BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3 …bpwtranspec.com.au/wp-content/uploads/2013/06/BPW_Transpec_Spa… · BPW Transpec Knorr Disc Brake Range 4 Exploded view of

BPW TRANSPEC KNORR DISC BRAKE SKH… SH… AXLES ECO & ECOPlus

SPARE PARTS CATALOGUE FOR AUSTRALIAN ASSEMBLED DISC BRAKE AXLES

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013 2

TABLE OF CONTENTS

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

CONTENTS PAGE

Axle Part Number Legend for Australian Assembled BPW Axles 3

BPW Transpec Knorr Disc Brake Range 4

Exploded view of rigid Knorr Disc Brake Axle 4

Knorr Disc Brake Identification 6 - 8

6

6

7

7

8

Knorr Replacement Calipers 9

Knorr SB3745 Disc Brake Components 10 - 11

Knorr SB3745T/SB4309T Disc Brake Components 12 - 13

Knorr Disc Brake Covers and Brake Pad Protectors 14

Knorr Disc and Brake Pad Wear Status 15

BPW Brake Monitor 16 - 17

BPW ECO Hub Components 18 - 19

BPW ECO Plus Hub Components 20 - 21

BPW ECO Plus Hub General Information 22

BPW ECO-Li Plus Grease, Grease Filling and Grease Shower Tools 23

ABS Components 24 - 25

BPW Hubcaps with Integrated Hubodometer 26– 27

26

27

Knorr Disc Brake Tools 28 - 29

Knorr Disc Brake Sizes

Caliper Types A, B and C

Caliper Mounting

Left and Right Handed Calipers

Caliper Type Plate and Operating Function

Non Digital

Digital

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.


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

AXLE PART NUMBER LEGEND For Australian Assembled BPW Axles


Axle Code Date Range Axle Type Brake Size Page No

SH9010 Up to Feb 2004 9 tonne ECO SB3745 4 to 5

SKH9008

SKH9008 Feb 2004 to Aug 2008 9 Tonne ECOPlus

SB3745T suit 19.5" tyres 8 to 9

SH9010 SB4309T suit 20" tyres

SH10110 From Aug 2008 10 tonne ECOPlus

SB4309T suit 20" tyres 8 to 9

SKH10108 SB3745T suit 19.5" tyres

Axle Type Rotor Diameter

SK…… 377 mm

SH…… 430 mm

DISC PROTECTORS Pg 14

HUBS COMPONENTS ECO Hub Pg 18 - 19

ECO Plus Hub Pg 20 - 21

BRAKE PARTS For SB3745 Pg 10 - 11

For SB3745T/SB4309T Pg 12 - 13

ABS PARTS Pg 24 - 25

WHEEL NUTS & STUDS For SB3745 Pg 10 - 11

For SB3745T/SB4309T Pg 12 - 13

BPW TRANSPEC KNORR DISC BRAKE RANGE

EXPLODED VIEW OF A KNORR DISC BRAKE AXLE


BPW TRANSPEC DISC BRAKE IDENTIFICATION

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 KNORR 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

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

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 Knorr Bremse caliper what is the brake size? Is the rotor 370mm in diameter or 430mm

in diameter? 3. Is the Knorr disc brake caliper type A, B or C? 4. Is the Knorr disc brake caliper left handed or right handed? Is the suspension underslung or overslung? 5. Is the caliper mounted axially or tangentially? Pages 5 to 8 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


Steel cap with o ring from

mid 2000. Bellow with hose clip up to

mid 2000. Two part housing

Type A - 8mm hex adjustment screw with flat plastic cover.

Type B - 10mm hex sacrificial adjuster screw with domed rubber

cover.

One part housing

Flat steel cover

10 mm hex sacrificial adjuster screw with domed rubber

cover

There have been changes to Knorr disc brake calipers since being introduced in 2000. Some of the service components are different between the different models. We classify these different models as Type A, Type B and Type C. Following is how to identify these models:

KNORR DISC BRAKE IDENTIFICATION

Type A

8mm adjuster screw

Flat plastic adjuster screw cover Divided housing

10mm adjuster screw

Domed rubber adjuster screw cover Divided housing

Type B

CALIPER TYPE (A, B AND C)

Type C

Domed rubber adjuster screw cover One part (monoblock) housing

SB3745 SB = Disc Brake 37 = Disc Ø 377 mm 45 = Disc thickness 45 mm = Axially mounted caliper

SB3745T SB = Disc Brake 37 = Disc Ø 370 mm 45 = Disc thickness 45 mm T = Tangentially mounted caliper

SB4309T SB = Disc Brake 43 = Ø 430 mm 09 = Standard axle load 9t T = Tangentially mounted caliper

BRAKE SIZES

IDENTIFYING FEATURES OF CALIPER TYPE C :

IDENTIFYING FEATURES OF CALIPER TYPES A AND B:


KNORR DISC BRAKE IDENTIFICATION

Brake Type SB 3745 Caliper bolts are bolted in line with the axle beam.

Axially Mounted Calipers:

Right Hand Caliper = Adjuster screw is on the opposite side of the caliper from the fixed guide pin.

Left Hand Caliper = Adjuster screw is adjacent to the fixed guide pin.

Please Note: For underslung suspensions the right hand caliper is used on the left hand side of the axle and the left hand caliper is used on the right hand side of the axle. When identifying right or left handed calipers you must know whether the suspension is underslung or overslung. Overslung = suspension springs over axle Underslung = suspension springs under axle

Brake TypeSB 3745T/4309T Tangential Mounting: Caliper bolts are bolted at an angle to the axle beam.

Tangentially Mounted Calipers:

CALIPER MOUNTING

LEFT AND RIGHT HANDED CALIPERS


KNORR DISC BRAKE CALIPER TYPE PLATE AND OPERATION FUNCTION

KNORR-BREMSE

SN7174 K009282

05.362.70.64.3

A 05373 ......

DayWeekYear

Production no.

BPW Code no.

KNORR Code no.

Type plate

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

(1) Push rod

(2) Lever

(3) Roller

(4) Bridge

(5) Threaded tubes

with tappets (6) Brake pads

(7) Brake disc

(8) Brake caliper

When the brake pedal is pressed, the push rod (1) of the brake cylinder presses against the lever (2) of the brake caliper. The roller (3) mounted eccentrically in the brake transfers the force onto the bridge (4). The clamping force acts on the internal brake pad (6) via the threaded tubes and the tappets (5). As a result, the brake pad (6) is forced against the brake disc (7). The reaction force which now arises on the caliper (8) is trans-ferred to the opposite brake pad by means of the sliding cali-per, so that the opposite pad (6) is also pressed against the brake disc with the same force. When the brake pressure is reduced, the spring force returns the bridge (4), the threaded tubes (5) and lever (2) to their original position.

OPERATING FUNCTION OF KNORR DISC BRAKES


KNORR REPLACEMENT CALIPERS

Important note: Rationalised calipers can be fitted to existing caliper carriers provided that these are not worn or broken.

RATIONALISED CALIPERS NOT INCLUDING CALIPER CARRIERS

Tangentially mounted caliper carrier Part numbers: 0330388550 Suits SB3745T Disc Brake (Ø 370 mm Rotor) 0330388560 Suits SB4309T Disc Brake (Ø 430 mm Rotor)

Axially mounted caliper carrier Suits SB3745 Disc Brake (Ø 370 mm Rotor) Part number: 0203131300

To suit SB3745 & SB3745T Disc Brake (Ø 370 mm Rotor) Caliper part numbers: 0536270600RAT - Right Hand Caliper 0536270610RAT - Left Hand Caliper To suit SB4309T Disc Brake (Ø 430 mm Rotor) Caliper part numbers: 0536270620RAT - Right Hand Caliper 0536270630RAT - Left Hand Caliper

CALIPERS COMPLETE WITH CALIPER CARRIERS

AXIALLY MOUNTED CALIPERS With caliper mounting bolts parallel with the axle

TANGENTIALLY MOUNTED CALIPERS With caliper mounting bolts at an angle to the axle

Caliper to be replaced Can be replaced with Caliper Carrier if required

(see note above)

0536270360 0536270600RAT 0203131300

0536270370 0536270610RAT 0203131300

0536270600 0536270600RAT 0330388550

0536270610 0536270610RAT 0330388550

0536270620 0536270620RAT 0330388560

CALIPER REPLACEMENT ALTERNATIVES

0536270630 0536270630RAT 0330388560

To suit SB3745 Disc Brake (Ø 370 mm Rotor) Caliper part numbers: 0536270360 - Right Hand Caliper 0536270370 - Left Hand Caliper

To suit SB3745T Disc Brake (Ø 370 mm Rotor) Caliper part numbers: 0536270600 - Right Hand Caliper 0536270610 - Left Hand Caliper To suit SB4309T Disc Brake (Ø 430 mm Rotor) Caliper part numbers: 0536270620 - Right Hand Caliper 0536270630 - Left Hand Caliper

CALIPER CARRIERS


REPLACEMENT CALIPERS (Refer page 9)

Caliper Item No Caliper Description Caliper carrier Item No

0536270600RAT Rationalised Caliper Right Hand SB3745 0203131300

0536270610RAT Rationalised Caliper Left Hand SB3745

0536270360 Caliper Right Hand SB3745 Monoblock ABS (Complete with carrier)

0536270370 Caliper Left Hand SB3745 Monoblock ABS (Complete with carrier)

KNORR SB3745 DISC BRAKE COMPONENTS

ROTORS

Part No Part No Qty Per Axle

0308834070 Rotor 10 stud 285mm PCD 2

0308834060 Rotor 10 stud 335mm PCD 2

0308834150 Rotor 8 stud 275mm PCD 2

0308834040 Rotor 10 stud 335mm PCD (ABS mounting) 2

old executions

(Renolit HLT 2)

(Renolit HLT 2)

348

396

397

398

390

394

364

363

315 318

362

354

355

345

373

368370

395

350

346

373

346

348

369

328

335

337

326

325

345

336

335

325

326

328

20 / 21

• SB3745 Disc Brake (Ø 377mm Rotor)

• In axles assembled up to February 2004

• 9 tonne ECO Hub


CALIPER CARRIER ATTACHING PARTS

Item No Part No Description Dimension Qty Per

Axle

310A 0316434020TS Caliper Spacer ** 4

315 0250298720 Bolt (Torque 280-330Nm) M 16x1.5x60 10/4 *

0250298521 Bolt (Torque 280-3300Nm) M 16x1.5x65 10

0250298821 Bolt Steer Axle (Torque 280-330Nm) M 16x1.5x60 4

0250511021 Bolt Steer Axle (Torque 280-330Nm) 2

318 0254011608 Washer Ø 17 10

Washer 10

*10 screws for non-steer axle, 4 screws for steer axle

** Caliper spacer item number 310A used on 10 stud 335 PCD and 8 stud 275 PCD models

BRAKE PARTS

Item No Part No Description Qty Per

Axle

Kits

0980106310 Guide pins and seal kit suits Caliper type A * See note below (Includes items 325 - 328, 335, 36, 345 - 348, 354, 355, 373)

2

0980106240 Guide pins and seal kit suits Caliper type B * See note below (Includes items 325 - 328, 335, 336, 345 - 348, 354, 355, 373)

2

0980106330 Guide pins and seal kit suits Caliper type C (Includes items 325 - 328, 345 - 348, 350, 352, 373)

2

0980102970 Main pin kit suits Caliper type A and B (Includes items 325 - 328, 335 - 337, 354, 355, 369, 373)

2

0980102630 Thrust pad and boot kit suits Caliper type A and B (Includes items 362 - 364)

2

0980106320 Thrust pad and boot kit suits Caliper type C (Includes items 362 - 364)

2

0980106250 Adjuster adaptor and cap kit (Includes items 368 and 370) ** See note below

2

0980107240 Brake Pad Kit *** See note below (Includes items 368, 369, 370, 390, 394, 396, 397, 398)

1

368 0224001100 Adjuster adaptor suits Caliper type B and C 2

369 0218270400 Cap, adjuster adaptor suits Caliper type A 2

KNORR SB3745 Disc Brake Components

** 0980106250 Adjuster adaptor and cap kit includes: 1 x item 370 rubber cap with 35mm diameter 1 x item 370 rubber cap with 38mm diameter

* Repair Kits differ in the design of the guide sleeve:

Guide sleeve for Caliper Type A Stop Ring ∅ = 35 mm

Guide sleeve for Caliper Type B & C Stop Ring ∅ = 39 mm

*** Disc Brake Pads: Are not available individually and can only be supplied in a kit which repairs one axle. The part number for the individual pads are found on the brake pad backing plate. Single disc brake pad part number 0509290050 to suit SB3745 can only be supplied in kit part number 0980107240.


• SB3745T (Ø 370mm Rotor) & 4309T ( Ø 430mm Rotor)

• 9 tonne ECOPlus Hub in axles assembled from February 2004 to August 2008

• 10 tonne ECOPlus Hub in axles assembled from August 2008

KNORR SB3745T/SB4309T Disc Brake Components

(Renolit HLT 2)

(Renolit HLT 2)

348

396

397

398

390

394

364

363

362

354

355

345

373

368370

395

350

346

373

328

335

326

325

318

31520 / 21

REPLACEMENT CALIPERS (Refer page 9)

Caliper Item No Caliper Description Caliper carrier Item No

0536270600RAT Rationalised Caliper Right Hand SB3745 033088550

0536270610RAT Rationalised Caliper Left Hand SB3745

0536270600 Caliper Right Hand SB3745T Monoblock (Complete with carrier)

0536270610 Caliper Left Hand SB3745T Monoblock (Complete with carrier)

0536270620RAT Caliper Right Hand SB4309T Monoblock 033088560

0536270630RAT Caliper Left Hand SB4309T Monoblock

0536270620 Caliper Right Hand SB4309T Monoblock (Complete with carrier)

0536270630 Caliper Left Hand SB4309T Monoblock (Complete with carrier)

ROTORS

Part No Description Dimension Qty Per Axle

0308834010 Rotor 8 stud 275mm PCD SB3745T Ø 377mm 2




SB3745T SB4309T

Rotor Outer Diameter 377 mm Rotor Outer Diameter 430 mm

Item No Description Part No Dimension Part No Dimension Qty Per

Axle

315 Caliper mount bolt 0334012260 M16x1.5x97-12.9 0334012260 M16x1.5x97-12.9 8

318 Washer 0254011608 Ø 17mm 0254011608 Ø 17mm 8

CALIPER CARRIER ATTACHING PARTS

Item No Description Part No Part No Qty Per

Axle

Guide pins and seal kit 0980106330 2

Kits

(Includes items 325 - 355, 373)

Guide pins and seals Kit suits caliper item numbers

0980106330KB 2 0536270620RAT and 0536270630RAT

(Includes items 325 - 355, 373)

Loose bearing ("secondary guide pin") kit 0980106910

2

(Items 345, 346, 348, 350, 373)

Thrust pad and boot kit 0980106320

2

(Items 362 - 364, 373)

Adjuster adaptor and cap kit * See note below 0980106250

2

(Items 368, 370)

Brake Pad Kit Axle Set ** See note below 0980106430 0980106440 1

(Items 368 - 370, 390, 394, 396 - 398)

368 Adjuster adaptor 0224001100 2

BRAKE PARTS

* 0980106250 Adjuster adaptor and cap kit includes: 1 x item 370 rubber cap with 35mm diameter 1 x item 370 rubber cap with 38mm diameter 1 x item 368 adjuster adaptor

** Disc Brake Pads: Are not available individually and can only be supplied in a kit which repairs one axle. The part number for the individual pads is stamped on the brake pad backing plate. Single disc brake pad part number 0509290050 to suit SB3745T can only be supplied in kit part number 0980107240. Single disc brake pad part number 0509290060 to suit SB4309T can only be supplied in kit part number 0980107260.

KNORR SB3745T/SB4309T Disc Brake Components


KNORR DISC COVERS AND BRAKE PAD PROTECTORS

510

530

502501

530

510

502501

DISC COVERS AND BRAKE PAD PROTECTORS

Item Description Dimensions SB3745 (Axial)

SB3745T (Tangential)

SB4309T (Tangential)

Qty Per Axle

501 502

Rotor Shield SB3745 0301091530 0301091740 0301091760 2

510 Hex Bolt M10 x 15 0250712200 2 for Axial 4 for Tangential

Disc Covers and Brake Pad Protectors for Axially mounted calipers

Disc Covers and Brake Pad Protectors for Tangentially mounted calipers


BRAKE DISC AND BRAKE PAD WEAR STATUS

max. 0.75 x a

max.1.5 mm

a

A

D C

B

max. 1.5 mm

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

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 above 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

45 mm

37 mm

2 mm

11 mm

9 mm

30 mm


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).


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)


BPW ECO HUB Hub Components

420

424

421

441

446

460

440

445

438

448447

380

435

37

56 / 57

428

437

422

423

430

431

62 - 75

ECO

47078 - 81

Steel hubcap

M = 800 Nm

For Rotors refer to page 10

For ABS parts refer to pages 24 - 25

ECO Hub From 1992 to Present

• Oval hub cap

• Hub cap has inner thread

• Bearings, seal carrier and seals retained in hub by circlips


HUBS AND HUB COMPONENTS

Item No

Description Part No Qty Per

Axle

Kits Wheel Bearing and Seal Kit includes items 422 - 424, 428, 430, 431, 440, 441, 445, 447, 448 0980102720TS 2

Wheel Bearing and Seal Kit includes items 421 - 424, 428, 430, 431, 440, 441, 445, 447, 448 0980102720TSSC 2

435

Hub 8/275 alloy (suits press in stud) 0327228720 2

Hub 10/335 alloy (suits press in stud) 0327232040 2

Hub 10/335 steel (suits press in stud) 0327232060 2

Hub 8/275 steel (suits press in stud) 0327228750 2

Hub 10/285 steel (suits back nut stud) 0327228770 2

421 Seal Carrier 0337007600TS 2

422 Grease Seal 0256645700 2

423 Seal Runner 0256836200 2

424 O-Ring 0256779040 2

428 Dust Seal 0256819800 2

430 Roller Bearing 0264102400 2

431 Grease shield inner 0301093330 2

437 Circlip 0256064090 2

438 Circlip 0256061290 2

440 Grease Shield outer 0337025160 2

441 Roller Bearing 0264102500 2

445 Washer 0332073130 2

446 Axle nut 0326646020 2

447 Locking pin 0308471170 2

448 Locking ring 0318803060 2

460

Hub cap (steel, standard) 0321224250 2

Hub cap (steel, chrome) 0321224260 2

Hub cap (steel, for alloy hub) 0321225080 2

Hub cap (alloy, for alloy hub) 0321225270 2

Item No Description Part No Dimension Qty Per

Axle

470-479

Press in stud (Aluminium hub) 0329633161 M22 x 1.5 x 97 16/20**

Press in stud (Steel hub) 0329633121 M22 x 1.5 x 114 16/20**

Wheel stud back nut style (Steel wheels) 0329623170 M22 x 1.5 x 114 20

Wheel stud back nut style (Aluminium wheels) 0329623240 M22x 1.5 x 136 20

Back Nut 0326004060 20

Wheel nut sleeve type 0526054140 M22 x 1.5, 32mm OD sleeve 16/20*

Wheel nut 0526054100 m22 x 1.5 16/20*

** Qty 16 for 8 stud hub/20 for 10 stud hub

WHEEL STUDS AND NUTS

BPW ECO HUB Hub Components


9 tonne ECOPlus Hub in axles assembled from February 2004 to August 2008

10 tonne ECOPlus Hub in axles assembled from August 2008

BPW ECO Plus HUB Hub Components

470

ECOPlus

380

37

78 - 81

428

437

422

423

430

431

432

56062 - 75 435

56 / 57

440

441

445

446

438

448447

460

Steel hubcap

M = 800 Nm

470

ECOPlus

380

37

78 - 81

43556 / 57

440

441

445

446

438

448447

460

423

430

431

420

424

421

428

437

422

56062 - 75

ECO Plus Hub From 2005

• Oval hub cap

• Hub cap has inner thread

• Bearings, seal carrier and seals retained in hub by circlips

• Axle nut is torque limiting


For ABS parts refer to pages

24 - 25

430

431

432

For ABS parts refer to pages 24 - 25



Item No Description Part No Dimension Qty Per Axle

For 8 stud 275mm PCD and 10 stud 335 mm PCD - Push in Wheel Stud style

472 to 479

Wheel stud - push in 0329633121 M22x1.5x97 16/20**

Wheel nut - dual steel wheels 0526054100 M22x1.5 16/20**

Wheel nut - dual aluminium wheels 0526054140 M22x1.5/Ø32 sleeve 16/20**

For 10 stud 285 mm PCD - Back nut Wheel Stud style (SB4309T)

472 to 479

Wheel Stud - for dual steel wheels 0329623170 M22x1.5x114 20

Wheel Stud - for dual aluminium wheels 0329623240 M22x1.5x136 20

Back nut 0326004060 M22x2 20

Wheel nut 0526054100 M22x1.5 20

Peg 0260103560 Ø6x19.5 20

** Qty 16 for for 8 stud hub/ 20 per axle for 10 stud hub

WHEEL STUDS AND NUTS (To suit 9t and 10t)

HUBS AND HUB COMPONENTS

Item Description

TO SUIT 9 TONNE TO SUIT 10 TONNE

Part No Dimension Part No Dimension Qty Per Axle

Kits

Wheel Bearing and Seal Kit 0980106360TS 0980107040TS

2 (Includes items 422,428,430-432,440,441,447,448)

Wheel Bearing and Seal Kit 0980107040TSSC

(Includes items 422,424,428,430-432,440,441,445,447,448)

435

Hub 8 stud 275mm PCD 0327246282 0327246340

2 Hub 10 stud 285mm PCD 0327247352 0327247380

Hub 10 stud 335mm PCD 0327243192 0327243262

420 421

Seal Carrier 0337007720 Ø96/117.5/132x22 2

422 Hub seal 0256647400 Ø 120/157.5x20 0256647400 Ø20/157.5x20 2

423 Seal Runner 0256838000 2

424 O Ring 0256780000 Ø100x3 2

428 Dust Seal 0312048150 Ø122/160x8.7 0312048150 Ø122/160x8.7 2

430 Roller Bearing Inner 0264102300 0264102300 2

431 Grease Shield Inner 0301093340 Ø94/149x8.5 0301093340 Ø94/149x8.5 2

432 Dust Seal 0312045150 Ø67/95x49.5 0312045160 Ø67/93x8.5 2

437 Circlip Inner 0256065890 0256065890 2

438 Circlip Outer 0256062290 0256062290 2

440 Thrust Washer 0337026240 Ø71/108x8 0337026240 Ø71/108x8 2

441 Roller Bearing Outer 0264102200 0264102200 2

445 Washer 0332064010 Ø53/76x5.8 0332064010 Ø53/76x5.8 2

446 Axle nut - Eco Plus 0526647060 M52x2/SW95 0526647060 M52x2/SW95 2

447 Locking wedge axle nut 0327700070 0327700070 2

448 Hooked ring spring - locking wedge 0318804100 Ø62x1.8 0318804100 Ø62x1.8 2

460 Hub cap 0321225310

M136x2.5/SW110 0321225310

M136x2.5/SW110 Hub cap, chrome 0321225310C 0321225310C

2

BPW ECO Plus HUB Hub Components


BPW ECO Plus HUB General Information

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-LI Plus GREASE, GREASE FILLING, GREASE SHOWER TOOLS

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 re-lubrication 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 re-lubrication periods.

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

Part Number Container Size

0210404500 400 gm cartridge

0210404700 5 kg container

0210404900-20 20 kg container

GREASE FILLING

ECO HUB ECO-LiPlus Grease quantity per taper roller bearing

Axle Load A =

Inner Bearing B =

Outer Bearing

6000 - 9000 kg 120 g 120 g

10000 - 12000 kg 170 g 120 g

1 2 A B

ECO HUB

1 2 A B

ECO Plus HUB

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

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


• SB3745

• ECO Hub

• 9 tonne

• SB3745T

• ECOPlus Hub

• 9 tonne and 10 tonne

• SB4309T

• ECOPlus Hub

• 9 tonne and 10 tonne

ABS COMPONENTS


Fig G Fig E Fig F

Fig D Fig A Fig B Fig C

*Please note: To determine which exciter ring is required you will need to know both the tyre size and the type of exciter ring. You can determine the type of exciter ring by referring to the figures above. The ABS Kits will only include the exciter ring that is relevant to the correct type and wheel size.

ABS PARTS

Item No Description Part Numbers Dimension

SB3745 & SB3745T SB4309T

ECO Hub ECOPlus Hub ECOPlus Hub

9 tonne 9 tonne 10 tonne 9 tonne 10 tonne

Axial Brake Tangential Tangential

Qty Qty Qty Qty Qty

Inc's all listed items

*See note above

ABS Kit for 19.5" wheels

0580173860 1

0580174090 1 1

0580173880 1

ABS Kit for 20" wheels

0580173870 1

0580174080 1

0580173840 1

510 Locking bolt 0250712200 M10 x 15 2 2 2 2 2

511 Locking bolt 0250712300 M8 x 20 2

541 Shaped plate 0316323040 2

542

Sensor bracket 0318912020 A 2

0318914610 B 2 2

Sensor bracket left hand 0318907580 C

2

Sensor bracket right hand 0318907590 2

551 Cylinder cap bolt 0250159480 M6 x 12 - 8.8 4

Locking screw 0250712300 M8 x 20 2

553 Spring washer 0256010690 A6 4

560

Exciter Ring - 80 teeth 0531007290 Ø105/152/156 x18 D 2

(For 19.5" wheels) 0331008530 Ø125/156 x 8.5 E 2

Exciter Ring - 100 teeth (For 20" wheels)

0531007300 Ø105/152/156 x18 D 2

0331008510 Ø125/156 x 8.5 E 2 2

0331009390 Ø177/215 x 22/5 x Ø6.5 F 2

0531008501 Ø150/176/180 x Ø19.5 F 2

561 Cylinder cap screw 0250154882 m6 x 30 10

563 Spring washer 0256010690 10

570 Sensor, straight 0233170700 L = 350 2 2 2 2

570 Sensor, angled 0233170500 L = 350 2

571 Bush 0203165900 2 2 2 2 2

585 Support 0318907350 Short - L 35 2 2 2 2 2

586 Support 0214211100 2 2 2 2 2

587 Serrated lock washer 0254141190 A 10.5 2 2 2 2 2

590 Heat protection plate 0316524640 2 2 2 2

Special silicone grease 0210401700 5gm 1 1 1 1 1

Fig

ABS COMPONENTS


BPW HUBCAPS With Integrated Non Digital Hubodometer

BPW HUBCAPS WITH INTERGRATED NON DIGITAL HUBODOMETER

Axle Load Axle Beam

Profile Hub Type

Hubcap Thread

Tyre Size Tyre Rolling

Circumference ± 2 % Part No

9 tonne SKH ECO M 125 x 2

11 R 22.5 3175 mm - 3220 mm 0521224490

315/70 R 22.5 3015 mm - 3134 mm 0521224330

255/70 R 22.5 2830mm - 2860 mm 0521224530

265/70 R 19.5 2620 mm - 2650 mm 0521224340

245/70 R 19.5 2560 mm 0521224440

9 & 10/12 tonne

SH/SKH ECOPlus M 136 x 2.5

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

265/70 R 19.5 2620 mm - 2650 mm 0521225380

12.00 R 22.5 3280 mm - 3310 mm 0521225470

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.


BPW HUBCAPS With Integrated 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.

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).

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


Details on the correct use of the tools can be found in the respective workshop manuals.

KNORR DISC BRAKE TOOLS


KNORR DISC BRAKE TOOLS

0201304200 0201309300 0201206200 0201306600 0201305700

0201306500

0201304000 0201306300 0201304100 0201305200

0201306400 0201305900 0201305800

TL-0044 TL-0045

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 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.

Tool Purpose Tool Name Caliper A & B Caliper C

Disassembling thrust pieces with bellows Tool Fork Thrust Pad 0201304200 0201304200

Fitting thrust pieces with bellows Tool Thrust Pad Boot 0201303900 0201306200

Pressing in inner secondary seal Tool Thrust Pad Seal 0201306600

Replacing brake caliper. Fitting fixed bearing cover cap Tool Slide Pin Cap 0201305700 0201306500

Inserting inner bellow, fixed bearing Tool Slide Pin Boot 0201304000 0201306300

Extracting and inserting brass bush, fixed bearing Tool Slide Pin Bush 0201304100 0201306400

Caulking brass bush Tool Caulking Slide Pin Bush 0201305200

Extracting and inserting bush, movable bearing Tool Second Slide Pin 0201305900 0201305900

Replacing brake caliper, fitting cover cap movable bearing Tool Punch Second Slide Pin 02010305800 0201305800

Assembly aid to fit calipers to axle brackets Caliper alignment bolt TL-0044

Assembly aid to fit calipers to axle brackets Caliper offset bolt TL-0045

SPECIAL TOOLS FOR KNORR DISC BRAKE CALIPERS


NOTES


NOTES

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

Documents

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3 …bpwtranspec.com.au/wp-content/uploads/2013/06/BPW_Transpec_Spa… · BPW Transpec Knorr Disc Brake Range 4 Exploded view of