2 and ship to a KB SfS

Service Center for repair.

Air discharging con-

stantly from exhaust

port O2 (provided the

air dryer unit is working

correctly, a short blast

of air must be dis-

charged at intervals of 4

minutes every second

time the valve magnet

toggles while the com-

pressor is delivering air)

Valve magnet (43) not

toggling while the com-

pressor is delivering air

(the working cycle must

be 2 minutes) and air

not discharging from

exhaust port O2

Air discharging con-

stantly from exhaust

port (O1)

Pressure dew point

above the boundary

curve of 35%

Desiccant dirty Exchange the desiccant as de-

scribed in Section 6.3.

* Observe the following note on disposal.

CAUTION

Undue disposal of substances harmful to the environment!

This would mean unnecessary and legally punishable harm to the environment.

Observe the officially applicable waste disposal regulations.

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Notes:

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DKnorr-BremseSysteme für Schienenfahrzeuge GmbHMoosacher Str. 80

80809 Munich

Germany

Phone: +49 89 3547-0

Fax: +49 89 3547-2767

USANew York Air Brake Corporation748 Starbuck Avenue

Watertown, NY 13601

USA

Phone: +1 315 786-52 00

Fax: +1 315 786-56 76

AKnorr-Bremse GmbHBeethovengasse 43-45

2340 Mödling

Austria

Phone: +43 2236 409-0

Fax: +43 2236 409-412

CDNKnorr Brake Ltd.675 Development Drive

Kingston, Ontario K7M 4W6

Canada

Phone: +1 613 389-46 60

Fax: +1 613 389-87 03

CHOerlikon-Knorr Eisenbahntechnik AGMandachstrasse 50

8155 Niederhasli

Switzerland

Phone: +41 44 852-31 11

Fax: +41 44 852-31 31

BRKnorr-BremseSistemas para Veículos Ferroviários Ltda.Av. Engenheiro Eusébio Stevaux, 1071

Jurubatuba, 04696-902 São Paulo

Brazil

Phone: +55 11 5681-1129

Fax: +55 11 5686-8344

GBKnorr-Bremse Rail Systems (UK) Ltd.Westinghouse Way, Hampton Park East

Melksham, Wiltshire SN12 6TL

United Kingdom

Phone: +44 1225 898 700

Fax: +44 1225 898 705

RSAKnorr-Bremse (SA) (Pty) Ltd.3 Derrick Road (Corner Chestnut Road)

1619 Spartan

South Africa

Phone: +27 11 961-7800

Fax: +27 11 975-8249

HKnorr-Bremse Vasúti JármûRendszerek Hungária Kft.Helsinki út 86.

1201 Budapest

Hungary

Phone: +36 1 421 1100

Fax: +36 1 421 1192

INDKnorr-Bremse India Private Ltd.14/6 Mathura Road

Faridabad-121003 Haryana

India

Phone: +91 129 227-64 09

Fax: +91 129 227-59 35

ESociedad Española de FrenosCalefacciõn y Señales, S.A.Nicolás Fúster, 2

28320 Pinto (Madrid)

Spain

Phone: +34 91 69 10-054

Fax: +34 91 69 10-100

JKnorr-Bremse Rail Systems Japan Ltd.Nishiikebukuro TS Bldg., 8F

3-1-15 Nishiikebukuro

Toshima-ku

Tokyo, 171-0021

Japan

Phone: +81 3 53 91-10 13

Fax: +81 3 53 91-10 22

FFreinrail Systèmes Ferroviaires S.A.47-49 rue Gosset

BP 185

51057 Reims Cedex

France

Phone: +33 3 2679-7200

Fax: +33 3 2679-7201

HKKnorr-Bremse Asia Pacific (Holding) Ltd.Suite 2901, 29/Fl Central Plaza

18 Harbour Road

Wanchai

Hong Kong

China

Phone: +852 2861-2669

Fax: +852 2520-6000

IFrensistemi S.r.l.Via della Cupola, 112

50145 FLorence

Italy

Phone: +39 055 3020-1

Fax: +39 055 3020-333

ROKKnorr-Bremse Rail Systems Korea Ltd.6th Floor, Bongwoo Bldg.

31-7, 1 Ka, Changchung-Dong, Choong-Ku

Seoul 100-391

Korea

Phone: +82 2 22 80-55 55

Fax: +82 2 22 80-55 99

SKnorr-Bremse Nordic Rail Services ABTraktorvägen 8

226 60 Lund

Sweden

Phone: +46 46 3293-50

Fax: +46 46 1489-71

AUSKnorr-Bremse Australia Pty. Ltd.1/2D Factory Street

Granville NSW 2142

Australia

Phone: +61 2 8863-6500

Fax: +61 2 9897-998001/07

Systeme für Schienenfahrzeuge GmbH

Moosacher Str. 80 · 80809 München · Germany · Phone +49 89 3547-0

Fax +49 89 3547-2767 · Homepage http://www.knorr-bremse.com Printed in Germany.


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