Pneumatic Disc Brake SN6... / SN7... / SK7... / ADB22X: Service Manual

Commercial Vehicle Systems
Service Manual Pneumatic Disc Brake

SN6.../ SN7.../ SK7.../ ADB22X
Description/Function
Service kits
Service
Accessories
Y006471: EN: 003: MAX1: Released:Webmaster: 2008/05/05-07:46:51

Overview of Toolkits and Service Manuals for Knorr-Bremse Air Disc Brakes
Brake Tool Kit Alternative

SB5… II37951004EN
SB6... II37951004EN
see note *)
SB7...
SN5… K004789
SN6...
SN7... K016947 K001288 + Supplemental Kit K017062
SK7... K005973 + Supplemental Kit K017062
ADB22X
Brake Service Manual

SB6...
C16352-EN
SB7...
SN5… Y015044-EN
SN6...
SN7... Y006471-EN
SX7...
ADB22X
* ) additional tools are required - available in kit
K001288 or K005973 or K016947
Disclaimer
The information contained in this document is intended for the exclusive use of trained persons within the commercial vehicle industry, and must not be
passed on to any third party.
All recommendations regarding products and their servicing or usage are with reference to Knorr-Bremse products and should not be considered
applicable to products from other manufacturers.
This information does not purport to be all-inclusive and no responsibility is assumed as a result of its use. We cannot accept any liability nor offer any
guarantee regarding data accuracy, completeness or timeliness. The information does not represent any guarantee or ensured characteristics of the
Products or Systems described.
No liability can be accepted based on the information, its use, recommendations or advice provided. 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.
Any legal disputes arising from the use of this information shall be subject to German law.
Note: If service work is carried out on the vehicle, it is the responsibility of the workshop to ensure the vehicle is fully tested and in full functional order
before the vehicle is returned into service. Knorr-Bremse accepts no liability for problems caused as a result of appropriate tests not being carried out.
This disclaimer is an English translation of a German text, which should be referred to for all legal purposes.

Contents
1. Overview . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Disc Brake Components. . . . . . . . . . . . . . . . . . . 6

1.2 Brake Disc Identification and Service Kits for Air Disc Brakes . . . . . . . 7
1.2.1 Wear Indicator Kits. . . . . . . . . . . . . . . . . . . . . 7
1.3 Brake Disc. . . . . . . . . . . . . . . . . . . . . . . 8
2. General Information. . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Service Tools . . . . . . . . . . . . . . . . . . . . . . 9

2.2 Diagnostic Equipment. . . . . . . . . . . . . . . . . . . 9
2.3 Lubricant . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Torque Requirements . . . . . . . . . . . . . . . . . . . 9
3. Description and Function. . . . . . . . . . . . . . . . . . . . 10
3.1 Disc Brake Sectioned View. . . . . . . . . . . . . . . . . 10

3.2 Description of Operation. . . . . . . . . . . . . . . . . . 11
3.2.1 Brake Actuation . . . . . . . . . . . . . . . . . . . . . 11
3.2.2 Brake Release. . . . . . . . . . . . . . . . . . . . . 11
3.2.3 Brake Adjustment . . . . . . . . . . . . . . . . . . . . 11
4. Inspection Points . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Safety Instructions for Service Work and Repair Work . . . . . . . . . 13
5. Functional and Visual Check . . . . . . . . . . . . . . . . . . . 14
5.1 Wear Check of Pads and Discs . . . . . . . . . . . . . . . . 14
5.1.1 Brake Wear Check using Rubber Bush (6a). . . . . . . . . . . . . 16
5.1.2 Brake Wear Check using Rubber Bush (6b). . . . . . . . . . . . . 17
5.1.3 Brake Wear Check using Carrier to Caliper position (6c). . . . . . . . . 18
5.1.4 Wear Indicators. . . . . . . . . . . . . . . . . . . . . 19
5.1.5 Diagnostic Equipment ZB9031-2 . . . . . . . . . . . . . . . . 19
5.2 Adjuster Check . . . . . . . . . . . . . . . . . . . . . 20
5.3 Caliper Checks. . . . . . . . . . . . . . . . . . . . . 22
5.3.1 Caliper Running Clearance . . . . . . . . . . . . . . . . . . 22
5.3.2 Caliper Movement along Guide Pins. . . . . . . . . . . . . . . 22
5.3.3 Rubber Bush (6a, 6b) and Guide Sleeve (6c) to Guide Pin clearance . . . . . . 22
5.4 Checking of Sealing Elements . . . . . . . . . . . . . . . . 23
5.4.1 Caliper Guide Pin Seals. . . . . . . . . . . . . . . . . . . 23
5.4.2 Checking of Tappet and Boot Assemblies (13) . . . . . . . . . . . . 24
6. Pad Replacement. . . . . . . . . . . . . . . . . . . . . . . 25
6.1 Pad Removal. . . . . . . . . . . . . . . . . . . . . . 25

6.2 Pad Fitting. . . . . . . . . . . . . . . . . . . . . . 26
6.3 Wear Indicator Fitting
(In-pad cable type). . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Contents
6.3.1 Cable Guide Variant (105). . . . . . . . . . . . . . . . . . 28

6.3.2 Cable Guide Variant (105a). . . . . . . . . . . . . . . . . . 29
6.3.3 Protection Plate (104). . . . . . . . . . . . . . . . . . . 29
7. Replacement of Tappet and Boot Assemblies (13) and Inner Seals (22). . . . . . 30
7.1 Tapped and Boot Assemblies (13) - Removal . . . . . . . . . . . 30

7.1.1 Threaded Tubes (16) - Inspection . . . . . . . . . . . . . . . . 31
7.2 Inner Seals (22) - Replacement. . . . . . . . . . . . . . . . 31
7.3 Tappet and Boot Assemblies (13) - Fitting . . . . . . . . . . . . 32
8. Caliper Replacement. . . . . . . . . . . . . . . . . . . . . . 34
8.1 Caliper Removal from Carrier . . . . . . . . . . . . . . . . 34

8.1.1 Removal of the Cover (10) . . . . . . . . . . . . . . . . . . 34
8.1.2 Removal of the Cover (68c) . . . . . . . . . . . . . . . . . 34
8.1.3 Removal of the Cap (68a). . . . . . . . . . . . . . . . . . 35
8.1.4 Remove Caliper from Carrier . . . . . . . . . . . . . . . . . 35
8.2 Caliper Fitting
(Carrier is fitted on the axle) . . . . . . . . . . . . . . . . . . . . . . . . 35
8.2.1 Fitting of Cover (10) and (68c) . . . . . . . . . . . . . . . . . 36
8.2.2 Fitting of Cap (68a). . . . . . . . . . . . . . . . . . . . 37
9. Replacement of Inner Boot (9). . . . . . . . . . . . . . . . . . . 38
10. Replacement of Guide Sleeves . . . . . . . . . . . . . . . . . . 40
10.1 Brass Bush (7) - Replacement . . . . . . . . . . . . . . . . 40

10.1.1 Removal of Brass Bush (7) . . . . . . . . . . . . . . . . . . 40
10.1.2 Fitting of Brass Bush (7) . . . . . . . . . . . . . . . . . . 40
10.2 Rubber Bush (6a, 6b) and Guide Sleeve (6c) - Replacement . . . . . . . 41
10.2.1 Removal of Rubber Bush (6a or 6b) . . . . . . . . . . . . . . . 41
10.2.2 Removal of Guide Sleeve (6c). . . . . . . . . . . . . . . . . 42
10.2.3 Fitting of Rubber Bush (6a or 6b). . . . . . . . . . . . . . . . 42
10.2.4 Fitting of Guide Sleeve (6c). . . . . . . . . . . . . . . . . . 43
11. Carrier Replacement . . . . . . . . . . . . . . . . . . . . . . 45
12. Brake Actuator Replacement. . . . . . . . . . . . . . . . . . . 46
12.1 Brake Chamber Removal. . . . . . . . . . . . . . . . . . 46

12.2 Brake Chamber Fitting . . . . . . . . . . . . . . . . . . . 46
12.3 Spring Brake Removal . . . . . . . . . . . . . . . . . . . 47
12.4 Spring Brake Fitting . . . . . . . . . . . . . . . . . . . 47

Safety Advice
Note: The safety advice listed below is applicable to general service and diagnostic work on braking systems and may not all be directly relevant to the
activities and products described in this document.
Before and during working on or around compressed air systems and devices, the following precautions should be observed in addition to any specific
advice given in this document:
• Always wear safety glasses when working with air pressure.
• Never exceed manufacturer’s recommended air pressures.
• Never look into air jets or direct them at anyone.
• Never connect or disconnect a hose or line containing pressure; it may whip as air escapes.
• Never remove a device or pipe plug unless you are certain all system pressure has been depleted.
• Park the vehicle on a level surface, apply the parking brakes, and always chock the wheels as depleting vehicle air system pressure may cause the
vehicle to roll.
• If work is being performed on the vehicle’s air braking system, or any auxiliary pressurised air systems, and if it is necessary to drain the air pressure
from reservoirs, etc., keep away from brake actuator push rods and levers since they may move as system pressure drops. Be aware that if the
vehicle is equipped with an air dryer system, it can also contain air pressure along with its purge reservoir, if fitted, even after pressure has been
drained from the other reservoirs.
• When working under or around the vehicle, and particularly when working in the engine compartment, the engine should be shut off and the ignition
key removed. Where circumstances require that the engine be running, EXTREME CAUTION should be taken to prevent personal injury resulting from
contact with moving, rotating, leaking, heated or electrically charged components. Additionally, it is advisable to place a clear sign on or near the
steering wheel advising that there is work in progress on the vehicle.
• Examine all pipework for signs of kinks, dents, abrasion, drying out or overheating. Be aware that kinks in pipework may result in air pressure
being trapped in the pipework and associated equipment. Replacement hardware, tubing, hose, fittings, etc. must be of equivalent size, type
and strength as original equipment and be designed specifically for such applications and systems. Check the attachment of all pipework; it
should be installed so that it cannot abrade or be subjected to excessive heat.
• Components with stripped threads or damaged/corroded parts must be replaced completely. Do not attempt repairs requiring machining or welding
unless specifically stated and approved by the vehicle or component manufacturer.
• Never attempt to install, remove, disassemble or assemble a device until you have read and thoroughly understood the recommended procedures.
Some units contain powerful springs and injury can result if not properly dismantled and reassembled. Use only the correct tools and observe all
precautions pertaining to use of those tools. Before removing any device note its position and the connections of all pipework so that the
replacement/serviced device can be properly installed. Ensure that adequate support or assistance is provided for the removal/installation of heavy
items.
• Use only genuine Knorr-Bremse replacement parts, components and kits.
• Prior to returning the vehicle to service, make certain that all components and the complete brake systems are leak free and restored to their
proper operating condition.
Welding
To avoid damage to electronic components when carrying out electrical welding, the following precautions should be observed:
• In all cases, before starting any electrical welding, remove all connections from any electronic control units or modules, noting their position and the
order in which they are removed.
• When re-inserting the electrical connectors (in reverse order) it is essential that they are fitted to their correct assigned position - if necessary this must
be checked by PC Diagnostics.

1
Overview
1 Overview
1.1 Disc Brake Components
(Wear Indicators see Section 1.2.1)
44
11
26
45
18/1 58*)
18/2
9*)
12/2
4c*)
) 4b*
) 12*)
Weißes Montagefett 4a* ; 12/1
White assembly grease
6b*) 13
6c*)
39c*)
61
68c*)
39b*) 6a*) 7
161
39a*) 37
5 22
68a*) 9 58
40
Weißes Montagefett
mikroverkapselt
pre-applied adhesive
10
2*)
FD00148-Äi01.eps
1 Caliper 13 Tappet and Boot

2* ) Carrier Assembly
4a* ) Guide Pin 18/1 Spring Brake
4b* ) Guide Pin 18/2 Brake Chamber
4c* ) Guide Pin 22 Inner Seal
5 Guide Pin 26 Spring Clip
*) Variants are possible
6a* ) Rubber Bush 37 Adjuster Cap
see also contents
6b* ) Rubber Bush 39a* ) Hexagon Socket head
leaflet in the
6c* ) Guide Sleeve (DU)

cap screw
service kit
7 Brass Bush 39b* ) Hexagon Socket head
9* ) Inner Boot

cap screw 45 Washer
10 Cover 39c* ) Hexagon Socket head 58 Ring
11 Pad Retainer cap screw 61 Shear Adapter

12* ) Pad ( complete ) 40 Hexagon Socket head 68a* ) Cap
cap screw )
12/1 Pad 68c* Cover
12/2 Pad Retainer Spring 44 Pad Retainer Pin 161 Tappet Bush

1
Overview
1.2 Brake Identification and Service Kits for Air Disc Brakes
Type of Caliper
Knorr-Bremse Part no.
Axle- or Vehicle Manufacturer’s no.
Date of Manufacture
Use only genuine Knorr-Bremse parts!
The following Service Kits are available :
Description Contents
Carrier 2
Guide and Seal Kit 4a* ) , 5, 6a* ) , 7, 9, 10, 39a* ) , 40, 58
For specific Service Part
(4b* ) , 4c* ) , 6b* ) , 6c* ) , 39b* ) , 68a* ) , 68c* )
Numbers allocated to the
Tappet and Boot Kit 13 (2x), 22 (2x), 161 (2x) Disc Brake see:
www.knorr-bremseCVS.com
Adjuster Cap Kit 37 (10 pcs), 61 (10 pcs)
www.knorr-bremseCVS.biz
Pad Kit (per axle) 11, 12, 26, 37, 44, 45, 61
Wear Indicator Kit (per axle) Variants see Section. 1.2.1
Knorr-Bremse offers a range

of specifically designed
Air Disc Brake without Carrier (2) rationalised Calipers to service
Caliper and without Brake Pads (12). a wide range of Disc Brakes.
Guide Pins and Seals Kit provided for assembly
of Caliper to existing Brake Carrier. For specific Caliper Part
Number, see:
Brochure Y028774 or
www.Knorr-BremseCVS.com
www.Knorr-BremseCVS.biz
1.2.1 Wear Indicator Kits (typical kits are shown below) * ) Variants
Type 1 Type 2
Type 3 Alternative to Item 105

11 Pad Retainer
105a 101 Sensor
103 Cable to electrical Supply
104 Cable Protection Plate
FD00306.eps
105 Cable Guide

105a Cable Guide

1
Brake Disc
1.3 Brake Disc

Replacing Brake Discs is subject to the instructions of the Vehicle Manufacturer,
including when fitting Knorr-Bremse Brake Discs.
When replacing Brake Discs, make sure to use the correct connections and tightening torques.
The use of non-approved Brake Discs will reduce levels of safety, invalidate warranty and not
be covered by any Knorr-Bremse liability
Brake Discs can be ordered through the Knorr-Bremse Aftermarket Organisation.

2
General Information
2 General Information
2.1 Service Tools
Tool combination Description consisting of

Part No. Identifier 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
Z004354 (D) Pull-in/Pull-out Tool including Grooving Tool for Brass Bush (7) T8, T12, T13, T14, T16
II32202 (A) Wedged Fork for removal of Tappet and Boot Assembly (13) T15
K015825 (H) Press-in Tool for Cover (10) T26 (replaces T17)
K016743 (M) Press-in Tool for Cover (68c) T27 (replaces T25)
Z004198 (R) Pull-in/Pull-out Tool for Rubber Bush (6a) and (6b) T5, T6, T18, T19,T20, T21, T22
K005986 (N) Pull-in/Pull-out Tool for Guide Sleeve (6c) T5, T6, T8, T14, T20, T21
Z003934 (K) Press-in Tool for Cap (68a) T11
Z004361 (L) Press-in Tool for Inner Seal (22) T3, T4, T9
K004082 (P) Ring for Tappet and Boot Assembly (13) T24
Note
The Service Tool Kit (Part No. K016947) contains the above listed tools, to fit tool combinations for items 6a, 6b, 6c, 7, 9,
10, 13, 22, 68a and 68c. This English Service Manual as well a German one and a Service DVD (Part No. K016953) are
included. Customers who already own the Service Tool Kits (Part No. K005973 or K001288) may supplement this with the
“Supplemental Tool Kit“ (Part No. K017062). This contains the tool combinations (Part No. K015825), (Part No. K016743)
and (Part No. K004082) as well as a revised Service-DVD (Part No. K016953). An English and a German Service Manual
are supplied in the “Supplemental Tool Kit“ as well.
2.2 Diagnostic Equipment
Part-Number Description
II40598F ZB9031-2 hand-held device for checking Potentiometer function (Pad plus Disc wear) where 13 pin
chassis plug is installed. ZB9031-2 replaces ZB9031 - see page 19.
2.3 Lubricant
Part Number Colour Quantity
II14525 white 5g
II32868 white 500g
2.4 Torque Requirements

I tem Number Torque Spanner Size
(mm)
39a: 39b; Caliper Bolts (2x) 180 Nm 14
39c; 40 M16x1,5 (Hexagon socket head) plus 90° (Hexagon key)
Follow the instructions of the _
18/1; 18/2 Brake Chamber or Spring Brake
Brake Actuator Manufacturer

3
Description and Function
3 Description and Function

3.1 Disc Brake Sectioned View
1 Caliper
2*) Carrier
4a*) Guide Pin
4b*) Guide Pin
4c*) Guide Pin
5 Guide Pin
6a*) Rubber Bush
6b*) Rubber Bush
6c*) Guide Sleeve (DU)
7 Brass Bush
9*) Inner Boot
10 Cover
11 Pad Retainer
12*) Pad (complete)
13 Tappet and Boot Assembly
16 Threaded Tube
17 Bridge
18/1 Spring Brake
18/2 Brake Chamber
19 Lever
20 Eccentric Bearing
22 Inner Seal
23 Adjuster Unit
24 Turning Device
26 Spring Clip
27 Spring
30 Chain
32 Chain Wheel
33 Wear Sensor
37 Adjuster Cap
39a*) Hexagon Socket head cap screw
39b*) Hexagon Socket head cap screw
39c*) Hexagon Socket head cap screw
40 Hexagon Socket head cap screw
43 Bolt
44 Pad Retainer Pin
45 Washer
46 Disc
58*) Ring
61 Shear Adapter
68a*) Cap
68c*) Cover
161 Tappet Bush *) Varianten beachten
10
3
Description and Function
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 Roller 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 by
the caliper 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 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 Pads and

Disc, 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.
11
4
Inspection Points
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, e.g. during the inspection regulated by law, the clearance of the caliper related to the running
clearance must be checked. Also inspect the Cover (10) and the Cap (37) as well as the Cap (68a) or the Cover (68c)
for correct fitting and condition.
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, condition and
damage as well as the caliper bearing clearance..
The brake discs are to be checked according to the specification of the axle or vehicle manufacturer.
In the unlikely event of a warranty claim, all relevant components - e.g. Pads (12/1) and Pad Retainer Springs (12/2) - must
be returned in order that an objective investigation of the cause can be made.
44
11
26
45
18/1 58* )
18/2
9*)
12/2
4c*)
)
12*
) 4b* ) 12/1
Weißes Montagefett 4a* ;
6b*) 13
6c*)
39c*)
61
68c*)
39b* ) 6a*) 7
161
39a*) 37
5 22
68a*) 9 58
40
Weißes Montagefett
mikroverkapselt
pre-applied adhesive
10
2*)
FD00148-€i01klein.eps
12
4
Inspection Points
4.1 Safety Instructions for Service Work

and Repair Work
Observe relevant safety instructions for service work and

repair work on commercial vehicles, especially for jacking
up and securing the vehicle.
Use only genuine Knorr-Bremse parts.
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 service 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 prescribed torque values.
Screw threads and tapped holes must be free

of lubrication and residuals of thread locking
products.
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
and the wheel.
After any service work:

Check the brake performance and the system
behaviour on a roller dynamometer. Check function
and effectiveness. Bear in mind that a lower
performance can appear during the breaking-in
phase of the brake pads and/or the brake disc.
13
5
Functional and Visual Check
5 Functional and Visual Check

5.1 Wear Check of Pads and Brake Discs
For optimum safety, stay within the Pad and Disc Wear Limits.
Pads
Sketch 1
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. Even if a Wear Indicator
is fitted and connected, this must be at least every
3 months.

If the friction material is less than 2mm at its thinnest
area (see dimension E, Sketch 3), the Pads must be
replaced.
Minor breakouts at the edges are permitted (see

arrow, Sketch 1). Sketch 2
Major breakouts on the surface of the brake Pad

are not permitted (see arrow, Sketch 2).
Brake discs
Measure the thickness of the brake disc at the thinnest

point. Avoid measuring near the edge of the disc as a
burr may be present.
A = Total thickness of the brake disc

new condition = 45 mm
worn condition = 37 mm (the disc must be replaced) Sketch 3
C = Overall thickness of Brake Pad 30mm (new
condition)
C A
D = Backplate - 9 mm with SN6... and SN7... .
Backplate - 7 mm with SK7... and ADB22X.
E = Minimum thickness of friction material 2mm
F = Minimum allowed thickness in worn condition
for backplate and friction material.
With 9 mm backplate, F = 11 mm.
D E
With 7 mm backplate, F = 9 mm.
If these minimum allowed thicknesses are reached,
replacement of the Brake Pads is necessary
If the Disc dimension A ≤ 39 mm, it is recommended

M+P-KN-002Äi01.eps
that the Disc should be renewed when the brake

pads are next changed. F
If the disc thickness is less than 37 mm, the disc
must be replaced.
If these recommendations are ignored, there is a danger of brake failure
and therefore increased risk of an accident.
14
5
Check Disc at each change of Pads for grooves and

cracks.
A1 B1
a
The diagram shows possible surface conditions of the
brake disc. max. 0,75 x a
A1 = Small cracks spread over the surface max. 1,5 mm

are allowed
B1 = Cracks less than 1.5mm deep or wide, running D1 C1

in a Radial direction are allowed A
C1 = Unevenness of the disc surface less than 1.5mm
deep is allowed
VF 00127_3_Äi01.eps
D1 = Cracks going through to the cooling duct or onto
the inner or to the outer friction ring are not allowed.
The Disc MUST BE REPLACED.
a = width of the friction surface
Note:
In case of surface conditions A1, B1 and C1, 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
C1
the Pads after severe grooving on the entire friction surface
has occurred. To meet safety requirements, the minimum
thickness after machining must be greater than 39 mm. B1
In addition, the recommendations of the Vehicle
Manufacturer about the machining of the brake disc MUST D1
be followed.
The adjacent picture shows some examples of cracks and
grooves on a Brake Disc.
If these recommendations are ignored, there is a risk of accident. If the brake

pads and/or the brake disc are worn down excessively, brake performance
will be reduced and may be lost completely.
15
5
5.1.1 Brake Wear Check using Rubber Bush (6a):

For all Disc Brakes which are equipped with a Rubber Bush that is axially ribbed (see H in sketch).
1 1
4 4
G
6a 6a
FD00190-1Äi03.eps
"X" G "Z"
The condition of the Pads can be visually determined, The wear limit (see “Z”)
without removing the road wheel, by viewing the position
Shown by the new position of the wear marking “G” on
of the wear marking “G” (change-over from the ribbed area
the Rubber Bush (6a). This condition requires a check of
to the flat area).
the brake pad thickness and the brake disc with the wheel
New Condition (see “X”) removed.
Shown by the position of the wear marking ‘G’ on the If necessary change the Pads (see Section 6) and/or the
Rubber Bush (6a). Disc - see Vehicle Manufacturer’s recommendations.
16
5
5.1.2 Brake Wear Check using Rubber Bush (6b):

For all Disc Brakes which are equiped with open Rubber Bush Version.
1 • ≤ 1
4 4
6b
6b
FD00217.eps
C
D
The condition of the Pads can be visually determined

without removing the wheel by checking the position of
C = new condition
the caliper (1) compared to the fixed Guide Pin (4).
D = brake pads and disc must be checked with the
wheel removed.
If dimension ‘C’ is less than 1mm, the brake pad
thickness and the brake disc must be checked with the
wheel removed.
If necessary change the Pads (see Section 6) and/or the

Disc - see Vehicle Manufacturer’s recommendations.
17
5
5.1.3 Brake Wear Check using Carrier to Caliper position (6c):

For all Disc Brakes which are equiped with a Caliper to Carrier marking.
P P
R R
FD00354.eps
“C” “D”
The condition of the Pads can be visually determined

without removing the road wheel by viewing the position
C = new condition
of the Caliper position (P) compared to the Carrier marking
(R). D = pads and disc must be checked with the wheel
removed.
If the condition “D” is reached the brake pad thickness and

the brake disc must be checked with the wheel removed.
If necessary change the Pads (see Section 6) and/or the

Disc - see Vehicle Manufacturer’s recommendations.
18
5
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
M+P-KN-007.eps
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
M+P-KN-008.eps
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 continuous
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, 13-Pin Plug
without removing the wheels. (DIN 72570)
to vehicle
Note:
A detailed instruction manual is included with each
unit. Plug to Potentiometer on Disc Brake (Adapter Cables
supplied to suit all variants of potentiometer connection)
19
5
5.2 Adjuster Check

Before starting work, ensure that the wheels
are chocked and the vehicle cannot roll away.
Ensure that service brake and parking brake, as well
as the bus stop temporary hold brake, if fitted, are
in the released condition.
Remove wheel.
61 37
The caliper assembly should be pushed inboard on its
Guide Bushes. Using a suitable tool, press the inboard pad
(12) away from the Tappets and check the gap between
Tappet and inboard pad backplate - it must be between
FD00150.eps
0.6 - 1.1mm.
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 be
checked as follows.
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
23
clearance). 61 37
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.
FD00151.eps
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 1
Make sure that the ring spanner or socket can
turn freely clockwise during the following procedure.
By applying the brake (about 2 Bar) 5 to 10 times the
spanner or socket should turn clockwise in small increments
if the Adapter is functioning correctly (see notes below).
Note:
As the number of applications increases, incremental
movement of the ring-spanner or socket will decrease.
Note:
If the spanner or socket does not turn or turns only with
the first application or turns forward and backward with
FD00218
every application, the automatic Adjuster has failed and

the Caliper must be replaced.
20
5
Note:
Even if pads are not being changed, a new adjuster cap
(37) should be fitted, having lightly greased the contact 37
surface with white grease (available as Part No. II14525
or II32868).
Notes:
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, or similar, is not
allowed since the seal may be damaged.
FD00144.eps
21
5
5.3 Caliper Checks
5.3.1 Caliper Running Clearance

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, even using a high level of hand pressure (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 Bush (4a) or (4b) (see arrows in
sketch).
Using hand pressure only (no tools), the Caliper (1) must short bearing side
slide freely along the whole length of the Guide Pin
arrangement; movement should be greater than 25mm.
5.3.3 Rubber Bush (6a, 6b) or Guide Sleeve (6c) to

Guide Pin clearance
*) Variants
Note:
Before removing the wheel, note that there is no contact
between Caliper and axle, vehicle, chassis sections or
Carrier. If necessary the Rubber Bush (6a, 6b) or Guide
Sleeve (DU) (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
brake.
22
5
Fasten a magnetic dial-gauge holder to the Carrier (2) on 12

the short bearing side of the Caliper (1) - see also adjacent
Sketch. 1
Use the casting tag on the Caliper (1) as the measuring
point - 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 of the bearing clearance on the
FD00383.eps
dial-gauge.
2
Note:
Knorr-Bremse distinguishes between the two bearing variants
- variant with Rubber Bush (6a) or (6b).
- variant with Guide Sleeve (6c).(DU)
If the short bearing side is open, or closed by Cap (68a),
and the measured bearing clearance 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).
If the short bearing side is closed by Cover (68c) and the
measured bearing clearance is greater than 1.0 mm, the
Guide Sleeve (6c) must be replaced using a suitable kit
(see Section 1.2 and Section 8).
Note that there must be no contact between Caliper and
axle, vehicle, chassis sections or Carrier. If necessary the
caliper bearing must be replaced using a suitable kit (see
Section 1.2 and Section 8).
Fit Pads and adjust running clearance (see Section 6.2).
Fit the wheel. (Refer to Vehicle Manufacturer’s
recommendations).
5.4 Checking of Sealing Elements

5.4.1 Caliper Guide Pin Seals
The Guide Pin (5) is sealed with Cover (10) and with the
Inner Boot (9).
The variant with the Guide Pin (4c) is also sealed with Inner
Boot (9) and with Cover (68c). short bearing side
The components (9), (10) and (68c) must be free of any
signs of damage.
For versions with Rubber Bushes (6a) and (6b), check that
the Rubber Bushes are free from damage.
Check for correct location and fitment.
Note:
If necessary remove the Pads to inspect the Inner Boots
(9) (see section 6.1).
If necessary, repair Caliper with suitable service Kit (see *) Varianten beachten
Section 1.2 and Section 8 and following).
23
5
5.4.2 Checking of Tappet and Boot Assemblies (13)

If necessary remove Pads (12) (see Section 6.1). Screw the
Shear Adapter (61) clockwise (see Section 5.2) until the
boots are clearly visible.
13
Note:
The tappet must not be extended more than 30 mm (see
sketch) because then the synchronisation is lost and the
caliper must be replaced.
The Tappet and Boot Assemblies (13) must not show any
FD00220.eps
signs of cracks or other damage. 30
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).
24
6
Pad Replacement
6 Pad Replacement

6.1 Pad Removal 44
Remove wheel (refer to Vehicle Manufacturer’s
recommendations). 11
45
FD00221.eps
Important:
Before removing Pads it is strongly recommended that the 26
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.
If the Pad Retainer (11) is corroded or damaged, it must
be replaced. Pull off the Adjuster Cap (37) using the tab,
taking care not to lose the Shear Adapter (61).
Removal of the adjuster cap with a screwdriver or similar is
not allowed since the seal may be damaged. ard
Inbo
Fully wind back the Tappet and Boot Assemblies (13) by
rotating the Shear Adapter (61) in an anti-clockwise Out
boa
rd
23
21
direction (see Section 5.2) – a clicking noise is generated. 613737
Shear Adapter is exceeded, then it is designed to Inboard Pad
12 FD00222.eps
With a second failure of the Shear Adapter the
Caliper must be exchanged since internal damage
is present. 12
Do not use an open-ended spanner as this may
damage the Adapter.
Note:
The shape of the backplate in SK7- and ADB22X- Disc Brakes
means that the steps below for removal of the brake pads (12)
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.
25
6
Pad Replacement
6.2 Pad Fitting

Pads must be changed as an axle set and 1
NOT individually. Use only Pads which are
permitted by the vehicle manufacturer, axle
manufacturer and disc brake manufacturer. Failure
to comply with this will invalidate any Knorr-Bremse
warranty, may invalidate the vehicle manufacturer’s
warranty and may impact on the vehicle’s operating
licence.
M+P-KN-014-Äi01.eps
Note:
Fully wind back the Tappet and Boot Assemblies (13) by
rotating the Shear Adapter (61) in an anti-clockwise
direction before fitting the pads (see Section 5.2),
12
Shear Adapter is exceeded, then it is designed to
With a second failure of the Shear Adapter the
Caliper must be exchanged since internal damage ard
Inbo
is present.
Do not use an open-ended spanner as this may rd
boa
Out
damage the Adapter.
23
Clean the Pad abutments. 613737
Note:
The shape of the backplate in SK7- and ADB22X- Disc
Brakes means that the fitting steps below must be
followed:
- slide Caliper (1) fully inboard,
12
Inboard Pad
- fit inboard Pad (12)
- slide Caliper (1) fully outboard Backplate of Pad with SK7
and ADB22X- Disc Brakes
- fit outboard Pad (12)
FD00223.eps
Note:
The fitting steps for SN6- and SN7-Disc Brakes can be 12
carried out in any order.
Fit new in-pad Wear Indicator kit, if appropriate (see 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. Do not overwind the adjuster
Then turn back the Adjuster two clicks (see Section 5.2)
and check the running clearance.
The hub should turn easily by hand after having applied
and released the brake.
26
6
Pad Replacement
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 44
M+P-KN-016-Äi01.eps
recommendations.
The Adjuster Cap (37) must then be replaced (use only a 1
new Cap) having lightly greased its contact surface with
11
white grease (available as Part No. II14525 or II32868). 45
26
Note:
The tag of the Adjuster Cap (37) should be positioned as
shown by the arrow in the adjacent Sketch. This ensures 37
access is maintained for subsequent removal.
After any service work: Check the brake per-

formance and the system behaviour on a roller
dynamometer. Check function and effectiveness.
Bear in mind that a lower performance can appear
FD00144.eps
during the breaking-in phase of the brake pads and/
or the brake disc.
6.3 Wear Indicator Fitting

(In-pad cable type)
Remove Pads (12) - see Section 6.1.

101
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 outer Pad
in the Pad material.
The longer end of the Wear Indicator cable (101) (see
arrow) must be fitted in the outer Pad (12/1). 12/1 12/1
FD00237/2.eps
27
6
Pad Replacement
Insert Pads (12/1) into the Pad abutments (see Section

6.2).
FD00237/1.eps
12/1
Fit Pad Holder Springs (12/2) onto the Pads (12/1). Pay 12/2
attention to correct installation of Wear Indicator Cable
(101) (see arrows).
12/2
FD00237/3.eps
101
12/1
Fit Pad Retainer (11), Pad Retainer Pin (44), Washer (45)
and Spring Clip (26) (see Section 6.2) Pay attention to
44
correct installation of the Wear Indicator Cable (101) (see 11
arrows). 45
26
101
FD00237/4.eps
6.3.1 Cable Guide Variant (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). 105
FD00237/5-Äi01.eps
28
6
Pad Replacement
Press Wear Indicator Cable (101) into the locating tabs of

the Cable Guide (105) (see arrows A).
101
According to vehicle type, install the cable that leads to the
electrical supply of the vehicle in one of the two locating B
tabs (see arrows B). A
The short cable end of the Wear Indicator Cable (101) must
not be secured by locating tabs of the Cable Guide.
FD00237/6-Äi01.eps
B
A
6.3.2 Cable Guide Variant (105a)

101 105a
Install Indicator Cable (101) in the middle of the Pad
Retainer (11).
Insert Cable Guide (105a) on one side of the Pad Retainer C
(11) (see arrow B). A A
Slightly press on the other side of the Pad Retainer (11)
(see arrows A). The Cable Guide (105a) snaps into place.
FD00305-Äi01.eps
According to vehicle type, install the cable that leads to the
electrical supply of the vehicle in one of the wire loop (see C
arrows C).
B
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).
104
6.3.3 Protection Plate (104)
11
Insert the Cable Protection Plate (104) on one side of the
pad retainer bar (11)
Pay attention to the correct position of the Cable Protection
FD00237/7-Äi01.eps
Plate’s catch (see arrows).

Exert radial hand pressure to the Cable Protection Plate
(104); it will snap into place.
29
7
Replacement of Tappet and Boot Assemblies (13) and Inner Seals (22)
7 Replacement of Tappet and Boot Assemblies (13) and Inner Seals (22)
The components of the tools are referred to by identification
number for ease of reference.
To remove the Tappet and Boot Assembly (13) use the

Wedge Fork (A) (II32202).
Press-in Tool arrange- Press-in Tool arrangement
ment for Tappet and Ring (P) for SK7- and for Tappet and Boot
ADB22X- Disc
To fit the Tappet and Boot Assembly (13) use the Press-in Boot Assembly (13)
whenCaliper is fitted on
Brakes. Installation Assembly (13) when
Caliper is removed from
device for Tappet
Tool (B) (Z004190). the vehicle. and Boot Assembly the vehicle.
(13) when Caliper is
Use the insert ring (P) (K004082) for brake type SK7 and removed from axle.
ADB22x.
Wedge Fork (A) Press-in Tool (B)
To fit the Inner Seal (22), use the Press-in Tool (L).
(Z004361).
Press-in Tool arrangement
for Inner Seal (22) when
Caliper is fitted on the
Press-in Tool arrangement
vehicle.
for Inner Seal (22) when
Caliper is removed from
the vehicle.
Press-in Tool (L)
7.1 Tappet and Boot Assemblies (13) - Removal
Note:
The removal of the tappet and boot assembly (13) can be
done with the brake caliper fitted to, or removed from, the B
vehicle (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). 13
13
Remove the Boot by using a screwdriver or similar (see
item B in adjacent sketch).
FD00154.eps
The inner sealing face (see arrow X in adjacent

sketch) must not be damaged. It cannot be 30
replaced.
Remove the Tappet and Boot Assemblies (13) from the

Threaded Tubes (16) by using Wedge Fork (A) (II32202) A 13
Drive the fork between the Tappet and the Threaded
Tube.
Remove the old Tappet Bush (161).
22 A
Check inner sealing face (see arrow X).

If the inner sealing surface (X) is damaged, the caliper must
X
be replaced.
When replacing Tappet and Boot Assemblies (13), the
13
3
FD00155.eps
Inner Seals (22) must also be replaced.

161
30
7
7.1.1 Threaded Tubes (16) - Inspection
Place a new Pad (12) into the outboard gap to avoid loss
of thread engagement of the Threaded Tubes. 12
Do not unscrew the threaded tubes totally out
of the bridge because then the synchronisation 16
is lost and the caliper must be replaced.
If the Caliper is not installed on the axle, put a spacer E
M+P-KN-019.eps
(length = 70mm) into the Caliper (1) to avoid loss of thread 46
engagement of the Threaded Tubes (16) when screwing
them out (see adjacent Sketch). Check the threads during
screwing for corrosion and damage.
In case of water ingress or corrosion, the Caliper must be
replaced (see Section 8). 70 mm
7.2 Inner Seals (22) - Replacement E

16
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).
VF 00127/13.eps
Remove the Inner Seal (22) by using a screwdriver or
similar (see A in adjacent sketch).
1
The sealing surface (X) in the caliper for the

Inner Seal (22), must not be damaged else
A
the caliper must be replaced (see arrow in
bottom sketch).
Clean sealing surface (X) .

For the inspection of the threads, the tubes must be
screwed out (max. 30mm) by turning the Shear Adapter
22
(61) clockwise. A
FD00239.eps
Grease threads with white grease (Part No. II14525 or

II32868) and then screw them into the caliper until they
stop. 16
Fit each Inner Seal (22) onto a Threaded Tube (16).
With Caliper installed on axle L

Remove the Tappet Bush (161).
Position Tool (L) (Z004361) with the short strut in the 22
position shown.
X
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
16
spanner - see adjacent Sketch.
FD00238.eps
31
7
To check the correct fit of the Inner Seal (22), screw out
the Threaded Tubes (16) four or five threads by turning the
Shear Adapter (61) clockwise.
The Inner Seal (22) must not turn.
With Caliper not installed on axle L
The fitting sequence of Inner Seal (22) is the same as when
the caliper is installed on the axle (see previous section).
When pressing in the Inner Seal (22) however, use the long 16
strut (T3+T4) for Tool (L) (Z004361) - see page 30. L
X
To check the correct fit of the Inner Seal (22), screw out
FD00240.eps
the Threaded Tubes (16) four or five threads by turning the
Shear Adapter (61) clockwise.
22
7.3 Tappet and Boot Assemblies (13) - Fitting 13 B
With Caliper installed on axle

The Threaded Tubes (16) must be screwed fully back (see 161
Section 5.2).
The sealing seat in the caliper for each boot of the Tappet
and Boot Assemblies (13) must be clean and free of
grease.
Fit a new Tappet Bush (161) onto the spigot of each
FD00156.eps
Threaded Tube (16).

Position a Tappet and Boot Assembly (13) onto the attachment Sketch 1
piece of the Threaded Tube (16).
Centre the Push-in Tool (B) (Z004190) with the short strut B
(T3) and press in the Boot - see Sketch 1.
13
Turn over the tool combination (B) and press in the tappet
(13) with the short strut (T3) see sketch 2.
After assembly the Tappets must be free to turn in both
directions.
FD00225.eps
Sketch 2
32
7
With Caliper not installed on axle
B
The Threaded Tubes (16) must be screwed fully back (see
Section 5.2). 13
The sealing seat in the caliper for each boot of the Tappet
and Boot Assemblies (13) must be clean and free of
grease.
Fit a new Tappet Bush (161) onto the spigot of each
FD00226.eps
Threaded Tube (16).
Position a Tappet and Boot Assembly (13) onto the Sketch 3
attachment piece of each Threaded tube (16).
Centre the Push-in Tool (B) (Z004190) with the long strut
(T3+T4) and press in the Boot - see Sketch 3.
Turn over the tool combination (B) and press in the tappet
(13) with the long strut (T3+T4) see sketch 2
After assembly the Tappet must be free to turn in both
directions.
13
Note: B
With brake types SK7 and ADB22x, insert the ring (T24)
FD00227.eps
into the tool in order to support the tool (B) correctly on the
caliper’s back - See figure 5. Sketch 4
13
B
T24
FD00355.eps
Sketch 5
33
8
Caliper Replacement
8 Caliper Replacement
The components of the tools are referred to by identification Tool for Tool for Tool for
number for ease of reference. pressing in pressing in pressing in

the Cap (68a) the Cover (68c) the Cover (10)
To fit the Cap (68a), use the Press-in Tool (K) (Z003934).
To fit the Cover (68c), use the Press-in Tool (M) (K016743). T11
T27
To fit the Cover (10) use Press-in Tool (H) (K015825).
8.1 Caliper Removal from Carrier

Remove Pads (12) (see Section 6.1). T26
Remove Brake Actuator (see Section 12.1, 12.3). Press- in Press- in Press- in
Tool (K) Tool (M) Tool (H)
If fitted, remove Wear Indicator Cable and Potentiometer
Cable.
Do not touch electrical contact points because 10

of static discharge!
V
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. 10
X
Remove Cover (10).
Cover (10) should be penetrated in the
middle. Do not drive the tool between Caliper
FD00161-Äi01.eps
bore and Cover (10) since Caliper bore may be

damaged.
Check the inside area of the removed cover (10) as well
as the inside area of the bearing for dirt or corrosion. If
corroded, the Caliper must be replaced.
8.1.2 Removal of the Cover (68c)
Because of the protruding Cover (68c) it must be
dissasembled using a screwdriver or similar as shown in
adjacent sketch.
Do not dissasemble the Cover (68c) in direction of the 68c
Caliper since the Caliper or its components might be
damaged.
Check the inside area of the removed cover (10) as well
FD00398.eps
as the inside area of the bearing for dirt or corrosion. If

corroded, the Caliper must be replaced.
34
8
Caliper Replacement
8.1.3 Removal of Cap (68a)
On Calipers with Rubber Bush (6a), pull the Cap (68a) from
the Guide Pin (4a) using a suitable tool (see adjacent figure).
Take care not to damage Rubber Bush (6a). If
necessary replace it by means of a suitable Guide
and Seals Kit.
8.1.4 Remove Caliper from Carrier
Before removing the Caliper Bolts (39 and 40) ensure

that the Caliper (1) cannot move or fall down when
the Caliper Bolts are removed causing damage or injury.
Remove Caliper Bolts (39) and (40) and discard.
Never hold the Caliper with your fingers between

Caliper and Carrier - there is a risk of injury! Do not 39c*)
fasten any lifting device to the Pad Retainer (11), since this
could be damaged.
The opening or dismantling of the Caliper is not 39a*)

authorised. Use only genuine Knorr-Bremse 68c* )
10
FD00208-Äi01.eps
replacement Calipers. 40
Remove Caliper (1) from Carrier (2).
68a* )
8.2 Caliper Fitting
B
(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
adjacent figure).
Remove the plastic cap or adhesive tape in the area of
the actuator attachment from the replacement caliper (see
arrow B in sketch ). Alternatively, if the replacement Caliper
has a breakthrough diaphragm, it should be left in place
A
(see arrow C in sketch).
Note:
The replacement Caliper includes Seals and Guide Pins
without Pads.
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.
C
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
35
8
Caliper Replacement
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 1
removed from the Carrier (2).
4c* )
Fit the Caliper to the Carrier.
Screw in new Caliper Bolts (39) and (40) and tighten to 180
Nm, then tighten by a further 90° (use only new parts).
39c*)
68c* ) 5
FD00356.eps
Screw threads and tapped holes must be clean and 2
dry (free of lubrication and residuals of pre-applied 10
adhesive). 40
Check that the Caliper slides easily on the Guide Pins.
Check the position of the Inner Boot (9) and the ring (58)
on the Guide Pin (5).
According to the Caliper variant check also the position of
the Inner Boot (9) and the ring (58) on the Guide Pin (4).
9
Fit Pads (see Section 6.2).
Check Adjuster function (see Section 5.2).
Fit Brake Actuator (see Section 12.2 or 12.4).
FD00228.eps
8.2.1 Fitting of Cover (10) and (68c) 5
Caliper bores and Covers (10) and (68c) must be clean and 58
free from lubrication.
Clean the new Cover (10) or (68c) thoroughly and check
H, (M)
that the plane surface and the chamfer areas (see arrows
in lower sketch) are clean and not damaged. 10,
Clean the interior of the Press-in tool (H) or (M) and place (68c)
the Cover (10) or (68c) inside - see adjacent figure.
Position the Press-in tool (H) or (M) including Cover (10) or
(68c) to the plane surface of the caliper bore. The centring
of the tool is achieved by using the diameter of the plane
surface.
Note:
Do not tilt the tools when assembling the Covers (10) or
(68c) - see adjacent figure.
X X
V
10 H M 68c
V
FD00538.eps
36
8
Caliper Replacement
The Inner Boot (9) must be in a compressed 2mm

condition - see adjacent figure -, otherwise
the calipers´s freedom of movement will be limited .
10
Press on the mandrel of the press in tool (H) or (M) by hand

until it stops. Use a hammer on the mandrel to insert the
cover to the end stop. H
9
/ FD00444.tif
Note:
After fitting the new Cover (10), ensure that it protrudes 2
mm from the plane surface of the caliper - see adjacent
figure.
Note: 68c M
After fitting the new Cover (68c), ensure that it protrudes
15,5 mm from the plane surface of the caliper - see 9
adjacent figure.
15.5 mm
/FD00537.eps
8.2.2 Fitting of Cap (68a)
Fit the Cap (68a) using Tool (K) (Z003934) and a hammer.
Force the Cap (68a) into the Guide Pin (4) until it is firmly
seated. The seal is achieved by the compression of the lip
of the Rubber Bush (6a) between the Guide Pin (4) and 68a K
Cap (68a) (see view “Y”).
If the Caliper (1) and Carrier (2) is not fitted to the

vehicle
6a
4ab
Check that the caliper slides easily on the Guide Pins.
"Y"
FD00182/2-Äi02.eps
Push the caliper into the shown clamping position (i.e.

bench vice) as far as possible against the carrier. The Inner 68a
Boot (9) must be in a compressed condition - see adjacent
figure -, otherwise the calipers´s freedom of movement will
be limited. Clamping device
9
10
Fit new Cover (10), Cover (68c) or Cap (68a) as described
above.
Pay attention to the vehicle manufacturer´s recommendations Direction of
during the following assembly to the vehicle axle. pressure
Fit the Pads (see Section 6.2).

Check Adjuster function (see Section 5.2).
FD00209DE-Äi02.eps
Attach Brake Actuator (see Section 12.2 or 12.4). 1

9 *) 68c *)
2 *) Variants
37
9
Replacement of Inner Boot (9)
9 Replacement of Inner Boot (9)

number for ease of reference.
Wa s h e r
To fit the Inner Boot (9) use the Pull-in Tool (C) (Z004357). DIN 125
Pull-in Tool arrangement for

pulling in the Inner Boot (9).
Remove Caliper (see Section 8.1).
Remove Ring (58).

Pull out Guide Pin (5).
Pull-in Tool (C)
Push out Inner Boot (9) with screwdriver or similar.
Note: 9*) 58*)

For variants with boot sealing on both sides:
Remove Ring (58).
Pull out Guide Pin (4c).
Push out Inner Boot (9) with screwdriver or similar.
4c*)
FD00210-Äi02.eps
5 58
9
The sealing face of Inner Boot (9) in the Caliper must
*) Variants
not be damaged (see arrow A in adjacent Sketch).
7 A
The contact surface of the boot on the Guide Pin (5) or (4c)
must be clean and free of lubrication. Check for corrosion
(see arrow A in adjacent Sketch).
Check Brass Bush (7) and, if installed, Guide Sleeve (6c), 9 9 C
for corrosion, dirt or damage and replace as necessary
(see Section 10.1 or 10.2)
Fit new Boot (9) into the Sleeve of the Tool (C) (Z004357).
FD00230.eps
See arrow B in adjacent Sketch.

Pay attention that the bellow-folds of Inner Boot (9) are B
positioned within the tool.
Position Sleeve of the tool (C) 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 figure).
38
9
Replacement of Inner Boot (9)
Grease Brass Bush (7) and if installed Guide Sleeve (6c)

with white grease (Part No. II14525 or II32868).
Fit Guide Pin (5) and if necessary Guide Pin (4c).
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). 9
Pushing on the Ring (58) ensures that the Boot (9) is
engaged in the groove of the Guide Pin (5) or, if installed, in
the groove of the Guide Pin (4c).
Fit Caliper (see Section 8.2).
FD00228.eps
5
58
39
10
Replacement of Guide Sleeves
10 Replacement of Guide Sleeves

number for ease of reference. Pull-out Tool arrangement for
pulling out of Brass Bush (7)
Pull-in Tool arrangement
In order to remove, fit and groove the Brass Bush (7) use forpulling in and grooving
the Pull-out/Pull-in and Grooving Tool (D) (Z004354). Washer of Brass Bush (7)
DIN 125
Remove Caliper (see Section 8.1 and following).
10.1 Brass Bush (7) - Replacement

Remove Guide Pin (5) and Inner Boot (9) (see Section 9).
Clean surface (X), surface (Y) and Brass Bush (7) (see
Sketch 2).
10.1.1 Removal of Brass Bush (7)

Sketch 1 Pull-in/Pull-out Tool including Grooving Tool (D)
Position tool combination (D) for pulling out Brass Bush (7)
(see Sketch 2).
Note:
Ensure that brass Nut (T14) is guided in Brass Bush (7).
Support tool (T12) must be placed plane on surface (X).
Pull out Brass bush with spindle (T13) - see Sketch 2.
D Brass Bush (7)
10.1.2 Fitting of Brass Bush (7) removed
Screw Brass Nut (T14) on to Spindle (T13) until it stops.

Place new Brass Bush (7) on the Groover (T16) and insert
into caliper bore - see Sketch 3a. X
Screw Spindle (T13) by hand up to stop. Brass Bush (7)
installed
FD00170.eps
Note:
Pay attention to Groover (T16) - see Sketch 3a. It must be
able to move freely. Sketch 2
Y
The tool element (T8) must be located flat onto the caliper
surface (X) see figure 3a.
Pull in Brass Bush (7) using Brass Nut (T14) up to stop
- see Sketch 3b.
To prevent longitudinal displacement of Brass Bush (7) it Sketch 3
must be “grooved” - see Sketch 3c.
To do so the hexagon bolt of the Groover (T16) must be
screwed in up to stop.
D
D D
Wind back the hexagon bolt of the Groover (T16)
approximately 20 mm.
Slacken the Brass Nut (T14) and rotate the Groover (T16) 7 7
through approximately 60º.
Repeat the process of “grooving”.
7
The new Brass Bush (7) is now grooved with the Caliper.
FD00236.eps
Before removing the Tool (D), the hexagon screw of the a b c

Groover (T16) should be set in the starting position.
40
10
Check contact area of Brass Bush (7) and remove any burrs. Pull-in Tool arrangement Washer Pull-out Tool arrangement
for pulling in the Rubber DIN 125 for pulling out the Rubber
Bush (6a) or (6b)
Grease Bush (7) with white Grease (Part No. II14525 or Bush (6a) or (6b)
II32868).
10.2 Rubber Bush (6a, 6b) and

Guide Sleeve 6c) - Replacement
Use Tool (R) for the removal and fitting of the Rubber Bush
(6a or 6b) - see adjacent sketch.
Threaded Pin
DIN 915
Note: Discs
Do not use the Disc T5 with Ø35 with SN Type Disc Pull-in / Pull-out Tool (R)
Brake. Pull-out Washer Pull-in

Toolarrangement for DIN 125 Toolarrangement for
Use Tool (N) for fitting of the Guide Sleeve (6c) (see adjacent pulling out the Guide pulling in the Guide
Sleeve (6c) T05 Sleeve (6c)
sketch).
T06
10.2.1 Removal of Rubber Bush (6a or 6b) T21 T08
T20
Remove Guide Pin (4a or 4b).
T14
Clean Caliper in the area of the Rubber Bush.
Pull-in / Pull-out Tool (N)
Select Disc T6 with Ø39.
Position the Tool (R) as shown in the adjacent picture. R

R
Screw on the Nut (T22) by hand.
Pay attention to suitable Disc Ø39 !
Lock the Nut (T22) with a ring spanner and with a suitable
socket or ring spanner tighten Spindle (T20) to remove the
Guide Sleeve.
41
10
10.2.2 Removal of Guide Sleeve (6c)

6c
Remove Guide Pin (4c). 6c
In order to separate the tab from the Guide Sleeve (6c) use
the 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 arrow in the adjacent Sketch).
Then separate the tab from the Guide Sleeve (6c) by means
of the screwdriver and a hammer (see adjacent Sketch).
FD00400.eps
Clean Caliper in the area of the Guide Sleeves (6c) and the
areas surrounding the Brake Pads.
T20 Wa s h e r
Note: DIN 125
Caliper groove can be on left or right side of the caliper

bore. T21
Position Tool (N) as shown in adjacent Sketch.
Screw on the Nut (T14) by hand.
Lock the Nut (T14) with a ring spanner and with a suitable 6c
socket or ring spanner tighten Spindle (T20) to remove the
FD00357.eps
Guide Sleeve (6c).
T14
10.2.3 Fitting of Rubber Bush (6a or 6b)

Check bore for corrosion and clean. R
R
Ensure that the Threaded Bush in the Tool (R) is unscrewed,
so that there is no projection at the contact surface. (6a) or (6b)
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.
Note: Threaded Pin

DIN 915
T22
Do not tilt the Rubber Bush (6a or 6b) when pulling-in.
Pull in Rubber Bush (6a or 6b) into the caliper up to stop.

Remove the Tool.
If the torque is < 8 Nm or > 45 Nm, then the

Caliper must be replaced.
42
10
The metal ring (see arrows in adjacent sketch)

must not move. When checking for movement,
ensure that the sealing elements of the Rubber Bush 4ab 6a
(6a or 6b) are not damaged.
Grease inside the Rubber Bush (6a or 6b) with white

Grease (Part No. Il14525 or II32868).
FD001981-Äi02.eps
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 abutment in the
Rubber Bush (6a or 6b).
10.2.4 Fitting of Guide Sleeve (6c)

Check bore for corrosion. Clean and, if necessary, protect
with corrosion protective paint.
Position the Guide Sleeve (6c) - (see adjacent Sketch). 6c
6c
T14
Before pressing in Guide Sleeve (6c) the tab
must be in such a position that it will snap
into the Caliper groove when Guide Sleeve (6c)
reaches its final position.
Note:
Caliper groove can be on left or right side of the caliper
FD00402.eps
bore.
Press in the Guide Sleeve (6c) by means of the tool (T14)
and a hammer making sure that the position of the tab is
aligned with the groove of the caliper.
Insert Tool (N) into the Guide Sleeve (6c) -see sketch below
right.
Tighten Spindle (T20) by hand. T14
Hold Nut (T14) by means of a ring spanner and with a
suitable socket or another suitable tool, tighten Spindle 6c
(T20) up to stop.
T08
FD00358.eps
T06
T05
Do not turn Nut (T14) because Guide Sleeve
(6c) may turn and lose its correct position. T20 Scheibe DIN 125
43
10
Remove Tool (N).

6c
In order to press in the tab from the Guide Sleeve, use 6c
a screwdriver or similar tool whose width is smaller than
the tab. Place the screwdriver as close as possible to the
top of the tab (see adjacent sketch). Bend the tab into the
groove of the caliper.
The Guide Sleeve (6c) is now secured against rotational
and axial movement.
Grease inside the Guide Sleeve (6c) with white Grease
(Part No. Il14525 or II32868).
FD00403.eps
Fit Guide Pin (4c).
44
11
Carrier Replacement
11 Carrier Replacement
If necessary remove Caliper (see Section 8.1)
Unscrew the bolts and remove the Carrier (2) from the axle
(if necessary with the caliper).
Note:
Do not fasten any lifting device to the Pad Retainer (11),
since this can be damaged.
Clean axle contact area.
2
Fit new Carrier (2) with new bolts supplied by the Vehicle
M+P-KN-036.eps
Manufacturer according to the vehicle manufacturer’s
specification. (Bolts are not Knorr-Bremse spare parts).
If necessary, refit Caliper (see Section 8.2).
45
12
Brake Actuator Replacement
12 Brake Actuator Replacement

12.1 Brake Chamber Removal
Unscrew air connection from Brake Chamber (18/2) – take B
care, air connection must be free of air pressure!
Unscrew Brake Chamber mounting nuts (see
arrow B). They must not be reused! A
Remove Brake Chamber (18/2).
12.2 Brake Chamber Fitting

18/2
Note:
B
FD00229.eps
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.
The sealing surface and the flange surface (see arrow C in
adjacent sketch) must be:
- free from dust and corrosion
- free of damage
- flat.
Take care that no dirt enters the brake!
Before fitting the new Brake Chamber, the Spherical Cup
(19) in the Lever and the sealing surface must be greased
C
FD00231.eps
with white Grease (Part No. II14525 or II32868).
The Seal, as well as the Push Rod area - see adjacent
19
picture - must be clean and free of lubrication.
Note, if the Brake Chamber’s seal protrudes less than 3
Seal
mm the Brake Chamber must be replaced – see adjacent
sketch.
3 mm
Push Rod area
Do not use Grease containing molybdenum

disulphate. Use only Actuators which are
recommended by the Vehicle Manufacturer.
Attach Brake Chamber using new nuts.

In order not to tilt the Brake Chamber during its attachment,
the new nuts must be gradually tightened symmetrically
with a suitable tool. After that, tighten the nuts according
to the specifications of the actuator manufacturer
Connect air hose and check for leakage.
Make sure that hose is not twisted and that chafing is not
possible.
Check function and effectiveness of the service

brake system.
46
12
12.3 Spring Brake Removal

Chock wheels before releasing Spring Brake
to ensure the vehicle cannot roll.
Release parking brake.
Screw-out release bolt (arrow D) with a maximum torque A
of 35 Nm to the release position (refer to the Vehicle
Manufacturer’s recommendations). B
Apply parking brake. A
Disconnect air connections from Spring Brake (18/1) – take
care, air connection must be free of air pressure D 18/1
Unscrew Spring Brake mounting nuts (see
arrow B). They must not be reused!
Remove Spring Brake (18/1).
VF 0012711-Äi01.eps
B
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.
The sealing surface and the flange surface (see arrow C in
adjacent sketch) must be:
- free from dust and corrosion
- free of damage
- flat
Take care, that no dirt enters the brake! C FD00231.eps
Before fitting the new Spring Brake, the Spherical Cup (19) 19
in the Lever and the sealing surface must be greased with
white Grease (Part No. II14525 or II32868).
3 mm
The Seal, as well as the Push Rod area - see adjacent
picture - must be clean and free of lubrication.
Note, if the Spring Brake’s seal protrudes less than 3
mm the Spring Brake must be replaced – see adjacent
sketch. Push Rod
area
Seal
Do not use grease containing molybdenum
disulphate. Use only Actuators which are
recommended by the Vehicle Manufacturer.
47
12
Attach Spring Brake using new nuts.

In order not to tilt the Spring Brake during its attachment,
the new nuts must be gradually tightened symmetrically
with a suitable tool. After that, tighten the nuts according
to the specifications of the actuator manufacturer.
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.
Screw in Spring Brake Release bolt with maximum 70
Nm.
Check air connections for leakage.
Check function and effectiveness of the service brake system

and parking brake system.
48
Notes
49
Notes
50
Notes
51
Commercial Vehicle Systems
Knorr-Bremse Systeme für

Nutzfahrzeuge GmbH
Moosacher Straße 80
80809 Munich
Germany
Tel: +49 89 3547-0
Fax: +49 89 3547-2767
www.knorr-bremseCVS.com
This publication is subject to alteration without notice. A printed copy of this document may not be the latest revision. Please check our website www.knorr-bremseCVS.com for the latest update or contact your local
Knorr-Bremse representative. The figurative mark “K” and the trademarks KNORR and KNORR-BREMSE are registered in the name of Knorr-Bremse AG. Copyright 2007 © Knorr-Bremse AG - all rights reserved,
Europe – Africa Italy Sweden A sia – Australia
Knorr-Bremse Knorr-Bremse
Austria Sistemi per Autoveicoli System for Tunga Fordon AB Australia
Knorr-Bremse GmbH Commerciali S.p.A. Malmö Knorr-Bremse
Systeme für Nutzfahrzeuge Arcore Tel: +46 40 680 5880 Australia Pty. Ltd.
Mödling Tel: +39 039 6075-1 Fax: +46 40 937490 Granville NSW
Tel: +43 2236 409-436 Fax: +39 039 6075-435 Tel: +61 2 8863-6500
Fax: +43 2236 409-434 Switzerland Fax: +61 2 8863-6151
Netherlands Knorr-Bremse
Belgium Knorr-Bremse Benelux B.V.B.A. Systeme für Nutzfahrzeuge GmbH China
Knorr-Bremse Benelux B.V.B.A. Mydrecht Bassersdorf Knorr-Bremse
Heist-op-den-Berg Tel: +31 297 239-330 Tel: +41 44 888 77-55 Brake Equipment (Shanghai)
including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as for copying and transferring. Released April/2008
Tel: +32 1525 7900 Fax: +31 297 239-339 Fax: +41 44 888 77-50 Co. Ltd.
Fax: +32 1524 9240 Shanghai
Poland Turkey Tel: +86 21 6891-7500
Czech Republic Knorr-Bremse Polska SfN Sp. z o.o. Knorr-Bremse Fax: +86 21 6891-7510
Knorr-Bremse Systémy pro Warsaw Systeme für Nutzfahrzeuge GmbH
uzitková vozidla, CR, s.r.o. Tel: +48 22 887-3870 Findikli - Istanbul China
Hejnice Fax: +48 22 531-4170 Tel: +90 212 293-4742 Knorr-Bremse
Tel: +420 482 363-611 Fax: +90 212 293-4743 Asia Pacific (Holding) Limited
Fax: +420 482 363-711 Russia Truck Brake Systems Division
Knorr-Bremse RUS United Kingdom Hong Kong
France Nizhniy Novgorod Knorr-Bremse Tel: +852 3657-9800
Knorr-Bremse Tel: +7 8312 57-6661 Systems for Commercial Fax: +852 3657-9901
Systèmes pour Véhicules Fax: +7 8312 57-6791 Vehicles Ltd.
Utilitaires France S.A. Bristol India
Lisieux Cedex Russia Tel: +44 117 9846-100 Knorr-Bremse
Tel: +33 2 3132 1200 Knorr-Bremse Fax: +44 117 9846-101 Systems for Commercial Vehicles
Fax: +33 2 3132 1303 Systeme für Nutzfahrzeuge GmbH India Private Ltd.
Moscow Americ a Pune
Germany Tel: +7 495 234-4995 Tel: +91 20 6674-6800
Hasse & Wrede GmbH Fax: +7 495 234-4996 Brazil Fax: +91 20 6674-6899
Berlin Knorr-Bremse
Tel: +49 30 9392-3101 South Africa Sistemas para Veículos Japan
Fax: +49 30 7009-0811 Knorr-Bremse S.A. Pty. Ltd. Comerciais Brasil Ltda. Knorr-Bremse
Kempton Park São Paulo Commercial Vehicle Systems
Germany Tel: +27 11 961-7800 Tel: +55 11 5681 1104 Japan Ltd.
Knorr-Bremse Systeme für Fax: +27 11 975-8249 Fax: +55 11 5686 3905 Saitama
Nutzfahrzeuge GmbH Tel: +81 49 273-9085
Spain USA Fax: +81 49 282-8601
Munich
Bost Ibérica, S.L. Bendix Commercial Vehicle
Tel: +49 89 3547-0 Systems LLC
Irun (Guipuzcoa) Korea
Fax: +49 89 3547-2767 Elyria, OH
Tel: +34 902 100-569 Knorr-Bremse
Fax: +34 943 614-063 Tel: +1 440 329-9100 Korea Ltd. Truck Brake Division
Hungary Fax: +1 440 329-9105 Seoul
Knorr-Bremse
Tel: +82 2 2273-1182
Fékrendszerek Kft.
Fax: +82 2 2273-1184
Kecskemét
Tel: +36 76 511 100
Fax: +36 76 481 100
Reference. No. K001262-003
Doc. No. Y006471-EN-003

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Commercial Vehicle Systems

Service Manual Pneumatic Disc Brake

Y006471: EN: 003: MAX1: Released:Webmaster: 2008/05/05-07:46:51

Brake Tool Kit Alternative

Brake Service Manual

Y006471: EN: 003: MAX1: Released:Webmaster: 2008/05/05-07:46:51

1.1 Disc Brake Components. . . . . . . . . . . . . . . . . . . 6

2.1 Service Tools . . . . . . . . . . . . . . . . . . . . . . 9

3.1 Disc Brake Sectioned View. . . . . . . . . . . . . . . . . 10

6.1 Pad Removal. . . . . . . . . . . . . . . . . . . . . . 25

6.3.1 Cable Guide Variant (105). . . . . . . . . . . . . . . . . . 28

7.1 Tapped and Boot Assemblies (13) - Removal . . . . . . . . . . . 30

8.1 Caliper Removal from Carrier . . . . . . . . . . . . . . . . 34

10.1 Brass Bush (7) - Replacement . . . . . . . . . . . . . . . . 40

12.1 Brake Chamber Removal. . . . . . . . . . . . . . . . . . 46

• Always wear safety glasses when working with air pressure.

• Never exceed manufacturer’s recommended air pressures.

• Never look into air jets or direct them at anyone.

• Use only genuine Knorr-Bremse replacement parts, components and kits.

1 Caliper 13 Tappet and Boot

Knorr-Bremse offers a range

Type 3 Alternative to Item 105

105 Cable Guide

1.3 Brake Disc

Tool combination Description consisting of

2.2 Diagnostic Equipment

2.4 Torque Requirements

3 Description and Function

3.2 Description of Operation

3.2.1 Brake Actuation

After overcoming the running clearance between the

3.2.2 Brake Release

3.2.3 Brake Adjustment (automatic)

To ensure a constant running clearance between Pads and

4.1 Safety Instructions for Service Work

Observe relevant safety instructions for service work and

Before starting service work, ensure the

Please follow service manual instructions and adhere to

Tighten bolts and nuts to the prescribed torque values.

Screw threads and tapped holes must be free

After re-fitting a wheel according to the Vehicle

After any service work:

5 Functional and Visual Check

Minor breakouts at the edges are permitted (see

Major breakouts on the surface of the brake Pad

Measure the thickness of the brake disc at the thinnest

A = Total thickness of the brake disc

If the Disc dimension A ≤ 39 mm, it is recommended

that the Disc should be renewed when the brake

Check Disc at each change of Pads for grooves and

A1 = Small cracks spread over the surface max. 1,5 mm

B1 = Cracks less than 1.5mm deep or wide, running D1 C1

a = width of the friction surface

Knorr-Bremse Discs are normally service-free and grinding

If these recommendations are ignored, there is a risk of accident. If the brake

5.1.1 Brake Wear Check using Rubber Bush (6a):

5.1.2 Brake Wear Check using Rubber Bush (6b):

The condition of the Pads can be visually determined

If necessary change the Pads (see Section 6) and/or the