Om501 Om502 Workshop Manual Abby

Doc. No. Y059594 (EN - Rev.
004)
March 2019
EconX®
CORE MANUAL
A COMPREHENSIVE GUIDELINE TO THE KNORR-BREMSE

TRUCKSERVICES CORE PROGRAM
WHAT IS THE CORE PROGRAM?

HOW TO IDENTIFY THE CORE?
HOW THE CORE IS GRADED?
HOW TO PACK AND RETURN THE CORE?
Y059594: 004: EN, English: Released:Webmaster: 2019/04/02-10:16:54

» Y059594 – (EN - REV. 004) | March 2019
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.
Revision Details
Rev. 003 January 2017 Complete revision and layout updated.
Rev. 004 February 2019 New Core acceptance criteria added, revision of old content, layout changes.
2
» EconX® Core manual
CONTENTS
SAFETY AND ENVIRONMENT GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 KNORR-BREMSE TRUCKSERVICES CORE PROGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1 Important information regarding the Core Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Core Return Processing at a glance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Core Accounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 CORE ACCEPTANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Why would Knorr-Bremse reject Cores that have been returned?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.2 Air Disc Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.3 Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.4 Mechatronics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.5 Core Acknowledgement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
4 PACKAGING GUIDELINE FOR CORES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.1 Transport protection and packaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5 CORE GROUP CLASSIFICATION & IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5.1 Air Disc Brakes (Core Group Identification: Y252531). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5.2 Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5.3 Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5.4 Mechatronics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5.5 Identification of Air Disc Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6 CORE ACCOUNT REPORTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

6.1 Core Summary Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
6.2 Core Group Detail Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
6.3 Reconciliation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7 APPENDIX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.1 Core Return Request form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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» Y059594 – (EN - REV. 004) | March 2019
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.
CAUTION: KNORR-BREMSE IS NOT LIABLE FOR ANY INJURIES OR DAMAGES CAUSED BY IMPROPER USE OF SPECIFIED SERVICE KITS AND/OR
SERVICE TOOLS. FURTHERMORE, MISUSE OF TOOLS OR INCORRECT INSTALLATION OR APPLICATION OF SERVICE KITS MAY RESULT IN DAMAGE OR
POTENTIALLY UNSAFE VEHICLE OPERATIONS. IN THIS CASE, KNORR-BREMSE DOES NOT HAVE ANY WARRANTY OBLIGATIONS.
Before and whilst working on or around compressed air systems and devices, the following precautions should be observed, along with the many
hazard notes contained throughout the document:
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 battery
disconnected. 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 Use only genuine replacement parts, components and kits as supplied by Knorr-Bremse or the vehicle manufacturer. Only use the recommended tools as
specified in related Knorr-Bremse 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 The use of impact screwdrivers or impact wrenches in conjunction with Knorr-Bremse service tools for air disc brakes is not permitted. The service tools are not
designed for such use. It is likely that the tools or the vehicle will be damaged and there is a serious risk of injury – see Caution above.
18 Do not use compressed air to clean the disc brake. Avoid air contamination of brake dust.
19 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.
4
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 electronic equipment. For more information about arrangements for waste equipment disposal
please contact your Knorr-Bremse distributor or local Knorr-Bremse representative.
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6
1 INTRODUCTION
During recent years Knorr-Bremse TruckServices has increased its efforts to collect Cores1 back from the market.
The main driving forces behind this philosophy are:
• To ensure the availability of high quality Knorr-Bremse EconX (genuine remanufactured) products in the market place.
• To prevent broken, damaged, or worn out safety-critical products being misused for reconditioning activities by unauthorized
parties.
• Protect customers from potential safety issues that could arise from incorrect/unauthorized parties repairing or reconditioning
activities.
• Environmental responsibility: Promoting a circular and sustainable economy by minimizing waste and CO2 Emissions. Each
returned Core is contributing to savings of up to 150 kg CO2 equivalents2 and recovery of 80% raw material.
• In order to support this approach, it is therefore important that the Core is returned, following the Knorr-Bremse TruckServices
Core Program and procedures.
APRA Definition of CORE: “A core is a previously sold, worn or non-functional product or part, intended for the remanufacturing
1
process. During reverse logistics, a core is protected, handled and identified for remanufacturing to avoid damage and to preserve
its value. A core is not waste or scrap and is not intended to be reused before remanufacturing.” [REMANUFACTURING ASSOCIA-
TIONS AGREE ON INTERNATIONAL INDUSTRY DEFINITION 2016]
Knorr-Bremse follows the circular economy strategy of the EU Commission and executes extensive Life Cycle Assessments to
2
analyze the CO2 footprints of Knorr-Bremse products
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» Y059594 – (EN - REV. 004) | March 2019
2 KNORR-BREMSE TRUCKSERVICES CORE PROGRAM
2.1 Important information regarding the Core Program
Which products are ›› Surcharged product part numbers are shown in the Aftermarket Price List and are marked
surcharged? by Core Groups
›› Group of products defined in detail in chapter 5.
Core Group Returned Core is assigned to a Core Group and is only credited against a surcharged purcha-
se from the same Core Group.
›› Surcharge Values are defined by Core Group and can be requested from your Knorr-Bremse
Sales Representative
›› Values are shown as a separate line on the invoice
Core Surcharge Value ›› Term of payment of the Core Surcharge Value as defined on the invoice
›› The Core Surcharge Value will be credited if a Core of the same Core Group is returned wit-
hin the Core Return Window and if the Core Acceptance criteria are met (details are shown
in chapter 3)
›› Validity window of the Core Surcharge Value in the Core Account: 12 months from the end
of the invoicing month
Core Return Window ›› A Core needs to be returned and registered within this time window at the central Core
collection point Knorr-Bremse Liberec
›› Validity window of the returned Core in the Core Account, in case there is no Core Return
Window existing: 24 months from the end of the Core registration month
Core Validity Window ›› If there are sufficient surcharged purchases in the Core Account within this time window, a
credit willbe given
›› Shows the balance between surcharged purchases and returned Cores
Core Account ›› Set up per Core Group
›› Monthly reports with the status of the Core Account can be found in the ePortal account or
Core Reporting can be requested from your local contact for Cores
›› Refer to section: Core Account Reports
›› At the end of the month a credit is given if there is a match between a surcharged purchase
Core Surcharge Crediting and returned Core within one Core Group
›› Credit is given against the oldest outstanding surcharge value – First in First out
›› The Transfer of Ownership/Property of the returned Core takes place with the handover to
the forwarding agent of Knorr-Bremse
Transfer of Ownership/ ›› The Goods Receipt is confirmed with a Core Acknowledgement, which is emailed after the
Property shipment has been completely processed by the central Core processing department loca-
ted within Knorr-Bremse Liberec
›› Note - incoming Core shipments are examined to check quantity and quality
›› The Core Acceptance Guideline details acceptance / rejection criteria for returned Cores
›› Cores with grade “Rejected“ will not be booked in the Core Account and will not be credited
Core Acceptance or sent back. Rejected Core will be then scrapped by Knorr-Bremse.
›› Cores with grade “Accepted“ will be booked in the Core Account
›› Both grades are reported on the Core Acknowledgement
Due Date of surcharged ›› Validity date of surcharge values under consideration of the Core Return Window
purchases ›› The option to return a Core and to receive a credit expires after that date
›› Validity date of the returned Core under consideration of the Core Validity Window
Due Date of Core returns ›› A returned Core expires after that date and a surcharged purchase will not be credited
against this return
›› Knorr-Bremse TruckServices reserves the right to make changes to the Core Policy, these
Core Policy Changes changes will be announced in detail via an official Knorr-Bremse Customer News
8
KNORR-BREMSE CORE PROGRAM 2
2.2 Core Return Processing at a glance
OLD
Collect & Pack

1 Collect Cores and pack them according to the Pack-
aging Guideline (see the chapter 4).
Collection Request
Option a: Online via ePortal
2.1. Log-in and navigate to Section Core
2.2. Fill out the Core Return Request form
2.3. Submit the filled-out form
Option b: Via Email https://bit.ly/2J1ANBs
2 2.1. Fill out the Core Return Request form
(Document No. Y071081, available under:
www.knorr-bremsecvs.com/en › Download Documentation)
2.2. Send the filled-out form to your responsible
Knorr-Bremse contact for Cores and request a Core
Return Memo Number (CRM No.)
The collection request will be confirmed by email.
Identify each pallet

3.1 Print out the Core Return Request form including
the CRM no. (if ePortal is not accessible).
3 3.2 Attach the form in an envelope outside and inside
each box. Failure to do so can result in a delay of
having the Core Return processed in the system or
not being assignable (thus not credited).
Send the shipment

4 Prepare the Core shipment for collection.
Check the Acknowledgement note

After the shipment has been sorted and Cores have
5
been graded, a Core Acknowledgement Report is
emailed. The Report shows the accepted or rejected RE
COR
quantity per Core Group in comparison with the
initial collection request (the CRM no. can be used as
a reference).
Get the Credit note

3.3 The Core Surcharge Value is credited if the returned
Core meets the Core Acceptance criteria and that
6 the Core Group is in a credit owed condition.
3.4 The monthly Core Summary Report shows the Core
Account status, accessible via ePortal or sent by
email.
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2 KNORR-BREMSE CORE PROGRAM
2.3 Core Accounting
Invoiced Surcharge
1) 01.01.2016
2) 15.01.2016
CORE ACCOUNT
Returned Core
Receipt
3) 03.05.2016
CUSTOMER CORE ACCOUNT

Core
Invoice/
Type Core Group Surcharge Quantity Due Date Comment
Return Date
Value
1 Purchase DC8 175 € 1 pc 01.01.2016 31.01.2017 Oldest outstanding purchase
2 Purchase DC8 175 € 1 pc 15.01.2016 31.01.2017
3 Return DC8 (-175 €) 1 pc 03.05.2016 31.05.2018 Core Return
1. Purchase of a surcharged product in Core Group DC8 invoiced on 01.01.2016. Due date: 12 months from the end of the invoicing month
(Core Return Window). A Core needs to be registered at Knorr-Bremse Liberec until this Due Date (31.01.2017).
2. Second purchase of surcharged product, invoiced on 15.01.2016. Due date of 31.01.2017.
3. A returned Core, registered on 03.05.2016 will be valid in the Core Account for 24 months (Core Validity Window).
Due date of 31.05.2018.
4. Core credit is given on 31.05.2016 since there is a match on Core Group level between the surcharged purchase and a Core Return. The
credit is given against the oldest outstanding surcharged purchase – event 1). After the credit is given, 1) and 3) are cleared from the Core
Account.
10
3 CORE ACCEPTANCE
3.1 Why would Knorr-Bremse reject Cores that have been returned?
1. The Core is a danger for the environment or persons handling those, e.g. Core is not properly drained
2. No Core Return Request form is attached to the box
3. The returned Core is not part of the Core Program
a) Product is not listed within the Aftermarket Price list
b) Product has no valid cross-reference to a Knorr-Bremse product 1
4. Core has been reconditioned by a 3rd party
5. Core has suffered mechanical damage 2
6. Core has suffered heavy external or internal corrosion
7. Core returned is incorrectly or incompletely assembled or in a disassembled condition
8. Core returned has no type label or the type label is manipulated
9. Core returned without proper packaging (refer to Packaging Guideline)
10. Core is of Old Level Design: (e.g. SB5 calipers are not part of the Core Program and will be rejected)
1
K norr-Bremse reserves the right to accept non-Knorr-Bremse Cores within certain Core Groups, if interchangeable with
Knorr-Bremse products, as long as it is returned as a result of the sale of an equivalent Knorr-Bremse product. See the Cross Ref-
erence section of the website www.knorr-bremseCVS.com for interchangeable products or contact the local Knorr-Bremse Sales
Representative for further details.
2
Refer to Core Sorting Guidance
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» Y059594 – (EN - REV. 004) | March 2019
3 CORE ACCEPTANCE
3.2 Air Disc Brakes
Mechanical damage Excessive corrosion Incomplete
The caliper casting should be The caliper shouldn‘t suffer a deep,

The caliper should be returned
unbroken, with no deep scratch, excessive corrosion on any of its
complete and fully assembled.
crack or cut. parts.
12
CORE ACCEPTANCE 3
3.3 Compressors
No damage to the compressor Compressor shouldn‘t suffer

Compressor should be returned
casting, flange, input ports and excessive external or internal
complete and fully assembled.
threads. corrosion.
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3 CORE ACCEPTANCE
3.4 Mechatronics
Mechatronic unit shouldn‘t suffer any

Mechatronic shouldn‘t suffer Mechatronic unit should be returned
mechanical damage on both body
excessive corrosion. complete and fully assembled.
and electronic part.
14
CORE ACCEPTANCE 3
3.5 Core Acknowledgement
Rejected Cores will be flagged with the Core Grade “Rejected” on the Core Acknowledgement with the reason of the rejection (see:
Figure 1: Core Acknowledgement). Rejected Cores will not be credited.
Accepted Cores will be flagged with the Core Grade “Accepted” and will be booked to the Core Account.
Knorr-Bremse decides whether a Core is accepted or rejected.
Announced quantities on the Core Return Request Form are shown as quantity advised on the Core Acknowledgement, compara-
ble with the actual quantity received, which enables a complete overview of the accurracy of the Core return.
Any claims need to be made within 14 days of the entry date (date of report creation) shown at the top of the Core Acknowledge-
ment. Please inform your local Knorr-Bremse contact if the email address to which you have the Core Acknowledgement sent
changes.
The CRM Number, provided by Knorr-Bremse at the time of the pick-up request, links your shipment with the Core Acknowledge-
ment.
CORE Acknowledgement
CRM Number yy-cw-0123-0xyz
Sold to Party: Customer Name Doc No.: 123456789
Ship to Party: Customer Branch Name Entry Date: dd.mm.yyyy
City/Country: Pick-Up City Number of Pallets: 02
CORE
Core Group Description Qty advised Qty received Core Grade Damage Desc. 1 Damage Desc. 2
Group
1CH EBS One Channel Module 0 4
1 Rejected* Mechanical Damage Corrosion
1 Rejected* Incomplete
2 Accepted
CT1 Compressor (Twin) 3 7
1 Rejected* Mechanical Damage Corrosion

Figure 1: Core Acknowledgement
1 Rejected* Corrosion
1 Rejected* Mechanical Damaged
4 Accepted
15
Caliper, Rationalised - SB7 axial,
DC8
Y059594: 004: EN, English: Released:Webmaster: 5 4
2019/04/02-10:16:54
SN7
» Y059594 – (EN - REV. 004) | March 2019
4 PACKAGING GUIDELINE FOR CORES
4.1 Transport protection and packaging
Ensure that boxes are adequately sealed or banded for transportation using plastic strapping or banding (no metal). The sender is
obliged to ensure that the packaging and its contents are in accordance with local laws (e. g. of EU).
Unsafe boxes will be returned at the expense of the sender.
› Wherever possible the Core should be returned in the packaging of the replacement product (in exceptional cases we accept
calipers, compressors or other heavy products without the box).
› Protect caliper Cores against inner corrosion by using the sticker delivered with the exchange product.
› Protect ports/threads by using protection caps delivered with the exchange product.
› Store Cores in a dry and clean place to avoid corrosion after dismounting from the vehicle.
› Heavy Cores on bottom, light ones on top, separated by interlayers. For large returns, please pack the Cores by product group
150 V4 294c
NEW OLD
CM
MY
CY
CMY
Back in the box 150 V4 294c
CM
MY
CY
CMY
Protection against corrosion
Protection of ports/threads
16
5 CORE GROUP CLASSIFICATION & IDENTIFICATION
Core Groups marked with “!” (Exclamation Mark) need to be returned product type specific (e.g. SB7 axial caliper Cores will not be
credited against purchased SN7 axial). Core Credit is only given within those technically grouped Core Groups.
5.1 Air Disc Brakes (Core Group Identification: Y252531)
Core Core
Description Description
Group Group
Air Disc Brakes (SM, SL Calipers) DC2 Air Disc Brakes (SN7 Calipers) ! DC8 !
Air Disc Brakes (SB7 radial Calipers) DC4 Air Disc Brakes (ST7 Calipers) DC9
Air Disc Brakes (SN5 Calipers) ! DC5 ! Air Disc Brakes (SB6 Calipers) ! DCA !
Air Disc Brakes (SN6 Calipers) ! DC6 ! Air Disc Brakes (SB7 axial Calipers) ! DCB !
Air Disc Brakes (SK7 Calipers) DC7
5.2 Compressors 5.3 Others
Core Core
Group Group
Clutch
CC1 Air Dryers AD1
Compressors
Single Cylinder
CS1 Filter Cartridges ADC
Compressors
K2 Spring Brakes and

Twin Cylinder
CT1 Spring Portions-S- SB1
Compressors
Cam, Wedge
Allmakes Single Exhaust Gas Turbo

CS3 X**
Cylinder Compressors Chargers
Allmakes Twin Cylinder

CT3
Compressors
Screw
SC1
Compressors
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5 CORE GROUP CLASSIFICATION & IDENTIFICATION
5.4 Mechatronics
Core Core
Group Group
EBS One Channel

EBS Electronic Control
Modules 1CH ECU
Units (ECU)
(EBS2, EBS5, EBS7)
EBS Two Channel EBS Foot Brake

Modules 2CH Modules FBM
(EBS2, EBS5, EBS7) (EBS2, EBS5, EBS7)
Electronic Clutch
CA1 Brake Servo Units SB3
Actuators
EBS Trailer Control

Allmakes Clutch
CA2 Modules TCM
Actuators
(EBS2, EBS5, EBS7)
Electronic Air Control Trailer

Units (EAC1) EA1 Electro-Pneumatic TE1
- First Generation Modules
Electronic Air
Trailer Brake Modules
Processing Units
EA2 - TEBS 4, TEBS G2.0, TE2
(EAC2)
G2.1, G2.2
- Second Generation
18
CORE GROUP CLASSIFICATION & IDENTIFICATION 5
5.5 Identification of Air Disc Brakes

(Document No. Y252531 available from www.knorr-bremsecvs.com > Download Documentation):
CORE GROUP IDENTIFICATION

OF KNORR-BREMSE AIR DISC BRAKE CALIPERS
Check List
2x Tappets 1x Tappet
1) Tappets Check casting
Mono SN5 Split SB5
Axial Radial
2) Flange SB7R
DC5 (Not in Core program)
DC4
Mono Split
3) Block Check screw casting area
SB6 SB7
3a) Monoblock
Base plate
Assembly DCA DCB
Direction
Check casting
2 outer screws 2 outer screws

assembled from assembled from
actuator side disc side
SM7 SN7 ST7
0 54mm 0 65mm
Check for
distinguishing features
Screw head deep

3b) Monoblock in casting DC2 DC8 DC9 ‘S’ shape
tension
SL7 strut
Identifiers
Casting shape 2 grooves
SK7 SN6
DC2 DC7 DC6

Y252531-EN-001
19
Copyright © Knorr-Bremse AG - all rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as for copying and transferring.
Knorr-Bremse Systeme für Nutzfahrzeuge GmbH . Moosacher Strasse 80 . 80809 Munich . Germany . Tel: +49 89 3547-0 . Fax: +49 89 3547-2767 . www.Knorr-Bremse.com . www.Knorr-BremseCVS.com

» Y059594 – (EN - REV. 004) | March 2019
6 CORE ACCOUNT REPORTS
6.1 Core Summary Report
Provides a monthly overview about total balance ofKNORRBREMSE SFNGMBH

Report: YYS_R_CORE_STATEMENTSUMMARY
the Core Account by Core Group.
Date: GROUP SUMMARY REPORT
CORE Parent:
Report: YYS_R_CORE_STATEMENTSUMMARY KNORRBREMSE SFNGMBH
Date: Period Ending MONTH YEAR
GROUP SUMMARY REPORT
CORE Parent:
GRP Previous Balance Purchases Returns Adjustments Expired Items Current Balance Credits Issued Due SEP Due OCT Due NOV Beyond DEC Curr
1CH EBS One Channel Module
2.400,00 0,00 0,00 MONTH YEAR
0,00 Period Ending0,00 2.400,00 0,00 0,00 0,00 400,00 1.600,00 EUR
GRP 12
Previous Balance 0
Purchases 0
Returns 0
Adjustments 0
Expired Items 12
Current Balance 0
Credits Issued 0
Due SEP 0
Due OCT 4
Due NOV 8
Beyond DEC Curr
2CH EBS Two Channel Module
1CH EBS One Channel Module
2.400,00
2.600,00 200,00
0,00 0,00 0,00 0,00 2.400,00
2.400,00 200,00
0,00 0,00 0,00 0,00
400,00 2.400,00
1.600,00 EUR
13
12 1
0 0 0 0 12
12 1
0 0 0 0
4 12
8
CS1 Compressor - Single Cylinder
1050,00
2.600,00 0,00
200,00 175,00-
0,00 0,00 0,00 875,00
2.400,00 175,00-
200,00 0,00 0,00 175,00
0,00 700,00
2.400,00 EUR
6
13 0
1 1
0 0 0 5
12 1 0 0 1
0 4
12
Compressor -- Twin
CT1 Compressor
CS1 Cylinder
Single Cylinder
350,00
1050,00 700,00
0,00 175,00-
0,00 0,00 0,00 350,00
875,00 175,00-
700,00 0,00 0,00 175,00
0,00 700,00
350,00 EUR
2
6 4
0 0
1 0 0 2
5 4
1 0 0 0
1 2
4
DC5 Caliper - type:
CT1 Compressor SN5Cylinder
- Twin
350,00
1.575,00 0,00
700,00 525,00
0,00 0,00 0,00 350,00
1.050,00 525,00
700,00 0,00 350,00
0,00 0,00 700,00
350,00 EUR
9
2 0
4 3
0 0 0 6
2 3
4 0 2
0 0 4
2
DC6 Caliper -- type:
DC5 Caliper type: SN5
SN6
525,00
1.575,00 525,00
0,00 0,00
525,00 0,00 0,00 1.050,00 0,00
525,00 0,00 0,00
350,00 0,00 1.050,00
700,00 EUR
3
9 3
0 0
3 0 0 6 0
3 0 0
2 0 6
4
- type: SN6
FBM EBS Foot Brake Module
DC6 Caliper
400,00
525,00 0,00
525,00 0,00 0,00 0,00 400,00
1.050,00 0,00 0,00 0,00 0,00 400,00
1.050,00 EUR
2
3 0
3 0 0 0 2
6 0 0 0 0 2
6
TCM EBS Trailer Control Modul
FBM EBS Foot Brake Module
1.400,00
400,00 0,00 600,00
0,00 0,00 0,00 700,00
400,00 600,00
0,00 0,00 0,00 0,00 700,00
400,00 EUR
7
2 0 3
0 0 0 4
2 3
0 0 0 0 4
2
TE2 Trailer Brake Module TE
TCM EBS Trailer Control Modul
0,00
1.400,00 200,00
0,00 600,00
0,00 0,00 0,00 200,00
700,00 600,00
0,00 0,00 0,00 0,00 200,00
700,00 EUR
0
7 1
0 0
3 0 0 1
4 0
3 0 0 0 1
4
TOTAL 4.400,00
TE2 Trailer Brake Module TE 1.625,00 130,00 0,00 0,00 4.625,00 2.200,00 0,00 350,00 575,00 3.300,00 EUR
24
0,00 9
200,00 7
0,00 0
0,00 0
0,00 26
200,00 12
0,00 0
0,00 2
0,00 5
0,00 19
200,00 EUR
0 1 0 0 0 1 0 0 0 0 1
TOTAL 4.400,00 1.625,00 130,00 0,00 0,00 4.625,00 2.200,00 0,00 350,00 575,00 3.300,00 EUR
24 9 7 0 0 26 12 0 2 5 19
The explanation of report columns:

Previous/Current Balance › Core Account balance at the beginning and the end of the reported month
› First line shows the monetary value. The second line shows the quantity
Purchases › Purchases of surcharged products summarized by Core Group
Returns › Returned Cores summarized by Core Group
Adjustments › Warranty returns/Product returns etc.
Expired Items › Expired Core Surcharge Values (Core Return Window exceeded) or expired Cores
(Core Validity Window exceeded)
Credits Issued › Credited Core Surcharge Values per Core Group 1
Due x/y/z › Three month outlook showing the quantity of Cores to be returned or Cores expiring in the
month shown. E.g. if Cores are not registered at the central Core collection point in Liberec
within shown month, the Core Surcharge Value will expired
Beyond OKT › Outlook beyond the 3 month horizon
1 In countries where standard credit notes are not issued, simulated values are shown in the “Credits Issued” column.
20
CORE ACCOUNT REPORTS 6
6.2 Core Group Detail Report
Shows current month’s activity for each Core Group. The details include Knorr-Bremse document number (invoice number or CRM
No.), customer purchase order and part numbers for purchases.
Report: YYS_R_CORE_STATEMENTCOREGRP KNORRBREMSE SFNGMBH Page 1

Date: dd.mm.yyyy CORE GROUP DETAIL REPORT
Period Ending MONTH YEAR
2.600,00 200,00 0,00 0,00 0,00 2.400,00 200,00 0,00 0,00 0,00 2.400,00 EUR
13 1 0 0 0 12 1 0 0 0 12
Due Date Trans Date Type Document P.O. / Ref Class Part Number Quantity Amount Curr Soldto City
New Purchases
dd.mm.yyyy dd.mm.yyyy SLS 0123456789 12345 D22 0486204019N50 1 200,00 EUR
Report: YYS_R_CORE_STATEMENTCOREGRP KNORRBREMSE SFNGMBH
CORE GROUP DETAIL REPORT
CS1 Compressor - Single Cylinder
1050,00 0,00 175,00- 0,00 0,00 875,00 175,00- 0,00 0,00 175,00 700,00 EUR
6 0 1 0 0 5 1 0 0 1 4
Due Date Trans Date Type Document P.O. / Ref Class Part Number Quantity Amount Curr Soldto City
New Returns
dd.mm.yyyy dd.mm.yyyy RTN YY-CW1234xxxx CS2 CORE_CS2 1 175,00- EUR
6.3 Reconciliation Report
This report 1 gives specific detail of any current month’s debit or credit. It shows the detail for the transactions that produced the
debit or credit.
Report: YYS_R_CORE_STATEMENT- KNORR-BREMSE SFN-GMBH

CREDIT Date: CREDIT RECONCILIATION
REPORT CORE Parent:
Due Date Trans Date Type Document P.O. / Ref Group Class Description Quantity Amount Curr Soldto City
31.01.2018 30.06.2016 RTN YY-CW-1234-xxxx 2CH D50 EBS TWO CHANNEL MODU 1- 200,00- EUR
Totals 2CH 1- 200,00- EUR
31.08.2018 23.08.2016 RTN YY-CW-1234-xxxx CS1 CS2 KNORR SINGLE CYLINDE 1- 60,00- EUR
Totals CS1 1- 60,00- EUR
31.01.2018 31.07.2016 RTN YY-CW-1234-xxxx CT1 CT2 KNORR TWIN CYLINDER 4- 700,00- EUR
Totals CT1 4- 700,00- EUR
31.08.2018 23.08.2016 RTN YY-CW-1234-xxxx DC3 DC3 AIR DISC BRAKE CALIP 3- 525,00- EUR
Totals DC3 3- 525,00- EUR
31.08.2018 23.08.2016 RTN YY-CW-1234-xxxx TCM T23 EBS TRAILER CONTROL 3- 600,00- EUR
Totals TCM 3- 600,00- EUR
Total Credits Issued 12- 2.085,00- EUR
1 This report is only relevant to customers whose country issue standard credit notes.
21
» Y059594 – (EN - REV. 004) | March 2019
7 APPENDIX
7.1 Core Return Request form
Document Number: Y071081 available under: www.knorr-bremsecvs.com > Download Documentation
T
N REQUES each pallet to enable a fluent crediting
res!
of your co
UR
CO R E R E T ls and att
ach this sh
eet on
detai
mplete all
Please co
-0281
-CW-0123
No. mo Number (CRM No.),)
CRM tur Format: YY
n Me
(Core Re /notified
nerated
-Bremse ge de
from Knorr
Country Co
Date: YY
DD/MM/YY
Name
Customer
No.
Customer CORE RETURN REQUES
T
Tel.
Customer No.
CONTACT
CRM No.
Name
Fax Description Core Weight
Group Quantity Total Weight
Core Mix
[kg/Pcs.]
[kg] Comment
MIX
Email EBS One-Channel-Mod No //
ule Yes
0 kg)? 1CH
se (min. 40EBS Two-Channel-Module
2
orr-Brem
tion by Kn 2CH
ansportaon: 4
Do yo u need tr cti this se
Air Dryers
complete AD1 12
If yes, please Air Dryer Cartridge (per
cargo unit)
ADC 500
Collection Electronic Clutch Actua
tors
Address
CA1
.
mpany House No 4
Name / Co Allmakes Clutch Actuators
CA2 4
Compressor with clutch
CC1 35
Street Compressor - Single Cylind
er
CS1 10
Compressor - Twin Cylind
City er
CT1 20
Post Code Allma
Goods kes Comp e
ressor - Single Cylinder
CS3
Av ailable Tim
Allma
10
kes Comp ressor - Twin Cylinder No
Yes
Goods CT3 20
Date Tail Lift
Caliper - type: SM,SL
Available
No
Required?
Yes DC2 30
Caliper - type: SB7 radial
Fork Lift DC4 30
Required? Caliper - type: SN5
e?
cess restrictions DC5 30 StackablNo
vehicle ac Caliper - type: SN6 Yes
details of
Please givehicle size) DC6
h/He igh t)
ght (Le ngth/Widt 30
Size of Frei
max. ve Caliper - type: SK7
(e.g.
DC7
es ght kg
WeiCalipe r - type: SN7
30
ag
No. of Pack DC8
ckaging 30
Type of Pa Caliper - type: ST7
DC9 30
Gitterbox Caliper - type: SB6
DCA 30
t
EUR palle Caliper - type: SB7 axial
DCB 30
pallet
One way Total Electronic Air Control EAC 1
sed!) EA1 9
Electroniced ms ca n be proces
fill Airfor
Contr ol EAC 2
completely EA2
to: (Note: only return tea
m. 9
is form EBS-Br
Electr coreContr
se send th Knorr em seonic ol Unit (ECU)
Plea r local ECU
-filled by you 1
ady be pre EBS - Foot Brake Module
n should alre
This sectio FBM 2
Spring Brakes & Spring
Email: Portions & Piston (K2...)
SB1 8
Brake Servo Units
(Rev. 005)
.
Fax: contact us SB3 8
Screw Comp day) please
y - Friressor
ho urs (Monda
within 48 SC1
1081- EN
t received 36
ation is no EBS - Trailer Control Modu
If confirm le
TCM 2
Doc. No. Y07
Trailer Electro-Pneumat
ic Modules
TE1 2
Trailer Brake ModulesTEB
S
TE2 6
Exhaust Gas Turbocharg
ers
X.. 13
Total
005)
Please note: Rejected core,

e.g. Caliper without adjust
Doc. No. Y071081- EN (Rev.
Please ensure that your er in place, will be scrapp

shipment is adequately ed without credit or furthe
secured for the transport. r notice. See core manua
With each core returned l (Y059594) for details.
to Knorr-Bremse you contrib
ute to a sustainable circula
r economy. Thank you!
Print Me
Send via Email
22
Your local TruckServices Workshops, Dealers and Branches can be found anytime online
at www.knorr-bremseCVS.com - or on a Smartphone with our Service Locator App
(available for Android and iOS).
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
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. 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 of disposal, such as for copying and transferring.

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Doc. No. Y059594 (EN - Rev.

A COMPREHENSIVE GUIDELINE TO THE KNORR-BREMSE

WHAT IS THE CORE PROGRAM?

Y059594: 004: EN, English: Released:Webmaster: 2019/04/02-10:16:54

SAFETY AND ENVIRONMENT GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 KNORR-BREMSE TRUCKSERVICES CORE PROGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4 PACKAGING GUIDELINE FOR CORES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5 CORE GROUP CLASSIFICATION & IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

6 CORE ACCOUNT REPORTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

SAFETY AND ENVIRONMENT GUIDELINES

1 Always wear safety glasses when working with air pressure.

Disposal of Waste Equipment by Business Users in the European Union

analyze the CO2 footprints of Knorr-Bremse products

2 KNORR-BREMSE TRUCKSERVICES CORE PROGRAM

2.1 Important information regarding the Core Program

KNORR-BREMSE CORE PROGRAM 2

2.2 Core Return Processing at a glance

Collect & Pack

Identify each pallet

Send the shipment

Check the Acknowledgement note

Get the Credit note

2 KNORR-BREMSE CORE PROGRAM

2.3 Core Accounting

CUSTOMER CORE ACCOUNT

2 Purchase DC8 175 € 1 pc 15.01.2016 31.01.2017

3 Return DC8 (-175 €) 1 pc 03.05.2016 31.05.2018 Core Return

3.2 Air Disc Brakes

Mechanical damage Excessive corrosion Incomplete

The caliper casting should be The caliper shouldn‘t suffer a deep,

Mechanical damage Excessive corrosion Incomplete

No damage to the compressor Compressor shouldn‘t suffer

Mechanical damage Excessive corrosion Incomplete

Mechatronic unit shouldn‘t suffer any

3.5 Core Acknowledgement

CRM Number yy-cw-0123-0xyz

Sold to Party: Customer Name Doc No.: 123456789

Ship to Party: Customer Branch Name Entry Date: dd.mm.yyyy

City/Country: Pick-Up City Number of Pallets: 02

1CH EBS One Channel Module 0 4

1 Rejected* Mechanical Damage Corrosion

CT1 Compressor (Twin) 3 7

1 Rejected* Mechanical Damage Corrosion

1 Rejected* Mechanical Damaged

4 PACKAGING GUIDELINE FOR CORES

4.1 Transport protection and packaging

Back in the box 150 V4 294c

Protection against corrosion

5 CORE GROUP CLASSIFICATION & IDENTIFICATION

5.1 Air Disc Brakes (Core Group Identification: Y252531)

Air Disc Brakes (SK7 Calipers) DC7

5.2 Compressors 5.3 Others

K2 Spring Brakes and

Allmakes Single Exhaust Gas Turbo

Allmakes Twin Cylinder

5 CORE GROUP CLASSIFICATION & IDENTIFICATION

EBS One Channel

EBS Two Channel EBS Foot Brake

EBS Trailer Control

Electronic Air Control Trailer

CORE GROUP CLASSIFICATION & IDENTIFICATION 5

5.5 Identification of Air Disc Brakes

CORE GROUP IDENTIFICATION

Mono SN5 Split SB5

Provides a monthly overview about total balance ofKNORRBREMSE SFNGMBH

Report: YYS_R_CORE_STATEMENTCOREGRP KNORRBREMSE SFNGMBH Page 1