Y006471 - AxleTech International
Contents
1. KANSANS FD00170 FD00236 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 Check contact area of Brass Bush 7 and remove any burrs Grease Bush 7 with white Grease Part No 1114525 or 1132868 10 2 Rubber Bush 6a or 6b and DIN 125 el Guide Sleeve 6c Replacement pulling in the pulling out the Rubber Bush 6a or 6b The components of the tools are referred by item RE LE ra number for ease of reference Use Tool R Part No Z004198 for the assembly of the Rubber Bush 6a or 6b see adjacent sketch Note Threaded Pin E Do not use the Disc T5 035 with SN Type T22 Pull in Pull out Tool R Use Tool N Part No K005986 for the assembly of the Guide Sleeve 6c see adjacent sketch en Washer arrangement for arrangement for pulling out the TO5 pulling the Guide Sleeve 6c Guide Sleeve 6c T06 T21 10 2 1 Removal of Rubber Bush 6a or 6b Remove Guide Pin 4a or 4b Clean Caliper in the area of the Rubber Bush Select Disc T6 039 Position the Tool R Part No Z004198 as shown in the adjacent picture Screw on the Nut T22 by Pay attention to suitable Disc 939 hand Hold the Nut T22 with a ring spanner and with a suitable socket or ring spanner tighten Spindle T20 to remove the Rubber Bush 39 Y006471 EN 001 MAX1 Lib r Sanson 2005 06 292. Part No 1132202 Remove the old Tappet Bush 161 Check inner sealing face See arrow X When replacing Tappet and Boot Assemblies 13 the Inner Seals 22 must also be replaced 28 T15 Press in Tool arrangement for Tappet and Boot Assembly 13 when Caliper is fitted on the vehicle T24 Ring P for SK7 and NA7 Disc Brakes Installation device for Tappet and Boot Assembly 13 when Caliper is removed from axle Wedge Fork A Press in Tool B Press in Tool arrangement for Inner Seal 22 when Caliper is fitted on the vehicle T4 T3 Press in Tool L Ths Pu i n T9 N T4 m Press in Tool arrangement for Tappet and Boot Assembly 13 when Caliper is removed from the vehicle Press in Tool arrangement for amp Inner Seal 22 when Caliper is removed from the vehicle Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 7 1 1 Threaded Tubes 16 Inspection Place an unwom Pad 12 into the outboard gap to avoid loss of thread engagement of the Threaded Tubes ATTENTION Threaded Tubes should not lose engagement with the inner thread of the Bridge The Caliper must be replaced if thread engagement and synchronisation is lost For the inspection of the threads the tubes must be screwed out max 30mm by turning the Shear Adapter 61 clockwise If Caliper is not installed on axl
3. Knorr Bremse Commercial Vehicle Systems Japan Ltd 3 1 15 Nishiikebukuro Toshimaku Tokyo 171 0021 Japan Tel 81 3 3971 8501 Fax 81 3 3971 8579 Knorr Bremse Korea Ltd Truck Brake Division 6th Floor Bongwoo Bldg 31 7 1 Ka Jangchoong Dong Chung Ku Seoul 100 39 Korea Tel 82 2 538 8726 Fax 82 2 538 8723 Knorr Bremse Benelux B V B A Rendementsweg 4N 3641 SK Mydrecht Netherlands Tel 431 297 239330 dO KNORR BREMSE Systeme f r Nutzfahrzeuge GmbH Moosacher Stra e 80 80809 M nchen Deutschland Tel 49 89 3547 0 Fax 49 89 3547 2767 www knorr bremse com www knorr bremsesfn com Fax 31 297 239339 Knorr Bremse Systeme f r Nutzfahrzeuge GmbH Representation Office Russia 1 Kasatschij Pereulok 5 2 119017 Moscow Russian Federation Tel 7 095 234 4995 Fax 7 095 234 4996 Knorr Bremse S A Pty Ltd 3 Derrick Road corner Chestnut Road 1610 Kempton Park South Africa Tel 27 11 961 7800 Fax 27 11 975 8249 Knorr Bremse System foer Tunga Fordon AB P 0 Box 6029 200 11 Malmoe Sweden Tel 46 40 680 5880 Fax 46 40 937490 Knorr Bremse Systeme fur Nutzfahrzeuge GmbH Office Switzerland Z richstra e 46 8303 Bassersdorf Switzerland Tel 41 1 888 77 55 Fax 41 1 888 77 50 Knorr Bremse Systeme f r Nutzfahrzeuge GmbH Liaison Office Istanbul Meclisi Mebusan Cad 139 A Atlantik Han Kat 3 80040 Findikli Istanbul Turkey Tel 90 212 293 4742 Fa
4. Check Adjuster function see Section 5 2 Attach Brake Chamber or Spring Brake see Section 12 2 or 12 4 Direction of pressure N d M 2 AM F Wl J E 8 i a f F3 e J N f LH 1 amp Variants 35 Y006471 EN 001 MAX1 Lib r Sanson 2005 06 29 16 23 21 9 Replacement of Inner Boot 9 Washer DIN 125 The components of the tools are referred to by item Piki tooi number for ease of reference arrangement for pulling in the Inner Boot 9 To fit the Inner Boot 9 use the Pull in Tool C Part No Z004357 Remove Caliper see Section 8 1 Remove Ring 58 Pull out Guide Pin 5 Push out Inner Boot 9 with screwdriver Note If the Inner Boot 9 is installed with Guide Pin 4c Remove Ring 58 Pull out Guide Pin 4c Push out Inner Boot 9 with screwdriver ATTENTION FD00210 i02 The sealing face of Inner Boot 9 in the Caliper must not be damaged see arrow A in adjacent Sketch Inspect and clean contact area of Inner Boot 9 Check for corrosion see arrow A in adjacent Sketch Check Brass Bush 7 and if is installed Guide Sleeve 6c for dirt and replace if damaged see Section 10 1 and 10 2 Fit new Boot 9 into the Sleeve of the Tool C Part No Z004357 See arrow B in adjacent Sketch FD00230 Pay attention that the bellow folds of Inner Boot 9 are positio
5. Cracks less than 1 5mm deep or wide running in a Radial direction are allowed Grooves circumferencial less than 1 5mm deep are allowed D Cracks going through until the cooling duct or until the inner or outher boarder are not allowed The Disc MUST BE REPLACED d x 2 N S S a Pad contact area Note In case of surface conditions and C the Disc can continue to be used until the minimum thickness of 37mm is reached Knorr Bremse Discs are normally service free and grinding when changing Pads is not necessary However grinding could be useful e g to increase the load bearing surface of the Pads after severe grooving on the entire friction surface has occurred To meet safety requirements the minimum thickness after regrinding must be greater than 39 mm In addition the recommendations of the Vehicle Manufacturer MUST be followed The adjacent sketch shows some examples of cracks and grooves ATTENTION If these recommendations are ignored there is a danger of brake failure If the Pads are worn down to the backplate or if Disc wear is excessive brake performance will be severely affected and may be lost completely 13 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 5 1 1 Brake Wear Check using Rubber Bush 6a For all Disc Brakes which are equiped with a Rubber Bush that is axially ribbed see H in sketch
6. may supplement this with Supplemental Tool Kit Part No K005975 The Supplemental Tool Kit contains the tool components T24 and T25 as well as this English and German Service Manual 2 2 Diagnostic Equipment Part Number Description ZB9031 2 hand held device for checking Potentiometer function also Pad plus Disc 140598F wear when 13 pin chassis plug installed ZB9031 2 replaces ZB9031 2 3 Lubrication Part Number Colour Quantity 114525 white 5g 132868 white 500g 2 4 Torque Requirements Item Number Torque Spanner Size mm 39 40 Caliper Bolts x2 180 Nm M16x1 5 plus 90 14 Brake Chamber Spring Brake Hexagon Nuts M16x1 5 x2 180 Nm 24 self locking EN ISO 10513 7 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 3 Description and Function 3 1 Disc Brake Sectioned View 4a 4b ac 6a 6b 6c 10 11 12 13 16 17 18 1 18 2 19 20 22 23 24 26 27 30 32 33 37 39a 39b 39c 40 43 44 45 46 58 61 68a 68b 161 Caliper Carrier Guide Pi Guide Pi Guide Pi Guide Pi Rubber Bush Rubber Bush Guide Sleeve Brass Bush Inner Boot Cover Pad Retainer Pad complete n n n n Tappet and Boot Assembly Threaded Tube Bridge Spring Brake Brake Chamber Lever Eccentric Bearing Inner Seal Adjuster Unit Turning Device Spring Clip Spring Chain Chain Wheel Wear Se
7. of the brake FD00229 d m A a Tosa 43 Y006471 EN 001 MAX1 Lib r Sanson 2005 06 29 16 23 21 12 3 Spring Brake Removal ATTENTION Chock wheels before releasing Spring Brake Release parking brake move Hand Control Valve to run position Screw out Release Bolt arrow D with a maximum torque of 35 Nm refer to the Vehicle Manufacturer s recommendations Release air from brake move Hand Control Valve lever to park position Disconnect air hoses from Spring Brake 18 1 air hoses must be free of air pressure Unscrew Spring Brake Mounting Nuts see arrow B They must not be re used Remove Spring Brake 18 1 12 4 Spring Brake Fitting Note New Spring Brakes 18 2 have drain plugs installed see arrows A Remove lowest plug as viewed when Spring Brake is installed All other drain holes should be plugged Refer to the Vehicle Manufacturer s recommendations Before fitting the new Spring Brake the sealing surface see arrow C must be cleaned and the Spherical Cup 19 in the Lever must be greased with white Grease Part No 1114525 or 132868 The surface area of the flange must be damage free and clean The Seal as well as the Push Rod area see adjacent picture must be clean and dry If the thickness of the Seal is less than 3 mm the Spring Brake must be replaced ATTENTION Do not use grease containing molybdenum d
8. 16 23 21 10 2 2 Removal of Guide Sleeve 6c Remove Guide Pin 4c In order to separate the tab from the Guide Sleeve 6c use a screwdriver or similar tool whose width is smaller than the tab Place the screwdriver as close as possible to the base of the tab see adjacent Sketch Then separate the tab from the Guide Sleeve 6c by means of a screwdriver and a hammer see adjacent Sketch Clean Caliper in the area of the Guide Sleeve 6c and the Pad abutement Scheibe Note DIN125 Caliper groove can be on left side or right side of the caliper bore 7 Position Tool N as shown in adacent Sketch Screw on the Nut T14 by hand CA Z FAV AV AV AV AV 84V AV AV AV A ATA I LJI ZJ Hold the Nut T14 with a ring spanner and with a suitable socket or ring spanner tighten Spindle T20 to remove the Guide Sleeve 6c n FD00357 10 2 3 Fitting of Rubber Bush 6a or 6b Check bore for corrosion and clean Unscrew Threaded Pin in the Tool R so that there is no projection at the contact surface Push Rubber Bush 6a or 6b into the Tool R Contact Surface Position Tool R with Rubber Bush 6a or 6b Lightly screw on the Nut T22 by hand Threaded pin DIN 915 Screw in Threaded Pin until it contacts the Caliper in order to adjust possible unevenness at the contact surface Note Do not tilt the Rubber Bush 6a or 6b w
9. For all Disc Brakes which are equiped with a Caliper to Carrier marking FD00354 The condition of the Pads can be visually determined C shown in new condition without removing the road wheel by viewing the D Pads and Disc must be checked with road position of the Caliper position P against the Carrier wheel removed marking R If the condition D is reached the wheel must be removed so that the wear of the Pads and Disc can be checked If necessary change the Pads see Section 6 and or the Disc see Vehicle Manufacturer s recommendations 16 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 5 1 4 Wear Indicators Due to different Vehicle Manufacturer and vehicle types there are several types of Pad Wear Indicator used a In pad Normally Closed Indicator Circuit is broken when Pad Wear reaches limit b In pad Normally Open Indicator Circuit is made when Pad Wear reaches limit C Wear Indicator using built in Potentiometer This is available either as an on off version or as a continuous signal version which can be linked to the vehicle s electronic monitoring Systems An optical or acoustic device may be linked to any of the above Note Please also refer to specifications provided by the Vehicle Manufacturer 5 1 5 Diagnostic Equipment The Knorr Bremse Diagnostic Unit ZB9031 2 is a hand held device suitable for vehicles that are fitted with Knorr Bremse Disc Brakes using a contin
10. available as Part No 1114525 or 1132868 Note The tag of the Adjuster Cap 37 should be positioned as shown by the arrow in the adjacent diagram This ensures access is maintained for subsequent removal Removal of the Adjuster Cap with a screwdriver for example is not recommended since the seal may be damaged o o a u 19 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 5 3 Caliper Checks 5 3 1 Caliper Running Clearance ATTENTION Before starting service work ensure the service brake and parking brake as well as the bus stop temporary hold brake if fitted are not applied and that the vehicle cannot roll away By pushing and pulling the Caliper in an axial direction by hand see arrow A in adjacent sketch a movement of 0 6 1 1 mm must be possible If using hand pressure only no tools the Caliper is not moveable the Caliper guidance must be further examined see Section 5 3 2 5 3 2 Caliper Movement along Guide Pins Remove Pads see Section 6 1 Clean dirt from Guide Pin 4a or 4b see arrows in Sketch Using hand pressure only no tools the Caliper 1 must slide freely along the whole length of the Guide Pin arrangement This should be greater than 25mm 5 3 3 Rubber Bush 6a 6b or Guide Sleeve 6c to Guide Pin clearance Note Before removing the wheel note that there is no contact between Caliper and axle vehicle chassis sections or Ca
11. be checked as follows o i o o al fy Pull off the Adjuster Cap 37 using the tag taking care not to lose the Shear Adapter 61 The Adjuster 23 must be turned with the Shear Adapter 61 anti clockwise for 2 or 3 clicks increasing running clearance ATTENTION Never turn Adjuster 23 without Shear Adapter 61 being fitted If the shear torque of the Shear Adapter is exceeded then it is designed to fail Try again with a new unused Shear Adapter With a second failure of the Shear Adapter the Caliper must be exchanged since internal damage is present Do not use an open ended spanner as this may damage the Adapter ATTENTION Make sure that the Ring Spanner or Socket can turn freely clockwise during following procedure By applying the brake about 2 Bar 5 10 times the Spanner or Socket should turn clockwise in small increments if the Adjuster is functioning correctly see notes below NOTE As the number of applications increases incremental movement will decrease NOTE If the Spanner or Socket does not turn or turns only with the first application or turns forward and backward with every application the automatic Adjuster has failed and the Caliper must be replaced FD00218 18 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 Even if Pads are not being changed a new Adjuster Cap 37 should be fitted having lightly greased it with white grease
12. nennen 32 8 1 2 Removal of the Cover 68C seem mener 32 8 1 3 Removal of Cap 68a 33 8 1 4 Removal of Caliper from Carrier emen 33 8 2 Galiper Piling ssa otto o te DP a baden aoi ota 33 8 21 Fitting of Cover 10 and 68c nne 34 8 2 2 Fitting of Cap GSA ces stie aee t ett ta e eene take Re n e ER de entire ern 35 2 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 9 Replacement of Inner Boot 9 36 10 Replacement of Guide Pin Bushes 10 1 Brass Bush 7 Replacement 44 38 10 1 1 Removal of Brass Bush 7 38 10 1 2 Fitting of Brass Bush 7 sss nee 38 10 2 Rubber Bush or 6b and Guide Sleeve 6c Replacement 39 10 2 1 Removal of Rubber Bush or 6b Henn 39 10 2 2 Removal of Guide Sleeve 6 40 10 2 3 Fitting of Rubber Bush or 6b mnes 40 10 2 4 Fitting of Guide Sleeve 6c nnn 41 11 Carrier Replacement eost dope ee a eia 42 12 Brake Actuator Replacement 12 1 Brake Chamber Removal corte bcr ente a D Lr Pr er E 43 12 2 Brake Chamber Fitting tee RU Ee mike 43 12 3 Spring Brake Removal sien else len 44 12 4 Spring Brake Fitting s c oit ret mee er PO Pe E en eee 44 PLEASE NOTE This Service manual is intended for the exclusive use of trained persons within the commercial vehicle industry and workshops and must not be passed to any third party This service ma
13. the Bridge 17 and Lever 19 back to the start position this ensures a running clearance between Pads and Disc is maintained 3 2 3 Brake Adjustment automatic To ensure a constant running clearance between Disc and Pads the brake is equipped with a low wearing automatic adjuster mechanism The Adjuster 23 operates with every cycle of actuation due to the mechanical connection with Lever 19 As the Pads and Disc wear the running clearance increases The Adjuster 23 and Turning Device 24 turn the Threaded Tubes 16 by an amount necessary to compensate for this wear The total running clearance sum of clearance both sides of Disc should be between 0 6 and 1 1 mm smaller clearances may lead to overheating problems 9 Y006471 EN 001 MAX1 Lib r Sanson 2005 06 29 16 23 21 4 Inspection Points Despite the use of long life materials it is necessary to check some of the components regularly for their general condition The following points ensure a long life and trouble free operation of the disc brake The inspection frequencies specified are minimum values Depending on the vehicle application a more frequent check of the components may be necessary The brake pad wear must be checked visually on a regular basis e g each time the tyre pressures are checked or at least every three months see Sections 5 1 1 5 1 2 5 1 3 At least annually inspect the pad to disc running clearance and the correct fitting and con
14. 6 23 21 12 Brake Actuator Replacement 12 1 Brake Chamber Removal Disconnect air hose from Brake Chamber 18 2 air hose must be free of air pressure Unscrew Brake Chamber Mounting Nuts see arrow B They must not be re used Remove Brake Chamber 18 2 12 2 Brake Chamber Fitting Note New Brake Chambers 18 2 have drain plugs installed see arrows A Remove lowest plug as viewed when Brake Chamber is installed All other drain holes should be plugged Refer to the Vehicle Manufacturer s recommendations Before fitting the new Brake Chamber the sealing surface see arrow C must be cleaned and the Spherical Cup 19 in the Lever must be greased with white Grease Part No 1114525 or 132868 The surface area of the flange must be damage free and clean The Seal as well as the Push Rod area see adjacent picture must be clean and dry If the thickness of the Seal is less than 3 mm the Brake Chamber must be replaced ATTENTION Do not use Grease containing molybdenum disulphate Use only Actuators which are recommended by the Vehicle Manufacturer Attach Brake Chamber using new Nuts self locking EN ISO 10513 In order not to tilt the Brake Chamber screw Nuts step by step alternately with a suitable tool and torque tighten to 180 Nm Connect air hose and check for leakage Make sure that hose is not twisted and that chafing is not possible ATTENTION Check function and effectiveness
15. ATTENTION Before removing the Caliper Bolts 39 and 40 ensure that the Caliper 1 cannot move or fall when the Caliper Bolts are removed causing damage or injury Remove Caliper Bolts 39 and 40 and discard They must not be re used ATTENTION Never hold the Caliper with your fingers between Caliper and Carrier there is a risk of injury Do not fasten any lifting device to the Pad Retainer 11 since this could be damaged ATTENTION The opening or dismantling of the Caliper is not authorised Use only Genuine Knorr Bremse Replacement Calipers x Variants Remove Caliper from Carrier 8 2 Caliper Fitting Carrier is fitted on the axle The correct choice of Caliper must be ensured by checking the part number on the identification label see arrow A in sketch 1 and Section 1 2 The replacement Caliper may have a plastic cap or adhesive tape in the area of the actuator attachment see arrow B in sketch 1 Remove the cap or tape after installing the caliper on the vehicle Alternatively if the replacement Caliper has a breakthrough diaphragm it should be left in place see arrow in sketch down Note The replacement Caliper includes Seals and Guide Pins The Pads are not included If the replacement Caliper is equipped with a potentiometer then the connection must be made using the appropriate mating plug refer to Vehicle Manufacturer s recommendations ATTENTION Never hold the Caliper wit
16. N S INS Z N A L 727 FD00190 K 03 The condition of the Pads can be visually determined without removing the road wheel by viewing the position of the Caliper 1 against the fixed Guide Pin 4 New Condition see x The position of Wear Indicator G on the Rubber Bush 6a in new condition 14 Wear Limit z When the Rubber Bush 6a is retracted to the level G of the Wear Indicator as shown the wheel must be removed so that the wear of the Pads and Disc can be checked If necessary change the Pads see Section 6 and or the Disc see Vehicle Manufacturer s recommendations Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 5 1 2 Brake Wear Check using Rubber Bush 6b For all Disc Brakes which are equiped with open Rubber Bush Version pin protrusion shown in new condition minimal pin protrusion Pads and Disc must be The condition of the Pads can be visually determined C without removing the road wheel by viewing the D position of the Guide Pin 4 in the Caliper 1 checked with road wheel removed If dimension C is less than 1mm a more accurate check of the Pads and Disc must be made If necessary change the Pads see Section 6 and or the Disc see Vehicle Manufacturer s recommendations 15 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 5 1 3 Brake Wear Check using Carrier to Caliper position 6c
17. Service Manual Y006471 EN 001 Pneumatic F e Brake SN6 5SN7 SK7 NA7 Disc Brake KNORR BREMSE Systems for Commercial Vehicles Y006471 EN 001 MAX1 Libere Sanson 2005 06 29 16 23 21 Index Page 1 Overview 1 1 Disc Brake Components ss 4 1 2 Disc Brake Identification and Service Kits 5 L2 WearlndiCator K Ee nicer aidera rte ne shi n ree as dattes oue r 5 1 3 Brake DISC he a ee se vade paa a dua 6 2 General Information 2 1 Service TO0ls 2 ee I eae e c ce P 7 2 2 Diagnostic Equipment e ch eodd e eee EC ens 7 2 3 NL Er EE EU 7 2 4 Torque Requirements 7 3 Description and Function 3 1 Disc Brake Sectioned View eene 8 3 2 Description of Op rations eee epe ie be tee DE pred doen 9 3 2 1z Brake Actuationizz i diee a A nent dad d tet e c o E PER PH 9 3 2 2 2 Brake Release ien bc ip tene be e cedi a ere oed be ER e tete Boe a 9 3 2 3 Brake Adjustment automatic 9 4 Inspection Points ode oe e eed p Rt podia E ce e RR 10 4 1 Safety Instruction for Service Work and Repair Work 11 5 Functional and Visual Checks 5 1 Wear Check of Pads and Brake Discs e 12 5 1 1 Brake Wear Check using Rubber Bush 6a 14 5 1 2 Brake Wear Check using Rubber Bush 6 15 5 1 3 Brake Wear Check using Carrier to Caliper position 16 5 1 4 Wear Indicatorsis firent eh pete
18. ar Adapter is exceeded then it is designed to fail Try again with a new unused Shear Adapter With a second failure of the Shear Adapter the Caliper must be exchanged since internal damage is present Do not use an open ended spanner as this may damage the Adapter Note the shape of the back plate in SK7 and NA7 Disc Brakes means that the removal steps below must be followed Slide Caliper 1 fully outboard remove outboard Pad 12 Slide Caliper 1 fully inboard remove inboard Pad 12 Note the removal steps for SN6 and SN7 Disc Brakes can be carried out in any order NZ m gt VEN CON ER W oe Fes SPA 7 26 FD00221 N N N o o a fy 23 Y006471 EN 001 MAX1 Lib r Sanson 2005 06 29 16 23 21 6 2 Pad Fitting ATTENTION Pads must be changed as an axle set and NOT individually Use only Pads which are permitted by the vehicle manufacturer axle manufacturer and disc brake manufacturer Failure to comply with this may invalidate the vehicle manufacturer s warranty Note Fully wind back the Tappet and Boot Assemblies 13 by rotating the Shear Adapter 61 in an anti clockwise direction see Section 5 2 ATTENTION Never turn Adjuster 23 without Shear Adapter 61 being fitted If the shear torque of the Shear Adapter is exceeded then it is designed to fail Try again with a new unused Shear Adapter With a second failure of the She
19. ar Adapter the Caliper must be exchanged since internal damage is present Do not use an open ended spanner as this may damage the Adapter Clean the Pad abutments Note the shape of the back plate in SK7 and NA7 Disc Brakes means that the fitting steps below must be followed Slide Caliper 1 fully inboard fit inboard Pad 12 Slide Caliper 1 fully outboard fit outboard Pad 12 Note the fitting steps for SN6 and SN7 Disc Brakes can be carried out in any order Backplate of Pad i ith SK7 and Fit new in pad Wear Indicator kit if appropriate see NU DES Bra de Section 1 2 1 and Section 6 3 Install the cable so that it cannot be damaged Turn the Shear Adapter 61 clockwise until the Pads come into contact with the Disc Then turn back the Adjuster 2 clicks see Section 5 2 The hub should turn easily by hand after having applied and released the brake 24 o d if D zZ T a FD00223 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 After fitting the Pad Retainer 11 into the groove of the Caliper 1 it must be depressed to enable the insertion of the Pad Retainer Pin 44 Fit washer 45 and Spring Clip 26 to the Pad Retainer Pin 44 use only new parts It is recommended that Pad Retainer Pin 44 is installed pointing downwards see Sketch Re fit wheel according to the Vehicle Manufacturer s recommendati
20. ate 104 Pay attention to the correct position of the Cable Protection Plate s catch see arrows Exert hand pressure to the Cable Protection Plate 104 it will snap into place NN IN 2 P FD00305 Ai01 27 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 7 Replacement of Tappet and Boot Assemblies 13 and Inner Seals 22 The components of the tools are referred to by item number for ease of reference To remove the Tappet and Boot Assembly 13 use the Wedge Fork A Part No 1132203 To fit the Tappet and Boot Assembly 13 use the Press in Tool B Part No Z004190 To fit the Inner Seal 22 use the Press in Tool L Part No Z004361 7 1 Tappet and Boot Assemblies 13 Removal Note It may be easier to remove the Caliper from the axle to replace the Tappet and Boot Assemblies 13 see Section 8 1 The Shear Adapter 61 must be screwed clockwise until the Boots can be reached max 30 mm see Section 7 1 1 To remove the Tappet Boot from the Caliper bore a Screwdriver B should be used to deform the Boot location ring see adjacent diagram ATTENTION The inner sealing face see arrow X in adjacent sketch must not be damaged It cannot be replaced The Tappet and Boot Assemblies 13 can be removed from the Threaded Tubes 16 by using Wedge Fork A
21. ch 1 Pull in Pull out Tool including Grooving Tool D Section 9 Clean surface X surface Y and Brass Bush 7 see Sketch 2 10 1 1 Removal of Brass Bush 7 Position Tool arrangement for pulling out of Brass Bush 7 see Sketch 2 Note Ensure that Nut T14 is located in Brass Bush 7 and the end of Tube 12 is firmly located see Sketch 2 Pull out Brass Bush 7 by means of a spanner or socket see Sketch 2 10 1 2 Fitting of Brass Bush 7 X Brush Bush 7 Fully wind Brass Nut T14 on to Spindle T13 installed Place new Brass Bush 7 on the Groover T16 and insert into caliper bore see Sketch 3a Screw Spindle T13 by hand up to stop Note Pay attention to Groover T16 see Sketch 3a It must be able to move freely The Flange T8 must be located in caliper recess Pull in Brass Bush 7 using Brass Nut T14 up to stop see Sketch 3b To prevent longitudinal displacement of Brass Bush 7 it must be grooved see Sketch 3c To do so the Groover T16 must be screwed in up to stop Wind back the Groover T16 approximately 20 mm Slacken the Brass Nut T14 and rotate the Groover T16 through approximately 60 Repeat the process of grooving The new Brass Bush 7 is now grooved with the Caliper Before removing the Tool D the hexagon screw of the Groover T16 should be wound out approximately 20 mm 38
22. charge Note It may be necessary for reasons of accessibility to remove the Caliper and Carrier from the axle refer to Vehicle Manufacturer s recommendations or remove only the Caliper 8 1 1 Removal of the Cover 10 Use a suitable Tool e g a Screwdriver to penetrate the Cover 10 During penetration the Cover may move approximately 10 mm inwards Remove Cover 10 ATTENTION Cover 10 should be penetrated in the middle Do not drive the tool between Caliper bore and Cover 10 since Caliper bore may be damaged 8 1 2 Removal of the Cover 68c Because of the protruding Cover 68c it must be dissasembled as shown in adjacent Sketch Use a srew driver or another suitable tool Do not dissasemble the Cover 68c in direction of the Caliper since itself or components of it might be damaged 32 Tool for pressing in the Cap 68a pressing in the Cover 10 Ti Press in Tool K an Tool arrangement for Press in Tool H Tool arrangement for pressing in the Cover 68c T25 Press in Tool M ur Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 8 1 3 Removal of Cap 68a On Calipers with Rubber Bush 6a pull the Cap 68a from the Guide Pin 4 using a suitable tool see Sketch ATTENTION Take care not to damage Rubber Bush 6a If necessary replace it by means of a Guide Pins and Seals Kit 8 1 4 Remove Caliper from Carrier
23. dition of the Cover 10 the Cap 68a the Cover 68c and the Adjuster Cap 37 see Section 5 3 1 With each Pad change check for the correct functioning of the Adjuster see Section 5 2 and the smooth operation of the caliper over its full range of movement see Section 5 3 2 Also inspect the Tappet and Boot Assemblies 13 the Adjuster Cap 37 and the sealing elements 6a 9 10 58 68a or 68c for correct fitting and condition The brake discs are to be checked according to the specification of the axle or vehicle manufacturer In the unlikely event of a problem all relevant components e g Pads 12 1 and Pad Holder Springs 12 2 must be returned in order that an objective investigation of the cause can be made A oT 18 1 18 2 2 2 rd 0 Wei es Montagefett 1 White assembly grease i 9 7 Van qs Re EI N A NZ DY 6b gt DR SUM e AGS 6 A LOSS o 399 9 10 N Qo SK 396 600 M A gt 393 37 TT ii d T 5 a oa LT LOS a o X mikroverkapselt pre applied adhesive 10 FD00148 i01klein 10 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 4 1 Safety Instructions for Service Work and Repair Work Please also refer to the relevant safety instructions for repair work and service work on commercial vehicles especially for jacking up and securing the vehicle Use only original Knorr B
24. e put a spacer E length 70mm into the Caliper 1 to avoid loss of thread engagement of the Threaded Tubes 16 when screwing them out see adjacent Sketch Check the threads for corrosion damage In case of water ingress or corrosion the Caliper must be replaced see Section 8 7 2 Inner Seals 22 Replacement Fully wind back the Threaded Tubes 16 by turning the Shear Adapter 61 anti clockwise see Section 5 2 Clean area of the Inner Seal 22 To remove the Inner Seal 22 a Screwdriver A should be used see adjacent Sketch ATTENTION The sealing face X for the Inner Seal 22 as well as the Threaded Tubes 16 must not be damaged They cannot be replaced see Section 7 Clean sealing face X Fit each Inner Seal 22 onto a Threaded Tube 16 With Caliper installed on axle Remove the Tappet Bush 161 Position Tool L Part No Z004361 with the short strut in the position shown The Tool L is guided over the spigot of the Threaded Tube 16 Fully press in the Inner Seal 22 by rotating Tool T3 using a Spanner see adjacent Sketch M P KN 019 VF 00127 13 FD00239 FD00238 29 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 To check the correct fit of the Inner Seal 22 screw out the Threaded Tubes 16 about 4 5 threads by turning the Shear Adapter 61 clockwise The Inner S
25. e available Description Contents Camer 2 For specific Service Part 4a 5 6a 7 9 10 39a 40 58 SUE rine aid Seis RE 4b 4c 6b 6c 39b 39c 68a 68c Numbers OLE ae Disc Brake see Tappet and Boot Kit 2 pieces 13 22 161 PR eon Adjuster Cap 37 10 pcs 61 10 pcs Www Knorr BremseSfN biz Pad Kit per axle 11 12 26 37 44 45 61 f Wear Indicator Kit per axle Variants see Section 1 2 1 Knorr Bremse offers a range of specifically designed rationalised Calipers to service Air Disc Brake without Brake Carrier 2 and a wide range of Disc Brakes Caliper without Brake Pads 12 For specific Caliper Part Guide Pins and Seals Kit provided for assembly Number see of Caliper to existing Brake Carrier Brochure P 3543 www Knorr BremseSfN com www Knorr BremseSfN biz 1 2 1 Wear Indicator Kits Variants Typical kits are shown below Type 2 FD00235 Ai01 FD00194 Ai01 o m a rm 101 Sensor Altemative to 103 Cable to Electrical Supply Item 105 104 Cable Protection Plate 11 Pad Retainer 105 Cable Guide 105a Cable Guide FD00246 Ai01 5 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 13 Brake Disc When replacing the Discs please refer to the instructions of the Vehicle Manufacturer This should also be done when fitting Knorr Bremse Brake Discs When replacing Discs please adhere to the recommended bo
26. eal 22 must not turn With Caliper not installed on axle The fitting sequence of Inner Seal 22 does not change When pressing in the Inner Seal 22 however use the long strut T3 T4 for Tool L Part No Z004361 see page 28 7 3 Tappet and Boot Assemblies 13 Fitting With Caliper installed on axle Grease threads with white grease Part No 1114525 or 1132868 Screw back Threaded Tubes 16 by turning the Shear Adapter 61 anti clockwise see Section 5 2 The sealing seat in the caliper for Tappet and Boot Assemblies 13 must be clean and free of grease Fit a new Tappet Bush 161 onto the spigot of each Threaded Tube 16 Sketch Position a Tappet and Boot Assembly 13 onto each Tappet Bush Use Push in Tool B Part No 2004190 with the short strut T3 for positioning and pressing in the Boot see Sketch 1 Using Tool B Part No 2004190 in reverse with the short strut T3 each Tappet can be pressed onto its Tappet Bush see Sketch 2 After assembly the Tappet 13 must be free to turn in both directions 30 FD00240 o 1 Q a Y006471 EN 001 MAXI Lib r 2005 06 29 16 23 21 With Caliper not installed on axle Grease threads with white grease Part No 1114525 or 1132868 Screw back Threaded Tubes 16 by turning the Shear Adapter 61 anti clockwise see Section 5 2 The
27. h your fingers between Caliper and Carrier there is a risk of injury Do not fasten any lifting device to the Pad Retainer 11 since this could be damaged 33 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 ATTENTION The Guide Pins 4 and 5 as well as the Caliper Bolts 39 and 40 are highly stressed items They must be replaced whenever the Caliper 1 is removed from the Carrier 2 Fit the Caliper to the Carrier Screw in new Caliper Bolts 39 and 40 and tighten to 180 Nm then tigthen by a further 90 ATTENTION Screw threads and tapped holes must be clean and dry free of lubrication and residuals of pre applied adhesive Check that the Caliper slides easily on the Guide Pins Check the position of the Inner Boot 9 on the Guide Pin 5 According to the Caliper variant check also the position on the Guide Pin 4 as well as the position of Ring 58 Fit Pads see Section 6 2 Check Adjuster function see Section 5 2 Attach Brake Chamber or Spring Brake see Section 12 2 or 12 4 8 2 1 Fitting of Cover 10 and 68c Caliper bore and Cover 10 must be clean and free of lubrication Press in the Cover 10 using the Press in Tool H Part No Z004197 and a hammer Move the Caliper against the Carrier and hold so that the Inner Boot 9 is in a compressed condition to prevent air being trapped when Cover 10 is fitted Caliper bore and Cover 68c mus
28. he remaining clauses This disclaimer is an English translation of a German text which should be referred to for all legal purposes 3 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 1 Overview 1 1 Disc Brake Components for Wear Indicators see Section 1 2 1 Q 1 2 4a 4b 4c 5 6a 6b 6c 7 9 10 11 12 12 1 12 2 13 18 1 18 2 22 26 37 39a 39b Wei es Montagefett 3 Caliper Carrier Guide Pin Guide Pin Guide Pin Guide Pin Rubber Bush Rubber Bush Guide Sleeve Brass Bush Inner Boot Cover Pad Retainer Pad complete Pad Pad Holder Spring Tappet and Boot Assembly Spring Brake Brake Chamber Inner Seal Spring Clip Adjuster Cap Caliper Bolt Caliper Bolt 18 1 18 2 39c 40 44 45 58 61 68a 68c 161 White assembly grease TX IX RI 9c Caliper B olt Caliper B olt Pad Retainer P in Washer Ring Shear Adapter Cap Cover Tappet Bush FD00148 i01 Variants See also contents leaflet in the Service Kit Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 1 2 Disc Brake Identification and Service Kits CO KNORR BREMSE KAKA AXKA QU Type of Caliper Ln rl KNORR BREMSE Part no Axle or Vehicle Manufacturer s No Date of Manufacture ATTENTION Use only genuine Knorr Bremse parts The following Service Kits ar
29. hen pulling in Using Torque Wrench pull in Rubber Bush 6a or 6b min 8 Nm up to max 45 Nm until its stop Remove the Tool ATTENTION If the torque is lt 8 Nm or gt 45 Nm then the Caliper must be replaced Failure to replace the Caliper could lead to a guidance failure 40 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 ATTENTION The Metal Ring see arrows in adjacent sketch must not move When checking for movement then the Sealing Elements of the Rubber Bush 6a or 6b must not be damaged Grease the interior of the Rubber Bush 6a or 6b with white Grease Part No 1114525 or 1132868 ATTENTION The Guide Pins 4 and 5 as well as the Caliper Bolts 39 and 40 are highly stressed items They must be replaced whenever the Caliper 1 is removed from the Carrier 2 Fit Guide Pins 4a or 4b via the Pad abutement in the Rubber Bush 6a or 6b 10 2 4 Fitting of Guide Sleeve 6c Check bore for corrosion and clean Position the Guide Sleeve 6c see adjacent Sketch ATTENTION Before pressing in Guide Sleeve 6c the tab must be in correct position The tab must snap in Caliper groove when Guide Sleeve 6c is reaching its end position Note Caliper groove can be on left side or right side of the caliper bore Slightly press in the Guide Sleeve 6c by means of the Nut T14 and a hammer The Guide Sleeve 6c is now adusted InsertTool N and posit
30. iepark zone D 2220 Heist op den Berg Belgium Tel 432 1525 7900 Fax 432 1524 9240 gt Knorr Bremse Sistemas para Ve culos Comerciais Brasil Ltda Av Eng Eus bio Stevaux 873 Bloco B Santo Amaro Cep 04696 902 Brazil Tel 55 11 5681 1104 Fax 455 11 5686 3905 gt Knorr Bremse Far East Ltd Truck Brake Systems Division 1301 MassMutual Tower 38 Gloucester Road Wanchai Hong Kong China Tel 4852 2861 2669 Fax 852 2520 6259 gt Knorr Bremse Brake Equipment Shanghai Co Ltd Truck Brake Division Section C Building 9 353 Riying North Road 200131 Waigaogiao Free Trade Zone Shanghai China Tel 86 21 5046 0776 Fax 86 21 5046 3427 gt Knorr Bremse Syst my pro uzitkova vozidla CR s r o Petra Bezruce 399 463 62 Hejnice Czech Republic Tel 420 482 363 611 Fax 420 482 363 711 gt Knorr Bremse Syst mes pour V hicules Utilitaires France S A BP 34178 RN 13 La Briqueterie Glos 14104 Lisieux Cedex France Tel 33 2 3132 1200 Fax 33 2 3132 1303 Knorr Bremse F krendszerek Kft Kecskem t Szegedi t 49 6000 Hungary Tel 36 76 511 100 Fax 36 76 481 100 Knorr Bremse Systems for Commercial Vehicles India Private 404 405 HM Geneva House Cunningham Road Bangalore 560 052 India Tel 91 80 20 88 273 Fax 91 80 51199068 Knorr Bremse Sistemi per Autoveicoli Commerciali S p A Via C Battisti 68 20043 Arcore Italy Tel 39 039 6075 1 Fax 39 039 6075 435
31. ion see Sketch down Pull on Spindle T20 slightly by hand Hold Nut T14 by means of an ring spanner and with a Suitable socket or an other suitable tool tighten Spindle T20 up to stop ATTENTION Do not turn Nut T14 because Guide Sleeve 6c may lose its correct position a o Washer DIN125 FD00358 41 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 Remove Tool N In order to press in the tab use a srewdriver or similar tool whose width is smaller than the tab Place the srewdriver as close as possible to the top of the tab see adjacent Sketch Then press in the tab by means of the screwdriver and a hammer The Guide Sleeve 6c is now secured against rotating and axial movement Grease the interior of the Guide Sleeve 6 with white Grease Part No 1114525 or 1132868 Fit Guide Pin 4c 11 Carrier Replacement If necessary remove Caliper see Section 8 1 Remove Carrier 2 from axle Note Do not fasten any lifting device to the Pad Retainer 11 since this can be damaged Clean axle contact area Fit new Carrier 2 with new bolts supplied by the Vehicle Manufacturer Bolts are not supplied by Knorr Bremse It may be necessary to firstly attach the Caliper see Section 8 2 42 Z T a Y006471 EN 001 MAX1 Lib r Sanson 2005 06 29 1
32. isulphate Use only Actuators which are recommended by the Vehicle Manufacturer 44 3 9 3 3 i R E 3 8 E 2 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 Attach Spring Brake using new Nuts self locking EN ISO 10513 In order not to tilt the Spring Brake screw Nuts step by step alternately with a Suitable tool and torque tighten to 180 Nm Connect air hoses ensuring that they are replaced in the correct ports Make sure that hoses are not twisted and that chafing is not possible Release parking brake move Hand Control Valve lever to run position and check for leakage Screw in Spring Brake Release bolt to maximum 70 Nm ATTENTION Check function and effectiveness of the brake 45 Y006471 EN 001 MAX1 Lib r Sanson 2005 06 29 16 23 21 46 Notes Y006471 EN 001 MAX1 Lib r Sanson 2005 06 29 16 23 21 47 Y006471 EN 001 MAX1 Lib r Sanson 2005 06 29 16 23 21 gt Knorr Bremse Systeme fur Nutzfahrzeuge GmbH Moosacher Stra e 80 80809 Munich Germany Tel 49 89 3547 0 Fax 49 89 3547 2767 gt Knorr Bremse Australia Pty Ltd 1 2D Factory Street Granville NSW 2142 Australia Tel 61 2 8863 6146 Fax 61 2 8863 6151 gt Knorr Bremse GmbH Systeme f r Nutzfahrzeuge Beethovengasse 43 45 2340 M dling Austria Tel 43 2236 409 436 Fax 43 2236 409 434 gt Knorr Bremse Benelux B V B A Impulsstraat 11 Industr
33. le kit see Section 1 2 and Section 8 and following Note that there must be no contact between Caliper and axle vehicle chassis sections or Carrier If necessary the Rubber Bush 6a 6b or the Guide Sleeve 6c must be replaced using a suitable kit see Section 1 2 Section 8 and following Fit Pads See Section 6 2 Fit the wheel Refer to Vehicle Manufacturer s recommendations 5 4 Checking of Seals 5 4 1 Caliper Guide Pin Seals The Guide Pin 5 is sealed with Cover 10 and with the Inner Boot 9 The Guide Pin 4c is also sealed with Inner Boot 9 and Cover 68c The components 9 10 and 68c must not show any signs of damage Check for correct location and fitment Note It may be necessary to remove the Pads to inspect the Inner Boots 9 dependent on the amount of pad wear If necessary service Caliper with suitable Kit see Section 1 2 Section 8 and following FD00383 x Variants 4a X 6b 39b 58 9 6c FD00219 Ai01 21 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 5 4 2 Checking of Tappet and Boot Assemblies 13 If necessary remove Pads 12 see Section 6 1 and screw the Shear Adapter 61 clockwise see Section 5 2 until the boots are clearly visible Note The tappet should not extend more
34. lt tightening torques The use of non approved Brake Discs will reduce levels of safety and invalidate warranty Brake Discs can be ordered through the Knorr Bremse Aftermarket Organisation Y006471 EN 001 MAX1 Lib r Sanson 2005 06 29 16 23 21 2 General Information 2 1 Service Tools Part Number Description consisting of Tool Combination Tool Components Z004190 B Press in Tool for Tappet and Boot Assembly 13 T1 T2 T3 T4 Z004357 C Pull in Tool for Inner Boot 9 T7 T8 T10 Pull in Pull out Tool including Grooving Tool Z004354 D for Brass Bush 7 T8 T12 T13 114 132202 A Wedged Fork for removal of Tappet and Boot Assembly 13 T15 Z004197 H Press in Tool for Cover 10 T2 T17 K004515 M Press in Tool for Cover 68c T2 T25 Z004198 R Pull in Pull out Tool for Rubber Bush 6a and 6b T5 T6 T18 719 720 T21 T22 K005986 N Pull in Pull out Tool for Guide Sleeve 6c T5 T6 T8 T14 T20 T21 2003934 K Press in Tool for Cap 68 T11 2004361 L Press in Tool for Inner Seal 22 T3 T4 T9 K004082 P Ring for Tappet and Boot Assembly 13 T24 Service Tool Kit Part No K005973 contains the above listed tool components to fit tool combinations for items 6a 6b 6c 7 9 10 13 22 68a and 68c This Service Manual and a Service Video Z004370 are included Customers who already own the Service Tool Kit Part No K001288
35. n of the Wear Indicator Cable 101 see arrows 6 3 1 Cable Guide 105 Fit Cable Guide 105 onto the Pad Retainer 11 In the right position the Cable Guide 105 snaps into place by pressing it lightly onto the Pad Retainer 11 26 FD00237 1 N m A o a FD00237 4 Y006471 EN 001 MAX1 Lib r Sanson 2005 06 29 16 23 21 Press Wear Indicator Cable 101 into the locating tabs of the Cable Guide 105 see arrows A The short cable end of the Wear Indicator Cable 101 must not be secured by locating tabs of the Cable Guide 105 According to vehicle type install the cable that leads to the electrical supply of the vehicle in one of the two locating tabs see arrows B 6 3 2 Cable Guide 105a Install Indicator Cable 101 in the middle of the Pad Retainer 11 Insert Cable Guide 105a at one side of the Pad Retainer 11 see arrow B Slightly press in on the other side of the Pad Retainer 11 see arrows A The Cable Guide 105a snaps into place According to vehicle type install the cable that leads to the electric supply of the vehicle in one of the wire loop see arrows C The short end of the Wear Indicator Cable 101 must not be secured by a wire loop of the Cable Guide 105a see arrows C 6 3 3 Protection Plate 104 Fit the Cable Protection Pl
36. ned within the tool Position Sleeve with Inner Boot 9 into the Caliper bore and pull in by hand Then pull in with a maximum torque of 8 Nm Note Pay attention to the correct position of Inner Boot 9 Carry out a pulling check see adjacent Sketch 36 Y006471 EN 001 MAX1 Lib r Sanson 2005 06 29 16 23 21 Grease Brass Bush 7 and ff installed Guide Sleeve 6c with white grease Part No 1114525 or 1132868 Insert Guide Pin 5 and also Guide Pin 4c if Guide Sleeve 6c is installed The lip in the end of the Inner Boot must engage in the groove of the Guide Pin 5 and if installed in the groove of the Guide Pin 4c see arrow Pushing on the Ring 58 ensures that the Boot 9 is engaged in the groove of the Guide Pins 5 or if installed in the groove of the Guide Pin 4c Fit Caliper see Section 8 2 37 Y006471 EN 001 MAX1 Lib r Sanson 2005 06 29 16 23 21 10 Replacement of Guide Pin Bushes Pull out Tool arrangement 4 for pulling out Washer The components of the tools are referred by item of Brass Bush 7 DIN125 number for ease of reference In order to remove fit and groove the Brass Bush 7 use the Pull out Pull in and Grooving Tool D Part No 2004354 Remove Caliper see Section 8 1 and following 10 1 Brass Bush 7 Replacement Pull in Tool arrangement for pulling in and grooving of Brass Bush 7 Remove Guide P in 5 and Inner Boot 9 see Sket
37. nsor Adjuster Cap Caliper Bolt Caliper Bolt Caliper Bolt Caliper Bolt Bolt Pad Retainer Pin Washer Disc Ring Shear Adapter Cap Cover Tappet Bush laa 4b 6b 39b RER FD00149 i01 Variants Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 3 2 Description of Operation Floating Caliper principle 3 2 1 Brake Actuation During actuation the Push Rod of the Actuator 18 1 or 18 2 moves the Lever 19 The input forces are transferred via the Eccentric Bearing 20 to the Bridge 17 The force is then distributed by the Bridge 17 and the two Threaded Tubes 16 to the Tappet and Boot Assemblies 13 and finally to the inboard Pad 12 After overcoming the running clearance between the Pads and the Disc the reaction forces are transmitted to the outboard Pad 12 The clamping forces on the Pads 12 and the Disc 46 generate the braking force for the wheel 3 2 2 Brake Release After releasing the air pressure the Return Spring 27 pushes
38. nti e ee e a Pen le tre a e 17 5 1 5 Diagnostic Equipment Hand held device 289031 2 17 5 2 Adjuster Check 8 naeh 18 5 3 Caliper C hacks inne eed aan ate T e ed ad i teat 20 5 3 1 Caliper Running Clearance nnns 20 5 3 2 Caliper Movement along Guide Pins sese 20 5 3 3 Rubber Bush 6b or Guide Sleeve 6c to Guide Pin clearance 20 5 4 Check of Seals eit ence detiene a dede rn n e lee ER CRM 21 5 4 1 Galiper Guide Pin Seal eh 21 5 4 2 Checking of Tappet and Boot Assemblies 13 22 6 Pad Replacement 6 1 P d Removal Oen 23 6 2 Pad PIttinGst stants e oe te i pete de tel eines 24 6 3 Wear Indicator Fitting icet e ert erdt ete o eo LO He 25 6 3 1 CabletGuide 105 u ree rre eet Cor e v e mee ee EE Cd da 26 0 3 2 Guide 105a cicer Han rer the e E C leeren 27 63 3 Protecti n Plate 104 enc en Pe En ht n n e n Pn a E 27 7 Replacement of Tappet and Boot Assemblies 13 and Inner Seals 22 7 1 Tappet and Boot Assemblies 13 Removal 28 7 1 1 Threaded Tubes 16 Inspection 29 7 2 Inner Seals 22 Replacement nennen 29 7 3 Tappet and Boot Assemblies 13 Fitting 30 8 Caliper Replacement 8 1 Galiper Removal ier ettet e et dia dt bed ied a radi 32 8 11 Removal of the Cover 10
39. nual has been prepared to assist customers to carry out their own service work on the product and does not purport to be all inclusive or to contain all of the information necessary for this No responsibility is assumed as a result of this or as a result of incorrect or inappropriate parts being fitted to the product Knorr Bremse SFN cannot accept any nor offer any guarantee regarding data accuracy completeness or timeliness The information in this service manual does not represent any guarantees or ensured characteristics in terms of the German civil code No liability can be accepted based on the information its use recommendations or advice provided within this service manual In no event may we be held liable for any damage or loss except in the case of wilful intent or gross negligence on our part or if any mandatory legal provisions apply Brand names mentioned in this service manual are not identified as such in all cases We would emphasise however that they are nevertheless subject to the provisions of trademark legislation Text and graphics created by us are subject to our regulations on utilisation and exploitation and may only be copied or reproduced with our express permission Any legal disputes arising from the use of this service manual or the information contained within shall be subject to German law Failure of any individual clause of this disclaimer to comply with current legal provisions does not affect the validity of t
40. ons The Adjuster Cap 37 must then be replaced use only a new Cap having lightly greased it with white grease available as Part No 1114525 or 1132868 Note The tag of the Adjuster Cap 37 should be positioned as shown by the arrow in the adjacent Sketch This ensures access is maintained for subsequent removal ATTENTION After every servicing Check the brake performance and the system behaviour on a rolling road Check function and effectiveness During the bedding in period there may be reduced braking effort 6 3 Wear Indicator Fitting Normally Closed or Normally Open Type Remove Pads 12 see Section 6 1 Wear Indicator Kits consist of items as shown in Section 1 2 1 Insert the Wear Indicator Cables 101 into the groove of the Pads The Wear Indicators snap into place in the holes in the Pad material The longer end of the Wear Indicator cable see arrow must be fitted in the outer Pad M P KN 016 Ai01 FD00144 101 outer Pad 12 1 12 1 FD00237 2 25 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 Insert Pads 12 1 into the Pad abutments see Section 6 2 Fit Pad Holder Springs 12 2 onto the Pads 12 1 Pay attention to correct installation of Wear Indicator Cable 101 see arrows Fit Pad Retainer 11 Pad Retainer Pin 44 Washer 45 and Spring Clip 26 see Section 6 2 Pay attention to correct installatio
41. remse parts ATTENTION Before starting service work ensure the service brake and parking brake as well as the bus stop temporary hold brake if fitted are not applied and that the vehicle cannot roll away Please follow repair manual instructions and adhere to the wear limits of the Pads and the Discs see Section 5 1 Use only recommended tools see Section 2 1 Tighten bolts and nuts to the recommended torque values see Section 2 4 ATTENTION Screw threads and tapped holes must be clean and dry free of lubrication and residuals of pre applied adhesive After re fitting a wheel according to the Vehicle Manufacturer s recommendations please ensure that there is sufficient clearance between the tyre inflation valve the caliper and the wheel rim to avoid damage to the valve ATTENTION After every service work Check the brake performance and the system behaviour on a rolling road Check function and effectiveness 11 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 5 Functional and Visual Check 5 1 Wear Check of Pads and Brake Discs ATTENTION For optimum safety stay within the Disc and Pad Wear Limits Pads The thickness of the Pads must be checked regularly dependent on the usage of the vehicle The Pads should be checked corresponding to any legal requirements that may apply If a Wear Indicator has not been fitted or is not connected this should be a
42. rrier If necessary the Rubber Bush 6a 6b or Guide Sleeve 6c must be replaced see Section 10 2 To measure the clearance the following steps must be taken Remove the wheel Refer to Vehicle Manufacturer s recommendations Remove Pad Retainer 11 but leave the Pads 12 in the abutment 20 x Variants F209153 2 Y006471 EN 001 MAX1 Lib r Sanson 2005 06 29 16 23 21 Fasten a magnetic dial gauge holder to the Carrier 2 on the short bearing side of the Caliper 1 see also Sketch above Use the measuring point on the Caliper 1 see arrow in adjacent Sketch Press Caliper 1 in the direction of Carrier 2 and set the dial gauge to zero Place a suitable tool e g Screwdriver between Carrier 2 and Caliper 1 forcing them in opposite directions Read the maximum value on the dial gauge Note Knorr Bremse distinguishes between the two bearing variants Rubber Bush 6a or 6b Guide Sleeve 6c If the short bearing side is open or closed by Cap 68a and the distance is greater than 2 0 mm the Rubber Bush 6a or 6b must be replaced using a suitable kit see Section 1 2 and Section 8 and following If the short bearing side is closed by Cover 68c and the distance is greater than 1 0 mm the Guide Sleeve 6c must be replaced using a suitab
43. sealing seat in the caliper for Tappet and Boot Assemblies 13 must be clean and free of grease Fit a new Tappet Bush 161 onto the spigot of each Threaded Tube 16 Position a Tappet and Boot Assembly 13 onto each Tappet Bush Use Push in Tool B Part No Z004190 with the long strut T3 T4 for positioning and pressing in the Boot see Sketch 3 Using Tool B Part No Z004190 in reverse with the long strut T3 T4 each Tappet can be pressed onto its Tappet Bush see Sketch 4 After assembly the Tappet 13 must be free to turn in both directions Note With SK7 and NA7 Disc Brakes the caliper s back plate is too small using only Tool B In order to support the Tool B correctly on the Caliper s back plate insert the Ring T27 see Sketch 5 N N A o o a uL FD00355 31 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 8 Caliper Replacement The components of the tools are referred to by item number for ease of reference To fit the Cover 10 use Press in Tool H Part No Z004197 To fit the Cap 68a use the Press in Tool K Part No 2003934 To fit the Cover 68c use the Press in Tool M Part No K004515 8 1 Caliper Removal Remove Pads 12 see Section 6 1 Remove Actuator see Section 12 1 12 3 If fitted remove Wear Indicator Cable or Cable to built in Potentiometer ATTENTION Do not touch electrical contact points because of static dis
44. t be clean and free of lubrication Press in the Cover 68c using the Press in Tool M Part No K004515 and a hammer Move the Caliper against the Carrier and hold so that the Inner Boot 9 is in a compressed condition to prevent air being trapped when Cover 68c is fitted 34 n e o o a Eu E FD00373 _ 72 Ai01 FDOO3 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 8 2 2 Fitting of Cap 68a Fit the Cap 68a using Tool K Part No Z003934 and a hammer Force the Cap 68a into the Guide Pin 4 until it contacts the Caliper Bolt The seal is achieved by the compression of the lip of the Rubber Bush 6a between the Guide Pin 4 and Cap 68a see view Y If the Caliper and Carrier Assembly is not fitted to the vehicle Move the Caliper against the Carrier and hold using a suitable clamping device so that the Inner Boot 9 is in a compressed condition to prevent air being trapped when Cover 10 or Cover 68c and Cap 68a is fitted Fit new Cover 10 Cover 68c or Cap 68a as described above If the Caliper and Carrier Assembly is to be fitted as a single unit to the vehicle do so in line with the Vehicle Manufacturer s recommendations Fit the Pads if not already fitted see Section 6 2
45. t least every 3 months If friction material is less than 2mm see E Sketch 3 the Pads must be replaced Minor damage at the edges is permitted see arrow Sketch 1 Major damage on the surface of the Pad is not permitted see arrow Sketch 2 Discs Measure thickness at thinnest point Avoid measuring near the edge of the disc as a burr may be present A Disc thickness new condition 45 mm wom condition 37 mm the disc must be replaced C Overall thickness of Pad 30mm new condition D Backplate 9 mm with SN6 and SN7 Backplate 7 mm with SK7 and NAT E Minimum thickness of friction material 2mm F Minimum allowed thickness in worn condition for backplate and friction material With 9 mm backplate F 2 11 mm With 7 mm backplate F 2 9 mm If these minimum allowed thicknesses are reached replacement of Pads is necessary If the disc dimension A x 39 mm it is recommended that the Disc should be renewed together with the Pads If the disc thickness is less than 37 mm the disc must be replaced KY 22272222 M P KN 002Ai01 ATTENTION If these recommendations are ignored there is a danger of brake failure 12 Y006471 EN 001 MAX1 Lib r Sanson 2005 06 29 16 23 21 Check Disc at each change of Pads for grooves and cracks The diagram shows possible surface conditions max 0 75 x a max 1 5 mm Small cracks spread over the surface are allowed B
46. than 30 mm see sketch The Tappet and Boot Assemblies 13 must not show any signs of damage Check for correct location and fitment Note The penetration of dirt and moisture into the brake will lead to corrosion and impair the function of the Disc Brake If necessary replace Tappet and Boot Assemblies see Section 7 22 o N A o Y006471 EN 001 MAXI Lib r 2005 06 29 16 23 21 6 Pad Replacement ATTENTION Before starting service work ensure the service brake and parking brake as well as the bus stop temporary hold brake if fitted are not applied and that the vehicle cannot roll away 6 1 Pad Removal Remove wheel refer to Vehicle Manufacturer s recommendations Note Before removing Pads it is strongly recommended that the Adjuster mechanism is checked for correct operation see Section 5 2 Remove Clip 26 and Washer 45 depress the Pad Retainer 11 and remove Pin 44 If necessary remove any in pad wear sensor components and discard If the Pad Retainer 11 is corroded or damaged it should be replaced Pull off the Adjuster Cap 37 using the tab taking care not to lose the Shear Adapter 61 Fully wind back the Tappet and Boot Assemblies 13 by rotating the Shear Adapter 61 in an anti clockwise direction see Section 5 2 ATTENTION Never turn Adjuster 23 without Shear Adapter 61 being fitted If the shear torque of the She
47. uous signal type of Wear Indicator Potentiometer The wear condition of each brake can be measured by connecting the device to a suitable 13 pin socket DIN 72570 where fitted This socket will have been connected to each sensor by the vehicle manufacturer The Diagnostic unit allows Quick and simple wear check A check of the potentiometer function A simultaneous check of up to six brakes without removing the wheels A detailed instruction manual is included with each unit ALT N 13 Pin Plug DIN 72570 to vehicle Plug to Potentiometer Disc Brake 17 Y006471 EN 001 MAXI Lib r Sanson 2005 06 29 16 23 21 5 2 Adjuster Check ATTENTION Before starting service work ensure the service brake and parking brake as well as the bus stop temporary hold brake if fitted are not applied and that the vehicle cannot roll away Remove wheel The caliper assembly should be pushed inboard on its Guide Pins Using a suitable tool press the inboard pad 12 away from the Tappets and check the gap between Tappet and inboard pad backplate it should be between 0 6mm amp 1 1mm ATTENTION If the clearance is too wide there is a danger of brake failure If the clearance is too small there is a danger of overheating That may lead to consequential damage If the running clearance is too small or too large the adjuster may not be functioning correctly and should
48. x 90 212 293 4743 Knorr Bremse Systems for Commercial Vehicles Ltd Douglas Road Kingswood Bristol BS15 8NL United Kingdom Tel 44 117 9846 100 Fax 44 117 9846 101 Bendix Commercial Vehicle Systems LLC 901 Cleveland Street Elyria OH 44035 USA Tel 1 440 329 9000 Fax 1 440 329 9203 Y006471 EN 001 MAX1 Lib r Sanson 2005 06 29 16 23 21 Die Bildmarke K sowie die Marken KNORR KNORR BREMSE sind f r die Knorr Bremse AG gesetzlich gesch tzt nderungen vorbehalten F r Projektierung und Einsatz unserer Produkte empfehlen wir individuelle Beratung und Dokumentation anzufordern Nachdruck auch auszugsweise nicht gestattet Printed in Germany K001263 001
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