Maintenance and service instructions for BPW chassis Chassis-englisc… · Maintenance and service...
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Maintenance and service instructions for BPW chassis ZAF-1 ZAF-2 Drawbar force Pull rod (thrust force) Brake lever Brake lever Tensile force Wheel brake DIRECTION OF TRAVEL Ø 48 mm 10,5 mm 105 mm Check wheel bolts for firm seating – after each wheel change – Tighten wheel bolts crosswise using a torque wrench to the tightening torque for wheel bolts 8.8 (spanner widths 19) M 12 x 1,5 M = 92 Nm ± 10% Refer to BPW and manufacturers handbook for correct torque! Heavy duty cranked support Cranked support Locking nuts Locking nuts Locking nuts Linkage rod Linkage rod Brake compensator Brake compensator Brake compensator Brake compensator SL-Lock SL-Lock SL-Lock Turn buckle Turn buckle Turn buckle Adjustment nut Adjustment nut Adjustment nut Remove the transport cover Lift off the upper cable hose support Insert the brake cable with its nipple into the expander lock tension bolt. Replace the cable hose support. Slide on the cable sleeve. Wheel stud Wheel stud Roller bearing Roller bearing Seal Roller bearing Locking ring Lock nut Lock nut Split pin Cap Cap Drum hub Drum hub Cable guide Plug Circlip Return spring Brake plate Reversing cam Bolt Expander Return spring Retaining pin Retaining clip Brake shoe kit Screw Adjusting nut Spring clip Cable link Adjusting bolt 1600 kg axle Check brake lining wear - every 5000 kilometres - The brake lining wear is dependent on the style of driving. Careful driving saves brake linings and tyres. As soon as a brake lining has been worn to a thickness of 2 mm, the brake shoe must be replaced. Stiff or stretched brake springs, the coils of which are no longer closed tightly together, must also be replaced. For visual check remove the plug (arrow) from the brake plate. Replacement brake pad assemblies must be replaced as a set for the individual axles. Readjustment of the brake system - every 2000 - 3000 kilometers of travel - Jack up the trailer. Release the towing equipment and handbrake lever and brake linkage (free from tension). Lock the reversing cam of the wheel brake from the outside by means of a locking pin (item A, pin Ø 4 mm) through the backplate. Tighten the adjustment nut on the wheel brake with a spanner turn hex adjuster until the wheel will not rotate in the direction of travel. Centre the brake shoes by applying the parking brake several times. Turn back the adjustment bolt by approx. one turn, until no braking effectcan be felt when the wheel is turned in a forward direction. With parking brake activated check equaliser bar is at right angles to brake rod. It may be necessary to readjust the brakes or adjust length of brake cables (screw clevis in/out as required). Remove 4 mm locking pin from reversing cam. To test, partially apply parking brake and check for similar brake torque on all wheels (in forward direction of travel). Brake Linkage (see fig. E) With the parking brake off and all brakes correctly set, readjust brake rod length with turnbuckle nut or equaliser until there is neither free play or tension. If necessary, adjust the nut of the brake cables. Tighten all lock nuts after adjustment. Note: Excessive travel on the handbrake lever or failure of the handbrake to operate properly may be due to brake wear or a poorly adjusted linkage. EXPLODED VIEW - Wheel brake FUNCTIONAL CHARACTERISTICS - Overrun brake systems MAINTENANCE WORK OF THE BRAKE SYSTEM WHEEL STUD EXPLODED VIEW - Overrun hitch INSTALLATION - Brake cable BRAKE LINKAGE - Single axle CORNER STEADIES JOCKEY WHEEL CLAMPING BPW Bergische Achsen Kommanditgesellschaft, P.O. Box 12 80, D51656 Wiehl, Phone +49 2262 780, [email protected], www.bpw.de TYPE PLATE - Axle TYPE PLATE - Overrun hitch / tow system A B A loose fixed B left and right wheel side BOLTED JOINT Chassis rail / Axle flanges BOLTED JOINT Angle flange / Drawbar BOLTED JOINT Drawbar / Chassis rail B A C D F H I K J E M L RUNNING WELL FOR YOU. BPW BERGISCHE ACHSEN Lmin = 237 Lmax = 337 max. 65° BPW order no. 05.803.00.60.0 05.803.00.61.0 05.803.00.63.0 Identification red blue black Weight ranges (Axle load) 550 - 1050 kg 1050 - 1350 kg 1350 - 1800 kg SHOCK ABSORBERS G MAINTENANCE SCHEDULE - Axle Lubrication and maintenance work initially every 2,000 - 3,000 kilometres or annually every 5,000 kilometres or annually every 10,000 kilometres or every 2 years In case of torsion bar axles: lubricate the trailing arm bearing via the grease nipple. Check wheel bolts for firm seating Check brake play, if necessary, readjust Check hub caps for firm seating Check tyres for uneven wear Check brake lining wear Check bearing end float, replace bearing if necessary. 1 2 2 3 - 4 5 MAINTENANCE SCHEDULE - Drawbar Lubricate initially ZAF-1 every 2,000 - 3,000 kilometres or annually ZAF-1 every 5,000 kilometres or annually ZAF-2 every 10,000 -12,000 kilometres or annually Drawbar bearings at the housing of the overrun hitch Oil or grease brake lever Grease sliding points on the height-adjusting device Maintenance work Check coupling head Check all movabel parts for ease of movement. Check safety cable for damage 2 1 2 3 1 3 1 1 2 2 3 3 1 2 Chassis specifications may vary according to market requirements. BPW’s policy of continuously improving their product may involve major or minor changes on the chassis or accessories. The manufacturer reserves the right to alter specification, with or without prior notice, at any time. Refer to BPW maintenance and operating instructions 5 1) 1) 1600 kg axle BRAKE LINKAGE - Tandem axle ZAF-1 ZAF-2 1 2) and after 500 kilometres 2) 3 1 2 BPW-PW-Caravan 05/1e
Transcript of Maintenance and service instructions for BPW chassis Chassis-englisc… · Maintenance and service...
MMaaiinntteennaannccee aanndd sseerrvviiccee iinnssttrruuccttiioonnss ffoorr BBPPWW cchhaassssiiss
ZAF-1 ZAF-2
Drawbar forcePull rod (thrust force)
Brake lever Brake lever
Tensile force
Wheel brake
DIRECTION OF TRAVEL
Ø 48 mm
10,5
mm
105 mm
CChheecckk wwhheeeell bboollttss ffoorr ffiirrmm sseeaattiinngg– after each wheel change –
Tighten wheel bolts crosswise using atorque wrench to the tightening torque forwheel bolts 8.8 (spanner widths 19)
M 12 x 1,5 M = 92 Nm ± 10%
Refer to BPW and manufacturershandbook for correct torque!
Heavy dutycranked support
Cranked support
Locking nuts
Locking nutsLocking nuts
Linkage rod
Linkage rod
Brakecompensator
Brakecompensator
Brakecompensator
Brakecompensator
SL-Lock
SL-Lock
SL-Lock
Turn buckle
Turn buckleTurn buckle
Adjustment nut
Adjustment nut
Adjustment nut
Remove the transportcover
Lift off the upper cablehose support
Insert the brake cable withits nipple into the expanderlock tension bolt.Replace the cable hosesupport.Slide on the cable sleeve.
Wheel stud Wheel stud
Roller bearing
Roller bearing
Seal
Roller bearing
Locking ring
Lock nut
Lock nutSplit pin
Cap
Cap
Drum hub Drum hub
Cable guidePlug
Circlip
Return spring
Brake plate
Reversing cam
BoltExpander
Return spring
Retaining pin
Retaining clip
Brake shoe kit
Screw
Adjusting nut
Spring clip
Cable link
Adjusting bolt
1600 kg axle
Check brake lining wear- every 5000 kilometres -The brake lining wear is dependent on thestyle of driving. Careful driving saves brakelinings and tyres. As soon as a brake lininghas been worn to a thickness of 2 mm, the brake shoe must be replaced. Stiff orstretched brake springs, the coils of whichare no longer closed tightly together, mustalso be replaced. For visual check remove the plug (arrow) from the brake plate. RReeppllaacceemmeenntt bbrraakkee ppaadd aasssseemmbblliieess mmuusstt bbee rreeppllaacceedd aass aa sseett ffoorr tthhee iinnddiivviidduuaall aaxxlleess..
Re�adjustment of the brake system- every 2000 - 3000 kilometers of travel -
Jack up the trailer. Release the towingequipment and handbrake lever and brakelinkage (free from tension).
Lock the reversing cam of the wheel brakefrom the outside by means of a locking pin(item A, pin Ø 4 mm) through the backplate.
Tighten the adjustment nut on the wheel brake with a spanner turn hex adjuster until the wheel will not rotate in the direction of travel.Centre the brake shoes by applying theparking brake several times.
Turn back the adjustment bolt by approx.one turn, until no braking effectcan be feltwhen the wheel is turned in a forwarddirection.
With parking brake activated check equaliser bar is at right angles to brakerod. It may be necessary to readjust thebrakes or adjust length of brake cables(screw clevis in/out as required).
Remove 4 mm locking pin from reversing cam.
To test, partially apply parking brake andcheck for similar brake torque on all wheels (in forward direction of travel).
BBrraakkee LLiinnkkaaggee ((sseeee ffiigg.. EE))With the parking brake off and all brakes correctly set, readjust brake rod length with turnbuckle nut or equaliser until there is neither free play or tension. If necessary, adjust the nut of the brake cables. Tightenall lock nuts after adjustment.
Note: Excessive travel on the handbrake lever or failure of the handbraketo operate properly may be due to brake wear or a poorly adjusted linkage.
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MMAAIINNTTEENNAANNCCEE WWOORRKK OOFF TTHHEE BBRRAAKKEE SSYYSSTTEEMM
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BBRRAAKKEE LLIINNKKAAGGEE -- SSiinnggllee aaxxlleeCCOORRNNEERR SSTTEEAADDIIEESS JJOOCCKKEEYY WWHHEEEELLCCLLAAMMPPIINNGG
BPW Bergische Achsen Kommanditgesellschaft, P.O. Box 12 80, D�51656 Wiehl, Phone +49 2262 78�0, [email protected], www.bpw.de
TTYYPPEE PPLLAATTEE -- AAxxllee
TTYYPPEE PPLLAATTEE -- OOvveerrrruunn hhiittcchh // ttooww ssyysstteemm
A
B
A
loose
fixed
B
left and rightwheel side
BBOOLLTTEEDD JJOOIINNTT CChhaassssiiss rraaiill // AAxxllee ffllaannggeessBBOOLLTTEEDD JJOOIINNTT AAnnggllee ffllaannggee // DDrraawwbbaarr BBOOLLTTEEDD JJOOIINNTT DDrraawwbbaarr // CChhaassssiiss rraaiill
BA C DF
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M
L
RUNNING WELL FOR YOU. BPW BERGISCHE ACHSEN
Lmin=
237
Lmax =337
max. 65° BPWorder no.
05.803.00.60.005.803.00.61.005.803.00.63.0
Identification
redblueblack
Weight ranges(Axle load)
550 - 1050 kg1050 - 1350 kg1350 - 1800 kg
SSHHOOCCKK AABBSSOORRBBEERRSS
G
MMAAIINNTTEENNAANNCCEE SSCCHHEEDDUULLEE -- AAxxllee
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In case of torsion bar axles: lubricate thetrailing arm bearing via the grease nipple.Check wheel bolts for firm seating
Check brake play, if necessary, readjust
Check hub caps for firm seating
Check tyres for uneven wear
Check brake lining wearCheck bearing end float, replace bearing ifnecessary.
1
2 2
3
-
4
5
MMAAIINNTTEENNAANNCCEE SSCCHHEEDDUULLEE -- DDrraawwbbaarr
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Drawbar bearings at the housing of theoverrun hitchOil or grease brake leverGrease sliding points on the height-adjustingdeviceMMaaiinntteennaannccee wwoorrkk
Check coupling head
Check all movabel parts for ease of movement.
Check safety cable for damage
2
1
2
3
1
3
1 1
2 2
33
1
2
Chassis specifications may vary according to market requirements. BPW’s policy of continuously improving their product may involve major or minor changes on the chassis or accessories. The manufacturer reservesthe right to alter specification, with or without prior notice, at any time.
Refer to BPW maintenance and operating instructions
51)
1) 1600 kg axle
BBRRAAKKEE LLIINNKKAAGGEE -- TTaannddeemm aaxxllee
ZZAAFF--11 ZZAAFF--22
1
2) and after 500 kilometres
2)
3
1
2
BPW-PW-Caravan 05/1e
