Truck System Technologies SL7 Service Manual Download

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» Pneumatic Disc Brake SL7 - SM7

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
1.3 Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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

6.1 Removal of Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
6.2 Fitting of Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

7. Tappet and Boot Assemblies (13) and Inner Seals (22) Replacement . . . . . . . . . . . . . . 31

7.1 Removal of Tappet and Boot Assemblies (13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

With caliper installed on the vehicle: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
With caliper removed from the vehicle: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

7.2 Replacement of Inner Seals (22) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

With caliper installed on the vehicle: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
With caliper removed from the vehicle: (not shown): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

7.3 Fitting of Tappet and Boot Assemblies (13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

With caliper installed on the vehicle: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
With caliper removed from the vehicle: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Summary of Contents for SL7

Page 1: ...T E C H N I C A L D O C U M E N T A T I O N Doc No Y081564 EN Rev 003 June 2022 PNEUMATIC DISC BRAKE SL7 SM7 SERVICE MANUAL ...

Page 2: ...an 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 referr...

Page 3: ...k 15 5 Functional and Visual Check 16 5 1 Wear Check of Pads and Brake Discs 16 Brake Pads 16 Brake Disc 18 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 7 Tappet and Boot Assemblies 13 and Inner Seals 22 Replacement 31 7 1 Removal...

Page 4: ...7 Fixed Bearing Side 45 Removal of Brass Bush 7 46 Fitting of Brass Bush 7 46 9 3 Replacement of Guide Sleeve 6 Floating Bearing 47 Removal of Floating Bearing Variants 48 9 3 1 Removal of Guide Sleeve 6a Rubber bush or 6b Floating Bearing 48 9 3 2 Removal of Double Roll Bearing 6f 48 Fitting of Floating Bearing Variants 50 9 3 3 Fitting of Guide Sleeve 6a Rubber Bush or 6b Open Bearing 50 9 3 4 F...

Page 5: ...he 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 t...

Page 6: ...t 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 K...

Page 7: ...s Bush fixed bearing side 9 Inner Boot 10 Cover 11 Pad Retainer 12 Pad complete 13 Tappet and Boot Assembly 18 Brake Actuator 22 Inner Seal 26 Spring Clip 37 Adjuster Cap 39 Caliper Bolt 40 Caliper Bolt 44 Pad Retainer Pin 45 Washer 58 Ring Variants possible see also contents leaflet in the service kit Brake chamber or spring brake 61 Shear Adapter 161 Tappet Bush 1 OVERVIEW 1 1 Disc Brake Compone...

Page 8: ...tification of the Guide and Seal Kit Variants Variants possible see also contents leaflet in the service kit a Rubber Bush b Open Bearing f Double Roll Bearing Floating Bearing 6 variants 5 40 9 58a 4a 4b 6a 6b 6f 7 10 68f 68a 58f 39b 39a 39f ...

Page 9: ...39b 39f 40 Ring 58a 58f Cap 68a 68f Tappet and Boot Kit Tappet and Boot 13 2x Inner Seal 22 2x Tappet Bush 161 2x Adjuster Cap Adjuster Cap 37 10x Shear Adapter 61 10x Brake Pads axle set Pad Retainer 11 2x Brake Pad 12 4x Spring Clip 26 2x Adjuster Cap 37 2x Pad Retainer Pin 44 2x Washer 45 2x Shear Adapter 61 2x Caliper Supplied without carrier 2 and without brake pads 12 GuidePinsandSealskitinc...

Page 10: ...the correct connections and tightening torques The use of non approved brake discs will reduce levels of safety and will not be covered by any Knorr Bremse liability Knorr Bremse recommends the brake disc be changed as an axle set Brake discs can be ordered through the Knorr Bremse aftermarket organisation Additionally Knorr Bremse recommends brake discs be changed at the latest every 6 years even...

Page 11: ...age 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 Tool Description Consisting of tool components A Wedged fork for removal of tappet and boot assembly 13 T15 C Pull in tool for inner boot 9 T06 T07 T08 T10 D Pull in Pull out tool including grooving tool for ...

Page 12: ...d 13 Tappet and Boot Assembly 16 Threaded Tube 17 Bridge 18 Brake Actuator 19 Lever 20 Eccentric Bearing 22 Inner Seal 23 Adjuster Unit 24 Turning Device 26 Spring Clip 27 Spring 30 Chain 32 Chain Wheel 33 Wear Sensor 37 Adjuster Cap 39 Caliper Bolt 40 Caliper Bolt 44 Pad Retainer Pin 45 Washer 46 Disc 58 Ring 61 Shear Adapter 68 Cover 161 Tappet Bush 3 DESCRIPTION AND FUNCTION 1 122 58 9 7 5 10 2...

Page 13: ...back to the start position Brake Adjustment The so called running clearance of the disc brake is the air gap between the brake pad 12 and the brake disc 46 This distance is necessary to achieve a free running and therefore unbraked disc when the brakes are in a non applied state Too large a running clearance can lead to a greater braking distance The designated running clearance is so designed to ...

Page 14: ...e sealing 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 Annually Check the caliper running clearance see Section 5 3 1 and the correct fitting and condition of the cover 10 the adjuster cap 37 and cover 68c 68d or 68e depending on the bearing variant Note These frequencies are a minimum and depending o...

Page 15: ...r any service work Check the brake performance and the system behaviour on a roller dynamometer Check function and effective ness Bear in mind that a lower performance can appear during the breaking in phase of the brake pads and or the brake disc 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...

Page 16: ... 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 5 1 1 Brake pad with minor damage permitted 5 1 2 Brake pad with major damage not permitted 5 1 3 Brake pad thicknesses A Overall thickness of new brake pad 30 mm B Backplate 9 mm C Minimum thickness of friction material 2 mm D M...

Page 17: ...on the axle or vehicle body Excessive dirt and grime present if necessary contact the vehicle manufacturer piping of the compressed air line Example a E 19 mm F 15 mm NOT OK b E 11 5 mm F 13 mm OK Exaggerated tangential oblique wear of brake pads 5 1 5 The total thickness of the friction material at either end of the pad should be equal If the difference between the two ends is greater than 2 mm s...

Page 18: ...s of the brake disc New condition 45 mm Worn condition 37mm or N 0 mm thediscmustbe replaced IfthediscdimensionM 39mmor N 1 mm itisrecommended that all brake discs on the same axle be renewed when the brake pads are changed Brake discs from Knorr Bremse have an optical wear indicator as a chamfer on the outer edge of the disck N Therefore the brake disc wear should be checked whenever the brake pa...

Page 19: ...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 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 The photograph shows a real life example of such cracks and wear grooves Note In case of surface conditions A1 B1 or C1 the...

Page 20: ...d and discs with wheel removed Brake Pad Disc Wear Check on vehicle with bearing variant 6a Rubber Bush and 6f Double Roll Bearing For all disc brakes equipped with rubber bush type 6a 6f with axial ribbing see arrow H 5 1 8 The pads disc wear can be visually determined without removing the wheel by noting the position of the wear marker point see arrow G the change over point from the ribbed to t...

Page 21: ...e Please also refer to specifications provided by the vehicle manufacturer 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 11 The Tester can be used on all current Knorr Bremse brake types with continues or black white Potentiometer N...

Page 22: ... may be damaged 5 2 3 Pull off the adjuster cap 37 using the tag taking care not to lose the shear adapter 61 see Fig 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 ...

Page 23: ...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 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 sm...

Page 24: ...eck 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...

Page 25: ...e any light corrosion using an emery cloth 5 3 3 Lightly apply grease order No II14525 K093430 or II32868 to the protruding area of the guide pin 4 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 Clean guide pin 4 from the inner area of the caliper removi...

Page 26: ...he measuring point see arrows A see Fig 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 The clearance must not exceed the given tolerance of 2 0...

Page 27: ...iper with suitable service kit see Section 1 2 and Section 8 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 Ifnecessaryreplacetappetandbootassemblie...

Page 28: ...he orientation of the caliper on the axle brake pads could fall out when removing the pad retainer 11 6 1 2 Remove spring clip 26 and washer 45 depress the pad retainer 11 and remove pin 44 see Fig 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 adju...

Page 29: ... lubricant K125122N50 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 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 Sec...

Page 30: ...sed 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 shown see arrow This ensures access is maintained for subse quent removal If required fit cable guides and pad wear indicators see Section 6 3 6 2 9 Re fit wheel according to the vehicle manufacturer s recommendations 6 2 5 Wind out the Adjuster 23...

Page 31: ...es 13 use the wedge fork A see Fig 7a To fit the tappet and boot assemblies 13 use tool E see Fig 7b To fit the inner seal 22 use tool L in configuration L1 when the caliper is mounted on the vehicle or configuration L2 when removed from the vehicle see Fig 7c 7b Tool for fitting the tappet and boot assemblies 7c Tool for fitting the inner seal L2 off vehicle application L1 on vehicle application ...

Page 32: ...hear adapter 61 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 2 Using tool A correctly positioned between the caliper and the boot carefully drive it down with the aid of a hammer torele...

Page 33: ...h caliper removed from the vehicle 7 1 6 If the caliper is not installed on the vehicle place spacer 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 The threaded tubes must not extend more than 30 mm other...

Page 34: ...rning the shear adapter 61 see Section 6 1 4 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 7 2 3 Clean sealing surface X see Fig 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 themforcorrosionordamage seeSection7 1 5 7 1 6 7 2 5 Lubricate threads with white grea...

Page 35: ...er 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 With caliper installed on the vehicle 7 2 ...

Page 36: ... 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 T55 touches the brake disc Using a spanner screw out T03 to press tappet and boot assembly 13 into place see Fig The Tappets are...

Page 37: ... fitting of each tappet and boot assembly 13 requires tool E2 see Section 7 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 on the boot and in the caliper must be clean and free of lubrication 7 3 10 Fit new tappet bushes 161 onto the spigots of the threaded tubes 16 then follow with the...

Page 38: ...Fig 7 3 14 Position tool E3 so that T03 screws out against the caliperasshown Usingaspanner screw out T03 topress in the boot Make sure that tool E3 is positioned square on to the caliper see Fig 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 7 3 15 Tappet should turn slightly in each direction E3 cal...

Page 39: ...orrosion If necessary replace with a new guide and seal kit In case of damage or excessive corrosion the caliper must be replaced Note It may be necessary for reasons of accessibility to remove the caliper and carrier from the axle refer to vehicle manufac turer s recommendations or remove only the caliper 8 1 4 Remove cover 10 using a suitable tool e g a screwdriver by inserting it into the creat...

Page 40: ...remse replacement calipers 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 1 7 Remove caliper 1 from carrier 2 8 1 6 Remove caliper bolts Removal of Cap 68a Rubber Bush or 68f Double Roll Bearing 8 1 5 Carefully remove cap 68a or 68f from the bearing vartiant 6a 6f u...

Page 41: ...ee Section 9 and 10 or the caliper replaced with the compatible rationalised caliper 8 2 Fitting Caliper to Carrier Carrier assembled on vehicle The guide pins 4 and 5 as well as the caliper bolts 39 and 40 arehighlystresseditems Theymustbereplaced whenever the caliper 1 is removed from the carrier 2 8 2 2 Lightly grease guide pins 4 and 5 8 2 3 Insert the guide pin 4 from inside the caliper to th...

Page 42: ... remove plastic cover or adhesive tape in the area of the actuator attachment from the replacement caliper see Fig 8 2 1 arrow Y 8 2 11 Fit brake actuator 18 see Fig and Section 11 2 or 11 4 8 2 12 Check adjuster function see Section 5 2 Fitting of Cover 10 Fixed Bearing Side With Caliper 1 and Carrier 2 Fitted on the Vehicle Before fixing the cover 10 slide the caliper as far as possible towards ...

Page 43: ...g tool T11 Cap 68a Rubber Bush Floating Bearing Side 8 2 16 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 the guide pin 4a and cap 68a see Fig Cap 68f Double Roll Bearing Floating Bearing Side 8 2 17 Fit the cap 68f using tool T11 and a hammer Tap the cap into the ...

Page 44: ...2 20 Assembly of covers 10 can now proceed as previously described see Section 8 2 12 8 2 14 8 2 21 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 manufacturer s recommendations 8 2 22 Fit brake pads see Section 6 2 8 2 23 Check adjuster function see Section 5 2 8 2 24 Fit brake actuator ...

Page 45: ... boot 9 with a screwdriver or similar tool see Fig 9 1 5 Check the sealing face of inner boot 9 for damage or corrosion see Fig arrow A 9 2 Replacement of Brass Bush 7 Fixed Bear ing Side 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 7 use the pull out combination D1 Before mounting the tool lightly lubricate the ...

Page 46: ...ntil it 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 7 by turning T14 until it stops see Fig 9 2 6 To prevent longitudinal displacement of brass bush 7 it must be grooved see arrow B The hexagon bolt arrow C of tool T16 must be screwed in up to its stop This process causes deformation within the brass bush see Fig 9 2 7 Wind back ...

Page 47: ...val and R2 for fitting see Fig 9 3a Washer DIN 125 Washer DIN 125 Tool combination for removing 6a b Tool combination for fitting 6 b Grub screw DIN 915 9 3a Tool combination R 9 3 Remove parts as described Variants Double roll bearing 6f requires tool U1 for removal and U2 for fitting see Fig 9 3b 9 3b Tool combination U1 and U2 Tool combination for removing 6f Note The supplementary tool kit K20...

Page 48: ...a ring spanner 24 A F and pull out the rubber bush 6 by turning tool T20 with a suitable tool see Fig 9 3 1 4 9 3 1 5 Removal of guide sleeve 6a b Removal of Floating Bearing Variants 9 3 2 Removal of Double Roll Bearing 6f 9 3 2 1 Remove the guide pin 6f 4 from the double roll bearing 6f by pushing from the outside arrow A to inside see Fig 9 3 2 2 Using a suitable tool trim off inner boot as clo...

Page 49: ... place 9 3 2 3 Position tool combination U1 on the floating bearing as shown see Fig 9 3 2 4 Pull out the double roll bearing 6f by turning spindle TSY01 using a suitable tool see Fig Remove tool combination U1 9 3 2 4 Pull out double roll bearing TSY01 TB17 TSY07 TSY04 TSY02 U1 6f TSY01 U1 6f ...

Page 50: ...n and clean 9 3 3 2 Wind out the grub screw from T19 on the tool R2 so it cannot contact the caliper surface see Fig insert 9 3 3 3 Push guide sleeve 6a b into T18 of tool R2 see Fig 9 3 3 4 Place tool R2 with assembled guide sleeve 6a b in position on the caliper as shown see Fig 9 3 3 5 Hand tighten T22 Note Take care not to tilt the guide sleeve 6a b when winding in 9 3 3 6 Stabilise T22 using ...

Page 51: ...l bearing 6f carefully into the caliper bore 9 3 4 2 Place tool U2 as shown through the double roll bearing 6f and hand tighten in place 9 3 4 3 Using a torque wrench max 23 Nm turn spindle TSY01 to pull in double roll bearing 6f see Fig If the torque value is 4 Nm or 23 Nm the caliper must be replaced 9 3 4 4 Remove tools and protective sleeve 9 3 4 4 Romove tool combination U2 and protective sle...

Page 52: ...ee Fig arrow C 9 3 4 6 Push on ring 58f onto the double roll bearing to secure engagement of its inner boot on the guide pin see Fig The smooth face of the ring i e flat side arrow D must face towards the brake carrier see Fig 9 3 4 7 To fit brake caliper to carrier see Section 8 2 9 3 4 5 Fit lip of inner boot into guide pin groove 9 3 4 6 Fit ring to secure inner boot D 58f 58f C C ...

Page 53: ...heck the sealing face of inner boot 9 for damage or corrosion see Fig arrow A 9 4 3 Fit new inner boot 9 into sleeve T07 of tool C Make sure the rubber folds of the boot sit inside the tool See Fig arrow B 9 4 4 Position sleeve T07 of tool C into the caliper bearing bore Then attach the assembled sleeve T07 with inner boot 9 pulling in firstly by hand by turning tool T10 see Fig 9 4 Fitting of Inn...

Page 54: ...ling test on inner boot 9 4 5 Pull in with max 8 Nm 9 5 1 9 5 2 Fit guide pin from outside 9 5 Fitting of Guide Pin 5 Fixed Bearing 9 5 1 Completely cover inside of brass bush 7 with white grease and in the area on the guide pin 5 as shown Part No II14525 K093430 or II32868 Make sure the grease pockets are filled see Fig 9 6 2 Fit guide pin 5 from outside the caliper into the caliper bore see Fig ...

Page 55: ...93430 or II32868 9 6 2 Fit guide pin 4 from inside the caliper into the caliper bore see Fig 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 2 Check complete engagement 9 7 2 Make sure the lip of inner boot 9 has fully engaged right round the guide pin 5 and is not twisted see Fig arrow B Note The following steps 9 7 9 8 do no...

Page 56: ...cure boot in groove of guide pin 9 7 3 Push on the ring 58 to secure engagement of inner boot 9 on guide pin 5 see Fig 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 9 7 4 Fit brake caliper to carrier see Section 8 2 C 5 9 58 ...

Page 57: ...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 t...

Page 58: ...and spring brakes in this section refer to Knorr Bremse brake actuators For other brake actuator manufacturers follow their respective instructions 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 recomm...

Page 59: ...ator 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 3 Removal of Knorr Bremse Spring Brake 11 3 1 Release parking brake 11 3 2 Screw out release bolt arrow D to the release position refer to the vehicle manufacturer s recommen dations see Fig 11 3 3 Apply parkin...

Page 60: ...d with white grease Part No II14525 K093430 or II32868 11 4 4 Attach the spring brake using new nuts see Fig Note In order not to tilt the spring brake during its attachment the nuts must be gradually tightened symmetri cally with a suitable tool 11 4 5 Tighten the nuts according to the specifications of the actuator manufacturer Only use new nuts 11 4 6 Connect air hoses making sure that the hose...

Page 61: ...61 Pneumatic Disc Brake SL7 SM7 Pneumatic Disc Brake SN6 SN7 SK7 NOTES ...

Page 62: ...62 Y081564 EN REV 003 JUNE 2022 Y006471 EN REV 008 NOVEMBER 2020 NOTES ...

Page 63: ...63 Pneumatic Disc Brake SL7 SM7 ...

Page 64: ...sponsibility 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 Copyright Knorr Bremse AG all rights reserved including industrial property rights applications Knorr Bremse AG retains any power of disposal such as f...

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