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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
B-MA20.21-en
06/2007 Rev.01

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


S have the skill, experience, safety awareness and professional ability
− to remove and install the unit,
− to inspect, service and debug the unit,
S have read and understood this document from start to finish and
S 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


LTZ011 LTZ012
LTZ011-H LTZ012-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:
S statutory accident prevention regulations
S statutory accident protection regulations
S 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:
S 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:
S 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)
S 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,
S Duplex piston valve (14)
S Silencer (17) to discharge the regeneration air and to drain the unit
S Valve magnet (27)
S 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 A1 Air inlet E1 Opening for electric con-


2 Bracket A2 Air outlet (optionally us- nection
17 Duplex piston valve able) K3 Regeneration air outlet
20 Silencer
26 Valve magnet
57 Housing

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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 12 Thrust ring 23 Connecting case


2 Frame 13 Sealing ring 24 Connector
3 Deep-groove ball bearing 14 Pipe 25 Socket case
4 Retaining ring 15 Screw plug 30 Rivet
5 Swivel fitting 16 Sealing ring 31 Name plate
6 Pipe 17 Thrust screw 32 Female connector
7 Machine screw 18 Sealing ring 34 Sleeve insert
8 Lock washer 19 Thrust ring A1 Air inlet
9 Extension 20 Extension A2 Air outlet
10 O-ring 21 O-ring E1 Electric connection
11 Thrust screw 22 Rubber-jacketed cable K3 Regeneration air outlet

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

1 Tower 21 Bracket A1 Air inlet


1.5 Bolt 27 Valve magnet A2 Air outlet
1.10 Bowl 28 Circuit board E1 Opening for electric con-
14 Duplex piston valve 57 Housing nection
17 Silencer K3 Regeneration air outlet

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

1.. Tower 14.8 KNORR K-ring 38 KNORR K-ring


1.5 Bolt 14.10 Piston 39 Piston, precontrol valve
1.6 Desiccant 17 Silencer A1 Air inlet
1.9 Raschig rings 21 Bracket A2 Air outlet
1.10 Bowl 26.. Valve head, check valve O.. Exhaust port
14 Duplex piston valve 27 Valve magnet K3 Regeneration air outlet
14.4 Piston V.. Valve seat
14.5 KNORR K-ring

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Fig. 6 Pneumatic diagram LTZ012

1 Tower 26 Check valve A1 Air inlet


14 Duplex piston valve 27 Valve magnet A2 Air outlet
17 Silencer 39 Precontrol valve K3 Regeneration air
21 Bracket 61 Choke 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:
S Compressor’s volumetric intake
S Working pressure
S Air inlet temperature
S Ambient temperature limit
S 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 LTZ011-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 temperature


and 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 K Compressor LTZ Air dryer unit


b Good aftercooler N Aftercooler HL Pipe to main reservoir
T Temperature (°C)
W Water content (g/m3)

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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.

S Prior to installing the dual-chamber air dryer unit, thoroughly clean the sealing
surfaces and threads.
S Carefully blow off and blow out the pipes with compressed air to remove and
expel any trace of dirt.
S Locate the air dryer unit on the onboard rack and attach by its fastening
screws.
S 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.

S Connect the ground circuit between the air dryer unit (see ground tag) and
vehicle rack.
S Detach housing (57), run the onboard connecting cable through the bracket
and connect as shown in the circuit diagram.
S Re-attach housing (57).
S 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.
S Test the pipe connections for leakage at the maximum acceptable working
pressure. Air bubbling is unacceptable.
S 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.

S Turn off the supply of compressed air and entirely vent all the air pipes con-
nected to the unit.
S Switch off the power supply and prevent it from being restored. Do not allow
electric power to reach the air dryer unit any longer.
S Unplug the connector from the mating socket.
S 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).
S Disconnect the pipes for compressed air inlet and compressed air outlet from
the air dryer unit.
S Disconnect the ground circuit between the air dryer unit and vehicle frame.
S Remove the fastening screws and lift the air dryer unit off the onboard rack.
S Cover up the ports of the air dryer unit.
S 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:


S Inspection S Servicing S Repair S 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- 1. According to vehicle operator’s project-spe-


ing (the cycle cific experience
timer must be
inspected and
the main reser- 2. In accordance with project-specific main-
voir checked tenance schedule, if any (*)
for water)
For all item
Making sure 3. According to vehicle operator’s project-spe- numbers cov-
that the si- cific experience ered by the
lencer’s regen- validity
eration air 4. In accordance with project-specific main-
outlet K3 is tenance schedule, if any (*)
clear

Function test- 5. Once a year before winter starts


ing with a pres-
sure dew point
meter**
* 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 F Micromesh oil filter L Air dryer unit


DM Pressure dew point K Compressor plus af- S Safety valve
meter tercooler

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 1 year


filter cartridges LTZ011,
1. In accordance with project-specific main- LTZ011-H
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):
S Chemical cleaning spirit for aluminium alloys, eroding less than 420 mg/(m2 h)
S Grease (order number: ID No. 502647)
S for LTZ012, LTZ012-H: Desiccant (order number: ID No. 503328 or ID No.
503329), see related parts list
S for LTZ011, LTZ011-H: Filter cartridge (item number II17793)

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


S Turn off the supply of compressed air and entirely vent all the air pipes con-
nected to the unit.
S Switch off the power supply and prevent it from being restored. Do not allow
electric power to reach the air dryer unit any longer.
S 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
S Turn off the supply of compressed air and entirely vent all the air pipes con-
nected to the unit.
S Switch off the power supply and prevent it from being restored. Do not allow
electric power to reach the air dryer unit any longer.
S Release bolt (1.5), and remove tower (1) from the bracket.
S Turn over the tower (1) and put down on the press bed.
S Apply thrust member (D) to spring retainer (1.12).
S Lower the press punch onto thrust member (D), and adjust the press force to
480 N.
S Unscrew the unloaded nut (1.13).
S Slowly draw back the press punch and remove the unloaded compression
spring (1.11).
S Dismantle the tower (1) (see Fig. 14).

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Fig. 12 Removing and installing the compression spring

1.1 Tower 1.12 Spring retainer D Thrust member


1.11 Compression spring 1.13 Nut

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.

S 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.

S 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.
S 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 3 O-ring 5 O-ring


(1) Filter cartridge 4 Ring 21 Bracket
2 O-ring

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Fig. 14 Tower (1)

1.1 Tower 1.6 Desiccant 1.11 Compression spring


1.2 Washer 1.7 Retaining ring 1.12 Spring retainer
1.3 O-ring 1.8 Strainer 1.13 Nut
1.4 Strainer 1.9 Raschig rings 1.14 Sign
1.5 Bolt 1.10 Bowl

Filling up with desiccant


S Put strainer (1.4) in tower (1.1).
S Close the pipe opening (see Fig. 15) and fill up with desiccant.

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S 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
S Assemble the tower (1) in the reverse sequence to disassembly.
S Lubricate O-rings (2) and (3) and O-ring (5) with a thin film of grease.
S 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.

S 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

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


Overhaul 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- Unit not being acti- Test the unit for correct pneumatic
ive vated pneumatically control.

Unit not being acti- Test the unit for correct electric
vated electrically control.

Air discharging con- Air pipe connec- Tighten the air pipe connections
stantly from the air pipe tions leaking and test for leakage in accord-
connections ance with Section 5.1.3.

White coating forming Desiccant is no Exchange the desiccant as de-


at regeneration air longer good scribed in Section 6.3.
outlet K3

Only for LTZ011-H, Air dryer frozen be- Thaw out the duplex piston valve.
LTZ012-H: MR pressure cause heater has
not rising, although failed
compressor is running Remove the unit as described in
Section 5.2 and ship to a KB SfS
Regeneration air not Unit defective Service Center for repair.
discharging from the si-
lencer’s regeneration air
outlet K3 while the com-
pressor is delivering air

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Problem Cause Remedy

Strong stream of air Unit defective Remove the unit as described in


from the silencer’s re- Section 5.2 and ship to a KB SfS
generation air outlet K3 Service Center for repair.
(provided the air dryer
unit is working correctly,
regeneration air must
be discharged as usual
while the compressor is
delivering air)

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 Desiccant dirty Exchange the desiccant as de-


above the boundary scribed in Section 6.3.
curve of 35%
* 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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Knorr-Bremse New York Air Brake Corporation


D Systeme für Schienenfahrzeuge GmbH USA 748 Starbuck Avenue
Moosacher Str. 80 Watertown, NY 13601
80809 Munich USA
Germany Phone: +1 315 786-52 00
Phone: +49 89 3547-0 Fax: +1 315 786-56 76
Fax: +49 89 3547-2767
Knorr-Bremse GmbH Knorr Brake Ltd.
A Beethovengasse 43-45 CDN 675 Development Drive
2340 Mödling Kingston, Ontario K7M 4W6
Austria Canada
Phone: +43 2236 409-0 Phone: +1 613 389-46 60
Fax: +43 2236 409-412 Fax: +1 613 389-87 03
Oerlikon-Knorr Eisenbahntechnik AG Knorr-Bremse
CH Mandachstrasse 50 BR Sistemas para Veículos Ferroviários Ltda.
8155 Niederhasli Av. Engenheiro Eusébio Stevaux, 1071
Switzerland Jurubatuba, 04696-902 São Paulo
Phone: +41 44 852-31 11 Brazil
Fax: +41 44 852-31 31 Phone: +55 11 5681-1129
Fax: +55 11 5686-8344
Knorr-Bremse Rail Systems (UK) Ltd. Knorr-Bremse (SA) (Pty) Ltd.
GB Westinghouse Way, Hampton Park East RSA 3 Derrick Road (Corner Chestnut Road)
Melksham, Wiltshire SN12 6TL 1619 Spartan
United Kingdom South Africa
Phone: +44 1225 898 700 Phone: +27 11 961-7800
Fax: +44 1225 898 705 Fax: +27 11 975-8249
Knorr-Bremse Vasúti Jármû Knorr-Bremse India Private Ltd.
H Rendszerek Hungária Kft. IND 14/6 Mathura Road
Helsinki út 86. Faridabad-121003 Haryana
1201 Budapest India
Hungary Phone: +91 129 227-64 09
Phone: +36 1 421 1100 Fax: +91 129 227-59 35
Fax: +36 1 421 1192
Sociedad Española de Frenos Knorr-Bremse Rail Systems Japan Ltd.
E Calefacciõn y Señales, S.A. J Nishiikebukuro TS Bldg., 8F
Nicolás Fúster, 2 3-1-15 Nishiikebukuro
28320 Pinto (Madrid) Toshima-ku
Spain Tokyo, 171-0021
Phone: +34 91 69 10-054 Japan
Fax: +34 91 69 10-100 Phone: +81 3 53 91-10 13
Fax: +81 3 53 91-10 22
Freinrail Systèmes Ferroviaires S.A. Knorr-Bremse Asia Pacific (Holding) Ltd.
F 47-49 rue Gosset HK Suite 2901, 29/Fl Central Plaza
BP 185 18 Harbour Road
51057 Reims Cedex Wanchai
France Hong Kong
Phone: +33 3 2679-7200 China
Fax: +33 3 2679-7201 Phone: +852 2861-2669
Fax: +852 2520-6000
Frensistemi S.r.l. Knorr-Bremse Rail Systems Korea Ltd.
I Via della Cupola, 112 ROK 6th Floor, Bongwoo Bldg.
50145 FLorence 31-7, 1 Ka, Changchung-Dong, Choong-Ku
Italy Seoul 100-391
Phone: +39 055 3020-1 Korea
Fax: +39 055 3020-333 Phone: +82 2 22 80-55 55
Fax: +82 2 22 80-55 99
Knorr-Bremse Nordic Rail Services AB Knorr-Bremse Australia Pty. Ltd.
S Traktorvägen 8 AUS 1/2D Factory Street
226 60 Lund Granville NSW 2142
Sweden Australia
Phone: +46 46 3293-50 Phone: +61 2 8863-6500
Fax: +46 46 1489-71 Fax: +61 2 9897-9980
01/07

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.

KNORR-BREMSE SfS ©
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