GH-ID.

: 171711
Workshop manual
Swivel axles

BPW BERGISCHE ACHSEN

BPW Swivel Axles 34.50.583.014 - 34.50.583.017

WORKSHOP MANUAL
 GH-ID.: 171711

Contents

Page/

1 Exploded view and spare parts list 34.50.583.014 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2 Exploded view and spare parts list 34.50.583.015  017 . . . . . . . . . . . . . . . . . . . . . . . . 21

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

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

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

6 Changing the brake drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

7 ABS / ABV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

8 Brake bolts, dust covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

9 Brake camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

10 Manual slack adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

11 Automatic slack adjuster ECOMaster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

12 Changing grease, amounts of grease  ECOPlus hub system . . . . . . . . . . . . . . . . . . . . . . 121

Valid May 2011  Subject to change (without notice)

 GH-ID.: 171711

1 Exploded view and spare parts list 34.50.583.014

295
294 292 284
293 280
215
215 268
264
214 262 258
190 192

264
210
255 256
510 254 241
240
520 503
501 312 360
314
510
513
363

330
335

311
340
319 319

316
350 318
420 357
428
437
421
424
422
423
430
431
432
380
472

435
440
441
445
446
438 448
447
460

11
 GH-ID.: 171711

1 Exploded view and spare parts list 34.50.583.014

Spare parts list 34.50.583.014

BPW Swivel axle NRDZFP 12010 BL ECOPlus,
Brake SN 30151 KWG / BA closed, track 735 mm, lever centre 126 mm,
for TRISTOP and diaphragm cylinder, GSK HL 180, for push rod length 69 mm, stroke min. 65 mm,
without ABS, steel brake shoes with thrust piece, brake lining Textar T0117, brake drums 210 mm breit,
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 05.182.19.35.0 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 05.097.62.65.2 A: 81 1
241 Brake camshaft, right 05.097.62.66.2 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 2
256 Oring 02.5679.23.00 Ø 40 x 2.5 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) 05.174.65.01.0 HL 180 2
284 Grease nipple 02.6850.01.02 AS 8x1 2
292 Brake compensator 03.110.01.07.0 1
293 Disc 02.5401.21.04 A 21 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 09.177.23.09.0 Ø 32 / 28 x 153 4
(item 311, 312, 314)
311 Threaded 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 05.091.15.25.0 4
(item 335, 350, 357)
335 Brake shoe assembly, without lining 05.091.15.11.0 4
(incl. item 340)
340 Bush 03.112.22.30.0 Ø 32 / 36 x 52 4
350 Brake lining 03.092.13.53.0 BPW 6202 (Textar T0117), 18 mm 8
357 Rivet 02.5805.80.35 B 8 x 15 64
360 Splined pin 03.001.08.03.0 Ø 12 x 70 4
363 Return spring 05.397.34.16.0 Ø 20 / 3.6 x 166 4
380 Brake drum 03.109.44.02.0 Ø 300 x 150 / B: 210 mm 2

12
 GH-ID.: 171711

Item Designation BPW Code number Dimension Quantity

416 Repair kit ECO Plus hub bearing, 09.801.06.27.0 2
(item 420, 423,428, 430, 431,432,
440, 441, 445
420 Thrust washer cpl. (item 421, 422, 424) 05.370.07.65.0 2
421 Thrust washer 03.370.07.62.0 Ø 97 / 135 / 159 x 22 2
422 Oil seal 02.5664.58.00 Ø 135 / 156.7 x 12 2
423 Ring 02.5683.63.00 Ø 151 / 160 x 12.5 2
424 Oring 02.5678.00.00 Ø 100 x 3 2
428 Dirt seal 03.120.48.13.0 Ø 133 / 168 x 15 2
430 Roller bearing 02.6410.23.00 33118 2
431 Dust cover 03.010.93.34.0 Ø 94 / 149 x 8.5 2
432 Seal 03.120.45.16.0 Ø 67 / 93 x 90.5 2
435 Hub 03.272.44.40.0 10 x Ø 22 / M 136 x 2.5 2
437 Locking ring 02.5606.60.90 Ø 160 x 4 2
438 Locking ring 02.5606.22.90 Ø 122 x 4 2
440 Thrust washer 03.370.26.24.0 Ø 71 / 108 x 8 2
441 Roller bearing 02.6410.22.00 33213 2
445 Disc 03.320.64.01.0 Ø 53 / 76 x 5.8 2
446 Axle nut 05.266.47.06.0 M 52 x 2 / SW 95 2
447 Locking piece 03.277.00.07.0 2
448 Hooked spring ring 03.188.04.10.0 Ø 62 x 1.8 2
460 Hubcap 03.212.25.62.0 M 136 x 2.5 / SW 120 2
472 Wheel stud (helical fit wheel stud ) 03.296.33.12.1 M 22 x 1.5 / 97 / 62 20
500 Set of dust cover assemblies 99.00.000.100 SN 30151 / Ø 127 / 0° 2
item 501, 503, 510, 513, 520
501 Dust cover 03.010.96.48.0 2
503 Dust cover 03.010.96.49.0 2
510 Locking screw 02.5070.60.02 M 10 x 12 8
513 Cable grommet 02.5681.78.00 Ø 6 / 10 / 13 x 7 2
513 Plug 02.3704.33.00 Ø 10.7 4
520 Plug 03.379.00.23.0 4
520 Plug 02.3704.42.00 4

13
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2 Exploded view and spare parts list 34.50.583.015 - 017

294
293 295 284
283
292 281
280
215
268
215 264
214 262 262
190 192 258
286
285
288 264
210
255 256
254 241
240
510
520 312 360
503 314
501
363
513 586 510
570 335
587 330

311
585 340
319 319
564

570 540
571 316 318
542 350
551 553 420
560 357
428
437
421
424
422
423
430
431
432
380

472

435
440 460
441
445 438
446 448
447

21
 GH-ID.: 171711

Spare parts list 34.50.583.015, 34.50.583.016, 34.50.583.017

BPW Swivel axle NRDZFP 12010 BL ECOPlus,
34.50.583.015: left axle side for ABS with sensor
34.50.583.016: right axle side for ABS with sensor
34.50.583.017: without ABS
Brake SN 30151 KWG / BA closed, track 735 mm, lever centre 131 mm,
for TRISTOPcylinder and diaphragm cylinder, AGS ECOMaster lever length 180, for push rod length 69 mm,
stroke min. 65 mm, steel brake shoes with thrust piece, brake lining Textar T0117, 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 05.182.19.35.0 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 05.097.62.65.2 A: 81 1
241 Brake camshaft, right 05.097.62.66.2 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 2
256 Oring 02.5679.23.00 Ø 40 x 2.5 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) 05.174.89.63.3 HL 180 1
incl. item 215, 283, 284
281 Slack adjuster (ECOMaster) 05.174.89.64.3 HL 180 1
incl. item 215, 283, 284
283 Cap 03.211.90.15.0 2
284 Grease nipple 02.6850.01.02 AS 8 x 1 2
285 Shaped plate for slack adjuster 03.165.25.15.0 Alpha = 60  210° 1
286 Shaped plate for slack adjuster 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 A 21 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 Threaded 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

22
 GH-ID.: 171711

2 Exploded view and spare parts list 34.50.583.015 - 017

Item Designation BPW Code number Dimension Quantity

330 Brake shoe assembly, with lining 05.091.15.25.0 4
(item 335, 350, 357)
335 Brake shoe assembly, without lining 05.091.15.11.0 4
(incl. item 340)
340 Bush 03.112.22.30.0 Ø 32 / 36 x 52 4
350 Brake lining 03.092.13.53.0 BPW 6202 (Textar T0117), 18 mm 8
357 Rivet 02.5805.80.35 B 8 x 15 64
360 Splined pin 03.001.08.03.0 Ø 12 x 70 4
363 Return spring 05.397.34.16.0 Ø 20 / 3.6 x 166 4
380 Brake drum 03.109.44.02.0 Ø 300 x 150 / B: 210 mm 2
416 Repair kit ECO Plus hub bearing, 09.801.06.27.0 2
(item 420, 423,428, 430, 431,432,
440, 441, 445
420 Thrust washer cpl. (item 421, 422, 424) 05.370.07.65.0 2
421 Thrust washer 03.370.07.62.0 Ø 97 / 135 / 159 x 22 2
422 Oil seal 02.5664.58.00 Ø 135 / 156.7 x 12 2
423 Ring 02.5683.63.00 Ø 151 / 160 x 12.5 2
424 Oring 02.5678.00.00 Ø 100 x 3 2
428 Dirt seal 03.120.48.13.0 Ø 133 / 168 x 15 2
430 Roller bearing 02.6410.23.00 33118 2
431 Dust cover 03.010.93.34.0 Ø 94 / 149 x 8.5 2
432 Seal 03.120.45.16.0 Ø 67 / 93 x 90.5 2
435 Hub 03.272.44.40.0 10 x Ø 22 / M 136 x 2.5 2
437 Locking ring 02.5606.60.90 Ø 160 x 4 2
438 Locking ring 02.5606.22.90 Ø 122 x 4 2
440 Thrust washer 03.370.26.24.0 Ø 71 / 108 x 8 2
441 Roller bearing 02.6410.22.00 33213 2
445 Disc 03.320.64.01.0 Ø 53 / 76 x 5.8 2
446 Axle nut 05.266.47.06.0 M 52 x 2 / SW 95 2
447 Locking piece 03.277.00.07.0 2
448 Hooked spring ring 03.188.04.10.0 Ø 62 x 1,8 2
460 Hubcap 03.212.25.62.0 M 136 x 2.5 / SW 120 2
472 Wheel stud (helical fit wheel stud) 03.296.33.12.1 M 22 x 1.5 / 97 / 62 20
500 Set of dust cover assemblies 99.00.000.100 SN 30151 / Ø 127 / 0° 2
item 501, 503, 510, 513, 520
501 Dust cover 03.010.96.48.0 2
503 Dust cover 03.010.96.49.0 2
510 Locking screw 02.5070.60.02 M 10 x 12 8
513 Cable grommet 02.5681.78.00 Ø 6 / 10 / 13 x 7 1
513 Plug 02.3704.33.00 Ø 10.7 2
520 Plug 03.379.00.23.0 4
520 Plug 02.3704.42.00 4
540 Attachment plate 03.080.03.28.0 2
542 Sensor bracket 03.189.07.87.0 H = 12.5 1
551 Cylinder cap screw 02.5015.00.80 M 6 x 16  8.8 2

23
 GH-ID.: 171711

Item Designation BPW Code number Dimension Quantity

553 Spring washer 02.5601.06.90 A6 2
560 Exciter ring 05.310.08.44.1 d: 150, z = 80 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
 GH-ID.: 171711

3 Care and maintenance

6 3 1 2 5 1 4 1 4

31
 GH-ID.: 171711

at every
Lubrication and maintenance work brake

after 5 years, there

every 1 to 3 weeks
lining

after every 3 years

1)2)
replace

every 12 weeks

every 26 weeks
Overview ment 2)

every 2 years

every 3 years
For detailed description see pages 32 to 38

latest every

every year
annually 1)

2 years
initially
Lubricate

latest
Maintenance work
Lubrication with BPW special longlife grease ECO-LiPlus:
1 Low maintenance camshaft bearing
Onroadconditions 1
Offroadconditions 1
outside Europe 1
2 Slack adjusters manual 2
Automatic slack adjuster ECOMaster
Onroadconditions 2
Offroadconditions 2
outside Europe 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.
ECOPlus hub system Onroadconditions 4
Offroadconditions 4
outside Europe: Onroadconditions 4
outside Europe: Offroadconditions 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!

Wartungsarbeiten
4)
1 Check wheel nuts for tightness. 1
2 With manual slack adjusters, check brake play, adjust if 2
necessary to 10  12% of the connected brake lever
length and activate by hand or with 0.5  0.8 bar.
(Not applicable in the case of automatic slack adjusters.)
3 Check brake lining thickness. Residual brake lining 3
thickness at least 5 mm
4 Check the brake drum for cracks and check the internal 4
diameter.
- Check the tyres for uneven wear, adjust the inflation -
pressure if necessary according to the manufacturer's
specifications.
3)
5 Check operation of automatic slack ajusters. 5 5
3)
 Visual inspection of all component parts for damage  
and wear.
6 Check wheel hub bearing play, adjust if necessary. 6
1)
after a long standing period, prior to initial operation actuate the brake lever and lubricate the brake camshaft bearing
2)
with the use under extreme conditions (e.g. extreme offroad use) more frequent lubrication with high pressure grease is necessary.
3)
for use outside Europe
4)
after the first run under load conditions and likewise after each wheel change

32
 GH-ID.: 171711

3 Care and maintenance

Lubricate 1 1

1 Low maintenance brake camshaft bearing

– every year and with each brake lining change
in onroad use –
– every 6 months in offroad use and in use
outside Europe –
Grease lubrication nipple with BPW special
longlife grease ECOLiPlus until fresh grease
emerges from the bearing points.

2 Slack adjusters (manual)

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

Automatic slack adjusters ECO-Master

– every year and with each brake lining change
in onroad use –
– every 6 months in offroad use and in use
outside Europe –
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 screw (keep clutch sleeve
pressed down) by approx. one turn using a ring 2
spanner. Actuate the brake lever several times by
hand. The adjustment must be carried out
smoothly. If necessary, repeat several times.
Once again only use BPW special longlife grease
ECOLiPlus.
Replace seal cap.

33
 GH-ID.: 171711

3 Brake shoes with closed anchor eye

– 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.
3

4 Change wheel hub bearing grease

– for the first time after 5 years in onroad use, or
every 3 years in offroad use in Europe, then at
least every 3 years depending on operating
conditions –
– every 2 years in onroad use or every year in
offroad use outside Europe –
For removing and refitting of the wheel hubs, see
page 41.
Clean the taper roller bearings (using e.g. diesel
oil) thoroughly, dry and check for reuseability.
Replace oil seal.
(Recommendation: Renew the tapered roller
bearings after 5 years in onroad use and after
3 years in offroad use.)
Work BPW special longlife grease ECOLiPlus tho
roughly into the cavities between the taper rollers
and the cage in both taper roller bearings.
(For grease quantity see illustration on page 35).
Smear any residual grease into the hub's outer
bearing race.
Smear the lip of 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
Apply BPW ECO Protection Grease (via micro
flow brush) as thin as possible and around the
entire area. Bare metal surfaces is prohibited after
application.

34
 GH-ID.: 171711

3 Care and maintenance

Fit the ECO Unit, tighten the axle nut whilst at the
same time turning the ECO Unit, until the axle
nut torque limiter operates.

Important!
Do not use an impact driver.

Fit the retaining key in the groove between the

axle stub and the nut (do not back off the axle
nut).

Insert the hooked spring ring behind the flange

on the axle nut. Tighten the hub cap to 800 Nm.

170 g 120 g

35
 GH-ID.: 171711

– 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 play with

manual slack adjusters
– frequent checks are necessary –
– depending upon application every 1 to 3 weeks – B
Actuate slack adjusters by hand, pulling against
the return spring. 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
a
brake lever length “B”, 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 3
3 Check brake lining thickness
– quarterly –
Open the observation hole by folding open
the rubber lug or removing the plug 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 or plug again.

36
 GH-ID.: 171711

3 Care and maintenance

4 Check the brake drum for cracks and,

check the internal diameter
– quarterly –
Wearing ed
g e of br EC
Check the condition of the brake drum and ensure
there is adequate remaining thickness. If the wear
ake d
ru m O
is approaching the wear edge, measure the brake
drum and renew it if the maximum permitted
amount of wear has been reached.

Max. amounts of wear, measured at the position

with the greatest wear: Wearing edge
of brake lining
Ø max. amount of wear (mm): 304 mm
Ø max. skimming size (mm): 303 mm

- Check the tyres for uneven wear, adjust the

inflation pressure if necessary according to
the manufacturer's specifications.
– quarterly –

5 Check operation of the automatic slack adjuster

– every 6 months –
– quarterly in use outside Europe (e.g. within the
scope of the statutory checks) –
Prevent the vehicle from rolling away.
Release the service brakes and the handbrake.
Idle stroke test:
Operate the slack adjuster by hand or with 0.8 bar. In
this case, the idle stroke „a“ corresponds to 10  15 %
of the connected brake lever length „B“, e.g. brake
lever length 180 mm = idle stroke 18  22 mm.
Check the adjustment if the idle stroke is not within
tolerance:
Remove rubber seal cap. Turn back adjustment screw,
keep clutch sleeve pressed down, by approx. 3/4 of a
turn in a counterclockwise direction using a ring
spanner. A play of at least 65 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
a

smoothly. Engagement of the clutch coupling is

B

audible and on the return stroke the adjustment

screw turns slightly in a clockwise direction.
Grease with ECOLiPlus, see also 2 page 33.
Fit seal cap.

37
 GH-ID.: 171711

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

6 Check wheel hub bearing play

– at every brake lining replacement, latest
annually –
Prevent the vehicle from rolling away.
In order to check the wheel hub bearing play lift
the axle until the wheels are off the ground.
Release the brake. Apply a lever between the
tyre and the ground and check the play.
If bearing play is detected:
Adjust the bearing play at ECOPlus hub system
1. Unscrew the hub cap.
2. Remove the hooked spring ring with a wedge
from the axle nut.
3. Use a spanner to tighten the axle nut whilst
at the same time turning the wheel hub, until
the axle nut torque limiter operates

Important!
Do not use an impact driver.

4. Fit the retaining key in the groove between

the axle stub and the nut (do not reset the
axle nut).
5. Insert the hooked spring ring behind the
flange on the axle nut.
6. Tighten the hub cap to 800 Nm .

38
 GH-ID.: 171711

4 Changing the brake lining

4 CHANGING THE BRAKE LINING

To check the brake lining thickness, open the
observation hole by folding open the rubber lug or
removing the plug. Look through the observation
hole and the opening for checking the lining (arrow)
to check the brake lining thickness. The brake lining
should be replaced at a residual lining thickness of
5 mm or on reaching the bottom of the indicator
machined into edge of the lining.

Fig. 1

Reset brake.
Unscrew the hub cap. Release the hooked spring
ring with a wedge from the axle nut.

Fig. 2

Unscrew axle nut. The complete hub bearing unit is

thus removed with the brake drum from the bearing
seats of the axle stub.

Fig. 3

41
 GH-ID.: 171711

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

shackle and orings.

Fig. 4

Press the brake shoes apart by means of pliers and

remove them from the brake bolts.
Knock the splined pins out of the brake shoes and
remove the return springs.

Fig. 5

Remove the old brake lining and clean the brake shoe.
The surface must be free of rust and be smooth.
 The rivets should always be pressed out
using a riveting machine, preferably with
hydraulic actuation. The equipment used
must be suitable for the rivet diameter.
Modern rivet punches can universally accept
hollow and semi hollow rivets.

The use of unsuitable rivet punches may

damage the brake shoe.

Fig. 6

42
 GH-ID.: 171711

4 Changing the brake lining

If there is no riveting machine available:

1 2
Shear off the closed head of the rivet with a chisel
(No. 1) or remove the closed head using 8.6 mm
diameter drill bit. (No. 2). Drive out the rivet with a
punch (No. 3).

Check the diameter of the rivet hole using a rivet hole

gauge. The diameter is not allowed to be more than
0.6 mm larger than the rivet diameter (DIN 7513). 3

Fig. 7

Frequent faults
1 loose rivets indicate enlarged rivet holes
2 rivet hole damaged during boring
3 damaged platform edge
4 worn shoe support Ø nicht in Ordnung

5 deformed shoe web n.i.O

6 rivet hole deformed during boring
7 rivet hole damaged by riveting machine i.O
8 corroded platform area
9 damaged shoe web end
Fig. 8
10 worn shoe roller bearings
11 cracked welding seam
12 damaged platform surface
13 corroded welding seam 14
14 deformed platform surface 1

2 5 12
6
11, 13
3
10
7
8

4 9 Fig. 9

43
 GH-ID.: 171711

 The brake shoe must snugly fit on the

platform, i.e. the platform must not be
concave. The shoes must carefully cleaned,
e.g. by sandblasting of by means of a shoe
grinding unit.
Insert all rivets and hold in position by crimping
edges. Rivet brake lining into place taking care to
follow the correct riveting order.
Make sure the brake lining quality is correct
BPW 6202 (Textar T 0117).

Fig. 10

 Rivet as shown from the inside out.

Riveting force: 21000 N (20000  22000 Nm)

Rivets: Semitubular rivets, galvanized steel 7 8
8 x 15 mm meeting DIN 7338 B
3 2

1 4

5 6

Fig. 11

RIVETING CHECK
Fig 12, Pos. 1:
Rivet length correct, the hole inner wall and strength
are correct.
1
Fig. 12, Pos. 2:
Rivet too short, no inner hole recess and poor closing
head formation.

Fig. 12, Pos. 3:

Rivet too long, inadequate closing head, crack
formation.
2 3

Fig. 12

44
 GH-ID.: 171711

4 Changing the brake lining

 A light tap with a hammer will determined

whether the riveting is satisfactory or not.
A dull thud indicates a loose lining.
A high-pitched response indicates that the
riveting is correct.

 A feeler gauge can be used to check for

cavities under the lining. A cavity of more
than 0.15 mm beyond the first row of rivet
holes can lead to noise problems.

 Finally, the linings should be checked for

cracks in the area of the rivets which would
indicate incorrect riveting.
Fig. 13

 Health and safety precautions

Brake dust contains large volumes of breathable
fine dust and is hazardous to your health, even
in case of non asbestos material. Safety regula
tions prescribe extraction systems with a
suction power between 40 and 50 m3/h.
Wheel brakes must never be cleaned down
using compressed air or cleaned using a dry
bush.
It is strongly recommended to use clean water
without chemical additives or a special vacuum
cleaner machine to clean down the brakes.
The use of detergents might impair the braking
effect.

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. 14

45
 GH-ID.: 171711

ABS/ABV
Check sensor for damage and displacement (displa
cement force 100  200 N). If necessary, smear clam
ping bush and sensor with special silicon 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), and replace retention bush and, Fig. 15
if necessary, sensor.

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

Smear brake bolts with BPW special longlife grease
ECOLiPlus.

Fig. 16

Mount new inner return springs on the brake shoes

and insert splined pins.

Fig. 17

46
 GH-ID.: 171711

4 Changing the brake lining

Push on brake shoes to the brake bolts to the stop.

Mount new Orings (Ø 28 x 2.5) onto the brake bolts.

Fig. 18

Fit shackle and secure with two split pins.

Fig. 19

Expand brake to small extent.

Using a brake lathe turn down the brake linings to fit

the brake drum diameter until an even wear surfaces
has been obtained.

 There is no need to machine the brake

linings when fitting genuine BPW replace-
ment lined brake shoe assemblies.

Fig. 20

47
 GH-ID.: 171711

Check the condition of the brake drum and ensure

there is adequate thickness remaining. If the wear is
approaching the wear edge, measure the brake drum
and renew it if the maximum permitted amount of Wearing ed
g e of br EC
wear has been reached. ake d
ru m O
Max. amounts of wear, measured at the position with
the greatest wear:
Ø max. amount of wear: 304 mm
Ø max. skimming size: 303 mm

Wearing edge
of brake lining

Fig. 21

Apply BPW ECO Protection Grease (via microflow

brush) as thin as possible and around the entire area.
Bare metal surfaces is prohibited after application.

Fig. 22

Mount complete hub bearing unit with brake drum

centrally onto the axle stub.

Align lug of the thrust washer (arrow) by turning the

axle nut with the keyway of the axle stub and lightly
press hub brake drum unit. Press the wheel hub with
bearing and brake drum onto the axle stub with the
axle nut.

Fig. 23

48
 GH-ID.: 171711

4 Changing the brake lining

Tighten the axle nut at the same time as turning the

wheel hub with a hexagon spanner until the torque
limiter activates i.e. the nut slips (do not use an
impact tool).

Fig. 24

Fit the retaining key in the groove between the axle

stub and the nut (do not back off the axle nut).

Insert the locking ring behind the flange on the axle

nut.

Fig. 25

Smear the threads of the hub cap all round with BPW
special longlife grease ECOLiPlus.
Screw hub cap onto wheel hub and tighen the hub
cap to 800 Nm.

 Important!
New brake linings only have maximum
effect after a few braking actions.

Fig. 26

49
 GH-ID.: 171711

5 Dismantling and re-fitting wheel hub

5 Dismantling and re-fitting wheel hub

 Important!
Removing the wheel/hub bearing before the
end of the warranty period invalidates the
ECOPlus warranty (see ECOPlus maintenance
regulations).

To remove the outer roller bearing, remove circlip and

axle nut from the wheel hub.

Fig. 27

Remove lug thrust washer and roller bearing.

 Important!
Mark both the hub and bearing to ensure
correct positioning during re-assembly.
It is essential for the bearing inner races
and rollers to be re-inserted in the same
hubs.

Fig. 28

Pry out the side brackets something of the groove of

the hub and simultaneously removing the exciter ring
from the hub.

 Important!
Do not bend or damage the exciter ring
when removing it.

Fig. 29

51
 GH-ID.: 171711

5 Dismantling and re-fitting wheel hub

Lever the coarse dirt seal out of the wheel hub or off
the thrust washer.

Fig. 30

To remove the inner roller bearing, remove circlip

from the wheel hub.

Fig. 31

Remove the thrust washer with oil seal and Oring.

Fig. 32

52
 GH-ID.: 171711

Remove the tapered roller bearing and then the seal

(bearing intermediate piece).

Remove both tapered roller bearings, clean

thoroughly and check for wear.
Renew if necessary.

Fig. 33

 We recommend removing the brake drum if

it is necessary to renew the bearing cups,
see chapter 6.

Removing the bearing cups

Drive the bearing outer races together with the race
out of the wheel hub.

Remove the dust cover from the wheel hub and

replace it with a new one.
 Mount the thrust washer making sure it is
in the right position, see page 3-5.

Fig. 34

Installing the bearing cups

Insert the new dust covers.

Centre the bearing outer races and insert them in the

wheel hub. Install using a press (min. 6 t) and the
BPW insertion tools 15.011.20052 and 15.013.20052.
 Make sure the bearing cups are correctly
seated in the wheel hub.

Insert the seal (bearing intermediate piece) between

the installed bearing outer races.

Fig. 35

53
 GH-ID.: 171711

5 Dismantling and re-fitting wheel hub

Take a new race and prepare the BPW insertion tool

16.014.22111.
Press the race centrally into the old wheel hub.

Fig. 36

Press in the new oil seal (with its open side facing
upwards) as far as the stop against the thrust washer.
Apply BPW special longlife grease ECOLiPlus to the Oil seal
sealing lip.

Trust washer

Fig. 37

Insert the oring into the groove in the thrust washer.

Fig. 38

54
 GH-ID.: 171711

Grease both tapered roller bearings with BPW

special longlife grease ECOLiPlus.
Note the total grease quantity (tapered roller bearing
33118  170 g and 33213  120 g).
Smear the remaining grease into the outer bearing
races of the hub.
 We recommend greasing the bearings with
BPW grease applicators 99.00.000.9.55.

Fig. 39

Fit inner roller bearing into wheel hub.

 Do not mix up bearing races and bearing

outer rings.

Fig. 40

Insert the thrust washer, oil seal and oring into the
race located in the hub.

Fig. 41

55
 GH-ID.: 171711

5 Dismantling and re-fitting wheel hub

Fit circlip into the groove of the wheel hub.

Fig. 42

Press seal onto the thrust washer.

Fig. 43

 Renew the exciter ring if the reduced preload

values mean that firm seating of the exciter
ring is no longer guaranteed.
Clean the groove and stop surfaces for the exciter
ring (free from dirt, paint, etc.).

Press the new exciter ring onto the wheel hub, turning
slightly anticlockwise.

The lateral brackets must clip into the groove on the

neck of the wheel hub.

Fig. 44

56
 GH-ID.: 171711

Place the brake drum onto the wheel hub.

Insert the wheel studs as far as possible into the hub
and draw in with the help of a sleeve and a nut.
 Make sure the wheel stud head is correctly
seated on the brake drum.

The flattened side of the wheel stud head must be

in contact with the brake drum collar (antirotation
lock).

Fig. 45

Fit outer roller bearing into wheel hub.

Fig. 46

Place the keyed thrust washer (with the embossed

BPW) next to the tapered roller bearing.

Fig. 47

57
 GH-ID.: 171711

5 Dismantling and re-fitting wheel hub

Fit circlip with axle nut into the groove of the wheel
hub.
Mounting the complete wheel hub, see pages 48
and 49.

Fig. 48

58
 GH-ID.: 171711

6 Changing the brake drum

6 Changing the brake drum

Dismantling the complete wheel hub bearing, see
page 41.

Strike out wheel studs from the dismantled hub

brake drum unit (do not damage thread of wheel
stud).

Replace brake drum.

Fig. 49

Lay new brake drum on the wheel hub. Insert wheel

stub as far as possible into the hub and draw in using
a sleeve and wheel nut.
Ensure that the wheel stud head sits correctly on the
brake drum.
The flat on the wheel bolt head must be in contact
with the brake drum collar (antirotation lock).

Fig. 50

Mounting the complete wheel hub, see pages 48

and 49.

For twin tyres with wheel stud alignment slide one

centring ring onto each wheel stud with the spherical
side pointing outwards.

Screw on wheel nuts and tighten with a torque

wrench diagonally to the tightening torque with
Bolt alignment:
M 22 x 1.5: M = 510 Nm (485  535 Nm)
Spigot alignment:
M 22 x 1.5: M = 630 Nm (600  660 Nm).

Fig. 51

61
 GH-ID.: 171711

7 ABS / ABV

7 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. 52

If the exciter ring does not fit tightly due to reduced

preloads, replace the exciter ring.

Clean the groove and stop surfaces for the exciter

ring (free from dirt, paint, etc.).

Press the new exciter ring onto the wheel hub,

turning slightly anticlockwise.

The lateral brackets must clip into the groove on the

neck of the wheel hub.

Fig. 53

71
 GH-ID.: 171711

8 Brake bolts, dust covers

8 Brake bolts and dust covers

Remove upper and lower dust cover.

 Dismantling and refitting the complete wheel

hub bearing, see pages 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. 54

81
 GH-ID.: 171711

9 Brake camshaft

 Remove the wheel/hub unit and brake shoes,

see pages 41 and 42.

Unhook return springs from the slack adjusters.

Remove the discs and split pin out of or from the

brake compensator.

Remove circlip (arrow) from the groove of the brake

camshaft.

Push the slack adjuster with the discs towards the

middle of the axle.

Fig. 55

Brake camshaft to be pulled out a bit of the brake

anchor plate.

Remove slack adjusters with two rings.

Pull rear spacer rings with washer off the brake

camshaft.

Take brake camshaft out of the brake anchor plate.

Unscrew the shaped plate if necessary.

Fig. 56

Check bush in brake anchor plate and, if necessary,

change bush (max. bearing play 0.8 mm).

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. 57

91
 GH-ID.: 171711

Insert plastic ring (A) and ORing (B, green, Ø 40 x 2.5)

up to the bearing seat.
C B A

Fig. 58

Position ORing (C, black, 37 x 2.6) in the front groove

of the brake camshaft (arrow).
Grease teeth and the bearing seats of brake cams
haft with BPW special longlife grease ECOLiPlus.

Fig. 59

Insert the brake camshaft into the brake anchor

plate.

Version with GSK: 3 2 1

Push washer (1) and spacer ring (3) onto the brake
camshaft.

Version with automatic slack adjuster:

Push washer (1) and spacer rings (2+3) onto the
brake camshaft.

Fig. 60

92
 GH-ID.: 171711

10 Manual slack adjuster

Slide slack adjuster onto the brake camshaft.

6 5 4
Mount two spacer rings (4+5) and locking ring (6),
see Fig. 65 page 111.

Fig. 61

Check that the brake camshaft rotates freely.

Grease the bearing surface of the brake camshaft via

the grease nipple, using BPW special longlife grease
BPW ECOLiPlus.

 Fit brake shoe and the complete hub unit,

see chapter 4.

Fig. 62

Insert brake compensator for brake cylinder and

parking brake into the bore of the slack adjusters,
mount one washer per side (arrows) and insert split
pins.
Mount brake cylinder.

Insert both return springs on shaped plate and brake

compensator.

Fig. 63

101
 GH-ID.: 171711

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 B
approximately 90° to each other when the brake is
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. a
Grease all points with BPW special longlife grease
ECOLiPlus.
Fig. 64

102
 GH-ID.: 171711

11 Automatic slack adjuster ECO-Master

Fig. 65

Check that the brake camshaft rotates freely.

Grease the bearing surface of the brake camshaft via

the grease nipple, using BPW special longlife grease
BPW ECOLiPlus.

Unscrew the screw connection of the shaped plate (8)

on the brake anchor plate a little, or if removed then
screw it back on slightly.

Slide automatic slack adjuster ECOMaster onto

the brake camshaft. Mount spacer rings (4+5) and
locking ring (6).

Fig. 66

Insert brake compensator for brake cylinder and

parking brake into the bore of the slack adjusters,
mount one washer per side (arrows) and insert split
pins.
Mount brake cylinder.

Insert both return springs on shaped plate and slack

adjuster.

Fig. 67

111
 GH-ID.: 171711

Screw on plate with two hexagon screws M 8 x 12.

 Control lever lug must point to the control point
after tightening up! (Arrow).

Fig. 68

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
R 1

compensator. The lug on the control lever will now

point to the control point.
80

75

Fig. 69

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
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 automatic slack
adjuster, the basic settings of the AGS slack
adjuster are to be carried out. Fig. 70

112
 GH-ID.: 171711

12 Changing grease, amounts of grease - ECOPlus hub system

1 2

Grease bearing seats of the stub axle with BPW Protection Grease.

The ECOPlus hub system is designed for long term lubrication. After the warranty expires (in Europe: 3 years
offroad and 5 years onroad; outside Europe: 1 year offroad and 2 years onroad), check the tapered roller
bearings, thoroughly clean the space inside the hub and the hub seal (diesel oil), dry, check for suitability for
reuse and regrease. See maintenance regulations.

Axle load BPW special longlife grease ECOLiPlus, quantity per tapered roller bearing
1 2
roller bearing inner grease quantity roller bearing outer grease quantity

6500  12000 kg 33118 170 g 33213 120 g

Work grease ECOLiPlus. into the spaces between the tapered rollers and the races. Apply
remainder to outer race of the hub. Smear seal lip of seal all round with BPW special
longlife grease ECOLiPlus.

121
GH-ID.: 171711
 GH-ID.: 171711

BPWWH34.50.583.014  017/1e

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