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Truck System Technologies SL7 Service Manual

Pneumatic disc brake
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Doc. No. Y081564 (EN - Rev. 003)
June 2022
SERVICE MANUAL
PNEUMATIC DISC BRAKE
SL7 - SM7

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  • Page 1 Doc. No. Y081564 (EN - Rev. 003) June 2022 SERVICE MANUAL PNEUMATIC DISC BRAKE SL7 - SM7...
  • Page 2 SB7... SN5... K037001 Y015044-# SN6... K039062K50* SN7... K209211K50 Y006471-# K158880K50 SK7... SL7... K039062K50* K209211K50 Y081564-# K158880K50 SM7... K039062K50* ST7... Y173241-# K158880K50 *These Tool Kits are no longer produced and now replaced by Tool Kit K158880K50. To service the new Double Roll Bearing of the caliper‘s floating bearing side, additional tools are required which are supplied in the supplemental kit K209211K50.

  • Page 3: Table Of Contents

    » Pneumatic Disc Brake SL7 - SM7 CONTENTS 1. Overview ........... . .7 Disc Brake Components .
  • Page 4 » Y081564 - (EN - REV. 003) | JUNE 2022 CONTENTS 8. Caliper Replacement ..........39 Removal of Caliper from Carrier .
  • Page 5 » Pneumatic Disc Brake SL7 - SM7 SAFETY AND ENVIRONMENT GUIDELINES Note: The safety advice listed below is applicable to general service and diagnostic work on braking systems. Also observe any recommendations from the axle or vehicle manufacturer concerning towing, jacking-up and securing the vehicle.
  • Page 6 » Y081564 - (EN - REV. 003) | JUNE 2022 SAFETY AND ENVIRONMENT GUIDELINES Disposal of Waste Equipment by Business Users in the European Union This symbol on the product, packaging or in user instructions, indicates that this product must not be disposed of with other general waste.

  • Page 7: Overview

    » Pneumatic Disc Brake SL7 - SM7 OVERVIEW Disc Brake Components Legend 61 Shear Adapter 1 Caliper* 13 Tappet and Boot Assembly 161 Tappet Bush 2 Carrier* 18 Brake Actuator** 4 Guide Pin* 22 Inner Seal* 26 Spring Clip 5 Guide Pin*...

  • Page 8: Identification Of The Guide And Seal Kit Variants

    » Y081564 - (EN - REV. 003) | JUNE 2022 1.1.1 Identification of the Guide and Seal Kit Variants 39f* * Variants possible (see also contents leaflet in the service kit) Floating Bearing (6) variants: a) Rubber Bush b) Open Bearing f ) Double Roll Bearing...

  • Page 9: Brake Identification And Service Kits

    » Pneumatic Disc Brake SL7 - SM7 OVERVIEW Brake Identification and Service Kits A = Axle or vehicle manufacturer’s identification number B = Knorr-Bremse brake type number C = Knorr-Bremse part number D = Knorr-Bremse date of manufacture KNORR-BREMSE KNORR-BREMSE...

  • Page 10: Brake Disc

    » Y081564 - (EN - REV. 003) | JUNE 2022 OVERVIEW Brake Disc Replacing brake discs is subject to the instructions of the vehicle or axle manufacturer, including when fitting Knorr-Bremse brake discs. When replacing brake discs, make sure to use the correct connections and tightening torques.

  • Page 11: General Information

    » Pneumatic Disc Brake SL7 - SM7 GENERAL INFORMATION The use of impact screwdrivers / impact wrenches in conjunction with Knorr-Bremse service tools for air disc brakes is not permitted. The service tools are not designed for such use. Never turn the Adjuster (23) without Shear Adapter (61). If the given shear point of the Shear Adapter (61) is reached, the adapter will fail.

  • Page 12: Description And Function

    » Y081564 - (EN - REV. 003) | JUNE 2022 DESCRIPTION AND FUNCTION Disc Brake Sectioned View 58* 9* Legend 1 Caliper* 2 Carrier* 4 Guide Pin* 5 Guide Pin* 6 Rubber Bush / Guide Sleeve (floating bearing side) 7 Brass Bush (fixed bearing side) 9 Inner Boot* 10 Cover*...

  • Page 13: Description Of Operation (Floating Caliper Principle)

    » Pneumatic Disc Brake SL7 - SM7 DESCRIPTION AND FUNCTION Description of Operation (Floating caliper principle) Brake Adjustment Brake Actuation During actuation, the push rod of the actuator (18) moves The so called running clearance of the disc brake is the air the lever (19).

  • Page 14: Inspection Points

    » Y081564 - (EN - REV. 003) | JUNE 2022 INSPECTION POINTS Annually Despite the use of long-life materials, it is necessary to check some of the components regularly for their general Check the caliper running clearance (see Section 5.3.1) condition.

  • Page 15: Safety Instructions For Service Work And Repair Work

    » Pneumatic Disc Brake SL7 - SM7 INSPECTION POINTS Safety Instructions for Service Work and Repair Work Observe relevant safety instructions for service work and Screw threads and tapped holes must be free repair work on commercial vehicles, especially for jacking up of lubrication and residuals of thread locking and securing the vehicle.

  • Page 16: Functional And Visual Check

    » Y081564 - (EN - REV. 003) | JUNE 2022 FUNCTIONAL AND VISUAL CHECK Wear Check of Pads and Brake Discs For optimum safety, the pad and disc wear limits must not be exceeded. Brake Pads The thickness of the pads must be checked regularly dependent on the usage of the vehicle.
  • Page 17 » Pneumatic Disc Brake SL7 - SM7 FUNCTIONAL AND VISUAL CHECK Exaggerated wear difference between inner and outer E-F > 3,5 mm? brake pads Outer 5.1.4 The total thickness of the friction material of the inner and outer pad should be equal. If the difference between the two pads is greater then 3.5 mm (see Fig.), then the following...

  • Page 18: Brake Disc

    » Y081564 - (EN - REV. 003) | JUNE 2022 FUNCTIONAL AND VISUAL CHECK Brake Disc 5.1.6 Measure the thickness of the brake disc at the thinnest point. Be aware of possible burring at the edge of the disc. Total thickness of the brake disc New condition = 45 mm.
  • Page 19 » Pneumatic Disc Brake SL7 - SM7 FUNCTIONAL AND VISUAL CHECK 5.1.7 Check the discs per axle at each change of pads for grooves and cracks. If necessary replace the disc. The figure shows possible surface conditions of the brake disc.
  • Page 20 » Y081564 - (EN - REV. 003) | JUNE 2022 FUNCTIONAL AND VISUAL CHECK 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).
  • Page 21 » Pneumatic Disc Brake SL7 - SM7 FUNCTIONAL AND VISUAL CHECK Wear Indicators 5.1.10 Due to different vehicle manufacturers and vehicles there are several types of pad wear indicator used. 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...

  • Page 22: Adjuster Check

    » Y081564 - (EN - REV. 003) | JUNE 2022 FUNCTIONAL AND VISUAL CHECK Adjuster Check 5.2.1.1 Before starting work, ensure that the wheels are chocked and the vehicle cannot roll away. 5.2.1.2 Ensure that service brake parking brake, as well as bus stop temporary hold brake, if fitted, are in the released condition.
  • Page 23 » Pneumatic Disc Brake SL7 - SM7 FUNCTIONAL AND VISUAL CHECK 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.).
  • Page 24 » Y081564 - (EN - REV. 003) | JUNE 2022 FUNCTIONAL AND VISUAL CHECK 5.2.9 If the air gap is smaller than 0.6 mm the parameters and functions must be checked as follows: 5.2.9.1 Function of the brake actuator, refer to specifications provided by the manufacturer.

  • Page 25: Caliper Check

    » Pneumatic Disc Brake SL7 - SM7 FUNCTIONAL AND VISUAL CHECK Caliper Check Caliper Running Clearance Before starting work, ensure that the wheels are chocked and the vehicle cannot roll away. Ensure that service brake and parking brake, as well as the bus stop temporary hold brake, if fitted, are in the released condition.

  • Page 26: Clearance Measurement Check Of Bearing Variants (6)

    » Y081564 - (EN - REV. 003) | JUNE 2022 FUNCTIONAL AND VISUAL CHECK Clearance Measurement Check of Bearing Variants (6) Note: Before commencing (removing the wheel), make sure there is no contact between caliper and axle, vehicle, chassis sections or carrier. In such cases it will be necessary to replace the caliper bearings (see Section 9).

  • Page 27: Sealing Elements Check

    » Pneumatic Disc Brake SL7 - SM7 FUNCTIONAL AND VISUAL CHECK Sealing Elements Check Caliper Guide Pin Seals 5.5.1 The guide pins (4 and 5) are sealed with inner boots (9) , guide pin 5 with additional cover (10) (see Fig. and also Section 1.1.1).

  • Page 28: Brake Pad Replacement

    » Y081564 - (EN - REV. 003) | JUNE 2022 BRAKE PAD REPLACEMENT Before starting work, ensure that the wheels are chocked and the vehicle cannot roll away. Ensure that service brake and parking brake, as well as bus stop temporary hold brake, if fitted, are in the released condition.

  • Page 29: Fitting Of Brake Pads

    (61) in an anti-clockwise direction (see Section 5.2). 6.2.4 Insert brake pads (12) as shown (see fig.). Note: With type SL7 and SM7 the inboard brake pad (12 ) and outboard brake pad (12 ) are different, make sure they are installed in their correct position.
  • Page 30 » Y081564 - (EN - REV. 003) | JUNE 2022 BRAKE PAD REPLACEMENT 6.2.5 Wind out the Adjuster (23) with shear adapter (61) until the brake pads come into contact with the disc. Then turn back the adjuster three clicks and check the running clearance (see Section 5.2) .

  • Page 31: Tappet And Boot Assemblies (13) And Inner Seals (22) Replacement

    » Pneumatic Disc Brake SL7 - SM7 TAPPET AND BOOT ASSEMBLIES (13) AND INNER SEALS (22) REPLACEMENT For ease of reference, each component of a tool is referred to by an identification number; a complete tool (containing one or more such components) has been given a letter code - see section 2.1.

  • Page 32: Removal Of Tappet And Boot Assemblies (13)

    » Y081564 - (EN - REV. 003) | JUNE 2022 TAPPET AND BOOT ASSEMBLIES (13) AND INNER SEALS (22) REPLACEMENT Removal of Tappet and Boot Assemblies (13) Note: The removal of the tappet and boot assemblies (13) can be done with the brake caliper fitted to, or removed from, the vehicle (see Section 8) With caliper installed on the vehicle: 7.1.1 Wind-out the adjuster (23) using the shear adapter...

  • Page 33: With Caliper Removed From The Vehicle

    » Pneumatic Disc Brake SL7 - SM7 TAPPET AND BOOT ASSEMBLIES (13) AND INNER SEALS (22) REPLACEMENT 7.1.3 Remove the old tappet bush (161) (see Fig.). 7.1.4 Check inner sealing face (arrow X ) (see Fig.). This sealing face (arrow X ) must not be damaged.

  • Page 34: Replacement Of Inner Seals (22)

    » Y081564 - (EN - REV. 003) | JUNE 2022 TAPPET AND BOOT ASSEMBLIES (13) AND INNER SEALS (22) REPLACEMENT Replacement of Inner Seals (22) 7.2.1 Fully wind back the threaded tubes (16) by turning the shear adapter (61) (see Section 6.1.4). 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.).

  • Page 35: With Caliper Installed On The Vehicle

    » Pneumatic Disc Brake SL7 - SM7 TAPPET AND BOOT ASSEMBLIES (13) AND INNER SEALS (22) REPLACEMENT With caliper installed on the vehicle: 7.2.7 Guide the tool (L ) over the spigot of the threaded tube (16) as shown, screw out (T03) until it touches the brake disc (see Fig.).

  • Page 36: Fitting Of Tappet And Boot Assemblies (13)

    » Y081564 - (EN - REV. 003) | JUNE 2022 TAPPET AND BOOT ASSEMBLIES (13) AND INNER SEALS (22) REPLACEMENT Fitting of Tappet and Boot Assemblies (13) The Tappets are supplied with a special long-life lubri- cant within a protective cap. Before fitting, the protective cap must be removed and discarded in the appropriate manner.

  • Page 37: With Caliper Removed From The Vehicle

    » Pneumatic Disc Brake SL7 - SM7 TAPPET AND BOOT ASSEMBLIES (13) AND INNER SEALS (22) REPLACEMENT 7.3.5 Release tool (E ) and then turn it over so that tool (T28) can make contact with the boot. Note: For this procedure tool (T55) should remain in tool (T28).
  • Page 38 » Y081564 - (EN - REV. 003) | JUNE 2022 TAPPET AND BOOT ASSEMBLIES (13) AND INNER SEALS (22) REPLACEMENT 7.3.12 Release and remove tool (E - caliper removed from vehicle 7.3.13 To press in the boot of the tappet (13) tool (E ) is required (see Fig.).

  • Page 39: Caliper Replacement

    » Pneumatic Disc Brake SL7 - SM7 CALIPER REPLACEMENT Use the following tools to replace: Press-in tool for cover (68a/68f ) • Cover (10); fixed bearing - press-in tool (T26) • Cover (68a; Rubber Bush and 68f; Double Roll Bearing)

  • Page 40: Removal Of Cap (68A; Rubber Bush Or 68F Double Roll Bearing)

    » Y081564 - (EN - REV. 003) | JUNE 2022 CALIPER REPLACEMENT Removal of Cap (68a; Rubber Bush or 68f Double Roll 4a/f Bearing) 8.1.5 Carefully remove cap (68a or 68f ) from the bearing vartiant (6a/6f ) using a suitable tool, avoid damaging the cap.

  • Page 41: Fitting Caliper To Carrier - (Carrier Assembled On Vehicle)

    » Pneumatic Disc Brake SL7 - SM7 CALIPER REPLACEMENT Fitting Caliper to Carrier - (Carrier assembled on vehicle) Only use original Knorr-Bremse replacement calipers! 8.2.1 The correct choice of caliper must be ensured by checking the part number on the identification label (arrow X) (see also Section 1.2).

  • Page 42: Fitting Of Cover (10) - Fixed Bearing Side

    » Y081564 - (EN - REV. 003) | JUNE 2022 CALIPER REPLACEMENT Screw threads and tapped holes must be clean and dry (free of lubrication and residuals of pre-applied adhe- sive). 8.2.7 Place caliper (1) onto the carrier (2) and insert the caliper bolts (39) and (40).

  • Page 43: Cap (68A; Rubber Bush) - Floating Bearing Side

    » Pneumatic Disc Brake SL7 - SM7 CALIPER REPLACEMENT The inner boot (9) must be in a compressed condition otherwise the caliper´s freedom of movement will be limited. 8.2.15 Press the mandrel of the press-in tool (T26) firstly by hand until it stops, then, using a hammer on the mandrel, insert the cover to the end stop (see Fig.).

  • Page 44: Fitting Of Cover (10) With Caliper (1) And Carrier (2) Removed From The Vehicle

    » Y081564 - (EN - REV. 003) | JUNE 2022 CALIPER REPLACEMENT Fitting of Cover (10) with Caliper (1) and Carrier (2) Removed from the Vehicle: 8.2.18 Check caliper slides freely along the whole length of the guide pin arrangement (see Section 5.3). 8.2.19 Fix the carrier securely as shown i.e.

  • Page 45: Caliper Bearings Replacement

    » Pneumatic Disc Brake SL7 - SM7 CALIPER BEARINGS REPLACEMENT To replace the caliper bearings, all components of the fixed and floating bearing must be replaced by new components. For ease of reference, each component of a tool is referred to by an identification number (see section 2.1).

  • Page 46: Removal Of Brass Bush (7)

    » Y081564 - (EN - REV. 003) | JUNE 2022 CALIPER BEARINGS REPLACEMENT Removal of Brass Bush (7) The use of impact screwdrivers / impact wrenches in conjunction with Knorr-Bremse service tools for air disc brakes is not permitted. The service tools are not designed for such use.

  • Page 47: Replacement Of Guide Sleeve (6) Floating Bearing

    » Pneumatic Disc Brake SL7 - SM7 CALIPER BEARINGS REPLACEMENT Replacement of Guide Sleeve (6) Floating Bearing For ease of reference, each component of a tool is referred to by an identification number (see section 2.1). Guide sleeve variants are:...

  • Page 48: Removal Of Floating Bearing Variants

    » Y081564 - (EN - REV. 003) | JUNE 2022 CALIPER BEARINGS REPLACEMENT Removal of Floating Bearing Variants 9.3.1 Removal of Guide Sleeve (6a; Rubber bush or 6b; Floating Bearing 6a/b 9.3.1.1 If present, remove guide pin (4). 9.3.1.2 Clean the area around the bearing. 9.3.1.3 Prepare tool combination (R ) with (T06) Ø39 mm.
  • Page 49 » Pneumatic Disc Brake SL7 - SM7 CALIPER BEARINGS REPLACEMENT 9.3.2.3 Position tool combination (U ) on the floating bearing TSY01 as shown (see Fig.). TB17 TSY07 TSY04 TSY02 9.3.2.3 - Tool combination (U ) in place 9.3.2.4 Pull-out the double roll bearing (6f ) by turning spindle (TSY01) using a suitable tool (see Fig.).

  • Page 50: Fitting Of Floating Bearing Variants

    » Y081564 - (EN - REV. 003) | JUNE 2022 CALIPER BEARINGS REPLACEMENT Fitting of Floating Bearing Variants 9.3.3 Fitting of Guide Sleeve (6a Rubber Bush or 6b Open Bearing) 6a/b 9.3.3.1 Check bore for corrosion and clean. 9.3.3.2 Wind out the grub screw (from (T19) on the tool (R so it cannot contact the caliper surface (see Fig.

  • Page 51: Fitting Of Double Roll Bearing (6F)

    » Pneumatic Disc Brake SL7 - SM7 CALIPER BEARINGS REPLACEMENT 9.3.4 Fitting of Double Roll Bearing (6f) TSY01 9.3.4.1 Remove protective plug (see Fig. arrow A). TB17 Making sure the protective sleeve is still fitted (see Fig. arrow TSY10 B), place double roll bearing (6f ) carefully into the caliper bore.
  • Page 52 » Y081564 - (EN - REV. 003) | JUNE 2022 CALIPER BEARINGS REPLACEMENT 9.3.4.5 Fit lip of inner boot into the groove of guide pin, make sure it has fully engaged right round and is not twisted (see Fig. arrow C). 9.3.4.5 - Fit lip of inner boot into guide pin groove 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...

  • Page 53: Fitting Of Inner Boot (9) Floating Bearing

    » Pneumatic Disc Brake SL7 - SM7 CALIPER BEARINGS REPLACEMENT Fitting of Inner Boot (9) Fixed Bearing Washer DIN 125 For ease of reference, each component of a tool is referred to by an identification number; a complete tool (containing one or more such components) has been given a letter code - see section 2.1.

  • Page 54: Fitting Of Guide Pin (5) Fixed Bearing

    » Y081564 - (EN - REV. 003) | JUNE 2022 CALIPER BEARINGS REPLACEMENT 9.4.5 Then, pull-in with a maximum torque of 8 Nm (see Fig.). 8 Nm (max.) 9.4.5 - Pull-in with max. 8 Nm 9.4.6 Check correct fitment of inner boot (9) by carrying out a pulling test (see Fig.).

  • Page 55: Fitting Of Guide Pin (4) Floating Bearing

    » Pneumatic Disc Brake SL7 - SM7 CALIPER BEARINGS REPLACEMENT Note: The following steps 9.7 - 9.8 do not apply to the double roll bearing (6f) on the floating bearing side (it already contains 4a/b its own guide sleeve variant).
  • Page 56 » Y081564 - (EN - REV. 003) | JUNE 2022 CALIPER BEARINGS REPLACEMENT 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.

  • Page 57: 10. Carrier Replacement

    » Pneumatic Disc Brake SL7 - SM7 10. CARRIER REPLACEMENT Depending on the installation, it may be possible to remove the caliper from the carrier and replace the carrier in situ. Else it may be necessary or more convenient to remove the complete carrier/calliper assembly from the vehicle where it can be separated and the carrier replaced.

  • Page 58: 11. Brake Actuator Replacement

    » Y081564 - (EN - REV. 003) | JUNE 2022 11. BRAKE ACTUATOR REPLACEMENT Note: All references to brake actuators (brake chambers and spring brakes) in this section refer to Knorr-Bremse brake actuators. For other brake actuator manufacturers, follow their respective instructions.

  • Page 59: 11.3 Removal Of Knorr-Bremse Spring Brake

    » Pneumatic Disc Brake SL7 - SM7 BRAKE ACTUATOR REPLACEMENT 11.2.4 Attach brake chamber using new nuts (see Fig.). In order not to tilt the brake chamber during its attachment, the nuts must be gradually tightened symmetrically with a suitable tool.

  • Page 60: 11.4 Fitting Of Knorr-Bremse Spring Brake

    » Y081564 - (EN - REV. 003) | JUNE 2022 BRAKE ACTUATOR REPLACEMENT 11.4 Fitting of Knorr-Bremse Spring Brake Note: New spring brakes (18) have drain plugs installed (see arrow A). Remove lowest plug (as viewed when spring brake is installed).
  • Page 61 » Pneumatic Disc Brake SN6 - SN7 - SK7 » Pneumatic Disc Brake SL7 - SM7 NOTES...
  • Page 62 » Y081564 - (EN - REV. 003) | JUNE 2022 » Y006471 - (EN - REV. 008) | NOVEMBER 2020 NOTES...
  • Page 63 » Pneumatic Disc Brake SL7 - SM7...
  • Page 64 Your local TruckServices Workshops, Dealers and Branches can be found anytime online at truckservices.knorr-bremse.com. Knorr-Bremse Systeme für Nutzfahrzeuge GmbH Moosacher Strasse 80 80809 Munich Germany Tel: +49 89 3547-0 Fax: +49 89 3547-2767 truckservices.knorr-bremse.com The information contained herein is subject to alteration without notice and therefore may not be the latest release. Please check our website truckservices.knorr-bremse.com for the latest update or contact your local Knorr-Bremse representative. The figurative mark “K” and the trademarks KNORR and KNORR-BREMSE are registered in the name of Knorr-Bremse AG.

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