Knorr-Bremse ZB44 Series Service Manual Download

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Knorr-Bremse Group

Europe – Africa

Austria

Knorr-Bremse GmbH

Systeme für Nutzfahrzeuge

Mödling

Tel: +43 2236 409-2436

Fax: +43 2236 409-2434

Belgium

Knorr-Bremse Benelux B.V.B.A.

Heist-op-den-Berg

Tel: +32 1525 7900

Fax: +32 1524 9240

Czech Republic

Knorr-Bremse Systémy pro

uzitková vozidla, CR, s.r.o.

Liberec

Tel: +420 482 363-611

Fax: +420 482 363-711

France

Knorr-Bremse

Systèmes pour Véhicules

Utilitaires France

Lisieux Cedex

Tel: +33 2 3132 1200

Fax: +33 2 3132 1303

Germany

Hasse & Wrede GmbH

Berlin

Tel: +49 30 9392-3101

Fax: +49 30 7009-0811

Germany

Knorr-Bremse Systeme für

Nutzfahrzeuge GmbH

Berlin

Tel: +49 180 223-7637

Fax: +49 30 9392-3426

Hungary

Knorr-Bremse

Fékrendszerek Kft.

Kecskemét

Tel: +36 76 511 100

Fax: +36 76 481 100

Italy

Knorr-Bremse

Sistemi per Autoveicoli

Commerciali S.p.A.

Arcore

Tel: +39 039 6075-1

Fax: +39 039 6075-435

Netherlands

Knorr-Bremse Benelux B.V.B.A.

Mydrecht

Tel: +31 297 239-330

Fax: +31 297 239-339

Poland

Knorr-Bremse Polska SfN Sp. z o.o.

Warsaw

Tel: +48 22 887-3870

Fax: +48 22 531-4170

Russia

Knorr-Bremse RUS

Nizhniy Novgorod

Tel: +7 8312 57-6661

Fax: +7 8312 57-6791

Russia

Knorr-Bremse

Systeme für Nutzfahrzeuge LLC

Moscow

Tel: +7 495 234-4995

Fax: +7 495 234-4996

South Africa

Knorr-Bremse S.A. Pty. Ltd.

Kempton Park

Tel: +27 11 961-7800

Fax: +27 11 975-8249

Spain

Bost Ibérica, S.L.

Irun (Guipuzcoa)

Tel: +34 902 100-569

Fax: +34 943 614-063

Sweden

Knorr-Bremse

System for Tunga Fordon AB

Lund

Tel: +46 46 440 0105

Fax: +46 46 148971

Switzerland

Knorr-Bremse

Systeme für Nutzfahrzeuge GmbH

Bassersdorf

Tel: +41 44 888 77-55

Fax: +41 44 888 77-50

Turkey

Knorr-Bremse

Ticari Araç Fren Sistemleri Tic. Ltd. Sti.

Findikli - Istanbul

Tel: +90 212 293-4742

Fax: +90 212 293-4743

United Kingdom

Knorr-Bremse

Systems for Commercial Vehicles Ltd.

Bristol

Tel: +44 117 9846-100

Fax: +44 117 9846-101

America

Brazil

Knorr-Bremse

Sistemas para Veículos

Comerciais Brasil Ltda.

São Paulo

Tel: +55 11 4593 4000

Fax: +55 11 4593 4698

USA

Bendix Commercial Vehicle

Systems LLC

Elyria, OH

Tel: +1 440 329-9100

Fax: +1 440 329-9105

Asia – Australia

Australia

Knorr-Bremse

Australia Pty. Ltd.

Granville NSW

Tel: +61 2 8863-6500

Fax: +61 2 8863-6510

China

Knorr-Bremse

Brake Equipment (Shanghai) Co. Ltd.

Shanghai

Tel: +86 21 3858-5800

Fax: +86 21 3858-5900

China

Knorr-Bremse

Asia Pacific (Holding) Limited

Commercial Vehicle Systems Division

Hong Kong

Tel: +852 3657-9800

Fax: +852 3657-9901

India

Knorr-Bremse

Systems for Commercial Vehicles

India Private Ltd.

Pune

Tel: +91 20 6674-6800

Fax: +91 20 6674-6899

Japan

Knorr-Bremse

Commercial Vehicle Systems

Japan Ltd.

Saitama

Tel: +81 49 273-9155

Fax: +81 49 282-8601

Korea

Knorr-Bremse

Korea Ltd. Truck Brake Division

Seoul

Tel: +82 2 2273-1182

Fax: +82 2 2273-1184

Head Office

Knorr-Bremse Systeme für
Nutzfahrzeuge GmbH

Moosacher Strasse 80
80809 Munich
Germany
Tel: +49 89 3547-0
Fax: +49 89 3547-2767
www.knorr-bremseCVS.com

C o m m e r c i a l V e h i c l e S y s t e m s

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Doc.- No. Y025030 (EN - Rev. 003)

November 2014

Summary of Contents for ZB44 Series

Page 1: ...heck valve Pressure regulator Pressurised air 18 Bar ZB44 type APU G1 T1 T2 T3 T4 T9 T10 T11 T12 T13 T14 T15 T16 G3 G4 G5 G6 3 nozzle defined in procedure Used part of test bench Unused part of test b...

Page 2: ...antee 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 b...

Page 3: ...he Heater Assembly B 11 3 3 Removal and Replacement of the Silencer Assembly C 12 3 4 Removal of the Air Processing Unit from the Vehicle 13 3 5 Removal and Replacement or Service of the Oil Separator...

Page 4: ...pipework it should be installed so that it cannot abrade or be subjected to excessive heat 10 Components with stripped threads or damaged corroded parts must be replaced completely Do not attempt repa...

Page 5: ...nd the correct grease The range of kits is designed to enable each device to be serviced in part or completely Knorr Bremse service kits are only designed for use with genuine Knorr Bremse devices and...

Page 6: ...circuit multi circuit protection valve function When the increasing air pressure in the braking system reaches a preset value cut out pressure the unloader valve signals the purge valve to open and t...

Page 7: ...om the desiccant bed passes through the timing choke and charges the integral timing reservoir During the Purge phase the loss of pressure in the inlet cavity will close the delivery check valve Some...

Page 8: ...n first and in a reasonable time circuits 21 and 22 have a bypass feature Series charging This configuration is designed so that at least one of the circuits 21 and 22 will open before circuits 23 and...

Page 9: ...70 C Silencer D Oil separator Oil separator complete Oil separator seals E Purge valve For standard applications For low temperature applications 45 C F High pressure tyre inflator H Double pressure s...

Page 10: ...er clockwise using suitable strap wrench 2 Remove O ring 2 3 Wipe the body with a clean rag Protect the clean air chamber and cartridge mounting thread from dirt Fitting the cartridge 1 Lightly lubric...

Page 11: ...pond to that shown on separate Service Kit leaflets Step Service task Removal of the heater assembly 1 Clean the outside of the air processing unit and the surroundings of the heater area 2 Unscrew el...

Page 12: ...silencer assembly 1 over its spigot on the base of the air processing unit 2 Lightly tap the silencer assembly 1 in the direction of the spigot so that it snaps into place 3 Check the fixation of new...

Page 13: ...le please refer to the safety checks on page 4 2 Vent the system air pressure completely 3 Disconnect air lines after noting which port they are connected to for correct reinstallation 4 Unscrew and r...

Page 14: ...x 2 5 mm 1 3 t O ring 42 x 2 5 mm 1 4 t Screw M 4 x 40 mm 2 5 t O ring 33 x 5 mm 1 6 Desiccant cartridge 1 Part Identification and Service Kits 3 2 1 5 6 For Service Kit Part Number see www knorr brem...

Page 15: ...urn using a suitable strap wrench 10 Refit if necessary the air processing unit to vehicle and check according to chapter 3 10 11 Charge the air system to just below cut out pressure and check the des...

Page 16: ...ommended pulling tool for Oil Separator Unit disassembly Components of pulling tool Correct fitting of pulling tool Dimensions of thrust plate Dimensions of pulling tool legs Holder with threaded bolt...

Page 17: ...ty 1 Air Processing Unit APU housing 1 2 Retaining ring 27 2 x 1 2 1 3 O ring 24 x 1 5 1 4 Exhaust piston assembly 1 5 Compression spring 1 6 O ring 25 12 x 1 78 1 7 End cover 3 or 2 8 Retaining ring...

Page 18: ...it retaining ring 8 or 2 securely into groove of the APU housing unit 1 using suitable tool e g circlip pliers Fitting the new purge valve Step Service task Read and understand all steps before commen...

Page 19: ...the new threaded connector 5 5 Fit the new metallic sealing ring 3 to the threaded connector 5 and screw in 6 Tighten the threaded connector 5 to a torque of 50 Nm 7 Check operation by pushing valve...

Page 20: ...ce against the O rings 1 until the new screws 2 are fitted and fully tightened to a torque of 6 Nm 3 Refit if necessary the air processing unit to vehicle and check according to chapter 3 10 4 Prior t...

Page 21: ...in a way to prevent movement but allowing for easy access to the required part 3 Remove the four screws 6 while holding the cover 5 against the compression spring see Fig 1 4 Remove the cover 5 and O...

Page 22: ...2 into APU housing 1 don t touch or move the K ring see Fig 8 8 If the K ring moves out of alignment from concentric position start again from Step 4 9 Place compression spring 3 onto piston 2 see Fi...

Page 23: ...See above table for recommended tightening torques 4 Charge the air system to cut out pressure 5 Check all fittings and seals for leakage using soap and water There should be no leakage 6 Deplete the...

Page 24: ...4698 USA Bendix CommercialVehicle Systems LLC Elyria OH Tel 1 440 329 9100 Fax 1 440 329 9105 Asia Australia Australia Knorr Bremse Australia Pty Ltd Granville NSW Tel 61 2 8863 6500 Fax 61 2 8863 651...

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