Workshop Manual. Agricultural - Bearings. we think transport. BPW-WH-Agrar e

Transcription

1 Workshop Manual Agrcultural - Bearngs we thnk transport

2 Page 2 Page 3 Table of Contents Basc rules Never overload axles, brakes and chasss In lght of ths No rregular overloadng of vehcles by exceedng the permssble gross vehcle weght. The permssble brake load must not be exceeded. No unlateral overloadng by mproper loadng or drvng on curbs etc. Use only approved wheels and tyres. Maxmum dfference between the track and the sprng centre must be observed. Do not overload by usng wheels wth a lateral mpact or nadmssble wheel offset. The permssble maxmum speed must not be exceeded. Before each use, check the proper adjustment of brakes and brake pads and ensure ther proper operaton. Warranty does not cover wear and unauthorsed changes. In order to mantan operatonal and road safety of the vehcle, mantenance must be carred out at predetermned ntervals. All relevant operaton, servce and safety regulatons of the vehcle manufacturer or other vehcle parts manufacturers must be observed. The elmnaton of reported defcences or the replacement of worn parts should be entrusted to a BPW Servce Centre f the vehcle owner does not have access to approprate professonals and necessary techncal equpment on ste. The exclusve use of orgnal BPW replacement parts s strongly advsed. BPW-approved parts for traler axles and axle unts are regularly subject to specal nspectons. BPW accepts product lablty for these. BPW cannot assess whether each ndvdual thrd-party product can be used n the BPW traler axles, axle assembles and overrun devces wthout safety rsks. Ths apples even f an authorsed testng organzaton has accepted the product. Usng spare parts other than orgnal BPW parts vods our warranty. 1 Product dentfcaton BPW dentfcaton plate agrcultural axle Type desgnaton and number key 5 2 Exploded vew Sold axle beam Hollow axle beam 7 3 Safety regulatons, safety nformaton Safety regulatons Safety nformaton 9 4 Specal tools Fastener torque values Checkng the tghtness of hub cap Checkng the tghtness of wheel nuts Check wheel hub bearng play Lubrcaton Dsassemblng and assemblng the hub unt Helcal studs Threaded studs Dsassembly of the bearng cone Sealng components ABS ABS-components Sensor ar gap Installaton of ABS sensors Installaton of the excter rng 33 As of : 02 January nd edton Subject to change wthout notce. Current versons and addtonal nformaton can be found onlne at

3 Page 4 Page 5 1 Product dentfcaton 1.1 BPW dentfcaton plate agrcultural axle Type desgnaton and number key 1.2 Every BPW axle has a type plate. It s affxed to the centre of the axle beam - opposte to the travel drecton. Data on the type plate can be used to defne the requred spare parts or - after an accdent, for nstance - the complete axle. Type plate Braked axle Axle loads: two-axles sngle axle tandem axles Type plate unbraked axle Brake type Type plate Suspenson unt Statc axle load Techncal axle load kg kg kg FL 4112 GS Code number 25 km/h 40 km/h 60 km/h GS TDB AL 224.1; AL km/h 40 km/h 60 km/h kg kg kg Code number Axle type GS PM BPW BERGISCHE ACHSEN KG D WIEHL GERMANY Date of manufacture and daly sequental number Permssble axle loads, Customer number dvded nto dfferent speed lmts and confguratons, (two-axles, sngle axle, tandem axles) Code number Suspenson unts type 9000 Axle type UTAC: 07/02281; 07/02282 CEMAGREF: Wheel brakes certfcate BPW BERGISCHE ACHSEN KG D WIEHL GERMANY GSOHRL 2/ Spur: 2100 Achs abst.: Tragkraft (kg) v max. 25 km/h v max. 40 km/h v max. 60 km/h BPW BERGISCHE ACHSEN KG D WIEHL GERMANY Date of manufacture and daly sequental number Customer number Track (mm) Permssble axle loads, dvded nto dfferent speed lmts and confguraton, (two-axles, sngle axle, tandem axles) Date of manufacture and daly sequental number Customer number Type desgnaton axles: Example G S LA G BPW traler axle for agrcultural vehcles S Sngle wheels, wheels wthout offset N Braked axle max. speed: 80 km/h ST Axle stub LA Unt steerng axle, type LA LL Unt steerng axle type LL HLL Unt steerng axle type LL for underneath brake cylnders L Steerng axle type L (postve steerng) Axle capacty and number of wheel studs per wheel (last two dgts) -1 Bearng type number Code number key, axles: Example or 36. Agrcultural traler axle, steered 55. Agrcultural traler axle, braked and unbraked 58. Agrcultural axle stub, braked and unbraked 53. GS 3606; Bearngs: GS 4006; Bearngs: GS 5006; Bearngs: GS 5506; Bearngs: x 66. GS ; Bearngs: 32310A GS 7006; GS 7008; Bearngs: x 70. GS ; GS ; Bearngs: GS 12010; GSN 12010; Bearngs: GS 9010; Bearngs: GS 12010; GSN 12010; Bearngs: GS 14010; Bearngs: GS ; GS ; Bearngs: 32310A Wthout brake 356. Wedge - type brake S 3008 RA (3081) 375. Wedge - type brake S RASK 376. Wedge - type brake S SK 381. Wedge - type brake S RAZG 384. Wedge - type brake S ZG 443. Cam brake N Cam brake N Cam brake N Cam brake N Wng cam brake FL Wng cam brake FL Cam brake N Cam brake N S-Cam brake SN Seral number

4 Page 6 Page 7 2 Exploded vew 2.1 Sold axle beam Hollow axle beam 2.2 Sold axle beam wthout brake Hollow axle beam wthout brake Sold axle beam wth Cam brake N 20 Hollow axle beam wth Wng cam brake FL Hollow axle beam wthout brake Hollow axle beam wth Wng cam brake FL Sold axle beam wthout brake Sold axle beam wth Cam brake N Item Name Item Name Item Name Item Name Item Name 1 Thrust washer 1 Thrust washer 13 Lock rng 2 Rng 2 Rng 14 Shm washer 3 Gasket 3 Seal rng 15 Lock rng 4 Roller bearng 4 Tapered roller bearng 16 Rng 5 Hub 5 Hub 17 O-Rng 6 Wheel studs 6 Wheel studs 18 Slack adjuster 7 Sprng washer 7 Sprng washer 19 Brake camshaft 8 Flat collar nuts 8 Flat collar nut 20 Brake shoes 9 Tapered roller bearng 9 Tapered roller bearng 21 Tenson sprng 10 Castle nut 10 Castle nut 22 Tenson sprng 11 Splnt 11 Splnt 12 Hub cap 12 Hub cap 1 Thrust washer 1 Thrust washer 15 Hub cap 2 Rng (Nylon) 2 Rng (Nylon) 16 Tenson sprng 3 Rng (Nylon) 3 Rng (Nylon) 17 Tenson sprng (Hook) 4 Roller bearng 4 Roller bearng 18 Tenson sprng (Eye) 5 Cover plate 5 Cover plate 19 Brake shoe 6 Wheel studs 6 Brake drum 7 Sprng washer 7 Hub 8 Wheel nuts 8 Wheel studs 9 Hub 9 Sprng washer 10 Tapered roller bearng 10 Wheel nuts 11 Washer 11 Roller bearng 12 Castle nut 12 Washer 13 Splnt 13 Castle nut 14 Hub cap 14 Cotter

5 Page 8 Page 9 3 Safety regulatons, safety nformaton 3.1 Safety regulatons Safety nformaton 3.2 All work must be performed by traned mechancs at competent repar facltes or authorsed specalsed workshops who have access to all relevant tools and have acqured the know-how requred for ths work. Anyone who performs mantenance and repar work must have been traned as an automotve mechanc and already have experence n reparng tralers. Anyone who performs brake work must be traned n brake systems. Ths workshop manual contans dfferent types of safety nstructons, each of whch s desgnated by an con and a sgnal word. The sgnal word descrbes the severty of the potental danger. Danger Immedate potental danger of serous or fatal njury (severe njury or death). Comply wth local safety regulatons. The relevant operatons and servce regulatons as well as safety regulatons of the vehcle manufacturer and of the manufacturers of the vehcle parts must be adhered to. The dust created from grndng brake lnngs comprses partcles that can cause lung damage. A safety mask must therefore be worn to prevent brake dust from beng nhaled. Warnng Cauton Possble potental danger of serous or fatal njury (severe njury or death). Possble dangerous stuaton (slght njury or damage to property). Use prescrbed dust washng devces or vacuum cleaners for cleanng, never use compressed ar or other hgh-pressure devces. Ensure adequate ventlaton at the workplace. The vehcle must be prevented from movng durng repar work. Please observe the relevant safety regulatons for repar work on commercal vehcles, n partcular the safety regulatons for jackng up and securng the vehcle. Durng repar work, make sure that the brake s not operated nadvertently. Repar Gude Rsk of damage to property or consequental damage f ths nformaton s not observed. Do not perform repar work unless wearng protectve clothng (gloves, safety boots, safety googles, etc.) and usng the recommended tools. Work on brake components removed from the vehcle must be carred out wth the components fxed n place such as n a vse. Only use recommended tools. Note Applcaton hnts and especally useful nformaton A second mechanc must provde assstance when workng wth heavy components (brake drums or brake removal/nstallaton). All ar lnes and components must be depressursed before beng removed. Followng each repar, perform a functon check or a test drve n order to make sure that the brakes are functonng correctly. New drums and lnngs only have maxmum effect after a few brakng actons. Avod hard brakng. All exchanged components must be reused or dsposed of n accordance wth the applcable envronmental regulatons, laws and drectves. Tghten bolts and nuts wth the prescrbed tghtenng torque.

6 Page 10 4 Page 11 Specal tools No. 1 Descrpton Illustraton of tool Tool n operaton No. 5 Sockets for hub caps ( BPW shape ) Hub puller BPW code number: SW 95 SW 110 SW 120 M 115 x 2 M 125 x 2 M 150 x 2 Order bolt separately SW 95 SW 110 BPW code number: Illustraton of tool BPW code number: SW Descrpton Rng spanner for hub caps ( flat shape / BPW shape ) 6 M 22 x 100 Puller for taper roller bearngs for axles 6,5-14 t SW BPW code number: BPW code number: SW 95 SW 110 SW Sockets for axle nuts ( BPW shape ) SW 7 Press tools for nsertng the outer rngs of roller bearngs BPW code number: SW 65 SW 80 Box spanner for axle nuts BPW code number: SW 65 SW 80 SW 85 SW Roller bearng Ø BPW code number Ø Tool n operaton

7 Page 12 Page 13 4 Specal tools Fastener torque values 5 No. Descrpton Illustraton of tool Tool n operaton 9 Impact tool for hub cap (wthout thread) Hub cap for axle Descrpton Thread /Wrench sze/ Bearng Fastener torque values M = 500 Nm D1 Ø Hub cap for axle 14 t M = 800 Nm Hub cap code number D1 Ø D2 Ø D3 Ø L Locknut for wheel studs /drumsde M 20 x 1,5 / SW 30 M = 300 Nm M 22 x 2 / SW 32 M = 400 Nm M 22 x 1,5 / SW 32 M = 400 Nm D2 Ø D3 Ø L Castle nut M 27 x 1,5 / SW 41 / M = 20 Nm M 36 x 1,5 / SW 55 / M = 90 Nm M 27 x 1,5 / SW 41 / M = 45 Nm M 52 x 2 / SW 80 / M 42 x 2 / SW 65 / M = 150 Nm M = 150 Nm 10 Impact tool for bearng Type of bearng D1Ø (mm) Tool D2Ø (mm) L (mm) M 52 x 2 / SW 80 / M = 150 Nm M 60 x 2 / SW 85 / M = 150 Nm Wheel nut / bolt centerng M 18 x 1,5 / SW 24 M = 270 Nm M 20 x 1,5 / SW 27 M = 380 Nm M 22 x 1,5 / SW 32 M = 510 Nm M 22 x 2 / SW 32 M = 460 Nm /Schwarz/ D1 Ø D2 Ø Wheel nut / central centerng M 22 x 1,5 / SW 32 M = 630 Nm Lockng screw for dust cover M 10 / SW 13 M = 38 Nm Self-tappng screw for dust cover M 10 / SW 13 M = 43 Nm Self-tappng screw for sensor bracket M 8 / SW 13 M = 25 Nm L Lockng screw for sensor bracket M 6 / SW 10 M = 8 Nm

8 Page 14 6 Checkng the tghtness of hub cap Page 15 Checkng the tghtness of wheel nuts 7 Wheel hub cap wthout thread after every 500 workng hours, at every brake lnng replacement, latest annually [1] Drve the hub cap frmly n correct poston usng a specal tool, see page 12. after the frst run under loaded condtons, after each wheel change and every 500 hours of operaton or annually. Tghten wheel nuts crosswse to the torque value specfed n the table usng a torque wrench. Wheel contact wth no addtonal applcaton of pant (rsk of loosenng dsc wheels) Fgure 1 Tghtenng torque for wheel nuts Fgure 4 Wheel hub cap wth thread It s mperatve that the prescrbed tghtenng torques are adhered to n order to ensure that the wheels are securely fastened [1] Check the tghtness of hub cap wth a torque wrench, f necessary re-tghten t. Thread Wrench sze mm Dacromet Geomet Geopett Max tghtenng torque Galvansed Black Pcture Stud algnment Fgure 2 M 14 x 1, Nm ( Nm) 125Nm ( Nm) M 18 x 1, Nm ( Nm) 320 Nm ( Nm) 290 Nm ( Nm) Tghtenng torque: 8-12 t M = 500 Nm 14t M = 800 Nm M 20 x 1,5 27 M 22 x 1, Nm ( Nm) 510 Nm ( Nm) M 22 x Nm ( Nm) 560 Nm ( Nm) 505 Nm ( Nm) 380 Nm ( Nm) 510 Nm ( Nm) 460 Nm ( Nm) Spgot algnment M 22 x 1, Nm ( Nm) Fgure 3

9 Page 16 7 Checkng the tghtness of wheel nuts Page 17 Check wheel hub bearng play 8 The values ndcated by a torque wrench can be reached almost exactly by usng an ordnary wheel nut spanner (vehcle tool kt). B Check wheel hub bearng play, adjust f necessary (conventonal) after every 500 workng hours, at every brake lnng replacement, latest annually Repar Gude However always check wth a torque wrench as soon as possble afterwards A Check wheel hub bearng play by lftng axle untl the tyres are free. Release brake. Apply a lever between the tyre and the ground and check the play. Warnng Fgure 5 Prevent the vehcle from rollng away Release the park and servce brake only after lftng Fgure 6 Reachng the tghtenng torque wth hand tools Tghtenng torque Ppe length A Body weght B 300 mm kg Nm 350 mm kg 400 mm kg 350 mm kg Nm 400 mm kg 450 mm kg 500 mm kg 400 mm kg Nm 450 mm kg 500 mm kg 600 mm kg 500 mm kg Nm 600 mm kg 700 mm kg If there s a sgnfcant bearng play: (the bearng hangs down) [1] Remove wheels and hub caps. [2] Remove splt pn and axle nut. [3] Tghten the axle nut wth a torque wrench whlst smultaneously turnng the wheel hub to the torque shown n the table: Type of external tapered roller bearngs) Tghtenng torques (Nm) Nm Nm Nm Nm Nm Nm Tolerance: +5% -15% Tghten castellated nut wth a normal axle nuts key (hand tools) untl the runnng of the wheel bearng drags slghtly. Fgure Nm 600 mm kg 700 mm kg 800 mm kg [4] If the cotter pn holes do not concde after tghtenng turn back the axle nut untl next hole. Hole devaton should be max. 30 [5] Insert the splt pn and bend t slghtly. 700 mm kg Nm 800 mm kg 900 mm kg 1000 mm kg Nm 1000 mm kg [6] Refll hub cap wth specal BPW specal longlfe grease (ECO-L 91). Observe the grease quantty (Table B), page 25. [7] Grease the threads of the hub cap all around wth BPW specal longlfe grease (ECO-L 91) and tghten to the specfed torque 500 Nm. Fgure 8

10 Page 18 8 Check wheel hub bearng play Page 19 Check wheel hub bearng play, adjust f necessary (for Central Tre Inflaton System wth KM axle nut) [1] Remove wheels. Screw the ar pressure connecton out of the wheel hub cap or the axle stub. [5] Put the new retanng plate n place. Screw up the KM axle nut by hand untl t tghtens slghtly. Refer to the operatng nstructons of the control system manufacturer. Install the retanng plate wth the convex sde facng the axle center. Pay attenton to the correct nstallaton of the axle nut. [2] Unscrew the hub cap. Fgure 9 Fgure 12 [3] Screw down the outer KM axle nut and remove the retanng plate. Repar Gude Reuse of the dsassembled lockng plate s prohbted It must be replaced [6] Turn the nner KM axle nut back to the next possble groove for the lockng collar and bend the nose nto the groove of the axle nut, when the lockng collar s opposte the next groove (max. 30 ). [7] Tghten outer KM axle nut wth 150 Nm tghtenng torque. Bend the lockng collar nto the groove of the KM axle nut. Fgure 10 Fgure 13 [4] Tghten the nner KM axle nut whle turnng the wheel hub at the same tme wth a tghtenng torque of 150 Nm usng a torque wrench. (Several turns have to be made untl the tghtenng torque s reached). [8] Grease the thread of the hub cap all round wth the BPW specal longlfe grease (ECO-L 91) and tghten t to the prescrbed 500 Nm tghtenng torque. When usng a normal axle nut wrench (on-board tool), tghten the axle nut untl the runnng of the wheel bearng drags slghtly. The ar connecton should be free from grease. [9] Install the Central Tre Inflaton System. Fgure 11 Fgure 14

11 Page 20 9 Lubrcaton Page 21 Change the grease from hub bearng (conventonal) after every 1000 workng hours, at every brake lnng replacement, latest annually [7] Push the thrust rng and new sealng rngs onto the axle stub. If necessary, push them carefully wth ppe bushngs wthout tltng and damagng. Warnng Lft the vehcle n an accdent-free manner and release the brake. Check the seals and bearngs for wear and damage. Contact surfaces of the bearngs must be free of damage. Replace f necessary [1] Remove wheels and dust caps. [2] Remove the splt pn from the hole and unscrew the axle nut. [3] Pull off the wheel hub wth brake drum, tapered roller bearng and sealng elements usng a sutable puller from the axle stub. Repar Gude Fgure 15 [8] Fll up the free spaces between tapered roller bearngs wth BPW specal longlfe grease (ECO-L 91) and work them together. Observe the fnal grease quantty (table A) see page 23. [9] Smear the remanng quantty of grease nto the bearng outer rng of the hub. [10] Push up the pre-assembled wheel hub and brake drum unt centrcally. Push sensor f avalable, back nto the correct poston by the wheel hub and brake drum unt carefully. Therefore wheel hub unt s not msalgned. Fgure 18 [4] Clean the brake, check the components for wear, damage, functon and replace worn parts. The nsde of the brake must be free of lubrcants and contamnaton. [5] Clean wheel hub nsde and outsde thoroughly. Remove old grease completely, clean tapered roller bearng (desel ol), dry and check them for re-usablty. Replace seals. [6] Clean the bearng seats of the axle stub (t must be metallc brght, dry and free from grease) and grease all over wth BPW specal longlfe grease (ECO-L 91). Mark hubs and bearngs together so that they are not nterchanged durng assembly. It s mperatve that the bearng nner rngs wth rollers be reused on the same hubs. Do not over-grease Make sure that the sealng elements can be pushed up easly on the axle stub. Fgure 16 Fgure 17 Check the dsplacement of the sensor f avalable, before nstallng the wheel hub, see page 32. [11] Insert outer taper roller bearng [12] Insert the washer and screw on the axle nut usng a torque wrench to tghten the wheel hub to the prescrbed tghtenng torque accordng to the table, see page 17. (several turns untl the tghtenng torque s reached). [13] Turn the axle nut back to the next possble hole. If the cover s the same, screw the axle nut back to the next hole (max 30 ). [14] Insert the splt pn and bend t slghtly. [15] Refll the hub cap wth BPW specal longlfe grease (ECO-L 91) the grease quantty (table B), see page 25. [16] Grease the threads of the hub cap all around wth specal BPW longlfe grease (ECO-L 91) and tghten to the specfed torque 500 Nm. [17] Adjust the brake. Fgure 19 Fgure 20

12 Page 22 9 Lubrcaton Page 23 Change the grease from hub bearng (for Central Tre Inflaton System wth KM axle nut) after every 500 workng hours, at every brake lnng replacement, latest annually [1] Rase the axle and remove wheels. Warnng [7] Clean the brake, check the components for wear, damage, functon and replace worn parts. The nsde of the brake must be free of lubrcants and contamnaton. [8] Clean wheel hub nsde and outsde thoroughly. Remove old grease completely, clean tapered roller bearng (desel ol), dry and check them for re-usablty. Replace seals. [2] Screw the ar pressure connecton out of the wheel hub cap or the axle stub. Prevent the vehcle from rollng away Release the park and servce brake only after lftng Refer to the operatng nstructons of the control system manufacturer. Fgure 21 [9] Clean the bearng seats of the axle stub (t must be metallc brght, dry and free from grease) and grease all over wth BPW specal longlfe grease (ECO-L 91). Do not over-grease Make sure that the sealng elements can be pushed up easly on the axle stub. Fgure 24 [3] Unscrew the wheel hub cap. [10] Push the thrust rng and new sealng rngs onto the axle stub. If necessary, push them carefully wth ppe bushngs wthout tltng and damagng. [4] Screw down the outer KM axle nut and remove the retanng plate. Repar Gude Reuse of the dsassembled lockng plate s prohbted It must be replaced [5] Unscrew KM axle nut and take out the washer. Fgure 22 Check the seals and bearngs for wear and damage. Contact surfaces of the bearngs must be free of damage. Replace f necessary [11] Fll up the free spaces between tapered roller bearngs wth BPW specal longlfe grease (ECO-L 91) and work them together. Observe the fnal grease quantty (table A) see page 25. Fgure 25 [6] Pull off the wheel hub wth brake drum, tapered roller bearng and sealng elements usng a sutable puller from the axle stub. [12] Smear the remanng quantty of grease nto the bearng outer rng of the hub. The wheel hub unt must be secured aganst fallng down. [13] Push up the pre-assembled wheel hub and brake drum unt centrcally. Push the sensor f avalable, back nto the correct poston by the wheel hub and brake drum unt carefully. Therefore wheel hub unt s not msalgned. Repar Gude Mark hubs and bearngs together so that they are not nterchanged durng assembly. It s mperatve that the bearng nner rngs wth rollers be reused on the same hubs. Fgure 23 Check the dsplacement of the sensor f avalable, before nstallng the wheel hub, see page 32. Fgure 26

13 Page 24 Page 25 9 Lubrcaton [14] Insert outer taper roller bearng [15] Insert the washer and screw on the axle nut usng a torque wrench to tghten the wheel hub wth the prescrbed tghtenng torque accordng to the table (several turns untl the tghtenng torque s reached). [16] Put the new retanng plate n place. Screw up the KM axle nut by hand untl t tghtens slghtly. A B Install the retanng plate wth the convex sde facng the axle center. Pay attenton to the correct nstallaton of the axle nut. Fgure 27 Type of bearng Wheel hub BPW Specal-Longlfe (ECO-LI 91) Grease quantty per tapered roller bearng Inner A Outer B GS g 60 g [17] Turn the nner KM axle nut back to the next possble groove for the lockng collar and bend the nose nto the groove of the axle nut, when the lockng collar s opposte the next groove (max. 30 ). [18] Tghten outer KM axle nut wth 150 Nm tghtenng torque. Bend the lockng collar nto the groove of the KM axle nut. [19] Refll the hub cap wth BPW specal longlfe grease (ECO-L 91) the grease quantty (table B), see page 25. The ar connecton should be free from grease. [20] Grease the thread of the hub cap all round wth the BPW specal longlfe grease (ECO-L 91) and tghten t to the prescrbed 500 Nm tghtenng torque. [21] Install the Central Tre Inflaton System. Fgure 28 Fgure GS g 60 g GS g 60 g GS 5506 GS g 60 g GS g 290 g wth KM axle nut wth KM axle nut GS 7006 GS 7008 GS GS GS GS GS GS GS GS GS GS g 180 g 90 g 200 g 100 g 290 g 100 g 350 g 130 g 320 g 130 g 370 g GS g 500 g Smear any resdual grease nto the bearng outer rng of the hub. Fll up the free spaces between tapered roller bearngs wth grease and work them together. The grease for the outsde tapered roller bearng s njected when the hub cap flled wth grease s screwed nto the bearng.

14 Page 26 Page Dsassemblng and assemblng the hub unt 10.1 Helcal studs Threaded studs 10.2 Dsassembly: [1] Drve out wheel studs from the dsmantled hub brake drum unt. (Do not damage the threaded studs, for ths reason use a bronze hammer) Installaton: [1] Place hub brake drum unt onto the wheel hub. The thread of the cap n the hub must not be damaged. Fgure 30 Dsassembly: [1] Turn over the dsmantled hub brake drum unt and lay t down wth the hub sde down. The thread of the cap n the hub must not be damaged [2] Remove the back nuts from the wheel studs on the drum sde. [3] Drve out wheel studs from the dsmantled hub brake drum unt and pull down the drum. (Do not damage the thread of the wheel studs; t s recommended to use a bronze hammer.) Fgure 33 [2] Insert the wheel bolts as far as possble nto the wheel hub by hand. Repar Gude Ensure correct seatng of the wheel stud head on the brake drum (arrow). The flattened sde of the head of the wheel bolt must rest on the brake drum collar (ant-rotaton soluton). Assembly: [1] Insert the wheel bolts nto the hub n accordance wth the notch pn and press each of them untl t stops, at the correct poston. [2] Turn over the wheel hub wth the wheel bolts and place the brake drum onto them. Ensure that contact surfaces are clean and parts are properly adjusted and centered. Fgure 31 Fgure 34 [3] Turn wheel studs untl contact wth the flange. Repar Gude The hub, whch s equpped wth flange, has to be nstalled agan [3] Screw n the back nuts and tghten wth the prescrbed tghtenng torque. Tghtenng torque: (Strength class 10) M 20 x 1,5 M 22 x 2 M 22 x 1,5 300 Nm (290 Nm Nm) 400 Nm (390 Nm Nm) 400 Nm (390 Nm Nm) Mount hub brake drums unt and adjust the hub bearng play. See pages Fgure 32 Fgure 35

15 Page 28 Page Dsassembly of the bearng cone Sealng components 10.4 Dsassembly: [1] Remove the bearng cups together wth the cover plate (grease plate) from the wheel hub. Protect the bearng seat from damage. at every brake lnng replacement, latest annually Dsassembly: [1] FL brake / Fg. 39: remove thrust washer (1) and sealng rngs (2,3), N brake / Fg. 40: pull down thrust washer (1) and sealng rng (2) from the axle stub. FL brakes N brake / Fg. 41: remove the shaft seal (1) from the axle stub Fgure 36 [2] Clean the sealng elements thoroughly (desel ol) and check for re-usablty, replace f necessary. Fgure 39 Assembly: Assembly: [1] Clean the bearng seats thoroughly. [2] Insert the new cover plate (grease pot) wth the convex sde facng down. [1] Clean the bearng seats of the axle stub (t must be metallc brght, dry and free from grease) and grease all over wth BPW specal longlfe grease (ECO-L 91). N brakes Do not over-grease Make sure that the sealng elements can be pushed up easly on the axle stub. [2] FL brake / Fg. 39: push thrust washer (1) and sealng rngs (2,3) onto axle stub. 1 2 Fgure 37 N brake / Fg. 40: push the thrust rng (1) and the sealng rng (2) onto the axle stub. Fgure 40 [3] Insert new bearng cups centered n the wheel hub and mount wth a press (at least 6 t) and the BPW press tools, see page 11. N brake / Fg. 41: nsert the shaft seal (1) wth the closed sde pontng towards the center of the axle untl t contacts wth the axle stub collar. N brakes Observe the correct poston of the bearng cups n the wheel hub. Fgure 38 There are also customzed seals used n the partcular condtons of use on the BPW axle. These have specal characterstcs. Please contact your busness partner or the vehcle manufacturer for mantenance nstructons regardng these washers. Fgure 40 Fgure 41 1

16 Page 30 Page ABS 11.1 ABS-components Sensor ar gap 11.2 In an ant-lock brakng system (ABS), the rotatonal movement s detected wthout contact by a excter rng secured to the hub and a pulse generatng sensor (speed sensor). Item Desgnaton 1 O-Rng 2 Clamp (clp for weldng studs) 3 Half rounded grooved pn 4 Fastenng (for grooved pn) 5 ABS Sensor (corner-desgn) BPW No.: Clampng bush 7 Sensor bracket (left/rght) 8 Bracket 9 Lockng screw 10 Serrated lock washer 11 Bracket 12 Lockng screw ABS-Sensor The ABS sensor ar gap s the gap between the excter rng and the sensor. The larger ar gap causes a smaller sensor sgnal. The sensor s nstalled n conjuncton wth a specal clampng sleeve and pressed to the pole wheel. Later on, durng operaton, the system automatcally adjusts the ABS sensor ar gap between the pole wheel and the sensor. Standard-holder for sensor Rgd axle Steerng axle Item Desgnaton 1 Clamp (clp for weldng studs) 2 Half rounded grooved pn 3 Fastenng (for grooved pn) 4 O-Rng 5 ABS Sensor (straght-desgn) BPW No.: Clampng bush 7 Bracket 8 Lockng screw 9 Serrated lock washer 10 Bracket 11 Screw 12 Lock washer 13 Sensor bracket Item Desgnaton 1 Clamp (clp for weldng studs) 2 Half rounded grooved pn 3 Fastenng (for grooved pn) 4 O-Rng 5 Speed and drecton sensor BPW No.: Clampng bush 7 Sensor bracket (welded 7a) 8 Lockng screw 9 Serrated lock washer 10 Bracket 11 Lockng screw a

17 Page Installaton of the excter rng Check the sensor for damage and dsplacement. (Dsplacement force N). The damaged sensor must be replaced. Dsassembly: [1] To replace a damaged excter rng, heat up the excter rng wth burner flame and pull t down. [2] Clean the contact surfaces of the hub (t must be free of drt, pant etc.) [3] Heat the new excter rng to a temperature of between 120 and 160 C and push the excter rng onto the undamaged hub surface. Unscrew the cover plate and the plug connecton screws, remove the sensor cable from the sealng rng, push the sensor and the clamp aganst ncorporaton of drecton. See Fg. 42. Fgure 42 Fgure 45 Repar Gude Assembly: [1] Page 33 Installaton of ABS sensors [1] Clean the sensor holder, replace the clamp and push t nto ts place, smear the socket wth specal slcone grease and slde the sensor to ts place, nsert the sensor cable nto the sealng rng. Mount the cover plate and the plug connector holder. max. 0,2 mm Do not apply mpact tools onto the gear teeth The gear teeth must not show any sgns of damage. See Fg. 43. Press-ftted sheet metal pole wheels If requred, press-ftted sheet metal excter rngs are replaced by sold metal excter rngs. Repar Gude The tght ft of the excter rng s very mportant for proper operaton. Maxmum tolerance s 0.2 mm Check the coverng plate for correct seatng on the brake drum. Tghten the screws wth a torque accordng to the table. Do not bend or pnch the connectng cable If replacement s requred. See table below. Fgure 43 ID number s located on the component sde engraved. Fgure 46 Tghtenng torques for sensor bracket: Screw sze Tghtenng torque M6 8 Nm M8 20 Nm M10 38 Nm Lockng screw M10 Sheet metal excter rng (default excter rng) Sold excter rng (replacement excter rng) /Ø152/ /Ø176/ Nm Repar Gude Mountng the sensor plug-n The connecton of the ABS cable (sensor cable cable for control unt) s the same as n a normal socket by smply pluggng the plug nto the brake carrer or n dust cover support. Ø Fgure 44 After the replacement of the sensor or the excter rng the operaton must be tested Durng the testng of the ABS unt, t must be ensured that the nstalled parts provde approprate nformaton durng the operaton of the vehcle Fgure

18 Page 34 Page 35 Notce Notce

19 BPW s a globally leadng manufacturer of ntellgent runnng gear systems for tralers and sem-tralers. As an nternatonal moblty and system partner, we offer a wde range of solutons for the transport ndustry from a sngle source, from axle to suspenson and brake to user-frendly telematcs applcatons. We thereby ensure outstandng transparency n loadng and transport processes and facltate effcent fleet management. Today, the well-establshed brand represents an nternatonal corporaton wth a wde product and servce portfolo for the commercal vehcle ndustry. Offerng runnng gear systems, telematcs, lghtng systems, composte solutons and traler superstructures, BPW s the rght system partner for automotve manufacturers. BPW, the owner-operated company, consstently pursues one target: To always gve you exactly the soluton whch wll pay off. To ths end, we focus our attenton on uncompromsng qualty for hgh relablty and servce lfe, weght and tme-savng concepts for low operatng and mantenance costs as well as personal customer servce and a close-knt servce network for quck and drect support. You can be sure that wth your nternatonal moblty partner BPW, you always use the most effcent method. Your partner on the path to economc vablty BPW Bergsche Achsen Kommandtgesellschaft Postbox Wehl, Germany Phone +49 (0) nfo@bpw.de