BPW Original spare parts

BPW Disc brakes

BPW BERGISCHE ACHSEN

BPW Original spare parts

Series SH..; SK..; S..LL..
with ECO Disc Trailer disc brakes
SH
SK BPW ORIGINAL SPARE PARTS

S..LL
BPW Original spare parts O Series SKH.., SH.., S..LL

Contents Page
Explanation of BPW axle type codes 4
Explanation of BPW axle code numbers 4
BPW type plate 5
1 Axle beams, steering axle beams 6 - 9
1.1 Axle beams, steering axle beams, view
1.2 Axle beams, steering axle beams, steering pivots, steering pivot bearing 8 / 9
2 Steering rods, steering rod attachments, steering lock 10 - 15
2.1 Steering axle, steering lock, view 10 / 11
2.2 Steering rods 12 / 13
2.3 Steering rod attachments, steering lock 14 / 15
3 Brake parts BPW ECO Disc 16 - 33
3.1 Brake parts BPW ECO Disc TSB 3709 / 4309 / 4312, view 16 - 19
3.2 Brake parts BPW ECO Disc TSB 3709 / 4309 / 4312 20 - 23
3.3 Brake discs, view 24
3.4 Brake discs 25
3.5 Disc protectors, brake pad slot protector 26 / 27
3.6 Brake cylinders, view 28 / 29
3.7 Brake cylinders 30 / 31
3.8 BPW Brake Monitor, view 32
3.9 BPW Brake Monitor 33
4 Hub bearings, hub seals 34 - 43
4.1 Hub bearings, hub seals, view 34 - 37
4.2 Hub bearing, ECO Plus 2 38
4.3 Hub bearing, ECOPlus 39
4.4 Hubs, ECO Plus 2, ECOPlus 40
4.5 Grease sprays for greasing taper roller bearings 41
4.6 Grease filling, bearing adjustment, ECO Plus 2 42
4.7 Grease filling, bearing adjustment, ECOPlus 43
5 ABS 44 - 50
5.1 ABS, view 44 / 45
5.2 ABS parts TSB 3709 / 4309 / 4312 - Rigid axles 46 / 47
5.3 ABS parts TSB 3709 / 4309 - Steering axles 48 / 49
5.4 ABS retrofit part sets 50
6 Wheel studs 52 - 55
6,1 Wheel studs, view 52 / 53
6.2 Wheel studs, single wheels / twin wheels 54 / 55
7 Steering dampers 56 / 57
7.1 Steering dampers, view 56
7.2 Steering dampers 57
8 Hubcaps with integrated Hubodometer 58 / 59
8.1 Hubcaps with integrated Hubodometer 58
8.2 Hubcaps with digital odometer (ECOMETER) 59
9 Special tools for BPW ECO Disc Trailer disc brakes 60 - 63

Valid: 1.9.2010
This spare parts list shows fast moving parts for BPW trailer axles and
steering axles s e r i e s S H . . / S K . . 8 - 1 2 t o n n e s from 2010 onwards.
Additional spare parts as per spare parts catalogue.
Subject to change (without notice).
/4
3

BPW-EL-TSB 31081001e
BPW Original spare parts O Series SKH.., SH.., S..LL

Rigid axle

5 - 5.4
44 - 50

1 - 1.2
6 - 9
4 - 4.7
34 - 43

3 - 3.9
16 - 33

6 - 6.2 SH..
SKH..
52 - 55

SHB..
SKHB..

Steering axle
7 56- - 7.2
2 - 2.3 57
10 - 15

5 - 5.4
44 - 50

3 - 3.9
16 - 33

1 - 1.2
6 - 9

3 BPW-EL-TSB 31081001e
Explanation of BPW axle type codes (extract)
Example:
SKH S F LL 9010 -15 ECO Plus 2
Axle series Brake Tyre
SH.. TSB 4309 22.5” / 24”
SH
SH.. TSB 4312 22.5“ / 24”
SKH SKH.. TSB 3709 19.5“ (22.5”)
SM SM.. TSB 4309 22.5” / 24”
TSB 4312
SKM SKM.. TSB 3709 19.5“ (22.5”)
B For single wheels, wheels with offset
S For single wheels, wheels without offset
Z For twin wheels
F Wheel studs M 22 x 1.5 without wheel nuts,
order wheel nuts for stud or spigot alignment separately
M For spigot alignment
LL Self steering axle, series LL
8008 - Axle load (kg) + quantity of wheel studs per hub
12010
-15 Axle beam - wall thickness, e.g. 15 mm
8° Steering angle of steering axle
-
27°
ECOPlus Trailer axle with ECOPlus Unit
ECO Plus 2 Trailer axle with ECO Plus 2 Unit

Explanation of BPW axle code numbers (extract)

Example:
27. 58. 616. 000
Axle type
26. Steering axle without suspension parts
27. Trailer axle without suspension parts
Axle load Roller bearings Bearing generation
50. 10000 - 12000 kg 33118 / 33213 ECOPlus
58. 8000 - 9000 kg 33118 / 33213 ECO Plus 2
Wheel brake type Dimension
616. TSB 3709 (ECO Disc) Ø 370 x 45
617. TSB 4309 (ECO Disc) Ø 430 x 45
618. TSB 4312 (ECO Disc) Ø 430 x 45
000 Consecutive number 000 - 999

4 BPW-EL-TSB 31081001e
BPW Type plate
Brake type Date of manuf.
Serial number
BPW Type plate BPW BERGISCHE ACHSEN KG
(Adhesive type plate) SHSF 9010 ECOP TSB 4309 095240189
D115 / 36104008
27.58.617.001 9000 105

Barcode

BPW Axle code number

Example:
The BPW type name is composed of a letter group and a SHSF 9010 ECO-P
number group.
The letter group identifies the type of axle and suspension SHSF - BPW axle series SH for single wheels
version as well as defining the hub version. (without offset), wheel studs M 22 x 1.5,
without wheel nuts
The number group specifies the axle load on the ground in 9010 - 9000 kg axle load
kilogrammes and the number of wheel studs per wheel hub - 10 wheel studs per wheel
(for disc wheel connection).
The group of letters at the end of the model name defines the ECO-P - ECOPlus bearing generation
type of hub bearing.
You can view the brake certificate referenced by certificate D115 / 36104008 - D115 Certificate type
type/test report number on the type plate by logging onto the - 36104008 Test report no.
BPW website at www.bpw.de (Download Centre in the German
version of the website - "Bremsgutachten").
All BPW components and assemblies have a 10-digit "speaking" code number.

BPW-EL-TSB 31081001e 5
BPW Original spare parts O Series SKH.., SH.., S..LL

1.1 Axle beam, steering axle beam View

General
BPW Axle beams
Square, reliable, light – the BPW axle beam.
It’s the stable foundation for a long vehicle life.
In combination with our brakes and suspension
systems, the square axle produces axle systems Axle stub
which offer convincing all round performance with
long service life and maintenance intervals.

Calliper anchor carrier

The BPW square axle beam consists of two

high-quality, specially rolled “U” sections which
are welded together inside and out.
This profile features more material at the corner
radii and less material in the top and bottom
areas. As a result, the axle cross-sections are
reinforced at the points where the force is
applied and are optimally shaped to cope with
the load.
The construction ensures a long service life.
BPW axle tubes are available with various
cross-sections and wall thickness values
depending on the axle load and the application
conditions.
BPW axle stubs are forged, quenched and
tempered.
They have two stepped bearing seats.
The axle stubs and axle tube are flash
butt-welded together to produce the one piece
BPW axle beam. Axle beam after flash
butt-welding
In this welding process, the axle tube and
the ends of the axle stubs are heated up
to welding temperature by an electric current
applied at their joining faces, whilst at the
same time being forced together.
This produces an absolutely homogeneous
connection without any inclusions. In contrast
to conventional welding processes, no filler
metals are needed.
At the same time, the axle beam is given its
camber and toe-in.

Axle beam after removing

the welding flash

6 BPW-EL-TSB 31081001e
View Axle beam, steering axle beam 1.1

Determining replacement axle beams

The BPW axle code number is shown on the

type plate.
If this is missing or no longer legible, the BPW BPW axle beam
axle code number can be read off the front end
welding number
of the axle stub in most cases.
When ordering the axle beam, quote this BPW
axle code number with the reference to a .616.
50

00 2
replacement axle beam.

27.
In steering axles and ECO Plus 2 bearings, there
is no code number embossed on the front end of BPW axle code number punched into
the stub. the front end of the axle stub

If there is no BPW axle code number or none is P

known, BPW can identify the axle on the basis of
the axle beam welding number or the dimensions.

1. Axle beam cross section ( 120 / 150 ) FM

2. Axle beam wall thickness ( if known )
3. Spring centre ( FM )
4. Track ( SP )
H
K

5. Overall width ( P )
6. Leaf spring width
7. Spring pad hole pattern ( if present ) Single wheels
8. Wheel seat ( H )
9. Pitch circle and number of wheel studs ( K )
SP
10. With steering axles steering pivot centre P

M
In addition to which the type of tyres, the wheel
size and the brake size should also be specified,
as well as the approximate year of manufacture
(initial registration). FM
H
K

Twin wheels

SP

BPW-EL-TSB 31081001e 7
BPW Original spare parts O Series SKH.., SH.., S..LL

1.2 Axle beam, steering axle beam, steering pivots, steering pivot bearing

Rigid axles

25
23

10

ECO Plus 2

445 - 447
38

ECO Plus

445 - 448
39

Steering axles (Series LL)

600
58 / 59
91 - 99 150
15 12 / 13
M 10
M = 43 Nm (40-47 Nm)
194
23 170 - 184
77 14 / 15

59
25
52
18
42
10 17
41
40

63
ECO Plus 2
64
215
55 214
445 - 447
61 38
42
60
56 77
57 ECO Plus
194

445 - 448
39

8 BPW-EL-TSB 31081001e
 Axle beam, steering axle beam, steering pivots, steering pivot bearing 1.2
Item Designation (Remark) BPW Code no. Dimension

Rigid axles
10 Axle beam assembly When ordering axle beam assembly, please
state axle type and BPW code-no. (axle type plate).
23 Plate 03.281.42.03.0
(Attachment air suspension valve)
25 Centering frame 03.295.46.21.0 72,5 x 60 x 8 For other spring plate designs, see the
(for clamped axle spring seat spares catalogues for the corresponding
assembly) suspension units.

Steering axles (Series LL)

10 Steering axle beam assembly When ordering steering axle beam assembly, please
state axle type and BPW code-no. (axle type plate).

17 Hexagon bolt 02.5026.64.80 M 20 x 50 - 8.8

02.5037.61.80 M 20 x 60 - 8.8
02.5026.69.80 M 20 x 70 - 8.8
03.340.13.19.0 M 20 x 70 - 8.8
18 Hexagon nut 02.5205.09.04 M 20
23 Shaped plate upon request
(Attachment steering lock cylinder)

25 Centering frame 03.295.46.21.0 72,5 x 60 x 8 For other spring plate designs, see the
spares catalogues for the corresponding
suspension units.
40 Steering pivot assembly, right When ordering steering pivot assembly,
41 Steering pivot assembly, left please state axle type, BPW code-no.
(axle type plate) and side (right or left).
42 Bush 03.112.76.08.0 Ø 60 / 65 x 90
45 Repair kit steering bolt 09.801.02.35.0
(item 42 , 52 - 64, 214)
52 Steering bolt 03.240.08.04.0 Ø 39 / 60 x 331
55 Thrust washer, upper 03.128.05.07.0 Ø 64 / 99 x 18,5
56 Thrust washer, lower 03.128.05.06.0 Ø 64 / 99 x 18,5
57 Seal 02.5681.03.00 Ø 70 / 62 / 59 x 5
59 Pressure spring 03.125.07.10.1 Ø 30 / 38 x 86 / Ø 8
60 Roll pin 02.6006.95.90 Ø 12 x 28
61 Roll pin 02.6016.01.90 Ø 7 x 28
63 Roll pin 02.6016.00.90 Ø 7 x 18
64 Roll pin 02.6016.11.90 Ø 12 x 12
77 Washer 03.320.66.04.0 Ø 100 x 4,75 / 3xØ11
194 Locking bolt 02.5070.60.02 M 10 x 12
02.5070.63.02 M 10 x 25
214 Grease nipple 02.6802.06.50 BM 10 x 1 / 45°
215 Cap 02.3505.20.00

BPW-EL-TSB 31081001e 9
BPW Original spare parts O Series SKH.., SH.., S..LL

2.1 Steering axle, steering lock View

General
BPW Steering axles series LL
No one wants to loose rubber from their tyres
every time they turn a corner.
So we’ve developed an axle which allows your
tyres to roll instead of slide.

The BPW LL self-steering axle

The enormous advantages of the steering axle
come to the fore when manoeuvring: Better
manoeuvrability, reduced wear on all tyres and
less fuel consumption.
As a result, the BPW self-steering axle is
the right economical solution for delivery and
distribution traffic chiefly consisting of journeys
in congested conurbations and cities.

Function
LL stands for “lload-dependent steering stabili-
sation” and it describes the unique functional
principle of the BPW self-steering axle.

Conventional steering axle designs require stee-

ring stabilisers powered from an external source
– this is not the case with the BPW self-steering
axle. The axle beam and axle stub are connected
to undulating thrust bearings via steering pivots.
When driving straight ahead (zero position), the
undulations in the thrust washers keep the
wheels on track. The weight of the vehicle
presses the undulating contours of the upper and
lower thrust washers together. The wheels remain
stable in the correct straight-ahead position.
When the semi-trailer follows the tractor unit into
a curve, the wheel castor action ensures the
wheels turn in accordance with the curve radius
(the thrust washers slide over one another).
The frictional resistance changes according to
the load on the axle. As a result, a steering
angle (of 8 to 27°, depending on the axle type)
is achieved according to the load, and is entirely
controlled by mechanical means.
The link connecting the wheels uses a steering
lock to prevent the wheels from steering when
the vehicle is reversing.

10 BPW-EL-TSB 31081001e
View Steering axle, steering lock 2.1

The effect of the steering axle is that the

suspension unit steers into corner better
and virtually follows in the tracks of the
tractor unit.
The lateral forces on the tyres, occurring for
example in the case of a three-axle trailer,
are thus ideally distributed between all the
axles.
As a result of the fact that each axle
experiences considerably lower lateral
forces, the mileage covered by the tyres
is demonstrably increased by up to 50 %
on the front axle and actually up to 70 %
on the rear axle.
The use of the BPW steering axle delivers
absolutely even wear.

BPW-EL-TSB 31081001e 11
BPW Original spare parts O Series SKH.., SH.., S..LL

2.2 Steering rods

Steering rods, spare parts for steering rods

91 - 99
15 150

23 170 - 184
9 162 163 14 / 15

155

164
M 12 x 1,5
M = 91 Nm

153
152

A B
L L

H H

C D
L L

H H

E F
L
L

28

39

12 BPW-EL-TSB 31081001e
 Steering rods 2.2
Steering rods, spare parts for steering rods
Item Designation (Remark) Dimension / Remark BPW Code no.

L H 2 clamps
150 Steering rod complete 1180 ( 1160 - 1199 ) 121 05.246.46.55.0 A
incl. item 152, 153, 162 - 164 129 05.246.46.30.0 A
1220 ( 1200 - 1239 ) 129 05.246.46.34.0 A
1260 ( 1240 - 1279 ) 121 05.246.46.64.0 A
129 05.246.46.39.0 A
1300 ( 1280 - 1319 ) 121 05.246.46.54.0 A
129 05.246.46.29.0 A
1340 ( 1320 - 1359 ) - 05.246.41.06.0 E
121 05.246.46.56.0 A
129 05.246.46.31.0 A
1380 ( 1360 - 1399 ) - 05.246.41.02.0 E
121 05.246.46.52.0 A
129 05.246.46.27.0 A
1420 ( 1400 - 1439 ) - 05.246.41.01.0 E
- 05.246.49.26.0 F
121 05.246.46.51.0 A
121 05.246.49.51.0 D
129 05.246.46.26.0 A
129 05.246.49.77.0 D
150 05.246.46.77.0 C
1460 ( 1440 - 1479 ) - 05.246.41.05.0 E
121 05.246.46.61.0 A
129 05.246.46.36.0 A
129 05.246.49.81.0 D
1500 ( 1480 - 1519 ) - 05.246.41.03.0 E
- 05.246.49.28.0 F
121 05.246.46.53.0 A
129 05.246.46.28.0 A
129 05.246.49.79.0 D
1520 ( 1520 - 1559 ) - 05.246.49.38.0 F
1540 ( 1520 - 1559 ) - 05.246.41.13.0 E
121 05.246.46.63.0 A
121 05.246.49.63.0 D
129 05.246.46.38.0 A
129 05.246.49.69.0 D

152 Track rod end assy. left threaded 05.353.68.27.0

incl. item 155
153 Track rod end assy. right threaded 05.353.68.26.0
incl. item 155
155 Bush Ø 35 / 64 x 56 05.113.92.04.0
162 Clamp 02.3507.25.00
163 Hexagon bolt M 12 x 1.5 x 60 - 8.8 02.5029.35.80
164 Lock nut VM 12 x 1.5 - 8 02.5220.15.82

BPW-EL-TSB 31081001e 13
BPW Original spare parts O Series SKH.., SH.., S..LL

2.3 Steering rod attachments

Steering rod attachments

Track rod position 24.5 mm A Track rod position 25 mm B

M 24 171
M = 550 Nm
184
178
173

X = 25
X = 24.5

178
171 184
M 24
M = 550 Nm

Track rod position 35 mm C Track rod position 45 mm D

171
171

173

X = 45
X = 35

178
178
184
184 M 24
M 24 M = 550 Nm
M = 550 Nm

Track rod position 171 mm E Track rod position 171 mm F

M 24
X = 171

M = 550 Nm
X = 171

M 24
M = 550 Nm 184
184 178

173

171 171

Track rod position 163 mm G Track rod position 190 mm H

M 24
X = 163

M = 550 Nm
X = 190

M 24
184 M = 550 Nm
178 184
178

173

171
171

14 BPW-EL-TSB 31081001e
 Steering rod attachments, steering lock 2.3
Steering rod attachments
Item Designation (Remark) BPW Code no. Dimension
Track rod position 24.5 mm A
Track rod position 45 mm D
Track rod position 163 mm G

M 24
170 Assembly kit 05.801.43.18.1 138
item 171 - 184
171 Threaded bolt 03.177.04.05.0 Ø 40 / 35 / M 24 x 138

Ø 40

Ø 35
178 Washer 03.320.24.05.0 Ø 24.5 / 70 x 65 x 6
184 Lock nut 02.5220.74.12 VM 24 / 980 - 10

Track rod position 25 mm B

170 Assembly kit 05.801.43.51.1

M 24
item 171 - 184 163
171 Threaded bolt 03.177.04.14.0 Ø 40 / 35 / M 24 x 163

Ø 40

Ø 35
173 Ring 03.310.03.22.0 Ø 35 / 40 / 65 x 25
178 Washer 03.320.24.05.0 Ø 24.5 / 70 x 65 x 6
184 Lock nut 02.5220.74.12 VM 24 / 980 - 10
Track rod position 35 mm C
Track rod position 190 mm H
170 Assembly kit 05.801.43.19.1

M 24
item 171 - 184 153
171 Threaded bolt 03.177.04.06.0 Ø 40 / 35 / M 24 x 153
173 Ring 03.310.03.06.0 Ø 35 / 40 / 65 x 15 Ø 40

Ø 35
178 Washer 03.320.24.05.0 Ø 24.5 / 70 x 65 x 6
184 Lock nut 02.5220.74.12 VM 24 / 980 - 10
Track rod position 171 mm E

M 24
118
170 Assembly kit 05.801.43.50.1
item 171 - 184
Ø 40

Ø 35
171 Threaded bolt 03.177.14.40.0 Ø 40 / 35 / M 24 x 118
184 Lock nut 03.260.56.03.0 M 24 - 10

Track rod position 171 mm F

170 Assembly kit 05.801.43.47.1
M 24
item 171 - 184 146
171 Threaded bolt 03.177.04.13.0 Ø 40 / 35 / M 24 x 146
173 Washer 03.320.33.24.0 Ø 35 / 64 x 8
Ø 40

Ø 35

178 Washer 03.320.24.05.0 Ø 24.5 / 70 x 65 x 6

184 Lock nut 02.5220.74.12 VM 24 / 980 - 10
Track rod position = Distance axle centre - steering rod centre

Steering lock
Item Designation (Remark) BPW Code no. Dimension
SH..LL.. / SK..LL..
91
91 Cylinder 02.0327.38.00
incl. item 98 + 99
96 Lock 03.060.00.13.0 96
98 Spring washer 02.5601.12.90 A 12 23
9
99 Hexagon nut 02.5202.16.80 M 12 - 8
98

99
M 12 x 1,5
M = 86 Nm

BPW-EL-TSB 31081001e 15
BPW Original spare parts O Series SKH.., SH.., S..LL

3.1 Brake parts BPW ECO Disc TSB 3709 / 4309 / 4312 View

General
Brakes that are under utilised glaze up and
their braking effort is reduced. Over utilisation
causes disproportionate wear.
Correct selection and dimensioning of the brake
is therefore of crucial significance.
BPW offers you the correct brake for every
application.

BPW ECO Disc Trailer disc brake (TSB)

3709 (Ø 370)
For versatile deployment in the haulage busi-
ness under normal conditions
(e.g. long-distance road haulage in Western
Europe).
Axle load: 9 – 10 t
Tyre size: 19.5" ( 9 + 10 t )
22.5" ( 9 t )
Wheel exec. : E, Z, ET 0
ET 120 ( only 9 t )

BPW ECO Disc Trailer disc brake (TSB)

4309 (Ø 430)
For conditions that demand greater disc and Brake disc (8)
pad volume, such as mountainous routes,
frequently changing tractor-trailer combinations,
when deployed in Eastern Europe or in regional
distribution. Brake calliper
Axle load: 9 – 10 t
Tyre size: 22.5"
Wheel exec.: E, Z, ET 0;
ET 120 ( only 9 t )
Advantage: Large diameter brake discs and
calliper matching the axle load.

BPW ECO Disc Trailer disc brake (TSB)

4312 (Ø 430)
For axle loads above 10 tonnes.
Push rod
Axle load: 11 – 12 t Brake lever (1)
Tyre size: 22.5" Traverse (5)
Wheel exec.: E, Z, ET 0 Thrust tappet (6)
Brake pad (7)

E = Single wheels
Z = Twin wheels
ET = Offset

16 BPW-EL-TSB 31081001e
View Brake parts BPW ECO Disc TSB 3709 / 4309 / 4312 3.1

Type plate
There is a manufacturer's nameplate fixed
Data-Matrix-Code
onto each brake calliper, on which are
BPW Brake code number
stamped the data necessary for the identifi-
cation of the brake in question.
BPW Bergische Achsen KG
O BPW Brake code number ECO-Disc
O Brake type + serial number
O For replacement, brake calipers will only
05.362.72.01.0
be supplied as a complete replacement
brake caliper ( 09 362 ....... ) with TSB 4309 09343A1234
complete lining set.
BPW Brake type and
serial number of the brake
BPW Brake code number

Type plate

BPW-EL-TSB 31081001e 17
BPW Original spare parts O Series SKH.., SH.., S..LL

3.1 Brake parts BPW ECO Disc TSB 3709 / 4309 / 4312 View

BPW ECO Disc Trailer disc brake TSB 3709 / 4309 / 4312
OPERATING PRINCIPLE: SLIDING CALLIPER BRAKE

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 counteracts 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 calliper.
The brake torque for the wheel is generated when the brake pads contact the brake disc.
The radial stabilizer force created by the responding brake pad at this time is transferred directly to the
axle via the brake calliper.

RELEASING THE BRAKE

When brake pressure rises, the pressure spring (9) moves the actuating unit back to its 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 (14) via the spring loaded indented ball coupling sleeve (12). When play increases
the threaded tube (14) is turned correspondingly via the indented ball coupling (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 0.8 mm +/- 0.2 mm.

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 mechanically connected to 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 surface,
are fitted with a so called "inner sealing".
This means that the pushrod acting on the lever (1) must be hermetically sealed from the secondary
chamber of the brake cylinder as otherwise the internal mechanism is completely open to its surroundings.

18 BPW-EL-TSB 31081001e
View Brake parts BPW ECO Disc TSB 3709 / 4309 / 4312 3.1

14 (390) (380)
13 7a 7b 8
1
2
3

12 10
11 5 9

(362) (390) (380) (390)

9 6 7a 8 7b

10 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
14
10 Adjustment device
11 / 11a 11 Adjuster pin with
11a Movement thread
5 12 Indented ball coupling
13 Return spring gear wheel
14 Threaded tube

BPW-EL-TSB 31081001e 19
BPW Original spare parts O Series SKH.., SH.., S..LL

3.2 Brake parts BPW ECO Disc TSB 3709 / 4309 / 4312

BPW ECO Disc TSB 3709

32 / 33 398 397
394
702
395

396

390
Type L

352 360
301
300
370 389
356
354 362
BPW ECO Disc Grease 365
373 363
M 16 x 1.5 364
M = 260 Nm (250 - 270 Nm) 352
328
356
326
Type F 354 S-Hub
325
355
335 323 348
346
352 345
SW 14
M = 15 Nm (15 - 20 Nm) 335 374 B-Hub
BPW ECO Disc Grease Plus

BPW ECO Disc TSB 4309 / 4312

32 / 33 398 397
394
702
395

396

390
Type L

352 360
301
300 389
356 370

354 362
BPW ECO Disc Grease 365
373 363
M 16 x 1.5 364
M = 260 Nm (250 - 270 Nm) 352
328
356 S-Hub
326
Type F 354
325
355
335 323 348
346
352 345
SW 14 B-Hub
M = 15 Nm (15 - 20 Nm) 335 374
BPW ECO Disc Grease Plus

20 BPW-EL-TSB 31081001e
 Brake parts BPW ECO Disc TSB 3709 / 4309 / 4312 3.2
BPW ECO Disc TSB 3709 / 4309 / 4312
TSB 3709 TSB 4309 TSB 4312
--.--.616.--- --.--.617.--- --.--.618.---

Item Designation (Remark) Dimension / Remark BPW Code no.

300 BPW replacement brake Type L / BPW 8200 09.362.72.03.0 1) 09.362.72.01.0 1) -
301 calliper cpl. ( pre-greased ) Type F / BPW 8200 09.362.72.04.0 1) 09.362.72.02.0 1) -
incl. guide pins, brake pads
and attachment parts. Type L / BPW 8101 09.362.72.03.1 1) 09.362.72.01.1 1) -
Order screws for steering Type F / BPW 8101 09.362.72.04.1 1) 09.362.72.02.1 1) _
axles (item 325 + 345) Type L / BPW 8301 - - 09.362.72.05.0 1)
separately.
Type F / BPW 8301 - - 09.362.72.06.0 1)

323 Repair kit guide pins for one axle side 09.801.07.61.0
item 325, 326, 328, 345,
346, 348, 373
325 Cylinder head screw M 16 x 1.5 x 100 - 10.9 02.5016.70.16 for rigid axle
M 16 x 1.5 x 105 - 10.9 03.340.12.30.0 for steering axle 2)

326 Guide pin, long (fixed bearing) Ø 17 / 26 / 37 x 123 05.001.00.41.0

328 Guide bush (fixed bearing) Ø 37 / 41 x 73 03.112.33.13.0
335 Sealing cap M 49 x 1.5 05.001.00.45.0
345 Cylinder head screw M 16 x 1.5 x 70 - 10.9 02.5015.78.16 for rigid axle
M 16 x 1.5 x 75 - 10.9 03.340.12.29.0 for steering axle 2)

346 Guide pin, short Ø 17 / 26 / 36 x 70 03.001.00.35.0

(floating bearing)
348 Guide bush (floating bearing) Ø 37 / 41 x 30 03.112.33.14.0
352 Repair kit seal for one axle side 09.801.07.62.0
for guide pins
item 335, 354, 355, 356,
370, 373
354 Bellow Ø 52 x 34 05.130.08.27.0
355 ‘O’-Ring Ø 36 x 3.5 02.5679.98.40
356 Ring Ø 38 / 48 x 5 03.310.11.19.0
360 Repair kit tappet for one axle side 09.801.07.63.0
item 362 - 365
362 Tappet Ø 24 / 27 / 84.5 x 94.5 03.127.18.02.0
363 Bellow Ø 26 / 55 x 17 05.130.07.07.0
364 Holding clamp Ø 25 x 7 03.001.57.01.0
365 Dirt seal Ø 55 x 1.5 03.121.30.15.0
370 Plug Ø 24 x 9 02.3704.69.00
373 BPW ECO Disc Grease 25 g 02.1040.60.00
374 BPW ECO Disc Grease Plus * 5 g 02.1040.61.00
* Grease the spherical cap in the lever with BPW ECO Disc Grease Plus.
1) For replacement, brake calipers will only be supplied as a complete replacement brake caliper ( 09 362 ....... )
with complete lining set.
2) Not included in the BPW replacement brake caliper 09.362...... . Order screws separately!

BPW-EL-TSB 31081001e 21
BPW Original spare parts O Series SKH.., SH.., S..LL

3.2 Brake parts BPW ECO Disc TSB 3709 / 4309 / 4312

BPW ECO Disc TSB 3709

32 / 33 398 397
394
702
395

396
393
388
390
Type L

301
300 389
356 370

354 362
BPW ECO Disc Grease 365
373 363
364

328
356
326 S-Hub
Type F 354
325
355
335 348
346
345
B-Hub
335 374
BPW ECO Disc Grease Plus

BPW ECO Disc TSB 4309 / 4312

32 / 33 398 397
394
702
395

396
393
388
390
Type L

301
300 389
356 370

354 362
BPW ECO Disc Grease 365
373 363
364

328
356 S-Hub
326
Type F 354
325
355
335 348
346
345
B-Hub
335 374
BPW ECO Disc Grease Plus

22 BPW-EL-TSB 31081001e
 Brake parts BPW ECO Disc TSB 3709 / 4309 / 4312 3.2
BPW ECO Disc TSB 3709 / 4309 / 4312
TSB 3709 TSB 4309 TSB 4312
--.--.616.--- --.--.617.--- --.--.618.---

Item Designation (Remark) Dimension / Remark BPW Code no.

388 Repair kit brake lining for one axle
( BPW 8200 ) 09.801.07.55.0 09.801.07.57.0 -
( BPW 8101 ) 09.801.07.56.1 09.801.07.58.1 09.801.07.60.1
( BPW 8301 ) - - 09.801.07.59.0
item 370, 389, 390, 394,
396 - 398
389 Wearing plate 03.163.04.02.0 03.163.04.03.0 03.163.04.04.0
390 Brake lining * BPW 8200 05.092.90.12.0 * 05.092.90.13.0 * -
BPW 8101 05.092.90.15.0 * 05.092.90.16.0 * -
BPW 8301 - - 05.092.90.20.0 *
393 Repair kit brake retaining clip for one axle 09.801.07.68.0
item 394 - 398
394 Clamping spring 03.352.00.08.0
395 Pad holding bar 03.001.00.54.0
396 Bolt Ø 8 / 10 / 14 x 75 03.084.32.33.0
397 Washer Ø 10.5 vzkt 02.5404.10.04
398 Lock 02.3301.31.00

* Only deliverable per kit (item 388)!

BPW-EL-TSB 31081001e 23
BPW Original spare parts O Series SKH.., SH.., S..LL

3.3 Brake discs View

BPW Brake discs

With the introduction of IBD brake discs, the
proven BPW design of the collar disc has BPW Brake disc - IBD version
been further improved.
Further development has focused on the
regulation of thermal efficiency in order to
optimise wear characteristics and to improve
reliability.
The quality of brake discs is the result of
a combination of the shape of the design,
the materials used and the quality of the
mechanical machining.
The chemical composition of the material alloy
is in particular responsible for a large number
of properties, and hence determines some
essential product features.
BPW has taken these technological influences
into account for many years in the development
of brake discs, matching them to the
requirements on the trailer.

The latest generation of BPW brake discs offers

the following advantages:

O Increased surface area for effective heat

dissipation
O Optimisation of material for improved heat
distribution over the surface of the disc
O Venuri contour for improved internal
air flow
O Optimally matched friction pairing
(Pads / Brake disc)
O High resistance to wear
O Simplified spare parts provision thanks to
uniform brake discs for 0 and 120 offsets

24 BPW-EL-TSB 31081001e
 Brake discs 3.4
Brake discs
Pitch circle /
Brake BPW Code no. Wheel hub Offset Series Remark
hole pattern
03.088.34.15.7 275 / 8-hole S, Z 0
03.088.34.16.7 275 / 8-hole S, Z 0 with mounting for
exciter ring
TSB 3709
03.088.34.14.7 335 / 10-hole S, Z, B 0 / 120 IBD
03.088.34.17.7 335 / 10-hole S 0 IBD with mounting for
exciter ring
TSB 4309 03.088.35.05.7 335 / 10-hole S, Z, B 0 / 120 IBD

TSB 4312 03.088.35.05.7 335 / 10-hole S, Z 0 IBD

S = Singe wheels, offset 0
B = Single wheels, offset 120
Z = Twin wheels

Wear status of the brake disc

The brake disc is to be regularly checked for
its residual thickness and any damage to the max.
1.5 mm
braking surface.
The residual thickness of the brake disc A B
a

must not be less than the permissible

max. 0.75 x a
minimum in any area of the disc.
Network-like heat cracking (A), radial cracks max. 1.5 mm
up to 1.5 mm in width and depth (B)
and pitting of the braking surface less
than 1.5 mm (C) are permissible.
D C
Continuous cracks (D) are not permissible.
If the brake disc has reached its wear
limit or its braking surface shows inad-
missible damage, it must be replaced.

Technical details:
O disc thickness, new = 45 mm
O minimum permissible disc thickness = 37 mm
(check with slide gauge)

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

BPW-EL-TSB 31081001e 25
BPW Original spare parts O Series SKH.., SH.., S..LL

3.5 Disc covers, brake pad protectors

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

502
501

510
M 10
M = 43 Nm (40-47 Nm)

530

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

501

510
M 10
M = 43 Nm (40-47 Nm)

530

26 BPW-EL-TSB 31081001e
 Disc covers, brake pad protectors 3.5
Disc covers
Item Designation (Remark) Dimension BPW Code no.
TSB 3709 TSB 4309 TSB 4312
120 120 150

Rigid axles
500 Supplementary installation for one axle 09.801.07.51.0 09.801.07.52.0 09.801.07.53.0
kit cover plates
item 501 - 510
501 Disc cover 03.010.71.59.0 03.010.71.61.0 03.010.71.57.0
502 Disc cover 03.010.71.60.0 03.010.71.62.0 03.010.71.58.0
510 Locking screw M 10 x 15 02.5071.22.00 02.5071.22.00 02.5071.22.00
513 Seal Ø 7 / 10 / 13 - 02.5681.78.00 -

Steering axles
500 Supplementary installation for one axle 05.801.50.48.0 05.801.50.47.0 -
kit cover plates
item 501 - 510
501 Disc cover 03.010.71.64.0 03.010.71.63.0 -
510 Locking screw M 10 x 15 02.5071.22.00 02.5070.22.00 -

Brake pad protectors

Item Designation (Remark) Dimension BPW Code no.
530 Brake pad protector * for one axle side 03.010.95.32.0 TSB 3709
TSB 4309
TSB 4312

* is mounted under the pad retaining clip without any additional attachment parts

BPW-EL-TSB 31081001e 27
BPW Original spare parts O Series SKH.., SH.., S..LL

3.6 Brake cylinder View

General
BPW Brake cylinder
BPW Brake cylinders come with a range of
special features justifying their high quality level:

O The cylinder size and the part number are

embossed on the unit
O Parts which are critical to function can be
traced back through the QA system by
means of their type plate data
O The extended compressed air connection
makes them easy to install
O Double seals on the twin compartment
O Effective anti-corrosion protection by powder
and Delta Tone coating
O Shot-peened, epoxy-coated compression
springs
O Spring-type accumulator chamber in
permanent, positive connection
O Long service life thanks to high-performance
rubber diaphragms
O Closely sealing bellows
O Chromated aluminium housing

Diaphragm cylinder

Types:
Diaphragm cylinders
These act as a service brake and are characteri-
sed by their compact external dimensions and
low weight.

Diaphragm-diaphragm cylinders ( M - M )
These act both as a service brake and an auxilia- Diaphragm-diaphragm cylinder ( M - M )
ry and parking brake. They are lighter than the
diaphragm-piston cylinder.

Diaphragm-piston cylinders ( M - K )
These have the same function as a diaphragm-
diaphragm cylinder.
Their greater spring accumulator force means
they are particularly suitable for vehicles with
higher axle loads.
Diaphragm-piston cylinder ( M - K )

28 BPW-EL-TSB 31081001e
View Brake cylinder 3.6

Release device
Release bolt inserted,
As of March 2004 the release bolt for M/M brake spring brake released
cylinders on axles with disc brakes will have a
new parking position. The release bolt will no
longer be accommodated in the parking pocket
on the outside of the cylinder, but can be left
in the cylinder cover plate.
All that is needed to use the parking position is
to turn the release bolt through 90° and then lock
it in place with a hex. nut. Release bolt in parking position,
plastic sleeve and split pin fitted
In addition to which it is still also possible to
remove the release bolt completely.
Further information can be found under the
heading Aktuell / BPW NEWS / News SB 04/01
on the BPW website www.bpw.de.

Compressed air connection extension ( DLAV )

Spring-type cylinders for disc brakes are fitted
with a compressed air connection extension
(DLAV) as standard.
A feature of DLAV is that it enables additional
compressed air systems to be mounted on the
axle quickly and easily.

Identification
BPW Type plate
The BPW part number and the cylinder model at brake cylinder
are stamped on the front of every brake cylinder.
BPW Code no.
e.g. 05.444.43.01.3
Each brake cylinder also has a manufacturer's
nameplate riveted onto it, with the details of the
BPW part number, cylinder type and production B P W
WIEHL-GERMANY
05.444.43.01.3
date. 20/24 FB 10 02

BPW Code no. Cylinder size

e.g. 05.444.43.01.3 e.g. 20/24”
Cylinder size manufacture date
e.g. 20/24” e.g. year 2010 / week 2

BPW-EL-TSB 31081001e 29
BPW Original spare parts O Series SKH.., SH.., S..LL

3.7 Brake cylinder

Diaphragm cylinder

Type A Type B
d 1
M 16 x 1.5
M 180 Nm ° 60
( 180 - 210 Nm) 60 °

D 1
A

S max.

L
L1
Brake cylinder size

BPW Code no.

Air connection

Piston stroke
S max. (mm)
Connection
dimension
D 1 (mm)
L 1 (mm)

A (mm)
L (mm)
thread
Type

d 1

05.444.30.01.0 A 60
14” 101 116 143
05.444.30.02.0 B
05.444.31.01.0 A
15” 101 116 143 60
05.444.31.02.0 B
05.444.32.01.0 A
16” 101 116 145 60
05.444.32.02.0 B
05.444.33.01.0 A
18” M 16 x 1.5 115 130 150 120.7 68
05.444.33.02.0 B
05.444.34.01.0 A
20” 115 130 150 68
05.444.34.02.0 B
05.444.35.01.0 A
22” 120 135 160 68
05.444.35.02.0 B
05.444.36.01.0 A 68
24”
05.444.36.02.0 B
Lock nuts for brake cylinder
Thread BPW Code no.
M 16 x 1.5 02.5202.21.80

30 BPW-EL-TSB 31081001e
 Brake cylinder 3.7
Diaphragm - diaphragm brake cylinder / Diaphragm - piston brake cylinder
Type A Type B M 16 x 1.5
L M 180 Nm
° 60
60 ° ( 180 - 210 Nm)
Diaphragm - diaphragm
brake cylinder

D 1
D 2
( M - M )

A
L
° 60 S max.
60 °
Diaphragm - piston
brake cylinder

D 1
D 2

A
( M - K )
Brake cylinder size

connection fittings

connection fittings

with compressed
with standard air

extension (DLAV)
BPW Code no.

BPW Code no.

BPW Code no.

Air connection
Brake cylinder

Brake cylinder

air connection

Piston stroke
S max. (mm)
Mounting kit

Connection
without air

dimension
D 1 (mm)

D 2 (mm)

A (mm)
L (mm)
thread
Type

Diaphragm - diaphragm brake cylinder ( M - M )

05.444.38.01.0 A 05.444.38.01.3
14 / 24” 05.801.09.77.0
05.444.38.02.0 B 05.444.38.02.3
232 162
05.444.39.01.0 A 05.444.39.01.3
15 / 24” 05.801.09.78.0 57
05.444.39.02.0 B 05.444.39.02.3
145
05.444.40.01.0 A 05.444.40.01.3
16 / 24” 05.801.09.79.0 M 16 x 1.5 120.7
05.444.40.02.0 B 05.444.40.02.3
233
05.444.42.01.0 A 05.444.42.01.3
18 / 24” 05.801.09.80.0 161
05.444.42.02.0 B 05.444.42.02.3
66
05.444.44.01.0 A 05.444.44.01.3
20 / 24” 05.801.09.81.0 258 152
05.444.44.02.0 B 05.444.44.02.3
Diaphragm - piston brake cylinder ( M - K )
05.444.41.01.0 A 05.444.41.01.3
05.801.21.38.0
05.444.41.02.0 B 05.444.41.02.3
16 / 16” 255 145 162 60
05.444.41.03.0 1) A 05.444.41.03.3 1)
05.801.21.39.0
05.444.41.04.0 1) B 05.444.41.04.3 1)

05.444.43.01.0 A 05.444.43.01.3
05.801.09.82.0
05.444.43.02.0 B 05.444.43.02.3
20 / 24” 280 152 66
05.444.43.03.0 1) A 05.444.43.03.3 1)
05.801.09.97.0
05.444.43.04.0 1) B 05.444.43.04.3 1)
M 16 x 1.5 120.7
05.444.45.01.0 A 05.444.45.01.3
05.801.09.83.0
05.444.45.02.0 B 05.444.45.02.3
22 / 24” 174
05.444.45.03.0 1) A 05.444.45.03.3 1)
05.801.09.98.0
05.444.45.04.0 1) B 05.444.45.04.3 1)
282 162 68
05.444.46.01.0 A 05.444.46.01.3
05.801.09.84.0
05.444.46.02.0 B 05.444.46.02.3
24 / 24”
05.444.46.03.0 1) A 05.444.46.03.3 1)
05.801.09.99.0
05.444.46.04.0 1) B 05.444.46.04.3 1)

1) for top trailing arm Lock nuts for brake cylinder

Thread BPW Code no.
M 16 x 1.5 02.5202.21.80

BPW-EL-TSB 31081001e 31
BPW Original spare parts O Series SKH.., SH.., S..LL

3.8 BPW Brake Monitor View

BPW Brake Monitor

With the BPW Brake Monitor retrofit kit for
our disc brakes, you can check your vehicle
from the outside at any time to see if the
wear limit has been reached.
As soon as only one of the brake pads has
worn down by approx. 80% the yellow
“WARNING” LED on the BPW Brake Monitor
starts flashing.
Once the minimum pad thickness of 2 mm
has been reached, the “SERVICE” indicator
changes to red, while the green and yellow
LEDs flash alternately.
The red SERVICE indicator remains visible even
if you have parked the vehicle and there is no
electrical power supply to the trailer. Warning:
This means you can still tell if the wear limit At least one brake pad is approx. 80% worn
has been reached on at least one brake pad. down!
If this is the case, you should change the Service:
brake pads as soon as possible. At least one brake pad as reached the
minimum pad thickness of approx. 2 mm.
Have the pads replaced immediately!

BPW Brake Monitor -

Features and benefitts

O Optimum use of the brake pad wear volume

O Longer service life for the brake discs and
brake
O No unscheduled downtime
O No expensive follow-on costs (e.g. due to a
complete failure)
Warning:
O The service indicator tells you exactly when Mindestens ein Bremsbelag ist zu ca. 80%
a brake pad needs changing, even if there verschlissen!
is no operating voltage
O Operates without a separate ECU and does Service:
not need EBS Mindestens ein Bremsbelag hat
die Mindestbelagdicke von ca. 2 mm erreicht.
O Individual composition of kits possible Beläge umgehend tauschen lassen!
because of modules (e.g. for four-axle
vehicles)
O Quick and easy to install
O Can easily be retrofitted
O No technical inspection is required, since
a general EU certification and hazchem
approval have already been obtained
O Can be connected to EBS for indication in
tractor vehicle

32 BPW-EL-TSB 31081001e
 BPW Brake Monitor 3.9
Component list for BPW brake lining wear indicator

4 4 (3)
Connection for external signal 1
(3) (3) 1.1
2 2 1.2
2m

2m

2m
2m
1.5 m 1.5 m 2m
2m

2m

2m
1.3

(3) (3) Power supply (5)

4 (3) 4 (3)

per axle per axle

Vehicle Type

Item B P W C o d e n o . Designation Quantity

1 05.801.50.38.0 Basic set 1 x 1x 1 x 1 x 1 x 1 x 1 x

incl.
1.1 02.0339.01.00 Brake Monitor
1.2 02.4312.58.00 Connecting cable
1.3 02.3713.08.00 Connecting plug

2 02.4312.57.00 Connection modul 1 x 2 x 3 x 4 x 2 x 3 x 4 x

3 Extension
3-pin K/E-connector
system
02.1819.26.00 1 m acc. to vehicle configuration
02.1819.25.00 3 m
02.1819.22.00 5 m

4 05.801.50.49.0 Wear indicator axle set 1 x 2 x 3 x 4 x 2 x 3 x 4 x

5 Extension
7-pin DIN bayonet
connector system acc. to vehicle configuration
02.1819.29.00 2 m
02.1819.30.00 10 m

BPW-EL-TSB 31081001e 33
BPW Original spare parts O Series SKH.., SH.., S..LL

4.1 Hub bearings, hub seals View

General
BPW hub bearungs
ECOPlus hub bearing Fig.
ECOPlus 10 - 12 t
If you require long service life, rapid maintenance
and low maintenance costs from your axle, there
is only one option for you: ECOPlus.
Working on the basis of the special BPW ECO
hub system, the ECO Unit has been further
developed to create the trendsetting ECOPlus
bearing system.
The maintenance-free hub has an integrated
multi-seal system for protecting the tapered
roller bearings against dust and dirt.
A central threaded connection with integrated
torque limiting function ensures the bearing
pre-load is always optimum.

BPW ECOPlus bearing – Features and benefits

Fig.
O Maintenance-free, encapsulated bearing ECOPlus 10 - 12 t
unit (ECO Unit) with integrated multi-seal
system to protect the taper roller bearings
from dust and dirt. Exciter ring
Circlip
O Integrated torque limiter in the axle nut ‘O’-Ring
(ECOPlus) / axle bolt (ECO Plus 2) prevents Thrust washer
improper use when tightening ECO Seal Seal

O Bearings are precisely re-adjusted after

every disc replacement
O 5+3 years ECO Plus warranty (on-road) Roller bearing
without mileage limit
Dust cover
O Compact bearing system with DIN-ISO Inner seal
taper roller bearings available worldwide
for excellent availability and rapid service
Thrust washer
O Removal of the complete hub unit - Roller bearing
thanks to central threaded connection -
Washer
with simple tools Axle nut
O Excellent bearing service life with minimal
life cycle costs
Circlip

Locking ring
with locking piece Hubcap

34 BPW-EL-TSB 31081001e
View Hub bearings, hub seals 4.1

ECO Plus 2 - the new generation of the tried

and tested BPW ECO Unit Fig.
ECO Plus 2
The BPW ECO Unit, proven a million times over 8 - 9 t
in its ECOPlus version, will be replaced from
September 2007 by the still further improved,
new E C O P l u s 2 design.
A rigorous upgrade of the components has
resulted in a significant weight reduction
compared with the current ECOPlus Unit.
In the case of the E C O P l u s 2 the hubcap has
a bayonet fitting, enabling convenient fitting and
removal of the cap.
Grease is supplied to the wheel bearings by
means of a grease cartridge located between
the bearings.
The axle nut previously used is replaced by an
axle bolt with integrated torque limiter.

ECO Plus 2 bearing - Features and benefits

Fig.
O Maintenance-free, encapsulated bearing ECO Plus 2
unit (ECO Unit) with integrated multi-seal 8 - 9 t
system to protect the taper roller bearings
from dust and dirt
Exciter ring
O Axle bolt with torque limiter prevents Circlip
improper use when tightening ECO Seal Seal
O Bearings are precisely re-adjusted after Roller bearing
every disc replacement Grease cartrige

O 5+3 years ECO Plus warranty (on-road)

without mileage limit
O Compact bearing system with DIN-ISO
taper roller bearings available worldwide
for excellent availability and rapid service
Roller bearing
O Removal of the complete hub unit - Toothed washer
thanks to central threaded connection - Axle bolt
with simple tools Locking ring
O with locking piece
Simple greasing of the bearing by means
of a grease cartridge
O Excellent bearing service life with minimal
life cycle costs Circlip
O In conjunction with the revised air ‘O’-Ring
suspension system there are weight-
Hubcap
savings of up to 25 kg, depending on
the axle model
O Existing approvals and homologations
remain in force

BPW-EL-TSB 31081001e 35
BPW Original spare parts O Series SKH.., SH.., S..LL

4.1 Hub bearings, hub seals View

ECO Plus 2
Hubcap / ECOMETER
BPW trailer axles with the ECO Plus 2 Unit
have hubcaps (and ECOMETERS) with a
bayonet fitting.
The bayonet fitting replaces the previously
usual threaded connection.
A 120 mm installation spanner (BPW part
number 03.339.05.02.0, see also BPW tool
catalogue) is needed for fitting or removing
the new hubcaps with the bayonet fitting.

 An impact driver must not be used for

fitting / removing hubcaps or ECOMETERS
with a bayonet fitting!

Removal
To remove the hubcap it is turned anticlock-
wise through approx. 30 degrees with the
installation spanner (Fig.).
When turned further, the hubcap lifts clearly
away from the hub seat.
The released position is also indicated by
markings on the hubcap and on the wheel
hub (Fig. / Arrows).
In the released position the hubcap can be
removed from the wheel hub by pulling it away.
Dismantling
Assembly
The seal between the hubcap and the wheel
hub takes the form of an ‘O’-ring in the case
of the ECO Plus 2 Unit.
The ‘O’-ring is inserted in the groove on the
hub collar of the wheel hub, and i s t o b e
replaced every time. The hubcap itself is to Assembling
be given a thin coating of BPW ECO-LiPlus
special long-life grease inside in the area of
the bayonet fitting, before assembly.
Corresponding markings in the hubcap and
on the hub make it easier to fit the hubcap.
The figure shows the hubcap in the correct
position for fitting, with the spanner engaged.
After been placed in position, the hubcap is
pressed onto the hub and at the same time
turned in clockwise direction.
The hubcap is firmly in place when the position
shown in Fig. (arrows) has been reached.

36 BPW-EL-TSB 31081001e
View Hub bearings, hub seals 4.1

H u b s e a l f o r E C OPlus bearings
Dust and dirt sealing lips
The innovative ECOSeal sealing system is used
on all axles with the BPW ECO Disc Trailer
disc brake.
With this hub seal, the primary seal lip (ECOSeal)
no longer seals directly against the race of the
hub but instead against a race which is integra-
ted in the seal itself.
This new design enables the 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
Main sealing lip
protection against dirt penetration by means of
the covering dust and dirt sealing lips. Fig.
ECO Plus 2
8 - 9 t

Benefits:
Dust and dirt sealing lips
O An introversive pre-stressed main seal lip
with a low circumferential speed and a
low thermal load, resulting in low wear
O An approximately 30% reduction in
frictional resistance inside the seal
(compared with conventional seals)
O The seal is well protected during service
due to the cartridge construction
O Pre-stressed main seal lip with ventilation
function, no opening at low pressures
Main sealing lip
O No coarse dirt seal required Fig.
ECOPlus
10 - 12 t

BPW-EL-TSB 31081001e 37
BPW Original spare parts O Series SKH.., SH.., S..LL

4.2 Hub bearings, hub seals

ECO Plus 2 bearing

560
46 - 49

380
25 470
54 - 55

422 447
437
432 448
430 449 459
SH..
SKH..

441

446
SHB.. 435
40 438 460
SKHB..

Item Designation (Remark) BPW Code no. Dimension

SH.. ECO Plus 2
SKH.. ECO Plus 2
8 - 9 t --.58.---.---
380 Brake disc see page 25
416 Repair kit roller bearing 09.801.07.33.0 for 1 axle side
with axle bolt and hubcap
(item 422, 430, 432, 437 - 460)
419 Repair kit roller bearing 09.801.07.34.0 for 1 axle side
without axle bolt and hubcap
(item 422, 430, 437, 438, 441, 459)
422 ECOSeal seal 02.5664.74.00 Ø 117.5 x 158 x 17.5
430 Roller bearing 02.6410.23.00 33118
432 Grease cartridge 03.120.47.08.0 Ø 101 / 130 x 50
435 Hub see page 40
437 Circlip 02.5606.58.90 158 x 4 / 472
438 Circlip 02.5606.22.90 122 x 4 / 472
441 Roller bearing 02.6410.22.00 33213
446 Axle bolt with toothed washer 09.001.37.03.0 M 32 x 2 / SW 46
(incl. item 447)
447 Locking ring cpl. 05.188.03.10.0
(item 448 + 449)
448 Locking ring 03.188.03.09.0
449 Locking piece 03.277.10.01.0
459 ‘O’-Ring 02.5678.65.00 Ø 128 x 3
460 Hubcap (Bayonet) 05.212.25.78.0 Ø 137 / 142 x 56 /
(incl. item 459) SW 120

38 BPW-EL-TSB 31081001e
 Hub bearings, hub seals 4.3

ECOPlus bearing

560
46 - 49

437
424
421
420

470
380 54 - 55
25
422
435
430 40 Steel hubcap
431 M = 800 Nm
432
448
447
460

441
440 445
446 438

Item Designation (Remark) BPW Code no. Dimension

S H . . / S K H . . E C OPlus
10 - 12 t
--.50.---.---
380 Brake disc see page 25
418 Repair kit roller bearing 09.801.07.04.0 for 1 axle side
without axle nut and hubcap
(item 420, 423, 428, 430,
431, 432, 440 - 445)
420 Thrust washer cpl. 05.370.07.73.0
(item 421, 424)
421 Thrust washer 03.370.07.72.0 Ø 96 / 117.5 / 132 x 22
422 ECOSeal seal 02.5664.74.00 Ø 117.5 x 158 x 17.5
424 ‘O’-Ring 02.5678.00.00 Ø 100 x 3
430 Roller bearing 02.6410.23.00 33118
431 Dust cover 03.010.93.34.0 Ø 94 / 149 x 8.5
432 Seal 03.120.45.16.0 Ø 67 / 93 x 90.5
435 Hub see page 40
437 Circlip 02.5606.58.90 158 x 4 / 472
438 Circlip 02.5606.22.90 122 x 4 / 472
440 Thrust washer 03.370.26.24.0 Ø 71 / 108 x 8
441 Roller bearing 02.6410.22.00 33213
445 Washer 03.320.64.01.0 Ø 53 / 76 x 5.8
446 Axle nut 05.266.47.06.0 M 52 x 2 / SW 95
447 Locking piece 03.277.00.07.0
448 Locking ring 03.188.04.10.0
460 Hubcap 03.212.25.31.0 M 136 x 2.5 / SW 110

BPW-EL-TSB 31081001e 39
BPW Original spare parts O Series SKH.., SH.., S..LL

4.4 Hubs

SKH..(LL) ECO Plus 2 (TSB 3709)

Hubcap 8 - 9 t Complete hub
thread --.58.---.--- BPW Code no.
435 Hub
220,8 / 275 / 8 x Ø 22
SKH.. ECO Plus 2 Steel and alloy wheels 03.272.46.33.0 09.801.07.36.0
SKMZ..LL ECO Plus 2 Steel wheels Bayonet lock
SKHZMLL ECO Plus 2 Alloy wheels
280,8 / 335 / 10 x Ø 22

SKH.. ECO Plus 2 Steel and alloy wheels 03.272.43.29.0 09.801.07.35.0

SKMS..LL ECO Plus 2 Steel wheels
Bayonet lock
03.272.43.28.0 09.801.07.32.0
SKHB.. ECO Plus 2 Steel and alloy wheels

SH..(LL) ECO Plus 2 (TSB 4309 / 4312)

Hubcap 8 - 9 t Complete hub
thread --.58.---.--- BPW Code no.
435 Hub
280,8 / 335 / 10 x Ø 22
SH.. ECO Plus 2 Steel and alloy wheels
03.272.43.29.0 09.801.07.35.0
SHS..LL ECO Plus 2 Steel and alloy wheels
Bayonet lock
SMS..LL ECO Plus 2 Steel wheels
SMZ..LL ECO Plus 2 Steel wheels
SHB.. ECO Plus 2 Steel and alloy wheels 03.272.43.28.0 09.801.07.32.0
SHB..LL ECO Plus 2 Steel and alloy wheels Bayonet lock
SMB..LL ECO Plus 2 Steel wheels

SKH..(LL) ECOPlus (TSB 3709)

Hubcap 10 - 12 t Complete hub
thread --.50.---.--- BPW Code no.
435 Hub
220,8 / 275 / 8 x Ø 22
SKH.. ECOPlus Steel and alloy wheels M 136 x 2.5 03.272.46.30.2 09.801.06.59.2
280,8 / 335 / 10 x Ø 22
SKH.. ECOPlus Steel and alloy wheels M 136 x 2.5 03.272.43.24.2 09.801.06.22.0
SKHZM.. ECOPlus Alloy wheels M 136 x 2.5 03.272.43.18.0 -

SH..(LL) ECOPlus (TSB 4309 / 4312)

Hubcap 10 - 12 t Complete hub
thread --.50.---.--- BPW Code no.
435 Hub
280,8 / 335 / 10 x Ø 22
SH.. ECOPlus Steel and alloy wheels M 136 x 2.5 03.272.43.22.2 09.801.06.62.2
SHZM.. ECOPlus Alloy wheels M 136 x 2.5 03.272.43.26.2 09.801.06.23.2

40 BPW-EL-TSB 31081001e
 Grease sprays for greasing taper roller bearings 4.5

Roller bearing grease

Roller bearing

BPW Code no. BPW Code no.

Grease spray for taper roller bearing grease spray loose complete set

33118 16.062.22935
99.00.000.9.55
33213 16.068.22935

Complete set including adapter for flat grease nipple

Adapter for flat grease nipple BPW Code no.

15.069.22935

BPW-EL-TSB 31081001e 41
BPW Original spare parts O Series SKH.., SH.., S..LL

4.6 Grease filling, bearing adjustment

ECO Plus 2 bearing

Grease filling per wheel hub Fig. ECO Plus 2, 8 - 9 t

1 2
130 g 90 g

The ECO Plus 2 hub system is designed for the use of longlife grease. On expiry of the guarantee, the roller bearings, the
inside of the hub and the seals are to be thoroughly cleaned (with diesel oil), dried, checked to see if they can be re-used;
and re-greased every three years when used off-road, or every 5 years when used on the road, within Europe (or every year
when off-road and every two years when on the road outside of Europe) (observe the current BPW maintenance instructions).
Spray the stub-axle bearing seats with BPW ECO Assembly and Protection Spray (BPW no. 02.3521.12.00).
BPW longlife roller bearing grease ECO-LiPlus,
quantity per tapered roller bearing

1 inner 2 outer
Axle load Axle type Roller bearing Quantity Roller bearing Quantity
SH.. 8 - 9 t ECO Plus 2
8000 - 9000 kg 33118 130 g 33213 90 g
SK.. 8 - 9 t ECO Plus 2
Clean the grease cartridge and fill it on both sides up to the edge with BPW ECO-LiPlus special long-life grease.
1 and 2 Apply a ring-shaped bead of grease to the running surfaces of the outer bearing races.
Apply a coat of BPW ECO-LiPlus special long-life grease all around the lip of the seal.
For other procedures see the current maintenance instructions.

When BPW grease applicators are used there is no need to fill the grease cartridge or to apply the bead of grease.
Greasing with grease cartridge see page 41.

Bearing adjustment
1. Undo the hubcap by turning it through approx. 30 degrees in an anticlockwise direction (see page 36).
When turned further the hubcap lifts clearly away from the ECO unit and can be removed by pulling it away.
2. Remove the hooked spring ring and retaining key from the axle bolt.
3. Tighten the axle bolt while at the same time turning the ECO unit with a 46 mm hexagon spanner until the
crown of the axle bolt clicks round.
NB! Do not use an impact driver.
4. Insert the retaining key into the recess in the axle bolt and into the crown of the toothed lock washer (do not
turn the axle bolt back).
5. Insert the hooked spring ring into the groove at the end of the hexagon profile of the axle bolt.
6. Insert a new ‘O’-ring into the groove in the wheel hub.
7. Apply a thin layer of BPW ECOLiPlus special long-life grease to the hubcap in the area of the bayonet fitting.
8. Put the hubcap on (position 1, page 36). Use the 120 mm hubcap spanner to lock the hubcap in place by
turning it through approx. 30 degrees in a clockwise direction, while at the same time pressing on the hubcap.
It is firmly in place when it reaches position 2 (page 36).
NB! Do not use an impact driver - bayonet fitting.

42 BPW-EL-TSB 31081001e
 Grease filling, bearing adjustment 4.7
ECOPlus bearing
Grease filling per wheel hub Fig. ECOPlus, 10 - 12 t

1 2

The ECOPlus hub system is designed for the use of longlife grease. On expiry of the guarantee, the roller bearings, the inside of
the hub and the seals are to be thoroughly cleaned (with diesel oil), dried, checked to see if they can be re-used; and re-greased
every three years when used off-road, or every 5 years when used on the road, within Europe (or every year when off-road and
every two years when on the road outside of Europe) (observe the current BPW maintenance instructions).
Spray the stub-axle bearing seats with BPW ECO Assembly and Protection Spray (BPW no. 02.3521.12.00).
BPW longlife roller bearing grease ECO-LiPlus,
quantity per tapered roller bearing

1 inner 2 outer
Axle load Axle type Roller bearing Quantity Roller bearing Quantity
S H . . 1 0 - 1 2 t E C OPlus 170 g 120 g
10000 - 12000 kg 33118 33213
S K . . 1 0 - 1 2 t E C OPlus 130 g * 90 g *
Work BPW longlife roller bearing grease ECO-LiPlus thoroughly into the spaces between the
1 and 2 tapered rollers and the races. Apply remainder to outer races in the hub.
Renew the lip seal and smear contact area with BPW longlife roller bearing grease ECO-LiPlus.
For other procedures see the current maintenance instructions.

* Greasing with grease cartridge see page 41.

Bearing adjustment
1. Unscrew the hubcap.
2. Remove the hooked spring ring and retaining key from the axle nut.
3. Use a spanner to tighten the axle nut whilst at the same time turning the wheel hub, until the axle nut torque
limiter operates (do not use an impact driver).
4. Fit the retaining key in the groove between the axle stub and the nut (do not reset the axle nut).
5. Insert the hooked spring ring, depending on the version, behind the flange on the axle nut or in the
thread on the axle stub.
6. Screw on hubcap and tighten to 800 Nm.

BPW longlife roller bearing grease Container BPW Code no.

ECO-LiPlus
0.4 kg Cartridge 02.1040.45.00
5 kg Bucket 02.1040.47.00
25 kg Bucket 02.1040.49.00
50 kg Drum 02.1040.50.00

BPW-EL-TSB 31081001e 43
44
5.1

ABS
General

the pulses.
ABS
BPW Original spare parts

signals. Using the pressure control valves

assigned to each wheel, it adjusts the air

fastening parts contained in the retrofit kit

with the supplied installation drawing, then

pressure and therefore the braking of each

and attach them to the axle in accordance

of the wheel as well as for calculating and
performing logical operations on the control
O

As a result, the wheel speed of each wheel

Almost all BPW axles can be retrofitted with

movement is recorded using a proximity-type

the received information about the movement

the exciter ring, sensor brackets, sensors and

connect them to the vehicle electronic system.

In the anti-lock brake system (ABS), the wheel

ABS without problems. To do this, simply take

is continuously sent to the central control ECU.
This runs a complex programme for processing
hub and a sensor (speed sensor) that generates
arrangement with an exciter ring attached to the

individual wheel (depending on the ABS system).

A A-A 1:1 0,2 A

02.1421.11.00 5

02.5681.78.00 4
03.189.07.35.0 6

X
02.5071.22.00 3
M10x15

A 12 02.5678.65.00
03.189.14.61.0 7 OR 128x3

02.5071.23.00 9
M8 x 20
Mmax.=30Nm

03.165.14.23.0 8
02.3317.07.00 2 *
Y A Sensor bei Montage
an Polrad angelegt

Y 2:1
* 10 Buchse und Sensor mit
13 03.310.08.51.0 Silikonfett eingesetzt.
02.0316.59.00 1 *
Polradmontage Z=100 Ausgetretenes Fett
abgewischt.
14 03.310.08.53.0 BPW-Sachnr.: 02.1040.17.00 fuer TSB 3709/4309/4312
1.) Nut und Anlageflaeche fuer Polrad in der Nabe
frei von Verschmutzungen, Farbe, etc. Z=80
Pos. Stk. Benennung Sach-Nr. Nachruestteilesatz
2.) Vor Montage Polrad-Nut und 1 2 Buchse WABCO * 02.0316.59.00
Bajonettverschluss am Polrad beidseitig fetten. 2 2 Sensor WABCO 02.3317.07.00 SH... 9010 / TK- 335
Polrad positionsgerecht einlegen, Anschlagnasen
* SKH... 9010 / TK- 335
11 02.5414.11.90 3 4 Sicherungsschraube M10x15 02.5071.22.00
des Polrades muessen in der Nabe an rechtwinkligen
DIN6798-A10,5-FSt 4 2 Dichtring ( Kabelfuehrung ) 02.5681.78.00
Anschlagflaechen anliegen. Pos. 1 13
5 2 Halter ABS-Stecker 02.1421.11.00
X 3.) Polrad mit stumpfem Gegenstand (z.B. Schraubendreher) 6 2 Halter ABS-Kurz 03.189.07.35.0
Polradmontage hinter Anschlagnocken mit leichten Schlaegen im
7 2 Sensor-Halter 03.189.14.61.0
05.801.74.54.0
Uhrzeigersinn von a nach b (ca. 70
) bis Anschlag drehen.
Series SKH.., SH.., S..LL

vorher nachher
8 2 Formblech 03.165.14.23.0
SKH... 9008 / TK- 275
Achtung ! 9 2 Sicherungsschraube M8x20 02.5071.23.00
Schlagwerkzeuge nicht in Verzahnung ansetzen. 10 1 Silikonfett * 02.1040.17.00
Verzahnung darf keine Beschaedigung aufweisen! 11 2 Faecherscheibe DIN6798 - A 10,5- FSt 02.5414.11.90 Pos. 1 12 + 14
12 2 O-Ring OR 128x3 02.5678.65.00
13 2 Polrad 100 Zaehne 03.310.08.51.0
05.801.74.55.0
14 2 Polrad 80 Zaehne 03.310.08.53.0
Werkstoff
Z
wahlweise

Buch- An-
Z Aenderungen Nummer Datum Bearb. Ges.
stabe zahl
Oberflaechen nach
WN 1.009 (DIN ISO 1302) Datum Name Massstab Benennung
u x
= RZ100 = RZ20
Bearb. 26.11.08 BRAUN.H
v y
= RZ40 = RZ12
a w
RZ30
z
RZ6,3
Geprueft 27.07.09 SPITZKAT 1:2 ABS-Anlage TSB
b = =
Polrad in der Nut s
Gesehen
Passmass Abmasse = = RZ beliebig 27.07.09 SCHLIM.A SKH... / SH... 9t ECO-Plus 2
von a nach b Fuer diese Zeichnung behalten wir
uns alle Rechte vor. Ohne unsere
Nummer
bis auf Anschlag vorherige Zustimmung darf sie we- BPW BERGISCHE ACHSEN
Polrad auf der Nabe der vervielfaeltigt noch Dritten zu-
nach rechts gedreht! gaenglich gemacht werden, und sie Kommanditgesellschaft C- 04.00.533322
positionieren darf durch den Empfaenger oder Werk
Dritte auch nicht in anderer Weise
missbraeuchlich verwendet werden. kennz. W 51674 Wiehl Ersatz fuer Ersetzt durch
View

BPW-EL-TSB 31081001e
View ABS 5.1

Attachments of the sensor brackets

Various sensor attachments are used, depending
on the axle design.

O Sensor attachment on the brake body

or the axle beam (lug), without any
additional components

O Bolted sensor attachment on the axle

beam / steering axle stub

BPW-EL-TSB 31081001e 45
BPW Original spare parts O Series SKH.., SH.., S..LL

5.2 ABS

ABS parts / TSB 3709 / 4309 / 4312 - Rigid axles

A B Ø 18 C D
Ø 18 Ø 18

12.5
12.7

37.5

32.5
Ø 8.5 Ø 6.5 14
39 32 Ø 18
39
E F G
Ø 215 Ø 8.5
174
Ø 156 Ø 193
150
Ø 125

22
19.5
8.5

176 Ø 177
180 5 x Ø 6.5 Fig. left

ECO Plus 2 ECOPlus

570
M 8 M 10
570 M = 25 Nm 586 M = 43 Nm
M 10
586 M = 43 Nm 511 510
510 585
543
585 542 570
570
571
513 M 8
571 M = 25 Nm 542
590
511
561
542 563

SKH.. SKH..
SH..
560 560
570
M 10
570 586 M = 43 Nm
M 10
586 M = 43 Nm 510
510 585
585 570
M 6
513 M = 12 Nm
570 571
590 551
571
553
542

SKHB..
SHB..
SKH..
560
SH..
560

46 BPW-EL-TSB 31081001e
 ABS 5.2
ABS parts / TSB 3709 / 4309 / 4312 - Rigid axles

TSB 3709

TSB 4309

TSB 4312
SKHB.. 8010 / 9010 ECO Plus 2
SKHS.. 8008 / 9008 ECO Plus 2

SKHS.. 8010 / 9010 ECO Plus 2

SKHZ.. 8008 / 9008 ECO Plus 2

SKHZ.. 8010 / 9010 ECO Plus 2

SHB.. 8010 / 9010 ECO Plus 2

SHS.. 8010 / 9010 ECO Plus 2
SHZ.. 8010 / 9010 ECO Plus 2

S H S . . 1 0 0 1 0 - 1 2 0 1 0 E C OPlus
S H Z . . 1 0 0 1 0 - 1 2 0 1 0 E C OPlus
SH.. 10110 ECO Plus 2
SKH.. 10008 ECOPlus
SKH.. 10010 ECOPlus
Item Designation Dimension Fig. BPW Code no.
510 Locking bolt M 10 x 15 02.5071.22.00 O O O O

511 Locking bolt M 8 x 20 02.5071.23.00 O O O O

513 Cable protection 02.5681.78.00 O O O

542 Sensor bracket A 03.189.14.61.0 O O O

B 03.189.07.87.0 O

C 03.189.15.76.0 O O

542 Sensor bracket, right D 03.189.07.58.0 O

543 Sensor bracket, left 03.189.07.59.0

551 Cylinder head bolt M 6 x 16 02.5015.00.80 O

553 Spring washer A 6 02.5601.06.90 O

560 Exciter ring Ø 125 / 156 x 8,5 / Z = 100 E 03.310.08.51.0 O O O O

Ø 125 / 156 x 8,5 / Z = 80 03.310.08.53.0 O

Ø 150 / 174 / 176 / F 05.310.08.50.1 O O

180 x 19,5 / Z = 100
Ø 177 / 193 / 215 x 14/22 G 03.310.09.38.0 O
Z = 80
Ø 177 / 193 / 215 x 14/22 03.310.09.39.0 O
Z = 100
561 Cylinder head bolt M 6 x 30 - 8.8 02.5015.48.82 O

M 6 x 20 - 8.8 02.5015.06.82 O

563 Spring washer Ø 6 02.5611.06.90 O O

570 Sensor, straight L = 350 02.3317.07.00 O O O O O O O

Sensor, cranked 02.3317.05.00 O O

571 Bush 02.0316.59.00 O O O O O O O O O

585 Support short - L 35 03.189.07.35.0 O O O O O O O O O

586 Support 02.1421.11.00 O O O O O O O O O

590 Heat protection plate 03.165.14.23.0 O O O O O

Special silicone grease 3 g 02.1040.17.00 O O O O O O O O O

BPW-EL-TSB 31081001e 47
BPW Original spare parts O Series SKH.., SH.., S..LL

5.3 ABS

ABS parts / TSB 3709 / 4309 - Steering axles

A B
Ø 156
Ø 18 Ø 125

8.5
Ø 8.5

BPW ECO Disc TSB 3709 / 4309

194
8 / 9
586

585 570
564
587
565

560

570

571

590
SK..LL
511 SH..LL
M 8
M = 25 Nm 542

SK..BLL
SH..BLL

48 BPW-EL-TSB 31081001e
 ABS 5.3
ABS parts / TSB 3709 / 4309 - Steering axles

TSB 3709

TSB 4309
SK..B..LL 7510 - 9010

SH..B..LL 8010 / 9010

SH..S..LL 9010 / 9010
SH..Z..LL 9010 / 9010
SK..S..LL 8010 / 9010
SK..Z..LL 8008 / 9008

SK..Z..LL 8010 / 9010

SK..S..LL 8008 / 9 0 0 8
Item Designation Dimension Fig BPW Code no.
511 Locking bolt M 8 x 20 02.5071.23.00 O O O O

542 Sensor bracket A 03.189.14.86.0 O O O O

560 Exciter ring Ø 125 / 156 x 8.5 / Z = 100 B 03.310.08.51.0 O O O

Ø 125 / 156 x 8.5 / Z = 80 B 03.310.08.53.0 O

564 Clip 1 x 6 02.0326.32.00 O O O O

565 Drive pin Ø 4 x 10 02.6005.25.40 O O O O

570 Sensor, straight L = 350 02.3317.07.00 O O O O

571 Bush 02.0316.59.00 O O O O

585 Support long - L 70 03.189.07.72.0 O O O O

586 Support 02.1421.11.00 O O O O

590 Heat protection plate 03.165.03.01.0 O O O O

Special silicone grease 3 g 02.1040.17.00 O O O O

BPW-EL-TSB 31081001e 49
BPW Original spare parts O Series SKH.., SH.., S..LL

5.4 ABS retrofit part sets

ABS retrofit part sets for one axle consisting of exciter rings, ABS-System
sensors, sensor brackets, fastening components and
mounting drawings. Wabco / Bosch
also for:
Grau DGX / M
Grau MGX 100
Knorr

Pitch
circle Exciter ring / Retrofit kit cpl.
Axle type (TK) Remark BPW Drawing Brake teeth BPW Code no.
SKH.. 8008 - 9008 275 120 C-04.005.33.32.2 80 05.801.74.55.0
SKH.. 8010 - 9010 335 120 C-04.005.33.32.2 100 05.801.74.54.0
SKH.. 10008 275 150 C-04.005.33.32.4 TSB 3709 80 05.801.74.58.0
SKH.. 10010 335 150 C-04.005.33.32.4 100 05.801.74.57.0
SKHB.. 9010 335 120 C-04.005.33.32.3 100 05.801.74.56.0
SH.. 8010 - 9010 335 120 C-04.005.33.32.2 100 05.801.74.54.0
TSB 4309
SHB.. 9010 335 120 C-04.005.33.32.3 100 05.801.74.56.0

50 BPW-EL-TSB 31081001e
 Notes

BPW-EL-TSB 31081001e 51
BPW Original spare parts O Series SKH.., SH.., S..LL

6.1 Wheel studs View

General

BPW wheel studs

The wheel nave (or wheel disc) connects the
rim to the wheel hub. It must absorb the vertical,
lateral and longitudinal forces which arise and
transmit them to the wheel hub via the wheel
studs (wheel bolts).

BPW axles with disc brakes are suitable for

wheels with either bolt or hub centring, and
with a few exceptions they are all supplied
with helical bolts.

Helical studs are easy to maintain and connect

the brake drum to the hub using a pressfit.
As a result, there is no need for internal nuts.

The hub bore is not damaged even after several

removal/installation operations (in contrast to the
situation with splined studs) and the holding
forces for the wheel studs remain constant.

The prescribed BPW tightening torques for

wheel attachment are listed in the current BPW
maintenance instructions and must be observed.

Assembly of the wheel bolts

7.5
. 10
The helical bolt is inserted from the rear through max
97
the hole in the brake disc / hub.
Then a sleeve is pushed over it, a wheel nut is
applied and the wheel bolt is drawn into its final
position.

 It is important to ensure that the flattened

head of the wheel bolt sits correctly!
Hub
Brake disc

!
Hub
Brake disc

52 BPW-EL-TSB 31081001e
View Wheel studs 6.1

Stud alignment
In stud centring, the wheel nave (with counter-
sunk stud holes) is centred using wheel studs
with (spring) centring rings.

Spigot alignment
In hub centring, the wheel nave is centred
Wheel nut with rotatable disc

using a centring spigot or ring surfaces on

the wheel hub.

In the case of 8-hole disc wheels with

Centring bush
countersunk stud holes and 10-hole disc
wheels, a centring bush is mounted on 2
opposite wheel studs for each hub.

Alloy wheels
In the case of aluminium wheels, the wheel
nave is centred using a centring cam or ring
surfaces on the wheel hub.
As the flange thickness is greater with alloy
wheels than with steel wheels, it is important
to check whether the axles are suitable for Ø 32 Ø 26
fitting alloy wheels (with 26 mm-diameter hole).
In the case of twin tyres the available centring
seat and wheel bolts must be of adequate
length (i.e. the thread of the wheel nut must
be completely engaged with the wheel bolt
thread).
If not, aluminium wheels with stud hole Ø 32
can be used in conjunction with shaft nuts
without replacing the hub or the wheel studs.

BPW-EL-TSB 31081001e 53
BPW Original spare parts O Series SKH.., SH.., S..LL

6.2 Wheel studs

Wheel studs
Hub Wheel type Wheel nut item 470 item 472 item 476 item 476

Alloy wheel Ø 26 without offset

Alloy wheel Ø 32 without offset

Alloy wheel Ø 26 with offset

Alloy wheel Ø 32 with offset

Steel wheel without offset

Wheel stud assemly cpl.

Steel wheel with offset

Shaft nut SW 32
Spigot alignment

(item 472 - 479)

Cap nut SW 33

1)
Stud alignment

normal SW 32

Centring ring
Wheel stud
wheel stud
Dimension
Steel hub

Thread M 2 2 x 1 . 5

2)
09.806.

03.296.

03.310.

03.112.
L / L1

Bush
Wheel studs Fig.

Single wheels
Helical fit wheel bolt O O O O O 1 A 33.75.0 80 / 45 33.11.1 - -
O O O O 1 C 33.11.0 89 / 54 33.14.1 - 00.43.0
O O O O O 1 C 33.76.0 80 / 45 33.11.1 - 00.43.0
O O O O 1 C 33.04.0 89 / 54 33.14.1 - 00.43.0
O O O O 1 C 33.77.0 80 / 45 33.11.1 - 00.43.0
O O O O 1 E 33.68.0 97 / 62 33.12.1 - -
O O O 1 E 33.69.0 97 / 62 33.12.1 - -
O O O 1 G 33.78.0 80 / 45 33.11.1 - -
O O O 1 G 33.79.0 97 / 62 33.12.1 - -

Twin wheels
Helical fit wheel bolt O O O O 1 B 33.67.0 97 / 62 33.12.1 10.13.0 -
O O O O 1 D 33.68.0 97 / 62 33.12.1 - 00.42.0
O O O 1 H - 89 / 54 33.14.1 - -
O O O 1 H - 97 / 62 33.12.1 - -
1)
Centring ring with helical fit wheel bolts and twin wheels.
2)
Bush not included in wheel stud assembly 09.806..... (see page 53).

54 BPW-EL-TSB 31081001e
 Wheel studs 6.2
Wheel studs
item 478 item 479 Helical fit wheel bolt 1
Steel hub

L
L1
472
Spring washer

Wheel nut
02.5615.

22.90 03.260.04.12.0 Single wheels Twin wheels

- 05.260.54.10.0 Steel wheels A B Tightening torques for
Stud alignment w h e e l n u t s item 479
- 05.260.54.10.0
- 05.260.54.19.0 479 479 Thread Stud alignment
- 05.260.54.19.0 M 22 x 1.5 510 Nm (485-535)
- 05.260.54.10.0
- 05.260.54.19.0
- 05.260.54.21.1
- 05.260.54.21.1 478 478 477

Steel wheels C D Tightening torques for

22.90 03.260.04.12.0 Spigot alignment w h e e l n u t s item 479
- 05.260.54.10.0 479 Thread Spigot alignment
479
- 05.260.54.14.1 M 22 x 1.5 630 Nm (600-660)
- 05.260.54.14.1

476 476

Alloy wheels Ø 26 E Tightening torques for

w h e e l n u t s item 479
479 Thread Alloy wheels
M 22 x 1.5 630 Nm (600-660)

max. 28

Alloy wheels Ø 32 G Alloy wheels Ø 32 H Tightening torques for

w h e e l n u t s item 479

479 Thread Alloy wheels

479
M 22 x 1.5 630 Nm (600-660)

max. 28 max. 44

BPW-EL-TSB 31081001e 55
BPW Original spare parts O Series SKH.., SH.., S..LL

7.1 Steering dampers View

BPW Steering dampers

For BPW trailing steering axles, series ..LL,
there are various steering damper parts kits.
A steering damper is absolutely essential
under the following operating conditions:

O Where the ratio of the number of rigid

X
axles to steering axles is 1:1 (2:2) A
O Where an axle lift is used in the
three-axle unit
O Where steering axle king pin bearings
are connected to a central lubricating A
system.

The steering damper is easy to install and also

to retrofit. Installation is carried out exclusively
by means of bolts (no welding).
The necessary attachment holes are present AA
on the steering axles. Each parts kit also
includes an installation drawing.

56 BPW-EL-TSB 31081001e
 Steering dampers 7.2

BPW Steering dampers

Item Designation (Remark) BPW Code no. Dimension

M 10-8
05.872.00.56.0 05.872.00.59.0 M = 26 Nm M 12-8.8
M = 43 Nm
610 635
650
M 10-10.9
M = 74 Nm 614 615 655
M 10-04
630 M = 26 Nm 630
610 623
620 605
625 M 10-8
618 635 M = 26 Nm

635 605 618 M 10-10.9

M 10-8 M 10-04 M = 74 Nm
M = 26 Nm 632 M = 26 Nm 620 614
M 12-8.8 625
M = 43 Nm 634 610
650 615
630
655

623 610
635
M 10-8
M = 26 Nm

Trailing arm above Trailing arm below

X = 163 / 171 X = 25 / 35 / 45
X
X

600 Steering damper assembly 05.872.00.56.0 05.872.00.59.0

(item 605 - 660)
605 Steering damper 02.3702.93.00 02.3702.93.00
610 Clamp cpl. 05.001.00.03.0 05.001.00.03.0
(incl. item 614)
614 Hexagon bolt 02.5025.56.11 M 10 x 50 - 10.9 02.5025.56.11 M 10 x 50 - 10.9
615 Ring 03.310.30.51.0 Ø 10.5 / 17 x 3.5 03.310.30.51.0 Ø 10.5 / 17 x 3.5
618 Lock washer 02.5403.10.92 B 10 02.5403.10.92 B 10
620 Hexagon nut 02.5205.03.24 M 10 02.5205.03.24 M 10
623 Shaped plate 03.165.56.35.0 03.165.35.12.0
625 Shaped plate 03.165.34.10.0 03.165.34.09.0
630 Hexagon bolt 02.5021.43.82 M 10 x 40 - 8.8 02.5021.43.82 M 10 x 40 - 8.8
632 Hexagon bolt 02.5021.50.82 M 10 x 70 - 8.8 -
634 Ring 03.310.30.68.0 Ø 10.2 / 13 x 30
635 Lock nut 02.5273.10.82 M 10 02.5273.10.82 M 10
650 Hexagon bolt 02.5025.75.82 M 12 x 16 - 8.8 02.5025.75.82 M 12 x 16 - 8.8
655 Lock washer 02.5403.12.92 B 12 02.5403.12.92 B 12

BPW-EL-TSB 31081001e 57
BPW Original spare parts O Series SKH.., SH.., S..LL

8.1 Hubcaps with integrated Hubodometer

Hubcap with
integrated
Developed Hubodometer
Axle load Axle series Axle type Hubcap thread for tyre e.g. area BPW Code no.

255 / 70 R 22.5 2830 - 2860 05.212.25.41.0

275 / 70 R 22.5 2915 05.212.25.42.0
385 / 55 R 22.5
3015 - 3134 05.212.25.44.0
315 / 70 R 22.5
10.00 R 20
3175 - 3220 05.212.25.45.0
10 - 12 t SH.. ECOPlus M 136 x 2.5 11.00 R 22.5
SH.. 385 / 65 R 22.5 3240 - 3260 05.212.25.46.0
SH..LL 12.00 R 22.5 3280 - 3310 05.212.25.47.0
SM..LL 425 / 65 R 22.5
3410 - 3470 05.212.25.48.0
13.00 R 22.5
445 / 65 R 22.5 3505 05.212.25.49.0
385 / 55 R 22.5
3015 - 3134 05.212.25.73.0
315 / 70 R 22.5
8 - 9 t SH.. ECO Plus 2 Bayonet lock
11.00 R 22.5 3175 - 3220 05.212.25.74.0
385 / 65 R 22.5 3240 - 3260 05.212.25.75.0
265 / 70 R 19.5 2620 - 2650 05.212.25.38.0
SKH.. 285 / 70 R 19.5 2712 - 2750 05.212.25.39.0
10 - 12 t SKH.. ECOPlus M 136 x 2.5
SKH..LL 445 / 45 R 19.5 2730 - 2790 05.212.25.40.0
SKM..LL 425 / 55 R 19.5 2960 05.212.25.43.0
8 - 9 t SKH.. ECO Plus 2 Bayonet lock 445 / 45 R 19.5 2730 - 2790 05.212.25.72.0

58 BPW-EL-TSB 31081001e
 Hubcaps with digital odometer (ECOMETER) 8.2
The BPW hubcap with its integrated digital
odometer is an important instrument for checking
the mileage of your trailer or semitrailer.
This means you can always track the real trailer
mileage, especially when the trailer is used with
different tractor units.
The digital ECOMETER can be used universally
for all tyre sizes.
The adjustment of the wheel size is carried out
by means of the display unit (basic setting
385/65 R 22.5).

A built-in watertight mini-computer counts the

wheel revolutions by means of a magnet and a
reed contact.

The digital ECOMETER with the special hooked

spring ring and integrated magnet is available for
all BPW ECOPlus axles with an M 136 x 2.5 hubcap
thread, as well as ECO Plus 2 axles with a bayonet
fitting.

BPW Code no.:

Thread M 136 x 2.5 05.212.75.02.0 KTLZn

Bayonet lock 05.212.75.05.0 KTLZn

incl. ‘O’-Ring

Circlip loose
ECOPlus 05.188.04.13.0
ECO Plus 2 05.277.10.03.0

Replacement battery 02.0130.97.00

Further information see service and installation

instruction 'Digital ECOMETER' - BPW No.:
04.001.21.24.0 and 04.001.21.25.0.

BPW-EL-TSB 31081001e 59
BPW Original spare parts O Series SKH.., SH.., S..LL

9 Special tools for BPW ECO Disc Trailer disc brakes

BPW Special tools and calibration equipment

Special tools and measuring devices have a

long tradition at BPW Bergische Achsen KG,
based on decades of experience.
The existing range of tools has been systemati-
cally improved and new products have been
added to it with every new generation of axles.

BPW offers a tool case (BPW Code no.

99.00.000.9.63) for service and repair of the
BPW ECO Disc Trailer disc brakes, containing
all tools that might be required.

In addition to which BPW offers special

measuring devices for checking dimensions
on axles and suspensions.

Tried and tested design

Tools must prove their worth in hard, everyday
use. Long service life, low wear
Only then does it become clear whether tools BPW tools are designed to be particularly
are up to the demands of the real world. resistant to wear and tear, and guarantee an
extremely long service life, even with frequent
Use of high-quality materials use.
High-quality materials are absolutely essential
for producing high-quality tools. Simple to handle
Continuous quality assurance guarantees Ideal solutions are always simple.
consistent quality. This statement also particularly applies to tools.
For that reason BPW tools are specifically
Favourable price/performance ratio designed to meet the technical requirements.
Quality is not always obvious at first glance Solutions that do not meet practical require-
(e.g. materials). ments are rigorously weeded out at the deve-
Buying quality tools is often the most cost lopment stage.
effective long term option.
This particularly applies in those cases where
tools are regularly needed and where their Details on the correct use of the tools can
trouble-free use must be guaranteed at all be found in the respective workshop manuals.
times. For more tools see the BPW tools catalogue.

O The special tools ensure that all recommended

service work on the BPW ECO Disc
(TSB 3709 / TSB 4309 / TSB 4312) can be
performed safely and easily.
O All work on the vehicle is only allowed to be
performed by employees of the commercial vehicle
industry and the commercial vehicle trade who
have the appropriate technical proficiency.
Always follow the safety instructions issued by
the vehicle manufacturer.

60 BPW-EL-TSB 31081001e
 Contents of ECO Disc tool case 9.1

13 2 5 16 4 7 12

9
3

6 8

14

15 1 11 10
Item Designation BPW Code no. Page
1 Threaded spindle 02.0130.39.10 62

2 Ball bearing 02.0130.40.10 62

3 Sleeve 02.1410.26.00 62

4 Press-out tool for movable and fixed bearings 02.0130.41.10 62

5 Pressing tool (movable bearing) 02.0130.42.10 62

6 Nut 02.5270.37.00 62

7 Counter-hold tool 02.1421.22.00 62

8 Pressing tool (fixed bearing) 02.0130.43.10 62

9 Press-on tool (plastic bellows) 02.0130.45.10 63

10 Torx spanner return mechanism 02.0130.44.10 63

11 Two-hole spanner for coarse dirt seal 02.3516.20.00 63

12 Adapter for movable bearing screw 02.0130.46.10 63

13 Adapter for plastic cap 02.0130.47.10 63

14 Adapter for torque wrench (movable bearing) 02.0130.48.10 63

15 Adapter for torque wrench (plastic cap) 02.0130.49.40 63

16 Ring for pulling in wheel studs 02.5683.92.00 63

BPW-EL-TSB 31081001e 61
BPW Original spare parts O Series SKH.., SH.., S..LL

9 Special tools for BPW ECO Disc Trailer disc brakes

BPW special tools at work

Item / BPW Code no. / Designation / Dimension

1 Press-out tool for movable bearing,

02.0130.39.10 consisting of item 1, 2, 3, 4, 6
Threaded spindle
M 18 / SW 22

2
02.0130.40.10
Ball bearing 3 4 6
1 2

3 Pressing tool for movable bearing,

02.1410.26.00 consisting of item 1, 2, 4, 5, 6, 7,
Sleeve Ø 20.5 / Ø 42 / Ø 55

4
02.0130.41.10
Press-out tool for movable
and fixed bearings 4 5 7 6
1 2

5 Press-out tool for fixed bearing,

02.0130.42.10 consisting of item 1, 2, 3, 4, 6
Pressing tool (movable bearing)

6
02.5270.37.00
Nut M 18 SW 32 3 2
6 4 1

7 Pressing tool for fixed bearing,

02.1421.22.00 consisting of item 1, 2, 6, 7, 8
Counter-hold tool

8
02.0130.43.10
Pressing tool (fixed bearing)

1 8 2
6 7

SW = Spanner width

62 BPW-EL-TSB 31081001e
 Special tools for BPW ECO Disc Trailer disc brakes 9.2
BPW special tools at work
Item / BPW Code no. / Designation / Dimension

9 9 10
02.0130.45.10
Press-on tool (plastic bellows)

10
02.0130.44.10
Torx spanner return mechanism

11 11 12
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 13 14
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 15 16
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

BPW-EL-TSB 31081001e 63
BPW Original spare parts O Series SKH.., SH.., S..LL

Notes

64 BPW-EL-TSB 31081001e
BPW-EL-TSB 31081001e 65
 BPW-EL-TSB 31081001e

BPW Bergische Achsen Kommanditgesellschaft, P.O. Box 12 80, D-51656 Wiehl, Phone: +49 2262 78-0, [email protected], www.bpw.de