Y025030 - (EN - Rev.

003)
NOVEMBER 2014

Service Manual Pressure regulator

T5

T7 G2
20 l

20 l
T6

T8

Pressurised air G1 T9 G3 T10

18 Bar Check valve Nozzle
1 21 0.25 l
T1
T2 T11 G4 T12

22 0.25 l
ZB44..
T13 G5 T14
type APU
23 0.25 l

Ø nozzle defined in procedure T15 G6 T16

Used part of test bench 24 0.25 l

29
Unused part of test bench
3

T3

T4

AIR PROCESSING UNIT

ZB44..
Disclaimer
The information contained herein 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.

This disclaimer is an English translation of a German text, which should be referred to for all legal purposes.

Any legal disputes arising from the use of this information shall be subject to German law.

Revision Details

Rev. 003 November 2014 Graphics updated to current parts, front cover reworked
 Contents

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

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Service Intervals . . . . . . . . . . . . . . . . . . . . . 5
1.2 Basic Principles . . . . . . . . . . . . . . . . . . . . . 6

2. Components . . . . . . . . . . . . . . . . . . . . . . . . . 9
Serviceable Components of the Air Processing Unit . . . . . . . . . . . . . 9

3. Service Instructions . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Removal and Replacement of the Desiccant Cartridge (A) . . . . . . . 10
3.2 Removal and Replacement of the 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 Unit (D) . . . . . 14
3.6 Disassembling and Assembling the Purge Valve (E). . . . . . . . . . 17
3.7 Disassembling and Assembling the Tyre Inflator (F). . . . . . . . . . 19
3.8 Replacement of the Double Pressure Sensor (H) . . . . . . . . . . 20
3.9 Removal and Replacement of the Time Switch Piston (I) . . . . . . . . 21
3.10 Refitting the Air Processing Unit to the Vehicle . . . . . . . . . . . 23

3
Safety and Environment Guidelines

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

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 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.
10 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.
11 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.
12 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.
13 Use only genuine replacement parts, components and kits as supplied by Knorr-Bremse or the vehicle manufacturer.
14 The serviced or replaced product must be checked for correct function and effectiveness.
15 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.
16 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.

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 arrangements for waste equipment
disposal please contact your Knorr-Bremse distributor or local Knorr-Bremse representative.

4
 1
Introduction

1.1 Service Intervals device is positioned so it cannot be inadvertently abused

or that external rubber boots/seals are not exposed to
The service interval is the length of time from the vehicle
abnormal influences.
first entering service, or from the last service, until the point
in time – or distance travelled by the vehicle (whichever is In general, Knorr-Bremse service kits contain all of the
the earlier) – when it is recommended that the specified components that can deteriorate with use, such as rubber
braking system device is serviced using a genuine parts (O-rings, special seals, bonded inlet/exhaust valves,
Knorr-Bremse service kit or replaced with a new part, or in exhaust flaps), plastic and metal parts (filter elements and
the case of ABS subjected to a system functionality check. springs), fasteners and the correct grease. The range of
kits is designed to enable each device to be serviced in
This service interval is provided for preventative
part or completely.
maintenance purposes so as to minimize the probability of a
vehicle breakdown. Knorr-Bremse service kits are only designed for use with
genuine Knorr-Bremse devices and are only to be used
The service interval does not preclude the intermediate
in the manner detailed in these service instructions.
testing of the device on the vehicle to ensure that it is
After servicing, the device must also be checked in
functioning in a correct manner, or the correct maintenance
accordance with Knorr-Bremse service instructions to
of other devices in the system that may influence the
ensure correct operation before the vehicle is placed back
service interval.
in service.
The service interval can be influenced by the application
and the operating conditions of the vehicle. The following
service intervals are based on the assumption that each

Service interval Service Notes

Clean the oil separator and replace the O-Rings Failure of the air processing unit to purge
Refer to vehicle manufacturer.
(If necessary the service interval can be revised, or non-replacement of the desiccant
30 000 km recommended.
depending on the amount of oil carryover). cartridge at the recommended interval
Refer to vehicle manufacturer. Replace the desiccant cartridge. can cause a reduction in the service
1 year recommended. Replace the oil separator, if necessary. interval of downstream components.

Additional checks
In addition to the above, and any legally required periodic for excess water in the reservoirs by operation of the
vehicle inspections, it is recommended that simple routine reservoir drain valves, and (2) the 6 monthly / (50,000 km)
inspections of a general nature are carried out to maintain checking of the complete braking system for excessive air
the braking system at a high level of functionality. These leakage during a maximum pressure foot brake application
simple routine inspections should be (1) the weekly checking with the vehicle stationary and the parking brake released.

5
1
Introduction

1.2 Basic principles

The ZB44.. range of air processing units combines
the functions of a conventional air dryer with those of a
pressure regulator and multi-circuit protection valve in one
monoblock housing.

1.2.1 Features
• Classic air drying functionality
• Multi-circuit protection valve functionality
• Integrated unloader function
• Integral safety function (air dryer)
• Exhaust safety function (Multi-circuit protection valve, EC)
• Two integrated pressure sensors (Optional)
• ESS Compressor control (Optional but recommended)
• Regeneration either via reservoir or by time switch
• High pressure tyre inflation with safety valve (Optional)
• System pressure tyre inflation (Optional)
• Air suspension supply (Optional)
• Heater (Optional)
• Oil separator (Optional)
• Silencer type (Optional)

1.2.2 Functionality
The air processing unit is fitted in the compressor discharge
line of an air braking system to remove water, dirt, carbon
and oil from the compressed air and therefore prevent it
entering the vehicle air reservoirs during the Charge phase.
It controls the system pressure (unloader function). It also
maintains a pre-set pressure in the unaffected circuits of a
multi circuit braking system in the event of a failure in one
circuit (multi-circuit protection valve function). 1.2.3 Air dryer element
When the increasing air pressure in the braking system
reaches a preset value (cut-out pressure), the unloader Drying function
valve signals the purge valve to open and the air processing During the Charge phase, compressed air enters the air
unit enters the Purge phase. This allows the trapped dirt processing unit through port 1 and passes through the
and condensate to be expelled and the desiccant to be oil separator element to remove particles and oil from the
regenerated with clean, dry air from a separate purge air using the cyclotron principle. This helps to maintain
reservoir or with air from the brake system using an integral the quality of the desiccant bed, prolonging its life and
timer. During this phase, air delivered by the compressor is effectiveness. It continues up the outside of the inner
discharged to atmosphere and does not enter the braking desiccant cartridge and then passes down through the
system. When, due to normal usage, the air pressure in desiccant bed to remove the water vapour. The now clean,
the braking system drops, to the closing pressure of the dry air opens the delivery check valve, flows through the
unloader valve, it signals the purge valve to close and the multi-circuit protection valve, and is delivered from ports
Charge phase begins again. 21, 22, 23 and 24 to charge the vehicle braking system.

6
 1
Introduction

Unloader function During the Purge phase, the loss of pressure in the inlet
The pressure after the delivery check valve also flows to cavity will close the delivery check valve. Some dry air
the unloader valve. When the increasing system pressure from the brake service reservoirs is permitted to return
reaches the preset cut-out pressure, the unloader valve through the multi-circuit protection valve then through the
sends a pressure signal to the purge valve. purge choke. This air flows back through the desiccant
bed and the oil separator and collects water from the
Purge function desiccant regenerating it ready for the next charge cycle.
After a predetermined time, determined by the size of the
The pressure from the unloader valve causes the purge
timing choke, the air pressure in the timing reservoir will
valve to open which connects the initial drainage chamber
drop sufficiently for its piston to close and stop the return
to atmosphere through exhaust port 3 and the accumulated
feed from the brake system. This stops the purge phase,
condensate. Oil and solid matter is then ejected. If the
but the compressor remains unloaded. The sizes of the
compressor control function is not used and the purge
timing choke and the purge choke are designed to match
valve is open, air from the compressor discharges directly to
the system requirements such that the Purge phase is
atmosphere through the purge valve seat and exhaust port 3.
completed well within the compressor off-load cycle and
sufficient air is returned to fully regenerate the desiccant.
Regeneration function
The resulting drop in pressure in the initial drainage 1.2.4 Multi-circuit protection element
chamber causes air to flow back through the desiccant
bed and allows the delivery check valve to close. At the Basic function
same time clean, dry air flows back through the desiccant The multi-circuit protection valve consists of four individual
bed, collecting water from the desiccant and regenerating pressure protection valves connected together in various
it ready for the next Charge phase. The wet air then flows configurations and each having limited feedback capability.
down the outside of the inner desiccant cartridge and is Air is supplied through the delivery check valve in the
discharged to atmosphere through the exhaust port 3. air dryer element, and is delivered from ports 21 - 24 to
Subsequent operation of the braking system will cause circuits 1 to 4 respectively. Circuits 1 and 2 may have a
the downstream air pressure to fall. When the pressure bypass feature (optional).
drops to the cut-in pressure, the pressure signal from the
unloader valve to the purge valve drops to zero and the When the opening pressure of each valve element
purge valve closes. The Charge phase will then begin is reached, the diaphragm will lift, allowing air to
again and the braking system pressure will build. flow past the valve seat into the respective delivery
port and to circuits 23 and 24 from circuits 21
For air processing units with time switch the compressed air and 22 depending on the valve configuration.
required for regeneration is taken from the supply air reser- Due to air usage or leakage etc, when the falling pressure
voirs mounted downstream in the system. The regeneration reaches the closing pressure, the diaphragm will drop
time is determined by the pneumatic time switch and and the supply-to-delivery path will close.
depends on the supply volume and the operating pressure
of the pneumatic system. Air processing units without time Opening pressure
switch require a separate reservoir for the regenerating air,
The opening pressure is the pressure required to open a
the size of which depends on the system volume and the
valve element when the respective downstream circuit is
cut-out pressure. During the Charge phase the separate
at zero pressure. If a circuit is not at zero pressure, the
purge reservoir is charged through port 25.
downstream pressure will also be acting on the diaphragm.
This means that a lower pressure will be required to open
Timing function (optional)
the valve element, i.e. the actual opening pressure is
During the Charge phase, some of the clean dry air from dependent on the downstream pressure and is therefore
the desiccant bed passes through the timing choke and usually lower than the stated value for the valve.
charges the integral timing reservoir.

7
1
Introduction

Static closing pressure Bypass

The static closing pressure is the pressure at which the The bypass feature is an air passage in each circuit 21 and
valve element will close in the event of slow air usage 22 which connects the supply to the respective delivery
(e.g. leakage) from any circuit while the compressor is not ports (21 and 22) when their valve elements are closed. As
charging. The closing pressure is determined by the area a result, pressure can build in the unaffected circuits and
of the diaphragm and the preload of the graduating spring. they will charge normally. The connections have a small
It is always lower than the opening pressure. non-return valve to prevent loss of air in the reverse direction.

Dynamic closing pressure Non-return valves

In the event of a rapid pressure drop in a circuit, the dynamic The non-return valves retain pressure in circuits 23 and 24
closing pressure will be maintained in the other circuits. in the event of a pressure drop in circuits 21 and 22.
It is always higher than the static closing pressure and is
determined by the rate of air pressure loss in the circuit, Exhaust safety function (EC function)
the amount of air being recharged and by the reservoir The exhaust safety function of the multi-circuit protection
volume of the individual circuits. valve ensures that once applied the spring brakes cannot
be released unless there is at least sufficient pressure in the
Charging sequence service brake system to achieve the prescribed residual
service braking performance of the laden vehicle.
Parallel charging
This configuration is not designed to charge each circuit
sequentially. In an initially empty air system there is no fixed
opening sequence. This is particularly true if the system
is already partly charged since the opening pressure of
circuits 23 or 24 could be much lower than that for circuits General note regarding graphical content
21 or 22. (See opening pressure section above). To ensure
All graphics contained in this document are for guidance
circuit 21 or 22 open first and in a reasonable time, circuits
only and subsequently some parts may vary slightly in
21 and 22 have a bypass feature.
appearance.
Series charging
This configuration is designed so that at least one of the
circuits 21 and 22 will open before circuits 23 and 24.
Between circuit 21/22 and 23/24 there are non-return
valves. Circuits 21 and 22 may also have a bypass feature
to speed up the filling of these circuits.

8
 2
Components

Serviceable Components of the Air Processing Unit

Exploded View

I H

B F

C
Part Identification and Service Kits
E
For Service Kit Part Number see
www.knorr-bremseCVS.com

Item Description Comments / Variants

For standard applications
A Desiccant cartridge
For low temperature applications (-45 ºC)
Heater 12 V 27x1
B Heater assembly Heater 24 V 27x1
Heater 24 V Bayonet - ISO15170
C Silencer
Oil separator complete
D Oil separator
Oil separator seals
For standard applications
E Purge valve
For low temperature applications (-45°C)
F High pressure tyre inflator
H Double pressure sensor
I Time switch

9
3
Service Instructions

3.1 Removal and Replacement of the Desiccant Cartridge (A)

Part Identification

Item Description Qty

1 1 Desiccant cartridge 1
2 O-ring 1

Note that component numbering may not correspond to that

shown on separate Service Kit leaflets.

For Service Kit Part Number see

www.knorr-bremseCVS.com
2

Service Steps

Step Service task

Removal with the air processing unit still fitted to the vehicle
1 Before starting work on the vehicle please refer to the safety and environment guidelines on page 4.
2 Clean the outside of the air processing unit and its surroundings to prevent entry of dirt.
3 Vent the air processing unit cartridge by charging the compressed air system until the cut-out pressure of the
unloader valve has been reached and the air processing unit has subsequently purged.
4 Switch off the engine.
To remove the air processing unit from the vehicle please refer to section “Removal of the Air Processing Unit from the Vehicle”.
Removing the cartridge
1 Unscrew desiccant cartridge (1) counter-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 lubricate the gasket at the base of the new cartridge (1) with grease.
2 Lubricate new O-ring (2) with grease.
3 Fit O-ring (2) over the cartridge retaining thread.
4 Screw desiccant cartridge (1) up to stop.
5 Fully tighten desiccant cartridge (1) by turning a further ½ turn using a suitable strap wrench.
6 Refit (if necessary) the air processing unit to vehicle and check according to chapter 3.10.
7 Charge the air system to just below cut-out pressure and check the new desiccant cartridge for leakage.

10
 3
Service Instructions

3.2 Removal and Replacement of the Heater Assembly (B)

Part Identification

Item Description Qty

1 Heater assembly 1
2 Screw 1
Note that component numbering may not correspond to that
shown on separate Service Kit leaflets.

For Service Kit Part Number see

www.knorr-bremseCVS.com

2 M27x1 (12V & 24V) Bayonet - ISO15170

Service Steps

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 electrical connector locking ring and unplug connector (not shown).
3 Undo screw (2).
4 Remove heater assembly (1).
Replacement of the heater assembly
1 Fit new heater assembly (1) into body.

2 Tighten new screw (2) to a torque of 3.5 Nm.

3 Refit the electrical connector and hand tighten the locking ring (not shown).

11
3
Service Instructions

3.3 Removal and Replacement of the Silencer (C)

Part Identification

Item Description Qty

1 Silencer assembly 1

For Service Kit Part Number see

www.knorr-bremseCVS.com

Service Steps

Step Service task

Removal of the silencer assembly
1 Remove silencer assembly (1)
Replacement of the silencer assembly
1 Locate new 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 silencer. Repeatedly charge and vent the air system between cut-out and cut-in
pressure. Silencer must not be blown out by venting air.

12
 3
Service Instructions

3.4 Removal of the Air Processing Unit from the Vehicle

Fig. 1 Fig. 2

Service Steps

Step Service task

1 Before starting work on the vehicle 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 remove the three M12 mountings (bolts, Fig. 1 or nuts, see Fig. 2).
5 Remove the air processing unit and cover the ports to prevent entry of dirt.

13
3
Service Instructions

3.5 Removal and Replacement or Service of the Oil Separator Unit (D)

Part Identification and Service Kits

Item Kit Description Qty

1 t Oil separator unit 1
2 t • O-ring Ø 92 x 2.5 mm 1
3 t • O-ring Ø 42 x 2.5 mm 1
4 t Screw M 4 x 40 mm 2
6
5 t • O-ring Ø 33 x 5 mm 1
6 Desiccant cartridge 1

t Oil Separator complete

• Oil Separator seals

Note that component numbering may not correspond to that

shown on separate Service Kit leaflets.

For Service Kit Part Number see

5 www.knorr-bremseCVS.com

Fig. 1

14
 3
Service Instructions

Service Steps

Removing the oil separator

Step Service task

1 Clean the outside of the air processing unit and its surroundings to prevent entry of dirt.

2 Secure the ZB44.. either to a simple fixture or using the mounting bolts/studs to make it stable.
3 Unscrew desiccant cartridge (6) counter-clockwise, using suitable strap wrench.
4 Remove the screws (4) and O-ring (5).
5 Fit a suitable pulling tool (7) into oil separator unit (Fig. 3). For detailed specification and correct fitting of
recommended tool see page 16.
6 Pull out the oil separator unit (1) by using of pulling tool (7).
If the oil separator unit (1) is not being replaced (depending on kit purchased), clean the the original unit (1) with
7
water using a high pressure hose or alternatively with gasoline. Also clean the housing using a soft cloth.

Fitting the oil separator

Step Service task
Check that the sealing surfaces of the oil separator unit (1) and the cartridge neck (not shown) are clean. Fit the
1
new O-rings (2 and 3) (Fig. 1 on Page 15) and lightly grease them.
2 Put 2 rods (Ø 2.5 mm) (Fig. 4) into the threads for screws (4) to guide the oil separator into the body (Fig. 4).
3 Place the new oil separator unit (1) or cleaned original unit (dependent on kit purchased) into the body. Push the
unit down until it is correctly seated.
4 Fit and tighten screws (4) to a torque of 2.5 Nm.
5 Lightly lubricate the gasket at the base of the cartridge (6) with grease.
6 Lubricate new O-ring (5) with grease.
7 Fit O-ring (5) over the cartridge retaining thread.
8 Screw desiccant cartridge (6) up to stop.
9 Fully tighten desiccant cartridge (6) by turning a further ½ turn 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 desiccant cartridge for leakage.

5
7
4

1 1

Fig. 2 Fig. 3 Fig. 4

15
3
Service Instructions

Recommended pulling tool for Oil Separator Unit disassembly

Holder with
threaded bolt

Adjustable
pulling arms

Thrust plate for

threaded bolt

Correct fitting of pulling tool

Components of pulling tool

Ø35

90º max.3º
15º
3
6
5

min.50

2,8
10

90º
R1
3

Ø3 R3
6,5 5
Ø20
10-60

59

Dimensions of thrust plate

Dimensions of pulling tool legs

16
 3
Service Instructions

3.6 Disassembling and Assembling the Purge Valve (E)

Service kit parts list
Item Kit Description Qty
1 Air Processing Unit (APU) housing 1
2 • Retaining ring Ø 27,2 x 1,2 1
3 • O-ring Ø 24 x 1,5 1
4 • Exhaust piston assembly 1
5 • Compression spring 1
6 • O-ring Ø 25,12 x 1,78 1
7 • End cover 3 or 2
8 • Retaining ring Ø 30 x 1,2 1
9 • Assembly grease 2g 1

• Included in kit
Note that component numbering may not correspond to that
1 shown on separate Service Kit leaflets.
For Service Kit Part Number see
www.knorr-bremseCVS.com

6
4 7
4.2
4.3 4.1 5 8

3
(S)
(S) For devices with steel
covers use the original cover, 2
clean and replace.

17
3
Service Instructions

Service Steps
Procedure with the Air Processing Unit (APU) removed from the vehicle (for removal see section 3.4)
Removing the old purge valve
Step Service task - Read and understand all steps before commencing work!
1 Clean the outside of the APU and its surroundings to prevent entry of dirt.
Position APU so that the purge valve points vertically upwards. Secure in a way to prevent movement but allow for
2
easy access to the required part.
Remove retaining ring (8 or 2) using suitable tool e.g. circlip pliers, whilst holding cover (7 or ‘S’) against
3 compression spring (5).

Check type of cover fitted ( 7 or ‘S’ as shown in above diagram) and carefully remove. Then remove compression
4
spring (5) and piston assembly (4) (see Fig.2).
5 Clean the purge valve bore of APU housing unit (1) with a soft cloth.

Fitting the new purge valve

Step Service task
1 Lubricate the purge valve bore of the APU housing unit (1) with grease (9).
Lubricate new O-ring (4.2) and new sealing ring (4.3) with grease (9) and fit onto new piston (4.1). Note: Make sure
2
O-ring and sealing ring are correctly fitted to piston (4.1).
3 Place assembled exhaust piston assembly (4) into APU housing unit (1).
4 Place new compression spring (5) centrally onto exhaust piston assembly (4).
Select required new cover (7 or ‘S’) in accordance to ZB44.. type (see removal steps), lubricate new O-ring (6 or 3)
5
with grease (9) and fit into groove on selected cover (7 or ‘S’).
6 Push assembled cover (7 or ‘S’) into APU housing unit (1).
Press down and hold cover (7 or ‘S’) against compression spring (5) and fit retaining ring (8 or 2) securely into groove of the
7
APU housing unit (1) using suitable tool e.g. circlip pliers.

18
 3
Service Instructions

3.7 Disassembling and Assembling the Tyre Inflator (F)

Part Identification

Item Description Qty

1 Compression spring 1
2 Valve tappet 1
3 Sealing ring 1
4 O-ring (7 x 1,5) 1
5 Threaded connector 1
6 Protective cap 1

Note that component numbering may not correspond to that

shown on separate Service Kit leaflets.

1
2 For Service Kit Part Number see
4 3
5 www.knorr-bremseCVS.com
6

Service Steps

Disassembling
Step Service task
1 Remove the rubber protective cap (6).
2 Screw-out the threaded connector (5) with sealing ring (3).
3 Remove the valve tappet (2) (along with O-ring (4)) if it has not come out with the threaded connector (5).
4 Remove the compression spring (1).
5 Clean the tyre inflator housing in the body.

Assembling
Step Service task
1 Place the new compression spring (1) into the tyre inflator housing.
2 Lubricate new O-ring (4) with grease and fit into the groove in the valve tappet (2).
3 Lubricate the new assembled valve tappet (2) with grease.
4 Place the assembled valve tappet (2) into 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 tappet (2) twice.
8 Fit the new rubber protective cap (6) .
9 Refit (if necessary) the air processing unit to vehicle and check according to chapter 3.10.
10 Charge the air system to just below cut-out pressure and check the new tyre inflator for leakage.

19
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Service Instructions

3.8 Replacement of the Double Pressure Sensor (H)

Part Identification

Item Description Qty

1 O-ring 2
2 Screw 2
3 Double pressure sensor assembly 1

Note that component numbering may not correspond to that

shown on separate Service Kit leaflets.

For Service Kit Part Number see

www.knorr-bremseCVS.com

Service Steps

Step Service task

Removal of the double pressure sensor.
1 Remove the two screws (2).
2 Remove the double pressure sensor (3) and the two O-rings (1).
3 Carefully clean the O-ring sealing surfaces.
Replacement of the double pressure sensor
1 Lubricate the two new O-rings (1) and place them into the body.
2 Push the new double pressure sensor (3) into the body and firmly hold in place 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 to returning the vehicle to service, check the new double pressure sensor for function and electrical
connection: during charging the air system, check the pressure signal on the dashboard.

20
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Service Instructions

3.9 Removal and Replacement of the Time Switch Piston (I)

Service kit parts list
Pos. Kit Description Qty
1 1 Air Processing Unit (APU) housing 1
2 l Piston (with K-ring) 1
3 Compression spring 1
4 l O-ring Ø 77 x 3 mm 1
5 Cover 1
2 6 Screws Torque 6+2 Nm 4
3 7 l Assembly grease 5g 1
4 • included in kit

5 Note that component numbering may not correspond to that

shown on separate Service Kit leaflets.
For Service Kit Part Number see
www.knorr-bremseCVS.com
7

Service Steps
Procedure with the Air Processing Unit (APU) removed from the vehicle (for removal see section 3.4)
Removing the old time switch piston and seals
Step Service task - Read and understand all steps before commencing work!
1 Clean the outside of the APU and its surroundings to prevent entry of dirt.
Place the APU horizontally on a level surface. Secure it in a way to prevent movement but allowing for easy access
2
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-ring (4) (see Fig.2).
5 Remove the compression spring (3) (see Fig.3).
6 Remove the piston (2) (see Fig.3).
7 Clean the cover (5) using a soft cloth.

8 Clean the APU housing (1) inside with a soft cloth. Pay attention not to contaminate the nozzle in the housing.

Step 3 (Fig.1) Step 4 (Fig.2) Step 5 (Fig.3)

5 3
5 6

4 2

21
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Service Instructions

Fitting the new time switch piston and seals

Step Service task - Read and understand all steps before commencing work!
1 Check that the sliding surfaces in housing (1) and in cover (5) are clean.
Lubricate new O-ring (4), inside wall and sealing surface of cover (5), and central bore of APU housing (1) with
2
grease (7) (see Fig.4).
3 Fit O-ring (4) into groove in cover (5) (see Fig.5).
4 Align the piston (2) K-ring centrally on the piston (see Fig.6).
5 Push the piston (2) carefully into cover (5) to fully centralise the K-ring (see Fig.7).
6 Pull out piston (2) from cover (5) - don‘t touch or move the K-ring!
7 Push piston (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 Fig.9).
Carefully place cover (5) onto APU housing (1) and push it down until it is correctly seated - pay
10
attention to keep correct alignment of K-ring within cover (5) (see Fig.10).
11 Hold cover (5) down against compression spring (3) and fit screws (6) (see Fig.11).

12 Tighten screws (6) to a torque of 6+2 Nm

13 The time switch function should then be tested - see following section “Time Switch Test Procedure”

Step 2 (Fig.4) Step 3 (Fig.5) Step 4 (Fig.6)

7 K-ring alignment position

4 5
5
1

Step 5 (Fig.7) Step 7 (Fig.8) Step 9 (Fig.9)

3
2 2
2
5 1

Step 10 (Fig.10) Step 11 (Fig.11)

5 6

22
 3
Service Instructions

3.10 Refitting the Air Processing Unit to the Vehicle

Fig. 1 Fig. 2

Recommended Tightening Torques for Air Ports

Max. torque
Conventional face sealing metric ports
[Nm]
M12 x 1.25 25
M12 x 1.5 25
M12 x 1.75 25
M16 x 1.5 45
M22 x 1.5 60
Service Steps
Step Service task
1 Locate the air processing unit in its position on the vehicle.

2 Fit and tighten the three M12 mountings (bolts, Fig. 1 or nuts, Fig. 2) to a maximum torque of 25 Nm.

Reinstall the air lines taking great care to ensure correct connection to ports. See above table for recommended
3
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 pressure in the system by operating the foot brake repeatedly until cut-in pressure is reached.

7 Ensure cut-in and cut-out pressures are correct (refer to vehicle manufacturer).

23
Commercial Vehicle Systems

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

Knorr-Bremse Systeme für November 2014
Nutzfahrzeuge GmbH
Moosacher Strasse 80
80809 Munich
Germany
Tel: +49 89 3547-0
Fax: +49 89 3547-2767
www.knorr-bremseCVS.com

Note: If service work is carried out on a vehicle based on information provided herein, 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 © Knorr-Bremse AG - all rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power
The information contained herein is subject to alteration without notice and therefore may not be the latest release. Please check our website www.knorr-bremseCVS.com for the latest update or contact your local Knorr-Bremse representative.
The figurative mark “K” and the trademarks KNORR and KNORR-BREMSE are registered in the name of Knorr-Bremse AG. Additional terms and conditions apply; please refer to our website knorr-bremseCVS.com for full Disclaimer.
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