Reference No.

K001262-006
Doc. No. Y006471 (EN - Rev. 006)
January 2017

SERVICE MANUAL

PNEUMATIC DISC BRAKE

SN6 - SN7 - SK7
 » Y006471 - (EN - REV. 006) | JANUARY 2017

Overview of Tool Kits and Service Manuals for Knorr-Bremse Air Disc Brakes

Brake Tool Kit Alternative

SB5... II37951004
SB6
II37951004*
SB7
SN5 K037001
SN6 K000469 + Supplemental Kit K017062 + Supplemental Kit K046291K50
SN7 K039062K50 K005972 + Supplemental Kit K017062 + Supplemental Kit K046291K50
SK7 K016947 + Supplemental Kit K046291K50
SL7...
K039062K50 K016947 + Supplemental Kit K046291K50
SM7...
ST7... K039062K50 K016947 + Supplemental Kit K046291K50
* ) Additional tools are required -
obtainable in kits K000469, K005972, K016947 and K039062K50

Brake Service Manual

SB6...
C16352-#
SB7...
SN5... Y015044-#
SN6...
SN7... Y006471-#
SK7...
SL7...
Y081564-#
SM7...
ST7... Y173241-#
# - Refer to website for latest revision www.knorr-bremseCVS.com

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.

Revision Details

Inclusion of previously withdrawn Rubber Bush (6a), Guide Pin (4a) and Cap (68a), tool T11 (K). Removal of reference to
Rev. 005 March 2013
ADB22X, small text changes throughout.

Rev. 006 September 2015 Adjuster Check chapter 5.2 changed; Chapters 9 and 10 merged into Chapter 9; diverse text changes throughout

2
 » Pneumatic Disc Brake SN6 - SN7 - SK7

CONTENTS

1. Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Disc Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.1.1 Identification of the Guide and Seal Kit Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Brake Identification and Service Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.2.1 Wear Indicator Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Brake Disc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2. General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Diagnostic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.4 Torque Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3. Description and Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.1 Disc Brake Sectioned View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Description of Operation (Floating caliper principle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brake Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brake Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brake Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4. Inspection Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1 Safety Instructions for Service Work and Repair Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5. Functional and Visual Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5.1 Wear Check of Pads and Brake Discs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Brake Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2 Adjuster Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.3 Caliper Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.4 Clearance Measurement Check of Bearing Variants (6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.5 Sealing Elements Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6 Brake Pad Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6.1 Removal of Brake Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2 Fitting of Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3 Fitting Pad Wear Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fitting of Cable Guide Variant (105). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fitting of Cable Guide Variant (105a). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fitting of Cable Protection Plate (104) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Removing Cable Protection Plate (104) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

7. Tappet and Boot Assemblies (13) and Inner Seals (22) Replacement . . . . . . . . . . . . . . . 34
7.1 Removal of Tappet and Boot Assemblies (13). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
With caliper installed on the vehicle:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
With caliper removed from the vehicle: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.2 Replacement of Inner Seals (22) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
With caliper installed on the vehicle: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
With caliper removed from the vehicle: (not shown):. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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 » Y006471 - (EN - REV. 006) | JANUARY 2017

CONTENTS

7.3 Fitting of Tappet and Boot Assemblies (13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

With caliper installed on the vehicle: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
With caliper removed from the vehicle: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

8. Caliper Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.1 Removal of Caliper from Carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Removal of Cover (10) - Fixed Bearing Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Removal of Cover (68c, 68e; Guide Sleeve) or (68d; Capped Rubber Sleeve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Removal of Cap (68a; Rubber Bush) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Removal of Caliper from Carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
8.2 Fitting Caliper to Carrier - (Carrier assembled on vehicle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Fitting of Cover Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Cover Variant (10) - Fixed Bearing Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Cap (68a; Rubber Bush) - Floating Bearing Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cover Variant (68c and 68e; Guide Sleeve) - Floating Bearing Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cover Variant (68d) - Floating Bearing Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Fitting of Cover Variants with Caliper (1) and Carrier (2) Removed from the Vehicle:. . . . . . . . . . . . . . . . . . . . . . . . . . . 47

9 Caliper Bearings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

9.1 Removal of Inner Boot (9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
9.2 Replacement of Brass Bush (7a or 7b) Fixed Bearing Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Removal of Brass Bush (7a or 7b). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Fitting of Brass Bush (7a or 7b). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.3 Replacement of Guide Sleeve Variant (6a, 6b, 6c, 6d or 6e) Floating Bearing . . . . . . . . . . . . . . . . . . . . .50
9.3.1 Removal of Guide Sleeve (6a Rubber Bush or 6b Open Bearing) Floating Bearing. . . . . . . . . . . . . . . . . . . . . . . . . 51
9.3.2 Removal of Guide Sleeve (6c and 6e; Guide Sleeve) Floating Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.3.3 Removal of Guide Sleeve (6d Capped Rubber Sleeve) Floating Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9.3.4 Fitting of Guide Sleeve (6a Rubber Bush or 6b Open Bearing) Floating Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . 52
9.3.5 Fitting of Guide Sleeve (6c - Guide Sleeve). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.3.6 Fitting of Guide Sleeve (6d - Capped Rubber Sleeve). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
9.3.7 Fitting of Guide Sleeve (6e - Guide Sleeve). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9.4 Fitting of Inner Boot (9a or 9b) Fixed Bearing or (9c, 9d, or 9e) Floating Bearing. . . . . . . . . . . . . . . . . . .56
9.5 Fitting of Guide Pin (5a or 5b) Fixed Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.6 Fitting of Guide Pin (4a, 4b, 4c, 4d or 4e) Floating Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
9.6.2 With Bearing Variant (6a; Rubber Bush) and (6b; Open Bearing):. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.6.3 With Bearing Variant (6c and 6e; Guide Sleeve): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.7 Engage Inner Boot (9) into Guide Pin (4c, 4d or 4e) Floating Bearing or (5a or 5b) Fixed Bearing. . . . . . . . 58

10. Carrier Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

11. Brake Actuator Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
11.1 Removal of Knorr-Bremse Brake Chamber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
11.2 Fitting of Knorr-Bremse Brake Chamber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
11.3 Removal of Knorr-Bremse Spring Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
11.4 Fitting of Knorr-Bremse Spring Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

4
 » Pneumatic Disc Brake SN6 - SN7 - SK7

SAFETY AND ENVIRONMENT GUIDELINES

Safety and Environment Guidelines

Note: The safety advice listed below is applicable to general service and diagnostic work on braking systems. Also observe any recommendations
from the axle or vehicle manufacturer concerning towing, jacking-up and securing the vehicle.
CAUTION: KNORR-BREMSE IS NOT LIABLE FOR ANY INJURIES OR DAMAGES CAUSED BY IMPROPER USE OF SPECIFIED SERVICE KITS AND/
OR SERVICE TOOLS. FURTHERMORE, MISUSE OF TOOLS OR INCORRECT INSTALLATION OR APPLICATION OF SERVICE KITS MAY RESULT IN
DAMAGE OR POTENTIALLY UNSAFE VEHICLE OPERATIONS. IN THIS CASE, KNORR-BREMSE DOES NOT HAVE ANY WARRANTY OBLIGATIONS.
Before and whilst working on or around compressed air systems and devices, the following precautions should be observed, along with
the many hazard notes contained throughout the document:

1 Always wear safety glasses when working with air pressure.

2 Never exceed the vehicle manufacturer’s recommended air pressures.
3 Never look into air jets or direct them at anyone.
4 Never connect or disconnect a hose or line containing pressure; it may whip as air escapes.
5 When removing or servicing a product, ensure all pressure related to the specific system it is contained in has been depleted to 0 bar.
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.
6 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. On vehicles fitted with air suspension, it is advised when undertaking such work, to support the chassis from
sudden lowering and therefore prevent any possibility of being trapped between the chassis and axle or ground.
7 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.
8 When working under or around the vehicle, and particularly when working in the engine compartment, the engine should be shut
off and the battery disconnected. 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.
9 When working on vehicles equipped with air suspension, to guard against injury due to unexpected downward movement of the
chassis caused by sudden pressure loss in the suspension system, ensure that the vehicle chassis is mechanically supported with a
‘prop’ between the chassis and the axle or between the chassis and the ground.
10 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.
11 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.
12 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.
13 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.
14 Use only genuine replacement parts, components and kits as supplied by Knorr-Bremse or the vehicle manufacturer containing
original Knorr-Bremse parts Only use the recommended tools as specified in related Knorr-Bremse instructions.
15 The serviced or replaced product must be checked for correct function and effectiveness.
16 If products have been dismantled, serviced or replaced, whose performance could affect braking performance or system behaviour,
this should be checked on a roller dynamometer. Bear in mind that a lower performance may be experienced during the bedding-in
phase if new brake pads/linings and/or brake discs/drums have been fitted.
17 The use of impact screwdrivers or impact wrenches in conjunction with Knorr-Bremse service tools for air disc brakes is not permitted.
The service tools are not designed for such use. It is likely that the tools or the vehicle will be damaged and there is a serious risk of
injury – see Caution above.
18 Do not use compressed air to clean the disc brake. Avoid air contamination of brake dust.
19 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.

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 » Y006471 - (EN - REV. 006) | JANUARY 2017

SAFETY AND ENVIRONMENT GUIDELINES

Disposal of Waste Equipment by Business Users in the European Union

This symbol on the product, packaging or in user instructions, indicates that this product must not
be disposed of with other general waste. Instead, it is your responsibility to dispose of the waste
electrical and electronic parts of this product by handing them over to a company or organisation
authorised for the recycling of waste electrical and electronic equipment. For more information about arrangements
for waste equipment disposal please contact your Knorr-Bremse distributor or local Knorr-Bremse representative.

6
 » Pneumatic Disc Brake SN6 - SN7 - SK7

1. OVERVIEW
44
1.1 Disc Brake Components

26
11*
45

12*

18**

58
9
13
161

22*

1*
7*
4* 5*
40*
6* 61 10*
39* 37

68*

2*

Legend

1 Caliper* 13 Tappet and Boot Assembly 61 Shear Adapter

2 Carrier* 18 Brake Actuator** 68 Cover*
4 Guide Pin* 22 Inner Seal* 161 Tappet Bush
5 Guide Pin* 26 Spring Clip
6 Rubber Bush or Guide Sleeve* (floating bearing side) 37 Adjuster Cap
7 Brass Bush* (fixed bearing side) 39 Caliper Bolt*
9 Inner Boot* 40 Caliper Bolt*
10 Cover* 44 Pad Retainer Pin * Variants possible
11 Pad Retainer* 45 Washer (see also contents leaflet in the service kit)

12 Pad (complete)* 58 Ring* ** Brake chamber or spring brake

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 » Y006471 - (EN - REV. 006) | JANUARY 2017

1 OVERVIEW

1.1.1 Identification of the Guide and Seal Kit Variants

58a/b*
9a/b*

7a/b*
5a*
4a* 6a*
58c/e*
9c/e* 4b*
58d* 40a/b*
4c/e* 10a/b*
9d* 6c* 5b*

4d* 39a*
6b*
39b* 68a*
6e*
39c/e*
6d*
68c/e*
39d*
68d*

* Variants possible (see also contents leaflet in the service kit)

Floating Bearing (6) variants:

a) Rubber Bush

b) Open Bearing

c) and e) Guide Sleeve

d) Capped Rubber Sleeve

8
 » Pneumatic Disc Brake SN6 - SN7 - SK7

OVERVIEW 1

1.2 Brake Identification and Service Kits

KNORR-BREMSE
Brake type
XXXXXX XXXXXXXX Knorr-Bremse
Part number
Axle or vehicle manufacturer’s iden-
tification number XXXXXXXXXXXXXX
X XXXXX XXXXX Knorr-Bremse
Date of manufacture

KNORR-BREMSE
Manufacturer
XXXXXXXXXXXXX
Manufacturer’s identification number
XXXXXXXXXXXXXX
Brake type XXXXXX XXXXXXX Knorr-Bremse
Part number

X XXXXX XXXXX Knorr-Bremse

Date of manufacture

Use only genuine Knorr-Bremse parts!

The following service kits are available:

Description Content (Position No.)

Carrier Carrier (2) 1x

Guide Pin (4a, 4b, 4c, 4d, 4e, 5a, 5b)
Guide Sleeve (6a, 6b, 6c, 6d, 6e,)
Brass Bush (7a, 7b)
Inner Boot (9a, 9b, 9c, 9d, 9e)
Guide and Seal Kit
Cover (10a, 10b)
Caliper Bolt (39a, 39b, 39c, 39d, 39e, 40a, 40b)
Ring (58a, 58b, 58c, 58d, 58e)
Cap (68a, 68c, 68d, 68e)
Tappet and Boot (13) 2x For specific service part numbers allocated to the disc brake see:
Tappet and Boot Kit Inner Seal (22) 2x www.Knorr-BremseCVS.com
Tappet Bush (161) 2x www.Knorr-BremseCVS.biz
Adjuster Cap (37) 10x
Adjuster Cap
Shear Adapter (61) 10x
Pad Retainer (11) 2x
Brake Pad (12) 4x
Spring Clip (26) 2x
Brake Pads (axle set) Adjuster Cap (37) 2x
Pad Retainer Pin (44) 2x
Washer (45) 2x
Shear Adapter (61) 2x

Knorr-Bremse offers a range of specifically

Supplied without carrier (2) and without brake pads (12). designed rationalised calipers to service a wide range of disc brakes.
Caliper Guide Pins and Seals kit included for assembly of caliper to existing brake For specific caliper part number, see:
carrier www.Knorr-BremseCVS.com
www.Knorr-BremseCVS.biz

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1 OVERVIEW

1.2.1 Wear Indicator Kits

Type 1 Type 2

104 104

101 101 103

105 105

11 11

Type 3 Alternative to Item (105)

105a
104

101

105
11 Pad Retainer*
11 101 Sensors with cable*
103 Cable to electrical supply*
104 Cable protection plate
105 Cable guide
105a Cable guide
* Variants possible

1.3 Brake Disc

Replacing brake discs is subject to the instructions of the vehicle Knorr-Bremse recommends the brake disc be changed
or axle manufacturer, including when fitting Knorr-Bremse as an axle set. Brake discs can be ordered through the
brake discs. Knorr-Bremse aftermarket organisation.
When replacing brake discs, make sure to use the correct Additionally Knorr-Bremse recommends brake discs be
connections and tightening torques. changed at the latest every 6 years, even if the wear limits have
The use of non-approved brake discs will reduce levels of safety, not been reached.
and will not be covered by any Knorr-Bremse liability.

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 » Pneumatic Disc Brake SN6 - SN7 - SK7

2. GENERAL INFORMATION
The use of impact screwdrivers / impact wrenches in conjunction with Knorr-Bremse service tools for air disc brakes
is not permitted. The service tools are not designed for such use.
Never turn the Adjuster (23) without Shear Adapter (61). If the given shear point of the Shear Adapter (61) is
reached, the adapter will fail. Try again using a brand new shear adapter. If the adapter fails a second time, the
whole caliper will need replacing due to internal damage. Do not use an open-ended spanner on the adapter as
this could damage it.
Attention: Risk of injury. Knorr-Bremse accepts no liability for damage or injury resulting from negligence; any
damage to service tools resulting from such actions will void all warranty.

2.1 Service Tools

Tool Part No. Description Consisting of tool components:
(A) II32202 Wedged fork for removal of tappet and boot assembly (13) T15
(C) Z004357 Pull-in tool for inner boot (9), capped rubber sleeve (6d) T06, T07, T08, T10
(D) Z004354 Pull-in/Pull-out tool including grooving tool for brass bush (7) T08, T12, T13, T14, T16
(E) K046290 Press-in tool for tappet and boot assembly (13) T02 T03, T04, T28, T55, T56
(H) K015825 Press-in tool for cover (10) T26
(K) K003934 Press-in tool for cap (68a) T11
(L) Z004361 Press-in tool for inner seal (22) T03, T04, T09
(M) K016743 Press-in tool for cover (68c) T27 (replaces T25)
(N) K005986 Pull-in/Pull-out tool for guide sleeve (6c and 6e) T05, T06, T08, T14, T20, T21
(R) Z004198 Pull-in/Pull-out tool for rubber bush (6a) and open bearing (6b) T05, T06, T18, T19,T20, T21, T22

Note: The current service tool kit (Part No. K039062K50) contains the above listed tool components. Older tool kits can be updated
by purchasing supplementary tools (see table on page 2).

2.2 Diagnostic Equipment

Part No. Description
A Knorr-Bremse hand-held device for checking potentiometer function
K154433N50
(see also Service News Y123889).

2.3 Lubricant
Part No. Quantity

II14525 5g
K093430 10g
II32868 500g

2.4 Torque Requirements

Item No. Description Torque Spanner Size (mm)

Caliper bolts (2x)

39; 40 180 Nm plus 90° 14 (Hexagon key)
M16x1.5 (hexagon socket head)
Follow the instructions of the brake
18 Brake chamber or spring brake -
actuator or vehicle manufacturer

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3. DESCRIPTION AND FUNCTION

3.1 Disc Brake Sectioned View

1* 122* 121* 46 58* 9* 7* 5* 40*

13

10*

16
23

32

61

44 37

11*
Legend 27

1 Caliper* 30
2 Carrier*
4 Guide Pin* 45 17
5 Guide Pin*
6 Rubber Bush / Guide Sleeve 26
(floating bearing side)*
33
7 Brass Bush (fixed bearing side)*
9 Inner Boot*
10 Cover* 24
11 Pad Retainer*
121 Pad (inboard)* 22*
122 Pad (outboard)* 68*
13 Tappet and Boot Assembly 39*
16 Threaded Tube 6*
17 Bridge 4*
18 Brake Actuator**
16 161 13 2*
19 Lever
20 Eccentric Bearing
22 Inner Seal*
23 Adjuster Unit
24 Turning Device
26 Spring Clip
27 Spring
30 Chain 1 122 46 121 19
32 Chain Wheel
33 Wear Sensor
37 Adjuster Cap
39 Caliper Bolt*
40 Caliper Bolt*
44 Pad Retainer Pin
45 Washer
46 Disc
58 Ring*
61 Shear Adapter
68 Cover*
161 Tappet Bush

* variants

** Brake Chamber or Spring Brake 27 17 20 18**

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 » Pneumatic Disc Brake SN6 - SN7 - SK7

DESCRIPTION AND FUNCTION 3

3.2 Description of Operation

(Floating caliper principle)

Brake Actuation Brake Adjustment

During actuation, the push rod of the actuator (18) moves the The so called running clearance of the disc brake is the air
lever (19). The input forces are transferred via the eccentric roller gap between the brake pad (12) and the brake disc (46). This
bearing (20) to the bridge (17). The force is then distributed by distance is necessary to achieve a free running (and therefore
the bridge (17) and the two threaded tubes (16) to the tappet unbraked) disc when the brakes are in a ‘non applied’ state. Too
and boot assemblies (13) and finally to the inboard pad (12¹). large a running clearance can lead to a greater braking distance.
The designated running clearance is so designed to compensate
After overcoming the running clearance between the for changes under typical use such as:
inboard pad (12¹) and the brake disc (46), the reaction forces - expansion of parts due to high temperatures.
are transmitted by the caliper to the outboard pad (12²). The - viscoelastic effect of the brake pads.
clamping forces on the pads and the disc (46) generate the - finish and runout tolerances of a brake disc and possible lip
braking force for the wheel. development.

To ensure a constant running clearance between pads and disc,

the brake is equipped with a non-wearing, automatic adjuster
mechanism. The adjuster (23) operates with every cycle of
actuation due to the mechanical connection with lever (19).
Brake Release
As the pads and disc wear, the running clearance increases. The
After releasing the air pressure, the return spring (27) pushes adjuster (23) and turning device (24) turn the threaded tubes
the bridge (17) with the threaded tubes and lever (19) back to (16) by an amount necessary to compensate for this wear.
the start position.

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4. INSPECTION POINTS
Despite the use of long-life materials, it is necessary to check Annually
some of the components regularly for their general condition.
Check the caliper running clearance (see Section 5.3.1) and the
The following inspection points will ensure a long-life and
correct fitting and condition of the cover (10), the adjuster cap
trouble-free operation of the disc brake.
(37) and cover (68c, 68d or 68e) (depending on the bearing
variant).
Every 3 months
Note: These frequencies are a minimum and, depending on the
The pad wear must be checked visually and independent of vehicle application, a more frequent check of the components
any wear indicator fitted to the vehicle (see Sections 5.1). may be necessary.
Refer also to vehicle and/or axle manufacturer’s instructions in
regard to service intervals.
With every pad replacement
The discs should be checked according to the specification of
It is important to check for the correct functioning of the adjuster the axle or vehicle manufacturer.
(see Section 5.2) and the smooth operation of the caliper over its
In the unlikely event of a problem, all relevant components
full range of movement (see Section 5.3). Also inspect the tappet
must be returned in order that an objective investigation of the
and boot assemblies (13), the adjuster cap (37) and the sealing
cause can be made.
elements (9, 58) for correct fitting and condition as well as the
caliper bearing in the area of the rubber bush/guide sleeve (6) (see
Section 5.3.3).

12

58
9
13

58
9

6*
37 10

68*

* Variants possible

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INSPECTION POINTS 4

4.1 Safety Instructions for Service Work and

Repair Work

Observe relevant safety instructions for service work and repair Screw threads and tapped holes must be free
work on commercial vehicles, especially for jacking up and of lubrication and residuals of thread locking
securing the vehicle. products.
Use only genuine Knorr-Bremse parts.
After re-fitting a wheel according to the vehicle
manufacturer’s recommendations, ensure that there is sufficient
Before starting service work, ensure the service brake and clearance between the tyre inflation valve, the caliper and the
parking brake, as well as the bus stop temporary hold wheel rim, to avoid damage to the valve and the wheel.
brake, if fitted, are not applied and that the vehicle cannot
roll away.
After any service work:
Check the brake performance and the system behaviour
Please follow service manual instructions and adhere to the on a roller dynamometer. Check function and effectiveness.
wear limits of the pads and the discs (see Section 5.1). Bear in mind that a lower performance can appear during
Use only recommended tools (see Section 2.1). the breaking-in phase of the brake pads and/or the brake
disc.

Tighten bolts and nuts to the prescribed torque values

(see Section 2.4). Observe the “Safety and Environment Guidelines” section on
pages 5 and 6.

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5. FUNCTIONAL AND VISUAL CHECK

5.1 Wear Check of Pads and Brake Discs

For optimum safety, the pad and disc wear limits must not
be exceeded.

Brake Pads
The thickness of the pads must be checked regularly dependent
on the usage of the vehicle. The pads should be checked 5.1.1 - Brake pad with minor damage (permitted)
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.
5.1.1 Minor breakouts at the edges are permitted (see arrow).
5.1.2 Major breakouts on the surface of the brake pad are not
permitted (see Fig.).
5.1.3 If the thickness of the friction material at its
thinnest point is less than 2 mm (dimension C) the pads must
be replaced (see Fig.).

A = Overall thickness of new brake pad 30 mm

B = Backplate 9 mm with SN6 and SN7
Backplate 7 mm (middle) - 9mm (outer edge) with SK7
C = Minimum thickness of friction material 2 mm* 5.1.2 - Brake pad with major damage (not permitted)
D = Minimum allowed thickness in worn condition for
backplate and friction material:
- With a 9 mm backplate D = 11 mm*
- With a 7 mm backplate D = 9 mm* Outboard side
Brake Pad
*If these minimum allowed thicknesses are reached, brake
pads must be replaced as an axle set.

Inboard side
Brake Disc Brake Pad

Measure the thickness of the brake disc at the thinnest point. New Brake Pads
Be aware of possible burring at the edge of the disc.
E = Total thickness of the brake disc
new condition = 45 mm
worn condition = 37 mm (the disc must be replaced)
Outboard side
Brake Pad
If the disc dimension E ≤ 39 mm, it is recommended that the disc
should be renewed when the brake pads are changed.

If these recommendations are ignored, there is a

Inboard side
danger of brake failure and therefore increased risk of Brake Pad
Worn Brake Pads
an accident.
5.1.3 - Brake pad and disc thicknesses

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FUNCTIONAL AND VISUAL CHECK 5

5.1.4 Check the disc at each change of pads for grooves and
cracks. If necessary replace the disc. ma
x.
1.5
The figure shows possible surface conditions of the brake disc. mm
A1 = Small cracks spread over the surface are allowed
B1 = Cracks less than 1.5 mm deep or wide, running
A1 B1
in a radial direction are allowed
max. 0.75 x a
Cracks to a max. length of 0.75 x’a’ are allowed
(a = width of the friction ring)
C1 = Unevenness of the disc surface less than 1.5 mm
a
deep is allowed
D1 = Cracks going through to the cooling duct or onto
the inner or to the outer edge of the friction ring are
not allowed and the disc MUST BE REPLACED.
D1 C1
Note:
In case of surface conditions A1, B1 or C1, the disc can continue
to be used until the minimum thickness E = 37 mm is reached.

Knorr-Bremse discs are normally service-free and grinding

when changing pads is not necessary. However, grinding
could be useful, e.g. to increase the load-bearing surface of the
pads after severe grooving on the entire friction surface has
occurred. To meet safety requirements, the minimum thickness
after machining must be greater than 39 mm.
In addition, the recommendations of the vehicle manufacturer C1
about the machining of the brake disc MUST be followed.

B1
Grinding of a Knorr-Bremse Splined Disc® is not allowed.
D1
The adjacent picture shows some examples of cracks and
grooves on a brake disc.

If these recommendations are ignored, there is a risk of an

accident. If the brake pads and/or the brake disc are worn
5.1.4 - Tolerances and examples of cracks and grooves
down excessively, brake performance will be reduced and on a brake disc.
may be lost completely.

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5 FUNCTIONAL AND VISUAL CHECK

Brake Pad/Disc Wear Check (on vehicle) with bearing

variant (6a; Rubber Bush)

For all disc brakes equipped with rubber bush type (6a) with G
axial ribbing (see arrow H).
1
5.1.5 The pads/disc wear can be visually determined without H
removing the wheel, by noting the position of the wear marker
point see arrow G - the change-over point from the ribbed to
the smooth surface) (see Figs.).
If dimension C is less than 1 mm (see Fig. 5.1.5b), the brake
pad thickness and brake disc must be checked with the wheel
removed. Depending on operating conditions, it may be
necessary to check brake pad thickness and brake disc even C
when dimension C is greater than 1 mm.
If any minimal tolerance limits have been reached (see Section
5.1.5a - Dimension C with new disc and brake pads
5.1) the pads and/or disc must be changed.

Pads must be changed as an axle set (see Section 6). For disc
replacement, follow vehicle manufacturer’s recommendations.

C
5.1.5b - Dimension C with worn disc/brake pads, to which it is a requirement
to check pad and discs with wheel removed

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FUNCTIONAL AND VISUAL CHECK 5

Brake Pad/Disc Wear Check (on vehicle) with bearing

variant (6b; Open Bearing)

5.1.6 The pads/disc wear can be visually determined without

removing the wheel by checking the position of the caliper (1) 1
compared to the fixed guide pin (4).

If dimension C is less than 1 mm (see Fig. 5.1.5b), the brake

pad thickness and the brake disc must be checked with the
wheel removed. Depending on operating conditions, it may 4
be necessary to check brake pad thickness and brake disc even
when dimension C is greater than 1 mm. C
If any minimal tolerance limits have been reached (see Section
5.1) the pads and/or disc must be changed.
5.1.6a - Dimension C with new brake pads and disc
Brake Discs and Pads must be changed as an axle set (see
Section 6).

5.1.6b - Dimension C with worn disc/brake pads, to which it is a requirement

to check pad and discs with wheel removed

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5 FUNCTIONAL AND VISUAL CHECK

Brake Pad/Disc Wear Check (on vehicle) using Carrier to

Caliper position with bearing variant (6c and 6e) Guide
Sleeve and variant (6d) Capped Rubber Sleeve

For all disc brakes which are equipped with a caliper to carrier
marking.

5.1.7 The pad/disc wear can be visually determined without

removing the road wheel by viewing the position of the caliper
position P compared to the carrier marking R (see Figs.).
If the positions of P and R are similar to those shown in 5.1.7b,
the brake pad thickness and the brake disc must be checked
with the wheel removed. Depending on operating conditions,
it may be necessary to check brake pad thickness and brake disc
even before these dimensions are reached. 5.1.7a - Position of points P and R with new brake pads and disc
If any minimal tolerance limits have been reached (see Section
5.1) the pads and/or disc must be changed.

Brake Discs and Pads must be changed as an axle set (see

Section 6).

5.1.7b - Position of points P and R with worn disc/brake pads, to which it is a

requirement to check pad and discs with wheel removed

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FUNCTIONAL AND VISUAL CHECK 5

Wear Indicators
5.1.8 Due to different vehicle manufacturers and vehicles
there are several types of pad wear indicator used.

a) In-pad normally closed indicator - circuit is broken w h e n

pad wear reaches limit (see Fig.).
b) In-pad normally open indicator - circuit is made when pad
wear reaches limit (see Fig.).
c) Wear indicator using built-in potentiometer. This is available
either as an on/off version or as a continuous signal version
which can be linked to the vehicle’s electronic monitoring
systems (see Fig.).
Either acoustic or optical diagnostic units can be connected. 5.1.8a - 5.1.8b - In-pad wear Indicator

Note: Please also refer to specifications provided by the vehicle

manufacturer.

5.1.8c - Wear Indicator with built-in potentiometer

Knorr-Bremse diagnostic unit K154433N50

The Knorr-Bremse Potentiometer Tester serves;

- To test the Potentiometer function on

Knorr-Bremse disc brakes
- To check the wear condition of the brake pads
and brake discs

5.1.9 The Tester can be used on all current Knorr-Bremse

brake types with continues or black/white Potentiometer.

Note: Knorr-Bremse recommends that before replacing a brake caliper

with a suspected potentiometer failure, that it first be tested using the
Potentiometer Tester. If no defect is found, the cause is not with the brake
caliper and therefore does not need replacing.

5.1.9 - Knorr-Bremse diagnostic unit K154433N50

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5 FUNCTIONAL AND VISUAL CHECK

5.2 Adjuster Check

5.2.1.1 Before starting work, ensure that the wheels are chocked
and the vehicle cannot roll away.
5.2.1.2 Ensure that service brake and parking
brake, as well as bus stop temporary hold brake, if
fitted, are in the released condition.
5.2.1.3 Check the supply pressure of the brake system (should
be > 6.5 bar). Connect an additional external supply to prevent
pressure drop. x3
5.2.1.4 Jack up the axle and remove the wheel (refer to the
respective vehicle /axle manufacturer’s instructions)
5.2.1.5 Check the brake disc temperature, it should be between
-10°C and 50°C.
5.2.2 Push and pull caliper three times in axial direction to 5.2.2 - Push caliper three times in axial direction
assess any existing air gap (see Fig.). If no movement is possible,
clean the disc brake and if necessary, replace the bearings (see
Section 9). Once movement is obtained, continue as follows:

Back wards
5.2.3 Pull off the adjuster cap (37) using the tag, taking care
not to lose the shear adapter (61) (see Fig.). Fo
r wa
rd
Removal of the adjuster cap (37) with a screwdriver, or 23 s
similar, is not allowed since the seal may be damaged.
61
5.2.4 Insert new brake pads (see Section 6.2)
37
5.2.5 Set the starting gap by turning the adjuster (23) with
the shear adapter (61) backwards and then forwards (note that
when turning backwards a noticeable clicking can be heard
and felt), until a value of 1.3 mm air gap has been achieved
(measure between the brake pad and Tappets (13).
5.2.3 - 5.2.5 - Remove cap, insert new brake pads, set the starting gap
5.2.6 Apply the brakes 20x with medium pressure (ca. 2-3
bar).

5.2.7 Check the gap between each of the tappets (13) and
inboard pad backplate (12). This must be measured over the
whole tappet surface of both tappets using two feeler gauges 22
simultaneously (feeler gauges must be at least 220 mm long) 0m
m
(see Fig.).
If the gap difference between the two tappets is
> 0.25 mm then the caliper bearing clearance must be checked
(see Section 5.3). 13
In addition each gap must measure between 0.6 - 1.2 mm.

If the clearance is too great, there is a danger of brake

failure. If the clearance is too small, there is a danger
of overheating that may lead to consequential 0,6 - 1,2 mm
damage. 5.2.7 - Check gap between tappets and inboard pad

22
 » Pneumatic Disc Brake SN6 - SN7 - SK7

FUNCTIONAL AND VISUAL CHECK 5

5.2.8 If the air gap is larger than 1.2 mm the adjuster must
be checked as follows:

5.2.8.1 Turn the adjuster with adapter (61) 3 clicks

anti-clockwise (increasing the air gap) (see Fig.).

Make sure the ring spanner or socket can turn freely

clockwise during the following procedure.

61

5.2.8.1 - Turn adapter 3 clicks anti-clockwise

5.2.8.2 As a visual aid, position a ring spanner or socket onto

the adjuster (including Adapter (61)) as shown. Apply the brake
5 to 10 times (ca. 2 bar), the spanner or socket should turn
clockwise (viewed from actuator side) in small increments if the
adapter is functioning correctly (see Fig. and note below).

Note: As the number of applications increases, incremental move-

ment of the ring-spanner or socket will decrease.
If the spanner or socket does not turn or turns only with the first
application or turns forward and backward with every application,
the automatic adjuster has failed and the caliper must be replaced.

61

5.2.8.2 - Apply the brake 5-10 times, spanner turns clockwise

5.2.8.3 Lightly grease the contact surface of the cap with white
grease (available as Part No. II14525, K093430 or II32868).

The tag of the adjuster cap (37) should be positioned as shown

37
by the arrow in the adjacent figure. This ensures access is
maintained for subsequent removal (see Fig.).

Note: A new adjuster cap (37) should be fitted even if the brake
pads are not being replaced.

5.2.8.3 - Tag positioning of the cap

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5 FUNCTIONAL AND VISUAL CHECK

5.2.9 If the air gap is smaller than 0.6 mm the parameters

and functions must be checked as follows:
19
5.2.9.1 Function of the brake actuator, refer to specifications
provided by the manufacturer.
5.2.9.2 Remove brake actuator (18) (see section 11.1 and 11.3)
5.2.9.3 Check position of lever (19) inside the caliper in its
released state (see arrow).
5.2.9.4 Remove brake pads (12) (see section 6.1). If necessary,
remove dirt from brake pads, caliper and carrier.
- Check brake pads for wear from the tappets and if necessary
replace brake pads.
- Check for abnormal wear of the contact areas of the carrier. If
necessary replace the carrier.
5.2.9.5 Check the brake disc. For Knorr-Bremse brake discs see
section 5.1. For other manufacturers refer to their specifications.
5.2.9.6 Check caliper running clearance (see Section 5.3.).
5.2.9.7 Fit the brake pads (see Section 6.2). 5.2.9.3 - Check lever position

5.2.9.8 Fit the brake actuator (see Section 11.2 or 11.4.).

5.2.9.9 Recheck the adjuster (see Section 5.2.6.).
If the air gap is still smaller than 0.6 mm between both tappets,
the brake caliper must be replaced.

5.2.10 Refit the wheel according to the vehicle manufac-

turers specifications

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 » Pneumatic Disc Brake SN6 - SN7 - SK7

FUNCTIONAL AND VISUAL CHECK 5

5.3 Caliper Check

Caliper Running Clearance

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.

5.3.1 By pushing and pulling the caliper in an axial direction

by hand, a movement within the running clearance (see 5.3.1 - Push and pull hand test
Section 5.2) must be possible (see Fig.).
If, even using a high level of hand pressure (no tools), the caliper
is not moveable the caliper guide pin seals must be examined
(see Section 5.5).

Caliper Movement along Guide Pins 5.3.5 - 5.3.6 -Rewind tappets completely and push caliper in direction of
middle of vehicle

5.3.2 With the open bearing variant (6b), firstly clean the
protruding area of the guide pin (4b) from outside of the 4a/b
caliper. If necessary remove any light corrosion using an emery
cloth.
5.3.3 Lightly apply grease (order No. II14525, K093430 or
II32868) to guide pin (4b).
5.3.4 Remove brake pads (see Section 6.1).
5.3.5 Fully wind back the tappets (13) using a ring spanner
and shear adapter (61) (see Fig.).
5.3.6 Push caliper inboard towards vehicle’s centre (see Fig.)
5.3.7 With both open bearing variants (6a and 6b), clean 5.3.7 - Free guide pin of dirt
guide pin (4a or 4b) from the inner area of the caliper, removing
any dirt or corrosion.
5.3.8 Lightly apply grease (order No. II14525, K093430 or
II32868) to guide pin (4a or 4b).
5.3.9 Caliper (1) must slide freely along the whole length of
the guide pin arrangement; movement should be greater than
25 mm. (see Fig.).
If the caliper does not move at least 25 mm, the caliper guide
pin seals must be examined (see Section 5.5).

1
> 25 mm
5.3.9 - Free movement of caliper > 25 mm

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5 FUNCTIONAL AND VISUAL CHECK

5.4 Clearance Measurement Check of Bearing

Variants (6) 12 1
Note: Before commencing (removing the wheel), make sure there
is no contact between caliper and axle, vehicle, chassis sections or
carrier. In such cases it will be necessary to replace the caliper bear-
ings (see Section 9).

To measure the clearance, the following steps must be taken:

5.4.1 Remove the wheel, refer to vehicle manufacturer’s

recommendations. A
5.4.2 Remove pad retainer (11) (see Section 6.1.2)
To achieve the correct reading it is necessary to have a pair of
new brake pads fitted. If the clearance measuring is not taking
place during a brake pad replacement, the current position of the
assembled pads must be noted before removing, so that they can 2
be re-assembled in the same position.
Remove old pads (see Section 6) (at this point Section 5.1 “Wear
Check of Pads and Brake Discs” must also be observed) and replace
with a pair of new pads.
5.4.3 Fasten a magnetic dial-gauge holder to the carrier (2)
on the floating bearing side of the caliper (1). Use the casting
tag on the caliper (1) as the measuring point - see arrows A (see
Fig.). 5.4.3 - 5.4.5 - Obtaining maximum value of bearing clearance

5.4.4 Set the dial-gauge to zero.

5.4.5 Place a suitable tool (e.g. screwdriver with at least 200
mm in length) in a central position between carrier (2) and
caliper (1) and lever them in opposite directions (using normal
hand-force) (see Fig.).
5.4.6 Read the maximum value of the bearing clearance on
the dial-gauge and compare with the values in the table (see Bearing variants (6) Max. bearing clearance
Table). 6a Rubber Bush 2 mm
If the clearance exceeds the given tolerance, the complete 6b Open Bearing 2 mm
bearing will need replacing using the relative service kit (see
6c Guide Sleeve 1 mm
Section. 1.2 and Section. 9).
6d Capped Rubber Sleeve 1 mm
If the clearance measuring is not taking place during a brake pad
replacement, the new pads should be removed and the previously 6e Guide Sleeve 2 mm
marked brake pads fitted in their original positions, otherwise 5.4.6 - Maximum bearing clearance tolerances of bearing variants
renew the brake pads as an axle set and adjust the air gap (see
Section 6.2).
5.4.7 Fit the wheel (refer to vehicle manufacturer’s
recommendations). After replacing the wheel check that it runs
interference free.

26
 » Pneumatic Disc Brake SN6 - SN7 - SK7

FUNCTIONAL AND VISUAL CHECK 5

5.5 Sealing Elements Check

9 5 10
Caliper Guide Pin Seals
5.5.1 The guide pin (5a or 5b) (as fitted to the fixed bearing
side) is sealed with cover (10a or 10b) and inner boot (9a or 9b)
(see also Section 1.1.1).
The floating bearing side with guide pin (4c, 4d or 4e) is sealed
with inner boot (9c, 9d or 9e) and with cover (68c 68d or
68e). All variants (9), (10) and (68) must be free of any signs of
damage (see Fig.).
Fixed bearing side

Check for correct location and fitting.

9 4 68
If necessary, remove pads (12) to inspect the inner boots (9)
(see section 6.1).
If necessary, repair caliper with suitable service kit (see Section
1.2 and Section 8).

Floating bearing side

5.5.1 - Checking of guide pin and seals

Checking of Tappet and Boot Assemblies (13)
Remove pads (12) (see Section 6.1).
< 30 mm
5.5.2 Screw out the tappets (13) using the shear adapter (61)
clockwise until the boots are clearly visible (see Fig).

The tappets must not be extended more than 30 mm,

otherwise synchronisation is lost and the caliper must be
replaced. 13

5.5.2 - Screw out tappets - max. 30 mm

5.5.3 The rubber boots on the tappets (13) must not have any
cuts/tears or show any other signs of damage (see Fig.).
Check for correct location and fitting.

Note: The penetration of dirt and moisture into the brake will lead
to corrosion and impair the function of the clamping mechanism
and wear adjuster.

If necessary replace tappet and boot assemblies (see Section 7).

5.5.3 - Check rubber boots for damage

27
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6 BRAKE PAD REPLACEMENT

Before starting work, ensure that the wheels are chocked
and the vehicle cannot roll away. 11
Ensure that service brake and parking brake, as well
as bus stop temporary hold brake, if fitted, are in the 44
released condition.
6.1 Removal of Brake Pads
6.1.1 Remove wheel (refer to vehicle manufacturer’s
recommendations).
Important! 45 26
Also be aware of the inspection points detailed in chapter 4.
Depending on the orientation of the caliper on the axle,
brake pads could fall out when removing the pad retainer
(11).
6.1.2 - Removing pad retainer
6.1.2 Remove spring clip (26) and washer (45), depress the
pad retainer (11) and remove pin (44) (see Fig).
If necessary remove any in-pad wear sensor components (see
Section 6.3).
6.1.3 Pull off the adjuster cap (37) using the tab, taking care
not to lose the shear adapter (61) (see Fig. insert).

Do not use any tools to remove the cap (37) as this can
damage the sealing elements of the adjuster. 23
6.1.4 Fully wind back the tappet and boot assemblies (13) 61
by rotating the adjuster (23) via the shear adapter (61) in an 61
anti-clockwise direction (as viewed from actuator side) – a
loud clicking noise is generated (see Fig.). 37
6.1.3 - 6.1.4 - Rewind adjuster using shear adapter

6.1.5 Remove brake pads (121) and (122) (see Fig.).

-
Vehicle side
Note: The geometry of the brake pad housing of SK7 disc inboard
-
brakes require the following removal procedure of the brake Vehicle
s id e
pads (12): outboard
- Pull caliper (1) towards the outboard side.
1
- Remove outer brake pad (122)
- Push caliper (1) to the inboard side.
- Remove inboard brake pad (121)

6.1.6 Check caliper running clearance (see Section 5.3) 121

122
6.1.5 - Remove brake pads

28
 » Pneumatic Disc Brake SN6 - SN7 - SK7

BRAKE PAD REPLACEMENT 6

6.2 Fitting of Brake Pads

Pads must be changed as an axle set and NOT
individually. Use only pads which are permitted by the
vehicle manufacturer, axle manufacturer and disc brake
manufacturer. Failure to comply with this will invalidate
any Knorr-Bremse warranty.

6.2.1 Depending on the intensity of contamination, clean the

brake pad bay area. use suitable tools (wire brush, caliper file,
blunt scraper)
Important! Take care not damage the Carrier and/or Rubber
Bush/Guide Sleeve seals.

6.2.2 Check the carrier (2) and rubber seals for damage,
replace if necessary. 6.2.3 - Areas to apply suitable lubricant
Important! Brake Pad contact surface must be clean, devoid of
moisture and free from any dirt and debris.
Inboard brake pad
6.2.3 Depending on the application, it may be necessary for
the abutments of the carrier and guiding surfaces of the brake
pad to be coated with a suitable permanent lubricant with the
1
following characteristics (see Fig.).
Important! Do not use copper based lubricant.

Important! Do not get any lubricant on the pad and/or disc

face or guide sleeve parts. 121
Refer also to specifications provided by the vehicle, axle and
brake system manufacturer.

Before inserting the brake pads, fully wind back the tappet
and boot assemblies (13) by rotating the shear adapter (61)
in an anti-clockwise direction (see Section 5.2). 6.2.4a - Insert inboard brake pad (SK7)

6.2.4 Insert the brake pads (12) as follows:

For SK7 disc brakes the geometry of the brake pads (12)
requires the following fitting procedure: Outboard brake pad
- Slide caliper (1) inboard and insert inner brake pad (121)
(see Fig. 6.2.4a)
- Slide caliper (1) outboard and insert outer brake pad (122)
(see Fig. 6.2.4b)
122
For SN6 and SN7 disc brakes there is no special fitting order for
the brake pads (12), therefore the inboard or outboard pad can
be fitted first.

6.2.4b - Insert outboard brake pad (SK7)

29
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6 BRAKE PAD REPLACEMENT

6.2.5 Wind out the Adjuster (23) with shear adapter (61) until
the brake pads come into contact with the disc. Then turn back 1
the adjuster three clicks and check the running clearance (see
Section 5.2) .
44

6.2.6 After fitting the pad retainer (11) into the groove of
caliper (1), it must be depressed to enable the insertion of the 11
pad retainer pin (44) (only use new parts) (see Fig.).

6.2.6 - Fitting pad retainer and pin

6.2.7 Fit new washer (45) and then new spring clip (26) to the
pad retainer pin (44) (use only new parts) (see Fig.).

44
6.2.8 The adjuster cap (37) must then be replaced (use only a
new cap) having lightly greased its contact surface with grease
(available as Part No. II14525, K093430 or II32868) (see Fig.).

Note: The tag of the adjuster cap (37) should be positioned as 26

shown (see arrow). This ensures access is maintained for subse- 45
quent removal.

If required, fit cable guides and pad wear indicators (see Section 6.2.7 - Fit new washer and new spring clip
6.3).

6.2.9 Re-fit wheel according to the vehicle manufacturer’s 37

recommendations.

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.

6.2.8 - Fit new adjuster cap, note tab position

30
 » Pneumatic Disc Brake SN6 - SN7 - SK7

BRAKE PAD REPLACEMENT 6

6.3 Fitting Pad Wear Indicators

101 122
Only use new pad wear indicators. The fitting of used pad
wear indicators is not allowed.

For pad removal see section 6.1.

The components of the wear indicator kits are shown in section

1.2.1.
Note: The longer end of the cable fits onto the outboard pad (122),
the short end onto the inboard pad (121).

6.3.1 Align each sensor in the groove of a brake pad (12) and
press down until it locks into place (see Fig.).
6.3.1 - Fitting pad wear indicators

6.3.2 Insert the brake pads (12) with pre-assembled wear

indicators into their respective brake pad bay area (see Fig.). 12
Note: See also section 6.2.2

6.3.2 - Insert pre-assembled pads

6.3.3 Fit pad retainer (11) with retainer pin (44), washer (45)
and spring clip (26) (see Fig. and Section 6.2). Note the correct
position of the cables (101) (see arrows). 44 11

26

45 101

6.3.3 - Fit pad retainer

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6 BRAKE PAD REPLACEMENT

Fitting of Cable Guide Variant (105)

6.3.4 Fit the cable guide variant (105) onto the pad retainer (11). 105
When correctly positioned, and whilst applying light pressure,
the cable guide (105) will lock easily into place (see Fig.).

6.3.4 - Fitting cable guide

6.3.5 Carefully insert the cable (101) into the retainer tabs
(arrows A) of the cable guide (105). Note that the shorter cable
from the inboard pad is not fixed to any part of the cable guide B
(105) (arrow C).
Depending on the vehicle type, the supply line of the cable 105 101
(101) is fixed into one of the outer retainer clips (arrow B).
A

Note: The short cable (inboard side) remains loose (arrow C).

6.3.5 - Cable fixture position on cable guide (105)

Fitting of Cable Guide Variant (105a)

B
6.3.6 Lay the cable (101) centrally on the pad retainer (11).
105a
101 11
Position the cable guide (105a) at the side of the pad retainer
(11) (arrow D) and with light pressure clip into place on the
opposite side (see Fig.).
Depending on the vehicle type, the supply line of the cable (101) is
fixed into one of the outer retainer clips (arrow B).

Note: The short cable (inboard side) remains loose (arrow C).
D
C

6.3.6 - Cable fixture position on cable guide (105a)

32
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BRAKE PAD REPLACEMENT 6

Fitting of Cable Protection Plate (104)

6.3.7 Position cable protection plate (104) on one side
E
of the pad retainer (11), making sure the tab (arrow E) is
located correctly. By applying central pressure on plate
(104) the tab will snap into place (see main Fig. and
detailed view).

11 104

6.3.7 - Fitting cable protection plate

Removing Cable Protection Plate (104)

6.3.8 Using a suitable tool, loosen one side of the cable
protection plate (104) and remove.
It is not permitted to reuse a cable protection plate.

6.3.8 - Removing cable protection plate

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7. TAPPET AND BOOT ASSEMBLIES (13) AND INNER SEALS (22) REPLACEMENT
For ease of reference, each component of a tool is referred to (A)
by an identification number; a complete tool (containing one
or more such components) has been given a letter code - see
section 2.1. T15

To remove the tappet and boot assemblies (13) use the wedge
fork (A) (see Fig 7a).

7a - Tool for replacing the tappet and boot assemblies

(B) Older tool kit version

To fit the tappet and boot assemblies (13), use tool (E) (see Fig T03 T04 T01 T24
7b).

Note: Older versions of the tool kit were supplied with tool
(B), which in this case, can be used instead of (E). Refer to the
service manual included in the old service kit.
T02

(E) Newer tool kit version

T03 T04 T28 T55 T56

T02

7b - Tool for fitting the tappet and boot assemblies

To fit the inner seal (22), use tool (L) in configuration (L1) when
the caliper is mounted on the vehicle or configuration (L2) when (L) T09 T03
removed from the vehicle (see Fig 7c).
(L1)
on vehicle application

T09 T04 T03

(L2)
off vehicle application

7c - Tool for fitting the inner seal

34
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TAPPET AND BOOT ASSEMBLIES (13) AND INNER SEALS (22) REPLACEMENT 7

7.1 Removal of Tappet and Boot Assemblies (13)

Note: The removal of the tappet and boot assemblies (13) can be < 30 mm
done with the brake caliper fitted to, or removed from, the vehicle
(see Section 8)

With caliper installed on the vehicle: X

7.1.1 Wind-out the adjuster (23) using the shear adapter (61) 13
until the boots are easily accessible (max. 30 mm) and with a
suitable lever carefully prise the boot away from the caliper (see
Fig.).
Take extra care not to damage the sealing surface on the
caliper for the inner boot (arrow X) as this cannot be replaced
(see Fig.).
7.1.1 - Wind-out the adjuster, prise out the inner boot.

7.1.2 Using tool (A), correctly positioned between the caliper

and the boot, carefully drive it down with the aid of a hammer
to release each tappet and boot assembly (13) from its threaded
tube (16). Take care to stay perpendicular and not damage the ‘A’
threaded tube (see Figs. ‘a’ and ‘b’).
‘A’

Make sure to keep tool (A) perpendicular to the

threaded tube 13 13

Do not remove the tappet by levering with tool (A) at

an angle, this will damage the internal mechanism.

7.1.2a - Remove tappet and boot assembly using tool (A)

‘A’ ‘A’
13 13

161 161

7.1.2b - Drive down wedge fork using hammer

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7 TAPPET AND BOOT ASSEMBLIES (13) AND INNER SEALS (22) REPLACEMENT

7.1.3 Remove the old tappet bush (161) (see Fig.).

X
7.1.4 Check inner sealing face (arrow X ) (see Fig.). 161 22

This sealing face (arrow X ) must not be damaged. It

cannot be replaced. If it is damaged, the caliper must be
replaced. (see Section 8).

If the seal is damaged then the caliper must be replaced (see

Section 8).
7.1.3 - 7.1.4 -Remove tappet bush, check sealing face
Note: When replacing tappet and boot assemblies (13), the inner
seals (22) must also be replaced (see Section 7.2).

Inspection of Threaded Tube (16) 46

7.1.5 Place a new brake pad (12) in the outboard 16
position and wind-out the threaded tube (16), by turning the
shear adapter (61), until it touches the brake disc. Check the
threads when winding-out for corrosion and damage (see Fig.).
In case of water ingress or corrosion, the caliper must be
replaced (see Section 8).
12

The threaded tubes must not extend more than 30 mm,

otherwise synchronisation is lost and the caliper must be
replaced. 7.1.5 - Inspection of threaded tube (installed on vehicle) using new brake pad

With caliper removed from the vehicle:

7.1.6 If the caliper is not installed on the vehicle, place spacer 70 mm
S (length = 70 mm) into the caliper (1) to avoid loss of thread
engagement of the threaded tubes (16). Check the threads when
winding-out for corrosion and damage (see Fig.).
In case of water ingress or corrosion, the caliper must be
replaced (see Section 8).

1 S 16

7.1.6 - Inspection of threaded tube (removed from vehicle) using spacer

36
 » Pneumatic Disc Brake SN6 - SN7 - SK7

TAPPET AND BOOT ASSEMBLIES (13) AND INNER SEALS (22) REPLACEMENT 7

7.2 Replacement of Inner Seals (22)

7.2.1 Fully wind back the threaded tubes (16) by turning the
shear adapter (61) (see Section 6.1.4).
Y
16
7.2.2 Clean area of the inner seal (22) and then, using a suitable
lever (Y), carefully remove the inner seal (22) (see Fig.).

The sealing surface for the inner seal (22), must not be
damaged else the caliper must be replaced.
22

7.2.2 - Clean area and remove inner seal

7.2.3 Clean sealing surface (X) (see Fig.).

Grease

7.2.4 Wind-out the threaded tubes via the shear adapter (61)
to a maximum of 30 mm whilst at the same time inspecting them for
corrosion or damage (see Section 7.1.5 -7.1.6) Siehe Kapitel
See Section
2.3
2.3
X
7.2.5 Lubricate threads with white grease (Part No. II14525, 16
K093430 or II32868) and then wind back the threaded tubes
until they stop (see Fig.).

7.2.6 Fit new inner seals (22) onto the threaded tubes (16) and
carefully push into position. 46
< 30 mm

7.2.3 - 7.2.5 - Wind out threads, inspect, grease threads and wind back

37
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7 TAPPET AND BOOT ASSEMBLIES (13) AND INNER SEALS (22) REPLACEMENT

With caliper installed on the vehicle:

7.2.7 Guide the tool (L1) over the spigot of the threaded tube (16)
as shown, screw out (T03) until it touches the brake disc (see
Fig.). 22
Note: The tappet bush (161) must be absent for this procedure. ‘L1’

7.2.8 Fully press in the inner seal (22) by securing (T09) with a
spanner 27 A/F and rotating (T03) against the brake disc using a
second spanner until it stops (see Fig.).
T03 T09
7.2.9 Unscrew (T03) and completely remove tool (L1).

7.2.7 - 7.2.8 - Using press-in tool L1 to fully press in inner seal

7.2.10 Check the correct fitting of the inner seal (22) by
winding out the threaded tubes (16) four or five threads via the
shear adapter (61).
Note: The inner seal (22) must not turn.

22

With caliper removed from the vehicle: (not shown):

The fitting sequence of inner seal (22) is basically the same as
when the caliper is installed on the axle (see previous section),
except the press-in tool (L2) with (T03+T04+T09) is required to 16
press in inner seal (22).

7.2.11 Guide the tool (L2) over the spigot of the threaded tube (16),
screw out (T03) until it touches the brake disc. 7.2.10 - wind out threaded tubes 4-5 threads via shear adapter
Note: The tappet bush (161) must be absent for this procedure.
7.2.12 Fully press in the inner seal (22) by securing (T09) with a
spanner 27 A/F and rotating (T03) against the brake disc using a
second spanner until it stops.

7.2.13 Unscrew (T03) and completely remove tool (L2).

7.2.14 Check the correct fitting of the inner seal (22) by

winding out the threaded tubes (16) four or five threads via the
shear adapter (61). Check that the inner seals (22) do not turn.

Note: If the inner seal (22) turns, then the seal must be removed
and the procedure repeated using a new inner seal.

38
 » Pneumatic Disc Brake SN6 - SN7 - SK7

TAPPET AND BOOT ASSEMBLIES (13) AND INNER SEALS (22) REPLACEMENT 7

7.3 Fitting of Tappet and Boot Assemblies (13)

The Tappets are supplied with a special long-life lubricant
within a protective cap.
Before fitting, the protective cap must be removed and
discarded in the appropriate manner. The lubricant must
not be smudged or removed. Transfer of the lubricant to
other parts should be avoided. Also adding additional
lubrication from any other substance is not allowed. 7.3 - Tappets supplied with long-life lubricant and protective cap

(E1) T03 T28 T56*

With caliper installed on the vehicle:

7.3.1. To fit the tappet and boot assemblies (13), use tool (E1)
(see Fig.). T02
* note direction of assembly

7.3.1 - Press-in tool (E1)

7.3.2. Wind back fully the threaded tube (16) until it stops and
then wind forward one full turn (see Section 6.1.4). 161
13
161
7.3.3. Fit new tappet bushes (161) onto the spigots of the
threaded tubes (16), then follow with the tappet and boot
assemblies (13) pushing them into position (see Fig.).
Note: The sealing surface (X) on the boot and in the caliper
must be clean and free of lubrication.

7.3.4. Position tool (E1) so that (T28) and outer rim of (T56) X
touches the brake disc. Using a spanner, screw out (T03) to
press tappet and boot assembly (13) into place (see Fig.).
7.3.3 - Fit new tappet bush / tappet with boot assembly to the spigot

‘E1’
13

T03

T56

7.3.4 - Press in the tappet using tool (E1)

39
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7 TAPPET AND BOOT ASSEMBLIES (13) AND INNER SEALS (22) REPLACEMENT

7.3.5 Release tool (E1) and then turn it over so that tool (T28) (E1)
can make contact with the boot. T56
T56
T28

T03
7.3.6 Bring tool (E1) into position making sure it is centralised T28
to the tappet (see Fig.).

T03
7.3.7 Press-in the boot of the tappet (13) using tool (E1) by T02
winding out (T03) against the brake disc (see Fig.).
T02
7.3.6 - 7.3.7 - Press-in boot using tool (E1).

7.3.8 Check that the tappet (13) turns slightly in each

direction (take care not to overstretch the tappet boot)
(see Fig.).

13

With caliper removed from the vehicle: 7.3.7 - Tappet should turn slightly in each direction
The fitting of each tappet and boot assembly (13) requires tool
(E2) (see Section 7).
(E2) - caliper removed from vehicle
T03 T04 T28 T56*

7.3.9 Wind back fully the threaded tube (16) using shear
adapter (61) until it stops and then wind forward one full turn
(see Section 6.1.4).

Note: The sealing surface (X) on the boot and in the caliper must
T02
be clean and free of lubrication. * note direction of assembly

7.3.10 Fit new tappet bushes (161) onto the spigots of the
threaded tubes (16), then follow with the tappet and boot
assemblies (13) pushing them into position. T02
13 T03
T28
7.3.11 Position tool (E2) as shown. Note that tool (T56) must
be inserted into tool (T28) with closed side facing out. Using T04
a spanner screw out (T03) to press tappet and boot assembly
(13) into place. ‘E2’ T56

Note: Tool (T56) is required to maximise grip on the caliper.

7.3.11 - Press in tappet using tool (E2) (with T56)

40
 » Pneumatic Disc Brake SN6 - SN7 - SK7

TAPPET AND BOOT ASSEMBLIES (13) AND INNER SEALS (22) REPLACEMENT 7

7.3.12 Release and remove tool (E2)

(E3)

T03 T04 T28 T56*

7.3.13 To press in the boot of the tappet (13) tool (E3) is

required. Note that (T56) must be inserted into (T28) with open
end facing outwards (see Fig.).

T02

* note direction of assembly

7.3.13 - Tool (E3)

7.3.14 Position tool (E3) so that (T03) screws out against the
caliper as shown. Using a spanner, screw-out (T03) to press-in
the boot (see Fig.).

‘E3’

T03

T28 T04

7.3.14 - Press-in the boot of the tappet using tool (E3)

7.3.15 Release and remove tool (E3), check that the tappet (13)
turns slightly in each direction (take care not to overstretch the
tappet boot) (see Fig.).

13

7.3.15 - Tappet should turn slightly in each direction

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8. CALIPER REPLACEMENT
8.0 To replace the cover (10; fixed bearing) use the press-in
Tool to press in cover
tool (T26), for cover (68a; floating bearing) use press-in tool (68a)
(T11), for cover (68c and 68e; guide sleeve) use press-in tool
(T27) and for cover (68d; capped rubber sleeve) tool (T08) is T11
Press-in tool for cover
required (see Fig.). Press-in tool for cover (68c/68e)
(10) T27
Tool to press in cover
(68d) T26
T08

8.1 Removal of Caliper from Carrier

8.1.1 Remove the brake pads (12) (see Section 6.1).
8.0 - Press-in tools for cap and covers
8.1.2 Remove brake actuator (see Section 12). If fitted, remove
wear indicator cable and potentiometer.

Do not touch electrical contact points - possible static

discharge!

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.
10 10

Removal of Cover (10) - Fixed Bearing Side

8.1.3 Use a suitable tool (e.g a chisel) to centrally penetrate
the cover (10) creating a hole to allow easy removal (see Fig.).
Note: during penetration the cover (10) may move
approximately 10 mm inwards 8.1.3 - Penetrate cover in the centre using suitable tool

Cover (10) should be penetrated in the middle. Do not drive

the tool between caliper bore and cover (10) since caliper
bore may be damaged.

Do not drive the tool too deeply, otherwise the seal for the
cover may get damaged when removing. 10

8.1.4 Remove cover (10) using a suitable tool (e.g a

screwdriver) by inserting it into the created hole and levering it
out.
Check the inside area of the bearing for dirt or corrosion. If
necessary replace with a new guide and seal kit. In case of
damage or excessive corrosion, the caliper must be replaced.
8.1.4 - Remove cover using suitable tool

42
 » Pneumatic Disc Brake SN6 - SN7 - SK7

CALIPER REPLACEMENT 8

Removal of Cover (68c, 68e; Guide Sleeve) or (68d;

Capped Rubber Sleeve)
68c 68d 68e
8.1.5 Due to the protrusion of covers (68c, 68d or 68e),
the removal procedure is from the side and in an upward
direction as shown (see Fig.).
Note: Do not hit the covers (68c, 68d or 68e) in direction of the
caliper as damage may occur to the caliper.

Check the inside area of the bearing and the cover for dirt or
corrosion. If necessary replace with a new guide and seal kit.
In case of damage or excessive corrosion, the caliper must be
replaced.

The capped rubber sleeve (6d) will release itself from the
carrier bore with cover (68d).
8.1.5 - Removal of cover (68c, 68d or 68e)

Removal of Cap (68a; Rubber Bush)

4a
8.1.6 Carefully remove cap (68a) from the guide pin (4a) using
a suitable tool, avoid damaging the cap.
Take care not to damage the rubber bush (6a).

6a 68a
8.1.6 - Removal of cap (68a)

Removal of Caliper from Carrier

Before removing the caliper bolts (39 and 40) ensure that
the caliper (1) cannot move or fall when the caliper bolts are
removed causing damage or injury.
40
8.1.7 Screw out the caliper bolts (39) and (40) (see Fig.).
1
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.

The opening or dismantling of the caliper is not authorised. 39

Use only genuine Knorr-Bremse replacement calipers.

2
8.1.8 Remove caliper (1) from carrier (2). 8.1.7 - Remove caliper bolts

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8 CALIPER REPLACEMENT

8.2 Fitting Caliper to Carrier -

(Carrier assembled on vehicle)
Only use original Knorr-Bremse replacement calipers!
8.2.1 The correct choice of caliper must be ensured by checking
the part number on the identification label (arrow X) (see also Y
Section 1.2).
Note: The replacement caliper includes seals and guide pins as well
as bolts and bushes for fitting the caliper to the carrier. Brake pads
X
and wear sensors are not included.

If the replacement caliper is equipped with a potentiometer, then

the connection must be made using the appropriate mating plug -
refer to vehicle manufacturer’s recommendations.

8.2.1 - Note identification label, remove adhesive tape

The caliper guide sleeves should be overhauled with the

respective guide and seal kit (see Section 9 and 10), or the
caliper replaced with the compatible rationalised caliper.

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).

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.

8.2.2 Lightly grease guide pins (4 and 5)

8.2.3 For bearing variant (68a; rubber bush) insert the guide
pins from inside the caliper to the outside for both fixed and
floating bearings.

8.24 For bearing variant (68b; open bearing, 68c and 68e;
metal guide sleeve and 68d; Capped rubber sleeve) insert the
guide pins from inside the caliper to the outside for both fixed
and floating bearings (see also Section 9.5 and 9.6). 5

8.2.5 Check that the inner boot (9) and ring (58) sit correctly
on the guide pin (4 and 5) (see Fig.), (see also Section 9.5 and 9
9.6). 58
8.2.5 - Check inner boot and ring

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CALIPER REPLACEMENT 8

Screw threads and tapped holes must be clean and dry

(free of lubrication and residuals of pre-applied adhesive).

8.2.6 Place caliper (1) onto the carrier (2) and insert the caliper 12 18*
bolts (39) and (40). Tighten bolts to 180 Nm, then tighten by a
further 90° (use only new parts) (see Fig.).

8.2.7 Check that the caliper slides easily on the guide pins.
(see Section 5.3). 1

8.2.8 Fit brake pads (12) (see Fig. and Section 6.2). 40
39
8.2.9 If present, remove plastic cover or adhesive tape in the
area of the actuator attachment from the replacement caliper
(see Fig 8.2.1 arrow Y).
2

8.2.10 Fit brake actuator (18) (see Fig. and Section 11.2 or 11.4).
*Brake chamber or spring brake
8.2.11 Check adjuster function (see Section 5.2).
8.2.6 - 8.2.10 - Fit caliper onto carrier, tighten caliper bolts , fit brake pads, fit
brake actuator

10
Fitting of Cover Variants
(T26)
Fitting of covers can only be done after the caliper has been
fully bolted to the carrier (see Section 8.2).

Cover Variant (10) - Fixed Bearing Side

Caliper bores and cover must be clean and free from lubrication.
8.2.12 Clean the new cover (10) and the interior of the press-in 8.2.12 - Insert cover into tool (T26)
tool (T26) and insert the cover (10) into tool (T26) as shown
(see Fig.).

8.2.13 Check the plane surface of caliper bore is clean and

(T26)
not damaged (see arrow) as well as the sealing surface for the
cover (10). Position the press-in tool (T26) including cover (10)
squarely and check it sits correctly as shown (see Fig.).
10
Note: Do not tilt the tool when assembling the cover (10)!

8.2.13 - Press-in tool (T26) with cover in position

on the plane surface of the caliper

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8 CALIPER REPLACEMENT

The inner boot (9) must be in a compressed

condition otherwise the caliper´s freedom of
movement will be limited. 10
T26
8.2.14 Press the mandrel of the press-in tool (T26) firstly by
hand until it stops, then, using a hammer on the mandrel, insert
the cover to the end stop (see Fig.).

Note: After fitting the new cover (10), ensure that it protrudes 2
mm from the plane surface of the caliper (see Fig.). 2 mm

8.2.14 - Fitting cover to stop, final position protruding 2 mm

Cap (68a; Rubber Bush) - Floating Bearing Side T11

8.2.15 Fit the cap (68a) using tool (T11) and a hammer. Force
the cap into the guide pin (4a) until firmly seated. The seal is
achieved by the compression of the lip of the rubber bush (6a)
between th guide pin (4a) and cap (68a) (see Fig.).
68a

4a 6a
8.2.15 - Insert Cap into Guide Pin using tool (T11)
Cover Variant (68c and 68e; Guide Sleeve) - Floating
Bearing Side
Caliper bores and cover must be clean and free from lubrication. 68c 68e
8.2.16 Clean the new cover (68c or 68e) and the interior of the
press-in tool (T27) and insert the cover as shown (see Fig.). T27

8.2.17 Check the plane surface of caliper bore is clean and not
damaged (see arrow). Position the press-in tool (T27) including
cover (68c or 68e) squarely and check it sits correctly as shown
(see Fig.). 8.2.16 - Insert cover into tool (T27)

Note: Do not tilt the tool!

68c/e

The inner boot (9) must be in a compressed (T27)

condition otherwise the caliper´s freedom of
movement will be limited.
8.2.17 - Press-in tool (T27) with cover in position
on the plane surface of the caliper

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CALIPER REPLACEMENT 8

8.2.18 Press the mandrel of the press-in tool (T27) firstly by

hand until it stops, then, using a hammer on the mandrel, insert 68c 68e
the cover to the end stop (see Fig.).
T27
Note: After fitting the new cover (68c or 68e), ensure that it
protrudes 15.5 mm from the plane surface of the caliper (see Fig.).

Cover Variant (68d) - Floating Bearing Side

8.2.19 Push cover (68d) over capped rubber sleeve (6d) by 15.5 mm
hand. Place tool (T08) onto cover (68d) and using a soft faced
8.2.18 - Fit cover to stop, cover should protrude 15.5 mm
hammer fit cover (68d) to the end stop (see Fig.).
Note: Use a soft faced hammer to avoid damage to tool (T08).

6d 68d
Fitting of Cover Variants with Caliper (1) and Carrier (2)
Removed from the Vehicle:
8.2.20 Check caliper slides freely along the whole length of the
guide pin arrangement (see Section 5.3).
8.2.21 Fix the carrier securely as shown i.e. bench vice, and
push the carrier against the caliper to ensure the inner boots T08
(9) are fully compressed (see Fig).

The inner boots (9) must be in a compressed state other-

wise the caliper´s freedom of movement will be limited.

8.2.19 - Fitting cover (68d)

8.2.22 Assembly of covers (10), (68a; rubber bush, 68b; open
bearing, 68c and (68e; guide sleeve and 68d; capped rubber
sleeve) can now proceed as previously described (see Section
8.2.12 - 8.2.19). 9
8.2.23 Fit the caliper complete with carrier onto the axle using
new bolts. Note the required torque value.
Note: When fitting to the axle, refer to axle and/or vehicle manu-
facturer’s recommendations

8.2.24 Fit brake pads (see Section 6.2).

8.2.25. Check adjuster function (see Section 5.2). 2
8.2.26. Fit brake actuator (18) (see Section 11.2 or 11.4).
8.2.27 Fit wheel (refer to axle and/or vehicle manufacturers
recommendations).
After any work carried out on air disc brakes, a thorough testing
of functioning and effectiveness is required. Note that during
the start-up phase, new discs and/or pads usually have a 1
bedding-in period before maximum performance is reached.

8.2.21 - Fix carrier, push carrier (2) against caliper (1)

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9 CALIPER BEARINGS REPLACEMENT

To replace the caliper bearings, all components of the fixed and 58a/b*
floating bearing must be replaced by new components. 9a/b*

9.1 Removal of Inner Boot (9)

7a/b*
9.1.1 Remove caliper (see Fig. and Section 8.1). 5a*
4a* 6a*
58c/e*
9c/e* 4b*
58d* 40a/b*
4c/e*
9.1.2 Remove ring (58) (see Fig.). 9d* 6c*
5b*
4d* 6b* 39a*
39b* 68a* 10a/b*
6e*
9.1.3 Pull out guide pins (4 and 5) (see Fig.). 39c/e*
6d*
68c/e*
39d* 68d*
*Variants
9.1.4 Ease out inner boot (9) with a screwdriver or similar tool
9.1.1 - 9.1.3 - Remove parts as described
(see Fig.).

9.1.5 Check the sealing face of inner boot (9) for damage or
corrosion (see Fig. arrow A).

Note: For caliper variants having an inner boot (9) on both bearing
sides, the steps 9.1.1 - 9.1.5 are to be carried out on both sides.

9.1.4 - Remove inner boot

9.2 Replacement of Brass Bush (7a or 7b) 9.1.5 - Check for damage or corrosion
Fixed Bearing Side
(D) T14 T13 T12 Washer
DIN 125
For ease of reference, each component of a tool is referred to
by an identification number (see section 2.1).
To remove the brass bush (7a or 7b) use the pull-out (D1)
combination (D1). Tool combination to push out the
brass bush (7)
To fit and groove the brass bush (7a or 7b) use the pull-out/
pull-in and grooving tool (D2).

(D2)
Tool combination to pull in Washer
T16 T13 T08 T14 DIN 125
brass bush (7)

9.2 - Tool combination (D)

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CALIPER BEARINGS REPLACEMENT 9

Removal of Brass Bush (7a or 7b) D1

The use of impact screwdrivers / impact wrenches in
conjunction with Knorr-Bremse service tools for air disc brakes
is not permitted. The service tools are not designed for such T12
use.
Risk of injury. Knorr-Bremse accepts no liability for damage
or injury resulting from negligence, any damage to service A
T14
tools resulting from such actions will void all warranty.

9.2.1 Clean the contact surface area (arrows A and B) as well 7a/b
as the brass bush (7a or 7b) (see Fig.)
9.2.2 Place tool (D1) in position as shown and ensure that
(T14) sits correctly into brass bush (7a or 7b). Pull out brass
bush (7a or 7b) via spindle (T13) using a ring spanner (see Fig.).
Note: Make sure that (T14) sits in the brass bush (7a or 7b).Tool
T13
(T12) must be placed square on the surface (see arrow A). Do not T14
B T14
tilt the tool when removing!
Tool (D1) in position
to extract Brass bush (7a or 7b) Tool (D1)
brass bush (7a or 7b) extracted incorrectly positioned!

Fitting of Brass Bush (7a or 7b) 9.2.1 - 9.2.2 - Remove old brass bush using tool combination (D1)

9.2.3 Prepare tool (D2) by firstly screwing (T14) onto the D2 T13
spindle (T13) until it stops and then place (T08) onto (T13). T14 T14
Place new brass bush (7a or 7b) onto (T16).
T08
9.2.4 From opposite ends place the prepared parts through
the caliper bore and screw (T13) into (T16) by hand until it
A
stops. Check the free movement of (T16); (T08) must lie square
on the surface (arrow A) (see Fig.).
9.2.5 Pull-in brass bush (7a or 7b) by turning (T14) until it
7a/b
stops (see Fig.).
9.2.6 To prevent longitudinal displacement of brass bush (7a 7a/b T16
or 7b) it must be “grooved” (see arrow B). The hexagon bolt
(arrow C) of tool (T16) must be screwed in up to its stop. This
T16
process causes deformation within the brass bush (see Fig.).

9.2.4 Positioning of 9.2.5 - Pull-in brass bush by

tool (D2)) with new brass bush turning (T14)

9.2.7 Wind back the hexagon bolt (arrow D) of tool (T16)

approximately 20 mm. Slacken brass nut (T14) and rotate tool
(T16) approximately 60°. Re-tighten brass nut (T14)and repeat T14 T14
step 9.2.6.
T08
The brass bush (7a or 7b) is now secured against longitudinal T08
displacement. Before removing tool (D2) the hexagon bolt of
tool (T16) must be screwed out again approximately 20 mm. B 7a/b 7a/b

9.2.8 Remove tool (D2) and check contact area of brass bush T16
(7a or 7b) and remove any burrs if necessary. Grease bush (7a or T16 600
7b) with white grease (Part No. II14525, K093430 or II32868).
C D

9.2.6 - Prevention of longitudinal 9.2.7 - Rotate 60°, repeat

displacement grooving

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9 CALIPER BEARINGS REPLACEMENT

9.3 Replacement of Guide Sleeve Variant (6a,

6b, 6c, 6d or 6e) Floating Bearing
6a*
For ease of reference, each component of a tool is referred to
by an identification number (see section 2.1).
Guide sleeve variants are:
6c*
6a - Rubber bush
6b* 39a*
6b - Open bearing
39b* 68a*
6c and 6e - Guide sleeve
6e*
6d - Capped rubber sleeve
39c/e*
6d*
68c/e*
39d* 68d*
*Variants

9.3 - Guide sleeve variants

The following tool combinations are used depending on the

variant: (R)
Washer T21 T20 T06 T22
DIN 125
(R1) (Ø 39 mm)
Guide sleeve (6a rubber bush and 6b open bearing) requires Tool combination
tool (R) - (R1) for removal and (R2) for fitting (see Fig.9.3a). for removing
(6a or 6b)

(R2)
Tool combination
for fitting (6a or 6b) Washer
DIN 125 T18 T20 T19
Grub screw
DIN 915 T22

9.3a - Tool combination (R)

Guide sleeve (6c and 6e; metallic version) requires tool (N) - (N1)
for removal and (N2) fitting (see Fig. 9.3b). (N)
Washer T21 T20 T14
DIN 125
(N1)
Tool combination
for removing
(6c or 6e)

(N2)
Tool combination
for fitting (6c or 6e)

Washer T05 T06 T08 T20 T14

DIN 125
(Ø 35 mm) (Ø 39 mm)

9.3b - Tool combination (N)

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CALIPER BEARINGS REPLACEMENT 9

Guide sleeve (6d capped rubber sleeve) requires tool (C) - (C2) (C) T08 Washer
T07 T10 DIN 125
with tool (T06) for fitting only. Variant (C1) is not required at this
time.
Note: The guide sleeve (6d) is removed at the time the cover (68d) (C1)
is removed (see Section 8.1.5). Therefore no special tool for the
removal process is required. Tool (C) is also required for the fitting of
the inner boot (9) variants.

(C2)

Tool combination
for fitting (6d) T06
T07 T10 Washer
DIN 125

9.3c - Tool combination (C)

9.3.1 Removal of Guide Sleeve (6a Rubber Bush or 6b

Open Bearing) Floating Bearing
T20
9.3.1.1 If present, remove guide pin (4a or 4b). (R1)
9.3.1.2 Clean the area around the bearing.
9.3.1.3 Prepare tool combination (R1) with (T06) Ø39 mm.
9.3.1.4 Place tool (R1) in position on the caliper. Hand tighten 6a/b
(T22) (see Fig.).
9.3.1.5 Hold (T22) using a ring-spanner 24 A/F and pull-out the
rubber bush (6a) or open bearing (6b) by turning tool (T20)
with a suitable tool (see Fig.).

T06
(Ø 39 mm)

T22

9.3.1.4 - 9.3.1.5 - Removal of guide sleeve (6a or 6b)

9.3.2 Removal of Guide Sleeve (6c and 6e; Guide Sleeve)

Floating Bearing
9.3.2.1 Remove guide pin (4c or 4e).
9.3.2.2 Clean the area around the bearing.
9.3.2.3 This procedure is only for guide sleeve (6c) with tab. For (6e)
without tab go to 9.3.2.5.
6c
Use a suitable tool to separate the tab from the guide sleeve
(6c) as described below:
The head of the screwdriver (or suitable tool) should be slightly
narrower than the tab and placed as close as possible to its
base (see Fig.).
9.3.2.4 separate the tab by striking the screwdriver in the
direction of the tab.
Note: The tab can be found positioned either left or right in the
caliper bore.
9.3.2.3 - 9.3.2.4 - Breaking off the tab from guide sleeve (6c)

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9 CALIPER BEARINGS REPLACEMENT

9.3.2.5 Clean the area around the bearing and brake pads.
(N1) T20

9.3.2.6 Position the tool (N1) as shown (see Fig.).

9.3.2.7 Hand tighten (T14)
9.3.2.8 Hold (T14) using a ring spanner 24 A/F and ease out the
guide sleeve (6c or 6e) by turning tool (T20) with a suitable tool T21 6c/e
(see Fig.).

9.3.3 Removal of Guide Sleeve (6d Capped Rubber Sleeve)

Floating Bearing
T14
Note: Capped rubber sleeve (6d) is removed when the cover (68d) is
removed. Therefore no removal procedure or special tool is required.
9.3.2.6 - 9.3.2.8 -Removal of guide sleeve (6c or 6e)

9.3.4 Fitting of Guide Sleeve (6a Rubber Bush or 6b Open R2

Bearing) Floating Bearing
T18
9.3.4.1 Check bore for corrosion and clean.

9.3.4.2 Wind out the grub screw (from (T19) on the tool (R2) so
it cannot contact the caliper surface (see Fig. insert). 6a/b

9.3.4.3 Push rubber bush (6a) or open bearing (6b) into (T18) of
tool (R2) (see Fig.). T19

T19
9.3.4.4 Place tool (R2) with assembled rubber bush (6a) or open Grub screw DIN 915
bearing (6b) in position on the caliper as shown (see Fig.). Grub screw T22
DIN 915

9.3.4.5 Hand tighten (T22). 9.3.4.3 - 9.3.4.5- Rubber bush and tool combination (R2) in situ
Note: Take care not to tilt the rubber bush (6a) or open bearing
(6b) when winding in.

9.3.4.6 Stabilise (T22) using an open spanner 24 A/F and using

a torque wrench (max. 45 Nm) turn (T20) to pull-in the rubber T20
bush (6a) or (6b) until it stops (see Fig.).

If the torque is < 8 Nm or > 45 Nm, then the caliper must 6a/b
be replaced.

T22

9.3.4.6 - Pull-in guide sleeve - max. torque 45 Nm

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CALIPER BEARINGS REPLACEMENT 9

9.3.4.7 Remove tool (R2).

9.3.4.8 Check that the metal ring of the rubber bush (6a) or
1
open bearing (6b) does not move (see Fig. arrow A).
A
When checking for movement, ensure that the sealing
elements are not damaged.

9.3.4.9 Grease inside the rubber bush (6a) or open bearing (6b)
with white grease (Part No. II14525, K93430 or II32868).
6a/b

9.3.4.8 - Check metal ring of guide sleeve

9.3.5 Fitting of Guide Sleeve (6c - Guide Sleeve)

The guide sleeve (6c) must be positioned so that its tab and
the groove in the caliper bore are aligned.

Note: Caliper groove can be on the left or right side of the caliper
bore.

9.3.5.1 Place (T14) onto the aligned guide sleeve (6c) and
lightly tap with a hammer to make sure it is seated correctly in
the caliper bore (see Fig.). T14

9.3.5.2 Complete the positioning of tool (N2) through the

caliper bore and guide sleeve (6c) (see Fig.).
9.3.5.3 Hand tighten spindle (T20).
6c
9.3.5.4 Stabilise spindle (T20) using a ring spanner on (T14) and
by using a torque wrench (max. 18 Nm) turn the spindle (T20)
to pull-in the guide sleeve (6c) until it stops (see Fig.). 9.3.5.1 - Guide sleeve (6c) lightly tapped in position

If the torque value is < 4 Nm or > 18 Nm, the caliper must

be replaced. N2
T14

Do not turn (T14) as this may cause the guide sleeve (6c) to
turn and lose its alignment with the groove in the caliper
bore.
6c
Remove all assembly tools.

T08
T06

T05
T20

9.3.5.2 - 9.3.5.4 tool combination (N2) in position

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9 CALIPER BEARINGS REPLACEMENT

9.3.5.5 Press in the tab of the Guide Sleeve (6c) using a punch Guide Sleeve secured
or similar tool whose width is smaller than the tab. Place the
punch as close as possible to the top of the tab and, using a
hammer, bend the tab into the groove of the caliper (see fig.)
6c
9.3.5.6 The guide sleeve (6c) is now secured against rotational
and axial movement.
Grease inside the guide sleeve (6c) with white grease (Part No.
II14525, K093430 or II32868).

9.3.5.5 - press in the tab of the guide sleeve

9.3.6 Fitting of Guide Sleeve (6d - Capped Rubber Sleeve) C2

9.3.6.1 Clean the area around the bearing.

9.3.6.2 Place capped rubber sleeve (6d) onto (T06) of tool (C2)
and place in position on caliper bore. T10
9.3.6.3 Bring the rest of tool (C) into position as shown (see
Fig.). T06 6d
9.3.6.4 Using a torque wrench turn (T10) to pull-in
(6d) until it stops with a torque between 8 Nm - 30 Nm (see
Fig.).
T07

If the torque value is < 8 Nm or > 30 Nm the caliper must

be replaced. 9.3.6.3 - 9.3.6.4 Tool combination (C2) in position

9.3.6.5 Remove tool (C2)

9.3.6.6 Check that the metal ring of the capped rubber sleeve
(6d) cannot move (see Fig. arrow A). 1

When checking for movement, ensure that the sealing A

elements of the capped rubber sleeve (6d) are not damaged.

9.3.6.7 Grease inside the capped rubber sleeve (6d) with white
grease (Part No. II14525, K93430 or II32868).
6d

9.3.6.6 - Check metal ring of capped rubber sleeve

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CALIPER BEARINGS REPLACEMENT 9

9.3.7 Fitting of Guide Sleeve (6e - Guide Sleeve)

N2
9.3.7.1 Place guide sleeve (6e) onto position on the caliper
bore and place (T14) onto the aligned guide sleeve (6e).
9.3.7.2 Complete the positioning of tool (N2) through the T14 6e
caliper bore, so that spindle (T20) passes through the guide
sleeve (6e) and into (T14) (see Fig.).
T08

9.3.7.3 Hand tighten spindle (T20). T06

T05
9.3.7.4 Stabilise spindle (T20) using a ring spanner on (T14) and T20
by using a torque wrench (max. 25 Nm) turn the spindle (T20)
to pull-in the guide sleeve (6e) until it stops (see Fig.).

If the torque value is < 4 Nm or > 25 Nm, the caliper must 9.3.7.2- 9.3.7.4 - Fit guide sleeve using tool combination (N2)
be replaced.

9.3.7.5 Remove all assembly tools.

9.3.7.6
Apply grease inside the guide sleeve (6e)
with white grease (Part No. II14525, II32868 or K093430) .

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9 CALIPER BEARINGS REPLACEMENT

9.4 Fitting of Inner Boot (9a or 9b) Fixed Bea- (C) T07 T10 T08 Washer
ring or (9c, 9d, or 9e) Floating Bearing DIN 125

For ease of reference, each component of a tool is referred to (C1)

by an identification number; a complete tool (containing one
or more such components) has been given a letter code - see
section 2.1. Tool combination for
fitting Inner Boot (9a, 9b,9c, 9e)
9.4.1 To fit the red coloured inner boot (9a, 9b, 9c or 9e ) use
the pull-in tool (C1) containing (T08).
For the black coloured inner boot (9d), use pull-in tool (C2)
(C2)
containing (T06).
Tool combination for
fitting Inner Boot (9d; black) T07 T10 T06 Washer
DIN 125
Note: The following shows only the process for the fixed bearing
side, but the assembly of the inner boot (9) is the same principle 9.4.1 - Tool combination (C)
whether for the floating or fixed bearing side.

9.4.2 The contact surface of the boot (9) on the guide pin (5)
and the caliper (1) must be clean and free of lubrication.

A
9.4.3 - check for corrosion and damage

9.4.3 Check the sealing face of inner boot (9) for damage or
corrosion (see Fig. arrow A).
T07
9

B
9.4.4 Fit new inner boot (9) into sleeve (T07) of tool (C1 or C2).
Make sure the rubber folds of the boot sit inside the tool (See
Fig. arrow B).
9.4.4 - Insert inner boot (9) in tool (T07)

9
T07

T10
9.4.5 Position sleeve (T07) of tool (C1 or C2) into the caliper
bearing bore. Then attach the assembled sleeve (T07) with T08 (T06*)
inner boot (9), pulling-in firstly by hand by turning tool (T10)
(see Fig.). *only for black inner
boot (9d)

9.4.5 - Position tool (C1 or C2) in the caliper bore and tighten by hand

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CALIPER BEARINGS REPLACEMENT 9

9.4.6 Then, pull-in with a maximum torque of 8 Nm

(see Fig.).
8 Nm
(max.)

T07

T10

T08 (T06*)
9
*only for black inner
boot (9d)

9.4.6 - Pull-in with max. 8 Nm

9.4.7 Check correct fitment of inner boot (9) by carrying out a

pulling test (see Fig.).

9.4.7 -Carry out pulling test on inner boot

9.5 Fitting of Guide Pin (5a or 5b) Fixed Bearing

9.5.1 Grease brass bush (7a or 7b) with white grease (Part No.
II14525 , K093430 or II32868).

9.5.2 Fit guide pin (5a or 5b) from outside the caliper into the
caliper bore (see Fig.).
5a/b

9
9.5.2 - Fit guide pin from outside

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9 CALIPER BEARINGS REPLACEMENT

9.6 Fitting of Guide Pin (4a, 4b, 4c, 4d or 4e)

Floating Bearing 4a/b

9.6.1 Grease guide sleeve (6a, 6b, 6c, 6d or 6e) with white
grease (Part No. II14525 , K093430 or II32868).

9.6.2 With Bearing Variant (6a; Rubber Bush) and (6b;

Open Bearing):
9.6.2.1 Fit guide pin (4a or 4b) from inside the caliper into the
caliper bore (see Fig.).

9.6.2.1 - Fit guide pin from inside caliper

9.6.3 With Bearing Variant (6c and 6e; Guide Sleeve):

9.6.3.1 Fit guide pin (4c, 4d or 4e) from outside the caliper into 4c/d/e
the caliper bore (see Fig.).

9.6.3.1 - Fit guide pin from outside caliper

9.7 Engage Inner Boot (9) into Guide Pin (4c,

4d or 4e) Floating Bearing or (5a or 5b) A
Fixed Bearing
9.7.1 The lip end of the inner boot (9) must engage in the
groove of the respective guide pin variant (see Fig. arrow A).

9.7.1 - Lip of inner boot engages in groove on guide pin (arrow A)

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CALIPER BEARINGS REPLACEMENT 9

9.7.2 Make sure the lip of inner boot (9) has fully engaged
right round the guide pin and is not twisted (see Fig. arrow B).
9
B

4c/d/e

5a/b

9.7.2 - Check complete engagement

9.7.3 Push on the ring (58) to secure engagement of inner

boot (9) on guide pin (4 and/or 5) (see Fig.).
C
The smooth face of the ring i.e. no lip (arrow C), must face
towards the brake carrier i.e. away from inner boot (9).

58
9.7.4 Fit brake caliper to carrier (see Section 8.2).

9.7.3 - Push on ring to secure boot in groove of guide pin

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10

10. CARRIER REPLACEMENT

Depending on the installation, it may be possible to remove
the caliper from the carrier and replace the carrier in situ.
Else it may be necessary or more convenient to remove the
complete carrier/calliper assembly from the vehicle where it
can be separated and the carrier replaced.
Note: The disc brake is very heavy, take great care in handling!
Do not fasten any lifting device to the pad retainer (11) since this
can be damaged.

Use only new parts from the guide and seal kit when
fitting the caliper to the carrier. This is not supplied with the
caliper and must be ordered separately.

Note: The carrier is fitted to the vehicle according to the vehicle

manufacturer’s specifications and with bolts supplied by the
vehicle manufacturer – they are not available from Knorr-Bremse.

See section 8 as applicable:

Either:

10.1 Remove caliper from carrier.

10.2 Replace carrier – ensure new bolts and correct torques are
used. Note, bolts to fit the calliper to the axle are not supplied
by Knorr-Bremse but from the vehicle manufacturer. Refer
to the vehicle manufacturer’s fitting instructions and torque
values.
10.3 Refit caliper to carrier.

Or:

10.1 Remove the complete caliper/carrier assembly.

10.2 Replace carrier.
10.3 Refit the complete caliper/carrier assembly – ensure new
bolts and correct torques are used.

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11

11. BRAKE ACTUATOR REPLACEMENT

Note: All references to brake actuators (brake chambers and
spring brakes) in this section refer to Knorr-Bremse brake actuators. 18
For other brake actuator manufacturers, follow their respective
instructions.

11.1 Removal of Knorr-Bremse Brake Chamber

11.1.1 Disconnect air connection from brake chamber (18) –
take care, air connection must be free of air pressure!

11.1.2 Unscrew brake chamber mounting nuts and remove

brake chamber (18) (see arrows in Fig.).

It is not allowed to reuse the nuts of the brake chamber (18).

11.1.2 - Brake chamber removal

11.2 Fitting of Knorr-Bremse Brake Chamber

Note: New brake chambers (18) have drain plugs installed (see
arrow 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).

11.2.1 The sealing surface and the flange surface (see Fig. arrow 19
B) must be:
- free from dust and corrosion
18
- free from damage
- flat
Take care that no dirt enters the brake caliper! B
11.2.2 Before fitting the new brake chamber, the
spherical cup (19) of the lever and the sealing surface of the A
caliper must be greased with white grease (Part No. II14525, 11.2.1 - 11.2.2 - Check seal and flange surface of caliper,
K093430 or II32868). grease spherical cup and flange surface

> 3 mm
Do not use grease containing molybdenum
disulphide. Use only actuators which are recommended by
the vehicle manufacturer.

11.2.3. The seal, as well as the push rod area of the brake
chamber (18) (see arrow C) must be clean and free of
lubrication.
The seal must not show any signs of damage.
C
Note, if the brake chamber’s seal protrudes less than 3 mm the
brake chamber must be replaced (see Fig.).

11.2.3 - Check seal, min. 3 mm

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11 BRAKE ACTUATOR REPLACEMENT

11.2.4 Attach brake chamber using new nuts (see Fig.).

In order not to tilt the brake chamber during its attachment, 18
the nuts must be gradually tightened symmetrically with a
suitable tool.

11.2.5 Tighten the nuts according to the specifications of the

actuator manufacturer.
Note: only use new self-locking nuts.

11.2.6 Connect air hose, making sure that the hose is not
twisted and chafing is not possible.

11.2.7 Check air connection for leakage.

11.2.4 - Attach brake chamber

Check function and effectiveness of the service brake

system.

11.3 Removal of Knorr-Bremse Spring Brake

Chock wheels before releasing spring brake to ensure the

vehicle cannot roll away.

11.3.1 Release parking brake.

11.3.2 Screw-out release bolt (arrow D) to the release position

D
(refer to the vehicle manufacturer’s recommendations) (see
Fig.).
11.3.2 - Screw out release bolt

11.3.3 Apply parking brake.

11.3.4 Disconnect air connections from spring brake (18) –

take care, air connections must be free of air pressure. 18

11.3.5 Unscrew spring brake mounting nuts (see arrows) and

remove the spring brake (18) (see Fig.).

It is not allowed to reuse the nuts of the spring brake (18).

11.3.5 - Knorr-Bremse spring brake removal

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BRAKE ACTUATOR REPLACEMENT 11

11.4 Fitting of Knorr-Bremse Spring Brake

Note: New spring brakes (18) have drain plugs installed (see arrow
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. 19

11.4.1 The sealing surface and the flange surface (see Fig. arrow
B) must be:
- free from dust and corrosion
- free from damage
- flat B
A
Take care that no dirt enters the brake caliper!
11.4.2 Before fitting the new spring brake, the spherical cup 11.4.1 - 11.4.2 - Check seal and flange surface of caliper,
(19) in the lever and the sealing surface must be greased with grease spherical cup
white grease (Part No. II14525, K093430 or II32868).

Do not use grease containing molybdenum

disulphide. Use only actuators which are recommended by
the vehicle manufacturer.

11.4.3 The seal, as well as the push rod area of the

spring brake (18) (see arrow C) must be clean and free of C
lubrication.
The seal must not show any signs of damage.
Note, if the spring brake’s seal protrudes less than 3 mm the spring
brake must be replaced (see Fig.).

11.4.4 Attach the spring brake using new nuts (see Fig.). 11.4.3 - Check seal, min. 3 mm
Note: In order not to tilt the spring brake during its
attachment, the nuts must be gradually tightened symmetrically
with a suitable tool.

11.4.5 Tighten the nuts according to the specifications of the

actuator manufacturer.
Note: Only use new nuts

11.4.6 Connect air hoses, making sure that the hoses are not
twisted and chafing is not possible.
11.4.7 Release parking brake.
11.4.8 Screw in spring brake release bolt as per instructions on
the spring brake itself.
11.4.9 Check air connections for leakage.

Check function and effectiveness of the service brake

system and parking brake system.
11.4.4 - Knorr-Bremse spring brake fitting

63
Your local TruckServices Workshops, Dealers and Branches can be found anytime online
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(available for Android and iOS).

Knorr-Bremse System für Nutzfahrzeuge GmbH

Moosacher Strasse 80
80809 Munich
Germany
Tel: +49 89 3547-0
Fax: +49 89 3547-2767
WWW.KNORR-BREMSECVS.COM

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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.
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