bpw tsb disc brake axle parts catalogue...

BPW TRANSPEC BPW TSB DISC BRAKE SKH… SH… AXLES ECOPlus

SPARE PARTS CATALOGUE FOR AUSTRALIAN ASSEMBLED DISC BRAKE AXLES

BPW Transpec TSB Disc Brake Axle Parts Catalogue 3/2013

CONTENTS PAGE

Axle Part Number Legend for Australian Assembled Axles 3

BPW Transpec TSB Disc Brake Range 4

Exploded view of rigid TSB Disc Brake Axle 4

BPW TSB Disc Brake Identification & general information Operating Principle

6 7

Disc Brake Components Disc Brake Components Rotors Disc Covers

8 9

10

Wheel Studs and Nuts 11

BPW Brake Monitor 12 - 13

BPW ECO Plus Hub

General Information BPW ECO-LI Plus Grease Grease fiilling Grease Shower Tools Hub Components

14 15 15 15

16 - 17

ABS Components 18 - 19

Hubcaps with integrated hubodometer 20

BPW TSB Disc Brake Tools 21 - 23

BPW Transpec Disc Brake Identification 5

This book is intended to assist with the identification of spare parts for Australian assembled axles fitted with BPW TSB Disc Brakes only. It is not intended to give detailed technical service and/or maintenance information. For technical service and/or maintenance information please refer to the BPW Operator’s Manual and workshop manual or contact your nearest BPW Transpec Branch listed on the back cover of this book.

TABLE OF CONTENTS

Important Note This catalogue contains parts information for Australian assembled axles fitted with BPW TSB DISC BRAKE CALIPERS only.

TABLE OF CONTENTS

2


AXLE PART NUMBER LEGEND For Australian Assembled BPW Axles

At time of assembly an identification Type Label is affixed to every Australian assembled BPW axle, usually along the axle centreline on the rear face of the axle beam. The characters that make up the axle part number gives important information about that axle which can assist in the correct identification of spare parts. Below is a legend that can be used to decipher BPW Transpec Axle Part Numbers. The legend is divided into blocks that represent specific information. They are Axle Beam Profile, Hub, Bearing Combination, Wheel Fixing, Brake Size, Serial No, Hubcap Type, Hub Lubrication, Slack Adjuster Type (Drum Brakes Only) and ABS. Within these blocks there are the various alternatives that are represented by different character sets in the axle part number. On the top, left hand side of the legend there is an example axle part number highlighted in blue. That part number is:

HZA10110A11SPSN Follow the grey lines moving down through each block of the legend to find the meaning of each character set within that example axle part number. The other character sets in each block of the legend represent all other alternatives that may appear in other BPW Transpec axle part numbers. The axles fitted to any one trailer may have different axle part numbers. Therefore, when using the BPW Transpec Axle Part Number for the purposes of the correct identification of spare part numbers it is important that the axle part number being used is the actual part number for the specific axle requiring the parts.

H ZA 101 10 A 11 S P S N

NR Round Beam 127mm, 15" Tyres

H Square Beam 120mm & 150mm, 20" Tyres

R Round Beam 127mm, 20" Tyres

KH Square Beam 120mm, 19.5" Tyres

SH Square Beam 120mm, 20" Tyres

SKH, SK Square Beam 120mm, 19.5" or 20" Tyres

NH Square Beam 120mm, 15"/17.5" Tyres

ZA 10 Stud 285 PCD Dual Wheel, Spigot Mount

ZM 10 Stud 335 PCD, 8 Stud 275 PCD, 10 Stud 225 PCD Dual Wheel, Spigot Mount

SA 10 Stud 285 PCD Single Wheel, Spigot Mount

SM 10 Stud 335 PCD Single Wheel, Spigot Mount

XZ Spider Dual Wheel

X Spider Single Wheel

90 9 tonne bearing combination, 120mm square or 127mm round axle beam

91 10/12 tonne bearing combination, 120mm square axle beam

100 10/12 tonne bearing combination, 150mm square or 127mm round axle beam

101 10/12 tonne bearing combination, 120mm square axle beam, ECOPlus

00 Spider

08 8 Stud

10 10 Stud

A Drum Brake �420 x 180mm, suits 20" Tyres

B Drum Brake �360 x 200mm, suits 19.5" Tyres

C Drum Brake �300 x 200mm, suits 15" Tyres

D Disc Brake SB3745 (Knorr Caliper), �370mm rotor, suits 19.5" and 20" Tyres

E Disc Brake SB4309T (Knorr Caliper), ø430mm rotor, suits 20" Tyres

F Disc Brake SB3745T (Knorr Caliper), ø370mm rotor, suits 19.5" Tyres

G Disc Brake TSB4309 (BPW Caliper), ø430mm rotor, suits 20" Tyres

H Disc Brake TSB3709 (BPW Caliper), ø370mm rotor, suits 19.5" Tyres

00

99

S Standard Hubcap

BPW TRANSPEC AXLE MODEL AND PART NUMBERS

For Australian Assembled Axles

Axle Part Number ExampleLegend

Axle Beam

Profile

Hub

Bearing

Combination

Wheel Fixing

Brake Size

Serial No Consecutive Serial No 00 - 99

Hubcap Type S Standard Hubcap

H Hubcap with Hubodometer

G Grease, Conventional Hub

O Oil, Conventional Hub

B Grease with Oil seal, Conventional Hub

E ECO Hub, Grease

M ECO Hub, Grease, Push in studs (ECO MAXX)

P ECO Plus

Hub, Grease

S Manual Slack Adjusters

M Manual Slack Adjusters with multihole

A (Drum Brake Only) Automatic Slack Adjusters

N No ABS fitted

A ABS fitted

Slack

Adjuster

ABS

Hubcap Type

Hub

Lubrication

3


Axle Code Date Range Axle Type Brake Size

SH10110 From May 2010

10/12 tonne ECOPlus

TSB4309 suit 20" tyres

SKH10108 From January 2011 TSB3709 suit 19.5" tyres

Axle Type Rotor Diameter

SK…… 374 mm

SH…… 430 mm

BPW TRANSPEC TSB DISC BRAKE AXLE RANGE

BPW TRANSPEC TSB DISC BRAKE RANGE

DISC PROTECTORS Pg 10

ROTORS Pg 9

Exciter ring

Circlip

Roller bearing

Dust cover

Inner seal

Thrust washer

Thrust washer‘O’-Ring

Roller bearing

Washer

Axle nut

Locking ring

with locking piece

Circlip

Hubcap

ECO SealSeal

Fig.

ECOPlus 10 - 12 tABS COMPONENTS Pg 18 - 19

WHEEL STUDS & NUTS Pg 11

4

EXPLODED VIEW OF RIGID BPW TSB DISC BRAKE AXLE

BRAKE COMPONENTS Pg 8

HUB COMPONENTS Pg 16 - 17


BPW TRANSPEC TSB DISC BRAKE GENERAL INFORMATION

BPW DISC BRAKE CALIPER IDENTIFICATION

5

Prior to May 2010 all Australian assembled BPW disc brake axles were fitted with SB type disc brake caliper (Manufacturer - Knorr Bremse). BPW Transpec have been assembling disc brake trailer axles in Australia fitted with the new BPW TSB type disc brake caliper (Manufacturer - BPW) since May 2010. For parts information for TSB Type calipers, please contact your nearest BPW Transpec branch to obtain the correct parts catalogue. The diagrams above show the basic differences between the SB and the TSB type disc brake calipers. These diagrams may assist in the correct identification of disc brake calipers.

Important Note: This catalogue contains parts Information for Australian assembled axles fitted with BPW TSB DISC BRAKE CALIPERS only.

Adjuster mechanism on rear of caliper

Red rubber boots

around sliding pistonsClip on wheel side of caliper

Separate caliper carrier

Adjuster mechanism on rear of caliper

Red rubber boots

around sliding pistonsClip on wheel side of caliper

Separate caliper carrier

Adjuster mechanism on front of caliper

Black plastic seals around sliding pistons

Clip on axle side of caliper

No separate caliper carrier

Adjuster mechanism on front of caliper

Black plastic seals around sliding pistons

Clip on axle side of caliper

No separate caliper carrier

Important note: To correctly identify spare parts for BPW Transpec Disc Brake Axles you will require the answers to the following questions: 1. Does the disc brake axle have Knorr Bremse or BPW TSB caliper fitted? 2. If the disc brake axle is fitted with a BPW TSB caliper what is the brake size? Is the rotor 370mm in diameter or 430mm

in diameter? 3. Is the BPW TSB disc brake caliper left handed or right handed? Is the suspension underslung or overslung? Pages 5 and 6 in this catalogue gives all of the information relevant to the questions above. Please read these pages carefully before attempting to identify spare parts.

KNORR BREMSE AND BPW TSB DISC BRAKE CALIPERS

SB Type Caliper (Knorr Bremse)

Fitted to Australian assembled axles up to May 2010

TSB Type Caliper (BPW)

Fitted to Australian assembled axles from May 2010


BPW TRANSPEC TSB DISC BRAKE GENERAL INFORMATION

BPW TSB DISC BRAKE IDENTIFICATION & GENERAL INFORMATION

When the TSB caliper is mounted to the front of the axle (ie in the direction of travel) the long or fixed guide pins will be towards the bottom whether the suspension is underslung or overslung. If the caliper is mounted behind the axle then the right handed caliper is used the left hand side of the axle and the left handed caliper is used on the right side of the axle. Overslung = suspension springs over the axle Underslung = suspension springs under the axle

Please Note: TSB4309 is the standard for Australian assembled disc brake axles to suit 20” tyres.

TSB4309 = 430 mm Rotor TSB3709 = 374 mm Rotor

6

LEFT AND RIGHT HANDED CALIPERS

BPW Brake type and

serial number of the brake

BPW Brake code number

Data-Matrix-Code

BPW Brake code number

BPW Bergische Achsen KG

ECO-Disc

05.362.72.01.0

TSB 4309 09343A1234

Type plate

TSB DISC BRAKE SIZES

There is a manufacturer’s nameplate fixed onto each brake caliper, on which are stamped the data necessary for the identification of the brake in question.


BPW TRANSPEC TSB DISC BRAKE IDENTIFICATION

APPLYING THE BRAKE During braking, the cylinder pushrod of the spring brake or diaphragm cylinder presses onto the brake lever (1). The offset position of the brake lever amplifies the force created by the brake cylinder and allows it to be transferred to the intermediate plate (2) with minimal loss via a needle bearing. Mounted in the pressure plate (4), the intermediate plate coun-teracts the vertical movement of the lever and ensures optimal transfer to the cross support. The clamping force acts on the inner brake pad (7a) via the cross support (5) and the pressure plates (6). Once the play between the inner brake pad and the brake disc (8) has been overcome, the reaction force is transferred to the outer brake pad (7b) via the brake caliper. RELEASING THE BRAKE When the brake pressure rises, the pressure spring (9) moves the actuating unit back to it’s initial position. ADJUSTMENT The brake is fitted with an automatic non wearing adjusting device (10) to maintain constant clearance between the brake pad and the brake disc. Each time the brake is operated the axial movement of the lever block (2) and pressure plate (4) causes the adjuster pin (11) to be rotated via a trapezoidal thread. The adjuster pin is connected to the threaded tube (14) by the movement thread (11a) which in turn can rotate the threaded tube (25) via the spring loaded in-dented ball coupling sleeve (12). Axial play in the trapezoidal thread between the pressure plate (4) and the adjuster pin determines the free play value of the disc brake. When the free play is set correctly the spring loaded indented ball coupling sleeve (12) can disengage without turning the threaded tube (14). The overall play (total play on both sides of the disc brake) measures 0.8mm +/- 0.2mm. RESET MECHANISM The disc brake features a reset mechanism at the front for replacing the brake pads and brake disc. The return spring gear wheel (13) is me-chanically connected t the external gearing of the threaded tube (14) so that the pressure plates (6) can return to their initial position. Only minimal torque is required to move the pressure plates (6) back to this position or preset the play. BRAKE CYLINDER Air pressure builds up behind the diaphragm due to the action of compressed air on the brake cylinder. Air pressure forces the thrust rod out of the cylinder via the diaphragm plate. The brakes may only be fitted with brake cylinders which, apart from the sealing of the flange surfaces, are fitted with a so called “inner sealing”. This means that the pushrod acting on the lever (1) must be her-metically sealed from the secondary chamber of the brake cylinder as otherwise the internal mechanism is completely open to it’s surround-ings.

BPW TSB DISC BRAKE OPERATING PRINCIPLE

Numbers in brackets above refer to figure numbers on diagrams above

7

7b87a69(390)(362) (380) (390)

5

14

10

11 / 11a

1 Brake lever

2 Intermediate plate

3 Needle bearing

4 Pressure plate

5 Traverse

6 Thrust tappets

7a Inner brake pad

7b Outer brake pad

8 Brake disc

9 Pressure spring

10 Adjustment device

11 Adjuster pin with

11a Movement thread

12 Indented ball coupling

13 Return spring gear wheel

14 Threaded tube

7b7a 8

5

(380)(390)

1

13

9

101211

4

2

3

14

The figure numbers on the diagrams above refer to the

Operating Principles below


389

BPW ECO Disc Grease

390

397

396

395

394398

388

348

346345

325

326

328

335

335

Type F

Type L

301300

356

354

355

354

356

373

362

365

363

364

393

70232 / 33

B-Hub

S-Hub

BPW ECO Disc Grease Plus

374

370

Left Hand

BPW TRANSPEC TSB 3709 / TSB 4309 BRAKE COMPONENTS

BPW TSB 3709 / TSB 4309 DISC BRAKE COMPONENTS

BRAKE COMPONENTS

TSB 3709 TSB 4309 Qty per

Axle Item Item Name Dimension/Remark Part Number

300 Replacement Caliper Left Hand 0936272031 0936272010TS 1

Right Hand 0936272041 0936272020TS 1

323 Repair Kit Guide Pins Inc’s items 325, 326, 328,

345, 346, 348, 373 0980107610 2

352 Repair Kit Seals for Guide Pins Inc’s items 335, 354, 355,

356, 370, 373 0980107620 2

360 Repair Kit Tappet Inc’s items 362 - 365 0980107630 2

388 Repair Kit Brake Pads Inc’s items 370, 389, 390,

394, 396 - 398 0980107951 0980107960 1

393 Repair Kit Brake Pad Retainer Inc’s items 394 - 398 0980107680 2

345 Loose Guide Pin Screw M16 x 1.5 x 70 - 10.9 0250157816 2

325 Main Guide Pin Screw M16 x 1.5 x 100 - 10.9 0250167016 2

Right Hand

For Brake Monitor parts see pages 11 - 12

8


BPW TRANSPEC TSB 3709 / TSB 4309 BRAKE DISCS

BPW TSB 3709 / TSB4309 DISC BRAKE ROTORS

Brake Part Number Description Qty per Axle

TSB 3709 0308834150 8 Stud 275mm PCD 2

TSB 4309 0308835060 10 Stud 285mm PCD 2

TSB 4309 0308835050 10 Stud 335mm PCD 2

ROTORS

TSB 3709 0308834160 8 stud 275mm PCD for ABS 2

BRAKE DISC AND BRAKE PAD WEAR STATUS

9

max. 0.75 x a

max.1.5 mm

a

A

D C

B

max. 1.5 mm

Technical details:

♦ Disc thickness when new = 45 mm

♦ Minimum permissible disc thickness = 37 mm (check with slide gauge)

In case of conditions A, B & C the brake disc can be used until the minimum permissible disc thickness has been reached.

Sections A - D in the figure show the possible conditions of the disc surface: A: Network-type tears = permissible B: Radial cracks up to max 1.5 mm width and depth = permissible C: Uneven disc surface less than 1.5 mm = permissible D: Continuous cracks = not permissible

To prevent damage to the brake discs, the brake pads should be replaced when their thickness (excluding the backing plate) is 2 mm or less. If this instruction is not adhered to, there is a danger that braking performance could be seriously reduced.

The latest generation of BPW brake discs offer the following advantages:

♦ Increased surface area for effective heat dissipation

♦ Optimisation of material for improved heat distribution over the surface of the disc

♦ Venuri contour for improved internal air flow

♦ Optimally matched friction pairing (Pads / Brake discs)

♦ Simplified parts provision thanks to uniform brake discs for 0 and 120 offsets

45 mm

37 mm

2 mm

30 mm

9 mm

11 mm

Check the condition of the brake disc: - every 12 weeks (quarterly) under harsh conditions - every 26 weeks (twice annually) under normal conditions

45 mm

37 mm

2 mm

11 mm

9 mm

30 mm


BPW ECO Disc TSB 3709 / 4309 / 4312 - Rigid axles

510

M 10M = 43 Nm (40-47 Nm)

530

502501

BPW TSB DISC COVERS

Item Description Dimension

Qty Per Axle

TSB 3709 TSB4309

501 Disc Cover - Left Hand 0301071590 0301071610 1

502 Disc Cover - Right Hand 0301071600 0301071620 1

510 Locking Screw M 10 x 15 0250712200 4

513 Seal ∅ 7 / 10 / 13 0256817800 2

Part Number

BPW TRANSPEC TSB 3709 / TSB 4309 DISC COVERS

BPW TSB 3709 / TSB 4309 DISC BRAKE DISC COVERS

10


BPW WHEEL STUDS & NUTS

BPW TSB DISC BRAKE WHEEL STUDS & NUTS

WHEEL STUDS & NUTS TO SUIT DUAL WHEELS

Axle Type

No of Studs

PCD Wheel Type

Tyre Size

Fig Stud

(Item 472)

Wheel Nut (Item 479) Rear Nut

(Item 474)

Fig E Fig H

SHZM 10 335 Steel

20” 1E

0329633121

0526054100

Aluminium 1H 0526054140

SKHZM 8 275 Steel

19.5” 1E 0526054100

Aluminium 1H 0526054140

SHZA 10 285 Steel

20” 2E 0329623170

0526054100 0326004060 Aluminium 2E 0329623240

WHEEL STUDS & NUTS TO SUIT SINGLE WHEELS

SHSA 10 285 Steel &

Aluminium 20”

2E 0329623170 0526054100 0326004060

SHSM 10 335 Steel &

Aluminium 1E 0329633121 0526054100

Wheel Stud, push in type

Fig E Fig H

Wheel Stud, back nut type

To help to determine replacement wheel studs and nuts select the wheel stud or bolt type from figures 1 and 2 below. Then determine the wheel nut type from Figures E or H below. Then select the appropriate combination using the table above. For example the combination 1E represents push in type wheel studs for steel wheels.

1 2

472

L

L1

479

max. 28

479

max. 44

474

472

11



BPW BRAKE MONITOR

BPW has recognized a need for cost-effective brake monitoring solutions, especially for disc brakes, which has led to the development of the BPW Brake Monitor. With either disc or drum brakes, once the friction material wears out you get metal to metal wear, which can lead to an expensive repair as well as less than ideal retardation performance. The BPW Brake Monitor is designed to indicate when BPW disc brake axles have worn brake pads that need to be replaced, alleviating a costly repair and helping to maintain the safety benefit of disc brakes. The benefits of the BPW Brake Monitor include:

• Indication when pads should be inspected, and separate indication when the pads must be exchanged

• Highly robust system

• Modular design

• Operating voltage of 10V to 30V

• Potential to connect to external displays, eg. EBS

The Brake Monitor is connected to all axles on the trailer using a modular design enabling easy and cost-effective connection to any trailer type. All connections in this system are made via a specially coated “distribution cable” using bayonet connections making it highly robust. The wear indication can be shown on additional display units, for example: connected to trailer EBS so the driver can get a warning signal in the cab of the prime mover. The Brake Monitor is a great tool to have with disc braked trailers, it will provide the driver with an easy to read monitor, giving peace of mind when on the road.

BPW Brake Monitor Model BWI 03 indicates when the disc brake pads have to be replaced. The 3 levels of indication are as follows: 1) Green LED on: Unit is powered and the wear limit on the brake pads have not yet been reached. 2) Yellow LED flashing — Warning Signal: Brake pad material has been reduced to approx. 4mm, the brake pads and wear sensors should be serviced as soon as possible. 3) Service indicator changes to red and Green/Yellow LED flashing — Service Signal: Brake pad material has been reduced to approx. 2mm, the brake pads and wear sensors require immediate attention. The Service indicator will remain red even without voltage supply (eg. trailer uncoupled).

12



BPW BRAKE MONITOR

Item Description

Quantity

1 Basis Set Including: 1.1 Brake-Monitor 1.2 Connection Cable 1.3 Connecting Plug

0580160070 0203390100 0243125800 0237130800

1 1 1 1 1 1 1

2 Connection Module 0243125700 1 2 3 4 2 3 4

3 Extension 3-pin K/E-connector system 1m 3m 5m

0218192600 0218192500 0218192200

1 1 1

1 1 1

1 1 1

4 Wear Indicator Axle Set

0580150490 1 2 3 4 2 3 4

Part Number

5 Extension 7-pin DIN bayonet connec-tor system 2m 10m

0218192900 0218193000

1 1

1 1

1 1

BPW Brake Monitor Component List

Technical Data

CHEMICAL RESISTANCE

• UV Stable SIZE Physical footprint of Brake Monitor 80mm x 130mm

ENVIRONMENTAL CONDITIONS

• Ambient Temperature 40°C to 60°C

• Moisture Protected

• Protection against EMC influences

• Cross-polarity safeguard

ELECTRICAL DATA

• 10 to 30 V operating Voltage

• ≤ 30mA

4

1.2

1.1

4

4 4

per axle per axle

2 m

2 m

2 m

1.5 m

2 m

2 m

2

1.5 m

2 m

2 m

1.3

2 m

1

2

Connection for external signal

Power supply

(3)

(3)

(3)

(5)(3)

(3)

(3)

(3)

13


BPW TRANSPEC ECO Plus HUBS - GENERAL INFORMATION

BPW ECO Plus HUB General Information

Please refer to the BPW Transpec Operator’s Manual or contact your nearest BPW Transpec branch for details of conditions that apply to the ECO Plus Hub Guarantee

14

Fig.

ECOPlus 10 - 12 t

Exciter ring

Circlip

Roller bearing

Dust cover

Inner seal

Thrust washer

Thrust washer‘O’-Ring

Roller bearing

Washer

Axle nut

Locking ring

with locking piece

Circlip

Hubcap

ECO SealSeal

Fig.

ECOPlus 10 - 12 t BPW ECO Plus bearing - Features & Benefits

♦ Low maintenance, encapsulated bearing unit (ECO Unit) with integrated multi-seal system to protect the taper roller bearings from dust & dirt.

♦ Integrated torque limiter in the axle nut (ECO Plus ) prevents improper use when

♦ tightening.

♦ Bearings are precisely re-adjusted after every disc replacement.

♦ The ECO Plus Hub is Guaranteed in Australia for 3 years or 1,000,000km (whichever comes first) for highways use and 1 year for off road use (conditions apply*).

♦ Compact bearing system with DIN-ISO taper roller bearings available worldwide

for excellent availability & rapid service.

♦ Removal of the complete hub unit - thanks to central threaded connection - with

simple tools.

♦ Excellent bearing service life with minimal life cycle costs.

Main sealing lip

Dust and dirt sealing lips

Fig.

ECOPlus

10 - 12 t

HUB SEAL FOR ECOPlus BEARINGS

The innovative ECO Seal sealing system is used on all axles with the BPW ECO Disc Trailer disc brake. With this hub seal, the primary seal lip (ECO Seal) no longer seals directly against the race of the hub but instead against a race which is integrated in the seal itself. This new design enables circumferential velocity of the seal to be significantly reduced, and with that, the amount of wear. In addition, the wheel bearing is provided with even better protection against dirt penetration by means of the covering dust & dirt sealing lips.

Benefits:

♦ An internal pre-stressed main lip seal with a low circumferential speed & a low thermal load, resulting in low wear.

♦ An approximately 30% reduction in frictional resistance inside the seal (compared with conventional seals).

♦ The seal is well protected during service due to the cartridge construction.

♦ Pre-stressed main seal lip with ventilation function, no opening at low pressures.

♦ No coarse dirt seal required.

BPW ECO Plus hub bearing If you require long service life, rapid maintenance & low maintenance costs from your axle there is only one option for you: ECO Plus. Working on the basis of the special BPW ECO hub system the ECO Unit has been further developed to create the ECO Plus bearing system. The low maintenance hub has an integrated multi-seal system for protecting the tapered roller bearings against dust and dirt. A central threaded connection with the integrated torque limiting function ensures the bearing per-load is always optimum.

Dust & dirt sealing lips

Main sealing lip

Figure shows ECO Plus

10 - 12 t


BPW ECO-LiPlus GREASE Is available in the following container sizes

Part Number Container Size

0210404500 400 g cartridge

0210404700 5 kg container

0210404900 - 20 20 kg container

BPW ECO - LI Plus GREASE & GREASE SHOWER TOOLS

BPW ECO-Li Plus GREASE, GREASE FILLING & GREASE SHOWER TOOLS

Roller bearing grease

Roller bearing

Grease Shower Part Number To Suit Bearing Size

ISO BPW Bearing Part Numbers

9900000954 33116 / 32310 0264102400 / 0264102500

9900000955 33118 / 33213 0264102300 / 0264102200

BPW GREASE SHOWER TOOLS Used to quickly, accurately and cleanly fill the bearing with the required amount of BPW ECO-LiPlus Grease

15

BPW ECO-LI Plus is:

• usable at temperature between -30°C and + 150°C

• resistant to aging

• protecting against corrosion, even in aggressive

surroundings

• wear reducing

• generally plastics compatible

• suitable for extremely long relubrication periods

ECO-LI Plus is suitable for the lubrication of high temperature roller and friction bearings of commercial vehicles. It has been especially developed for highly loaded taper roller bearings and hub units with very long relubrication periods.

GREASE FILLING

Axle Load A = Inner Bearing B = Outer Bearing

8000 - 12000 kg - Manual greasing 170 g 120 g

8000 - 12000 kg - Greasing with grease applicator 130 g 90 g

ECO Plus Hub ECO-LiPlus Grease quantity per taper roller bearing

1 2 A B


• 10 - 12 tonne ECOPlus Hub in axles assembled from August 2008

BPW ECO Plus HUB COMPONENTS

For ABS Parts refer to pages 18 - 19

470

ECOPlus

380

37

78 - 81

43556 / 57

440

441

445

446

438

448447

460

432

420

424

421

428

437

422

423

430

431

56062 - 75

Steel hubcap

M = 800 Nm

For Rotors refer to page 9

For Wheel Studs refer to

pages 11

16

435

440

441

445

446

438

448 447

460

432

431

430

423

421 420

424

424

437

428


Item No Description Part No Qty Per Axle

435

Hub 8 stud 275mm PCD 0327246340 2

Hub 10 stud 285mm PCD 0327247380 2

Hub 10 stud 335mm PCD 0327243262 2

ECO Plus Hubs

BPW ECOPlus HUB COMPONENTS

Item Description Dimension/Remark Part No Qty Per

Axle

Kits

Wheel Bearing & Seal Kit (Including seal carrier)

Inc’s items 421, 422, 424, 428, 430 - 432, 440, 441, 445, 448, 447

0980107040TSSC 2

Wheel Bearing & Seal Kit (NOT including seal carrier)

Inc’s items 422, 424, 428, 430 - 432, 440, 441, 445, 448, 447

0980107040TS 2

420/421 Seal Carrier ∅ 96 / 117.5 / 132 x 22 0337007720 2

422 Hub Seal ∅ 117.5 x 158 x 17.5 0256647400 2

424 O Ring ∅ 100 x 3 0256780000 2

428 Dust Seal ∅ 117.5 / 160 x 9.5 0312048150 2

430 Wheel Bearing Inner 33118 0264102300 2

431 Grease Shield Inner ∅ 94 / 149 x 8.5 0301093340 2

432 Dust Seal ∅ 67 / 93 x 8.5 0312045160 2

437 Circlip Inner ∅ 158 x 4 0256065890 2

438 Circlip Outer ∅ 122 x 4 0256062290 2

440 Thrust Washer ∅ 71 / 108 x 8 0337026240 2

441 Wheel Bearing Outer 33213 0264102200 2

445 Washer - axle nut ∅ 53 / 76 x 5.8 0332064010 2

446 Axle Nut M 52 x 2 / SW 95 0526647060 2

447 Locking Wedge - axle nut 0327700070 2

448 Hooked ring spring - locking wedge ∅ 62 x 1.8 0318804100 2

460 Hub cap

M 136 x 2.5 / SW 110 0321225310

Hub cap, chrome 0321225310C 2



17


ABS PARTS

Item Description Dimension/Remark

Part Number Qty per

Axle TSB 3709 TSB 4309

510 Locking Bolt M 10 x 15 0250712200 2

511 Locking Bolt M 8 x 20 0250712300 2

513 Sealing Plug M 8 x 20 0256817800 2

542 Sensor Bracket 0318915760 2

542 Sensor Bracket, right 0318907580 2

543 Sensor Bracket, left 0318907590 2

560 Pole Ring

80 teeth (TSB 3709) 0331009390 2

100 teeth (TSB 4309) 0531008501 2

561 Cylinder Head Bold M 6 x 20 - 8.8 0250150682 4

563 Spring Washer ∅ 6 0256110690 4

570 Sensor Cranked L = 350 0233170500 2

570 Sensor Straight L = 350 0233170700 2

571 Bush 0203165900 2

585 Support Short - L 35 0318907350 2

586 Support 0214211100 2

590 Heat Protection Plate 0316514230 2

Kits ABS Kit Inc’s all items as indicated in table

below 0580174580 1 0580174590

BPW WHEEL ABS

BPW TRANSPEC TSB DISC BRAKE ABS COMPONENTS

18

ABS General Information In the anti-lock brake system (ABS), the wheel movement is recorded using a proximity type arrangement with an exciter ring attached to the hub and a sensor (speed sensor) that generates the pulses. As a result, the wheel speed of each wheel is continuously sent to the central control ECU. This runs a complex system for processing the received informant about the movement of the wheel as well as for cal-culating and performing logical operations on the control signals. Using the pressure control valves assigned to each wheel, it adjusts the air pressure and therefore the braking of each individual wheel (depending on the ABS system).


571

SKH..

SH..

560

560

570

570

551

585

510

513

590

586

553

M 6

M = 12 Nm

M 10

M = 43 Nm

542

SKH..

560

571

561

563

570

570

585

510

586M 10

M = 43 Nm

542

Sensor Bracket

37.5

14

Ø 1832

Ø 8.5

570

511

543542

M 8

M = 25 Nm

32

.5

Ø 18

Sensor Bracket

TSB 4309

TSB 3709

BPW TRANSPEC TSB DISC BRAKE ABS COMPONENTS

Pole ring mounted on rotor

19

M 10 M = 43 Nm

M 10 M = 43 Nm

M 8 M = 25 Nm

570

586

510

585

570

571

542

561

563

560

570

586

510

585

570

571

586

543 542

560 Pole ring mounted on hub


BPW TSB DISC BRAKE TOOLS

BPW HUBCAPS With Integrated Non Digital and Digital Hubodometer

General Information: The BPW hubcap with it’s integrated digital odometer is an important instrument for checking the mileage of your trailer.

A built in, watertight mini computer counts the wheel revolutions by means of a magnet and a reed contact.

The tyre rolling circumference is set initially, before fitting the hubo to the axle, and cannot be changed subsequently.

Read out takes place when two silver contacts on the older style ECOMETER or the two BPW logos on the face of the newer style ECOMETER are connected with a metallic object eg a spanner.

Important! • Please refer to the BPW Operator’s Manual (valid for operational use in Australia) for instructions on the fitting and setting of

Digital Hubodometers. • The reed contact in the cap should always be protected against damage. For this reason, caps should not be stacked one

inside the other. • Always remove and install correctly. • For information regarding the fitting and setting of the digital hubodometers, please refer to the BPW Operator’s Manual.

HUBCAP WITH INTEGRATED DIGITAL HUBODOMETER

Hubcap Thread = M136 x 2.5

Part Number

Black 0521275060

Chromed 0521275030

Available for ECOPlus axles only

Battery to suit 0201309700

20

BPW HUBCAPS WITH INTERGRATED NON DIGITAL HUBODOMETER

Axle Load Brake Type Axle Beam

Profile Hubcap Thread

Tyre Size Tyre Rolling

Circumference ± 2 % Part No

10 - 12 tonne

SH ECOPlus

255/70 R 22.5 2830 mm - 2860 mm 0521225410

275/70 R 22.5 2915 mm 0521225420

315/70 R 22.5 3015 mm - 3134 mm 0521225440

11 R 22.5 3175 mm - 3220 mm 0521225450

385/65 R 22.5 3240 mm - 3260 mm 0521225460

12.00 R 22.5 3280 mm - 3310 mm 0521225470

SKH ECOPlus M 136 x 2.5 265/70 R 19.5 2620 mm - 2650 mm 0521225380

M 136 x 2.5

Tyre rolling circumference: The tyre rolling circumferences in the table below are based according to standard ETRTO (European Tyre and Rim Technical Organisation). Data of various tyre manufacturers can vary slightly.

HUB CAPS WITh INTEGRATED DIGITAL HUBODOMETER

Battery information:

A row of flashing dots appears on the display when the battery voltage has fallen below the necessary value, which is a warning that the battery should be changed. After the battery has been changed, the program and display are resumed (the distance value in kilometers continues to be stored in a permanent memory).


BPW TSB DISC BRAKE TOOL KIT OVERVIEW

Description BPW Part No Details on Page No

1. Threaded spindle 0201303910

22

2. Ball bearing 0201304010

3. Sleeve 0214102600

4. Press out tool (both bearings) 0201304110

5. Press tool (movable bearing) 0201304210

6. Nut 0252703700

7. Counter-hold tool 0214212200

8. Pressing tool (fixed bearing) 0201304310

9. Press-on tool (plastic bellows) 0201304510

10. Torx spanner return mechanism 0201304410

11. Two-hole spanner - coarse dirt seal 0235162000

12. Adapter for movable bearing screw 0201304610

13. Adapter for plastic cap 0201304710

14. Adaptor for torque wrench (movable bearing)

0201304810

15. Adaptor for torque wrench (plastic cap)

0201304940

16. Ring for pulling wheel studs 0256839200

Complete tool case (Contains all sixteen tools)

9900000963

23

BPW TSB 3709 / TSB 4309 DISC BRAKE TOOLS

In order to simplify the maintenance procedures on BPW axles a comprehensive range of special tools are available. BPW tools offer the following advantages:

• Tried and tested design Tools must prove their worth in everyday use. Only then does it become clear whether tools are up to the demands of the real world.

• Use of high quality materials High quality materials are absolutely essential for producing high quality tools. Continuous quality assurance guarantees consistent quality.

• Favourable price/performance ratio Quality is not always obvious at first glance (e.g. materials). Buying quality tools is often the cheaper option in the long term. This particularly applies in those cases where tools are regularly needed and where their trouble free use must be guaranteed at all times.

• Long service life, low wear BPW tools are designed to be particularly resistant to wear and tear, and guarantee an extremely long service life, even with frequent use.

• Simple to handle Ideal solutions are always simple. This statement also particularly applies to tools. For that reason BPW tools are Designed strictly to meet the necessary technical requirements. Solutions that do not meet practical requirements are rigorously weeded out at the development stage. The following pages show a representative range of the tools available. For complete details please contact your local BPW Transpec Office or BPW distributor.

21


BPW TSB DISC BRAKE TOOLS


1

02.0130.39.10

Threaded spindle

M 18 / SW 22

Press-out tool for movable bearing,

consisting of item 1, 2, 3, 4, 6

1 2 3 4 6

2

02.0130.40.10

Ball bearing

3

02.1410.26.00

Sleeve Ø 20.5 / Ø 42 / Ø 55

Pressing tool for movable bearing,

consisting of item 1, 2, 4, 5, 6, 7,

7 61 2 4 5

4

02.0130.41.10

Press-out tool for movable

and fixed bearings

5

02.0130.42.10

Pressing tool (movable bearing)

Press-out tool for fixed bearing,


1 2346

6

02.5270.37.00

Nut M 18 SW 32

7

02.1421.22.00

Counter-hold tool

Pressing tool for fixed bearing,


1 2876

8

02.0130.43.10

Pressing tool (fixed bearing)

SW = Spanner width

0201303910

0201304010

0214102600

0201304110

0201304210

0252703700

0214212200

0201304310

22



9

02.0130.45.10

Press-on tool (plastic bellows)

10

02.0130.44.10

Torx spanner return mechanism

11

02.3516.20.00

Two-hole spanner for coarse

dirt seal

12

02.0130.46.10

Adapter for movable

bearing screw

SW 14 / SW 24

13

02.0130.47.10

Adapter for plastic cap

SW 14 / SW 13

14

02.0130.48.10

Adapter for torque wrench

(movable bearing)

SW 14

15

02.0130.49.10

Adapter for torque wrench

(plastic cap)

SW 14

16

02.5683.92.00

Ring for pulling in wheel studs

SW = Spanner width

9 10

11

13 14

15 16

12

0201304510

0201304410

0235162000

0201304610

0201304710

0201304810

0201304910

0256839200

23

STATE BRANCHES

VICTORIA (Head Office) 1 - 11 Cherry Lane, North Laverton VIC 3026 Phone: (03) 9267 2444 Fax: (03) 9369 4826

Internet: www.bpwtranspec.com.au e-mail: [email protected]

NEW SOUTH WALES

10 Squill Place, Arndell Park, NSW 2148 Phone: (02) 8811 7000 Fax: (02) 8811 7050

QUEENSLAND

Cnr Archerfield Road & Bernoulli Street, Darra, QLD 4076 Phone: (07) 3217 0877 Fax: (07) 3217 0230

WESTERN AUSTRALIA

20 Brennan Way, Belmont, WA 6104 Phone: (08) 9479 5822 Fax: (08) 9479 6922

FREE CALL: 1300 651 652

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