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Commercial Vehicle Systems

Service Manual
Clutch Servo
VG3286 / VG3287

Description/Function
Service kit
Service instructions
Disclaimer

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.

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 referred to for all legal purposes.
Contents

Safety and Environment Guidelines . . . . . . . . . . . . . . . . . . . 4

1. Overview . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1 Clutch Servo Components. . . . . . . . . . . . . . . . . . . 7


1.2 Product identification and available Service Kit. . . . . . . . . . . . . 8

2. General Information. . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Lubricant . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Torque Requirements . . . . . . . . . . . . . . . . . . . . 9

3. Description and Function. . . . . . . . . . . . . . . . . . . . 10

3.1 Clutch Servo Sectioned View. . . . . . . . . . . . . . . . . . 10


3.2 Description of Operation. . . . . . . . . . . . . . . . . . . 11

4. Removing the Clutch Servo from the Gearbox . . . . . . . . . . . . . . 12

5. Disassembly Process for Booster Cylinder . . . . . . . . . . . . . . . 13

6. Disassembly Process for Control Unit . . . . . . . . . . . . . . . . 15

7. Assembly Process for Booster Cylinder . . . . . . . . . . . . . . . . 17

8. Assembly Process for Control Unit . . . . . . . . . . . . . . . . . 21

9. Refitting the Clutch Servo to the Gearbox. . . . . . . . . . . . . . . 23


Safety and Environment Guidelines

Safety and Environment Guidelines

Note: The safety advice listed below is applicable to general service and diagnostic work on pneumatic systems. Also observe
any recommendations from the axle or vehicle manufacturer concerning towing, jacking-up and securing the vehicle.

Before and during working on or around compressed air systems and devices, the following precautions should be observed:
1 Always wear safety glasses when working with air pressure.
2 Never exceed the vehicle manufacturer’s recommended air pressures.
3 Never look into air jets or direct them at anyone.
4 Never connect or disconnect a hose or line containing pressure; it may whip as air escapes.
5 When removing or servicing a product, ensure all pressure related to the specific system it is contained in has been depleted
to 0 bar. Be aware that if the vehicle is equipped with an air dryer system, it can also contain air pressure along with its purge
reservoir, if fitted, even after pressure has been drained from the other reservoirs.
6 If it is necessary to drain the air pressure from reservoirs, etc., keep away from brake actuator push rods and levers since
they may move as system pressure drops. On vehicles fitted with air suspension, it is advised when undertaking such work,
to support the chassis from sudden lowering and therefore prevent any possibility of being trapped between the chassis and
axle or ground.
7 Park the vehicle on a level surface, apply the parking brakes, and always chock the wheels as depleting vehicle air system
pressure may cause the vehicle to roll.
8 When working under or around the vehicle, and particularly when working in the engine compartment, the engine should
be shut off and the ignition key removed. Where circumstances require that the engine be running, EXTREME CAUTION
should be taken to prevent personal injury resulting from contact with moving, rotating, leaking, heated or electrically charged
components. Additionally, it is advisable to place a clear sign on or near the steering wheel advising that there is work in
progress on the vehicle.
9 When working on vehicles equipped with air suspension, to guard against injury due to unexpected downward movement
of the chassis caused by sudden pressure loss in the suspension system, ensure that the 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, type and strength as original equipment and be designed specifically for such applications
and systems. Check the attachment of all pipework; it should be installed so that it cannot abrade or be subjected to
excessive heat.
11 Components with stripped threads or damaged/corroded parts must be replaced completely. Do not attempt repairs
requiring machining or welding unless specifically stated and approved by the vehicle or component manufacturer.
12 Never attempt to install, remove, disassemble or assemble a device until you have read and thoroughly understood the
recommended procedures. Some units contain powerful springs and injury can result if not properly dismantled and
reassembled. Use only the correct tools and observe all precautions pertaining to use of those tools.
13 Before removing any device note its position and the connections of all pipework so that the replacement/serviced device
can be properly installed. Ensure that adequate support or assistance is provided for the removal/installation of heavy
items.
14 Only use genuine replacement parts, components and kits as supplied by Knorr-Bremse or the vehicle manufacturer. Only
use the recommended tools as specified in related service instructions.
15 The serviced or replaced product must be checked for correct function and effectiveness.
16 If products have been dismantled, serviced or replaced, whose performance could affect braking performance or system
behaviour, this should be checked on a roller dynamometer. Bear in mind that a lower performance may be experienced
during the bedding-in phase if new brake pads/linings and/or brake discs/drums have been fitted.
17 Prior to returning the vehicle to service, make certain that all components and the complete brake systems are leak free and
restored to their proper operating condition.


Safety and Environment Guidelines

Welding
To avoid damage to electronic components when carrying out electrical welding, the following precautions should be observed:
1 In all cases, before starting any electrical welding, remove all connections from any electronic control units or modules, noting their
position and the order in which they are removed.
2 When re-inserting the electrical connectors (in reverse order) it is essential that they are fitted to their correct assigned position - if
necessary this must be checked by PC Diagnostics.

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. 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 electrical equipment. For more information about arrange-
ments for waste equipment disposal please contact your Knorr-Bremse distributor or local Knorr-Bremse
representative.



1
Overview

1 Overview
1.1 Clutch Servo Components

12 13

10 11
14 15
8 9
21
7
18
6 19
21 20
4 5 19 20
2 3 18
17
1

16 27 28

26
25
24
23

22
31

30
29

1 Retaining Ring 13 Compression Spring 25 Guide Ring


2 Locking Plug 14 Bush 26 O-Ring
3 O-Ring 15 O-Ring 27 Disc
4 Ring 16 Main Housing 28 Retaining Ring
5 Grooved Ring 17 Compression Spring 29 Bellows
6 Control Piston 18 Slide Ring 30 Flange
7 Compression Spring 19 Grooved Ring 31 Screw (4x)
8 Sleeve 20 Disc
9 Retaining Ring 21 Retaining Ring
10 O-Ring 22 Push Rod Assembly
11 Valve Seat 23 Piston
12 Valve Head 24 Grooved Ring


1
Overview

1.2 Product Identification and available


Service Kit

KNORR-BREMSE

XXXXXX
XXXXXXX
XXXXX XXXXX
Type of Clutch Servo Knorr-Bremse
Part no.

Knorr-Bremse
Date of Manufacturer

Use only genuine Knorr-Bremse parts!

The following service kit is available :

Description Contents Comments


Service Kit 1, 3, 4, 5, 6, 8, 10, 12, 15, 18, 19, 24, 25, 26, 29 includes grease


General Information
2
2 General Information
2.1 Lubricant
Part Number Discription Quantity
I90693 Silicon Grease 25g

2.2 Torque Requirements

Thread Size Description Torque Spanner Size (mm)


M8 Mounting Bolts refer to vehicle manufacturer`s _
recommendations
M8 Bleed Screws 10 Nm Hexagon key (9 mm)
M14 Hydraulic 35 Nm Hexagon key (19 mm)
M16 Pneumatic 45 Nm Hexagon key (22 mm)


3
Description and Function

3 Description and Function


3.1 Clutch Servo Sectioned View
18 19 20 21 20 19 18 21 22 23 24 25 27 30 26 28 29

Hydraulic Chambers
Pneumatic Chambers

1
2

31

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Hydraulic Port

Pneumatic Port

Exhaust Port

1 Retaining Ring 13 Compression Spring 25 Guide Ring


2 Locking Plug 14 Bush 26 O-Ring
3 O-Ring 15 O-Ring 27 Disc
4 Ring 16 Main Housing 28 Retaining Ring
5 Grooved Ring 17 Compression Spring 29 Bellows
6 Control Piston 18 Slide Ring 30 Flange
7 Compression Spring 19 Grooved Ring 31 Screw
8 Sleeve 20 Disc
9 Retaining Ring 21 Retaining Ring
10 O-Ring 22 Push Rod Assembly
11 Valve Seat 23 Piston
12 Valve Head 24 Grooved Ring

10
Description and Function
3
3.2 Description of Operation

Clutch Engaging Phase Clutch Disengaging Phase


(Driver releases the clutch pedal) (Driver pushes the clutch pedal)

As the driver allows the clutch pedal to lift, hydraulic As the driver pushes the clutch pedal, hydraulic pressure
pressure decreases and the control piston (6) moves increases on both the push rod assembly (22) and the
under the influence of compression spring (7) and control piston (6). At a certain pressure, the control piston (6)
of pressurized air. However, since the valve head (12) is overcomes the compression spring (7) and moves forward,
not able to move, due to being in contact with the valve therefore exhaust gap between control piston (6) and valve
seat (11), a gap is created between control piston (6) and head (12) is closed. As the valve head (12) continues to
valve head (12) and air is released to the exhaust port. move it is lifted from valve seat (11), pressurized air can
As both hydraulic and pneumatic pressure decrease, the therefore enter the pneumatic space and act on piston
push rod assembly (22) moves backwards and hence the (23); thus assisting the forward load on the push rod and
clutch starts to engage. If the driver holds the clutch pedal helping the driver to disengage the clutch (servo effect).
at any mid position, hydraulic pressure stops decreasing. When the driver stops pushing the clutch pedal further,
Air pressure will however continue to decrease resulting hydraulic pressure no longer increases. However, the gap
in a reduction in force on the control piston. The latter will between valve head (12) and valve seat (11) is still open
therefore eventually move forward until it reaches the valve and air pressure continues to rise, eventually moving the
head (12) and the exhaust of air is stopped. At this point, control piston (6) backwards until the gap between valve
the clutch is therefore only partly engaged. head (12) and valve seat (11) is closed. No further increase
of air pressure therefore takes place, an equilibrium state
If the driver subsequently allows the clutch pedal to lift further,
is reached and the push rod assembly (22) stops moving.
the above process will be repeated until hydraulic pressure
Depending on the height of the clutch pedal, the clutch is
becomes zero. When this happens, the control piston (6)
therefore partly disengaged. Further pushing of the clutch
moves fully backwards and the gap between control piston
pedal will repeat the above process. Full depression of the
(6) and valve head (12) is continuously open. The clutch is then
clutch pedal will of course fully disengage the clutch
fully engaged.

11
4
Removing the Clutch Servo from the Gearbox

4 Removing the Clutch Servo from the Gearbox

Step Service task

Before starting work on the vehicle please refer to the “Safety and Environment Guidelines“
1
- see Page 4. !
2 Vent the system air pressure using reservoir drainage points.

3 Disconnect hydraulic and pneumatic lines.

Disconnect the push rod of the device from the push rod of the gearbox - refer to vehicle manufacturer`s
4
recommendations.

5 Unscrew and remove the four M8 mounting bolts and remove device.

Mounting Bolts
M8
M8 Mounting Bolts

M8 Mounting Bolts M14 Hydraulic


Connection
Pneumatic
M16 Connection M8
Mounting Bolts

12
Disassembly Process for Booster Cylinder
5
5 Disassembly Process for Booster Cylinder

Step Service task

1 Clean the outside of the clutch servo to prevent entry of dirt.

2 Clamp the body in a vice to provide proper support for the disassembly (Fig.1).

Remove screws (31) and remove flange (30).


3 CAUTION: Pre-tensioned spring is under the flange; while unscrewing, maintain hand pressure
!
on the push rod assembly (22) (Fig.2). !

Detach push rod assembly (22) from bellows (29). Use a tool with a round profile in order to avoid
4
damage to the bellows (Fig. 3).

5 Detach bellows (29) from flange (30) (Fig. 4 and 5).

6 Remove retaining ring (28) and detach disc (27) (Fig. 6 and 7).

7 Remove O-ring (26) and detach push rod assembly (22) from piston (23) (Fig. 8 and 9).

Fig.1 Fig.2 Fig.3

30
31
22
29

Fig.4 Fig.5 Fig.6

29
30
28

30

Fig.7 Fig.8 Fig.9


27
23

26

13
5
Disassembly Process for Booster Cylinder

Step Service task

8 Detach guide ring (25) and grooved ring (24) from piston (23) (Fig. 10 and 11).

Remove compression spring (17) to gain access to the seals between the hydraulic and pneumatic
9
sides.

10 Remove retaining ring (21) (Fig. 12).

11 Remove slide ring (18) (Fig 13).

12 Remove grooved ring (19) and disc (20) (Fig. 14).

13 Remove second retaining ring (21) (Fig. 15).

14 Remove second grooved ring (19) and disc (20) (Fig. 16).

15 Remove second slide ring (18) (Fig 17).

Fig.10 Fig.11 Fig.12

25 24

21
23
Fig.13 Fig.14 Fig.15

19

21

20
18

Fig.16 Fig.17

20

19 18

14
Disassembly Process for Control Unit
6
6 Disassembly Process for Control Unit

Step Service task

1 Clean the outside of the clutch servo to prevent entry of dirt.

2 Clamp the body in a vice to provide proper support for the disassembly process (Fig. 18).

3 Remove retaining ring (1) (Fig. 19).

Remove locking plug (2) using suitable grips. DO NOT use a spanner to break the plug free, because
4
the housing or the plug can easily be damaged (Fig. 20). !

5 Remove plastic ring (4) (Fig. 21)..

6 Remove control piston (6) (Fig. 22).

7 Remove grooved ring (5) with a suitable tool taking care not to damage the cylinder bore (Fig. 23). !

Fig.18 Fig.19 Fig.20


1

3 2

Fig.21 Fig.22 Fig.23


6

5
4 6

15
6
Disassembly Process for Control Unit

Step Service task

8 Remove compression spring (7) (Fig. 24).

9 Remove sleeve (8) with a suitable tool (Fig. 25). Do not damage the sealing surface.

Remove retaining ring (9) from the groove inside the control cylinder. Use a small circlip clamp.
10
Do not damage the sealing surface (Fig. 26).

Remove O-ring (10) and valve seat (11) as an assembly, valve head (12), compression spring (13), bush
11
(14) and O-ring (15) with a suitable tool (Fig. 27 - 31). Do not damage the sealing surface.

Fig.24 Fig.25 Fig.26


sealing
surface
8

7
9

Fig.27 Fig.28 Fig.29


13
12
11

10

Fig.30 Fig.31

15
14

16
Assembly Process for Booster Cylinder
7
7 Assembly Process for Booster Cylinder
! All parts included in the service kit must be changed, even if no visible damage can be seen on the old parts.
! Use only the grease provided in the kit.

Step Service task

Clean all the sealing surfaces from dirt and grease with a dry piece of cloth or paper and ensure they
1
are free of damage. Note the correct alignment and orientation of each component (Fig. 1).

Grease slide ring (18) evenly and place it in the housing with the “crowns“ pointing upwards (Fig. 2).
2
Ensure it is properly seated (Fig. 3).

Grease grooved ring (19) and place it in the bore, so that the groove fits over the “crown“ points of the
3
slide ring (18) (Fig. 4).

4 Grease disc (20) and place it on grooved ring (19) (Fig. 5).

5 Grease retaining ring (21) and fit to the housing with a suitable tool (Fig. 6).

6 Grease disc (20) and place it on retaining ring (21) (Fig. 7).

7 Grease grooved ring (19) and place it on disc (20) with the groove upwards (Fig. 8).

Fig.1 Fig.2 Fig.3

21 22

18 18
18
19
20
21 Fig.4 Fig.5
20 19
19
20
18

18 19

Fig.6 Fig.7 Fig.8


20
19

21 20
21

17
7
Assembly Process for Booster Cylinder

Step Service task

Grease slide ring (18) and place it in the bore so that the “crowns“ point downwards and fit in the
8
groove of the grooved ring (19) (Fig.9). Ensure it is properly seated (Fig.10).

9 Grease retaining ring (21) and fit to the housing with a suitable tool (Fig. 11).

10 Grease the whole inner surface of the booster cylinder (Fig. 12).
!
11 Place compression spring (17) in the housing (Fig. 13).

Note: Parts 22-30 have to be separately assembled.

Grease grooved ring (24) and fit to piston (23) so that the grooved side of the ring is as shown in
12
(Fig.14).

13 Grease O-ring (26) and fit to piston (23) (Fig. 15).

14 Fit the piston assembly on the push rod assembly (22) as shown in (Fig.16).

Fig.9 Fig.10 Fig.11


21
18

18

19

Fig.12 Fig.13 Fig.14


24
17

23

Fig.15 Fig.16
26 24

23 23

22

18
Assembly Process for Booster Cylinder
7

Step Service task

15 Grease guide ring (25) and fit to the piston assembly (Fig. 17).

16 Attach disc (27) to the piston assembly so that it fits into the recess of guide ring (25) (Fig. 18).

17 Fit retaining ring (28) in the groove on push rod assembly (22) to secure the piston assembly (Fig. 19).

!
Attach bellows (29) to flange (30). Use a round-headed tool to avoid damage to the bellows (Fig. 20 and
Fig.21).
18
CAUTION: If the two parts are not correctly assembled or bellows is damaged, dirt can enter the
booster cylinder and the lifetime of the device will be shortened. !
19 Grease push rod assembly (22) and place it in the housing (Fig. 22).

20 By compressing the spring (17), push the piston assembly to its end position (Fig. 23).

Fig.17 Fig.18 Fig.19


25
25 22
24

28
27

Fig.20 Fig.21 Fig.22


29 29
17

30
30

Fig.23

19
7
Assembly Process for Booster Cylinder

Step Service task

Hold the piston in this position and re-grease the inner surface of the booster cylinder. (Fig. 24).
21
After re-greasing, DO NOT let the piston assembly come fully out of the cylinder. !
Attach the flange and bellows assembly to the piston assembly and fix flange (30) to the housing with screw
22
(31) x4 (Fig.25).

23 Expose the threaded end of the push rod assembly (22) (Fig. 26 - Fig. 27).

Fig.24 Fig.25 Fig.26


22
31

30

Fig.27
22

20
Assembly Process for Control Unit
8
8 Assembly Process for Control Unit

Step Service task

Clean all the sealing surfaces from dirt and grease with a dry piece of cloth or paper and ensure they
1
are free of damage. Note the correct alignment and orientating of each component (Fig. 28).
2 Grease the inner surfaces of the control cylinder evenly (Fig. 29)
Grease O-ring (15) and carefully place it in the control cylinder. Check if part is properly seated by visual
3
inspection (Fig. 30).

4
!
Grease bush (14) and place it in the control cylinder so that the larger diameter side touches the O-ring
(15) (Fig. 31).
5 Insert compression spring (13) in the control cylinder so that it sits on bush (14) (Fig. 32).
Grease and place valve head (12) in the control cylinder; the smaller diameter portion slides inside the
6
compression spring (13) (Fig. 33).
Grease and attach O-ring (10) to valve seat (11), grease both parts and place in the control cylinder as
7
shown in (Fig 34).
Fit retaining ring (9) in the groove inside the control cylinder while valve seat (11) is pushed to its end
8 position. Take care not to damage the sealing surface. Check carefully if retaining ring (9) is !
securely seated in the groove (Fig. 35).

Fig.28 Fig.29 Fig.30


15
1
2 3

4
5

Fig.31 Fig.32
7
8
9
10
11
12
13 14
14 13
15

Fig.33 Fig.34 Fig.35


sealing
surface
10
control cylin der

11

12
9
10
11

21
8
Assembly Process for Control Unit

Step Service task

9 Grease sleeve (8) and place it in the control cylinder with “crowns“ pointing upwards (Fig. 36).

Place compression spring (7) in the control cylinder, larger diameter end fitting within “crowns“ of sleeve (8)
10
(Fig. 37).

Place control piston (6) in the cylinder with smaller diameter end fitted inside compression spring (7)
11
(Fig. 38).
!
Grease grooved ring (5) and place it on control piston (6) with grooved side pointing upwards
12
(Fig. 39).

Grease and attach O-ring (3) to locking plug (2), grease both parts again and mount ring (4) on locking
13
plug (2). Ring (4) must snap on locking plug (2) (Fig. 40).

Place locking plug assembly in the control cylinder so, that ring (4) pushes grooved ring (5) in the
14
cylinder (Fig. 41).

15 While pushing locking plug (2) in the cylinder, fit retaining ring (1) in the groove (Fig. 42).

Fig.36 Fig.37 Fig.38


8

Fig.39 Fig.40 Fig.41


grooved side
3

4
5
2

Fig.42
1
CAUTION: Test the clutch servo ONLY when
it is securely mounted to the gearbox with the !
correctly torqued mounting bolts - see section 9 !
2

22
Refitting the Clutch Servo to the Gearbox
9
9 Refitting the Clutch Servo to the Gearbox

Step Service task

1 Reconnect the push rod and adjust the position - refer to vehicle manufacturer`s recommendations.

2 Tighten the four M8 mounting bolts - refer to vehicle manufacturer`s recommendations.

3 Reconnect hydraulic and pneumatic lines. For tightening torques - see section 2.2.

4 Do the bleeding process carefully - refer to vehicle manufacturer`s recommendations. !


5 After the bleeding process tighten the bleed screw carefully. For tightening torque - see section 2.2 .

Check all fittings and seals for leakage using soap and water while engaging and disengaging the
6
clutch several times. There must be no leakage! !

Mounting Bolts
M8
M8 Mounting Bolts

Bleed Screws M8

M8 Mounting Bolts M14 Hydraulic


Connenction
M16 Pneumatic M8
Connenction Mounting Bolts

23
Commercial Vehicle Systems

Knorr-Bremse Systeme für


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Germany
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The figurative mark “K” and the trademarks KNORR and KNORR-BREMSE are registered in the name of Knorr-Bremse AG. Additional terms and conditions apply; please refer to our website knorr-bremseCVS.com under the “Documentation”
tab. Note: If service work is carried out on a vehicle as a result of information taken from this document, 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.Copyright 2010 © Knorr-Bremse AG – all rights reserved, including industrial property rights applications. Knorr-Bremse AG
This document is subject to alteration without notice and therefore a printed copy 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.
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Fax: +49 89 3547-2767 Elyria, OH
Tel: +34 902 100-569 Knorr-Bremse
Fax: +34 943 614-063 Tel: +1 440 329-9100 Korea Ltd. Truck Brake Division
Hungary Fax: +1 440 329-9105 Seoul
Knorr-Bremse
Tel: +82 2 2273-1182
Fékrendszerek Kft.
Fax: +82 2 2273-1184
Kecskemét
Tel: +36 76 511 100
Fax: +36 76 481 100
Y093009-EN-000