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Safety and Environment Guidelines

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.

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