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164642-1 A Betriebsanleitung en-US PDF
164642-1 A Betriebsanleitung en-US PDF
055/057/058
34.08.583.037 - 039
Workshop manual
WORKSHOP MANUAL
Contents
Page
312
314
215 214
190
295
311
319
330
192 335
319
285 210
280 286
255
256 254
288
292 240
268 241 316 318
264
264 262 262 258 363
366
363
364
284 364 361
215 340
293 360
294
293 330
335
350
380
357
474
472
420
422
430
431
560
510 501
503 441
520
446
570 513
586 564 460
570
510 571 435
551 436
587 553
585 447
542
540
517
513
502
504 34.10.583.055 / 34.10.583.057
513
34.08.583.037 / 34.08.583.038 / 34.08.583.039
11
312
314
215 214
190
295
311
319
330
192 335
319
210
255
256 254
215
280 240
292 241 316 318
268 264
262 258 363
264 284
366
364
363
364 361 340
360
294 330
293 335
350
380
357
474
472
420
422
430
431
560
510 501
503 441
520
446
570 513
586 564 460
570
510 571 435
551 436
587 553
585 447
542
540
517
513
502
504
513
34.10.583.058
12
2 Spare parts list
21
Item Designation BPW Code number Dimension Quantity
350 Brake lining 03.092.13.44.0 18 mm 6
357 Rivet 02.5805.80.35 B 8 x 15 48
360 Bolt 03.084.42.04.0 Ø 12 x 135 4
361 Lock 02.3301.17.00 12 SXN 09 8
363 Return spring 03.397.34.14.0 Ø 20 / 3.2 x 107 4
364 Return spring 03.397.34.15.0 Ø 20 / 3.2 x 84 4
366 Plate 03.285.23.21.0 2
380 Brake drum 03.109.44.01.0 Ø 300 x 150 / B: 200 2
420 Thrust washer 03.370.07.45.0 Ø 86 / 125 x 22 2
422 Oil seal 02.5664.26.57 Ø 125 / 143 x 11 2
430 Roller bearing 02.6408.80.00 33116 2
431 Dust cover 03.010.04.15.0 Ø 84 / 129 x 5.5 2
435 Hub incl. item 436 03.272.27.20.0 10 x Ø 22 / M 115 x 2 2
436 Splined pin 02.6010.35.60 6 x 19.5 20
441 Roller bearing 02.6406.50.00 32310 2
446 Castle nut 03.262.16.10.0 M 42 x 2 / SW 65 2
447 Split pin 02.6201.82.01 8 x 50 2
460 Hub cap 03.212.23.32.0 M 115 x 2 / SW 95 2
472 Wheel stud 03.296.23.15.1 M 22 x 1.5 / M 22 x 2 / 20
100 / 46 / 49
474 Lock nut 03.260.04.06.0 M 22 x 2 10 20
500 Set of dust cover assemblies
item 501 504, 510, 513, 517, 520 99.00.000.100 SN 30151 / Ø 127 / 0° 1
501 Dust cover, left upper 03.010.96.48.0 Dust covers available as sets
upper + lower! 1
502 Dust cover, left lower 03.010.96.40.0 Dust covers available as sets
upper + lower! 1
503 Dust cover, right upper 03.010.96.49.0 Dust covers available as sets
upper + lower! 1
504 Dust cover, right lower 03.010.96.41.0 Dust covers available as sets
upper + lower! 1
510 Locking screw 02.5070.60.02 M 10 x 12 8
513 Plug 02.3704.33.00 Ø 10.7 2
513 Cable grommet 02.5681.78.00 Ø 6 / 10 / 13 x 7 2
517 Seal 05.121.30.06.0 L = 340, 8 2
520 Plug 03.379.00.23.0 4
520 Plug 02.3704.42.00 2
540 Attachment plate 03.080.03.30.0 U 60 x 4 2
542 Sensor bracket 03.189.07.87.0 1
551 Cylinder cap screw 02.5015.00.80 M 6 x 16 8.8 2
553 Spring washer 02.5601.06.90 A6 2
560 Exciter ring 03.310.08.27.0 d: 145 1
564 Clamp 02.3507.32.00 1
570 Sensor 02.3317.05.00 1
571 Bush for ABS 02.0316.59.00 1
585 Support 03.189.07.72.0 1
586 Support for sensor plug 02.1421.11.00 1
587 Serrated lock washer 02.5414.11.90 A 10.5 1
22
2 Spare parts list
23
Item Designation BPW Code number Dimension Quantity
350 Brake lining 03.092.13.44.0 18 mm 6
357 Rivet 02.5805.80.35 B 8 x 15 48
360 Bolt 03.084.42.04.0 Ø 12 x 135 4
361 Lock 02.3301.17.00 12 SXN 09 8
363 Return spring 03.397.34.14.0 Ø 20 / 3.2 x 107 4
364 Return spring 03.397.34.15.0 Ø 20 / 3.2 x 84 4
366 Plate 03.285.23.21.0 2
380 Brake drum 03.105.36.12.0 Ø 300 x 150 / B: 210 2
420 Thrust washer 03.370.07.44.0 Ø 96 / 145 x 22 2
422 Oil seal 02.5664.46.57 Ø 145 / 167 x 13 2
430 Roller bearing 02.6408.92.00 33118 2
431 Dust cover 03.010.05.22.0 Ø 94 / 149 x 5.5 2
435 Hub incl. item 436 03.272.44.30.0 10 x Ø 22 / M 125 x 2 2
436 Splined pin 02.6010.35.60 6 x 19.5 20
441 Roller bearing 02.6407.67.00 33213 2
446 Castle nut 03.262.17.12.0 M 42 x 2 / SW 65 2
447 Split pin 02.6201.84.01 8 x 63 2
460 Hub cap 03.212.24.07.0 M 125 x 2 / SW 110 2
472 Wheel stud 03.296.23.17.0 M 22 x 1.5 / M 22 x 2 / 20
114 / 60 / 49
474 Lock nut 03.260.04.06.0 M 22 x 2 10 20
500 Set of dust cover assemblies
item 501 504, 510, 513, 517, 520 99.00.000.100 SN 30151 / Ø 127 / 0° 1
501 Dust cover, left upper 03.010.96.48.0 Dust covers available as sets
(upper and lower)! 1
502 Dust cover, left lower 03.010.96.40.0 Dust covers available as sets
(upper and lower)! 1
503 Dust cover, right upper 03.010.96.49.0 Dust covers available as sets
(upper and lower)! 1
504 Dust cover, right lower 03.010.96.41.0 Dust covers available as sets
(upper and lower)! 1
510 Locking screw 02.5070.60.02 M 10 x 12 8
513 Plug 02.3704.33.00 Ø 10.7 2
513 Cable grommet 02.5681.78.00 Ø 6 / 10 / 13 x 7 2
517 Seal 05.121.30.06.0 L = 340, 8 2
520 Plug 03.379.00.23.0 4
520 Plug 02.3704.42.00 2
540 Attachment plate 03.080.03.30.0 U 60 x 4 2
542 Sensor bracket 03.189.10.53.0 1
551 Cylinder cap screw 02.5015.00.80 M 6 x 16 8.8 2
553 Spring washer 02.5601.06.90 A6 2
560 Exciter ring 05.310.08.39.0 d: 145 1
564 Clamp 02.3507.32.00 1
570 Sensor 02.3317.05.00 1
571 Bush for ABS 02.0316.59.00 1
585 Support 03.189.07.72.0 1
586 Support for sensor plug 02.1421.11.00 1
587 Serrated lock washer 02.5414.11.90 A 10.5 1
24
2 Spare parts list
25
Item Designation BPW Code number Dimension Quantity
360 Bolt 03.084.42.04.0 Ø 12 x 135 4
361 Lock 02.3301.17.00 12 SXN 09 8
363 Return spring 03.397.34.14.0 Ø 20 / 3.2 x 107 4
364 Return spring 03.397.34.15.0 Ø 20 / 3.2 x 84 4
366 Plate 03.285.23.21.0 2
380 Brake drum 03.105.36.12.0 Ø 300 x 150 / B: 210 2
420 Thrust washer 03.370.07.44.0 Ø 96 / 145 x 22 2
422 Oil seal 02.5664.46.57 Ø 145 / 167 x 13 2
430 Roller bearing 02.6408.92.00 33118 2
431 Dust cover 03.010.05.22.0 Ø 94 / 149 x 5.5 2
435 Hub incl. item 436 03.272.44.30.0 10 x Ø 22 / M 125 x 2 2
436 Splined pin 02.6010.35.60 6 x 19.5 20
441 Roller bearing 02.6407.67.00 33213 2
446 Castle nut 03.262.17.12.0 M 42 x 2 / SW 65 2
447 Split pin 02.6201.84.01 8 x 63 2
460 Hub cap 03.212.24.07.0 M 125 x 2 / SW 110 2
472 Wheel stud 03.296.23.17.0 M 22 x 1.5 / M 22 x 2 / 20
114 / 60 / 49
474 Lock nut 03.260.04.06.0 M 22 x 2 10 20
500 Set of dust cover assemblies
item 501 504, 510, 513, 517, 520 99.00.000.100 SN 30151 / Ø 127 / 0° 1
501 Dust cover, left upper 03.010.96.48.0 Dust covers available as sets
(upper and lower)! 1
502 Dust cover, left lower 03.010.96.40.0 Dust covers available as sets
(upper and lower)! 1
503 Dust cover, rechts oben 03.010.96.49.0 Dust covers available as sets
(upper and lower)! 1
504 Dust cover, rechts unten 03.010.96.41.0 Dust covers available as sets
(upper and lower)! 1
510 Locking screw 02.5070.60.02 M 10 x 12 8
513 Plug 02.3704.33.00 Ø 10.7 2
517 Seal 05.121.30.06.0 L = 340, 8 2
520 Plug 03.379.00.23.0 4
520 Plug 02.3704.42.00 2
26
3 Care and maintenance
5 4 1 1 2 6 2 6 1 4
31
each brake lining change
2)
Lubrication and maintenance work
2)
For detailed description see pages 33 to 38
every 12 weeks
every 26 weeks
initially
Lubricate
Maintenance work
shortdistance haulage 1 1)
longdistance haulage 1
Maintenance work 3)
1)
after a long standing period, prior to initial operation actuate the brake lever and lubricate the brake camshaft bearing.
2)
under extreme conditions, increase frequency (e.g. construction sites and poor roads).
3)
after the first run under load conditions and likewise after each wheel change.
32
3 Care and maintenance
Lubricate 1 1
2 Slack adjusters
– quarterly –
2
Grease lubrication nipple with BPW special
longlife grease ECOLiPlus until fresh grease
emerges.
33
4 Automatic slack adjusters ECO-Master
34
3 Care and maintenance
6 - 9 t: 170 g 6 - 9 t: 290 g
10 - 12 t: 180 g 10 - 12 t: 320 g
35
– Maintenance work
36
3 Care and maintenance
- Visual inspection
– every six months –
Check all components for damage and wear.
37
5 Check hub cap for firm seating
– every six months –
Check hub caps for firm seating using a torque
wrench or power tool.
38
4 Changing the brake lining
Fig. 1
Reset brake.
Unscrew the hub cap. Remove the split pin from the
axle nut and unscrew.
Screw on extractor cap and withdraw the wheel hub
with the wheels from the axle stub.
Fig. 2
Fig. 3
41
Remove lock from the pins. Detach and remove
return springs (arrow) at the top and bottom.
Fig. 4
Fig. 5
Unrivet the old brake lining and clean the brake shoe.
The surface must be free of rust and be smooth. With
skimmed brake drums use the relative oversized brake
linings. Insert all rivets and hold in position by crimping
edges.
Rivet brake lining on.
Riveting force: 21000 N (20000 22000 N)
Rivets: semitubular rivets,
galvanized steel 8 x 15 mm
meeting DIN 7338 B
Fig. 6
42
4 Changing the brake lining
Fig. 7
ABS
Check sensor for damage and displacement (displace
ment force 100 200 N). If necessary, smear clamping
bush and sensor with special silicone grease. Before
fitting hubs, always press clamping bush and sensor to
the endstop.
When fitting hub, the sensor will be pushed back into
the correct position by the exciter ring.
Note:
If the press in force is too low, replace
retention bush.
If the press in force is too high, dismantle
sensor and retention bush, open bore hole
dia. (18H7), replace retention bush and, if Fig. 8
necessary, sensor.
Fig. 9
43
Mount new inner return springs on the brake shoes
and insert lock.
Fig. 10
Fig. 11
Fig. 12
44
4 Changing the brake lining
Important:
The braking effect of new brake drums and
brake linings is only at its optimum after a
few braking actions.
Fig. 13
Fig. 15
45
Insert outer taper roller bearing. Screw on axle nut
and tighten with torque wrench to 150 Nm, turning
the hub at the same time. Alternatively, use a normal
axle nut wrench and tighten, turning the hub at the
same time, until the hub’s rotation is slightly checked.
Unscrew axle nut to next hole or, if the axle nut is
already positioned opposite a hole, turn back to the
one before (max. 30°).
Fig. 16
Fig. 17
Fill the hub cap with 320 g BPW special longlife grease
ECOLiPlus. Grease thread of hub cap all round with
BPW special longlife grease ECOLiPlus and screw in.
Fig. 18
46
5 Dismantling and re-fitting wheel hub
Fig. 20
51
Press in new shaft sealing ring, with the sealing lip
pointing to the wheel hub, into the wheel hub by
means of a pressingin device.
Grease sealing lip with BPW special longlife grease
ECOLiPlus.
Fig. 22
Fig. 23
Fig. 24
52
6 ABS / ABV
6 ABS / ABV
Check sensor for damage and displacement
(displacement force 100 200 N). If necessary,
smear clamping bush and sensor with special
silikone grease (replace clamping bush). Before
fitting hubs, always press clamping bush and
sensor up to endstop.
Fig. 25
Fig. 26
Fig. 27
61
7 Brake bolts, cover plates
Fig. 28
71
8 Brake camshaft
8 BRAKE CAMSHAFT
Dismantling and refitting the complete
wheel hub bearing, see page 41.
Remove circlip from the groove of the brake cams
haft. Remove slack adjusters with two rings. Pull rear
spacer ring with washer off the brake camshaft.
Take brake camshaft out of the brake anchor plate.
Fig. 29
Fig. 30
Fig. 31
81
9 Manual slack adjuster
12 3 4 5
Fig. 32
Fig. 33
Brake adjustment.
Align the slack adjuster to the brake compensator
using the hexagon adjuster. Attach piston rod with
split pins to the brake compensator. The cylinder
push rod and slack adjuster should be at an angle of
approximately 90° to each other when the brake is B
applied.
A clearance "a" of 10 12 % (=18 21 mm) of the
lever length "B" (=180 mm) must be measured at the
holes in the compensator.
Both slack adjusters must be parallel to each other in
the direction of the brake compensator.
Grease all points with BPW special longlife grease a
ECOLiPlus.
Fig. 34
91
10 Automatic slack adjuster ECO-Master
8
9
6
5
1 4
2 7
3
101
Adjusting the brake
When the brake is applied, the cylinder push rod and
slack adjuster must be at an angle of approximately
90° to each other. Set free play”a” to 10 12% of the
connected brake lever length “B” by turning the
adjusting hexagon (keep clutch sleeve pressed B
down).
E.g brake lever length 180 mm = play 18 21 mm.
102
BPWWH34.10.583.03706/1e
BPW Bergische Achsen Kommanditgesellschaft, P.O. Box 12 80, D51656 Wiehl, Phone +49 2262 780, info@bpw.de, www.bpw.de