BPW Maintenance Manual 2021
BPW Maintenance Manual 2021
BPW Maintenance Manual 2021
Contents
Important information 1
1.1. General
1.1. General
The following maintenance instructions apply to BPW trailer axles and BPW suspensions for drawbar trailers
andfollowing
The semi-trailers (manufactured
maintenance from apply
instructions 1982 onwards). Theyaxles
to BPW trailer are part
and of
BPWthesuspensions
Terms and Conditions
for drawbarfor the ECO
trailers and
Plus Warranty
semi-trailers (see warranty
(manufactured documents
from at www.bpw.co.za).
1982 onwards). They are part of the Terms and Conditions for the ECO Plus
Warranty (see warranty documents at www.bpw.de).
Carry out the latest maintenance instructions in accordance with the prescribed intervals in order to maintain
Carry out the latest maintenance instructions in accordance with the prescribed intervals in order to main-
thethe
tain safesafe
operation andand
operation roadworthiness
roadworthinessof the vehicle.
of the TheThe
vehicle. latest version
latest of the
version maintenance
of the maintenanceinstructions
instructionscan
can
alwaysbebefound
always foundatatwww.bpw.de.
www.bpw.co.za. The latest
The latest printed
printed versionversion is available
is available by postbyonpost on request.
request. The relevant
The relevant operation
operation
and service and service regulations
regulations of the
of the vehicle vehicle manufacturer
manufacturer and the manufacturers
and the manufacturers of other
of other vehicle vehicle
parts must parts
also be
must also
adhered to. be adhered to.
These maintenance intervals are set out in calendar weeks and are listed to coincide with statutory testing require-
These maintenance intervals are set out in calendar weeks and are listed to coincide with statutory testing
ments (ZU, HU, BSU).
requirements.
2 Safety instructions
The following instructions should also be adhered to by the driver in addition to the statutory regulations:
– After the first two weeks (after the first runs under load conditions):
• Check that the bolt connections of the spring attachments and axle steering devices are secure, depending
on the application (On-Road or Off-Road). Observe the stipulated tightening torques.
Quarterly:
Quarterly:
– Clean line filter (in accordance with manufacturer’s instructions).
– Clean line filter (in accordance with manufacturer’s instructions).
Proper
Proper use of the
use of the braking
brakingsystem:
system:
– In the event of premature wear of the brake pads, a tractor/trailer harmonisation (according to ISO 20918 is to
– Inbe
thecarried
eventout.
of premature wear of the brake pads, a tractor/trailer harmonisation (according to ISO 20918
is to be carried out.
– To maintain the efficiency of the braking system, regular use of the wheel brakes with the appropriate level of
– Toheat generation is recommended.
maintain the efficiency of the braking system, regular use of the wheel brakes with the appropriate level
– ofBefore
heat generation
proceedingiswith
recommended.
an HU or SP (PTI), the braking system performance where applicable, must be measured
(see ISO 7634).
–– Before proceeding
The appropriate with a C.and
installation O. F., the braking
operating systemfor
instructions performance where applicable,
BPW brake components must be
(see www.bpw.de) should be
measured
observed.(see ISO 7634).
– The appropriate installation and operating instructions for BPW brake components (see www.bpw.co.za)
should be observed.
We wish you a safe journey!
3 Trailer
BPW BPWaxles
Trailer axlesSteering
/ BPW / BPW Steering
axles axles
3.1
Lubrication Lubrication
Years, thereafter
Years, thereafter
every 500,000 km 2)
500,000 km 2)
Every 26 weeks 1) 2)
Every 26 weeks 1) 2)
2)
Every 6 weeks 2)
weeks
Every 12 weeks
3 years or min.
3 years or min.
Every 6 weeks
yearly 2 years
Every 3 years
2 years
2 years
After 5 years,
Every53years,
Latest every
yearly every
every
2 yearsevery
1)
1)
thereafter
Every 12
Annually
Annually
annually
annually
Every 3
2 years
Latest
Latest
Latest
Latest
Latest
Every
Every
Every
every
For detailed
ailed description description
see pages 8 - 21 see pages 8 - 21
After
ering pivot 1 Steering
bearing, top pivot bearing, top and 1bottom
and bottom 1
ck adjusters3 manual
Slack adjusters manual 3 3
4 Brake
ke shoes with closedshoes with
anchor eyeclosed anchor eye 4 4
5 ECO
O Plus 3, ECO Plus
Plus 2 and3,ECO
ECO Plus
Unit:2 and ECO
Plus Plus
Unit:
On-Road conditions
On-Road conditions 5 5
Off-Road conditions
Off-Road conditions 5 5
tside Europe: Outside Europe:conditions
On-Road On-Road conditions 5 5
tside Europe: Outside
OffEurope: Off-Road conditions
-Road conditions 5 5
Trailer axles
Series R / KR / NR Series H / K / N
Series ...LL
2 Brake camshaftbearing,
Brake camshaft bearing,outer
outer and
and inner
inner
Low maintenancebrake
Low maintenance brakecamshaft
camshaft bearing
bearing
(from year
(from of of
year manufacture
manufacture1993)
1993)
–– every 6 months
every year andeach
and with withbrake
eachlining
brakechange
lining change
in
in On-Road
On-Road useuse
– –
–– every
every 63 months
monthsininOff
Off-Road
-Road use
use and in use
outside Europe –
Prevent the vehicle from rolling away.
Prevent the
Release the vehicle
servicefrom rolling
brakes andaway.
the handbrake.
Release the service brakes and the handbrake.
Lubricate the brake camshaft bearing through the
Lubricate the brake camshaft bearing through the
grease nipple with BPW special longlife grease
grease nippleuntil
ECO-LiPlus withfresh
BPW special
grease longlifefrom
emerges grease
the
ECO-Li Plus
until fresh grease emerges from the
bearing points.
bearing points.
Important!
Important!
Use of other grease is not permitted!
Use of other grease is not permitted!
ZA-BPW-W
BPW-W 33112101e
33112101e Page 9
Trailer axles
grease ECO-LiPlus until fresh grease emerges.
Automatic slackadjuster
Automatic slack adjuster ECO-Master
ECO-Master
–– every
every 6 months
year and each
and with with each
brake brake
lining lining
changechange
in
in On-Road
On-Road useuse
– –
–– every
every 36months
monthsininOffOff
-Road
-Roaduse
use and in use
outside Europe –
Remove rubber seal cap. Grease with BPW special
Removegrease
longlife rubberECO-LiPlus
seal cap. Grease
(approx.with
80BPW spe-
g) until
suffi cient new
cial longlife grease
grease emerges
ECO-Li Plus
from the
(approx. 80adjustment
g) until
bolt.
sufficient new grease emerges from the adjustment
bolt.
Turn back adjustment screw (keep clutch sleeve
Turn back
pressed adjustment
down) screw
by approx. one(keep
turn clutch
using asleeve
ring
pressed down)
spanner. Actuatebythe
approx.
brake one
leverturn usingtimes
several a ring
by
spanner. Actuate the brake lever several times
hand. The adjustment must be carried out smoothly. by
hand. The adjustment must be carried
If necessary, repeat several times. out smoothly.
If necessary, repeat several times.
Once again only use BPW special longlife grease
Once again only use BPW special longlife grease
ECO-LiPlus.
ECO-Li
Install seal. cap.
Plus
3
Page 10 BPW Trailer axles / BPW Steering axles BPW-W 33112101e
3.1 Lubrication
3 BPW Trailer axles / BPW Steering axles
3.1 Lubrication
5 ECOPlus
ECO Plus 3 Unit
3 Unit
–- for the first
for the first time
time after
after 35 years
years inin On-Road
On-Road use,
use,
or every
and after 3
2 years
years in
in Off
Off -Road
-Road use
use in in
Europe,
South Africa,
5 ECO Plus 3 Unit
thenat at
then leastleast
every every
year 3depending
years depending on
on operating
–operating
for the first
conditions – time after
conditions – 5 years in On-Road use,
or every 3 years in Off-Road use in Europe,
–– every
after
then 22atyears
years in
leastin On-Road
Africa 3 use
every then atorleast
years every year year
every
dependingin on
Off -Road use
depending
operating on outside –Europe
operating
conditions –
conditions.
Prevent
Prevent 2the
– every the vehicle
vehicle
years from
from
in On-Road rolling
rolling
use away.away.year in
or every
Remove
Remove the
the
Off-Road wheel.
wheel.
use outside Europe –
Unscrew
Unscrew thecap
Prevent the capwith
with
vehicle aa 110
110
from mmmm
rolling cap
cap spanner.
spanner.
away.
Remove the wheel.
Dismantlethe
Dismantle the ECO
ECO Unit
Unit -- see
see the
the corresponding
corresponding
workshop
workshop manuals.
manuals.
Unscrew the cap with a 110 mm cap spanner.
Mark
Mark boththe
both
Dismantle the
the hub
hub
ECO and and
Unit -bearing
bearing see to tocorresponding
theensure ensure correct
correct
positioning
positioning during
during
workshop manuals. re-assembly.
re-assembly.
ItIt is
isessential
essentialforfor thethe bearing
bearing inner innerringsrings
with with
rollers
rollers
Mark bothtotobebe
the re-inserted
hub and in
re-inserted in the
bearing
the sametosame
ensure
hubs. hubs.
correct
positioning during re-assembly.
Thoroughly
Thoroughly
It is essential clean
clean
for thetaper
taper roller
rollerinner
bearing bearings
bearings ringsandwithseals
and seals
(using
(using e.g.
rollerse.g.
to be diesel
diesel oil),
oil),
re-inserted drydry inand
and check
the check
same for re-useability.
for hubs.
re-useability.
Replacegrease
Replace greaseseal.seal.
Thoroughly clean taper roller bearings and seals
(Recommendation:
(Recommendation:
(using e.g. diesel oil), On-road
Renew
dry and the use-
tapered
check Evaluate
roller the
bea-taper
for re-useability.
roller
rings
Replace bearings,
after 5 years
grease replace
seal.in On-Road if necessaryand after after 3 years.
3 years in
Thereafter
Off -Road use.) evaluate yearly.
(Recommendation:
-Off-road use - Evaluate Renewthe thetaper
tapered rollerroller bea-
bearings,
Work
replace BPW
rings after special
if necessary
5 years longlife
in after
On-Road 2 years. grease ECO-Li
Thereafter
and after Plus
3 yearsevaluate
in
thoroughly
yearly.)
Off-Road use.) into the cavities between the taper
rollers and the cage in both taper roller bearings.
Work
Work
(For BPW
BPWspecial
grease special
quantity longlife
seelonglife grease
illustration grease ECO-LiPlus
ECO-Li
on page
Plus
11.)
thoroughly
thoroughly
Smear into
into the
any residual the cavities
cavities
grease into between
between
the hub‘s theouter
taper
the taper
be-
rollers
rollers
aring and
and the
race. the cage
cage in in both
both taper taper roller
roller bearings.
bearings.
(For
(For grease
grease quantity
quantity see see illustration
illustration on on page
page 11.)
11.)
Smear
Smear any
Thoroughly residual
any clean
residual grease
thegrease
bearinginto into
journals
thethehub‘s
hub‘s
of the outer
axlebe-
outer
bearing
stub
aringwith race.
race. a microfibre cloth. The journals must be
bright, dry and free from grease.
Thoroughly
Thoroughly
Apply Castrol clean
clean
White the
the bearing
Tbearing
using ajournalsfijournals
ne bristled of of
thethe axle
axle
brush
stub
stub with
evenly andaathinly
with microfibre
microfi tobre cloth.The
thecloth.
bearing The journals
journals
journals. must
must
Ensure bebe
bright,
that the dry
bright, dry and free
and
bearing freefrom
journal from grease. coated.
is grease.
completely
Apply
Apply Castrol
Castrol White T White
Castrol White
must not T
T using
using aa fifine
be diluted. bristledbrush
ne bristled brush
evenly
evenly andand thinly
thinlyto tothethebearing
bearingjournals. journals. Ensure
Ensure
that
that the
Install theECO bearing journalcontinuously
unit journal
bearing whilst isiscompletely
completely coated.
rotating
coated. axle
Castrol
nut of ECO
Castrol White
White TTmust
unit. must
It should notbe
not be
take diluted.
several turns until
diluted.
the clutch on the axle nut slips.
Install
Install ECO
ECO unit unit whilst
whilst continuously
continuously rotating rotating axle
axle
nut
nut ofof ECO
ECO unit.
unit. ItIt should
Important! should take take several
several turnsturns until
until
the clutch
the clutch on
Doonnot the
theuse axle
axle nut
annutimpact slips.
slips.driver.
the retaining
Fit Important!
key in the groove between the
Important!
stub DoDo
axle and not
the
not use
nut
use anan
(do impact
not reset
impact driver.
the
driver.axle nut).
Fit the
Fit the retaining
retaining key
keyininthe
thegroove
groovebetween
between thethe
stub axle
stub axle and
and the
thenut
nut(do
(donot
notreset
resetthe axle
the nut).
axle nut).
ZA-BPW-W
BPW-W 33112101e
33112101e Page 11
Trailer axles
life grease ECO-LiPlus to the O-ring contact surface
and thread of the hub cap.
ECO Plus
ECO Plus 2 Unit
2 Unit
– for the first time after 5 years in On-Road use,
- for the first
or every time inafter
3 years 3 years
Off-Road in inOn-Road
use Europe, use,
orthen
everyatyear in Off
least -Road
every 3 use
years depending on
then at leastconditions
operating every year – depending on operating
conditions –
– every 2 years in On-Road use or every year in
Off-Road use outside Europe –
Trailer axles
Thereafter
rings after 5evaluate yearly. -Off-road
years in On-Road use and use
after-3Evaluate
years
the taper
in Off roller
-Road bearings, replace if necessary after 2
use.)
years. Thereafter evaluate yearly.)
Clean the grease cartridge and fill it on both sides
Clean
up to the
the grease
edge with cartridge and fi lllonglife
BPW special it on both sides
grease
up to the
ECO-Li Plusedge with BPW special longlife grease
. It is important to ensure that it is filled
ECO-LiPlus. It is important
without any trapped to ensure that it is filled
air or cavities.
without any trapped air or cavities.
Apply
Apply a a ring-shaped
ring-shaped bead beadofofgrease
greasetotothetherunning
running
surfaces
surfaces of of the
the bearing outer races
bearing outer races(see
(seearrows
arrowsinin
illustration below).
illustration below).
1 2
Inner bearing Outer bearing
Manual
170 g 120 g
greasing
Greasing
with a grease 130 g 90 g
applicator
Important!
Do not apply too much grease!
It is necessary to make sure that the axle bolt can
be completely screwed into the axle stub.
Important!
Do not use an impact driver.
Insert the retaining key into the recess in the axle
bolt and the gearing of the toothed lock washer. (Do
not turn back the axle bolt.)
Insert a new O-ring into the groove in the wheel hub. Position 1 Position 2
Apply a thin layer of BPW ECO-LiPlus special longlife
grease to the cap in the area of the O-ring contact
surface and the bayonet fitting.
Trailer axles
Screw on the cap with a 120 mm cap spanner.
Important!
Do not use an impact driver -
bayonet lock.
Push on the cap, see position 1.
Press on the cap and turn it by approx. 30° in a
clockwise direction to lock it in place. A tight seat is
provided when position 2 is reached.
Page 16 ZA-BPW-W
BPW-W 33112101e
33112101e
3.1 Lubrication
3 BPW Trailer axles / BPW Steering axles
3.1 Lubrication
ECOPlus
Plus
Unit
ECO Unit
-– for
for the
the first
first time
time after
after35years
yearsininOn-Road
On-Roaduse,use,
and or after
every 23 years
years inin Off
Off -Road
-Road use
use inin
Europe,
South Africa,
5 ECO thenatPlus
at 3least
Unit every 3 years depending on
then least every year depending on operating
–operating
for the fi–rst
conditions time after
conditions – 5 years in On-Road use,
or every 3 years in Off-Road use in Europe,
– every
– after 2
then2 at years
years in
least On-Road
in Africa 3 use
every then ator
years every
least yearyear
every
dependingin on
depending
Off -Road use
operating on operating – conditions.
outside Europe
conditions –
Prevent
Prevent 2the
– every the vehicle
vehicle
years from
from rolling
rolling
in On-Road away.year in
use away.
or every
Remove
Remove theuse
the
Off-Road wheel.
wheel.
outside Europe –
Unscrew
Unscrew thecap
Prevent the
the capwith
with
vehicle aa110
from110mm mm
rolling cap
cap spanner.
spanner.
away.
Remove the wheel.
Dismantle the ECO
Dismantle the ECO Unit
Unit -- see
see the
the corresponding
corresponding
workshop
workshop manuals.
manuals.
Unscrew the cap with a 110 mm cap spanner.
Mark
Mark boththe
both
Dismantle thehub
the huband
ECO and bearing
bearing
Unit - see to tocorresponding
ensure
ensure
the correct
correct
positioning
positioning duringre-assembly.
during
workshop manuals. re-assembly.
It
It is essentialfor
is essential forthe
the bearing
bearing inner
inner rings
rings withwith
rollers
Mark both
rollers tobe
to be re-inserted
the hub and in
re-inserted in
thethe
bearing same
to
same hubs.
ensure
hubs. correct
positioning during re-assembly.
Thoroughly clean
Thoroughly clean
It is essential taper
taper roller
for the bearing bearings
roller bearings and
and seals
inner rings with
seals
(using e.g.diesel
(using e.g. dieseloil),
oil),dry
dry and
and check
check for for
rollers to be re-inserted in the same hubs.
re-useability.
re-useability.
Replace greaseseal.
Replace grease seal.
Thoroughly clean taper roller bearings and seals
(Recommendation:
(Recommendation: On-road
Renew
(using e.g. diesel oil), dry and use-
thecheck Evaluate
tapered rollerthe taper
bea-
for re-useability.
roller
rings bearings,
after
Replace replace
5 years
grease if necessary
in On-Road
seal. after
and after 3 years.
3 years in
Thereafter
Off-Road use.)evaluate yearly.
-Off-road use - Evaluate
(Recommendation: Renew thethe
taper rollerroller
tapered bearings,
bea-
Work
replace BPW
rings after special
if necessary
5 years longlife
inafter grease
2 years.
On-Road afterECO-Li
and Thereafter
3 yearsevaluate
Plus
in
yearly.)
thoroughly
Off-Road use.)into the cavities between the taper
rollers and the cage in both taper roller bearings.
Work
Work
(For BPWBPWspecial
grease special
quantity longlife
see grease
longlife ECO-LiPlus
grease
illustration ECO-Li
on page 17.)
Plus
thoroughly
thoroughly
Smear into
intothe
any residual thecavities
cavities
grease intobetween
between
the theouter
hub‘s taper
the taper
be-
rollers
rollers
aring and
andthe
race. thecage
cageininbothbothtaper
taperroller
rollerbearings.
bearings.
(For
(Forgrease
greasequantity
quantityseeseeillustration
illustration on
onpage
page11.)
11.)
Smear
Smearany
Thoroughly residual
any clean grease
thegrease
residual bearingintointo thehub‘s
journals
the hub‘s
of the outer
axlebe-
outer
bearing
stub withrace.
aring race.a microfi ber cloth. The journals must be
bright, dry and free from grease.
Thoroughly
Thoroughly
Apply Castrolclean
clean
White theTbearing
the bearing fijournals
using ajournals ofofthe
ne bristled the axle
axle
brush
stub
stubwith
evenly andaathinly
with microfibre
microfitobre cloth.
thecloth.
bearing The
The journals
journals
journals. must
must
Ensure bebe
bright,
bright,
that
dry
the dry
and
and free
bearing free
journal
from
from grease.
is grease.
completely coated.
Apply
ApplyCastrol
Castrol Castrol White
White T White
must not
TTusing
using aa fine bristled brush
fine bristled
be diluted.
brush
evenly and thinly to the bearing journals. Ensure
evenly and thinly to the bearing journals. Ensure
that theECO
Install bearing
unit journal is completely coated.axle
whilst continuously
that the bearing journal is completely rotating
coated.
Castrol
nut of ECOWhite T must
unit. not be
It should diluted.
take several turns until
Castrol White T must not be diluted.
the clutch on the axle nut slips.
Install ECO unit whilst continuously rotating axle
Install ECO unit whilst continuously rotating axle
nut of ECO unit. It should take several turns until
Important!
nut of ECO
the clutch unit.
onnot
theuseIt should
axle take several turns until
Do annut slips.
impact
the clutch on the axle nut slips. driver.
Fit the retaining
Important!
key in the groove between the axle
Important!
stub and the Donut
Do not
not use
(do
use
notan impact
reset
an impact driver.
the axle nut).
driver.
Fit
Fitthe
theretaining
retaining key in the
key in the groove
groovebetween
betweenthethe
stub
stubaxle
axle and
and the nut (do
the nut (do not
notreset
resetthe
theaxle
axlenut).
nut).
ZA-BPW-W
BPW-W 33112101e
33112101e Page 17
Trailer axles
ECOPlus Unit
Page 18 ZA-BPW-W
BPW-W 33112101e
33112101e
3 BPW Trailer axles / BPW Steering axles
3
3.1 BPW Trailer axles / BPW Steering axles
Lubrication
3.1 Lubrication
ECO Unit
– latest every 3 years or min. every 500,000 km
ECO Unit European road conditions), annually
(Western
-– annually
latest
in - 3 Europe
every
use outside years or
– min. every 500,000 km
(Western European road conditions), annually
Prevent
in use the vehicle
outside from– rolling away.
Europe
Remove the wheel.
Prevent the vehicle from rolling away.
Unscrew
Remove thethe cap with a 110 mm cap spanner.
wheel.
Dismantle
Unscrew the thecapECO withUnita 110- see
mmthe capcorresponding
spanner.
workshop manuals.
Dismantle the ECO Unit - see the corresponding
Mark
workshop both manuals.
the hub and bearing to ensure correct
positioning during re-assembly.
Mark
It both thefor
is essential hub theand bearing
bearing to ensure
inner correct
rings with
positioning
rollers to beduring re-assembly.
re-inserted in the same hubs.
It is essential for the bearing inner rings with
Thoroughly clean taper roller bearings and seals
rollers to be re-inserted in the same hubs.
(using e.g. diesel oil), dry and check for re-useability.
Thoroughly
Replace grease cleanseal.taper roller bearings and seals
(using e.g. diesel oil), dry and check for re-useability.
Work
Replace BPWgrease special
seal. longlife grease ECO-Li
Plus
ECO Unit
Trailer axles
3
3 BPW Trailer
BPW Trailer axles
axles // BPW
BPW Steering
Steering axles
axles
3.1
3.1 Lubrication
Lubrication
�
� Change wheel hub bearing grease
Change wheel hub bearing grease
(Conventional)
(Conventional)
– whenever brake linings are changed: at the latest
– whenever brake linings are changed: at the latest
– annually
annually or after 150,000 km –
annually or after 150,000 km –
For demounting and re-fitting of wheel hubs, see
For demounting and re-fitting of wheel hubs, see
workshop manuals.
workshop manuals.
�
� Mark both the hub and bearing to ensure correct
Mark both the hub and bearing to ensure correct
positioning during re-assembly.
positioning during re-assembly.
It is essential for the bearing inner rings with
It is essential for the bearing inner rings with
rollers to be re-inserted in the same hubs.
rollers to be re-inserted in the same hubs.
Clean wheel hubs thoroughly inside and outside.
Clean wheel hubs thoroughly inside and outside.
Remove old grease completely.
Remove old grease completely.
Thoroughly clean taper bearings (using e. g. diesel
Thoroughly clean taper bearings (using e. g. diesel
oil) dry and check for re-useability. Replace seals.
oil) dry and check for re-useability. Replace seals.
Work BPW special longlife grease ECO-LiPlus into
Work BPW special longlife grease ECO-LiPlus into
the cavities between the taper rollers and cage.
the cavities between the taper rollers and cage.
Comply with total grease quantity (table A ), smear
Comply with total grease quantity (table A ), smear
any residual grease into the hub’s outer bearing
any residual grease into the hub’s outer bearing
race.
race.
Fit wheel hubs and adjust bearing play (see point
Fit wheel hubs and adjust bearing play (see point
7 page 38).
7 page 38).
Fill hub caps with BPW special longlife grease
Fill hubPluscaps with BPW special longlife grease
ECO-Li (table B ) and screw on.
ECO-LiPlus (table B ) and screw on.
For tightening torques see 5 page 31.
For tightening torques see 5 page 31.
� For
� For 16 - 18 t axles with BPW oval shape hub
16 - 18 t axles with BPW oval shape hub
cap, a new O-ring must be fitted on reassembly.
cap, a new O-ring must be fitted on reassembly.
ZA-BPW-W
BPW-W 33112101e
33112101e Page 21
Trailer axles
3000 kg 70 g 100 g
3500 - 3800 kg 80 g 120 g
4500 kg 90 g 180 g
Page 22 ZA-BPW-W 33112101e
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33112101e Page 23
In order to distribute the braking effort evenly to all the brakes in the unit, adjustment must always be carried out
according to the vehicle manufacturer’s specifications, or after 5,000 km. Tractor units with EBS cannot have
their brakes adjusted in the normal manner. As a result, the trailer or semi-trailer merely has to be checked for compli-
ance with the EC tolerance bands. Always check the tractor vehicle if the trailer is in the EC band despite premature
brake pad wear. The EBS parameters in the tractor unit must be modified in order to improve compatibility, see ECE
Trailer axles
R 13 in this connection. Failure to do so will invalidate the warranty (see warranty documents).
Even at high temperatures, disc brakes display stable braking properties and a high level of safety. Excessive tempe-
ratures do not make themselves apparent through brake fading and should be avoided. This effect leads to increased
wear when used under these conditions.
Page 24 ZA-BPW-W 33112101e
BPW-W 33112101e
Overview
2)
latest annually 2)
Every 12 weeks
Every 26 weeks
replacement,
For detailed description, see pages 26 - 39
Disc brakes, see pages 40 - 50
Initially
Air suspension, see pages 52 - 80
Suspension, see pages 82 - 91
Maintenance work - Drum brakes
1)
1 Check wheel nuts for tightness. 1
- Check the tyres for uneven wear, adjust the inflation pressure if necessary, -
according to the manufacturer‘s specifications.
4 Check brake drum for cracks and check the internal diameter. 4
5 Check caps for firm seating (not necessary with ECO Plus 3, ECO Plus 2 5
and ECOPlus axles).
3)
2)
6 Check operation of automatic slack adjusters. 6 6
3)
2)
Visual inspection of all component parts and welding seams for damage
° ° °
and wear.
1) After the first run under load conditions, likewise after each wheel change.
2) Under extreme conditions, increase frequency (e.g. construction sites and poor roads).
3) For use outside Europe.
Note: Components that have damage due to improper mounting are to be exchanged after a review by a
BPW Service Centre.
ZA-BPW-W
BPW-W 33112101e
33112101e Page 25
Trailer axles
Series R / KR / NR Series H / K / N
Series ....LL
Series NE / NM / NR / M
Page 26 ZA-BPW-W 33112101e
BPW-W 33112101e
It is imperative that the prescribed tightening torques are adhered to in order to ensure the
wheels are securely fastened! The wheel studs must be clean and free of damage and the nuts
must be easily tightened and loosened. If needed, lightly oil the contact surface between the
wheel nut and the pressure disc. Do not oil or grease the thread of the wheel studs and wheel nuts.
The use of aggressive and acidic rim cleaners is not permitted. Such agents can seriously impair the
anti-corrosion coating of wheel bolts and wheel nuts.
Trailer axles
soon as possible afterwards.
350 mm 91 - 99 kg
400 mm 80 - 88 kg
320 - 350 Nm
450 mm 71 - 78 kg
500 mm 64 - 70 kg
400 mm 90 - 99 kg
450 mm 80 - 89 kg
360 - 400 Nm
500 mm 72 - 80 kg
600 mm 60 - 67 kg
500 mm 88 - 96 kg
600 mm 73 - 80 kg
440 - 480 Nm
700 mm 63 - 69 kg
600 mm 80 - 90 kg
700 mm 67 - 77 kg
480 - 540 Nm
800 mm 60 - 67 kg
700 mm 85 - 95 kg
800 mm 75 - 83 kg
600 - 660 Nm
900 mm 67 - 73 kg
1000 mm 60 - 66 kg
Trailer axles
flap (not required with ECO Drum brakes).
!
In certain cases the slack adjusters may not
be fitted in the normal (i.e. vertical) position.
In such instances, the position of the wear
Trailer axles
Check caps for tightness using a torque wrench or
power tool. Tightening torque:
° Visual inspection
3 months –
– every 6
– quarterly in use outside Europe –
7 –Check
ECO wheel
Unit und hubconventional
bearing playhub bearing every
Trailer axles
–- 6 months
every
ECO –3, ECO-Plus 2 and ECOPlus Unit at every
6 months
Plus
brake lining replacement, latest annually –
Prevent the vehicle from rolling away.
– ECO Unit und conventional hub bearing every
Trailer axles
In6order
monthsto –check the wheel hub bearing play, lift
the axle until the wheels are off the ground.
Release
Prevent thethe vehicle
brake. Apply a leveraway.
from rolling between the tyre
and the ground and check the play.
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.
Attention!
Do not use an impact driver -
bayonet lock.
2. Remove the hooked spring ring and retaining
key from the axle bolt.
Position 1 Position 2
Attention!
Do not use an impact driver.
ZA-BPW-W
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Trailer axles
the hexagon profile of the axle bolt. Make sure
that the hooked spring ring assembly is correctly
seated in the annular groove of the axle bolt.
Attention!
Do not use an impact driver -
bayonet lock.
Push on the hubcap, see position 1.
Press on the hubcap and turn it by approx. 30°
in a clockwise direction to lock it in place.
A tight seat is provided when position 2 is
reached.
Page 36 ZA-BPW-W
BPW-W 33112101e
33112101e
Attention!
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).
Trailer axles
2. Loosen axle nut.
6. Screw on caps.
Tightening torque:
Steel / cast cap 800 Nm
Aluminium cap 350 Nm
Page 38 ZA-BPW-W 33112101e
BPW-W 33112101e
Tightening torques:
hub caps with BPW oval shape:
Up to an axle load of 5.5 tons (up to calendar
week 38/2011) = 100 Nm,
from 6 to 18 tons axle load = 150 Nm,
Trailer axles
1. Unscrew the cap.
Overview
1)
Every 12 weeks
Every 26 weeks
latest annually
replacement,
For detailed description, see pages 42 - 50
Initially
Air suspension, see pages 52 - 80
Suspension, see pages 82 - 91
Maintenance work - Disc brakes
Brake type: TS2 3709, TS2 4309 and TSB 3709, TSB 4309, TSB 4312
2)
1 Check wheel nuts for tightness. 1
- Visual check, check all components and welding seams for damage, wear -
and corrosion.
3)
3 Check brake disc thickness and visually check for cracks. 3 3
3)
4 Check caliper guide system. 4 4
1)
Under extreme conditions, increase frequency (e.g. Off-Road, heavy-duty braking work).
2)
After the first run under load conditions and likewise after each wheel change.
3)
For use outside Europe.
Note: Components that have damages due to improper mounting are to be exchanged after a review by a
BPW Service Centre.
ZA-BPW-W 33112101e
BPW-W 33112101e Page 41
Trailer axles
Series SR with disc brakes type TS2 Series SH with disc brakes type TS2
Series SH with disc brakes type TSB
Trailer axles
new, distance between
brake caliper and brake
anchor plate)
max. permissible
brake pad wear
19 mm 31 mm -- 28 mm
21 mm -- 30 mm --
max. permissible wear 35 mm 34 mm 32 mm
for brake pad and 8 8
brake disc
Brake type TS2
The brake pads must be removed to inspect them
more closely - see relevant workshop manual.
8 8
Brake type TSB
- Visual inspection
– every six months –
Brake lining
Check all components and welding seams for da-
mage, wear and corrosion.
2 mm
Brake lining
thickness Total brake lining
thickness
Page 44 ZA-BPW-W
BPW-W 33112101e
33112101e
3 Brake disc
(Check the condition of the brake disc)
-– every
every 3
6 months
months when
- used within Europe,
quarterly when used outside Europe –
Sections A - D (see fig.) show the possible condi-
tions of the disc surface:
Technical details:
• Disc thickness, new = 45 mm
• Minimum permissible
disc thickness = 37 mm
• Maximum wear per side = 4 mm
(Use a caliper gauge where the pads make
contact)
Attention!
To prevent damage to the brake discs, the brake
pads should be replaced when the minimum thick-
ness (excluding backing plate) is 2 mm or less.
Trailer axles
(e.g. within the scope of the statutory checks)
Trailer axles
2. Using a torx wrench (T25), depress the return
spring and turn clockwise until it „clicks“ 2
times.
5 TS2:
Check the bellow with pressure plate
–- every sixbrake
at every months - replacement, latest
lining
annually in Europe –
– every six months in use outside Europe –
TSB:
Check coarse dirt seals and the tappets
–- at
every sixbrake
every months - replacement, latest
lining
annually in Europe –
– every six months in use outside Europe –
Trailer axles
Prevent the vehicle from rolling away.
Release the service and parking brakes.
Note:
Penetrating dirt and damp cause corrosion and
affect the operation of the clamping mechanism
and adjustment.
Page 50 ZA-BPW-W 33112101e
BPW-W 33112101e
Trailer axles
Page 52 ZA-BPW-W
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Overview
subsequently yearly
6 months -
72 months,
For detailed description, see pages 54 - 59
Air suspension series EAC, see pages 60 - 67
- every
Air suspension series O, SL, AL, see pages 68 - 80
and
Suspension, see pages 82 - 91
1 Check air suspension levelling valve for condition, seal-tightness and general tightness. 1
- Visual inspection, check all component parts and welding seams for damage and wear. -
6 Check the spring bolt to gusset plate connecting bolt for tightness. 6
Tightening torques with a torque wrench:
M 18 x 1.5 (SW 27) M = 420 Nm (390 - 460 Nm)
Note:
Components that have damage due to improper mounting are to be exchanged after a review by a
BPW Service Centre.
ZA-BPW-W 33112101e
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Serie EABO Serie EABO with Kombi-Air Bag II
Air suspension
Series EAAM / EABM Serie EABM with bolt-on gusset plate
with two-sided axle lift
Series EAAU Serie EAAM with side mounted axle lift
Page 54 ZA-BPW-W 33112101e
BPW-W 33112101e
%&
æ
ª
Ride height
Valve lever
æ
Guide rod
ª
!&æ
Axle travel up
æ
ª
Guide linkage
Axle travel down
DIRECTION OF TRAVEL
ZA-BPW-W
BPW-W 33112101e
33112101e Page 55
2 Air bags
– Service intervals as shown on page 52 –
Safety notice
No welding should be carried out on steel parts
of air bags and pressure vessel!
Air suspension
Danger of injury!
- Visual inspection
– Service intervals as shown on page 52 –
5 Axle clamping
– Service intervals as shown on page 52 –
Tightening torque:
M 18 (SW 27) M = 420 Nm (390 - 460 Nm)
Air suspension
three M 16 bolts at the top on the crossmember
and one M 18 bolt at the bottom on the spring
bolt and tighten further until contact is made.
8 Axle lift
– Service intervals as shown on page 52 –
Tightening torque:
M 20 (SW 30) M = 350 Nm (325 - 385 Nm)
Two-sided lift:
D
a) Check the M 16 lock nuts on the diaphragm B
cylinder to make sure they are tight. Tighten
with a torque wrench if necessary.
Tightening torque:
M 16 (SW 24) M = 190 Nm (180 - 210 Nm)
3PRINGæBOLT !DJUSTINGæPLATEæWITH
ANTIçROTATIONæDEVICE
!DJUSTINGæPLATE 3HAPEDæ
PART
"USH
Air suspension
"USH ,OCKæNUTæ
"USH
"OLT
3HAPEDæPLATE
4UBE
3UPPORT
,EVER
#YLINDER
Page 60 ZA-BPW-W 33112101e
BPW-W 33112101e
Overview
6 months -
subsequently yearly
72 months,
For detailed description, see pages 62 - 67
Air suspension series EA, see pages 52 - 59
- every
Air suspension series O, SL, AL, see pages 68 - 80
and
Suspension, see pages 82 - 91
1 Check air suspension levelling valve for condition, seal-tightness and general tightness. 1
- Visual inspection, check all component parts and welding seams for damage and wear. -
6 Check the spring bolt to gusset plate connecting bolt for tightness. 6
Tightening torques with a torque wrench:
M 18 x 1.5 (SW 27) M = 420 Nm (390 - 460 Nm)
Note:
Components that have damage due to improper mounting are to be exchanged after a review by a
BPW Service Centre.
ZA-BPW-W
BPW-W 33112101e
33112101e Page 61
Serie ACBO Serie ACBO with Kombi-Air Bag II
Air suspension
Series ACAM / ACBM Serie ACBM with bolt-on gusset plate
with two-sided axle lift
Series ACAU Serie ACAM with side mounted axle lift
Page 62 ZA-BPW-W 33112101e
BPW-W 33112101e
*
(
#
%
)
(
%
&'
(
2 Air bags
– Service intervals as shown on page 60 –
Safety notice
No welding should be carried out on steel parts
of air bags and pressure vessel!
Air suspension
Danger of injury!
- Visual inspection
– Service intervals as shown on page 60 –
5 Axle clamping
– Service intervals as shown on page 60 –
Tightening torque:
M 18 (SW 27) M = 420 Nm (390 - 460 Nm)
Air suspension
three M 16 bolts at the top on the crossmember
and one M 18 bolt at the bottom on the spring
bolt and tighten further until contact is made.
Page 66 ZA-BPW-W
BPW-W 33112101e
33112101e
8 Axle lift
– Service intervals as shown on page 60 –
Tightening torque:
M 20 (SW 30) M = 350 Nm (325 - 385 Nm)
Two-sided lift:
D
a) Check the M 16 lock nuts on the diaphragm B
cylinder to make sure they are tight. Tighten
with a torque wrench if necessary.
Tightening torque:
M 16 (SW 24) M = 190 Nm (180 - 210 Nm)
3HAPEDæ
PART
Air suspension
,OCKæNUTæFROMæ
,OCKINGæDISCæUNTILæ
"OLT
3HAPEDæPLATE
3UPPORT
#YLINDER
Page 68 ZA-BPW-W
BPW-W 33112101e
33112101e
Overview
60 and- 72 months.
under load, between 1000km
Within 2 weeks of first journey
months
latest5000km
For detailed description, see pages 72 - 80
12,636,
Annually 2)
Air suspension series EA, see pages 52 - 59
every
Air suspension series EAC, see pages 60 - 67
-after
and
Suspension, see pages 82 - 91
3)
1 Grease stabilizer bearing bushes with BPW special longlife grease ECO-LiPlus 1 1
and check for wear.
3)
2)
- Visual inspection, check all component parts and welding seams for damage - -
and wear.
2)
1 Check strap: Check condition and fastening. 1 1
2)
2 Check air suspension levelling valve for condition, seal-tightness and general 2 2
tightness.
2)
3 Check condition of air bags. 3 3
1)
ECO Plus Units with Airlight II and Airlight Direct air suspension are maintenance-free in On-Road applications and do not need to be
retightened (see warranty documents ECO Plus).
2) Under extreme conditions, with more frequency.
3)
Check twice annually.
ZA-BPW-W
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Air suspension
Series ALM/SLM Series ALU/SLU
with bolted-on air suspension hanger with sidewise mounted axle lift
bracket and bolt-on double-sided lift
Page 70 ZA-BPW-W
BPW-W 33112101e
33112101e
Overview
60 and-72 months.
Within 2 weeks of first journey
months
and 5000km
For detailed description, see pages 72 - 80
12, 636,
Annually 2)
Air suspension series EA, see pages 52 - 59
- every
Air suspension series EAC, see pages 60 - 67
latest
after
Suspension, see pages 82 - 91
7 Check the bolt connection between the air suspension hanger bracket and the 7 7 2)
7
longitudinal member for tightness.
Tightening torques with a torque wrench:
M 16 M = 260 Nm (240 - 285 Nm)
8 Tighten the spring bolt to gusset plate connecting bolt. 8 8 2) 8
Tightening torques with a torque wrench:
M 18 x 1.5 (SW 27) M = 420 Nm (390 - 460 Nm)
1)
ECO Plus Units with Airlight II and Airlight Direct air suspension are maintenance-free in On-Road applications and do not need to be
retightened (see warranty documents ECO Plus).
2)
Under extreme conditions, with more frequency.
Note:
Components that have damage due to improper mounting are to be exchanged after a review by a BPW Service Centre.
ZA-BPW-W
BPW-W 33112101e
33112101e Page 71
Serie ALO Series ALO/SLO
Air suspension
Series ALM/SLM Series ALU/SLU
with bolted-on air suspension hanger with sidewise mounted axle lift
bracket and bolt-on double-sided lift
Page 72 ZA-BPW-W 33112101e
BPW-W 33112101e
- Visual inspection
– Service intervals as shown on page 68 –
1 Check straps
– Service intervals as shown on page 68 –
Air suspension
Air suspension valve
*
(
#
%
)
(
%
&'
(
3 Air bags
– Service intervals as shown on page 68 –
Check air bags for external damage (surface cra-
cking, abrasion, crease formation, trapped for-
eign bodies etc.). Replace air bags in the event of
damage.
Safety notice
No welding should be carried out on steel parts
of air bags and pressure vessel!
Tightening torque:
M 20 (SW 30) M = 320 Nm (300 - 350 Nm)
M 24 (SW 36) M = 420 Nm (390 - 460 Nm) Shock absorber fastening - round axle beam
In the case of aluminium hanger brackets:
M 24 (SW 36) M = 320 Nm (300 - 350 Nm)
Air suspension
Tightening torque with a torque wrench:
Channel crossmember:
M 30 (SW 46) M = 900 Nm (840 - 990 Nm)
The serviceable life of the rubber / steel bush is de-
pendent on the tightness of the inner steel bushing.
Page 76 ZA-BPW-W
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33112101e
Tightening torque:
M 16 M = 260 Nm (240 - 285 Nm)
Air suspension
8 Bolted connection, gusset plate spring bolts
– Service intervals as shown on page 70 –
Tightening torque:
M 18 x 1.5 (SW 27) M = 420 Nm (390 - 460 Nm)
9 Axle lift
– Service intervals as shown on page 70 –
Single-sided lift
Two-sided lift:
a) Check the M 16 lock nuts on the diaphragm
cylinder to make sure they are tight. Tighten
with a torque wrench if necessary.
Tightening torque:
M 20 (SW 30) M = 350 - 380 Nm
M 16 (SW 24) M = 180 - 210 Nm
Two-sided lift
c) Check that the attachment bolts of the front
bracing strut of the mount on the air suspension
hanger bracket are tight, and in the case of the
bolt-on two-sided lift, the bolted connection on
the air suspension hanger bracket.
Tightening torque:
M 12 (SW 17) M = 75 Nm
Air suspension
Page 80 ZA-BPW-W 33112101e
BPW-W 33112101e
11 Stabilizer
– Service intervals as shown on page 70 –
Air suspension
Page 82 ZA-BPW-W
BPW-W 33112101e
33112101e
Overview
1)
Every 26 weeks
(twice annually)
Every 6 weeks
after 2 weeks
Initially
For detailed descriptions, see pages 84 - 87
For BPW trailer axles / steering axles, see pages 6 - 50
1) 1)
1 Grease bearings (suspension type E) with BPW special longlife grease ECO-LiPlus.
(Not applicable in the case of rubber/steel bushes.)
2 Check axle connecting rod bolts for tightness using a torque wrench.
M 24 x 2 (SW 36) M = 650 Nm
M 30 (SW 46) M = 725 Nm
M 36 (SW 55) M = 1425 Nm
- Visual inspection, check all component parts and welding seams for wear and damage.
Note:
Components that have damage due to improper mounting are to be exchanged after a review by a
BPW Service Centre.
ZA-BPW-W 33112101e
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Series ECO Cargo VB ...M ...ME
ECO Cargo VB / VB HD
Series ECO Cargo VB HD / HDE
Series ECO Cargo VB 5,5 t
Page 84 ZA-BPW-W 33112101e
BPW-W 33112101e
2 Slide elements
– initially after 2 weeks then every 6 weeks –
– under extreme conditions, lubricate with more
frequency –
Tightening torques:
up to an axle load of 5.5 tonnes (from 03/2016)
M 30 (SW 46) M = 725 Nm
Series HD / HDE
M 48 x 3 (SW 65) M = 1200 - 1300 Nm
ECO Cargo VB / VB HD
Tightening torques:
M 24 x 2 (SW 36) M = 650 Nm
M 30 (SW 46) M = 725 Nm
M 36 (SW 65) M = 1425 Nm
Tightening torques:
M 12 (SW 19) M = 66 Nm
M 14 (SW 22) M = 140 Nm
Page 86 ZA-BPW-W 33112101e
BPW-W 33112101e
4 Spring U-bolts
– initially after 2 weeks then twice annually –
Tightening torques:
M 20 (SW 30) M = 315 - 375 Nm
M 24 (SW 36) M = 600 - 650 Nm
- Visual inspection
– twice annually –
6 Slide elements
– twice annually –
Tightening torques:
ECO Cargo VB / VB HD
Page 88 ZA-BPW-W 33112101e
BPW-W 33112101e
Overview
(twice annually) 1)
Every 26 weeks
Every 6 weeks
after 2 weeks
Initially
For detailed description, see pages 90 - 91
BPW trailer axles / steering axles, see pages 6 - 50
1) 1)
1 Grease axle support bearing series W, BW using BPW special longlife grease
ECO-LiPlus.
2 Grease spring housing series W using BPW special longlife grease ECO-LiPlus.
- Visual inspection, check all component parts and welding seams for wear and damage.
Note:
Components that have damage due to improper mounting are to be exchanged after a review by a
BPW Service Centre.
ZA-BPW-W
BPW-W 33112101e
33112101e Page 89
ECO Cargo W / BW / GW
Series ECO Cargo BW / GW
Page 90 ZA-BPW-W 33112101e
BPW-W 33112101e
- Visual inspection
– twice annually –
Tightening torques:
M 30 x 2 (SW 46) M = 980 Nm
M 36 (SW 55) M = 1555 Nm
Tightening torques:
M 20 (SW 30) M = 320 Nm
M 24 (SW 36) M = 570 Nm
ECO Cargo W / BW / GW
3 Spring U-bolts on the spring housings
– twice annually, initially after 2 weeks –
BPW-WH-VB 35431501e
33112101e
BPW-W
ZA-BPW-W 33112101e
Your partner
Your partner ononthe
thepath
path
toto economic
economic viability
viability