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34.10.583.

055/057/058
34.08.583.037 - 039
Workshop manual

BPW BERGISCHE ACHSEN

BPW swivel axles 34.08.583.037 - 34.08.583.039


34.10.583.055 - 34.10.583.058

WORKSHOP MANUAL
Contents

Page

1 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2 Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3 Care and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4 Changing the brake lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5 Dismantling and refitting wheel hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6 ABS / ABV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

7 Brake bolts, cover plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

8 Brake camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

9 Manual slack adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

10 Automatic slack adjuster ECO Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101


1 Exploded view

312
314

215 214
190
295
311

319
330
192 335
319
285 210
280 286
255
256 254
288
292 240
268 241 316 318
264
264 262 262 258 363
366
363
364
284 364 361
215 340
293 360
294
293 330
335

350
380
357
474

472

420
422

430
431
560

510 501
503 441
520
446
570 513
586 564 460
570
510 571 435
551 436

587 553
585 447
542
540

517
513

502
504 34.10.583.055 / 34.10.583.057
513
34.08.583.037 / 34.08.583.038 / 34.08.583.039

11
312
314

215 214
190
295
311

319
330
192 335
319
210
255
256 254

215
280 240
292 241 316 318
268 264
262 258 363
264 284
366
364
363
364 361 340
360

294 330
293 335

350
380
357
474

472

420
422

430
431
560

510 501
503 441
520
446
570 513
586 564 460
570
510 571 435
551 436

587 553
585 447
542
540

517
513

502
504
513
34.10.583.058

12
2 Spare parts list

Spare parts list 34.08.583.037 - 039


BPW swivel axle NMSFP 8010 BL, with brake SN 30151 KWG / BA closed, track 680 mm, lever centre 111 mm,
for TRISTOPcylinder and diaphragm cylinder, AGS ECOMaster, HL 180, for push rod length 56 mm, stroke min.
65 mm, brake drums 200 mm wide, wheel connection 175,8 / 225 / 10, wheel studs M 22 x 1,5, without wheel
nuts, 34.08.583.037 left axle side for ABS with sensor, 34.08.583.038 right axle side for ABS with sensor,
34.08.583.039 without ABS.
Item Designation BPW Code number Dimension Quantity
190 Booster bracket 05.182.19.20.0 1
192 Shaped plate 03.161.47.13.0 1
210 Bush 03.112.44.34.0 Ø 42 / 46 x 72.6 2
214 Grease nipple 02.6802.06.50 BM 10 x 1 / 45° 2
215 Cover 02.3505.20.00 4
240 Brake camshaft, left 05.097.62.49.2 A: 81 1
241 Brake camshaft, right 05.097.62.50.2 A: 81 1
254 Ring 03.310.81.02.0 Ø 42 / 46 x 4 2
255 Oring 02.5677.37.42 Ø 37 x 2.6 ( black ) 2
256 Oring 02.5679.23.00 Ø 40 x 2.5 ( green ) 2
258 Disc 03.320.32.27.0 2
262 Ring 03.310.31.51.0 Ø 37.4 / 42.4 x 5.2 4
264 Ring 03.310.31.42.0 Ø 37.4 / 42.4 x 8.9 4
268 Locking ring 02.5603.37.90 2
280 Slack adjuster (ECOMaster)
incl. item 215, 283, 284 05.174.82.90.3 HL 150/180 2
283 Cap 03.211.90.15.0 2
284 Grease nipple 02.6850.01.02 AS 8 x 1 2
285 Shaped plate 03.165.25.15.0 Alpha = 60  210° 1
286 Shaped plate 03.165.25.16.0 Alpha = 60  210° 1
288 Locking screw 02.5070.84.82 M 8 x 12 4
292 Brake compensator 03.110.01.07.0 1
293 Disc 02.5401.21.04 2
294 Split pin 02.6201.50.01 5 x 28 2
295 Return spring 05.397.28.01.0 Ø 31 / 2.8 x 120 2
310 Thread bolt assembly, item 311, 312, 314 09.177.23.09.0 Ø 32 / 28 x 153 4
311 Thread bolt 03.177.23.10.1 M 20 x 1.5 / Ø 28 / 32 x 153 4
312 Hexagon nut 02.5201.76.06 BM 20 x 1.5 4
314 Spring washer 03.143.00.02.0 Ø 22.5 / 34 x 10 4
316 Shackle 03.232.44.04.0 2
318 Split pin 02.6201.80.01 8 x 45 4
319 Oring 02.5677.86.40 Ø 28 x 2.5 8
330 Brake shoe assembly, with lining 05.091.13.90.0 2
item 335, 350, 357 (with 1 brake lining)
330 Brake shoe assembly, with lining 05.091.13.88.0 2
item 335, 350, 357
335 Brake shoe assembly, with lining 05.091.13.45.0 2
item 340
335 Brake shoe assembly, with lining 05.091.15.10.0 2
item 340
340 Bush 03.112.22.30.0 Ø 32 / 36 x 52 4

21
Item Designation BPW Code number Dimension Quantity
350 Brake lining 03.092.13.44.0 18 mm 6
357 Rivet 02.5805.80.35 B 8 x 15 48
360 Bolt 03.084.42.04.0 Ø 12 x 135 4
361 Lock 02.3301.17.00 12 SXN 09 8
363 Return spring 03.397.34.14.0 Ø 20 / 3.2 x 107 4
364 Return spring 03.397.34.15.0 Ø 20 / 3.2 x 84 4
366 Plate 03.285.23.21.0 2
380 Brake drum 03.109.44.01.0 Ø 300 x 150 / B: 200 2
420 Thrust washer 03.370.07.45.0 Ø 86 / 125 x 22 2
422 Oil seal 02.5664.26.57 Ø 125 / 143 x 11 2
430 Roller bearing 02.6408.80.00 33116 2
431 Dust cover 03.010.04.15.0 Ø 84 / 129 x 5.5 2
435 Hub incl. item 436 03.272.27.20.0 10 x Ø 22 / M 115 x 2 2
436 Splined pin 02.6010.35.60 6 x 19.5 20
441 Roller bearing 02.6406.50.00 32310 2
446 Castle nut 03.262.16.10.0 M 42 x 2 / SW 65 2
447 Split pin 02.6201.82.01 8 x 50 2
460 Hub cap 03.212.23.32.0 M 115 x 2 / SW 95 2
472 Wheel stud 03.296.23.15.1 M 22 x 1.5 / M 22 x 2 / 20
100 / 46 / 49
474 Lock nut 03.260.04.06.0 M 22 x 2  10 20
500 Set of dust cover assemblies
item 501  504, 510, 513, 517, 520 99.00.000.100 SN 30151 / Ø 127 / 0° 1
501 Dust cover, left upper 03.010.96.48.0 Dust covers available as sets
upper + lower! 1
502 Dust cover, left lower 03.010.96.40.0 Dust covers available as sets
upper + lower! 1
503 Dust cover, right upper 03.010.96.49.0 Dust covers available as sets
upper + lower! 1
504 Dust cover, right lower 03.010.96.41.0 Dust covers available as sets
upper + lower! 1
510 Locking screw 02.5070.60.02 M 10 x 12 8
513 Plug 02.3704.33.00 Ø 10.7 2
513 Cable grommet 02.5681.78.00 Ø 6 / 10 / 13 x 7 2
517 Seal 05.121.30.06.0 L = 340, 8 2
520 Plug 03.379.00.23.0 4
520 Plug 02.3704.42.00 2
540 Attachment plate 03.080.03.30.0 U 60 x 4 2
542 Sensor bracket 03.189.07.87.0 1
551 Cylinder cap screw 02.5015.00.80 M 6 x 16  8.8 2
553 Spring washer 02.5601.06.90 A6 2
560 Exciter ring 03.310.08.27.0 d: 145 1
564 Clamp 02.3507.32.00 1
570 Sensor 02.3317.05.00 1
571 Bush for ABS 02.0316.59.00 1
585 Support 03.189.07.72.0 1
586 Support for sensor plug 02.1421.11.00 1
587 Serrated lock washer 02.5414.11.90 A 10.5 1

22
2 Spare parts list

Spare parts list 34.10.583.055 / 34.10.583.057


BPW swivel axle NMZFP 10010 BL, with brake SN 30151 KWG / BA closed, track 735 mm, lever centre 120 mm,
for TRISTOPcylinder and diaphragm cylinder, AGS ECOMaster, HL 180, for push rod length 69 mm,
stroke min. 65 mm, brake drums 210 mm wide,
wheel connection 175.8 / 225 / 10, wheel studs M 22 x 1.5, without wheel nuts,
34.10.583.055 left axle side for ABS with sensor
Item Designation BPW Code number Dimension Quantity
190 Booster bracket 05.182.19.20.0 1
192 Shaped plate 03.161.47.13.0 1
210 Bush 03.112.44.34.0 Ø 42 / 46 x 72.6 2
214 Grease nipple 02.6802.06.50 BM 10 x 1 / 45° 2
215 Cover 02.3505.20.00 4
240 Brake camshaft, left 05.097.62.49.2 A: 81 1
241 Brake camshaft, right 05.097.62.50.2 A: 81 1
254 Ring 03.310.81.02.0 Ø 42 / 46 x 4 2
255 Oring 02.5677.37.42 Ø 37 x 2.6 ( black ) 2
256 Oring 02.5679.23.00 Ø 40 x 2.5 ( green ) 2
258 Disc 03.320.32.27.0 2
262 Ring 03.310.31.51.0 Ø 37.4 / 42.4 x 5.2 4
264 Ring 03.310.31.42.0 Ø 37.4 / 42.4 x 8.9 4
268 Locking ring 02.5603.37.90 2
280 Slack adjuster (ECOMaster)
incl. item 215, 283, 284 05.174.82.90.3 HL 150/180 2
283 Cap 03.211.90.15.0 2
284 Grease nipple 02.6850.01.02 AS 8 x 1 2
285 Shaped plate 03.165.25.15.0 Alpha = 60  210° 1
286 Shaped plate 03.165.25.16.0 Alpha = 60  210° 1
288 Locking screw 02.5070.84.82 M 8 x 12 4
292 Brake compensator 03.110.05.09.0 1
293 Disc 02.5401.21.04 4
294 Split pin 02.6201.50.01 5 x 28 2
295 Return spring 05.397.28.01.0 Ø 31 / 2.8 x 120 2
310 Thread bolt assembly item 311, 312, 314 09.177.23.09.0 Ø 32 / 28 x 153 4
311 Thread bolt 03.177.23.10.1 M 20 x 1.5 / Ø 28 / 32 x 153 4
312 Hexagon nut 02.5201.76.06 BM 20 x 1.5 4
314 Spring washer 03.143.00.02.0 Ø 22.5 / 34 x 10 4
316 Shackle 03.232.44.04.0 2
318 Split pin 02.6201.80.01 8 x 45 4
319 Oring 02.5677.86.40 Ø 28 x 2.5 8
330 Brake shoe assembly, with lining 05.091.13.90.0 2
item 335, 350, 357 (with 1 brake lining)
330 Brake shoe assembly, with lining 05.091.13.88.0 2
item 335, 350, 357
335 Brake shoe assembly, without lining 05.091.13.45.0 2
incl. item 340
335 Brake shoe assembly, without lining 05.091.15.10.0 2
incl. item 340
340 Bush 03.112.22.30.0 Ø 32 / 36 x 52 4

23
Item Designation BPW Code number Dimension Quantity
350 Brake lining 03.092.13.44.0 18 mm 6
357 Rivet 02.5805.80.35 B 8 x 15 48
360 Bolt 03.084.42.04.0 Ø 12 x 135 4
361 Lock 02.3301.17.00 12 SXN 09 8
363 Return spring 03.397.34.14.0 Ø 20 / 3.2 x 107 4
364 Return spring 03.397.34.15.0 Ø 20 / 3.2 x 84 4
366 Plate 03.285.23.21.0 2
380 Brake drum 03.105.36.12.0 Ø 300 x 150 / B: 210 2
420 Thrust washer 03.370.07.44.0 Ø 96 / 145 x 22 2
422 Oil seal 02.5664.46.57 Ø 145 / 167 x 13 2
430 Roller bearing 02.6408.92.00 33118 2
431 Dust cover 03.010.05.22.0 Ø 94 / 149 x 5.5 2
435 Hub incl. item 436 03.272.44.30.0 10 x Ø 22 / M 125 x 2 2
436 Splined pin 02.6010.35.60 6 x 19.5 20
441 Roller bearing 02.6407.67.00 33213 2
446 Castle nut 03.262.17.12.0 M 42 x 2 / SW 65 2
447 Split pin 02.6201.84.01 8 x 63 2
460 Hub cap 03.212.24.07.0 M 125 x 2 / SW 110 2
472 Wheel stud 03.296.23.17.0 M 22 x 1.5 / M 22 x 2 / 20
114 / 60 / 49
474 Lock nut 03.260.04.06.0 M 22 x 2  10 20
500 Set of dust cover assemblies
item 501  504, 510, 513, 517, 520 99.00.000.100 SN 30151 / Ø 127 / 0° 1
501 Dust cover, left upper 03.010.96.48.0 Dust covers available as sets
(upper and lower)! 1
502 Dust cover, left lower 03.010.96.40.0 Dust covers available as sets
(upper and lower)! 1
503 Dust cover, right upper 03.010.96.49.0 Dust covers available as sets
(upper and lower)! 1
504 Dust cover, right lower 03.010.96.41.0 Dust covers available as sets
(upper and lower)! 1
510 Locking screw 02.5070.60.02 M 10 x 12 8
513 Plug 02.3704.33.00 Ø 10.7 2
513 Cable grommet 02.5681.78.00 Ø 6 / 10 / 13 x 7 2
517 Seal 05.121.30.06.0 L = 340, 8 2
520 Plug 03.379.00.23.0 4
520 Plug 02.3704.42.00 2
540 Attachment plate 03.080.03.30.0 U 60 x 4 2
542 Sensor bracket 03.189.10.53.0 1
551 Cylinder cap screw 02.5015.00.80 M 6 x 16  8.8 2
553 Spring washer 02.5601.06.90 A6 2
560 Exciter ring 05.310.08.39.0 d: 145 1
564 Clamp 02.3507.32.00 1
570 Sensor 02.3317.05.00 1
571 Bush for ABS 02.0316.59.00 1
585 Support 03.189.07.72.0 1
586 Support for sensor plug 02.1421.11.00 1
587 Serrated lock washer 02.5414.11.90 A 10.5 1

24
2 Spare parts list

Spare parts list 34.10.583.058


BPW swivel axle NMZFP 10010 BL,
with brake SN 30151 KWG / BA closed, track 735 mm, lever centre 126 mm,
for TRISTOPcylinder and diaphragm cylinder, GSK HL 180, for push rod length 69 mm,
stroke min. 65 mm, brake drums 210 mm wide,
wheel connection 175.8 / 225 / 10, wheel studs M 22 x 1.5, without wheel nuts
Item Designation BPW Code number Dimension Quantity
190 Booster bracket 05.182.19.20.0 1
192 Shaped plate 03.161.47.13.0 1
210 Bush 03.112.44.34.0 Ø 42 / 46 x 72.6 2
214 Grease nipple 02.6802.06.50 BM 10 x 1 / 45° 2
215 Cover 02.3505.20.00 4
240 Brake camshaft, left 05.097.62.49.2 A: 81 1
241 Brake camshaft, right 05.097.62.50.2 A: 81 1
254 Ring 03.310.81.02.0 Ø 42 / 46 x 4 2
255 Oring 02.5677.37.42 Ø 37 x 2.6 ( black ) 2
256 Oring 02.5679.23.00 Ø 40 x 2.5 ( green ) 2
258 Disc 03.320.32.27.0 2
262 Ring 03.310.31.51.0 Ø 37.4 / 42.4 x 5.2 2
264 Ring 03.310.31.42.0 Ø 37.4 / 42.4 x 8.9 4
268 Locking ring 02.5603.37.90 2
280 Slack adjuster (GSK)
incl. item 215, 284 05.174.65.01.0 HL 180 2
284 Grease nipple 02.6850.01.02 AS 8 x 1 2
292 Brake compensator 03.110.05.09.0 1
293 Disc 02.5401.21.04 4
294 Split pin 02.6201.50.01 5 x 28 2
295 Return spring 05.397.28.01.0 Ø 31 / 2.8 x 120 2
310 Thread bolt assembly item 311, 312, 314 09.177.23.09.0 Ø 32 / 28 x 153 4
311 Thread bolt 03.177.23.10.1 M 20 x 1.5 / Ø 28 / 32 x 153 4
312 Hexagon nut 02.5201.76.06 BM 20 x 1.5 4
314 Spring washer 03.143.00.02.0 Ø 22.5 / 34 x 10 4
316 Shackle 03.232.44.04.0 2
318 Split pin 02.6201.80.01 8 x 45 4
319 Oring 02.5677.86.40 Ø 28 x 2.5 8
330 Brake shoe assembly, with lining 05.091.13.90.0 2
item 335, 350, 357 (with 1 brake lining)
330 Brake shoe assembly, with lining 05.091.13.88.0 2
item 335, 350, 357
335 Brake shoe assembly, without lining 05.091.13.45.0 2
incl. item 340
335 Brake shoe assembly, without lining 05.091.15.10.0 2
incl. item 340
340 Bush 03.112.22.30.0 Ø 32 / 36 x 52 4
350 Brake lining 03.092.13.44.0 18 mm 6
357 Rivet 02.5805.80.35 B 8 x 15 48

25
Item Designation BPW Code number Dimension Quantity
360 Bolt 03.084.42.04.0 Ø 12 x 135 4
361 Lock 02.3301.17.00 12 SXN 09 8
363 Return spring 03.397.34.14.0 Ø 20 / 3.2 x 107 4
364 Return spring 03.397.34.15.0 Ø 20 / 3.2 x 84 4
366 Plate 03.285.23.21.0 2
380 Brake drum 03.105.36.12.0 Ø 300 x 150 / B: 210 2
420 Thrust washer 03.370.07.44.0 Ø 96 / 145 x 22 2
422 Oil seal 02.5664.46.57 Ø 145 / 167 x 13 2
430 Roller bearing 02.6408.92.00 33118 2
431 Dust cover 03.010.05.22.0 Ø 94 / 149 x 5.5 2
435 Hub incl. item 436 03.272.44.30.0 10 x Ø 22 / M 125 x 2 2
436 Splined pin 02.6010.35.60 6 x 19.5 20
441 Roller bearing 02.6407.67.00 33213 2
446 Castle nut 03.262.17.12.0 M 42 x 2 / SW 65 2
447 Split pin 02.6201.84.01 8 x 63 2
460 Hub cap 03.212.24.07.0 M 125 x 2 / SW 110 2
472 Wheel stud 03.296.23.17.0 M 22 x 1.5 / M 22 x 2 / 20
114 / 60 / 49
474 Lock nut 03.260.04.06.0 M 22 x 2  10 20
500 Set of dust cover assemblies
item 501  504, 510, 513, 517, 520 99.00.000.100 SN 30151 / Ø 127 / 0° 1
501 Dust cover, left upper 03.010.96.48.0 Dust covers available as sets
(upper and lower)! 1
502 Dust cover, left lower 03.010.96.40.0 Dust covers available as sets
(upper and lower)! 1
503 Dust cover, rechts oben 03.010.96.49.0 Dust covers available as sets
(upper and lower)! 1
504 Dust cover, rechts unten 03.010.96.41.0 Dust covers available as sets
(upper and lower)! 1
510 Locking screw 02.5070.60.02 M 10 x 12 8
513 Plug 02.3704.33.00 Ø 10.7 2
517 Seal 05.121.30.06.0 L = 340, 8 2
520 Plug 03.379.00.23.0 4
520 Plug 02.3704.42.00 2

26
3 Care and maintenance

5 4 1 1 2 6 2 6 1 4

31
each brake lining change
2)
Lubrication and maintenance work

brake pad replacement


every 2 years and with
annually and at every
every 1 to 3 weeks
Overview

2)
For detailed description see pages 33 to 38

every 12 weeks

every 26 weeks
initially
Lubricate
Maintenance work

Lubrication with BPW special longlife grease ECO-LiPlus:


1 Low maintenance camshaft bearing 1)

shortdistance haulage 1 1)

longdistance haulage 1

2 Slack adjuster manual 2

Automatic slack adjuster type ECO Master


shortdistance haulage 2
longdistance haulage 2

3 Brake shoes with closed anchor eye 3

4 Change grease in wheel hub bearings, check taper roller


bearings and oil seal for wear.
conventional hub bearing 4

The use of a highpressure central lubrication system which is


capable of feeding special longlife grease of consistency class 23
is permissible. The use of liquid lubricants is not permitted!

Maintenance work 3)

1 Check wheel nuts for tightness. 1

2 With manual slack adjusters, check brake free play, adjust 2


if necessary to 10  12% of the connected brake lever length.
(Not applicable in the case of automatic slack adjusters.)

3 Check brake lining thickness. Residual brake lining thickness 3


at least 5 mm or wear indicator.

- Check tyres for uneven wear. -

- Visual inspection of all component parts for damage -


and wear.

4 Check wheel hub bearing play, adjust if necessary. 4

5 Check hub caps for firm seating. 5

6 Check functioning of automatic slack adjusters. 6

1)
after a long standing period, prior to initial operation actuate the brake lever and lubricate the brake camshaft bearing.
2)
under extreme conditions, increase frequency (e.g. construction sites and poor roads).
3)
after the first run under load conditions and likewise after each wheel change.

32
3 Care and maintenance

Lubricate 1 1

1 Low maintenance brake camshaft bearing


– every 6 months with shortdistance traffic,
every year and with each brake lining change
with longdistance haulage –
Grease lubrication nipple with BPW special
longlife grease ECOLiPlus until fresh grease
emerges from the bearing points.

2 Slack adjusters
– quarterly –
2
Grease lubrication nipple with BPW special
longlife grease ECOLiPlus until fresh grease
emerges.

3 Brake shoes with closed anchor eye


– latest every 2 years and with each brake
lining change –
Clean the bush and roller, check for wear and, if
necessary replace. Smear BPW special longlife
grease ECOLiPlus onto bearing points of brake
shoe.

33
4 Automatic slack adjusters ECO-Master

– every 6 months for shortdistance traffic –


– every year and with each brake lining
change for longdistance haulage –
Remove rubber seal cap. Grease with BPW
special longlife grease ECOLiPlus (approx. 80 g)
until sufficient new grease emerges from the
adjustment bolt.
Turn back adjustment bolt by approx.
one turn using a ring spanner. Actuate the brake
lever several times by hand.
The adjustment must be carried out smoothly.
If necessary, repeat several times.
Replace seal cap. Once again only use
BPW special longlife grease ECOLiPlus.

34
3 Care and maintenance

4 Change wheel hub bearing grease


– whenever brake linings are changed, at the latest
annually or after 150,000 km –
For demounting and refitting of wheel hubs, see
pages 41.
Mark demounted wheel hubs and bearing races so
that their identity is not mistaken during reassemb
ly.
Clean wheel hubs thoroughly inside and outside.
Clean taper bearings (using diesel e.g. oil) tho
roughly, dry and check for reuseability.
Replace seals.
Work BPW special longlife grease ECOLiPlus into the
cavities between the taper rollers and cage. (For
grease quantity see illustration below). Smear any
residual grease into the hub’s outer bearing race.
Smear the new seal all round with BPW special
longlife grease ECOLiPlus. Clean the bearing seats
of the axle stub (metal must be bright, dry and free
from grease). Spray with BPW ECO Assembly and
Protection Spray.
Fit the wheel hub, tighten the axle nut whilst at the
time turning the wheel hub.
Tightening torque : 150 Nm
If a normal axle nut spanner is used (vehicle tool kit),
tighten the axle nut until the wheel bearing race
drags slightly.
Turn back the axle nut to the next available split pin
hole. Should they already be in line turn back to the
next hole (30° at the maximum).
Insert the split pin and bend upwards slightly.
Refill the hub cap as required with BPW special
longlife grease ECOLiPlus and replace.
Tightening torque : 500 Nm

6 - 9 t: 170 g 6 - 9 t: 290 g
10 - 12 t: 180 g 10 - 12 t: 320 g

35
– Maintenance work

1 Check wheel nuts for tightness


– after the first run under load conditions,
and after each wheel change –
Tighten wheel nuts diagonally using a torque
wrench to the tightening torque shown in the table.
Wheel contact surfaces should not have additional
coats of paint (risk of the wheels becoming detached!)
Tightening torques for wheel nuts:
Wheel stud arrangement:
M 22 x 1.5: M = 510 Nm (485 535 Nm)
Spigot arrangement:
M 22 x 1.5: M = 630 Nm (600 660 Nm)

2 Check and adjust wheel brake free play with


manual slack adjusters
– frequent checks are necessary –
– depending upon application every 1 to 3 weeks –
Actuate slack adjusters by hand, pulling against
the return spring. B
If there is more than 35 mm of play, the slack
adjuster must be reset.
This can be done by adjusting the nut on the
slack adjuster as shown.
Adjust the play “a” to 10 12% of the connected
brake lever length “B”, a
e. g. lever length 180 mm = 18 21 mm of play.
Automatic slack adjusters make this adjustment
automatically whenever the camshaft is rotated by
more than 15°.

3 Check brake lining thickness 3


– quarterly –
Open the observation hole by folding open
the rubber lug to check the lining (arrow). The
brake lining should be renewed at a residual
lining thickness of 5 mm or on reaching the
bottom of the indicator machined into edge of
the lining.
Insert the rubber lug again.

- Check the tyres for uneven wear, adjust the


inflation pressure if necessary according to
the manu ufacturer’s specifications
– quarterly –

36
3 Care and maintenance

- Visual inspection
– every six months –
Check all components for damage and wear.

4 Check wheel hub bearing play


– every six months –
In order to check the wheel hub bearing play
lift up the axle until the wheels are free of the
ground. Release the brake. Apply a lever be
tween the tyre and the ground and check the
play.
In the event of any perceivable bearing play:
1. Unscrew the hub cap.
2. Remove the split pin from the axle nut.
3. Tighten by using a torque wrench whilst
simultaneously turning the wheel.
Tightening torque : M = 150 Nm
 If a normal axle nut spanner is used (vehicle
tool kit), tighten the axle nut until the wheel
bearing race drags slightly.
4. Turn back the axle nut to the next available
split pin hole. Should they already be in line
turn back to the next hole (30° at the
maximum).
5. Insert the split pin and bend upwards slightly.
6. Refill hub cap as required with BPW special
longlife grease ECOLiPlus and replace.
Tightening torque : M = 500 Nm

37
5 Check hub cap for firm seating
– every six months –
Check hub caps for firm seating using a torque
wrench or power tool.

Tightening torque : 500 Nm

In an emergency the hub caps can be tightened


using a normal cap spanner (vehicle tool kit) by
striking the latter with a hammer, or also with the
aid of a piece of tubing, inserted into the spanner.
Tighten to the correct tightening torque as
soon as possible.

6 Check operation of the automatic slack adjuster


– every six months and / or as part of any other
service inspection –
Remove rubber seal cap.
Turn back adjusting bolt by approx. 3/4 of a turn in a
counterclockwise direction using a ring spanner. A
play of at least 50 mm with a lever length of 180 mm
must be available.
Actuate the brake lever several times by hand. When
this is done automatic adjustment must take place
smoothly. Engagement of the clutch coupling is
audible and on the return stroke the adjustment bolt
turns slightly in a clockwise direction.
Fit seal cap. Grease with BPW special longlife grease
ECOLiPlus, see also 2 on page 33.

38
4 Changing the brake lining

4 CHANGING THE BRAKE LINING


To check the brake lining thickness, open the
inspection hole by pulling the rubber flap.
Minimum brake lining thickness 5 mm or wear edge
or wear indicator of brake lining.

Fig. 1

Prevent the vehicle from rolling away.


Release the service brakes and the handbrake.

Reset brake.
Unscrew the hub cap. Remove the split pin from the
axle nut and unscrew.
Screw on extractor cap and withdraw the wheel hub
with the wheels from the axle stub.

Fig. 2

Pull off the inner taper roller bearing.


Position extractor. Pull off the inner taper roller bearing
and the thrust washer together from the axle stub.
Extractors:
BPW no. 02.0125.10.00
for axles 6.5 to 14 tonnes (see figure)
BPW no. 02.0125.01.00
for all types of axles

Mark both the hub and bearing races to


ensure correct positioning during reassembly.

Fig. 3

41
Remove lock from the pins. Detach and remove
return springs (arrow) at the top and bottom.

Fig. 4

Remove split pins (arrow) on the brake pins, remove


shackle. Pull brake shoes off the brake pins.

Fig. 5

Unrivet the old brake lining and clean the brake shoe.
The surface must be free of rust and be smooth. With
skimmed brake drums use the relative oversized brake
linings. Insert all rivets and hold in position by crimping
edges.
Rivet brake lining on.
Riveting force: 21000 N (20000  22000 N)
Rivets: semitubular rivets,
galvanized steel 8 x 15 mm
meeting DIN 7338 B

Rivet as shown from the inside out.

Fig. 6

42
4 Changing the brake lining

Every time the brake lining is changed or at the latest


every 2 years, clean the bush and roller, check for
wear and, if necessary replace. Smear BPW special
longlife grease ECOLiPlus onto bearing points of brake
shoe (arrowed).

Fig. 7

ABS
Check sensor for damage and displacement (displace
ment force 100  200 N). If necessary, smear clamping
bush and sensor with special silicone grease. Before
fitting hubs, always press clamping bush and sensor to
the endstop.
When fitting hub, the sensor will be pushed back into
the correct position by the exciter ring.

Note:
If the press in force is too low, replace
retention bush.
If the press in force is too high, dismantle
sensor and retention bush, open bore hole
dia. (18H7), replace retention bush and, if Fig. 8
necessary, sensor.

Push new Orings (Ø 28 x 2.5) to the brake bolts.


Smear brake bolts with BPW special longlife grease
ECOLiPlus.

Fig. 9

43
Mount new inner return springs on the brake shoes
and insert lock.

Fig. 10

Attach return springs of the upper brake shoes to the


brake anchor plate. Mount brake shoe on the brake
pin. Install lower brake shoe in the same way.
Push on brake shoes to the brake bolts to the stop.
Mount new Orings (Ø 28 x 2.5) onto the brake bolts.

Fig. 11

Insert outer return springs in the top and bottom


spring pins and mount lock. Insert return springs into
the plate and install with pliers into the groove on the
end of the brake camshaft (arrow).

Fit shackle and secure with two split pins.

Fig. 12

44
4 Changing the brake lining

Expand brake to small extent.


Turn down the brake linings on a brake lining cutter
to fit the brake drum diameter until an even wear
surface has been obtained.
(The brake drum may be maichined out to a max.
Ø 303 mm).

Important:
The braking effect of new brake drums and
brake linings is only at its optimum after a
few braking actions.

Fig. 13

Push thrust washer and grease seals onto the axle


stub. Vent groove in cone is on top.

Clean the bearing seats of the axle stub (metal must


be bright, dry and free from grease). Spray with
BPW ECO Assembly and Protection Spray.

Clean and inspect taper roller bearing thoroughly.


Heat bearing race properly to approximately 80° C
and slide on until it contacts the thrust washer.
Work in BPW special longlife grease ECOLiPlus (180 g)
into the spaces between the conical rollers and the
race.
Do not mix up bearing races and outer
rings. Fig. 14

Slide on the cpl. hub and brake drum assembly


concentrically. When the hub is fitted, the ABS
sensor is pushed back to the correct position by
the exciter ring. For this reason, do not misalign the
hub.

Fig. 15

45
Insert outer taper roller bearing. Screw on axle nut
and tighten with torque wrench to 150 Nm, turning
the hub at the same time. Alternatively, use a normal
axle nut wrench and tighten, turning the hub at the
same time, until the hub’s rotation is slightly checked.
Unscrew axle nut to next hole or, if the axle nut is
already positioned opposite a hole, turn back to the
one before (max. 30°).

Fig. 16

Secure axle nut with a split pin.

Fig. 17

Fill the hub cap with 320 g BPW special longlife grease
ECOLiPlus. Grease thread of hub cap all round with
BPW special longlife grease ECOLiPlus and screw in.

Tightening torque: 500 Nm

For adjusting the brake, see page 91 or 102.

Fig. 18

46
5 Dismantling and re-fitting wheel hub

5 WHEEL HUB, BEARING, WHEEL


BOLT, BRAKE DRUM
Prevent the vehicle from rolling away.
Release the service brakes and the handbrake.

Reset brake (remove wheels).


Unscrew the hub cap. Remove the split pin from the
castle nut and unscrew. Screw on extractor cap and
withdraw the wheel hub with the brake drum from the
axle stub (see page 41).

Mark both the hub and bearing races to


ensure correct positioning during re-assembly.
Fig. 19

Position extractor. Pull off the inner taper roller


bearing and the thrust washer together from the
axle stub.
Extractors:
BPW no. 02.0125.10.00
for axles 6.5 to 14 t (see figure)
BPW no. 02.0125.01.00
for all types of axles.

Fig. 20

To replace wheel bearings press out inner and outer


bearing cups complete with grease retention plates.

Insert the larger bearing outer track with the grease


shield and the small bearing outer track (without a
grease shield), into the wheel hub using a pressingin
device until contact is made.
BPW no. 15.012.20052 for bearing 33116
BPW no. 15.005.20052 for bearing 32310
BPW no. 15.013.20052 for bearing 33213
BPW no. 15.011.20052 for bearing 33118

For the correct position of the grease shield, refer to


page 35.
Fig. 21

51
Press in new shaft sealing ring, with the sealing lip
pointing to the wheel hub, into the wheel hub by
means of a pressingin device.
Grease sealing lip with BPW special longlife grease
ECOLiPlus.

Fig. 22

Check wheel studs and, if necessary, insert new


wheel studs taking account of the splined pin
(arrowed).

Fig. 23

Insert wheel hub with wheel studs into the rim.


Fit brake drum ensuring it is centred correctly and
sits well. Screw on the nuts with the locking notches
facing upwards and tighten with a torque of
640 Nm (610  670 Nm).

Mount hub and set hub bearing play,


see page 46.

For twin tyres with wheel stud alignment and wheel


studs without spherical collars: slide one centring
ring onto each wheel stud with the spherical side
pointing outwards.

Fig. 24

52
6 ABS / ABV

6 ABS / ABV
Check sensor for damage and displacement
(displacement force 100  200 N). If necessary,
smear clamping bush and sensor with special
silikone grease (replace clamping bush). Before
fitting hubs, always press clamping bush and
sensor up to endstop.

Fig. 25

For models with ABS / ABV up to 9 t (shrinkfitted


exciter ring)
To change a damaged exciter ring heat the exciter
ring with a torch and extract. Heat the exciter ring
from 80° to max. 120° C and press into place,
ensuring the seat is clean and undamaged.

Fig. 26

For models with ABS / ABV from 10 tonnes upwards


(exciter ring bolted on)
To change the brake drum or the exciter ring release
hexagonal nuts M 6 / SW 10 and grub screws /hexa
gon socket SW 3 (arrowed). Fit exciter ring ensuring
the seat is clean and undamaged. Tighten fixing
screws and lock with hexagon nuts.
(Exciter ring with mounted bore Ø 176 mm can also
be bolted to hub with exciter ring seat Ø 175 mm).

Fig. 27

61
7 Brake bolts, cover plates

7 Brake bolts, cover plates


Remove upper and lower cover plates.

Dismantling and refitting the complete wheel


hub bearing, see page 41 and 42.

Unscrew nut from the brake bolt. By means of a light


tapping action with a hammer, extract the brake
bolts, apply counterpressure to brake anchor plate if
necessary. For installation drive in the brake pin to
the stop, insert tapered spring washer and fasten the
nut with a torque of 200 Nm.

Fig. 28

71
8 Brake camshaft

8 BRAKE CAMSHAFT
Dismantling and refitting the complete
wheel hub bearing, see page 41.
Remove circlip from the groove of the brake cams
haft. Remove slack adjusters with two rings. Pull rear
spacer ring with washer off the brake camshaft.
Take brake camshaft out of the brake anchor plate.

Fig. 29

Check bush in brake anchor plate and, if necessary,


change bush.
Drive in new bush with mandrel (BPW no.
05.001.04.04.0), with the ring groove pointings
towards the grease nipple.
On the outside, the bush must stand back
7.2 + 0.5 mm. Only apply light strokes when driving
in and out, apply counterpressure to brake anchor
plate if necessary.

Fig. 30

Insert plastic ring (C) and ORing (D, green, Ø 40x2.5)


up to the bearing seat. Position ORing (E) in the
front groove of the brake camshaft (arrow).
Insert the brake camshaft into the brake anchor
plate. Push on washer and spacer ring.
Fit slack adjuster, see pages 91 or 102.

Fig. 31

81
9 Manual slack adjuster

9 MANUAL SLACK ADJUSTER


Apply BPW special longlife grease ECOLiPlus onto
splines of brake camshaft.
Push on washer (1) and spacer ring (2).
Slide slack adjuster onto the brake camshaft.
Mount two spacer rings (3+4) and locking ring (5).

12 3 4 5

Fig. 32

Insert brake compensator for brake cylinder and


parking brake into the hole of the slack adjusters,
8 t  mount one washer per side (arrow inwards)
10 t  mount two washers per side (arrows)
and insert split pins.
Mount brake cylinder.

Insert both return springs on base plate and brake


compensator.

Fig. 33

Brake adjustment.
Align the slack adjuster to the brake compensator
using the hexagon adjuster. Attach piston rod with
split pins to the brake compensator. The cylinder
push rod and slack adjuster should be at an angle of
approximately 90° to each other when the brake is B
applied.
A clearance "a" of 10  12 % (=18  21 mm) of the
lever length "B" (=180 mm) must be measured at the
holes in the compensator.
Both slack adjusters must be parallel to each other in
the direction of the brake compensator.
Grease all points with BPW special longlife grease a
ECOLiPlus.
Fig. 34

91
10 Automatic slack adjuster ECO-Master

8
9

6
5
1 4
2 7
3

Grease splines of the brake camshaft with BPW


special longlife grease ECOLiPlus.
Push washer (1) and spacer rings (2+3) onto the
brake camshaft.
Slide automatic slack adjuster ECOMaster onto the
brake camshaft. Mount spacer rings (4+5) and lock
ing ring (6).
Insert brake compensator for brake cylinder and
parking brake into the bore of the slack adjusters
8 t mount one washer per side (arrow inwards)
10 t mount two washers per side (arrows)
and insert split pins.
Mount brake cylinder.
Insert both return springs on base plate and brake
compensator.
Fig. 35

Remove cap (7). Press down clutch sleeve with ring


spanner and, by turning to left or right. Align pin hole
in the brake compensator exactly with the round hole
in the fork head.
Insert pin and lock.
When the brake is applied, the cylinder push rod and
slack adjuster must be at an angle of approximately
90° to each other. Both slack adjusters must be
parallel to each other in the direction of the brake
compensator. The lug on the control lever will now
point to the control point. In this position, fit yoke of
attach plate (8) onto control lever (9) (note left and
fight versions).
Screw on plate with two hexagon screws M 8 x 12.
Control lever lug must point to the control point
after tightening up! (Arrow diagram at bottom
right). Fig. 36

Observe installation instructions tor ECOMaster!

101
Adjusting the brake
When the brake is applied, the cylinder push rod and
slack adjuster must be at an angle of approximately
90° to each other. Set free play”a” to 10  12% of the
connected brake lever length “B” by turning the
adjusting hexagon (keep clutch sleeve pressed B
down).
E.g brake lever length 180 mm = play 18  21 mm.

Fit plastic cap and grease slack adjusters again.

After changing or replacing the brake


cylinder, the brake camshaft or the a
automatic slack adjuster, the basic
settings of the AGS slack adjuster are Fig. 37
to be carried out.

102
BPWWH34.10.583.03706/1e

BPW Bergische Achsen Kommanditgesellschaft, P.O. Box 12 80, D51656 Wiehl, Phone +49 2262 780, info@bpw.de, www.bpw.de