Service Manual
Contents
1. Thrust Plate 15 Insert the locking mechanism retainer 11 4 into the small groove in the Fork 16 Lower the Pad Retainer with the spring 11 3 and secure by means of a retention bar and split pin Attach the connecting cable to the wear indicator 20 Operate the vehicles brakes several times and manually check the freewheeling of the hub Re Fit road wheel Perform a test run IMPORTANT Bed in new brake pads Initially avoid long duration or heavy brake applications 17 11 18 Check of the automatic adjusting function Remove the pad retainer as per Section 7 1 to 7 3 For checking the automatic adjusting function a running clearance between the brake pad and disc of gt 2 mm is required See Section 9 2 for checking This should be set by rotating the Fork 16 see Section 9 3 Actuate the brake about ten times with low oressure about 2 bar Again measure the running clearance If the running clearance has reduced notably the automatic adjusting function is working correctly Running clearance values between 0 6 and 1 2 mm are permissible a IMPORTANT Running clearance values that are smaller than 0 6 mm may cause rubbing or hot running of the brake If the automatic adjusting function of the brake caliper is not working the Adjuster Mechanism or Caliper must be replaced 12 12 1 12 1 1 Replacement of Brake Chamber General since t2. not pictured All Types Il 34564 Pad Locating Pins and Retainer Spring Kit Axle set not pictured All Types Il 37400 Boot for Adjuster Axle set 14 4 All Types If the original Wedge and Brake Chamber Assembly have been replaced with the Clip Type Brake Chamber the Clip tyoe must be used again 1 2 1 2 1 1 2 2 Brake discs and pads General notes The replacement of brake discs and pads is subject to the specifications of the respective vehicle manufacturer When replacing brake discs make sure that the correct screw fittings are used and observe the specified bolt tightening torques refer to Section 2 3 and to IVECO manual Measurement of brake discs and pads WARNING For optimum safety stay within the Disc and Pad wear limits Dimensions refer to ADB 4300 Dimensions in brackets refer to ADB 3700 A Disc thickness new condition 50 45 mm A B Minimum Disc thickness a 47 42 mm zA The disc must be replaced A 1 C Overall thickness of new Pad Y 25 mm Y Ea D Backplate 7mm E Minimum thickness of friction ei material2 mm F Minimum thickness brake pad backplate 9 0 mm brake pads must be replaced 1 2 3 Wear limits of Brake Discs 1 2 4 Check Disc at each change of Pads for grooves and cracks The diagramm shows possible conditions of the Brake disc surface A Small cracks spread over the surface are allowed B Cracks less th
3. retracted 15 15 1 L IN SES Z 9777 a Boar VF 00142 11 15 2 Replacement of Wedge Assembly See Section 12 1 to identify version of Caliper Old Version A complete Brake Chamber and Wedge Assembly must be fitted see Section 12 2 Or If the original Wedge and Brake Chamber Assembly have been replaced with the Clip type Brake Chamber see Section 12 the Wedge Assembly may be changed separately as 15 2 below New Version Remove Brake Chamber see Section 12 3 Clean local area around Wedge Assembly and ensure no loose road dirt etc remains Pull out Wedge Assembly complete with Boot and clean around rim of hole Liberally grease new Wedge Assembly and internal ramp surfaces of Caliper with grease supplied Insert new Wedge Assembly Refit Brake Chamber see Section 12 3 2 VF 00142 12 29 Notes KNORR BREMSE SYSTEME FUR NUTZFAHRZEUGE GMBH Moosacher Stra e 80 80809 M nchen Telefon 089 35 47 0 Telefax 089 35 47 27 67 RA SB0003 EN 3000 01 98 HD Subject to modification For application studies and use of our product please contact us requesting specific documentation Reproduction in full or in part is not permitted Printed in Germany Stand 12 97
4. damage The sliding capability of the brake caliper must be checked Care should be taken to not trap fingers and the caliper should slide freely along the guide pins If sliding forces are high the brake caliper must be removed and the guiding system checked 35697a 19 8 8 1 8 2 9 1 9 2 9 3 16 Pad installation Move the brake caliper 1 toward the vehicle centre then install the Thrust Plate 15 and the inboard Brake Pad 12 1 Move the brake caliper toward the road wheel and install the outboard Brake Pad 12 2 Note The two pins of the Thrust Plate must insert into the bores of the Brake Pad backplate The Thrust Plate and Brake Pads must be freely movable Setting of running clearance between Brake Pad and Disc Firmly move brake caliper 1 toward the vehicle centre Insert a feeler gauge between the inboard pad 12 1 and the brake disc specified dimension 1 2 0 2 mm Turn the Adjuster 14 screw by using the Fork 16 such that the feeler gauge is tight Pull out the feeler gauge and check that the wheel hub rotates freely IMPORTANT Use only new Genuine pads approved by the vehicle manufacturer Replace brake pads only as an axle set 35698a 10 10 1 10 2 10 3 10 4 10 5 10 6 Final Checks Connect the wire spring 19 to retain the Fork 16 Note The spring presses the Fork 16 on to the
5. Discs of the new version Contents 2 Brake Discs part no 7180177 without bolts Note This kit had been provided for vehicles where the discs have already been converted to the new design 2 4 Note Brake discs of the new version part no 7180177 may only be installed with long bolts M16x80 part no 16683434 For bolt tightening torques refer to Chapter PD General Information Brake data Brake Brake discs Wheel size Weight Pad to Disc dia mm thickness without actuator Running mm clearance ADB 4300 430 50 229 57 kg 0 9 1 2 mm ADB 3700 3 0 45 19 5 45 kg 0 9 1 2 mm Lubricants Part no Designation Colour 423 243 Shell Darina R2 yellow Torque requirements Item no Designation Bolt tightening Spanner refer 3 1 torque in Nm size 10 Guide Bolt 300 20 24 mm T Guide Pin Retaining Bolt 400 40 32 mm Brake Chamber 100 10 24mm Mounting Nuts brake carrier steering knuckle 615 60 30 mm 4 hexagon bolts brake disc hub 280 13 18mm Tools dismantling tool 2 off Il 33905 see pages 19 23 3 3 1 Legend 1 1 1 2 3 1 3 2 3 3 11 12 12 1 12 2 13 1 13 2 14 15 16 20 10 Description and Function 3 2 Sectional drawing Caliper Fixed ramp Movable ramp Carrier Brake Chamber Boot Push rod Guide pin retaining bolt primary guidance Guide bolt secondary guidance Pad retainer a
6. Service Manual RA SB0003 EN Pneumatic Disc Brake Bendix ADB 3700 ADB 4300 for IVECO Commercial Vehicles KNORR BREMSE ry Systeme f r Nutzfahrzeuge Table of Contents Exploded VIEW of brake iach abieedcashcg sc ied Einteilung Service kits for Bendix ADB 3700 4300 Brake discs and pads General notes Measurement of brake discs and pads res 2 i ls SENSE Nee ISG ND 3 2 3 6 1 6 2 10 11 12 12 1 12 2 12 3 13 13 1 13 2 14 14 1 14 2 14 3 15 19 1 19 2 Wear limits of Brake Discs Notes on Brake Discs for the ADB 4800 ouenna General information Brake data Lubricants aa Torque requirements Tools Description and Function Sectional drawing Description of operation Brake application Brake release Brake pad check Brake BaaltHnickNESS E nannte are ne einen AEAEE IGEN 1A ers 0 IVA S s tern mare a ee ORT ah LTR E ans er at Pad removal Setting of running clearance Pad to Disc Final Checks Check of the automatic adjustment function Replacement of Brake Chamber General nennen Removal of Brake Chamber Replacement of Brake Caliper Removal of Brake Caliper Installation of Brake Caliper ansatz te tine a A outed aka ca aati Repair of removed Brake Caliper Replacement of Brake Caliper Guide Pin Seals Replacement of Adjuster Boot Replacement of Adjuster Assembly Replacement of Wedge Assembly FOLIEN ON Gre C1 nee ht nee ann ta un burn war d
7. an 1 5 mm deep or wide running in a Radial direction are allowed C Grooves circumferencial less than 1 5 mm wide are allowed D4 Cracks in the vanes are not allowed and the Disc MUST BE REPLACED a Pad Contact area Notes In case of surface conditions A1 to C1 the disc can continue to be used until the maximum wear limit B 47 42 mm is reached see Section 1 2 2 Machine the faces of the brake disc in conformity with the specifications of the respective vehicle manufacturer The brake disc must be machined evenly on both sides Notes on Brake Discs for the ADB 4300 Vehicles up to chassis numbers 4165557 or C014648 have been equipped with Brake Discs with smooth continuous cooling channels IVECO part number 19076341 old version If required these discs must be replaced by the version with interrupted cooling channels pillar design Since they have a reduced susceptibility to cracking IVECO part number 7180177 new version As brake discs and pads are only replaced in complete sets the following IVECO repair kits for Brake Discs are available 2 1 max 0 75 x a 2 2 g VF 0012773 e IVECO kit no 1908729 2 3 for replacement of Brake Discs of the old version Contents 2 Brake Discs part no 7180177 24 bolts M16x80 part no 16683434 Note The repair kit replaces the old Brake Disc version e IVECO kit no 1908614 for replacement of the Brake
8. e Pad thickness Make a visual check of the brake pads The thickness of the pads must be in order to checked regularly dependent on the usage of the vehicle The pads must be a ascertain the wear condition or checked in conformity with any legal thickness of the pads regulations but at least every three refer Section 1 2 months b compare the thicknesses of the inboard A Minimum thickness of friction and outboard pads of a brake material 2 mm refer Section 6 2 B Thickness of friction material 18 mm when new Check the electrical wear indicator 20 for its correct fit and make sure that it does 6 2 Uneven Pad wear not show any signs of damage KN 004 If the difference in thickness of the two Check the visible rubber parts to make pads is greater than 4 mm brake checks sure that they are not damaged should be made see Section 5 Check the condition of the Brake Discs refer Section 1 2 2 Check the wheel hub for tightness and make sure that its bearing clearance is correct to vehicle manufacturers WARNING recommendation To avoid damage to the Disc surfaces the Pads must to be replaced If there are any signs indicating malfunction when 2mm of friction material thickness is reached at any point such as uneven pad wear pad distortion or if a high residual brake torque is evident the brakes must be checked to verify a the sliding capability of the brake caliper refer Section 7 8 b t
9. ed with a low wearing automatic adjusting mechanism 14 This operates when pad wear had taken place 4 Safety Instructions for service work Please also refer to the relevant safety instructions for repair work on commercial vehicles especially for jacking up and securing the vehicle Use only original KNORR BREMSE parts Please follow repair manual instructions and adhere to the wear limits of the Pads and the Disc see Section 1 2 2 and 6 Tighten bolts and nuts to the recommended torque values see Section 2 3 WARNING Pads must be changed as an axle set and NOT individually Use only Pads which are permitted by the vehicle manufacturer Failure to comply with this may invalidate the Vehicle Manufacturer s Warranty After re fitting the 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 After service work Check the brake performance and the system behaviour on a rolling road or by actual road test 11 Brake Inspection 6 Brake pad check a WARNING If these recommendations are ignored there is a danger of brake failure Observe the wear limits of the pads WARNING 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 6 1 Brak
10. ee en m neh dan ze ei New version Oaliper OONNNOIPO OOO O 12 13 13 14 16 16 17 18 19 22 24 25 26 28 29 29 30 1 Exploded view of brake 1 1 Service kits for Bendix ADB 3700 4300 KNORR BREMSE Description Contains For Brake Service Kit No Item No s Type No 381 391 Guide Pin Kit no seals Caliper set 2 5 7 0 10 All Types S u 381 412 Wear Indicator Kit Axle set 20 131 766 3 or 131 767 ee 131 720 131 721 Kh EL 381 425 Wear Indicator Kit Axle set 20 131 790 131 791 131 774 131 775 381 413 Seal Kit Caliper set 6 9 17 18 14 4 All Types 381 419 Pad Retainer Kit Caliper set 11 16 19 131 720 131 721 131 774 131 775 381 422 Pad Retainer Kit Caliper set 11 16 19 131 766 131 767 131 790 131 791 381 426 Wedge Assembly Caliper set 13 131 766 131 767 131 790 131 791 381 427 Wedge Assembly Caliper set 13 131 720 Tolza 131 774 181 705 381 428 Adjuster Assembly Caliper set 14 131 766 131 767 131 790 131 791 VF 00142 1 neu 381 429 Adjuster Assembly Caliper set 14 131 720 131 721 101 704 131 775 Il 32955 Brake Pads with Pad Retainers 11 12 16 19 131 766 Caliper 12 Brake pads Axle set for ADB 3700 131 767 131 790 131 791 Carrier 13 Wedge assembly Brake actuator 14 Brake adjustment mechanism with boot Bush 14 4 Boot Guide pin 15 Thrust plate Boot 16 For
11. er Chapter 2 3 b install Brake Chamber refer Section 12 3 c install Brake Pads refer Section 8 d set running clearance refer Section 9 e perform final checks refer Section 10 25 14 14 1 26 Repair of removed Brake Caliper 14 2 Replacement of Brake Caliper Guide Pin Seals a clamp Brake Caliper into a vice b loosen and remove Guide Pin Retaining Bolt 7 and Guide Bolt 10 c remove Carrier 2 d remove Boots 6 9 17 and 18 also refer to figure on page 4 35704a CAUTION The Caliper is very heavy take care e press Bushes 4 and Resilient Mount 8 out of the Caliper f clean bush bores in Caliper g install new parts from Seal Kit performing operations b to e in reverse sequence h tighten Guide Pin Retaining Bolt 7 and Guide Bolt 10 with specified torques refer Section 2 3 N VF 0014278 Replacement of Adjuster Boot Clean road dirt from area surrounding Adjuster Hexagon and Boot Rotate Adjuster Screw several turns anti clockwise and lever Boot edge out of Caliper housing Rotate further and remove Adjuster Screw Remove the boot 14 4 from the Adjuster screw Check the threads of the Adjuster and inside the Brake Caliper as well as all movable parts for corrosion Note Make sure that all parts of the Brake Caliper are completely clean Remove any dirt particles with a rag moistened with is
12. he automatic adjustment function refer Section 11 The inside of the brake caliper should be checked for corrosion after removal of the wedge unit refer Section 12 13 7 1 7 2 7 3 1 4 7 9 14 Pad removal The road wheel must be removed Remove the connection cable of the Pad Wear Indicator 20 Remove the Split Pin 11 1 from the retention bar 11 2 Depress the Pad Retainer 11 3 and carefully push out the retention bar noting positions of washers Lift the Pad Retainer 11 3 and the locking mechanism retainer 11 4 Unhook the wire spring 19 Rotate the hexagon of the Adjuster 14 to its stop by means of the Fork 16 see arrow 35695a 35695a1 7 6 1 1 7 8 By displacing the Brake Caliper 1 toward the vehicle centre the Thrust Plaste 15 can be pulled out of its location After pulling out the inboard brake pad 12 1 the Caliper can be slid toward the road wheel whereupon the outboard Brake Pad 12 2 can also be removed Note The inboard Brake Pad 12 1 is held in place by two pins to the Thrust Plate 15 These insert in the bores provided in the backplate of the brake pad The Thrust Plate 15 must be checked for wear at its contact points Wear of more than 0 4 mm is not permissible After removing the Brake Pads dirt must be removed from the pad abutments which together with the rubber parts must be inspected for any visible
13. he brake was introduced the design of the Push Rod connecting the Brake Chamber to the Wedge Assembly has been modified At the time of change the Part Number Label was changed as below and this will allow identification of the Caliper as an Old version or a New version Old Version The Old version used a No Clip version Push Rod Figure A Wedge Assembly supplied as part of Brake Chamber Note The No Clip version may have been replaced at an earlier service by a Clip version see below 19a EN Figure A VF 00142 3 EN 19 12 1 2 20 New Version The New version uses a Clip version Figure B Wedge Assembly supplied as part of the Caliper Brake Chamber available separately 19b EN IVECO Consecutive type number starting from the beginning each month even left odd right type number i BENDIX NECO Soom XX XXX XXX XXX XXX XX XXXXXXXX 1 A January 4 1994 B February 5 1995 99 C March 6 1996 D April 7 1997 E May F June G July H August September J October K November L December J4 e g means October 1994 VF 00142 6 EN Figure B 3 2 N _ dismantling tool Il 33905 VF 00142 4 EN 12 1 3 12 2 Notes regarding changing of Brake Chambers On account of the increased Service Return Spring force introduced into B
14. ht get squeezed g place the brake actuator into right position in relation to the air connection and the bores of the two bolts then exhaust the actuator Ensure that the bolts slide into the bores h press the brake actuator against the flange of the caliper and screw both nuts with washers onto the threaded bolts of the brake actuator for specified bolt tightening torque refer to Section 2 3 23 13 13 1 24 Replacement of Brake Caliper Note When replacing the Brake Caliper please observe the following points On account of design changes made in October 1994 only Calipers with a Date Code J4 or later should be used refere page 20 See Sections 12 1 3 regarding Brake Chambers Removal of Brake Caliper a disconnect air line from Brake Chamber b remove Brake Pads refer Sections 7 1 to 7 6 c remove hexagon head bolts 21 from the brake carrier d take Brake Caliper 1 and Carrier 2 assembly off the steering knuckle e remove Brake Chamber refer Section 12 Note Check type plates of the Brake Caliper and Brake Chamber to ensure correct replacement Replacement Brake Calipers are supplied without Brake Chamber 357024 The Caliper is very heavy take care 13 2 Installation of Brake Caliper a Fasten the Brake Caliper 1 and Carrier 2 assembly to the steering knuckle by means of hexagon head bolts 21 For bolt tightening torques ref
15. k Guide pin retaining bolt 17 Boot assembly Il 32957 Brake Pads with Pad Retainers 11 12 16 19 131 720 Axle set for ADB 4300 131 721 1831 7774 131 775 Resilient mount 18 Boot assembly Boot assembly 19 Wire spring Only suitable if the original Wedge and Brake Chamber Assembly have been replaced with the Guide bolt 20 Wear indicator Clio Type Brake Chamber see Section 12 a a O O ONO AO N Pad retainer assy KNORR BREMSE Description Contains For Brake Service Kit No Item No s Type No Il 33683 T 18 Brake Chamber with Wedge Assy 3 13 131 766 Il 33684 T 20 Brake Chamber with Wedge Assy 3 13 131 767 Il 33685 T 22 Brake Chamber with Wedge Assy 3 13 Il 33686 T 24 Brake Chamber with Wedge Assy 3 13 Il 33687 T 27 Brake Chamber with Wedge Assy 3 13 Il 33688 T 18 Brake Chamber with Wedge Assy 3 13 131 720 Il 33689 T 20 Brake Chamber with Wedge Assy 3 13 131 721 Il 33690 T 22 Brake Chamber with Wedge Assy 3 13 Il 33691 T 24 Brake Chamber with Wedge Assy 3 13 Il 37371 T 18 Brake Chamber Clio Type 3 131 790 Il 37372 T 20 Brake Chamber Clip Type 3 131 791 Il 37373 T 22 Brake Chamber Clip Type 3 131 774 Il 37374 T 24 Brake Chamber Clip Type 3 131 775 Il 37375 T 27 Brake Chamber Clip Type 3 Il 33692 Pad Retention Pins and Clips Kit Axle set 11 Pins amp Clips only All Types Il 33693 Clio for Brake Chamber 2 off
16. opropyl alcohol or similar solvent When assembling the parts ONLY use original Shell Darina R2 grease see Section 2 2 Grease the Adjuster Screw Slide new Boot 14 4 from Seal Kit onto the Adjuster and ensure correctly seated iN groove behind hexagon Screw Adjuster into the Caliper 1 by a few threads Lightly grease the Boot seat Carefully drive the boot seat into the housing bore by means of an aluminium mandrel Check proper fit of the Boot Rotate Adjuster Screw clockwise until fully retracted VF 00142 9 VF 00142 10 2 14 3 28 Replacement of Adjuster Assembly Clean road dirt from area surrounding Adjuster Hexagon and Boot Rotate Adjuster Screw several turns anticlockwise and lever Boot edge out of Caliper housing Rotate further and remove Adjuster Screw Remove Circlip and withdraw Adjuster Assembly from Caliper The Adjuster Assembly is not repairable Thoroughly clean all internal surfaces of Adjuster Assembly hole If there are signs of serious corrosion wear or damage the Caliper should be replaced Liberally grease new Adjuster Assembly and Adjuster hole with grease supplied Refit new Adjuster Assembly ensuring correct orientation by aligning slot and peg Replace Circlip Lightly grease the Boot seat Carefully drive the Boot seat into the housing bore by means of an aluminium mandrel Rotate Adjuster Screw clockwise until fully
17. rake Chambers after Feb 1995 Week Date Code 0895 checks should be made of the date codes on both Disc Brake Chambers of the vehicle In the event that either shows a date code before this it is recommended that both Brake Chambers are replaced It is important that both Brake Chambers have the same Return Spring force Removal of Brake Chamber a disconnect both nuts 3 4 from the threaded bolts of the brake actuator and remove them together with the washers b charge brake actuator with compressed air 2 bar max to obtain the greatest possible piston stroke for the following tasks c introduce a safety tool II83905 spacer tube between the brake actuator flange and the brake caliper flange to ensure that the return spring remains com pressed and the working space is kept free CAUTION The dismantling tool must be correctly positioned since otherwise the hands might get squeezed d pull the Boot 3 2 away from the Push Plate to expose the Push Rod see Figure A and Figure B on Page 19 and 20 eee 35701a EN dismantling tool part number Il 33905 VF 00142 5 EN 21 e If the unit is a No Clip version Remove the Dismantling Tool Exhaust the Brake Chamber Disconnect the air hose Remove complete Brake Chamber and Wedge Assembly f If the unit is a Clip version Remove the Clip with a small screwdriver Pull the Brake Chamber out of the Wedge As
18. sembly Remove the Dismantling Tool Exhaust the Brake Chamber Disconnect the air hose Remove Brake Chamber 12 3 Installation of anew Brake Chamber 12 3 1 No Clip Version Remove plastic protection cap from the assembly Insert the assembly into the Caliper Screw both nuts 3 4 with washer onto the threaded bolts of the Brake Chamber see Section 2 3 for Torque settings Connect air hose 22 Figure A Ryd r EAL lah J N dismantling tool VF 00142 3 EN Figure B 3 2 N Rot VD ZA S j j dismantling tool VF 00142 4 EN 12 3 2 Clip Version a Remove plastic protection cap from the brake actuator b remove boot 8 2 to get access to the groove for the clip 8 6 introduce a new clip into the groove of the thrust rod 3 3 by means of a small screwdriver c rub grease Shell Darina R2 into the grooves of the boot and return the latter into the right installation position d connect air hose to the brake actuator e charge brake actuator with compressed air 2 bar max to obtain the greatest possible piston stroke for the following operations f press brake actuator into the thrust rod until the clip engages check correct fit by lightly exerting a light pull on the actuator Note If you pull too strongly the wedge support is placed out of its correct position CLIP VF 00142 3 Do not slide your fingers between the flanges They mig
19. ssy Brake Pads Inboard Brake Pad Outboard Brake Pad Wedge Roller set Adjuster assy Thrust plate Fork Wear indicator 3 2 1 wi TH nl ry TT a 10 11 3 2 2 3 2 3 12 DEE TEEN 12 2 12 1 15 N breeehehugh A a A j an Lh SIE m VF 00142 2 EN Description of operation Floating Caliper principle Brake application Refering to Fig 3 1 When applying the brake the brake pressure P causes the piston rod force F1 of the Brake Chamber 3 1 to be transmitted to a wedge assembly equipped with two rollers 13 2 One of the rollers is supported by a fixed ramp 1 1 whereas the second roller displaces a movable ramp 1 2 in an axial direction giving an increased application force F2 This force F2 is then transmitted through an integral adjuster assembly 14 and an intermediate Thrust Plate 15 to the inboard brake pad 12 1 and through the brake caliper to the outboard brake pad 12 2 The contact pressure between the brake pads 12 and the brake disc generates the braking torque for the wheel Brake release As the braking pressure P is reduced springs inside the brake as well as inside the Brake Chamber cause the wedge unit to resume its initial position Brake adjustment automatic To maintain a constant running clearance between the brake pads and the brake disc the brake is equipp
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