Service Manual: Pneumatic

Service Manual
C16352-EN-005
Pneumatic
Disc Brake
SB6.../SB7...
Axial and Radial Disc Brake
KNORR-BREMSE
Systems for Commercial Vehicles
C16352: EN: 005: MAX1: Released:Webmaster: 2010/07/21-17:35:19

Index
Page
1 Overview
1.1 Axial Disc Brake Components............................................................................. 4
1.2 Axial Disc Brake Identification and Service Kits................................................... 5
1.2.1 Axial Disc Brake Wear Indicator Kits .................................................................. 5
1.3 Radial Disc Brake Components.......................................................................... 6
1.4 Radial Disc Brake Identification and Service Kits ............................................... 7
1.4.1 Radial Disc Brake Wear Indicator Kits ................................................................ 7
1.5 Brake Disc.......................................................................................................... 8
2 General Information
(for Axial and Radial Disc Brakes)
2.1 Service Tools...................................................................................................... 9
2.2 Diagnostic Equipment......................................................................................... 9
2.3 Lubrication.......................................................................................................... 9
2.4 Torque Requirements......................................................................................... 9
3 Description and Function

3.1 Axial Disc Brake Sectioned View......................................................................... 10
3.2 Description of Operation..................................................................................... 11
3.2.1 Brake Actuation.................................................................................................. 11
3.2.2 Brake Release..................................................................................................... 11
3.2.3 Brake Adjustment (automatic)............................................................................. 11
3.3 Radial Disc Brake Sectioned View...................................................................... 12
3.4 Description of Operation..................................................................................... 13
3.4.1 Brake Actuation.................................................................................................. 13
3.4.2 Brake Release.................................................................................................... 13
3.4.3 Brake Adjustment (automatic)............................................................................. 13
4 Inspection Points for the Axial and Radial Disc Brake ................................. 14
4.1 Safety Instructions for Service Work and Repair Work........................................ 15
5 Functional and Visual Checks

5.1 Wear Check of Pads and Brake Discs................................................................ 16
5.1.1 Brake Wear Check using Rubber Bush (6a, 6d).................................................. 18
5.1.2 Brake Wear Check using Rubber Bush (6b)........................................................ 19
5.1.3 Brake Wear Check using Rubber Bush (6c, axially ribbed).................................. 20
5.1.4 Wear Indicators................................................................................................... 21
5.1.5 Diagnostic Equipment - Hand held device ZB9031-2......................................... 21
5.2 Adjuster Check................................................................................................... 22
5.2.1 Version without Shear Adapter (61)..................................................................... 22
5.2.2 Version with Shear Adapter (61).......................................................................... 23
5.3 Caliper Checks................................................................................................... 25
5.3.1 Caliper Running Clearance.................................................................................. 25
5.3.2 Caliper Movement along Guide Pins................................................................... 25
5.3.3 Rubber Bush to Guide Pin Clearance................................................................. 25
5.4 Check of Seals.................................................................................................... 27
5.4.1 Caliper Guide Pin Seals....................................................................................... 27
5.4.2 Check of Tappet and Boot Assembly (13).......................................................... 27
6 Pad Replacement
6.1 Pad Removal ..................................................................................................... 28
6.1.1 Version without Shear Adapter (61)..................................................................... 28
6.1.2 Version with Shear Adapter (61).......................................................................... 29
6.2 Pad Fitting.......................................................................................................... 30
6.3 Wear Indicator Fitting (Normally Closed or Normally Open Type)......................... 31
6.3.1 Cable Guide Type (105)...................................................................................... 32
6.3.2 Cable Guide Type (105a)..................................................................................... 32
6.3.3 Protection Plate (104)......................................................................................... 32

7 Replacement of Tappet and Boot Assemblies (13) as well as Inner Seals (22)
7.1 Tappet and Boot Assemblies (13) Removal........................................................... 33
7.1.1 Threaded Tubes (16) Inspection............................................................................ 34
7.2 Inner Seals (22) Replacement................................................................................ 34
7.3 Tappet and Boot Assemblies (13) Fitting............................................................... 35
8 Caliper Replacement
8.1 Caliper Removal................................................................................................... 37
8.2 Caliper Fitting....................................................................................................... 38
8.2.1 Fitting of Caliper (1) to Carrier (2).......................................................................... 38
8.2.2 Fitting of Outer Boot (10)...................................................................................... 39
8.2.3 Fitting of Steel Cap (10a)...................................................................................... 39
8.2.4 Fitting of Cap (68)................................................................................................. 40
9 Replacement of Inner Boot (9) .......................................................................... 41

10 Guide Pin Bush Replacement

10.1 Brass Bush (7) Replacement................................................................................. 43
10.2 Rubber Bush (6a or 6b) Replacement................................................................... 44
10.3 Rubber Bush (6c or 6d) Replacement................................................................... 44
10.3.1 Removal of Rubber Bush (6c or 6d)...................................................................... 45
10.3.2 Fitting of Rubber Bush (6c or 6d).......................................................................... 45
11 Carrier Replacement .......................................................................................... 46

12 Brake Actuator Replacement

12.1 Brake Chamber Removal...................................................................................... 47
12.2 Brake Chamber Fitting ......................................................................................... 47
12.3 Spring Brake Removal.......................................................................................... 48
12.4 Spring Brake Fitting.............................................................................................. 48
PLEASE NOTE
This Service manual is intended for the exclusive use of trained persons within the commercial vehicle industry
and workshops, and must not be passed to any third party.
This service manual has been prepared to assist customers to carry out their own service work on the product
and does not purport to be all-inclusive or to contain all of the information necessary for this. No responsibility
is assumed as a result of this or as a result of incorrect or inappropriate parts being fitted to the product.
Knorr-Bremse SFN cannot accept any nor offer any guarantee regarding data accuracy, completeness or
timeliness. The information in this service manual does not represent any guarantees or ensured
characteristics in terms of the German civil code.
No liability can be accepted based on the information, its use, recommendations or advice provided within this
service manual. In no event may we be held liable for any damage or loss except in the case of wilful intent or
gross negligence on our part, or if any mandatory legal provisions apply.
Brand names mentioned in this service manual are not identified as such in all cases. We would emphasise
however, that they are nevertheless subject to the provisions of trademark legislation.
Text and graphics created by us are subject to our regulations on utilisation and exploitation and may only be
copied or reproduced with our express permission.
Any legal disputes arising from the use of this service manual or the information contained within shall be
subject to German law.
Failure of any individual clause of this disclaimer to comply with current legal provisions does not affect the
validity of the remaining clauses.
This disclaimer is an English translation of a German text, which should be referred to for all legal purposes.

1 Overview
1.1 Axial Disc Brake Components

(for Wear Indicators see Section 1.2.1)
11 44
26
45
12/2
18/1 18/2 4d*)
Weißes Montagefett 4c*)
4b*) 12/1
12
White assembly grease 4a*)
Grünes Montagefett
Green assembly grease
6d*)
1
13
6b*)
39d*)
6c*)
37
39c*)
61*)
68*) 6a*)
37a*) 7 161
39b*)
39a*)
5 22
5a*) 9 58
Weißes Montagefett
White assembly grease
40 40a*)
31*) 10*)
31a *)
mikroverkapselt
10a * ) pre-applied adhesive 2
1 Caliper
FD00249/1
2 Carrier 18/1 Spring Brake

4a*) Guide Pin 18/2 Brake Chamber
4b*) Guide Pin 22 Inner Seal
4c*) Guide Pin 26 Spring Clip
4d*) Guide Pin 31 Outer Boot Clip
5 Guide Pin 31a*) O-Ring
5a*) Guide Pin 37 Adjuster Cap
6a*) Rubber Bush 37a*) Adjuster Cap
6b*) Rubber Bush 39a*) Caliper Bolt
6c*) Rubber Bush 39b*) Caliper Bolt
6d*) Rubber Bush 39c*) Caliper Bolt
7 Brass Bush 39d*) Caliper Bolt
9 Inner Boot 40 Caliper Bolt
10 Outer Boot 40a*) Caliper Bolt
*) Variants
10a*) Steel Cap 44 Pad Retainer Pin
See also contents leaflet in the Service Kit
11 Pad Retainer (reinforced) 45 Washer
12 Pad (complete) 58 Ring
12/1 Pad 61*) Shear Adapter
12/2 Pad Holder Spring 68*) Cap
13 Tappet and Boot Assembly 161 Tappet Bush

1.2 Axial Disc Brake Identification and Service Kits
Type of Caliper Knorr-Bremse Part No.

Axle-or Vehicle
Manufacturer`s No.
Date of Manufacture
ATTENTION!
Use only genuine Knorr-Bremse parts!
The following Service Kits are available :
Description Contents
Carrier 2
4a*), 5, 6a*), 7, 9, 10*), 31*), 39a*), 40, For specific Service Kit Part
Guide Pins and Seal Kit 58, (4b*), 4c*), 4d*), 5a*), 6b*), 6c*), Numbers for each Disc Brake,
6d*), 10a*), 31a*), 39b*), 39c*), 39d*), see Disc Brake Product
40a*), 68*))
Set for Rubber Bush 4a*), 6a*), 39a*), (4b*), 6b*), 39b*))
Catalogue (Part
Tappet and Boot Kit (2 pieces) 13, 22, 161 Number Y000875)
Set for Outer Boot and Steelcap (6 pieces) 10, 31, 10a*), 31a*) or
Adjuster Cap (10 pieces) 37, 37a*), 61*) www.knorr-bremsesfn.com
Pad Kit (per axle) 11, 12, 26, 37, 37a*), 44, 45, 61*)
Wear Indicator Kit (per axle) see section 1.2.1
Exchange Caliper r.h.
only in assembled condition see Identification Plate
Exchange Caliper l.h. on the Caliper
1.2.1 Axial Disc Brake Wear Indicator Kits *) Variants
Type 4
Type 1
Type 2
105a
Type 5
FD00306
Alternative to
Item 105
Type 3
Type 6
101 Sensor
102 Sensor 115 Spring Washer
104 Cable Protection Plate 116 Screw
105 Cable Guide 117 Wear Indicator Cable
105a Cable Guide 119 Bracket
112 Clip 120 Bracket

1.3 Radial Disc Brake Components
(for Wear Indicators see 1.4.1)
18/1
11 44
18/2 26
45
4d*)
4c*) 12/2
Weißes Montagefett 4b*)
4a*)
White assembly grease 12
Grünes Montagefett 12/1
6d*)
13
6b*)
39d*)
6c*) 37
39c*)
61*)
68*) 6a*)
37a*) 7 161
39b*)
39a*) 5 22
5a*)
9 58
Weißes Montagefett
40 40a*)
31 10
31a *) mikroverkapselt
VF00113/2-Äi05
10a * ) pre-applied adhesive

1 Caliper 2
2 Carrier 18/1 Spring Brake
4a*) Guide Pin 18/2 Brake Chamber
4b*) Guide Pin 22 Inner Seal
4c*) Guide Pin 26 Spring Clip
4d*) Guide Pin 31 Outer Boot Clip
5 Guide Pin 31a*) O-Ring
5a*) Guide Pin 37 Adjuster Cap
6a*) Rubber Bush 37a*) Adjuster Cap
6b*) Rubber Bush 39a*) Caliper Bolt
6c*) Rubber Bush 39b*) Caliper Bolt
6d*) Rubber Bush 39c*) Caliper Bolt
7 Brass Bush 39d*) Caliper Bolt
9 Inner Boot 40 Caliper Bolt
10 Outer Boot 40a*) Caliper Bolt
10a*) Steel Cap 44 Pad Retainer Pin *) Variants
45 Washer See also contents leaflet in the Sevice Kit
11 Pad Retainer (reinforced)
12 Pad (complete) 58 Ring
12/1 Pad 61*) Shear Adapter
12/2 Pad Holder Spring 68*) Cap
13 Tappet and Boot Assembly 161 Tappet Bush

1.4 Radial Disc Brake Identification and Service Kits
Type of Caliper Knorr-Bremse Part No.

Axle-or Vehicle
Manufacturer`s No.
Date of Manufacture
ATTENTION!
Use only genuine Knorr-Bremse parts!
The following Service Kits are available :
Description Contents
Carrier 2
4a*), 5, 6a*), 7, 9, 10*), 31*), 39a*), 40, For specific Service Kit Part
Guide Pins and Seal Kit 58, (4b*), 4c*), 4d*), 5a*), 6b*), 6c*), Numbers for each Disc Brake,
6d*), 10a*), 31a*), 39b*), 39c*), 39d*), see Disc Brake Product
40a*), 68*))
Set for Rubber Bush 4a*), 6a*), 39a*), (4b*), 6b*), 39b*))
Catalogue (Part
Tappet and Boot Kit (2 pieces) 13, 22, 161 Number Y000875)
Set for Outer Boot and Steelcap (6 pieces) 10, 31, 10a*), 31a*) or
Adjuster Cap (10 pieces) 37, 37a*), 61*) www.knorr-bremsesfn.com
Pad Kit (per axle) 11, 12, 26, 37, 37a*), 44, 45, 61*)
Wear Indicator Kit (per axle) see section 1.2.1
Exchange Caliper r.h.
only in assembled condition see Identification Plate
Exchange Caliper l.h. on the Caliper
1.4.1 Radial Disc Brake Wear Indicator Kits *) Variants
Type 4
Type 1
Type 2
105a
Type 5
FD00306
Alternative to
Item 105
Type 3
Type 6
101 Sensor
102 Sensor 115 Spring Washer
104 Cable Protection Plate 116 Screw
105 Cable Guide 117 Wear Indicator Cable
105a Cable Guide 119 Bracket
112 Clip 120 Bracket

1.5 Brake Disc
When replacing the Discs, please refer to the instructions of the Vehicle Manufacturer.
This should also be done when fitting Knorr-Bremse Brake Discs.
When replacing Discs, please adhere to the recommended bolt tightening torques.
The use of non-approved Brake Discs will reduce levels of safety and invalidate warranty.
Brake Discs can be ordered through the Knorr-Bremse Aftermarket Organisation.
Detailed information can be found in our Disc Brake Product Catalogue (Part Number Y000875) or
at www.knorr-bremsesfn.com.

2 General Information
2.1 Service Tools
Part Number Description

ll19252 Press-in Tool for Tappet and Boot Assembly (13)
ll19253 Pull-in Tool for Inner Boot (9)
ll19254 Pull-in/Pull-out Tool for Brass Bush (7)
II32202 Wedged Fork for removal of Tappet and Boot Assembly (13)
II36797 Grooving Tool for Brass Bush (7)
Z001105 Press-in Tool for Steel Cap (10a)
Z004198 Pull-in/Pull-out Tool for Rubber Bush (6c) and (6d)
Z003934 Press-in Tool for Cap (68)
Z004361 Press-in Tool for Inner Seal (22)
Service tool kit ZB9032 (Part No. II37951004EN) contains the above listed tools for
items 7, 9, 10a, and 13 as well as this Service manual and a service video. The service
video in English is available separately in the UK as Part No. KBP2060/1 and in other
territories as B98283EN.
The tools for items 6c, 6d, 22 and 68 are not part of the Service Tool Kit ZB9032
(Part No. II37951004EN)
2.2 Diagnostic Equipment

Part Number Description
ZB9031-2 hand held device for checking
Potentiometer function (also Pad plus Disc
ll40598F wear) when 13 pin chassis plug installed.
ZB9031-2 replaces ZB9031
2.3 Lubrication
Part Number Colour Quantity

ll14525 white 5g
II32793 green 8g
ll32868 white 500g
Z000046 green 500g
Important Note: The correct grease MUST be used for each Bush !
2.4 Torque Requirements
Item Number Torque Spanner Size

(mm)
39a; 39b; 39c; Caliper Bolts (x2) 180 Nm
39d; 40; 40a; M16x1,5 - 10.9 plus 90° 14
Brake Chamber, Spring Brake
Hexagon Nuts M16x1,5 (x2)
+30
(self-locking) EN ISO 10531 180 Nm 24

3 Description and Function
3.1 Axial Disc Brake Sectioned View
1 Caliper
2 Carrier
4b*) Guide Pin
5*) Guide Pin
6b*) Rubber Bush
6c*) Rubber Bush
7 Brass Bush
9 Inner Boot
10*) Outer Boot
10a*) Steel Cap
12 Pad (complete)
13 Tappet and Boot Assembly
16 Threaded Tube
17 Bridge
18/1 Spring Brake
18/2 Brake Chamber
19 Lever
20 Eccentric Bearing
22 Inner Seal
23 Adjuster Unit
24 Turning Device
26 Spring Clip
27 Spring
28 Spring
30 Chain
31 Outer Boot Clip
31a*) O-Ring
32 Chain Wheel
33 Wear Sensor
37 Adjuster Cap
37a*) Adjuster Cap
39b*) Caliper Bolt
40*) Caliper Bolt
43 Bolt
44 Pad Retainer Pin
45 Washer
46 Disc
61*) Shear Adapter
68*) Cap *) Variants
161 Tappet Bush
10

3.2 Description of Operation
(Floating Caliper principle)
3.2.1 Brake Actuation
During actuation, the Push Rod of the Actuator (18/1

or 18/2) moves the Lever (19). The input forces are
transferred via the Eccentric Bearing (20) to the
Bridge (17). The force is then distributed by the
Bridge (17) and the two Threaded Tubes (16) to the
Tappet and Boot Assemblies (13) and finally to the
inboard Pad (12).
After overcoming the running clearance between the

Pads and the Disc, the reaction forces are
transmitted to the outboard Pad (12). The clamping
forces on the Pads (12) and the Disc (46) generate
the braking force for the wheel.
3.2.2. Brake Release
After releasing the air pressure, the two Return

Springs (27/28) push the Bridge (17) and Lever (19)
back to the start position; this ensures a running
clearance between Pads and Disc is maintained.
3.2.3 Brake Adjustment (automatic)
To ensure a constant running clearance between

Disc and Pads, the brake is equipped with a low
wearing, automatic adjuster mechanism.
The Adjuster (23) operates with every cycle of
actuation due to the mechanical connection with
Lever (19). As the Pads and Disc wear, the running
clearance increases. The Adjuster (23) and Turning
Device (24) turn the Threaded Tubes (16) by an
amount necessary to compensate for this wear. The
total running clearance (sum of clearance both sides
of Disc) should be between 0.5 and 1.0 mm.; smaller
clearances may lead to overheating problems.
11

3.3 Radial Disc Brake Sectioned View
31a*)
7 31 10
9 5*) 40*)
161
10a*)
16
24
22
33
44
32
26
45
61*)
11
30
1 Caliper
17
2 Carrier
4b*) Guide Pin 37
5*) Guide Pin
6b*) Rubber Bush 43
6c*) Rubber Bush 37a*)
7 Brass Bush 23
9 Inner Boot 1
68*)
10*) Outer Boot
2
10a*) Steel Cap
13 39b*) 4b*) 6b* )
VF 00113/3-Äi03
12 Pad (complete)
6c* )
13 Tappet and Boot Assembly
16 Threaded Tube
17 Bridge 12
18/1 Spring Brake
18/2 Brake Chamber
19 Lever
20 Eccentric Bearing
22 Inner Seal
23 Adjuster Unit
24 Turning Device
26 Spring Clip
27 Spring
28 Spring
30 Chain
27; 28 20 19 18/1; 18/2
31 Outer Boot Clip
31a*) O-Ring
32 Chain Wheel
33 Wear Sensor
37 Adjuster Cap 46
37a*) Adjuster Cap
39b*) Caliper Bolt
40*) Caliper Bolt
43 Bolt
VF 00113/4
44 Pad Retainer Pin

45 Washer
46 Disc
61*) Shear Adapter
68*) Cap *) Variants
161 Tappet Bush
12

3.4 Description of Operation
(Floating Caliper principle)
3.4.1. Brake Actuation
During actuation, the Push Rod of the Actuator (18/1

or 18/2) moves the Lever (19). The input forces are
transferred via the Eccentric Bearing (20) to the
Bridge (17). The force is then distributed by the
Bridge (17) and the two Threaded Tubes (16) to the
Tappet and Boot Assemblies (13) and finally to the
inboard Pad (12).
After overcoming the running clearance between the

Pads and Disc, the reaction forces are transmitted to
the outboard Pad (12). The clamping forces on the
Pads (12) and the Disc (46) generate the braking
force for the wheel.
3.4.2. Brake Release
After releasing the air pressure, the two Return

Springs (27/28) push the Bridge (17) and Lever (19)
back to the start position; this ensures a running
clearance between Pads and Disc is maintained.
3.4.3 Brake Adjustment (automatic)
To ensure a constant running clearance between

Disc and Pads, the brake is equipped with a low
wearing, automatic adjuster mechanism. The
Adjuster (23) operates with every cycle of actuation
due to the mechanical connection with Lever (19). As
the Pads and Disc wear, the running clearance
increases. The Adjuster (23) and Turning Device (24)
turn the Threaded Tubes (16) by an amount
necessary to compensate for this wear. The total
running clearance (sum of clearance both sides of
Disc) should be between 0.5 and 1.0 mm.; smaller
clearances may lead to overheating problems.
13

4 Inspection Points for the Axial and Radial Disc Brake
Despite the use of long-life materials, it is necessary to check some of the components regularly for their
general condition. The following points ensure a long-life and trouble-free operation of the disc brake. The
inspection frequencies specified are minimum values. Depending on the vehicle application a more frequent
check of the components may be necessary.
The brake pad wear must be checked visually on a regular basis, e.g. each time the tyre pressures are
checked, or at least every three months (see Sections 5.1.1, 5.1.2, 5.1.3).
At least annually inspect the pad to disc running clearance and the correct fitting and condition of the Outer
Boot (10) or Steel Cap (10a) and the Adjuster Cap (37 or 37a) (see Section 5.3.1).
With each Pad change check for the correct functioning of the Adjuster (see Section 5.2) and the smooth
operation of the caliper over its full range of movement (see Section 5.3.2). Also inspect the Tappet and
Boot Assemblies (13), the Adjuster Cap (37 or 37a) and the sealing elements (6c, 9, 10, 10a, 31, 58, 68)
for correct fitting and condition.
The brake discs are to be checked according to the specification of the axle or vehicle manufacturer.
In the unlikely event of a problem, all relevant components - e.g. Pads (12/1) and Pad Holder
Springs (12/2) - must be returned in order that an objective investigation of the cause can be made.
11 44
26
45
12/2
18/1 18/2 4d*)
Weißes Montagefett 4c*)
4b*) 12/1
12
White assembly grease 4a*)
Grünes Montagefett
6d*)
1
13
6b*)
39d*)
6c*)
37
39c*)
61*)
68*) 6a*)
37a*) 7 161
39b*)
39a*)
5 22
5a*) 9 58
Weißes Montagefett
40 40a*)
31*) 10*)
31a *)
mikroverkapselt
10a *) pre-applied adhesive 2
FD00249/1
14

4.1 Safety Instructions for Service Work and
Repair Work
Please also refer to the relevant safety instructions for

repair work on commercial vehicles, especially for
jacking up and securing the vehicle.
Use only original Knorr-Bremse parts.
ATTENTION!
Before starting service work, ensure the

service brake and parking brake, as well
as the bus stop brake with buses, are not
applied and that the vehicle cannot
roll away.
Please follow service manual instructions and adhere

to the wear limits of the Pads and the Discs - see
Section 5.1.
Use only recommended tools - see Section 2.1.
Tighten bolts and nuts to the recommended torque

values - see Section 2.4.
ATTENTION!
Screw threads and tapped holes must be
clean and dry (free of lubrication).
After re-fitting a wheel according to the Vehicle

Manufacturer’s recommendations, please ensure that
there is sufficient clearance between the tyre inflation
valve, the caliper and the wheel rim, to avoid damage
to the valve.
After service work:

Check the brake performance and the system
behaviour on a rolling road.
15

5 Functional and Visual Check
5.1 Wear Check of Pads and Brake Discs
ATTENTION!
For optimum safety, stay within the Disc and Pad Wear Limits.
Sketch 1
Pads
The thickness of the Pads must be checked regularly

dependent on the usage of the vehicle.
The Pads should be checked corresponding to any
legal requirements that may apply.
If a Wear Indicator has not been fitted or is not
connected, this should be at least every 3 months.
If friction material is less than 2mm (see E, Sketch 3),

the Pads must be replaced.
Minor damage at the edges is permitted (see arrow,

Sketch 1). Sketch 2
Major damage on the surface of the Pad is not

permitted (see arrow, Sketch 2).
Discs
Measure thickness at thinnest point. Avoid measuring Sketch 3

near the edge of the disc as a burr may be present.
C A
A = Disc thickness
new condition = 45 mm
worn condition = 37 mm (must be replaced)
C = Overall thickness of Pad (new condition) 30mm
D = Backplate 9mm
E = Minimum thickness of friction material 2mm D E
F = Minimum allowed thickness in worn condition
for backplate and friction material 11mm
(replacement of Pads necessary).
If the disc dimension A ≤ 39 mm, it is

M+P-KN-002Äi01
recommended that the Disc should be renewed

together with the Pads. F
ATTENTION!
If these recommendations are ignored, there is a danger of brake failure.
16

Check Disc at each change of Pads for grooves and
cracks. A1 B1
a
The diagram shows possible surface conditions. max. 0,75 x a
max. 1,5 mm
A1 = Small cracks spread over the surface
are allowed
B1 = Cracks less than 1.5mm deep or wide, running

in a Radial direction are allowed D1 C1
A
C1 = Grooves (circumferencial) less than 1.5mm
deep are allowed
D1 = Cracks in the vanes are not allowed and the

Disc MUST BE REPLACED.
VF 00127/3/Äi01
a = Pad contact area
Note:
In case of surface conditions A1, B1 and C1, the Disc
can continue to be used until the minimum
thickness A of 37mm is reached.
Knorr-Bremse Discs are normally service-free and

grinding when changing Pads is not necessary.
However, grinding could be useful, e.g. to increase
the load-bearing surface of the Pads after severe
grooving on the entire friction surface has occurred.
To meet safety requirements, the minimum thickness
after regrinding must be greater than 39 mm.
In addition, the recommendations of the Vehicle
Manufacturer MUST be followed.
ATTENTION!
If these recommendations are ignored, there is a danger of brake failure. If the Pads
are worn down to the backplate or if Disc wear is excessive, brake
performance will be severely affected and may be lost completely.
17

5.1.1 Brake Wear Check using Rubber Bush (6a; 6d): For all Axial and Radial Disc Brakes except
those listed in Section 5.1.2 and 5.1.3. These Calipers do not have a cast rib in position B (see also
Section 5.1.2)
1 1
4a/4d 4a/4d
6a/6d 6a/6d
B
M+P-KN-005Äi01
C
D
The condition of the Pads can be visually determined B = without rib (see also Section 5.1.2)
without removing the road wheel by viewing the C = pin protrusion - shown in new condition
position of the Guide Pin (4a or 4d) in the Caliper (1). D = 1 mm or less - Pads and Disc must be checked
with road wheel removed
If dimension ‘C’ is less than 1mm, a more accurate
check of the Pads and Disc must be made.
If necessary change the Pads - see Section 6, or the

Disc - see Vehicle Manufacturer’s recommendations.
18

5.1.2 Brake Wear Check using Rubber Bush (6b): Only for Axial Disc Brakes SB 7541,
SB 7551 to SB 7629, SB 7639 and Radial Disc Brakes SB 7102, SB 7112, SB 7103, SB 7113,
SB 7104, SB 7114, SB 7105, SB 7115, SB 7108, SB7118, SB 7109, SB 7119, SB 7120, SB 7130.
These Calipers do have a cast rib in position B (see also Section 5.1.1)
1 1
4b 4b
6b 6b
B
C
M+P-KN-006Äi01
D
The condition of the Pads can be visually determined B = with rib (see also Section 5.1.1)
without removing the road wheel by viewing the C = new condition
position of the Guide Pin (4b) in the Caliper (1). D = 18 mm or more, Pads and Disc must be
checked with road wheel removed
If the head of the Guide Pin (4b) is inside the Rubber
Bush (6b) by a dimension D greater than 18mm, then
a more accurate check of the Pads and Disc must
be made.
If necessary change the Pads - see Section 6, or the

Disc - see Vehicle Manufacturer’s recommendations.
19

5.1.3 Brake Wear Check using Rubber Bush (6c, axially ribbed): For all Axial and Radial Disc Brakes
which are equiped with a Rubber Bush that is axially ribbed (see H in sketch).
1
1
4c
4c
G
6c 6c
FD00190/1Äi02
"X" G "Z"
The condition of the Pads can be visually Wear Limit (see “Z”)
determined without removing the road wheel, by
viewing the position of the Wear Indicator “G”. When the Rubber Bush (6c) is retracted to the level
“G” of the Wear Indicator as shown, the wheel must
be removed so that the wear of the Pads and Disc
can be checked.
If necessary change the Pads - see Section 6 or the
New Condition (see “X”) Disc - see Vehicle Manufacturer’s recommendations.
The position of Wear Indicator “G” on the Rubber

Bush (6c) in new condition.
20

5.1.4 Wear Indicators
Due to different Vehicle Manufacturer and vehicle

types there are several types of Pad Wear Indicator
used.
a) In-pad Normally Closed Indicator - Circuit is

broken when Pad Wear reaches limit.
b) In-pad Normally Open Indicator - Circuit is
made when Pad Wear reaches limit.
M+P-KN-007
c) Wear Indicator using built in Potentiometer. This
is available either as an on/off version or
as a continuous signal version which can be
linked to the vehicle’s electronic monitoring
systems.
An optical or acoustic device may be linked to any of

the above.
Note:
Please also refer to specifications provided by the
Vehicle Manufacturer.
M+P-KN-008
5.1.5 Diagnostic Equipment
The Knorr-Bremse Diagnostic Unit ZB9031-2 is a

hand held device suitable for vehicles that are fitted
with Knorr-Bremse Disc Brakes using a continuous
signal type of Wear Indicator Potentiometer.
The wear condition of each brake can be measured
13-Pin Plug
by connecting the device to a suitable 13 pin socket
(DIN 72570)
(DIN 72570) where fitted. This socket will have
to Vehicle
been connected to each sensor by the vehicle
manufacturer.
The Diagnostic unit allows:
- Quick and simple wear check.
- A check of the potentiometer function.
- A simultaneous check of up to six brakes,
without removing the wheels.
Plug to Potentiometer
(Disc Brake)
A detailed instruction manual is included with
each unit.
21

5.2 Adjuster Check
5.2.1 Version without Shear Adapter (61)
ATTENTION!

23
applied and that the vehicle cannot 37
roll away.
M+P-KN-039/Äi01
Remove wheel.
The caliper assembly should be pushed inboard on

its Guide Pins. Using a suitable tool, press the
inboard pad (12) away from the Tappets and check
the gap between Tappet and inboard pad backplate
- it should be between 0.5mm & 1.0mm. If the
running clearance is too small or large, the adjuster
may not be functioning correctly and should be
checked as follows.
Remove Adjuster Cap (37).

23
ATTENTION!
Do not overload or damage the Adjuster 37

(23). Use only 8mm Ring Spanner or 1/4”
M+P-KN-015/Äi01
drive Socket with a lever length no greater
than 100mm. A maximum torque of
25 Nm is admissible.
DO NOT use an Open Ended Spanner
since this may damage the Adjuster shaft. 1
The Adjuster should be turned anti-clockwise for 2 or
3 clicks (increasing running clearance).
ATTENTION!
Make sure that the Ring Spanner or
Socket can turn freely clockwise
during following procedure.
By applying the brake (to at least 2 Bar) 5 - 10 times

the Spanner or Socket should turn clockwise in small
M+P-KN-043
increments if the Adjuster is functioning correctly

(see notes below).
NOTE:
As the number of applications increases, incremental
movement will decrease.
NOTE:
If the Spanner or Socket does not turn or turns only
with the first application or turns forward and
backward with every application, the automatic
Adjuster has failed and the Caliper must be replaced.
Even if Pads are not being changed, a new Adjuster

Cap (37) should be fitted having lightly greased it with
white grease (available as Part No. II14525 or
II32868).
22

5.2.2 Version with Shear Adapter (61)
ATTENTION!

61 37a
roll away.
Remove wheel.
FD00150/1
The caliper assemply should be pushed inboard on
its Guide Pins. Using a suitable tool, press the
inboard pad (12) away from the Tappets and check
the gap between Tappet and inboard pad backplate
- it should be between 0.5mm & 1.0mm. If the
running clearance is too small or large, the adjuster
may not be functioning correctly and should be
checked as follows.
Pull off the Adjuster Cap (37a) using the tag, taking
care not to lose the Shear Adapter (61).
The Adjuster (23) must be turned with the Shear
23
Adapter (61) anti-clockwise for 2 or 3 clicks 61 37a
(increasing running clearance).
ATTENTION!
FD00151/1
Never turn Adjuster (23) without Shear
Adapter (61) being fitted. If the given
shear torque of the Shear Adapter is 1
exceeded, then it is destroyed. Try with a
new (unused) Shear Adapter. With a
second failure of the Shear Adapter the
Caliper must be exchanged since internal
damage is present. Do not use an open
ended spanner, because it may damage
the Shear Adapter (61).
ATTENTION!
Make sure that the Ring Spanner or

Socket can turn freely clockwise
during following procedure.
By applying the brake (to at least 2 Bar) 5 - 10 times

the Spanner or Socket should turn clockwise in small
increments if the Adjuster is functioning correctly
(see notes below).
NOTE:
As the number of applications increases, incremental
movement will decrease.
M+P-KN-043
NOTE:
If the Spanner or Socket does not turn or turns only
with the first application or turns forward and
backward with every application, the automatic
Adjuster has failed and the Caliper must be replaced.
23

Even if Pads are not being changed, a new Adjuster
Cap (37a) should be fitted having lightly greased it
with white grease (available as Part No. II14525 or
37a
II32868).
Note:
The tag of the Adjuster Cap (37a) should be
positioned as shown by the arrow in the adjacent
diagram. This ensures access is maintained for
FD00144/1
subsequent removal. Removal of the Adjuster Cap
with e.g. a screwdriver is not recommended since
the seal may be damaged.
24

5.3 Caliper Checks
5.3.1 Caliper Running Clearance

31a* )
ATTENTION!
as the bus stop brake with buses, are not 10a* )
9 5*) 7
roll away. 10
By pushing and pulling the Caliper in an axial

direction by hand (see arrow A in adjacent sketch), a
movement of 0,5 - 1.0 mm must possible.
If using hand pressure only (no tools) the Caliper is
not movable, the Caliper guidance must be further
examined (see Section 5.3.2).
5.3.2 Caliper Movement along Guide Pins
Remove Pads (see Section 6.1)
Clean dirt from Guide Pin (4a, 4b, 4c, 4d) (see arrows
in Sketch).
Using hand pressure only (no tools), the Caliper (1)

must slide freely along the whole length of the Guide
Pin arrangement. This movement should be greater
than 25mm.
4b* ) 6b*)
1
68*)
M+P-KN-013-Äi03
5.3.3 Rubber Bush to Guide Pin Clearance
A
Note:
Before removing the wheel, note that there is no *) Pay attention to the variants 6c* )
contact between Caliper and axle, vehicle, chassis
sections or Carrier. If necessary the Rubber Bush
(6a, 6b, 6c, 6d), must be replaced (see Section 10.2,
10.3).
To measure the clearance, the following steps must

be taken:
Remove the wheel. Refer to Vehicle Manufacturer’s

recommendations.
Remove Pads (see Section 6.1).
Fully wind-back the Tappet and Boot Assemblies (13)

by rotating the Adjuster (23) in an anti-clockwise
direction (see Section 5.2.1, 5.2.2).
FD00196/6
Slide Caliper as far as possible towards the outside

Sketch 1
of the vehicle (see Sketch 1).
25

Push the Caliper in the direction of the arrow (see
Sketch 2).
Note that there is no contact between Caliper and
axle, vehicle, chassis sections or Carrier. If
necessary the Rubber Bush (6a, 6b, 6c, 6d), must be
replaced (see Section 10.2 and 10.3).
Whilst maintaining pressure on the Caliper, measure
X
the distance ‘x’ (see Sketch 2).
Pull the Caliper away from the Carrier and measure

distance ‘y’ (see Sketch 3).
FD00196/4
If the distance (y-x) is greater than 3mm, the Rubber Sketch 2
Bush (6a, 6b, 6c, 6d) must be replaced (see Section
10.2 and 10.3).
Fit Pads (see Section 6.2).
Fit the wheel. Refer to Vehicle Manufacturer’s

recommendations.
FD00196/5
Sketch 3
26

5.4 Check of Seals
5.4.1 Caliper Guide Pin Seals 31a* )
The Guide Pin (5, 5a ) is sealed with the Inner Boot

(9) and the Adjuster Cap (10) or the Steel Cap (10a)
and the O-Ring (31a). The items (9) and (10) or (10a)
must not show signs of cracking or damage. On ver-
sions with Rubber Bush (6c) this is also to be 10a* )
9 5*) 7
checked for damage.
10
Check for correct location and fitment.
Note:
It may be necessary to remove the Pads to inspect
the Inner Boot (9) - dependant on the amount of pad
wear.
If necessary repair Caliper with suitable Service Kit

(see Section 1.2 or 1.4).
4b*) 6b*)
1
68*)
5.4.2 Check of Tappet and Boot Assembly (13)
FD00205
If necessary remove Pads (12) (see Section 6.1) and *) Pay attention to the variants 6c* )
screw the Adjuster (23) clockwise (see Section 5.2.1,
5.2.2) until the boots are clearly visible.
Note:
The tappets should not extend more than 30 mm
(see sketch).
The Tappet and Boot Assemblies (13) must not show

any signs of damage.
13
Check for correct location and fitment.
M+P-KN-012/Äi01
Note:
The penetration of dirt and humidity into the brake
will lead to corrosion and impair the function of the 30
Disc Brake.
If necessary replace Tappet and Boot Assemblies

(see Section 7).
27

6 Pad Replacement
(for Axial- and Radial Disc Brakes)
ATTENTION!
Before starting repair work, ensure the

roll away.
6.1 Pad Removal
Remove wheel (refer to Vehicle Manufacturer’s

recommendations).
Note:
Before removing Pads it is strongly recommended
that the Adjuster mechanism is checked for correct 44
operation (see Section 5.2).
Remove Clip (26) and Washer (45), depress the Pad 11
M+P-KN-010
Retainer (11) and remove Pin (44). 45
If necessary remove any in-pad wear sensor
components and discard. 26
If the Pad Retainer (11) is corroded or damaged, it
should be replaced.
6.1.1 Version without Shear Adapter (61)
Remove Adjuster Cap (37).
Fully wind-back the Tappet and Boot Assemblies (13)

direction (see Section 5.2.1).
23
ATTENTION!
Do not overload or damage the Adjuster

(23). Use only 8mm Ring Spanner or 1/4” 37
drive Socket with a lever length no greater
M+P-KN-011/Äi01
than 100mm. A maximum torque of

25 Nm is admissible. 12
DO NOT use an Open Ended Spanner
since this may damage the Adjuster shaft. 12
Push inboard Pad (12) toward Actuator.
Pull out both Pads (12).
28

6.1.2 Version with Shear Adapter (61)
Pull off the Adjuster Cap (37a) using the tab, taking
care not to lose the Shear Adapter (61).
Fully wind-back the Tappet and Boot Assembly (13)

by rotating the Adjuster (23) in an anti-clockwise 23
23
direction (see Section 5.2.2). 6137
37a
ATTENTION!
Never turn Adjuster (23) without Shear
FD00152/1
Adapter (61) being fitted. If the given
shear torque of the Shear Adapter is 12
exceeded, then it is destroyed. Try with a 12
new (unused) Shear Adapter. With a
second failure of the Shear Adapter the
Caliper must be exchanged since internal
damage is present. Do not use an open
ended spanner, because it may damage
the Shear Adapter (61).
Push inboard Pad (12) toward Actuator.
Pull out both Pads (12).
29

6.2 Pad Fitting
ATTENTION!
Pads must be changed as an axle set
and NOT individually. Use only Pads which
are permitted by the vehicle
manufacturer, axle manufacturer and disc
brake manufacturer. Failure to comply
with this may invalidate the vehicle
manufacturer’s warranty
Note:
Fully wind-back the Tappet and Boot Assemplies (13)
direction (see Section 5.2.1, 5.2.2) - Do not
overload the Adjuster (23). 1
Clean the Pad abutments.
Push Caliper (1) outboard and fit the outboard Pad
(12).
Push Caliper (1) inboard and fit the inboard Pad (12).
Fit new In-pad Wear Indicator kit, if appropriate (see
Section 6.3 and 1.2.1 or 1.4.1).
Install the cable so that it can not be damaged.
Rotate the Adjuster clockwise until the Pads come
M+P-KN-014
into contact with the Disc - Do not overload the
Adjuster (23).
12
Then turn back the Adjuster 2 clicks (see Section
5.2.1, 5.2.2).
The hub should turn easily by hand after having
applied and released the brake.
37a
The Adjuster Cap (37 or 37a) must then be replaced
(use only a new Cap) having lightly greased it with
white grease (available as Part No. II14525 or
II32868).
Note:
The tag of the Adjuster Cap (37a) should be
positioned as shown by the arrow in the adjacent
Sketch. This ensures access is maintained for
subsequent removal. Removal of the Adjuster Cap
FD00144/1
with e.g. a screwdriver is not recommended since

the seal may be damaged.
After setting the Pad Retainer (11) into the groove of
the Caliper (1), it must be depressed to enable the
positioning of Pad Retainer Pin (44).
Fit washer (45) and Spring Clip (26) to the Pad
Retainer Pin (44) (use only new parts).
It is recommended that Pad Retainer Pin (44) is
installed pointing downwards (see Sketch).
Re-fit wheel according to the Vehicle Manufacturer’s
recommendations.
44
1
ATTENTION! 11
M+P-KN-016
New Pads need bedding in. Heavy or 45

long duration braking should initially be
avoided. 26
30

6.3 Wear Indicator Fitting
(Normally Closed or Normally Open Type)
101
Remove Pads (12) - see Section 6.1.

outer Pad
Wear Indicator Kits (for SB6... / SB7...) consist of
items as shown in Section 1.2.1 and 1.4.1.
Insert the Wear Indicator Cables (101) into the groove 12/1 12/1
of the Pads. The Wear Indicators snap into place in
FD00237/2
the holes in the Pad material.
The longer end of the Wear Indicator cable (see
arrow) must be fitted in the outer Pad.
Insert Pads (12/1) into the Pad abutments (see

Section 6.2).
FD00237/1
12/1
Fit Pad Holder Springs (12/2) onto the Pads (12/1).

Pay attention to correct installation of Wear Indicator 12/2
Cable (101) (see arrows).
12/2
101 FD00237/3
12/1
Fit Pad Retainer (11), Pad Retainer Pin (44), Washer

(45) and Spring Clip (26) (see Section 6.2)
Pay attention to correct installation of the Wear 44
Indicator Cable (101) (see arrows). 11
45
26
101
FD00237/4
31

6.3.1 Cable Guide Type (105)
Fit Cable Guide (105) onto the Pad Retainer (11).
In the right position, the Cable Guide (105) snaps into
place by pressing it lightly onto the Pad Retainer (11).
105
FD00237/5
Press Wear Indicator Cable (101) into the locating
tabs of the Cable Guide (105) (see arrows A). 101
The short cable end of the Wear Indicator Cable
(101) must not be secured by locating tabs of the B
Cable Guide (105). A
According to vehicle type, install the cable loom that
leads to the electrical supply of the vehicle, in one of short cable end
the two locating tabs (see arrows B).
B
A
FD00237/6
6.3.2 Cable Guide Type (105a)
Install Indicator Cable (101) in the middle of the Pad 101 105a
Retainer (11).
Insert Cable Guide (105a) at one side of the Pad
Retainer (11) (see arrow B).
Slightly press in on the other side of the Pad Retainer C
(11) (see arrows A). The Cable Guide (105a) snaps A A
into place.
According to vehicle type, install the cable loom that
leads to the electric supply of the vehicle, in one of
the wire loop (see arrows C).
C
The short end of the Wear Indicator Cable (101)
FD00305
must not be secured by a wire loop of the Cable B

Guide (105a) (see arrows C).
6.3.3 Protection Plate (104)
Fit the Cable Protection Plate (104).

104
Pay attention to the correct position of the Cable
Protection Plate’s catch (see arrows). 11
Exert hand pressure to the Cable Protection Plate
(104); it will snap into place.
FD00237/7
32

7 Replacement of Tappet and Boot
Assemblies (13) as well as
Inner Seals (22) .
The components of the tools are referred to by item Press-in Tool Press-in Tool
number for ease of reference. arrangement for arrangement for
Tappet and Boot Tappet and Boot
Assembly (13) when Assembly (13) when
To remove the Tappet and Boot Assembly (13) use Caliper is fitted on the Caliper is removed
vehicle. from the vehicle.
the Wedge Fork (A) (Part No. II32203).
To fit the Tappet and Boot Assembly (13) use the

Press-in Tool (B) (Part No. II19252).
Wedge Fork (A) Press-in Tool (B)
To fit the Inner Seal (22), use the Press-in Tool (L) Press-in Tool Werkzeug-
arrangement for Press-in Tool
(Part No. Z004361). Inner Seal (22) when arrangement for
Caliper is fitted on the Inner Seal (22) when
vehicle. Caliper is removed
from the vehicle.
Press-in Tool (L)
7.1 Tappet and Boot Assemblies (13) Removal
Note:
It may be easier to remove the Caliper from the axle
to replace the Tappet and Boot Assemblies (13) (see
Section 8.1).
The Adjuster (23) must be screwed clockwise until

the Boots can be reached (max. 30 mm) (see
Section 7.1.1). B
To remove the Tappet Boot from the Caliper bore, a
Screwdriver should be used to deform the Boot 13
location ring - see diagram.
13
ATTENTION!
Ä i02
Great care must be taken not to damage M+P-KN-017/
the Sealing Seat of the Tappet Boot since
it is not a replaceable item. 30
See arrow X in adjacent Sketch.
The Tappet and Boot Assemblies (13) can be

removed from the Threaded Tubes (16) by using
Wedge Fork (A) (Part No. II32202).
Remove the old Tappet Bush (161). A

Check Inner Seal (arrow X) and if damaged, the
Caliper must be replaced (see Section 8). 13
Note: 22 x
If the sealing seat of the Tappet Boot has been
A 13
damaged the caliper must be replaced (see Section
8.1).
VF 00127/4/Äi03
The Inner Seal (22) must also be replaced if Tappet

and Boot Assemblies (13) have been removed (see
Section 7.2).
161
33

7.1.1 Threaded Tubes (16) Inspection
Place an unworn Pad (12) into the outboard gap

to avoid overrunning of the Threaded Tubes.
ATTENTION! 12
Threaded Tubes should not overrun the 16
inner thread of the Bridge.
The Caliper must be replaced if
synchronisation is lost.
46
M+P-KN-019
For the inspection of the threads, the tubes must be
screwed out (max. 30mm) by turning the Adjuster
(23) clockwise.
If Caliper is not installed on axle, put a spacer E

(length = 70mm) into the Caliper (1) to avoid
overrunning of the Threaded Tubes (16) when
screwing them out (see adjacent Sketch). During 70 mm
screwing, the threads can be checked for corrosion
damage.
In case of water ingress or corrosion, the Caliper
must be replaced (see Section 8).
16 E
VF 00127/13
1
7.2 Inner Seals (22) Replacement
Fully wind back the Threaded Tubes (16) by turning

the Shear Adapter (61) anti- clockwise (see Section
5.2). A
Clean area of the Inner Seal (22).
To remove the Inner Seal (22) a Screwdriver (A)

should be used - see adjacent Sketch.
ATTENTION! A
The sealing face (X) for the Inner Seal
(22), as well as the Threaded Tubes (16)
22
FD00297
must not be damaged. They cannot be

replaced (see Section 7.1).
Clean sealing face (X) .

L
Fit each Inner Seal (22) onto a Threaded Tube (16).
With Caliper installed on axle
Remove the Tappet Bush (161).

Position Tool (L) (Part No. Z004361) with the short
X
strut in the position shown. 22
The Tool (L) is guided over the spigot of the
Threaded Tube (16).
Fully press in the Inner Seal (22) by rotating Tool (T3)
FD00298
using a spanner - see adjacent Sketch. L
34

To check the correct fit of the Inner Seal (22), screw
out the Threaded Tubes (16) about 4-5 threads by
turning the Adjuster (23) or (according Version) with
Shear Adapter (61) clockwise.
The Inner Seal (22) must not turn.
L
With Caliper not installed on axle
The fitting sequence of Inner Seal (22) does not 16

change. 22 L
When pressing in the Inner Seal (22) however, use
the long strut (T3+T4) for Tool (L) (Part No. Z004361)
FD00299
- see page 33.
7.3 Tappet and Boot Assemblies (13) Fitting

B
With Caliper installed on axle:
Grease threads with white grease (Part No. II14525
or II32868). 161
Screw back Threaded Tubes (16), by turning the 13

Adjuster (23) or (according Version) with Shear
Adapter (61) anti-clockwise (see Section 5.2.1,
5.2.2).
The sealing seat in the caliper for Tappet and Boot

VF 00127/5-Äi01
Assemblies (13) must be clean and free of grease.

Sketch 1
Place new Tappet Bush (161) onto the spigot of the
Threaded Tube (16).
B
Place Tappet and Boot Assembly (13) onto the 13
Tappet Bush.
Use Push-in Tool (B) with the short strut (T3)

(Part No. II19252) for positioning and pressing-in the
Boot - see Sketch 1.
Using Tool (B) in reverse, the Tappet can be pressed

M+P-KN-022Äi01
onto the Tappet Bush - see Sketch 2.
Sketch 2
35

With Caliper not installed on axle
Grease threads with white grease (Part No. II14525
or II32868).
B
Screw back Threaded Tubes (16), by turning the
Adjuster (23) or (according Version) with Shear
13
Adapter (61) anti-clockwise (see Section 5.2.1,
5.2.2).
The sealing seat in the caliper for Tappet and Boot
M+P-KN-021Äi01
Assemblies (13) must be clean and free of grease.
Place new Tappet Bush (161) onto the spigot of the

Threaded Tube (16). Sketch 3
Place Tappet and Boot Assembly (13) onto the

Tappet Bush.
Use Push-in Tool (B) with the long strut (T3+T4) (Part
No. II19252) for positioning and pressing-in the Boot,
- see Sketch 3. 13
Using the Tool (B) in reverse, the Tappet can be
pressed on to the Tappet Bush - see Sketch 4.
M+P-KN-023Äi01
Sketch 4
36

8 Caliper Replacement
To remove and to fit the Steel Cap (10a) use the

Press-in Tool (G) (Part No. Z001105).
To fit the Cap (68) the Press-in Tool (K) (Part No.
Z003934) must be used.
8.1 Caliper Removal

Remove Pads (see Section 6.1).
Remove Actuator (see Section 12.1, 12.3). Press-in Tool (G) Press-in Tool (K)
Disconnect Potentiometer Type Wear Indicator if

fitted.
Note: 10
It may be necessary to remove the Caliper (1) and
the Carrier (2) as a single unit, depending upon the 31
vehicle installation, in line with vehicle manufaturer’s 39
recommendations. 10a 31a
Proceed as follows if the Caliper (1) is to be removed 31
from the Carrier (2), with the Carrier remaining on the
M+P-KN-024-Äi01
vehicle. 40
Remove Outer Boot Clip (31) and take off Outer Boot 10
(10), or on Calipers with Steel Cap (10a) and O-Ring
(31a), place tool (G) (Part No. Z001105) onto the
Steel Cap and tighten the threaded pins. Then use
hammer as shown.
On Calipers with Rubber Bush (6c) pull the Cap (68)
from the Guide Pin (4c) using a suitable tool (see
Sketch).
Remove Caliper Bolts (39a, 39b, 39c or 39d) and (40
or 40a).
ATTENTION!
Before removing the Caliper Bolts (39 and
40) ensure that the Caliper (1) cannot
move or fall when the Caliper Bolts are
removed causing damage or injury.
ATTENTION!
Do not damage Rubber Bush (6c).
If necessary replace it by means of a
Rubber Bush and Guide Pin kit.
ATTENTION!
Hold Caliper only at its outer side.
Never get your fingers between
Caliper and Carrier!
Do not fasten any lifting device to the Pad
Retainer (11), since this can be damaged.
Remove Caliper from Carrier.
37

ATTENTION!
The opening or dismantling of the
Caliper is not authorised.
Use only Genuine Knorr-Bremse
Replacement Calipers.
8.2 Caliper Fitting
FD00114
The correct choice of Caliper must be ensured by Sketch 1
checking the part number on the identification label
(see arrow in sketch 1) .
The replacement Caliper may have a plastic cap or

adhesive tape in the area of the actuator attachment
(see arrow in sketch 2). Remove the cap or tape
after installing the caliper on the vehicle. Alternatively,
if the replacement Caliper has a breakthrough
diaphragm, it should be left in place (see arrow in
FD00116
sketch 3).
Sketch 2
Note:
The service exchange Caliper includes seals and
Guide Pins. The Pads are not included.
If the service exchange Caliper is equiped with a
potentiometer, then the connectoin must be closed
using the appropriate mating plug - refer to Vehicle
Manufacturer’s recommendations.
ATTENTION!
Hold Caliper only at its outer side.
Never get your fingers between Sketch 3
Caliper and Carrier!
Do not fasten any lifting device to the Pad
Retainer (11), since this can be damaged.
8.2.1 Fitting of Caliper (1) to Carrier (2)
Note: 10a 31a

It may be necessary for reasons of accessibility to fit
39
the Caliper and Carrier assembly as a single unit to
the vehicle - refer to Vehicle Manufacturer’s 31
recommendations.
ATTENTION!
40
10
FD00113
Screw threads and tapped holes must be

clean and dry (free of lubrication).
ATTENTION!
The Guide Pins (4 and 5) as well as the
Caliper Bolts (39 and 40) are highly
stressed items. They must be replaced
whenever the Caliper (1) is removed
from the Carrier (2).
9
Screw in Caliper Bolts (39a, 39b, 39c, 39d) and (40,
40a) and tighten to 180 Nm + 90°.
Check that the Caliper slides easily on the Guide
Pins.
M+P-KN-027
Check the position of the Inner Boot (9) on the Guide

Pin (5, 5a). 5
Check Adjuster function (see Section 5.2). 58
38

When the Caliper and Carrier Assembly with Steel Clamping device
Cap (10a) is not fitted to the vehicle, move the 9
Caliper against the Carrier and retain using a suitable
clamping device so that the Inner Boot (9) is in a
compressed condition. This is to prevent air being
trapped when Steel Cap (10a) is fitted. Direction
of pressure
Fit new Outer Boot (10) or Steel Cap (10a) (see

Section 8.2.1, 8.2.2).
Fit the Pads, if not already fitted (see Section 6.2).
FD00110EN
If the Caliper and Carrier Assembly is to be fitted as a
single unit to the vehicle, do so in line with the
Vehicle Manufacturer’s recommendations.
Attach Brake Chamber or Spring Brake (see Section

12.2 or 12.4).
8.2.2 Fitting of Outer Boot (10)

39 31
Check that the seat for the Outer Boot (10) on the
Caliper (1) is free of grease and fit the Outer Boot.
Tighten Outer Boot Clip (31).

31
M+P-KN-042
Pay attention to correct fitment of the Outer Boot
Clip (31) and check Outer Boot (10) for damage.
8.2.3 Fitting of Steel Cap (10a)
ATTENTION!
Replacing Outer Boot (10) with Steel
Cap (10a).
This is only allowed if Guide Pin (5) and
10
Caliper Bolt (40) are also replaced with
the Guide Pin (5a) and Caliper Bolt (40a).
Replace only with the permission of axle
or Vehicle Manufacturer. On SB6... (19.5”) 31 5a
Calipers, only permissable after
manufacturing date A0026 40a
(see identification lable).
FD00108Äi01
31a
ATTENTION! 10a
ATTENTION!
The Steel Cap (10a) and the O-Ring
(31a) must only be used once.
39

When the Caliper is on the vehicle the fitting of the
Steel Cap (10a) must be carried out with the Pads
installed. 31a
- Clean area.
- Using the white Grease supplied (II14525), lightly
lubricate the O-Ring (31a) and place it over the cast
spigot (see Sketch).
- Remove threaded pins from assembly tool G
(Part No. Z001105) to avoid damaging the
FD00106- i01
Steel Cap.
- Hold the new Steel Cap on the end of the spigot.
2mm
By using a suitable press or assembly tool (G) and
a hammer, press the Steel Cap fully on the spigot
making sure not to deform the Cap.
After removal, the Steel Cap and the O-Ring must

never be re-used.
8.2.4 Fitting of Cap (68) K

68
Fit the Cap (68) using Tool (K) (Part No. Z003934)
and a hammer. Force the Cap (68) into the Guide Pin
(4c) until it contacts the Caliper Bolt. The seal is
achieved by the compression of the lip of the Rubber
Bush (6c) between the Guide Pin (4c) and Cap (68) 6c
(see view “Y”). 4c
"Y"
FD00182/1
68
40

9 Replacement of Inner Boot (9)
To fit the Inner Boot (9) use the Pull-in Tool (C) (Part
No. II19253).
Pull-in Tool (C)
Remove Caliper (see Section 8.1).
Remove Ring (58).
Pull out Guide Pin (5 or 5a).
Push out Inner Boot (9) with screwdriver.
5, 5a
M+P-KN-025-Äi01
58
ATTENTION!
9
The Sealing Seat of Inner Boot (9) in
the Caliper must not be damaged
(see arrow A in adjacent Sketch).
7 A
Inspect and clean contact area of Inner Boot (9).

9 9
Check for corrosion (see arrow A in adjacent Sketch). C
Check Brass Bush (7) for dirt and replace if Ä i02
M+P-KN-026/
damaged (see Section 10).
Put new Boot (9) into the Sleeve of the Tool (C) (Part B
No. II19253). See arrow B in adjacent Sketch.
Pay attention that the Bellow-folds of Inner Boot (9)

are positioned within the tool.
Position Sleeve with Inner Boot (9) into the Caliper

bore and tigthen by hand.
Then pull in with a maximum torque of 8 Nm.
Note:
Pay attention to the correct position of Inner Boot (9).
Carry out a pulling check (see adjacent Sketch).
41

Grease Brass Bush (7) with white grease (Part No.
II14525 or II32868).
Fit Guide Pin (5 or 5a).
The Boot end must engage in the groove of the

Guide Pin (5 or 5a) (see arrow).
Fit Ring (58) by pushing until it engages.

58
VF 00127/15-Äi01
Fit Caliper (see Section 8.2).
5, 5a 9
42

10 Guide Pin Bush Replacement
(for Axial and Radial Disc Brakes) Pull-in/Pull-out Tool
arrangement for
pulling in/out
Brass Bush (7)
In order to remove and fit Brass Bush (7) use the

Grooving Tool (F)
Pull-in/Pull-out Tool (D) (Part No. II19254).
To groove Brass Bush (7), Grooving Tool (F) (Part No.

II36797) must be used.
Remove Caliper (see Section 8.1). Pull-in/Pull-out Tool (D)
Remove Guide Pin (5 or 5a) and Inner Boot (9) (see

Section 9).
10.1 Brass Bush (7) Replacement 7 D

Pull out Brass Bush (7) with Tool (D) (Part No.II19254)
- see Sketch 1.
If Caliper has a groove (see arrow A):

Pull in new Brass Bush (7) with Tool (D)
- see Sketch 2.
Remove Tool (D).
To prevent longitudinal displacement of the
VF 00127/16
new Brass Bush (7) it must be grooved
(see arrow B). Sketch 1
Before insertion of the Grooving Tool (F)
(Part No. II36797), its hexagon screw must
be wound out so that the head of the screw
is approximately 20mm from the tool face
Insert the Grooving Tool (F) fully into the
A D
Brass Bush (7).
Wind in the hexagon screw of the Grooving
Tool (F) to its stop.
Slacken the screw and rotate the Grooving
Tool (F) in the Brass Bush (7) by
approximately 60 degrees.
Again wind in the hexagon screw of the
Grooving Tool (F) to its stop. VF 00127/17-Äi01
The new Brass Bush (7) is now firmly

retained in the Caliper (see arrow B). 7
Before removing the Grooving Tool (F), its Sketch 2
hexagon screw should be wound out
approximately 20 mm.
If Caliper has no groove:

(Note: Groove is always located on the
inboard side).
hexagon
screw
Pull in new Brass Bush (7) with Tool (D)
- see Sketch 2.
Check contact area of Brass Bush (7) for burrs and

remove any burrs.
Grease Bush with white Grease (Part No. II14525 or

II32868).
Sketch 3
43

10.2 Rubber Bush (6a or 6b) Replacement
Note:
A short or long version of the Rubber Bush (6a or
6b) is possible. The two versions are not 6a
interchangeable - see Sketch 4.
If necessary remove the Caliper (see Section 8.1).
Remove Guide Pin (4a or 4b).
Pull Rubber Bush (6a or 6b) out of bore.
M+P-KN-030-Äi02
Check bore for corrosion, clean and if necessary use
a corrosion protection paint (e.g. Zinc spray).
6b 4a/4b
Sketch 4
Note:
Grease new Rubber Bush (6a or 6b) inside and
outside with green Grease (Part No. II32793 or
Z000046). 6a
ATTENTION!
Under no circumstances must the white
Grease (containing mineral oil) be used for
lubricating the Rubber Bush (6a or 6b) and
Guide Pin (4a or 4b). Use only synthetic
based green Grease
(Part Number II32793 or Z000046).
M+P –KN –031Äi01

Deform new Rubber Bush (6a or 6b) and push from
the inside of the Caliper into the bore.
Push Rubber Bush (6a or 6b) so that the external
positioning ring(s) locate in the groove(s) (see arrows).
6b
ATTENTION!
Assemble Guide Pin (4a or 4b).

Re-fit Caliper (see Section 8.2).
FD00206
Note:
Torque Caliper Bolts (39a) and (39b) to 180 Nm plus
90°. Check that the Caliper slides easily.
Washer
ATTENTION! Pull-in Tool
arrangement for
DIN 125 Pull-out Tool
arrangement for
Screw threads and tapped holes must be pulling in the pulling out the
Rubber Bush (6c) or Rubber Bush (6c) or
clean and dry (free of lubrication). (6d) (6d)
10.3 Rubber Bush (6c or 6d) Replacement

If necessary remove Caliper (see Section 8.1).
Use tool (H) (Part No. Z004198) for the assembly of
the Rubber Bush (6c or 6d), (see adjacent picture).
Note: Threaded Pin
Depending upon shape of the Rubber Bush (6c or DIN 915 Discs
6d) the appropriate disc must be selected, for

pressing out (see also Section 10.3.2). Pull-in / Pull-out Tool (H)
44

10.3.1 Removal of Rubber Bush (6c or 6d)
Remove Guide Pin (4c or 4d) .
Clean Caliper in the area of the Rubber Bush.
Select appropriate disc for pressing out the Rubber

Bush (6c or 6d). The disc locks into the Rubber
Bush.
Pay attention to the size of the Disc
Position the Tool (H) (Part No. Z004198) as shown in
the adjacent picture. Lightly screw on the nut by
hand.
Hold the nut with a ring spanner and with a suitable

socket or ring spanner tighten to remove the Rubber
Bush.
10.3.2 Fitting of Rubber Bush (6c or 6d)
Check bore for corrosion and clean.
Rubber Bush (6c) is existing in two different versions.
Make sure, that the diameter (ø) of the Metal Ring is 6c 6c

the same as the diameter (ø) of the Rubber Bush
Stopper.
Metal Ring
ATTENTION!
If the wrong Rubber Bush (6c) is 35 39
fitted, it can become loose, affect the
Caliper Movement along the Guide Pins
and reduce the braking force.
Insert Metal Ring of the Rubber Bush (6c or 6d) into 35 39 FD00313
the caliper bore.
ATTENTION! Rubber Bush Stopper
The Metallic Sleeve of the Rubber Bush
(6c or 6d) must not enter the caliper bore
by more than 4 mm.
If the Metallic Sleeve of the Rubber Bush
Caliper 6c
(6c or 6d) enters the caliper bore by more
than 4 mm then the caliper bore is worn
and the Caliper must be replaced. "z" Metallic Sleeve z
Unscrew Threaded Pin in the Tool (H), so that there is
max. 4 mm
6c
no projection at the contact surface - see sketch 2
on page 46.
Push Rubber Bush (6c or 6d) into the Tool (H) - see
sketch 1 on page 46.
FD00319
Position Tool (H) with Rubber Bush (6c or 6d) as

Metal Ring
shown in adjacent picture - see sketch 1 on page 46.
45

Lightly screw on the nut by hand. Sketch 1
Screw in Threaded Pin until it contacts the Caliper in
order to adjust possible unevenness at the contact
surface - see sketch 2.
Rubber Bush (6c or 6d)
Using Torque Wrench pull in Rubber Bush (6c or 6d)
(min. 8 Nm up to max. 45 Nm). Contact Surface
Note:
Do not tilt the Rubber Bush (6c) or (6d) when
pulling-in.
Remove the Tool.
Threaded pin
ATTENTION!
If the torque is < 8 Nm or > 45 Nm,
then the Caliper must be replaced. Sketch 2
Failure to replace the Caliper could lead
to a guidance failure.
ATTENTION!
The Metal Ring (see arrows in sketch 3)
must not move. When checking for
movement, then the Sealing Elements of
the Rubber Bush (6c or 6d) must not be
damaged.
Grease the interior of the Rubber Bush (6c or 6d)
with white Grease (Part No. Il14525 or II32868).
ATTENTION!
4c 6c
Push Guide Pin (4c or 4d) from the inside of the

Caliper into the Rubber Bush (6c or 6d).
11 Carrier Replacement
FD00198
ATTENTION!
Before removing Caliper / Carrier bolts Sketch 3
ensure that the Caliper / Carrier cannot
move or fall when the bolts are removed
causing damage or injury.
If necessary remove Caliper (see Section 8.1).

Remove Carrier (2) from axle.
Note:
Do not fasten any lifting device to the Pad Retainer
(11), since this can be damaged.
2
Clean axle contact area.
Fit new Carrier (2) with new bolts from the relevant
Vehicle Manufacturer. Bolts are not supplied by
M+P-KN-036
Knorr-Bremse.
It may be necessary, to firstly attach the Caliper (see
Section 8.2).
46

12 Brake Actuator Replacement
(for Axial and Radial Disc Brakes) B
12.1 Brake Chamber Removal
A
Disconnect air hose from Brake Chamber (18/2)
Unscrew Brake Chamber Mounting Nuts (see arrow

B). They must not be re-used.
18/2
VF 00127/10-Äi01
Remove Brake Chamber
B
12.2 Brake Chamber Fitting
Note:
New Brake Chambers (18/2) have drain plugs
installed (see arrows A). Remove lowest plug (as
viewed when Brake Chamber is installed). All other
drain holes should be plugged. Refer to the Vehicle
M+P-KN-034-Äi02
Before fitting the new Brake Chamber, the sealing
surface (see arrow C) must be cleaned, and the
Spherical Cup (19) in the Lever must be greased with
C
white Grease (Part No. II14525 or II32868).
19
The surface area of the flange must be damage free
and clean.
The Seal, as well as the piston area - see arrow in

adjacent picture - must be clean and dry.
ATTENTION!
Do not use Grease containing

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

(self-locking EN ISO 10513).
In order not to tilt the Brake Chamber, screw Nuts
step by step alternately with a suitable tool and
+30
torque tighten to 180 Nm.
Connect air hose and check for leakage.
Make sure that hose is not twisted and that chafing

is not possible.
ATTENTION!
Check function and effectiveness

of the brake.
47

12.3 Spring Brake Removal A
ATTENTION! B
A
Chock wheels before releasing
Spring Brake.
D 18/1
Release parking brake, move Hand Control Valve to
‘run’ position.
Screw-out Release Bolt (arrow D) with a maximum

B
VF 00127/11-Äi01
torque of 35 Nm (refer to the Vehicle Manufacturer’s
recommendations).
Release air from brake, move Hand Control Valve to

‘park’ position.
Disconnect air hoses from Spring Brake (18/1).
Unscrew Spring Brake Mounting Nuts (see arrow B).

They must not be re-used.
Remove Spring Brake.
12.4 Spring Brake Fitting
M+P-KN-034-Äi02
Note: C
New Spring Brakes (18/2) have drain plugs 19
installed (see arrows A). Remove lowest plug (as
viewed when Spring Brake is installed). All other drain
holes should be plugged. Refer to the Vehicle
ATTENTION!
On Radial Disc Brakes the drain holes in

the Actuator mounting face must
be open (see arrow E).
E
Before fitting the new Spring Brake, the sealing
surface (see arrow C) must be cleaned, and the
FD00115-Äi01
Spherical Cup (19) in the Lever must be greased with

white Grease (Part No. II14525 or II32868).
The surface area of the flange must be damage free

and clean.
The Seal, as well as the piston area - see arrow in

adjacent picture - must be clean and dry.
ATTENTION!
Do not use grease containing

molybdenum disulphate.
Use only Actuators which are
recommended by the
Vehicle Manufacturer.
48

Attach Spring Brake using new Nuts
(self-locking EN ISO 10513).
In order not to tilt the Spring Brake, screw Nuts
step by step alternately with a suitable tool and
+30
torque tighten to 180 Nm.
Connect air hoses, ensuring that they are replaced in

the correct ports.
Make sure that hoses are not twisted and that

chafing is not possible.
Release parking brake, move Hand Control Valve to

‘run’ position, and check for leakage.
Screw in Spring Brake Release bolt to maximum

70 Nm.
ATTENTION!
Check function and effectiveness
of the brake.
49

Notes:
50

51

Knorr-Bremse
Die Bildmarke ” K” sowie die Marken KNORR, KNORR-BREMSE sind für die Knorr-Bremse AG gesetzlich geschützt.
Änderungen vorbehalten. Für Projektierung und Einsatz unserer Produkte empfehlen wir, individuelle Beratung und Dokumentation anzufordern. Nachdruck, auch auszugsweise, nicht gestattet. Printed in Germany
Systeme für Nutzfahrzeuge GmbH
Moosacher Straße 80
80809 Munich
Germany
Phone: +49 89 3547-0
Fax: +49 89 3547-2767
Knorr-Bremse Knorr-Bremse Knorr-Bremse

Australia Pty. Ltd. Systèmes pour Véhicules Utilitaires France S.A. Systeme für Nutzfahrzeuge GmbH
27-29 George Street BP 34178 Representation Office Russia
Concord West NSW 2138 RN 13, La Briqueterie 1 . Kasatschij Pereulok 5/2
Australia Glos 119017 Moscow
Phone: +61 2 9352-4146 14104 Lisieux Cedex Russian Federation
Fax: +61 2 9352-4445 France Phone: +7 095 234-4995
Phone: +33 2 3132-1200 Fax: +7 095 234-4996
Knorr-Bremse GmbH Fax: +33 2 3132-1303
Systeme für Nutzfahrzeuge Knorr-Bremse S.A. Pty. Ltd.
Beethovengasse 43-45 Knorr-Bremse 3 Derrick Road
2340 Mödling Fékrendszerek Kft. (corner Chestnut Road)
Austria Kecskemét 1610 Kempton Park
Phone: +43 2236 409-436 Szegedi út 49 South Africa
Fax: +43 2236 409-434 6000 Phone: +27 11 961- 7800
Hungary Fax: +27 11 975-8249
Knorr-Bremse Phone: +36 76 511-100
Benelux B.V.B.A. Fax: +36 76 481-100 Knorr-Bremse
Impulsstraat 11 System for Tunga Fordon AB
Industriepark zone D Knorr-Bremse P.O. Box 6029
2220 Heist-op-den-Berg Systems for Commercial Vehicles India Private 200 11 Malmoe
Belgium Ltd. Sweden
Phone: +32 1525 7900 Infra House, 2nd floor Phone: +46 40 680 5880
Fax: +32 1524 9240 118 Cunningham Road Fax: +46 40 937490
Bangalore 560 052
Knorr-Bremse India Knorr-Bremse
Sistemas para Veículos Comerciais Brasil Ltda. Phone: +91 80 20 88-273 Systeme für Nutzfahrzeuge GmbH
Av. Eng º Eusébio Stevaux Office Switzerland
873 Bloco B-Jurubatuba Knorr-Bremse Zürichstraße 46
Cep: 04696-902 Sistemi per Autoveicoli Commerciali S.p.A. 8303 Bassersdorf
Brazil Via C. Battisti, 68 Switzerland
Phone: +55 11 5681-1104 20043 Arcore Phone: +41 1 888 77-55
Fax: +55 11 5686-3905 Italy Fax: +41 1 888 77-50
Phone: +39 039 6075-1
Knorr-Bremse Far East Ltd. Fax: +39 039 6075-435 Knorr-Bremse
Truck Brake Systems Division Systeme für Nutzfahrzeuge GmbH
1301 MassMutual Tower Knorr-Bremse Liaison Office Istanbul
38 Gloucester Road Commercial Vehicle Systems Japan Ltd. Meclisi Mebusan Cad. 139/A
Wanchai 3-1-15, Nishiikebukuro Atlantik Han Kat: 3
Hong Kong Toshimaku- 80040 Findikli-Istanbul
China Tokyo 171-0021 Turkey
Phone: +852 2861 2669 Japan Phone: +90 212 293-4742
Fax: +852 2520 6259 Phone: +81 3 3971-8501 Fax: +90 212 293-4743
Fax: +81 3 3971-8579
Knorr-Bremse Knorr-Bremse
Systémy pro uz̆itková vozidla, CR, s.r.o. Knorr-Bremse Systems for Commercial Vehicles Ltd.
Petra Bezruc̆e 399 Benelux B.V.B.A. Douglas Road
463 62 Hejnice Rendementsweg 4N Kingswood
Czech Republic 3641 SK Mydrecht Bristol
Phone: +420 482 363-611 Netherlands BS15 8NL
Fax: +420 482 363-711 Phone: +31 297 239330 United Kingdom
Fax: +31 297 239339 Phone: +44 117 9846-100
Fax: +44 117 9846-101
Doc. No.: C16352-EN-005 replaces RA-SB0002-EN
Bendix Commercial Vehicle Systems LLC

901 Cleveland Street
Elyria, OH 44035
USA
Phone: +1 440 329-9000
Fax: +1 440 329-9203
Reference No.: C16352-EN-005
KNORR-BREMSE
Systems for Commercial Vehicles
www.knorr-bremse.com www.knorr-bremsesfn.com

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Service Manual

C16352: EN: 005: MAX1: Released:Webmaster: 2010/07/21-17:35:19

3 Description and Function

5 Functional and Visual Checks

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9 Replacement of Inner Boot (9) .......................................................................... 41

10 Guide Pin Bush Replacement

11 Carrier Replacement .......................................................................................... 46

12 Brake Actuator Replacement

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1.1 Axial Disc Brake Components

2 Carrier 18/1 Spring Brake

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Type of Caliper Knorr-Bremse Part No.

1.2.1 Axial Disc Brake Wear Indicator Kits *) Variants

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10a * ) pre-applied adhesive

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Type of Caliper Knorr-Bremse Part No.

1.4.1 Radial Disc Brake Wear Indicator Kits *) Variants

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This should also be done when fitting Knorr-Bremse Brake Discs.

Brake Discs can be ordered through the Knorr-Bremse Aftermarket Organisation.

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2.1 Service Tools

Part Number Description

2.2 Diagnostic Equipment

Part Number Colour Quantity

2.4 Torque Requirements

Item Number Torque Spanner Size

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3.2.1 Brake Actuation

During actuation, the Push Rod of the Actuator (18/1

After overcoming the running clearance between the

3.2.2. Brake Release

After releasing the air pressure, the two Return

3.2.3 Brake Adjustment (automatic)

To ensure a constant running clearance between

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44 Pad Retainer Pin

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3.4.1. Brake Actuation

During actuation, the Push Rod of the Actuator (18/1

After overcoming the running clearance between the

3.4.2. Brake Release

After releasing the air pressure, the two Return

3.4.3 Brake Adjustment (automatic)

To ensure a constant running clearance between

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Please also refer to the relevant safety instructions for

Use only original Knorr-Bremse parts.

Before starting service work, ensure the

Please follow service manual instructions and adhere

Use only recommended tools - see Section 2.1.

Tighten bolts and nuts to the recommended torque

After re-fitting a wheel according to the Vehicle

After service work: