or 2007/2008 Trailer Handbook ...for Trailer Aftermarket Commercial Vehicle Systems Product Catalogue • ABS/EBS Schematic • A18 & KB4TA ABS Blink Code Information • LSV Setting Instructions • Knorr-Bremse Service Centre Information www.knorr-bremseCVS.com 2 0 0 8 / 2 0 0 9 E d i t i o n Includes cross reference section for OE part numbers
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Transcript
New For 2007/2008
Trailer Handbook
...for Trailer Aftermarket
Commercial Vehicle Systems
Product Catalogue
• ABS/EBS Schematic
• A18 & KB4TA ABS Blink Code Information
• LSV Setting Instructions
• Knorr-Bremse Service Centre Information
www.knorr-bremseCVS.com
20
08/2009 Edition
Includes cross reference section for OE part numbers
Trailer Handbook
Disclaimer
www.knorr-bremseCVS.com
The information contained in this document is intended for the exclusive use of trained persons within the commercial vehicle industry, and must not be passed on to any third party.
All recommendations regarding products and their servicing or usage are with reference to Knorr-Bremse products and should not be considered applicable to products from other manufacturers.
This information does not purport to be all-inclusive and no responsibility is assumed as a result of its use. We cannot accept any liability nor offer any guarantee regarding data accuracy, completeness or timeliness. The information does not represent any guarantee or ensured characteristics of the Products or Systems described.
No liability can be accepted based on the information, its use, recommendations or advice provided. In no event may we be held liable for any damage or loss except in the case of wilful intent or gross negligence on our part, or if any mandatory legal provisions apply.
Any legal disputes arising from the use of this information shall be subject to German law.
This disclaimer is an English translation of a German text, which should bereferred to for all legal purposes.
1. Coupling Head with Filter “Supply”2. Coupling Head with Filter “Control”3. ABS Connection, ISO 76384. Relay Emergency Valve5. Combined Park/Shunt Valve6. Load Sensing Valve7. Air Reservoir, Brakes8. ABS Trailer Module9. Brake Chamber10. Air Disc Brake11. Brake Disc12. Sensing Ring and Wheel Speed Sensor13. Double Check Valve
14. Quick Release Valve15. Spring Brake16. Charging Valve without Feedback17. Air Reservoir, Suspension18. In-line Filter19. 3/2 Control Valve20. Lift Axle Valve - Pneumatically Controlled21. Lift Bellows22. Air Suspension Bellows23. Levelling Valve24. Raise/Lower Valve25. Test Connector
1
Trailer Handbook
KB4TA ABS Trailer Braking System - 2S/2M
www.knorr-bremseCVS.com
1. Coupling Head with Filter “Supply”2. Coupling Head with Filter “Control”3. ABS Connection, ISO 76384. Relay Emergency Valve5. Combined Park/Shunt Valve6. Load Sensing Valve7. ABS Trailer Module8. Air Reservoir, Brakes9. Charging Valve10. In-line Filter
11. Air Reservoir, Suspension12. Test Connector13. Levelling Valve14. Spring Brake 15. Air Disc Brake16. Brake Chamber17. Air Suspension Bellows18. Brake Disc19. Sensing Ring & Wheel Speed Sensor
2
Trailer Handbook
TEBS 4 EBS Trailer Braking System - 2S/2M
www.knorr-bremseCVS.com
1. Coupling Head with Filter, “Supply”2. Coupling Head with Filter, “Control”3. EBS Connection, ISO 76384. Park/Shunt Valve with Emergency Function5. Air Reservoir, Brakes6. EBS Trailer Module7. Brake Chamber8. Spring Brake9. Air Disc Brake 10. Brake Disc11. Sensing Ring and Wheel Speed Sensor
12. Wear Sensor13. Charging Valve14. Air Reservoir, Suspension15. Levelling Valve16. Raise/Lower Valve17. Lift Axle Valve - Electrically Controlled18. Air Suspension Bellows19. Lift Bellows20. Junction Block21. Test Connector22. 24N Connector ISO1185
3
Trailer Handbook
TEBS-G2 EBS Trailer Braking System - 2S/2M
www.knorr-bremseCVS.com
1. Coupling Head with Filter, “Supply”2. Coupling Head with Filter, “Control”3. EBS Connection, ISO 76384. Park/Shunt Valve with Emergency Function (with built-in charging valve)
5. Air Reservoir, Brakes6. TEBS G2 Trailer Module7. Brake Chamber8. Spring Brake9. Air Disc Brake 10. Brake Disc
11. Sensing Ring and Wheel Speed Sensor12. In Pad Wear Sensor13. Air Reservoir, Suspension14. Levelling Valve15. Raise/Lower Valve16. Lift Axle Control Valve17. Air Suspension Bellows18. Lift Bellows19. Junction Block20. Test Connector21. 24N Connector ISO 1185
4
Trailer Handbook
Valves
Coupling Heads
fig 1 fig 2 fig 3 fig 4 fig 5 fig 6
Part No Type No Fig Port sizes A Note
K000952 KU1400 1 M16 x 1.5 A1 with built-in filter K000953 KU1401 1 M16 x 1.5 A2 with built-in filterK000954 KU1410 2 M16 x 1.5 A1 with built-in filterK000957 KU1413 2 M16 x 1.5 A2 with built-in filterII17354 KU1310 3 M16 x 1.5 A1 & A2
K004231 KU4124 3 M16 x 1.5 - tractor unit end onlyII17355 KU1311 4 M16 x 1.5 A1 & A2
K004230 KU4128 4 M16 x 1.5 - tractor unit end onlyEX5 KU2002 5 M22 x 1.5 A1 & A2
114/1X/5 KU2001 6 M22 x 1.5 A1 & A2
A - applicationA1
- semi-trailersA2
- centre-axle & draw-bar trailers
Coup
ling
Hea
ds
www.knorr-bremseCVS.com
In-line Filter & Trailer Air Dryer
Part No Type No Fig Supply Port (s) Delivery port (s) Note
I99660* LA2103 1 M22 x 1.5 M22 x 1.5 with bypass feature800765** 2 1/4”NPTF 1/4”NPTF 10 bar max working pressure
fig 1 fig 2
* - the filter should be cleaned regularly** - fits between the red supply line & the yellow control line, removes moisture from the trailer braking system
In-li
ne F
ilter
& T
raile
r Air
Dry
er
5
Trailer Handbook
Valves
Part No Type No Fig Port sizes Note
Park/Shunt Valves
K015849N00* AE4311 1 M16 x 1.5, M22 x 1.5 (x2) replaces K001664K020123N00* AE4311 2 M16 x 1.5, M22 x 1.5 (x2) includes push in fittings & charging valve (6.0 bar)K015380N00* AE4311 2 M16 x 1.5, M22 x 1.5 (x2) with charging valve (6.0 bar)II36129** AE4247 3 M16 x 1.5 II19802 AE4262 4 M16 x 1.5 red control buttonII19803 AE4261 5 M16 x 1.5 black control buttonII36159 AE4216 6 M22 x 1.5 (voss) often attached to RE valvesII36160 AE4217 6 M16 x 1.5 (voss) often attached to RE valves
* - instruction plate Pt No: Z006845** - red button Pt No: EB001473 black button Pt No: EB001471
fig 1 fig 2 fig 3 fig 4 fig 5 fig 6
Park
/Shu
nt V
alve
s
www.knorr-bremseCVS.com
Part No Type No Fig Supply Delivery Control Note
Relay Valves
fig 1 fig 2 fig 3
I76204 RE1115 1 M22 x 1.5 M16 x 1.5 M16 x 1.5I76202 RE1121 1 M22 x 1.5 M16 x 1.5 M16 x 1.5 I85168 RE1131 1 M22 x 1.5 M22 x 1.5 M16 x 1.5AC574AXY 2 M22 x 1.5 M22 x 1.5 M22 x 1.5 integrated silencer280375DK 3 1/2”NPTF 3/8”NPTF 1/4”NPTF R6 Valve
Rela
y va
lves
6
Trailer Handbook
Valves
Relay Emergency Valves
Part No Type No Fig Supply Delivery Control Predominance
fig 1 fig 2 fig 3 fig 4
AS3100A * 1 M22 x 1.5 M22 x 1.5 M22 x 1.5 0.5 barAS3050A 2 M22 x 1.5 M22 x 1.5 M22 x 1.5 withoutAS3000A 2 M22 x 1.5 M22 x 1.5 M22 x 1.5 0.5 bar281865N** 3 3/4” NPTF (x1) 1/4”NPTF 1/4”NPTF without 1/2” NPTF (x1)SEB01162 AS3054 4 M16 x 1.5 (x1) M16 x 1.5 (x4) M16 x 1.5 without M22 x 1.5 (x1) M22 x 1.5 (x2)SEB00409 AS3018 4 M22 x 1.5 M16 x 1.5 (x4) M22 x 1.5 0.0 bar M22 x 1.5 (x2)SEB00034*** AS3250 4 M16 x 1.5 (x1) M16 x 1.5 (x4) M16 x 1.5 (x2) without M22 x 1.5 (x1) M22 x 1.5 (x2)
* - comes with manoeuvring valve Pt No: AE4232** - supplied with port adaptors*** - comes with DR4501 fitted in port 1
Rela
y Em
erge
ncy
Valv
es
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Part No Type No Fig Supply Delivery Control Signal
Air Suspension Load Sensing Valves
fig 1 fig 2
II36836 BR5522 1 M22 x 1.5 M16 x 1.5 (x2) - M12 x 1.5 (x2)SEB00658* BR5503 2 M22 x 1.5 M16 x 1.5 (x4) M16 x 1.5 M12 x 1.5 (x2) M22 x 1.5 (x2)SEB00651** BR5504 2 M16 x 1.5 (x1) M16 x 1.5 (x4) M16 x 1.5 M12 x 1.5 (x2) M22 x 1.5 (x1) M22 x 1.5 (x2)I73358*** BR56 3 M22 x 1.5 M22 x 1.5 - M12 x 1.5
fig 3
* - with relay function & inshot 0.4 bar** - with relay emergency function*** - this valve is factory set to match any coded variant. the code is on the valve’s identification plate e.g. BR56H9G, this code is CRITICAL and must be quoted when ordering
Air S
uspe
nsio
n Lo
ad S
ensin
g Va
lves
7
Trailer Handbook
Valves
Mechanical Suspension Load Sensing Valves
Part No Type No Fig Supply Delivery Control Inshot
fig 1 fig 2 fig 3 fig 4 fig 5
KY890/1 1 M22 x 1.5 M22 x 1.5 - without1111999000* 2 M16 x 1.5 (x1) M16 x 1.5 (x4) M16 x 1.5 without M22 x 1.5 (x1) M22 x 1.5 (x2)KY2248/1 3 M22 x 1.5 M22 x 1.5 - 0.5 bar1111951000 4 M16 x 1.5 M16 x 1.5 - 0.5 barSEB00933** BR4370 5 M22 x 1.5 (x2) M16 x 1.5 (x4) M16 x 1.5 SEB00659*** BR4352 5 M16 x 1.5 (x1) M16 x 1.5 (x4) M16 x 1.5 M22 x 1.5 (x1) M22 x 1.5 (x2)
* - with relay emergency function** - static operation without relay emergency function*** - dynamic operation with emergency function
Mec
hani
cal S
uspe
nsio
n Lo
ad S
ensin
g Va
lves
www.knorr-bremseCVS.com
Part No Type No Fig Port (s) Note
Double Check Valves
fig 1 fig 2 fig 3 fig 4
1111419000 1 M16 x 1.5 without mounting bracketI40405 AE4105 2 M22 x 1.5 without mounting bracket295358 3 M16 x 1.5 with mounting bracketI85731 AE4146 4 M16 x 1.5 without mounting bracket
Dou
ble
Chec
k Va
lves
8
Trailer Handbook
Single Check Valves
Part No Type No Fig Supply Delivery Note
fig 1
Valves
fig 2
I75598 AE5115 1 M22 x 1.5 (f ) M22 x 1.5 (f )KW2966/1 2 1/2”NPTF (f ) 1/2”NPTF (m)KW3205/1 2 1/2”NPTF (f ) 1/2”NPTF (m) slightly longer body than KW2966/1KW4455/1 2 M22 x 1.5 (f ) M22 x 1.5 (m)
f = female threadm = male thread
Sing
le C
heck
Val
ves
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Part No Type No Fig Supply Delivery Exhaust Note
Quick Release Valves
fig 1 fig 2 fig 3
KX1294/1 1 M22 x 1.5 M16 x 1.5 M16 x 1.5KX1294/2 1 M16 x 1.5 M16 x 1.5 M16 x 1.5KX2000/1 1 M22 x 1.5 M22 x 1.5 M22 x 1.51194339 2 M16 x 1.5 M16 x 1.5 (x4) M22 x 1.5 4 port quick release valveI43387* DB2110 3 M22 x 1.5 M22 x 1.5 - limited quick release valve
* - can be adjusted with gauges
Qui
ck R
elea
se V
alve
s
9
Trailer Handbook
Charging Valves
Part No Type No Fig Ports Opening Pressure Note
fig 1
Valves
K000630 DR4256 1 M22 x 1.5 6.0 bar limited feedbackK000644 DR4378 1 M22 x 1.5 6.0 bar non-feedbackK000618 DR4155 1 M22 x 1.5 6.0 bar full feedback
Char
ging
Val
ves
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Part No Type No Fig Ports Pressure Setting Note
Pressure Limiting Valves
fig 1 fig 2
1111340000 1 M16 x 1.5 - adjustable 1.5 to 8.0 barI61236 DB1103 2 M22 x 1.5 5.3 bar adjustable 1.5 to 8.0 bar
adjustable delivery out
Pres
sure
Lim
iting
Val
ves
10
Trailer Handbook
Pressure Protection Valves
Part No Fig Ports Pressure Setting Note
fig 1
Valves
277147N 1 1/4”NPTF 4.4 bar277148DK 1 1/4”NPTF 5.8 bar adjustable 2.0 to 6.9 bar277227N 1 1/4”NPTF 5.1 bar
Pres
sure
Pro
tect
ion
Valv
es
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Part No Type No Fig Ports Reduction Ratio
Pressure Proportioning Valves
fig 1
I86154 DB2115 1 M22 x 1.5 1.50:1I86155 DB2116 1 M22 x 1.5 1.15:1I86156 DB2118 1 M22 x 1.5 1.35:1I86158 DB2122 1 M22 x 1.5 1.25:1
Note - is available in various ratios & are NOT interchangeable! correct part number is essential
Pres
sure
Pro
port
ioni
ng V
alve
s
11
Trailer Handbook
Valves
Shut Off Cocks
fig 1
I28323 AE2100 1 M22 x 1.5 with one shut off positionII33261 AE2110 1 M22 x 1.5 with two shut off positions
Note - these modules require programming, for this you require Knorr-Bremse ECU Talk® software Pt No: KB915
TEBS
4 E
BS T
raile
r Sys
tem
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Part No Type No Fig Length Description
TEBS 4 Connecting Cables
fig 1 fig 3fig 2 fig 4 fig 5 fig 6 fig 7
Note - all cables are available in different lengths & connection, please call Technical Services Tel: 01179 846222RTR - return to ride heightLAC - lift axle control
TEBS
4 C
onne
ctin
g Ca
bles
II3674112000 EK3110 1 12m ISO 7638 power supply cable complete with socketII3674115000 EK3110 1 15m ISO 7638 power supply cable complete with socket
Note - all cables are available in different lengths & connection, please call Technical Services Tel: 01179 846222
www.knorr-bremseCVS.com
Trai
ler I
nfor
mat
ion
Mod
ule
(TIM
)
Part No Type No Fig Description
Trailer Information Module (TIM)
fig 1
II39810FSP EZ1035 1 TIM with fixed cable (as shown)KB914 1 TIM with fixed cable + adaptor cable for older trailersKB925 1 TIM retro fit kit complete with TIM & X1 connecting cable
Note - NOT interchangeable with TEBS G2 TIM
19
Trailer Handbook
ABS/EBS Components
TEBS G2 EBS Trailer System
fig 1
TEBS
G2
EBS
Trai
ler S
yste
m
Part No Type No Fig Length Description
Note - these modules require programming, for this you require Knorr-Bremse ECU Talk® software.
For part numbers please call Knorr-Bremse Technical Services Tel: 0117 9846 222
www.knorr-bremseCVS.com
TEBS
G2
Conn
ectin
g Ca
bles
Part No Fig Length Description
TEBS G2 Connecting Cables
fig 1
K008430N00 1 10m ISO 7638 power supply cableK008431N00 1 13m ISO 7638 power supply cable
K002274 2 2m X2 Aux cable, RTR or LACK002275 2 6.5m X2 Aux cable, RTR or LACK002276 2 10m X2 Aux cable, RTR or LACK021340N00 3 - X2 Aux cable (RTR/LAC), stop lamp & “Traction Help” with diagnostic
K002287N00 5 - X2 Plug assembly (pins NOT included)
Note - NOT interchangeable with TEBS 4 power cablesRTR - Return To Ride height functionLAC - Lift Axle Control
20
fig 2 fig 3 fig 4
fig 5
Trailer Handbook
ABS/EBS Components
TEBS G2 Trailer Information Module (TIM G2)
fig 1
Part No Fig Description
TEBS
G2
Trai
ler I
nfor
mat
ion
Mod
ule
(TIM
G2)
K009166N00 1 Trailer Information Module (TIM G2)
Note - NOT interchangeable with TEBS 4 TIM
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Part No Type No Fig Description
ABS Modulator & Wheel Speed Sensor
fig 1
ABS
Mod
ulat
or &
Whe
el S
peed
Sen
sor
fig 2 fig 3
II37091N00 BR9234 1 used for the 3rd ABS Modulator on TEBS 4 & TEBS G2
0486000134000 2 wheel speed sensor with mounting bushII16774 3 mounting bush for wheel speed sensor
21
Trailer Handbook
ABS/EBS Components
Trailer Data Plates & Warning Stickers
Part No Fig Description
Trai
ler D
ata
Plat
es &
War
ning
Stic
kers
fig 1 fig 2 fig 3 fig 4
KBP2172/1 1 “EBS with RSP” stickerKBP2153/2 2 ISO 7638 headboard warning stickerKBP2146/2 3 aluminium chassis data plateII39797F 4 silver foil data plate (requires ECU Talk® software to print)
www.knorr-bremseCVS.com
Part No Type No Fig Description
ABS/EBS Diagnostics
fig 1
ABS/
EBS
Dia
gnos
ticsfig 2 fig 3 fig 4 fig 5
II36381 EZ1022 1 blink code switch used on various ABS systemKBP2240/1 2 ABS diagnostic handbook, contains blink codes & wiring diagrams for all Knorr-Bremse ABS systems (including truck & buses)KB914 3 for reading faults codes on TEBS4 ONLYKB915* 4 diagnostics software for TEBS 4 & all connecting cablesK009166N00 5 for reading fault codes on TEBS G2 ONLY
22
* - comes with training, which can be carried out on the customers premises
Trailer Handbook
ABS/EBS Components
ABS/EBS Retrofit Kits
Part No Type No Fig Description
ABS/
EBS
Retr
ofit k
itsfig 1 fig 2 fig 3
K023164B90 KB4TA 1 ABS retrofit kit, contains ABS ECU/module & all power cables + RE ValveKB908* 2 EBS retrofit kit, contains TEBS Module without RSP, park/shunt valve & all power cables KB909* 2 EBS retrofit kit, contains TEBS Module with RSP & park/shunt valve all power cablesKB940* 3 EBS retrofit kit, contains TEBS Module without RSP & all power cables
* - when carrying out an EBS retrofit kit the ECU of the TEBS Module requires programming, for this you require a Brake Calculation. For further information contact Knorr-Bremse Technical Services Tel: 01179846222RSP - Roll Stability Programe
Note - Installation of a retrofit kit is a notifiable alteration. A VTG10 form must be completed & sent to VOSA. The trailer must also be signed off by an official Knorr-Bremse service centre or authorised agent (page 57 for Service Centres).
www.knorr-bremseCVS.com
Part No Fig Description Note
Tractor to Trailer Connecting Cables
fig 1
Trac
tor T
o Tr
aile
r Con
nect
ing
Cabl
es
fig 2 fig 3
K002290 1 ISO 7638 socket & pinsK018857K50 1 ISO 7638 socket & pins with screw type terminals1194511SP 2 15 pin to 24N & 24SKB7638 3 7 pin connecting cable ADR approved
23
Trailer Handbook
Brake Actuators
S-Cam Brake Chambers
S-Ca
m B
rake
Cha
mbe
rs
Part No Type No Type Port(s) Stroke A B Diaphragm
II39906FA BZ3259 12 M16 x 1.5 75mm M16 x 1.5 190mm -II33457A BZ3374 16 M16 x 1.5 75mm M16 x 1.5 190mm 16LSII33782A BX3419 20 M16 x 1.5 75mm M16 x 1.5 190mm 20LSII33442A BX3535 24 M16 x 1.5 75mm M16 x 1.5 190mm 24LSII33783A BX3538 24 M16 x 1.5 75mm M16 x 1.5 190mm 24LSII33488A BX3607 30 M16 x 1.5 75mm M16 x 1.5 190mm 30LS30010077/A** 24 1/4”NPTF 75mm 5/8”UNF 190mm -
A - push rod threadB - push rod length* - without mounting & push rod nuts, but with push rod bellow** - double diaphragm chamber
Double Diaphragm Brake Chamber
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S-Cam Spring Brake
S-Ca
m S
prin
g Br
ake
Part No Type No Type Port(s) Stroke A B Diaphragm
II37272 BZ9324 16/24 see note 57/57mm M16 x 1.5 300mm C60491II37274 BX9400 20/24 see note 57/57mm M16 x 1.5 300mm C60489II37276 BX9402 20/30 see note 57/57mm M16 x 1.5 300mm C60489II37029 BX9509 24/24 M16 x 1.5 64/64mm M16 x 1.5 200mm C72337II37277 BX9519 24/24 see note 57/57mm M16 x 1.5 300mm B64322II37279 BX9521 24/30 see note 57/57mm M16 x 1.5 300mm B64322 II37281 BZ9657 30/30 see note 64/64mm M16 x 1.5 300mm B75383
A - push rod threadB - push rod lengthNote - this spring brake comes complete with yoke (pin dia 14mm) & port adaptors (M22 voss, M22 x 1.5 & M16 x 1.5).
24
Trailer Handbook
Brake Actuators
Anchorlok Double Diaphragm Spring Brakes
Anch
orlo
k D
oubl
e D
iaph
ragm
Spr
ing
Brak
es
Part No Type Port(s) Stroke A B Diaphragm Portion
2024GCMSS 20/24 M16 x 1.5 57/57mm M16 x 1.5 241mm 234099K 2024GPM2024GCSS 20/24 3/8”NPTF 57/57mm 5/8”UNF 241mm 234099K 2024GP2424GCLS 24/24 3/8”NPTF 64/64mm 5/8”UNF 241mm 234100K 2424GP2424GCMLS 24/24 M16 x 1.5 64/64mm M16 x 1.5 241mm 234100K 2424GPM2430GCLS 24/30 3/8”NPTF 64/64mm 5/8”UNF 241mm 234100K 2430GP2430GCMLS 24/30 M16 x 1.5 64/64mm M16 x 1.5 241mm 234100K 2430GPM2430GCMEXLS 24/30 M16 x 1.5 75/75mm M16 x 1.5 241mm 24LS 2430GPMEXLS3030GCLS 30/30 3/8”NPTF 64/64mm 5/8”UNF 241mm 234101K 3030GP3030GCMLS 30/30 M16 x 1.5 64/64mm M16 x 1.5 241mm 234101K 3030GPM
A - push rod threadB - push rod length
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Clam
p Ri
ngs
Clamp Rings
Part No Fig Type Note
fig 1 fig 2
SK2950/8 1 24 one piece clampSK2950/9 1 30 one piece clamp SK2950/7 2 20 two piece clamp1133M005-CA* 2 20 two piece clamp1127M005-CA* 2 24 two piece clamp1126M005-CA* 2 30 two piece clamp
* - Anchorlok clamp rings
25
Trailer Handbook
Yoke
s
Yokes
Part No Fig Thread Size Pin Dia Jaw Width Note
Brake Actuators
269700 1 M14 x 1.5 16mm 14.7mm272917 1 M16 x 1.5 12.60mm 14.7mm274520 1 5/8”UNF 13.7mm 14.7mm295517 1 M16 x 1.5 14.0mm 14.7mm295518 1 M14 x 1.5 14.0mm 14.7mm205948 1 1/2”UNF 1/2” 9/16”228791DK 1 5/8”UNF 1/2” 9/16”267086 1 M16 x 1.5 16.0mm 15.2mm11M018M 2 M16 x 1.5 14.0mm 14.5mm Anchorlok yoke1185157 4 M16 x 1.5 12.5mm 14.7mm228790DK 5 5/8”UNF 1/2” 9/16” longer thread than 228791SEB01316 6 M16 x 1.5 14.0mm 14.5mm complete with nuts & washers
fig 1 fig 2 fig 3 fig 4 fig 5 fig 6
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Air D
isc B
rake
Cha
mbe
rs
Air Disc Brake Chambers
Part No Type No Type Port(s) Stroke Diaphragm Note
II31782SP BS3251 14 M16 x 1.5 (radial) 57mm C67204 with mounting nutsII38924F BS3361 16 M16 x 1.5 (axial) 57mm C72596 without mounting nutsII14535SP BS3300 16 M16 x 1.5 (radial) 57mm C72956 with mounting nutsII38111F BS3321 16 M16 x 1.5 (radial) 57mm C72596 without mounting nutsII15229SP BS3350 18 M16 x 1.5 (radial) 57mm B493632 with mounting nutsII31098SP BS3404 20 M16 x 1.5 (radial) 57mm C60489 with mounting nutsII31099 BS3453 22 M16 x 1.5 (radial) 57mm C52066 without mounting nutsII30618 BS3509 24 M16 x 1.5 (radial) 57mm B64322 without mounting nutsII31100 BS3551 27 M16 x 1.5 (radial) 57mm C72568 without mounting nuts
Note - when fitting chamber to caliper always position one drain hole open & facing down
26
Trailer Handbook
Air Disc Brake Spring Brake
Brake Actuators
Part No Type No Type Port(s) Stroke Diaphragm
II31783SP BS9297 14/16 M16 x 1.5 57/57mm C67204 II31227SP BS9397 16/16 M16 x 1.5 57/57mm C60491II38595F BS9375 16/16 M16 x 1.5 57/57mm C60491II31663 BS9349 18/16 M16 x 1.5 57/57mm B493632II30619SP BS9304 16/24 M16 x 1.5 57/57mm C60491II35736 BS9356 18/24 M16 x 1.5 57/57mm C66410II31407000 BS9404 20/24 M16 x 1.5 57/57mm C60489II31226 BS9451 22/24 M16 x 1.5 57/57mm C52066II31097 BS9426 20/30 M16 x 1.5 57/57mm C60489II31408SP BS9503 24/24 M16 x 1.5 57/57mm B64322
Note - when fitting chamber to caliper always position one drain hole open & facing down
Air D
isc B
rake
Spr
ing
Brak
e
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Anch
orlo
k D
oubl
e D
iaph
ragm
Spr
ing
Brak
es
Anchorlok Double Diaphragm Spring Brakes
Part No Type No Type Port(s) Stroke Diaphragm Note
Note - when fitting chamber to caliper always position one drain hole open & facing down
II39355FSP BS7309 16/24 M16 x 1.5 57/57mm C72596 with mounting nutsII38120FSP BS7350 18/24 M16 x 1.5 57/57mm C72596 with mounting nuts
27
Trailer Handbook
BPW
Air
Disc
Bra
kes
Air Disc Brakes
BPW Air Disc Brakes
Type No Part No Pad Kit Guide Pin Kit Tappet/Boot Kit RC Caliper/Carrier
(1) - These are Jurid pads see page 37 for other pad types.(2) - User may have fitted metal cap kit, so use II39769F0062 kit.R C = Rationalised Caliper (Caliper only, NO carrier NO pads).
Note - Pad retaining springs should NEVER be re-used - this can cause excessive abutment wear.
(1) - These are Jurid pads see page 37 for other pad types.(2) - User may have fitted metal cap kit, so use II39769F0062 kit.R C = Rationalised Caliper (Caliper only, NO carrier NO pads).
Note - Pad retaining springs should NEVER be re-used - this can cause excessive abutment wear.
(1) - These are Jurid pads see page 37 for other pad types.(2) - User may have fitted metal cap kit, so use II39769F0062 kit.R C = Rationalised Caliper (Caliper only, NO carrier NO pads).
Note - Pad retaining springs should NEVER be re-used - this can cause excessive abutment wear.
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DaimlerChrysler Air Disc Brakes
Dai
mle
rChr
ysle
r Air
Disc
Bra
kes
Type No Part No Pad Kit Guide Pin Kit Tappet/Boot Kit RC Caliper/Carrier
(1) - These are Jurid pads see page 37 for other pad types.(2) - User may have fitted metal cap kit, so use II39769F0062 kit.R C = Rationalised Caliper (Caliper only, NO carrier NO pads).
Note - Pad retaining springs should NEVER be re-used - this can cause excessive abutment wear.
(1) - These are Jurid pads see page 37 for other pad types.(2) - User may have fitted metal cap kit, so use II39769F0062 kit.R C = Rationalised Caliper (Caliper only, NO carrier NO pads).
Note - Pad retaining springs should NEVER be re-used - this can cause excessive abutment wear.
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Hendrickson Air Disc Brakes
Hen
dric
kson
Air
Disc
Bra
kes
Type No Part No Pad Kit Guide Pin Kit Tappet/Boot Kit RC Caliper/Carrier
(1) - These are Jurid pads see page 37 for other pad types.(2) - User may have fitted metal cap kit, so use II39769F0062 kit.R C = Rationalised Caliper (Caliper only, NO carrier NO pads).
Note - Pad retaining springs should NEVER be re-used - this can cause excessive abutment wear.
(1) - These are Jurid pads see page 37 for other pad types.(2) - User may have fitted metal cap kit, so use II39769F0062 kit.R C = Rationalised Caliper (Caliper only, NO carrier NO pads).
Note - Pad retaining springs should NEVER be re-used - this can cause excessive abutment wear.
(1) - These are Jurid pads see page 37 for other pad types.(2) - User may have fitted metal cap kit, so use II39769F0062 kit.R C = Rationalised Caliper (Caliper only, NO carrier NO pads).
Note - Pad retaining springs should NEVER be re-used - this can cause excessive abutment wear.
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Assembly Grease
Part No Fig Qty Colour Note
Asse
mbl
y G
reas
e
fig 1 fig 2
II14525 - 5 g white used on caliper guide pinsII32868 1 500 g white used on caliper guide pinsII32793 - 5 g green used on SB type rubber bush ONLYZ000046 2 500 g green used on SB type rubber bush ONLY
35
Trailer Handbook
Rationalised Calipers
Type No Part No Pad Kit Guide Pin Kit Tappet/Boot Kit
II180220062 3 SB/SN 7 Jurid-539FF Not for SN calipers using keypadK001104 3 SB/SN 7 Ferodo-455 Not for SN calipers using keypadK000543 3 SB 7 Ferodo-4569 For some SMB axles - no keypadK015946 4 SN 7 Textar-T3030 Keypad BPWK004476 3 SB/SN 7 Textar-T3030
K015947 5 SK 7 Textar-T3030 Keypad BPWK004169 6 SK 7 Jurid-539-FF29 For caliper without keypad II376580062 2 SB/SN 6 Jurid-539-20 Not for SN calipers using keypadK000464 2 SB/SN 6 Ferodo-4550 Not for SN calipers using keypadK002733 2 SB/SN 6 Textar-T3030 Not for SN calipers using keypadK011469 1 SN 6 Textar-T3030 Keypad - BPW
Pad Kit Contents:- Axle set of brake pads fitted with patended pad retaining springs- Two pad retainer bars- Two sets of retaining pin, washer & split pin- Two new adjuster caps (to suit both old & new style caliper)- Adjuster adapter
92.5mm
210.8mmfig 1 fig 2
92.5mm
210.8mmfig 3
109.5mm
247.6mmfig 4
109.5mm
247.6mm
fig 5
102.1mm
210.8mmfig 6
102.1mm
210.8mm
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Breakaway Adjuster Old Level Cap New Level Cap
A
Adjuster Cap Kits
Adju
ster
Cap
KitsPart No Fig A Note
K000945 1 38mm contains new level cap, old level cap & breakaway adjuster (10 off each)K000029 1 38mm SB/SN contains new level cap & breakaway adjuster (10 off each)K003902 1 35mm SK7 contains new level cap & breakaway adjuster (10 off each)
fig1
37
Trailer Handbook
Carriers
Part No Fig Caliper A B C D Main User
Air Disc Brakes
Carr
iers
fig 1 fig 2 fig 3 fig 4
fig 5 fig 6 fig7 fig 8
fig 9 fig 10
K000690 1 SB6/SN6 6 M16 x 1.5 M16 x 1.5 1L, 1R SAFK002979 1 SB6/SN6 6 M16 x 1.5 M16 x 1.5 none SMBK001105 1 SB6/SN6 6 M16 x 1.5 M16 x 1.5 none BPWK000027 2 SB7/SN7 6 M16 x 1.5 M16 x 1.5 1L, 1R DC (Discos axles)K004680 3 SB7/SN7 6 M16 x 1.5 M16 x 1.5 none BPWK001505 4 SB7/SN7 6 M18 x 1.5 M16 x 1.5 none BPW
A - Number of mounting holesB - Carrier to axle threadsC - Carrier to caliper threadsD - Counter sunk holes
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K001525 5 SB7/SN7 4 M20 x 1.5 M16 x 1.5 none SMBK000026 6 SB7/SN7 6 M16 x 1.5 M16 x 1.5 1L, 1R SAF, DC (Discos axles)K001531 6 SB7/SN7 6 M16 x 1.5 M16 x 1.5 none SMBK004099 7 SK7 6 M16 x 1.5 M16 x 1.5 1L, 1R SAFK001521 8 SB7/SN7 6 M18 x 1.5 M16 x 1.5 none BPWK004678 9 SB7/SN7 6 M20 x 1.5 M16 x 1.5 none HendricksonK001275 10 SB7/SN7 6 M16 x 1.5 M16 x 1.5 1L, 1R DCK001494 - SB6/SN6 6 M16 x 1.5 M16 x 1.5 none DC (Discos axle)K001493 - SB6/SN6 6 M16 x 1.5 M16 x 1.5 none BPWK001496 - SB6/SN6 6 M16 x 1.5 M16 x 1.5 1L, 1R SAFK001497 - SB6/SN6 5 M16 x 1.5 M16 x 1.5 1R BPWK004206 - SB6/SN6 5 M16 x 1.5 M16 x 1.5 1L BPW
38
Carr
iers
Trailer Handbook
Air Disc Brakes
Fig 1 Fig 2 Fig 3
Brake Discs
Part No Fig D T(t) T(k) T(i) S(new) S(min) L(k) B Brak
e D
iscs
II379830061 1 430 159.5 335 290 45 37 12 10 x Ø23II376380061 2 430 132.5 238 197 45 37 12 10 x M14 x 1.5K005938 3 430 130 168 131 45 37 12 12 x Ø19 & 3 x M12 x 1.5
BPW & Schmitz SB7/SN7 DaimlerChrysler SB7/SN7 SAF SB7/SN7
Note - all measurements are in Millimeters (mm)
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Air Disc Brake Tool Kits
Calip
er To
ol K
its
Part No Fig A Note
Fig 1 Fig 2
II37951004EN ZB9032 1 for servicing “SB” type calipers, includes service manual & videoK016947 ZB9036 2 for servicing “SN” type calipers, includes service manual & video
39
Trailer Handbook
Slack Adjusters (Automatic)
Slack Adjusters (Automatic)
fig 1
Part No Fig Spline Hole(s) Hand Hole Centre Opposite side
KB1000 1 A 14.0 x 5 L & R 115/127/140/153/205 -KB1005 2 A 14.0 x 6 L & R 120/135/150/165/180/250 -KB1010 3 A 14.0 x 6 L & R 120/135/150/165/180/250 -KB1015 4 A 14.0 x 4 L & R 125/150/180/210 -KB1020 5 B 14.0 x 3, 16.0 x 1 L & R 105/129/153/215 -KB1025 17 A 14.0 x 3, 16.0 x 1 L & R 105/129/153/215 -KB1030 - A 14.0 x 6 L & R 105/125/140/155/180/250 -KB1035 3 A 14.0 x 5 L & R 125/150/180/210/250 -
A - 10 SAE 1-1/2”-10cB - 37 Spline (fine)
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KB1040 14 A 14.0 x 5 L & R 105/129/153/181/215 -KB1045 19 A 14.0 x 6 L & R 120/135/150/165/180/250 -KB1050 5 B 14.0 x 3, 16.0 x 1 L & R 105/129/153/215 -KB1055 8 A 14.0 x 5 L & R 105/129/153/181/215 -KB1060 14 A 12.8 x 5 L & R 105/129/153/181/215 -KB1065 13 A 12.8 x 4 L & R 127/152/178/203 -KB1070 15 A 14.0 x 2, 16.0 x 1 L & R 118/142/215 -KB1075 16 A 14.0 x 5 L & R 125/150/180/210/250 -KB1080 10 A 14.0 x 4 L & R 127/152/176/200 -KB1085 7 A 14.0 x 3 L 125/150/180 KB1090KB1090 7 A 14.0 x 3 R 125/150/180 KB1085KB1095 9 A 14.0 x 3 L & R 105/129/153 -KB1100 8 A 14.0 x 5 L & R 105/129/153/181/215 -KB1110 20 A 14.0 x 3 R 127/152/178 KB1160KB1115 18 A 14.0 x 3 R 151/179/203 KB1120KB1120 11 A 14.0 x 3 L 153/181/205 KB1115KB1130 21 A 14.0 x 3 R 127/152/178 KB1135KB1135 21 A 14.0 x 3 L 127/153/179 KB1130KB1160 20 A 14.0 x 3 L 127/152/178 KB1110KB1170 6 A 14.0 x 3 L & R 127/141/153 -
Slac
k Ad
just
ers (
Auto
mat
ic)
40
Trailer Handbook
Slack Adjusters (Automatic)
Slack Adjusters (Automatic) Axle Sets
Part No Fig Spline Hole(s) Hand Hole Centre Opposite side
Slac
k Ad
just
ers (
Auto
mat
ic) A
xle
Sets
fig 1 fig 2 fig 3 fig 4 fig 5 fig 6 fig 7 fig 8
KB1000D 1 A 14.0 x 5 L & R 115/127/140/153/205 -KB1005D 2 A 14.0 x 6 L & R 120/135/150/165/180/250 -KB1010D 3 A 14.0 x 6 L & R 120/135/150/165/180/250 -KB1015D 4 A 14.0 x 4 L & R 125/150/180/210 -KB1020D 5 B 14.0 x 3, 16.0 x 1 L & R 105/129/153/215 -KB1025D 7 A 14.0 x 3, 16.0 x 1 L & R 105/129/153/215 -KB1030D A 14.0 x 6 L & R 105/125/140/155/180/250 -KB1045D 6 A 14.0 x 6 L & R 120/135/150/165/180/250 -
A - 10 SAE 1-1/2”-10cB - 37 Spline (fine)
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Slack Adjusters (Manual)
Part No Fig Spline Hole(s) Hand Hole Centre Opposite side
Slac
k Ad
just
ers (
Man
ual)
fig 1 fig 2
1194360 1 A 14.0 x 4 L & R 127/152/177/203 -1194361 1 A 1/2” x 4 L & R 127/152/177/203 -1194362 2 A 1/2” x 4 L & R 127/152/177/203 -1194363 2 A 14.0 x 4 L & R 127/152/177/203 -
A - 10 SAE 1-1/2”-10c
41
Trailer Handbook
Self-setting Automatic Slack Adjusters
Self-setting Automatic Slack Adjusters
Part No Fig Spline Hole(s) Hand Hole Centre Opposite side
Self-
sett
ing
Auto
mat
ic S
lack
Adj
uste
rs
fig 1 fig 2 fig 3 fig 4 fig 5 fig 6 fig 7 fig 8
A - 10 SAE 1-1/2”-10cB - 37 Spline (fine)
KB1500 1 A 14.0 x 6 L & R 120/135/150/165/180/250 -KB1505 2 A 14.0 x 5 L & R 115/127/140/153/205 -KB1510 3 B 14.0 x 3,16.0 x 1 L & R 105/129/153/215 -KB1515 4 A 14.0 x 6 L & R 105/125/140/155/180/250 -KB1520 5 A 14.2 x 3, 16.2 x 1 L & R 105/129/153/215 -KB1525 6 A 14.0 x 4 L & R 125/150/180/210 -KB1530 7 B 12.7 x 2 L & R 125/150 -KB1535 8 A 14.2 x 4 L & R 125/140/155/180 -
www.knorr-bremseCVS.com 42
Trailer Handbook
Air Suspension/Lift Axle Control
Raise/Lower Valves
Part No Type No Fig Supply Port(s) Delivery Port(s) Note
Raise
/Low
er V
alve
s
fig 1
I86024* SV3115 1 M16 x 1.5 M16 x 1.5 single circuit valve with one leverI83153* SV3111 2 M16 x 1.5 M16 x 1.5 dual circuit valve with one leverK002018 ** SV3240 3 M22 x 1.5 M16 x 1.5 manual operation with test point
Part No Type No Fig Supply Port(s) Delivery Port(s) Control Port(s) Note
Leve
lling
Val
ves
fig 1 fig 2
I87823 SV1307 1 M12 x 1.5 M12 x 1.5 - II19425 SV1395 1 M12 x 1.5 M12 x 1.5 - with increased flow rateII36114* SV1465 2 M12 x 1.5 M12 x 1.5 x2 M12 x 1.5 M16 x 1.5 M16 x 1.5 x1II36115* SV1466 2 M12 x 1.5 M12 x 1.5 x2 M16 x 1.5 M16 x 1.5 x1 -
* - with datum adjustment & height limitation (adjustable 20 to 50 degrees)
44
Trailer Handbook
Air Suspension/Lift Axle Control
Height Limiting Valves
Part No Type No Port(s) Upper Connection Lower Connection
Hei
ght L
imiti
ng V
alve
s
I83425 AE1122 M12 x 1.5 M8 threaded rod 4.2mm holeI60496 AE1103 M12 x 1.5 M8 threaded rod M8 threaded rod
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Linkages
Part No Type No Fig Note
Link
ages
fig 1 fig 2 fig 3 fig 4 fig 5 fig 6
fig 7 fig 8
KW3027/1 1 SKW3027/1 comes with mounting nutsSEB00256 ZB3117 2 K001406 3 KX1037/1 4 single axle LSV lower linkageKX1178/1 5 tandem/tri axle LSV lower linkageKX1125/1 6II19099 ZB3130 7 300mm lever lengthII19422 ZB3131 8 300mm lever length
45
Trailer Handbook
Useful Information
Electrical Plugs - Pin Allocation
Elec
tric
al P
lugs
- Pi
n Al
loca
tion
ISO 7638 ISO 1185 (24N-24V) ISO 3731 (24S-24V)
1(red) - Positive (modulator)2(black) - Positive (ECU)3(yellow) - Negative (ECU)4(brown) - Negative (modulator)5(white) - Warning device (lamp)6(white/green) - Data line CAN H7(white/brown)- Data line CAN L
1(white) - Common return2(black) - L/H side lights3(yellow) - L/H indicator lamps4(red) - Stop lamps5(green) - R/H indicator lamps6(brown) - R/H side lights7(blue) - Trailer braking control
1(white) - Common return2(black) - Spare3(yellow) - Reversing lamps4(red) - Power supply5(green) - Sensing device with common return6(brown) - Spare7(blue) - Rear fog lamps
By the means of a blink code adaptor (Part No.: EZ1022), connected to the diagnostic socket fitted as standard in the wiring harness,A blink code display may be initiated (i.e. a sequence of flashes on the LED built into the blink code adaptor switch or on the towing vehicles trailer ABS warning lamp).With the ECU powered (ignition on), Wait at least 1 second then press the diagnostic button of the blink code adaptor switch for between 2 & 5 seconds, then release.Note: ECU stores only one fault code.
To erase the stored fault code the diagnostic button must be pressed & held during & for approx 2 seconds after power up of the system.
If the blink code adaptor switch is connected to a system that has no faults stored, then the LED will flash constantly indicating a correctly functioning system.
Note: If the ECU is replaced with a new unit, the trailer ABS warning lamp will stay on even though there are no stored faults in the ECU. This is normal for safety reasons. A new ECU needs to confirm that both wheel speed sensors are physically working, therefore , it will not turn the warning lamp off until the trailer moves.The following procedure should be followed:-Connect the electrical plugs ISO 7638 & ISO 1185 (24N) to the trailer-Drive the vehicle combination to approx 30 km/h, apply the footbrake & bring the trailer to a complete stop, with the foot brake constantly applied. Release the foot brake. The warning lamp will go out providing the dynamic sensor check has been successfully completed.
11 ECU/Modulator ground 12 Power supply 13 Fault in equipment connected “UNI” circuit 14 ECU internal fault
* If the ECU detects an excessive air gap between the sensor & sensing ring, the last pulse is of double the normal length (approx. 0.4s)
A18
Trai
ler S
yste
m B
link
Code
Info
rmat
ion
47
Trailer Handbook
KB4T
A Tr
aile
r Sys
tem
Blin
k Co
de In
form
atio
n
Useful Information
KB4TA Trailer System Blink Code Information
ECU Pt No: ES1305/K004246
- Ensure that the ABS is powered via the IS0 7638 connection.- Apply and release the brake pedal at 1 second intervals: a) 3 times to read current active faults b) 4 times to read stored faults- After a period of 5 seconds the blink codes will be displayed.- Observe the trailer ABS lamp in the towing vehicle and record the blink code sequence.- A description of each blink code is shown in the table below.- After rectifying any faults, check that the trailer ABS warning lamp in the towing vehicle is not illuminated after turning the ignition off & on. This may necessitate driving the vehicle over 10km/h.
Note: Blink code information is only available when the stop lamp power option and either 2S/2M or 4S/3M ABS are configured.
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1st Blink Code 2nd Blink Code
Code Location Code Description
1 All 1 No faults present2 Sensor SL 1 Wheel speed sensor air gap too big3 Sensor SR 2 Loss of wheel speed sensor signal4 Sensor SAL 3 Noisy wheel speed sensor signal5 Sensor SAR 4 Short or open circuit wheel speed sensor 5 Tyre size differential out of range 6 Wheel speed sensor configuration error
6 Power 1 Voltage too high 2 Voltage too low 3 Excessive resistance on ISO 7638 pin 1
7 Modulator 22 2 Exhaust solenoid short or open circuit8 Modulator 21 3 ABS valve installation error9 AUXI01/Modulator 2 4 Valve configuration error
10 Common 1 Internal short to ground 2 AUXI01 or modulator 2 short to ground 3 ABS valve dynamic error-all valves 4 Excessive ABS activity 5 AUXI01 or modulator 2 short to battery
11 ECU 1 Internal error 2 Configuration error
12 AUXI01 1 Short or open circuit13 AUXI02
14 System 2 Service interval exceeded
KB4T
A Tr
aile
r Sys
tem
Blin
k Co
de In
form
atio
n
48
Trailer Handbook
ABS A18 System
ABS KB3-TA System
KB4TA ABS System
Approx 2sIgnition On
Note: If the light continues to stay on, this indicates there is an active fault in the ABS system.
ECU Part no: ES2005/II36413
Approx 2sIgnition On
Note: If the light continues to stay on, this indicates there is an active fault in the ABS system.
ECU Part no: ES2001/II36383 ES2002/II36384Not shown in catalogue
Approx 2sIgnition On
Note: If the light continues to stay on, this indicates there is an active fault in the ABS system.
OR
Approx 2sIgnition On
Note: If the light continues to stay on, this indicates there is an active fault in the ABS system.
Light will stay on until approx 7-10 km/h
Useful Information
ABS Warning Light Sequences
ABS
War
ning
Lig
ht S
eque
nces
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TEBS 4 EBS System
Approx 2sIgnition On
Note: If the light continues to stay on, this indicates there is an active fault in the EBS system.
OR
Approx 2sIgnition On
Note: If the light continues to stay on, this indicates there is an active fault in the EBS system.
Light will stay on until approx 7-10 km/h
EBS Warning Light Sequences
EBS
War
ning
Lig
ht S
eque
nces
Approx 2sIgnition On
Note: If the light continues to stay on, this indicates there is an active fault in the EBS system.
TEBS-G2 EBS System
49
Trailer Handbook
Safety instructions for service work
Please carefully follow the instructions on the next pages & also refer to the relevant safety instructions for repair work on commercial vehicles, especially for jacking up & securing the vehicle. DO NOT under take any of this work, unless you have been trained.
Before starting service work on a brake actuator, ensure the service brake & parking brake are not applied and the wheels are chocked to ensure the vehicle the cannot roll away.
1. Removal of old spring brake
Check that the hand brake valve lever is in the “run” position (brakes released).Fully wind off the parking brake spring using the release bolt - see fig 1 (NG3 type) fig 2 (Anchorlok type).NG3 type - Using a 24mm spanner, rotate the wind off bolt in an anti-clockwise direction DO NOT EXCEED 35Nm TORQUE.
Anchorlok type - Remove the dust cover plug from the rear of the chamber to uncover the release tool keyhole. Remove release tool assembly from the side pocket of the chamber. Insert the release tool through the keyhole on the rear of the chamber. Turn release tool 1/4 turn clockwise to lock in position. Pull on release tool to ensure the tool is properly seated in the pressure plate. Assemble release tool stud washer & nut on release tool finger tight. To wind off the spring brake tighten release tool nut clockwise with a hand wrench & make certain push rod is retracting, DO NOT EXCEED 47Nm TORQUE
Fig 1 Fig 2
Useful Information
S-Cam Spring Brake Fitting Instructions
S-Ca
m S
prin
g Br
ake
Fitt
ing
Inst
ruct
ions
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Make sure hand valve is in the “off” - Park position. Disconnect air hoses from ports 11 & 12 taking careful note of which hose is Connected to each port.
Remove split pin & yoke pin from yoke assembly.
Unscrew & remove spring brake mounting nuts & remove washers (if fitted) -NUTS & WASHERS MUST NOT BE RE-USED.
Remove spring brake from vehicle.
2. Determine the correct push rod length from the old unit
In order to measure the push rod length , the parking brake spring MUST be in the fully wound off condition - See section 1 for instructions.
Measure the distance between the push rod end & the mounting face. If the old unit has a yoke welded to the push rod, measure between the yoke pin centre line & the mounting faceNote: If the old unit is damaged, it is possible that the push rod is not fully retracted. To check for this, push the push rod into the unit & hold it there whilst taking this measurement.
3. Selection of correct size of replacement spring brake
Refer to actuator section of this catalogue, if you have problems identifying the chamber, Please call Technical Service 01179 846222.
Continued on next page...
50
S-Ca
m S
prin
g Br
ake
Fitt
ing
Inst
ruct
ions
Trailer Handbook
Useful Information
S-Cam Spring Brake Fitting Instructions
S-Ca
m S
prin
g Br
ake
Fitt
ing
Inst
ruct
ions
4. Installation of replacement spring brake
A. Check parking brake spring is fully wound off.
Important - Do not cut the push rod to length until the parking brake spring is fully wound off. Check that the wind off bolt is fully wound out as shown in section 1, fig 1/2. If it is not. Follow the instructions in section 1 - Removal of old spring brake.
B. Push rod length.
The measured length, from section 2 above, should now be marked on the push rod of the replacement unit. However, if the dimension included the old welded yoke, firstly screw on a new yoke & adjust it to the same dimension - measured to the yoke pin centre line. Mark the push rod to allow for full thread engagement of the yoke.Saw the push rod to the marked length with a hacksaw & finally, using a suitable file, clean the end thread to accept the yoke.
C. Air port & clamp ring orientations.
If the replacement spring brake clamp & air port positions are different to those on the original unit, the following procedure must be carefully followed.IMPORTANT - Before any adjustments are made to the air port or clamp ring angles, the parking brake spring MUST be fully wound off - see instructions in section 1 above.
Remove the push rod lock nut & place a suitable metal tube (not supplied by Knorr-Bremse) over the push rod.
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Replace & hand tighten the lock nut against the tube end then rotate it 2 or 3 more turns to relieve the load of the service return spring. The clamp ring fasteners can now be loosened so that it is possible to reposition the spring case & clamp ring as required.
Ensure the clamp ring is correctly located before tightening the fasteners. Tighten the clamp ring fasteners to 12+/-2Nm.
Remove the lock nut & the tube from the push rod.
Fully apply & release air to port 11 approximately 10 times.
Re-tigthen the clamp ring fasteners to NG3 type: 17 +/-2Nm, Anchorlok type: 40Nm.
Check for leakage by applying a soap solution around the clamp ring. NO LEAKAGE IS ALLOWED.
D. Preparation of the replacement unit before installation.
Make a final check that the replacement unit matches the original in respect of air port angle, clamp angle & push rod length.
Fit the yoke assembly but do not tighten the lock nut.
Check that the parking brake spring is fully wound off - see instructions in section 1 above.
Check that the mounting bracket surface is not cracked, damaged or bent. Assemble the spring brake to the mounting bracketTighten the mounting nuts to 180 +/- 20Nm.Do not re-use the old nuts.Important: Washers are not supplied. In case you decide to use washers, they must fitted between the mounting nuts & the mounting bracket - NEVER between the spring brake & the mounting bracket.
S-Ca
m S
prin
g Br
ake
Fitt
ing
Inst
ruct
ions
Continued on next page...
51
Trailer Handbook
E. Setting of yoke assembly
Check that the yoke thread is fully engaged on the push rod.Rotate the yoke assembly so that its jaw is correctly aligned with the slack adjuster.Wind the slack adjuster to meet the yoke. Never pull the yoke & push rod to meet the slack adjuster.Note: This applies to manual & to auto slack adjusters.
After applying grease to the yoke pin & yoke holes, insert yoke pin into yoke assembly & fit the new split pin. Ensure the legs of the split pin are spread so that it cannot fall out.
Finally, tighten the push rod nut to a maximum of 70Nm.
F. Connection to the air circuit
Pipes can now be connected, take care to connect the service brake hose to air port 11 & the parking brake hose to air port 12. Fittings should be tightened to 40+/-5 Nm & checked to ensure no leakage.
G. Release the power spring
Move the hand control valve lever to the “run” position (brakes released).
Rotate the release bolt clockwise for NG3 type chamber (Max 30Nm) or wind the nut anti-clockwise for Anchorlok type chamber.
Useful Information
S-Cam Spring Brake Fitting Instructions
S-Ca
m S
prin
g Br
ake
Fitt
ing
Inst
ruct
ions
www.knorr-bremseCVS.com
Move hand control lever to the “park” position (brakes applied).
Before driving the vehicle, perform several applications of the service & parking brake.Note: Refer to the vehicle manufacturers instruction for any further recommendations regarding correct adjustment of the brakes & checks for correct operation.
S-Ca
m S
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Trailer Handbook
Useful Information
Auto Slack Adjuster Set-up Instructions
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Stage 1A. Grease the camshaft spline
B. Check that the brake chamber push rod is in its fully released position. With spring brakes a minimum pressure of 6 bar is required in the system to ensure that the piston is fully released.
C. The new slotted anchor bracket supplied with the auto slack adjuster should be fitted to the existing camshaft bracket but not tighten.Note: Different brackets, which may be handed, are used with different axles. Knorr-Bremse ASA are supplied with the Appropriate bracket.
Stage 2D. Fit the ASA onto the camshaft, so that the arrow on the Housing points in the direction of the application of the ASA & the control arm end mates with the anchor bracket.
E. Wind the ASA into the clevis on the brake chamber piston rod by rotating the hexagon on the ASA in a clockwise direction until the hole in the ASA coincides with the holes in the clevis.
F. Fit the clevis pin into the clevis through the ASA & secure . The pin should rotate freely when no load is applied.
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Stage 3G. Rotate the control arm as far as possible, following the Direction of the arrow cast on the ASA body. Do not hammer the control arm.The indicator A on the control arm should now be aligned with notch B in the cover plate.
H. With out moving the position of the control arm, fix the anchor bracket in place by tightening the mounting bolts.
Stage 4I. Adjust the clearance by rotating the hexagon on the ASA clockwise (1) until the brake lining touches the drum, then back off by rotating the hexagon a 3/4 turn anti-clockwise (2).Backing off produces a loud clicking noise.
J. Fit the lining wear indicator (C) in a vertical position.
K. Secure the ASA on the camshaft ensuring it is not pinched or restricted.
L. Check that the ASA is functioning by applying the brakes a few times. The ASA is working when the hexagon rotates Clockwise on the return stroke.
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Trailer Handbook
Before Setting Valve
1) Read and understand these instructions fully before starting work. 2) The values of the Inlet pressure and the Laden and Unladen Outlet pressures will be needed, along with the corresponding Air Bag pressures. These will be available from the Load Sensing Valve Plate or the Vehicle Manufacturer. 3) Ensure that all normal safety precautions are observed, particularly when setting the Valve in situ on a vehicle.4) A source of clean dry air at the Inlet port will be needed. 5) Only BR550- Valves have the Static/Dynamic switch. This must be set to ‘S’ for trailer applications. 6) For BR550- Valves, the Outlet pressures should be measured at the Test Connection. There is no need to plug the Delivery ports. 7) For BR552- Valves, the Outlet pressure must be measured at a Delivery Port 2 and the other Port 2 must be plugged. 8) All references to clockwise/anticlockwise refer to looking directly at the adjuster. 9) There must be ready access to Port 43, the Valve’s Air Suspension Test Connection, if fitted, and all of the adjusting screws. Note: The position of Port 43 will vary from one part number to another.
V1
V2
Useful Information
BR550- & BR552- Setting Instructions
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Setting The Unladen Brake Pressure
10) Slacken locknut (a) and unscrew (A) to the dimension to suit the part number as shown in the drawing above. Retighten Locknut (a) to prevent leakage during testing. 11) Undo screws (b) and (c) using a 2.5mm Allen key. 12) Apply V2 to give the required Unladen Air Bag pressure on gauge PG2. 13) Apply V1 to give the required Inlet pressure on gauge PG1. 14) Check that gauge PG3 shows the required Unladen Outlet pressure. 15) If adjustment is necessary, release V1 and V2, hold (C) with a suitable spanner and turn (B) (clockwise to increase the pressure). 16) Repeat steps 13 to 15 as necessary. 17) Release V1 and V2.
Setting The Laden Brake Pressure
18) Apply V2 to give the required Laden Air Bag pressure on PG2.19) Apply V1 to give the required Inlet pressure on PG1.20) Check that PG3 shows the required Laden Outlet pressure.20.1) If the pressure is too low release V1 and V2, hold (B) with a suitable spanner and turn (C) (anticlockwise to increase pressure). Or20.2) If the pressure is correct release V1 and move to step 22.21) Repeat steps 19 and 20 as necessary.22) Using V2, reduce the pressure on PG2 to approximately 0.3 bar below the Laden Air Bag pressure.23) Apply V1 to give the required Inlet pressure on PG1 and check that PG3 shows a pressure lower than the Laden Outlet pressure. 23.1) If the pressure has dropped release V1 and V2 and move to step 25.OR23.2) If PG3 still shows the laden Outlet pressure release V1, hold (B) with a suitable spanner and turn (C) clockwise. Then repeat steps 19 to 23.24) Release V1 and V2.
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Trailer Handbook
Useful Information
BR550- & BR552- Setting Instructions
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Final Check
25) Repeat the “Setting the Unladen Brake pressure” section.26) Repeat the “Setting the Laden Brake pressure” section.27) PLEASE NOTE: It may be necessary to repeat the adjustments of (B) and (C) several times in order to set the valve correctly for the Unladen and Laden conditions.
Setting The Minimum Brake Pressure (simulation of failed air suspension)
28) Ensure that zero pressure is shown on PG2.29) Apply V1 to give the required Inlet pressure on PG1.30) Slacken locknut (a) and adjust (A) until PG3 shows a pressure of 0.2 bar lower than the Unladen Outlet pressure. 31) Release V1. 32) Apply V2 to give the Unladen Bag pressure. Tighten the screws (b) and (c).33) Release V2. 34) Tighten locknut (a).
Every effort has been made to ensure that this information is correct but we reserve the right to amend or change it without notice.
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Adjusting Procedure1. Please read safety instructions on page 4 before carrying out any work on the vehicle.2. Connect test rig as shown in fig 1.3. Refer to chassis plate for pressure settings.
Fig 1
Adjusting Unladen Pressure1. Remove connection from port 4.2. Ensure that screw A is in contact with spring.3. Apply inlet pressure to port 1. Read outlet pressure at port 2.4. Adjust stop screw B as required.5. Repeat steps 3 & 4 as necessary.
Adjusting Laden Pressure1. Connect port 4. Apply laden suspension pressure.2. Apply inlet pressure to port 1. Read outlet pressure at port 2.3. Adjust screw A as required.4. Repeat steps 2 & 3 as necessary.
05.174.82.24.0 KB1010 4005.174.82.24.2 KB1010 4005.174.82.31.0 KB1010 40 05.174.82.31.2 KB1010 4005.174.82.47.0 KB1010 4005.174.82.47.2 KB1010 4005.174.82.49.0 KB1005 4005.174.82.49.2 KB1005/KB1045 4005.174.82.63.2 KB1045/KB1005 4005.174.82.67.2 KB1045/KB1005 4005.362.70.01.0 K003784 see note 1 36 05.362.70.02.0 K003783 see note 1 3605.362.70.12.0 K003784 see note 1 3605.362.70.13.0 K003783 see note 1 3605.362.70.16.0 K003780 see note 1 3605.362.70.17.0 K003779 see note 1 3605.362.70.22.0 K002923 see note 1 3605.362.70.22.1 K002923 see note 1 3605.362.70.23.0 K002924 see note 1 36
Note 1 - The OE number was a full Air Disc Brake , this part number is a rationalised caliperNote 2 - KB parts are dual stroke diaphragms, do not fit Wabco in place!* - NOT shown in catalogue
Note 1 - The OE number was a full Air Disc Brake , this part number is a rationalised caliperNote 2 - KB parts are dual stroke diaphragms, do not fit Wabco in place!* - NOT shown in catalogue
A 942 420 68 01 K003781 see note 1 36A 942 420 69 01 K013182 see note 1 36A 942 420 70 01 K013181 see note 1 36A 942 421 12 12 II376380061 37A 942 421 21 12 II376380061 37A 944 420 28 01 K013182 see note 1 36A 944 420 29 01 K013181 see note 1 36A 946 420 03 01 K013174 see note 1 36A 946 420 04 01 K013173 see note 1 36A 946 420 13 01 K013174 see note 1 36A 946 420 14 01 K013173 see note 1 36A 946 420 15 01 K013174 see note 1 36A 946 420 16 01 K013173 see note 1 36A 946 420 17 01 K013174 see note 1 36A 946 420 18 01 K013173 see note 1 36A 946 420 19 01 K013174 see note 1 36A 946 420 20 01 K013173 see note 1 36A 975 420 26 01 K003779 see note 1 36A 975 420 27 01 K003780 see note 1 36
Note 1 - The OE number was a full Air Disc Brake , this part number is a rationalised caliperNote 2 - KB parts are dual stroke diaphragms, do not fit Wabco in place!* - NOT shown in catalogue
Note 1 - The OE number was a full Air Disc Brake , this part number is a rationalised caliperNote 2 - KB parts are dual stroke diaphragms, do not fit Wabco in place!* - NOT shown in catalogue
Note 1 - The OE number was a full Air Disc Brake , this part number is a rationalised caliperNote 2 - KB parts are dual stroke diaphragms, do not fit Wabco in place!* - NOT shown in catalogue
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Gig
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Gigant Knorr-Bremse Page
Gigant Cross References
2100090 K003781 see note 1 362100091 K003782 see note 1 362100192 K003781 see note 1 362100193 K003782 see note 1 369285022 K003782 see note 1 369285023 K003781 see note 1 3692850312 K003779 see note 1 3692850322 K003780 see note 1 369285098 K003780 see note 1 369285099 K003779 see note 1 369285157 K003781 see note 1 369285158 K003782 see note 1 369285159 K003783 see note 1 369285160 K003784 see note 1 369285165 K003779 see note 1 369285166 K003780 see note 1 36
64
Note 1 - The OE number was a full Air Disc Brake , this part number is a rationalised caliperNote 2 - KB parts are dual stroke diaphragms, do not fit Wabco in place!* - NOT shown in catalogue
Note 1 - The OE number was a full Air Disc Brake , this part number is a rationalised caliperNote 2 - KB parts are dual stroke diaphragms, do not fit Wabco in place!* - NOT shown in catalogue
Note 1 - The OE number was a full Air Disc Brake , this part number is a rationalised caliperNote 2 - KB parts are dual stroke diaphragms, do not fit Wabco in place!* - NOT shown in catalogue
Note 1 - The OE number was a full Air Disc Brake , this part number is a rationalised caliperNote 2 - KB parts are dual stroke diaphragms, do not fit Wabco in place!* - NOT shown in catalogue
HB100406 K003793 see note 1 36HB100407 BS3444 - II39694F *S-26923-1L K003783 see note 1 36S-26923-1R K003784 see note 1 36
67
Note 1 - The OE number was a full Air Disc Brake , this part number is a rationalised caliperNote 2 - KB parts are dual stroke diaphragms, do not fit Wabco in place!* - NOT shown in catalogue
Note 1 - The OE number was a full Air Disc Brake , this part number is a rationalised caliperNote 2 - KB parts are dual stroke diaphragms, do not fit Wabco in place!* - NOT shown in catalogue
Note 1 - The OE number was a full Air Disc Brake , this part number is a rationalised caliperNote 2 - KB parts are dual stroke diaphragms, do not fit Wabco in place!* - NOT shown in catalogue
Note 1 - The OE number was a full Air Disc Brake , this part number is a rationalised caliperNote 2 - KB parts are dual stroke diaphragms, do not fit Wabco in place!* - NOT shown in catalogue
7000327W KB1025 40M023565 KB1025 40M076154 BS9397 - II31227SP 27M076162 BS9397 - II31227SP 27M076634 K003782 see note 1 36M076642 K003781 see note 1 36M079048 BS9397 - II31227SP 27M079056 BS9397 - II31227SP 27M200024-01 BS8518 - II39220F *M200024-02 BS8517 - II39219F *M200124-01 K003781 see note 1 36M200124-02 K003782 see note 1 36M200124-11 K003781 see note 1 36M200124-12 K003782 see note 1 36M200124-41 K003781 see note 1 36M200124-42 K003782 see note 1 36M200164-01 K003781 see note 1 36M200164-02 K003782 see note 1 36M200164-21 K003781 see note 1 36
M200164-22 K003782 see note 1 36M200164-31 K003781 see note 1 36M200164-32 K003782 see note 1 36M200177-01 K003780 see note 1 36M200177-02 K003779 see note 1 36M200192-01 K003780 see note 1 36M200192-02 K003779 see note 1 36M910001-01 K000464M910045-02 II180220062MO023565 KB1025MO02416 KB1520
Note 1 - The OE number was a full Air Disc Brake , this part number is a rationalised caliperNote 2 - KB parts are dual stroke diaphragms, do not fit Wabco in place!* - NOT shown in catalogue
Note 1 - The OE number was a full Air Disc Brake , this part number is a rationalised caliperNote 2 - KB parts are dual stroke diaphragms, do not fit Wabco in place!* - NOT shown in catalogue
Note 1 - The OE number was a full Air Disc Brake , this part number is a rationalised caliperNote 2 - KB parts are dual stroke diaphragms, do not fit Wabco in place!* - NOT shown in catalogue
Note 1 - The OE number was a full Air Disc Brake , this part number is a rationalised caliperNote 2 - KB parts are dual stroke diaphragms, do not fit Wabco in place!* - NOT shown in catalogue
Note: This publication is subject to alteration without notice. A printed copy of this document may not be the latest revision.Please check our website www.knorr-bremseCVS.com for the latest update or contact your local Knorr-Bremse representative