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

SPARE PARTS CATALOGUE FOR AUSTRALIAN ASSEMBLED DISC BRAKE AXLES

TABLE OF CONTENTS

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

CONTENTS

PAGE

Axle Part Number Legend for Australian Assembled BPW Axles

3

BPW Transpec Knorr Disc Brake Range

4

Exploded view of rigid Knorr Disc Brake Axle

4

Knorr Disc Brake Identification

6-8 Knorr Disc Brake Sizes

6

Caliper Types A, B and C

6

Caliper Mounting

7

Left and Right Handed Calipers

7

Caliper Type Plate and Operating Function

8

Knorr Replacement Calipers

9

Knorr SB3745 Disc Brake Components

10 - 11 12 - 13

Knorr SB3745T/SB4309T Disc Brake Components Knorr Disc Brake Covers and Brake Pad Protectors

14

Knorr Disc and Brake Pad Wear Status

15

BPW Brake Monitor

16 - 17

BPW ECO Hub Components

18 - 19

BPW ECO Plus Hub Components

20 - 21

BPW ECO Plus Hub General Information

22

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

23

ABS Components

24 - 25

BPW Hubcaps with Integrated Hubodometer

26– 27 Non Digital

26

Digital

27

Knorr Disc Brake Tools

28 - 29

This book is intended to assist with the identification of spare parts for Australian assembled axles fitted with BPW TSB Disc Brakes only. It is not intended to give detailed technical service and/or maintenance information. For technical service and/or maintenance information please refer to the BPW Operator’s Manual and workshop manual or contact your nearest BPW Transpec Branch listed on the back cover of this book.

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

2

AXLE PART NUMBER LEGEND For Australian Assembled BPW Axles At time of assembly an identification Type Label is affixed to every Australian assembled BPW axle, usually along the axle centreline on the rear face of the axle beam. The characters that make up the axle part number gives important information about that axle which can assist in the correct identification of spare parts. Below is a legend that can be used to decipher BPW Transpec Axle Part Numbers. The legend is divided into blocks that represent specific information. They are Axle Beam Profile, Hub, Bearing Combination, Wheel Fixing, Brake Size, Serial No, Hubcap Type, Hub Lubrication, Slack Adjuster Type (Drum Brakes Only) and ABS. Within these blocks there are the various alternatives that are represented by different character sets in the axle part number. On the top, left hand side of the legend there is an example axle part number highlighted in blue. That part number is: HZA10110A11SPSN Follow the grey lines moving down through each block of the legend to find the meaning of each character set within that example axle part number. The other character sets in each block of the legend represent all other alternatives that may appear in other BPW Transpec axle part numbers. The axles fitted to any one trailer may have different axle part numbers. Therefore, when using the BPW Transpec Axle Part Number for the purposes of the correct identification of spare part numbers it is important that the axle part number being used is the actual part number for the specific axle requiring the parts.

BPW TRANSPEC AXLE MODEL AND PART NUMBERS For Australian Assembled Axles Axle Part Number Example H

ZA

101

10

A

11

S

P

S

Legend

N

NR H

Round Beam 127mm, 15" Tyres Square Beam 120mm & 150mm, 20" Tyres

R

Axle Beam Profile

KH SH SKH, SK NH

Round Beam 127mm, 20" Tyres Square Beam 120mm, 19.5" Tyres Square Beam 120mm, 20" Tyres Square Beam 120mm, 19.5" or 20" Tyres Square Beam 120mm, 15"/17.5" Tyres

ZA ZM

10 Stud 285 PCD Dual Wheel, Spigot Mount 10 Stud 335 PCD, 8 Stud 275 PCD, 10 Stud 225 PCD Dual Wheel, Spigot Mount

SA

Hub

SM XZ X

10 Stud 285 PCD Single Wheel, Spigot Mount 10 Stud 335 PCD Single Wheel, Spigot Mount Spider Dual Wheel Spider Single Wheel

90 91

9 tonne bearing combination, 120mm square or 127mm round axle beam

Bearing 10/12 tonne bearing combination, 120mm square axle beam Combination 10/12 tonne bearing combination, 150mm square or 127mm round axle beam

100 101

Plus

10/12 tonne bearing combination, 120mm square axle beam, ECO 00 08 10

Spider

Wheel Fixing 8 Stud 10 Stud A B

Drum Brake Ɔ420 x 180mm, suits 20" Tyres Drum Brake Ɔ360 x 200mm, suits 19.5" Tyres

C

Drum Brake Ɔ300 x 200mm, suits 15" Tyres

D

Brake Size

E

Disc Brake SB3745 (Knorr Caliper), Ɔ370mm rotor, suits 19.5" and 20" Tyres Disc Brake SB4309T (Knorr Caliper), ø430mm rotor, suits 20" Tyres

F

Disc Brake SB3745T (Knorr Caliper), ø370mm rotor, suits 19.5" Tyres

G H

Disc Brake TSB4309 (BPW Caliper), ø430mm rotor, suits 20" Tyres Disc Brake TSB3709 (BPW Caliper), ø370mm rotor, suits 19.5" Tyres 00

Serial No

99 S H

Hubcap Type G O

Consecutive Serial No 00 - 99 Standard Hubcap Hubcap with Hubodometer Grease, Conventional Hub Oil, Conventional Hub

Grease with Oil seal, Conventional Hub Hub Lubrication ECO Hub, Grease

B E M P

ECO Hub, Grease, Push in studs (ECO MAXX) ECO

Slack Adjuster

S M A

(Drum Brake Only)

N A

ABS

Plus

Hub, Grease

Manual Slack Adjusters Manual Slack Adjusters with multihole Automatic Slack Adjusters No ABS fitted ABS fitted

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

3

BPW TRANSPEC KNORR DISC BRAKE RANGE Axle Code

Date Range

Axle Type

Brake Size

Page No

Up to Feb 2004

9 tonne ECO

SB3745

4 to 5

Feb 2004 to Aug 2008

9 Tonne ECOPlus

SH9010 SKH9008 SKH9008

SB3745T suit 19.5" tyres 8 to 9

SH9010

SB4309T suit 20" tyres

SH10110 From Aug 2008

SB4309T suit 20" tyres

10 tonne ECOPlus

8 to 9

SKH10108

SB3745T suit 19.5" tyres

Axle Type

Rotor Diameter

SK……

377 mm

SH……

430 mm

EXPLODED VIEW OF A KNORR DISC BRAKE AXLE

ABS PARTS Pg 24 - 25

DISC PROTECTORS Pg 14

BRAKE PARTS For SB3745 Pg 10 - 11 For SB3745T/SB4309T Pg 12 - 13

WHEEL NUTS & STUDS For SB3745 Pg 10 - 11 For SB3745T/SB4309T Pg 12 - 13

HUBS COMPONENTS ECO Hub Pg 18 - 19 ECO Plus Hub Pg 20 - 21

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

4

BPW TRANSPEC DISC BRAKE IDENTIFICATION Important note: To correctly identify spare parts for BPW Transpec Disc Brake Axles you will require the answers to the following questions: 1. 2. 3. 4. 5.

Does the disc brake axle have Knorr Bremse or BPW TSB caliper fitted? If the disc brake axle is fitted with a Knorr Bremse caliper what is the brake size? Is the rotor 370mm in diameter or 430mm in diameter? Is the Knorr disc brake caliper type A, B or C? Is the Knorr disc brake caliper left handed or right handed? Is the suspension underslung or overslung? Is the caliper mounted axially or tangentially?

Pages 5 to 8 in this catalogue gives all of the information relevant to the questions above. Please read these pages carefully before attempting to identify spare parts. KNORR BREMSE AND BPW TSB DISC BRAKE CALIPERS Prior to May 2010 all Australian assembled BPW disc brake axles were fitted with SB type disc brake caliper (Manufacturer - Knorr Bremse). BPW Transpec have been assembling disc brake trailer axles in Australia fitted with the new BPW TSB type disc brake caliper (Manufacturer - BPW) since May 2010. For parts information for TSB Type calipers, please contact your nearest BPW Transpec branch to obtain the correct parts catalogue. The diagrams above show the basic differences between the SB and the TSB type disc brake calipers. These diagrams may assist in the correct identification of disc brake calipers.

Separate caliper carrier

SB Type Caliper (Knorr Bremse) Fitted to Australian assembled axles up to May 2010

Adjuster mechanism on rear of caliper Red rubber boots around sliding pistons

Clip on wheel side of caliper

Clip on axle side of caliper

TSB Type Caliper (BPW) Fitted to Australian assembled axles from May 2010

Adjuster mechanism on front of caliper No separate caliper carrier

Black plastic seals around sliding pistons

Important Note: This catalogue contains parts Information for Australian assembled axles fitted with KNORR BRAKE CALIPERS only.

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

5

KNORR DISC BRAKE IDENTIFICATION BRAKE SIZES SB3745 SB = 37 = 45 = =

Disc Brake Disc Ø 377 mm Disc thickness 45 mm Axially mounted caliper

SB3745T SB = 37 = 45 = T =

Disc Brake Disc Ø 370 mm Disc thickness 45 mm Tangentially mounted caliper

SB4309T SB = 43 = 09 = T =

Disc Brake Ø 430 mm Standard axle load 9t Tangentially mounted caliper

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

Type A - 8mm hex adjustment screw with flat plastic cover. Type B - 10mm hex sacrificial adjuster screw with domed rubber cover. Steel cap with o ring from mid 2000. Bellow with hose clip up to mid 2000.

Type A

Two part housing

Type B

8mm adjuster screw

10mm adjuster screw Flat plastic adjuster screw cover Divided housing

Domed rubber adjuster screw cover Divided housing

IDENTIFYING FEATURES OF CALIPER TYPE C :

Type C

10 mm hex sacrificial adjuster screw with domed rubber cover

Flat steel cover One part housing Domed rubber adjuster screw cover One part (monoblock) housing

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

6

KNORR DISC BRAKE IDENTIFICATION

CALIPER MOUNTING

Axially Mounted Calipers:

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

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

LEFT AND RIGHT HANDED CALIPERS

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

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

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

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

7

KNORR DISC BRAKE CALIPER TYPE PLATE AND OPERATION FUNCTION

KNORR-BREMSE SN7174 K009282

05.362.70.64.3 A 05373 ......

KNORR Code no. BPW Code no. Production no.

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

Day Week Year

Type plate

OPERATING FUNCTION OF KNORR DISC BRAKES

(1) Push rod (3) Roller (4) Bridge When the brake pedal is pressed, the push rod (1) of the brake cylinder presses against the lever (2) of the brake caliper.

(2) Lever

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

(8) Brake caliper (7) Brake disc (5) Threaded tubes with tappets

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

(6) Brake pads

8

KNORR REPLACEMENT CALIPERS

CALIPERS COMPLETE WITH CALIPER CARRIERS

AXIALLY MOUNTED CALIPERS With caliper mounting bolts parallel with the axle

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

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

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

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

RATIONALISED CALIPERS NOT INCLUDING CALIPER CARRIERS

CALIPER CARRIERS

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

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

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

0330388560 Suits SB4309T Disc Brake (Ø 430 mm Rotor)

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

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

CALIPER REPLACEMENT ALTERNATIVES Caliper to be replaced

Can be replaced with

Caliper Carrier if required (see note above)

0536270360

0536270600RAT

0203131300

0536270370

0536270610RAT

0203131300

0536270600

0536270600RAT

0330388550

0536270610

0536270610RAT

0330388550

0536270620

0536270620RAT

0330388560

0536270630

0536270630RAT

0330388560

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

9

KNORR SB3745 DISC BRAKE COMPONENTS

• • •

SB3745 Disc Brake (Ø 377mm Rotor) In axles assembled up to February 2004 9 tonne ECO Hub

395

396

old executions

397 398

346 394 348

373

390

(Renolit HLT 2)

362

348 345 346

350

345

364 363

368 370

328

355

326

328

354

369

326

373 325

(Renolit HLT 2)

337

325

335

335 336

318 315 20 / 21

REPLACEMENT CALIPERS (Refer page 9) Caliper Item No

Caliper Description

0536270600RAT

Rationalised Caliper Right Hand SB3745

0536270610RAT

Rationalised Caliper Left Hand SB3745

0536270360

Caliper Right Hand SB3745 Monoblock ABS (Complete with carrier)

0536270370

Caliper Left Hand SB3745 Monoblock ABS (Complete with carrier)

Caliper carrier Item No 0203131300

ROTORS Part No

Part No

Qty Per Axle

0308834070

Rotor 10 stud 285mm PCD

2

0308834060

Rotor 10 stud 335mm PCD

2

0308834150

Rotor 8 stud 275mm PCD

2

0308834040

Rotor 10 stud 335mm PCD (ABS mounting)

2

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

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KNORR SB3745 Disc Brake Components CALIPER CARRIER ATTACHING PARTS Item No

Part No

310A

0316434020TS

Description

Dimension

Qty Per Axle

Caliper Spacer **

4

0250298720

Bolt (Torque 280-330Nm)

M 16x1.5x60

10/4 *

0250298521

Bolt (Torque 280-3300Nm)

M 16x1.5x65

10

0250298821

Bolt Steer Axle (Torque 280-330Nm)

M 16x1.5x60

4

0250511021

Bolt Steer Axle (Torque 280-330Nm)

0254011608

Washer

315

2 Ø 17

10

318 Washer

10

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

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

BRAKE PARTS Item No

Part No

Qty Per Axle

Description

0980106310

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

2

0980106240

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

2

0980106330

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

2

0980102970

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

2

0980102630

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

2

0980106320

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

2

0980106250

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

2

0980107240

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

1

368

0224001100

Adjuster adaptor suits Caliper type B and C

2

369

0218270400

Cap, adjuster adaptor suits Caliper type A

2

Kits

* Repair Kits differ in the design of the guide sleeve: Guide sleeve for Caliper Type A Stop Ring ∅ = 35 mm

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

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

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

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

11

KNORR SB3745T/SB4309T Disc Brake Components

• • •

SB3745T (Ø 370mm Rotor) & 4309T ( Ø 430mm Rotor) 9 tonne ECOPlus Hub in axles assembled from February 2004 to August 2008 10 tonne ECOPlus Hub in axles assembled from August 2008

395

396 397 398

346 394 373

390

(Renolit HLT 2)

348

362

345 350 370

364 363

368 328

355

326

354 373 (Renolit HLT 2) 325

335

318 315 20 / 21

REPLACEMENT CALIPERS (Refer page 9) Caliper Item No

Caliper Description

Caliper carrier Item No

0536270600RAT

Rationalised Caliper Right Hand SB3745

0536270610RAT

Rationalised Caliper Left Hand SB3745

0536270600

Caliper Right Hand SB3745T Monoblock (Complete with carrier)

0536270610

Caliper Left Hand SB3745T Monoblock (Complete with carrier)

0536270620RAT

Caliper Right Hand SB4309T Monoblock

0536270630RAT

Caliper Left Hand SB4309T Monoblock

0536270620

Caliper Right Hand SB4309T Monoblock (Complete with carrier)

0536270630

Caliper Left Hand SB4309T Monoblock (Complete with carrier)

033088550

033088560

ROTORS Part No

Description

Dimension

Qty Per Axle

0308834010

Rotor 8 stud 275mm PCD

SB3745T Ø 377mm

2

0308835060

Rotor 10 stud 285mm PCD

SB4309T Ø 430mm

2

0308835050

Rotor 10 stud 335mm PCD

SB4309T Ø 430mm

2

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

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KNORR SB3745T/SB4309T Disc Brake Components

CALIPER CARRIER ATTACHING PARTS

Item No

Description

SB3745T

SB4309T

Rotor Outer Diameter 377 mm

Rotor Outer Diameter 430 mm

Part No

Dimension

Part No

Dimension

Qty Per Axle

315

Caliper mount bolt

0334012260

M16x1.5x97-12.9

0334012260

M16x1.5x97-12.9

8

318

Washer

0254011608

Ø 17mm

0254011608

Ø 17mm

8

BRAKE PARTS Item No

Description

Part No

Guide pins and seal kit

Part No

Qty Per Axle

0980106330

(Includes items 325 - 355, 373)

2

Guide pins and seals Kit suits caliper item numbers 0536270620RAT and 0536270630RAT

0980106330KB

2

(Includes items 325 - 355, 373) Loose bearing ("secondary guide pin") kit Kits

0980106910

(Items 345, 346, 348, 350, 373) Thrust pad and boot kit

0980106320

(Items 362 - 364, 373) Adjuster adaptor and cap kit * See note below

0980106250

(Items 368, 370) Brake Pad Kit Axle Set ** See note below

0980106430

0980106440

2 2 2 1

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

Adjuster adaptor

0224001100

2

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

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

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

13

KNORR DISC COVERS AND BRAKE PAD PROTECTORS

Disc Covers and Brake Pad Protectors for Axially mounted calipers

502 501 510

530

Disc Covers and Brake Pad Protectors for Tangentially mounted calipers

510 502 501

530

DISC COVERS AND BRAKE PAD PROTECTORS Item

Description

501 502

Rotor Shield SB3745

510

Hex Bolt

Dimensions

M10 x 15

SB3745 (Axial)

SB3745T (Tangential)

SB4309T (Tangential)

Qty Per Axle

0301091530

0301091740

0301091760

2

0250712200

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

2 for Axial 4 for Tangential

14

BRAKE DISC AND BRAKE PAD WEAR STATUS

max. 1.5 mm B

a

A

max. 0.75 x a Check the condition of the brake disc:

max. 1.5 mm

- every 12 weeks (quarterly) under harsh conditions - every 26 weeks (twice annually) under normal conditions

C

D

Sections A - D in the figure above show the possible conditions of the disc surface: A: B: C: D:

Network-type tears Radial cracks up to max 1.5 mm width and depth Uneven disc surface less than 1.5 mm Continuous cracks

= = = =

permissible permissible permissible not permissible

Technical details:

♦ ♦

Disc thickness when new = 45 mm Minimum permissible disc thickness = 37 mm (check with slide gauge)

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

4545mm mm 3030 mm mm

37 mm

37 mm

99 mm mm

2 2mm mm

To prevent damage to the brake discs, the brake pads should be replaced when their thickness (excluding the backing plate) is 2 mm or less. If this instruction is not adhered to, there is a danger that braking performance could be seriously reduced.

1111 mm mm

The latest generation of BPW brake discs offer the following advantages:

♦ ♦ ♦ ♦ ♦

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

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

15

BPW BRAKE MONITOR

BPW has recognized a need for cost-effective brake monitoring solutions, especially for disc brakes, which has led to the development of the BPW Brake Monitor. With either disc or drum brakes, once the friction material wears out you get metal to metal wear, which can lead to an expensive repair as well as less than ideal retardation performance. The BPW Brake Monitor is designed to indicate when BPW disc brake axles have worn brake pads that need to be replaced, alleviating a costly repair and helping to maintain the safety benefit of disc brakes. The benefits of the BPW Brake Monitor include:

• • • • •

Indication when pads should be inspected, and separate indication when the pads must be exchanged Highly robust system Modular design Operating voltage of 10V to 30V Potential to connect to external displays, eg. EBS

The Brake Monitor is connected to all axles on the trailer using a modular design enabling easy and cost-effective connection to any trailer type. All connections in this system are made via a specially coated “distribution cable” using bayonet connections making it highly robust. The wear indication can be shown on additional display units, for example: connected to trailer EBS so the driver can get a warning signal in the cab of the prime mover. The Brake Monitor is a great tool to have with disc braked trailers, it will provide the driver with an easy to read monitor, giving peace of mind when on the road.

BPW Brake Monitor Model BWI 03 indicates when the disc brake pads have to be replaced. The 3 levels of indication are as follows: 1) Green LED on: Unit is powered and the wear limit on the brake pads have not yet been reached. 2) Yellow LED flashing — Warning Signal: Brake pad material has been reduced to approx. 4mm, the brake pads and wear sensors should be serviced as soon as possible. 3) Service indicator changes to red and Green/Yellow LED flashing — Service Signal: Brake pad material has been reduced to approx. 2mm, the brake pads and wear sensors require immediate attention. The Service indicator will remain red even without voltage supply (eg. trailer uncoupled).

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

16

BPW BRAKE MONITOR

BPW Brake Monitor Component List

Item

Description

Part Number Quantity

1

Basis Set Including: 1.1 Brake-Monitor 1.2 Connection Cable 1.3 Connecting Plug

0580160070

2

Connection Module

0243125700

3

Extension 3-pin K/E-connector system 1m 3m 5m

1

1

1

1

1

1

1

1

2

3

4

2

3

4

1 1 1

1 1 1

1 1 1

2

3

4

1 1

1 1

1 1

0203390100 0243125800 0237130800

4

Wear Indicator Axle Set

5

Extension 7-pin DIN bayonet connector system 2m 10m

0218192600 0218192500 0218192200 0580150490

1

2

3

4

0218192900 0218193000

4

(3)

4

1

Connection for external signal

(3)

(3)

1.1

2

(3)

4

1.5 m

(3)

4

(3)

per axle

2m

2m

1.5 m

2m

2m

2m

1.3

2m

1.2

2m

2m

2

Power supply

(5)

(3)

per axle

Technical Data CHEMICAL RESISTANCE • UV Stable SIZE Physical footprint of Brake Monitor 80mm x 130mm

ENVIRONMENTAL CONDITIONS Ambient Temperature 40°C to 60°C

• • • •

Moisture Protected Protection against EMC influences

ELECTRICAL DATA • 10 to 30 V operating Voltage • ≤ 30mA

Cross-polarity safeguard

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

17

BPW ECO HUB Hub Components

ECO Hub From 1992 to Present

• • •

Oval hub cap Hub cap has inner thread Bearings, seal carrier and seals retained in hub by circlips

For ABS parts refer to pages 24 - 25

380 For Rotors refer to page 10 37 470 78 - 81

62 - 75 428 435 56 / 57

437 424 421 420

440

422 423 430

441 445 446 438 448 447

431

460

ECO

Steel hubcap M = 800 Nm

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

18

BPW ECO HUB Hub Components

HUBS AND HUB COMPONENTS Part No

Qty Per Axle

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

0980102720TS

2

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

0980102720TSSC

2

Hub 8/275 alloy (suits press in stud)

0327228720

2

Hub 10/335 alloy (suits press in stud)

0327232040

2

Hub 10/335 steel (suits press in stud)

0327232060

2

Hub 8/275 steel (suits press in stud)

0327228750

2

Hub 10/285 steel (suits back nut stud)

0327228770

2

Item No

Description

Kits

435

421

Seal Carrier

0337007600TS

2

422

Grease Seal

0256645700

2

423

Seal Runner

0256836200

2

424

O-Ring

0256779040

2

428

Dust Seal

0256819800

2

430

Roller Bearing

0264102400

2

431

Grease shield inner

0301093330

2

437

Circlip

0256064090

2

438

Circlip

0256061290

2

440

Grease Shield outer

0337025160

2

441

Roller Bearing

0264102500

2

445

Washer

0332073130

2

446

Axle nut

0326646020

2

447

Locking pin

0308471170

2

448

Locking ring

0318803060

2

Hub cap (steel, standard)

0321224250

2

Hub cap (steel, chrome)

0321224260

2

Hub cap (steel, for alloy hub)

0321225080

2

Hub cap (alloy, for alloy hub)

0321225270

2

460

WHEEL STUDS AND NUTS Part No

Dimension

Qty Per Axle

Press in stud (Aluminium hub)

0329633161

M22 x 1.5 x 97

16/20**

Press in stud (Steel hub)

0329633121

M22 x 1.5 x 114

16/20**

Wheel stud back nut style (Steel wheels)

0329623170

M22 x 1.5 x 114

20

Wheel stud back nut style (Aluminium wheels)

0329623240

M22x 1.5 x 136

20

Back Nut

0326004060

Wheel nut sleeve type

0526054140

M22 x 1.5, 32mm OD sleeve

16/20*

Wheel nut

0526054100

m22 x 1.5

16/20*

Item No

470-479

Description

20

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

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

19

BPW ECO Plus HUB Hub Components ECO Plus Hub From 2005

• • • •

Oval hub cap Hub cap has inner thread Bearings, seal carrier and seals retained in hub by circlips Axle nut is torque limiting

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

380 For Rotors refer to page 12 37 470 78 - 81 For ABS parts 560 refer to pages 24 - 25 62 - 75

435

56 / 57

428

440 441

437

445 422

446 438

423

448 447

430

460 431

ECOPlus

Steel hubcap M = 800 Nm

432

10 tonne ECOPlus Hub in axles assembled from August 2008

380 For Rotors refer to page 12 37 470 78 - 81

For ABS parts refer 560 to pages 24 - 25 62 - 75

428

435

56 / 57 437 440

424 441

421 420

445 446

422

438

423

430 431 432

448 447

430

460 431

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

ECOPlus

20

BPW ECO Plus HUB Hub Components HUBS AND HUB COMPONENTS TO SUIT 9 TONNE Item

Qty Per Axle

Description Part No Wheel Bearing and Seal Kit (Includes items 422,428,430-432,440,441,447,448)

Kits

TO SUIT 10 TONNE

Dimension

0980106360TS

Part No

Dimension

0980107040TS 2

Wheel Bearing and Seal Kit

0980107040TSSC

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

435

Hub 8 stud 275mm PCD

0327246282

0327246340

Hub 10 stud 285mm PCD

0327247352

0327247380

Hub 10 stud 335mm PCD

0327243192

0327243262

2

420 421

Seal Carrier

422

Hub seal

0256647400

423

Seal Runner

0256838000

424

O Ring

428

Dust Seal

0312048150

430

Roller Bearing Inner

0264102300

431

Grease Shield Inner

0301093340

Ø94/149x8.5

0301093340

Ø94/149x8.5

2

432

Dust Seal

0312045150

Ø67/95x49.5

0312045160

Ø67/93x8.5

2

437

Circlip Inner

0256065890

0256065890

2

438

Circlip Outer

0256062290

0256062290

2

440

Thrust Washer

0337026240

441

Roller Bearing Outer

0264102200

445

Washer

0332064010

Ø53/76x5.8

0332064010

Ø53/76x5.8

2

446

Axle nut - Eco Plus

0526647060

M52x2/SW95

0526647060

M52x2/SW95

2

447

Locking wedge axle nut

0327700070

448

Hooked ring spring - locking wedge

0318804100

Hub cap

0321225310

Ø 120/157.5x20

0337007720

Ø96/117.5/132x22

2

0256647400

Ø20/157.5x20

2 2

Ø122/160x8.7

0256780000

Ø100x3

2

0312048150

Ø122/160x8.7

2

0264102300

Ø71/108x8

0337026240

Hub cap, chrome

Ø71/108x8

2

0264102200

2

0327700070 Ø62x1.8

2

0318804100

Ø62x1.8

2

M136x2.5/SW110

2

0321225310 M136x2.5/SW110

460

2

0321225310C

0321225310C

WHEEL STUDS AND NUTS (To suit 9t and 10t) Item No

Description

Part No

Dimension

Qty Per Axle

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

472 to 479

Wheel stud - push in

0329633121

M22x1.5x97

16/20**

Wheel nut - dual steel wheels

0526054100

M22x1.5

16/20**

Wheel nut - dual aluminium wheels

0526054140

M22x1.5/Ø32 sleeve

16/20**

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

472 to 479

Wheel Stud - for dual steel wheels

0329623170

M22x1.5x114

20

Wheel Stud - for dual aluminium wheels

0329623240

M22x1.5x136

20

Back nut

0326004060

M22x2

20

Wheel nut

0526054100

M22x1.5

20

Peg

0260103560

Ø6x19.5

20

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

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

21

BPW ECO Plus HUB General Information

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

Fig. ECOPlus 10 - 12 t Exciter ring Circlip ‘O’-Ring Thrust washer ECO Seal Seal

Roller bearing Dust cover

BPW ECO Plus bearing - Features & Benefits ♦ Low maintenance, encapsulated bearing unit (ECO Unit) with integrated multi-seal system to protect the taper roller bearings from dust & dirt. ♦ Integrated torque limiter in the axle nut (ECO Plus ) prevents improper use when

♦ ♦ ♦ ♦

Inner seal

♦ Thrust washer Roller bearing Washer Axle nut

Fig. ECOPlus 10 - 12 t

♦

tightening. Bearings are precisely re-adjusted after every disc replacement. The ECO Plus Hub is Guaranteed in Australia for 3 years or 1,000,000km (whichever comes first) for highways use and 1 year for off road use (conditions apply*). Compact bearing system with DIN-ISO taper roller bearings available worldwide for excellent availability & rapid service. Removal of the complete hub unit - thanks to central threaded connection - with simple tools. Excellent bearing service life with minimal life cycle costs.

Circlip Locking ring with locking piece

Hubcap

HUB SEAL FOR ECOPlus BEARINGS

Dust & and dirtsealing sealing lips Dust dirt lips

Mainsealing sealing lip Main lip

The innovative ECO Seal sealing system is used on all axles with the BPW ECO Disc Trailer disc brake. With this hub seal, the primary seal lip (ECO Seal) no longer seals directly against the race of the hub but instead against a race which is integrated in the seal itself. This new design enables circumferential velocity of the seal to be significantly reduced, and with that, the amount of wear. In addition, the wheel bearing is provided with even better protection against dirt penetration by means of the covering dust & dirt sealing lips.

Fig. shows Figure Plus ECOPlus ECO 12t t 10 -- 12

Benefits: An internal pre-stressed main lip seal with a low circumferential speed & a low thermal load, resulting in low wear.

♦ ♦ ♦ ♦ ♦

An approximately 30% reduction in frictional resistance inside the seal (compared with conventional seals). The seal is well protected during service due to the cartridge construction. Pre-stressed main seal lip with ventilation function, no opening at low pressures. No coarse dirt seal required.

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

22

BPW ECO-LI Plus GREASE, GREASE FILLING, GREASE SHOWER TOOLS

BPW ECO-Li Plus is:

• • • • • •

usable at temperature between -30°C and + 150°C resistant to aging protecting against corrosion, even in aggressive surroundings wear reducing generally plastics compatible suitable for extremely long re-lubrication periods

ECO-Li Plus is suitable for the lubrication of high temperature roller and friction bearings of commercial vehicles. It has been especially developed for highly loaded taper roller bearings and hub units with very long re-lubrication periods.

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

Container Size

0210404500

400 gm cartridge

0210404700

5 kg container

0210404900-20

20 kg container

GREASE FILLING ECO HUB

ECO HUB ECO-LiPlus Grease quantity per taper roller bearing A1

ECO

Plus

B 2

A= Inner Bearing

B= Outer Bearing

6000 - 9000 kg

120 g

120 g

10000 - 12000 kg

170 g

120 g

Axle Load

ECO Plus HUB ECO-LiPlus Grease quantity per taper roller bearing

HUB

A= Inner Bearing

B= Outer Bearing

8000 - 12000 kg Manual greasing

170 g

120 g

8000 - 12000 kg Greasing with grease applicator

130 g

90 g

Axle Load A1

B2

BPW GREASE SHOWER TOOLS Used to quickly, accurately and cleanly fill the bearing with the required amount of BPW ECO-LiPlus Grease To Suit Bearing Size Grease Shower Part Number ISO

BPW Bearing Part Numbers

9900000954

33116 / 32310

0264102400 / 0264102500

9900000955

33118 / 33213

0264102300 / 0264102200

Roller bearing

grease

Roller bearing

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

23

ABS COMPONENTS

• • •

• • •

SB3745 ECO Hub 9 tonne

• • •

SB3745T ECOPlus Hub 9 tonne and 10 tonne

SB4309T ECOPlus Hub 9 tonne and 10 tonne

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

24

ABS COMPONENTS

Fig A

Fig B

Fig E

Fig C

Fig D

Fig F

Fig G

*Please note: To determine which exciter ring is required you will need to know both the tyre size and the type of exciter ring. You can determine the type of exciter ring by referring to the figures above. The ABS Kits will only include the exciter ring that is relevant to the correct type and wheel size. ABS PARTS SB3745 & SB3745T ECO Hub Item No

Description

Part Numbers

Dimension

Fig

9 tonne Axial Brake Qty

Inc's all listed items

0580173860 ABS Kit for 19.5" wheels

0580174090

Locking bolt

0250712200

M10 x 15

511

Locking bolt

0250712300

M8 x 20

541

Shaped plate

1

1

0580173840

1 2

2

2

2

2

2

0316323040

2

0318912020

A

0318914610

B

Sensor bracket left hand

0318907580

Sensor bracket right hand

0318907590

Cylinder cap bolt

0250159480

M6 x 12 - 8.8

Locking screw

0250712300

M8 x 20

Spring washer

0256010690

A6

Exciter Ring - 80 teeth

0531007290

Ø105/152/156 x18

D

(For 19.5" wheels)

0331008530

Ø125/156 x 8.5

E

0531007300

Ø105/152/156 x18

D

0331008510

Ø125/156 x 8.5

E

0331009390

Ø177/215 x 22/5 x Ø6.5

F F

Exciter Ring - 100 teeth (For 20" wheels)

0531008501

Ø150/176/180 x Ø19.5

Cylinder cap screw

0250154882

m6 x 30

563

Spring washer

0256010690

570

Sensor, straight

0233170700

L = 350

570

Sensor, angled

0233170500

L = 350

571

Bush

0203165900

Support

0318907350

586

Support

0214211100

587

Serrated lock washer

0254141190

590

Heat protection plate

0316524640

Special silicone grease

0210401700

2 2

2 2

C

561

585

Qty

1

510

560

Qty

1

0580174080

553

Tangential

Qty

1

0580173870

551

10 tonne 9 tonne 10 tonne

Tangential Qty

ECOPlus Hub

1

*See note ABS Kit for 20" wheels above

542

9 tonne

0580173880

Sensor bracket

SB4309T

ECOPlus Hub

2 4 2 4 2 2 2 2

2 2 2 10 10

Short - L 35 A 10.5 5gm

2

2

2

2 2

2 2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

1

1

1

1

1

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

25

BPW HUBCAPS With Integrated Non Digital Hubodometer

Tyre rolling circumference: The tyre rolling circumferences in the table below are based according to standard ETRTO (European Tyre and Rim Technical Organisation). Data of various tyre manufacturers can vary slightly.

BPW HUBCAPS WITH INTERGRATED NON DIGITAL HUBODOMETER Axle Load

9 tonne

9 & 10/12 tonne

Axle Beam Profile

SKH

SH/SKH

Hub Type

ECO

ECOPlus

Hubcap Thread

M 125 x 2

M 136 x 2.5

Tyre Size

Tyre Rolling Circumference ± 2 %

Part No

11 R 22.5

3175 mm - 3220 mm

0521224490

315/70 R 22.5

3015 mm - 3134 mm

0521224330

255/70 R 22.5

2830mm - 2860 mm

0521224530

265/70 R 19.5

2620 mm - 2650 mm

0521224340

245/70 R 19.5

2560 mm

0521224440

255/70 R 22.5

2830 mm - 2860 mm

0521225410

275/70 R 22.5

2915 mm

0521225420

315/70 R 22.5

3015 mm - 3134 mm

0521225440

11 R 22.5

3175 mm - 3220 mm

0521225450

385/65 R 22.5

3240 mm - 3260 mm

0521225460

12.00 R 22.5

3280 mm - 3310 mm

0521225470

265/70 R 19.5

2620 mm - 2650 mm

0521225380

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

26

BPW HUBCAPS With Integrated Digital Hubodometer

General Information: The BPW hubcap with it’s integrated digital odometer is an important instrument for checking the mileage of your trailer. A built in, watertight mini computer counts the wheel revolutions by means of a magnet and a reed contact. The tyre rolling circumference is set initially, before fitting the hubo to the axle, and cannot be changed subsequently. Read out takes place when two silver contacts on the older style ECOMETER or the two BPW logos on the face of the newer style ECOMETER are connected with a metallic object eg a spanner. Battery information: A row of flashing dots appears on the display when the battery voltage has fallen below the necessary value, which is a warning that the battery should be changed. After the battery has been changed, the program and display are resumed (the distance value in kilometers continues to be stored in a permanent memory).

HUBCAP WITH INTEGRATED DIGITAL HUBODOMETER Hubcap Thread = M136 x 2.5

Available for ECOPlus axles only

Part Number Black

0521275060

Chromed

0521275030

Battery to suit

0201309700

Important!

•

Please refer to the BPW Operator’s Manual (valid for operational use in Australia) for instructions on the fitting and setting of Digital Hubodometers.

•

The reed contact in the cap should always be protected against damage. For this reason, caps should not be stacked one inside the other.

•

Always remove and install correctly.

•

For information regarding the fitting and setting of the digital hubodometers, please refer to the BPW Operator’s Manual.

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

27

KNORR DISC BRAKE TOOLS

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

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

28

KNORR DISC BRAKE TOOLS

In order to simplify the maintenance procedures on BPW axles a comprehensive range of special tools are available. BPW tools offer the following advantages:

•

Tried and tested design Tools must prove their worth in everyday use. Only then does it become clear whether tools are up to the demands of the real world.

•

Use of high quality materials High quality materials are absolutely essential for producing high quality tools. Continuous quality assurance guarantees consistent quality.

•

Favourable price/performance ratio Quality is not always obvious at first glance (e.g. materials). Buying quality tools is often the cheaper option in the long term. This particularly applies in those cases where tools are regularly needed and where their trouble free use must be guaranteed at all times.

•

Long service life, low wear BPW tools are designed to be particularly resistant to wear and tear, and guarantee an extremely long service life, even with frequent Use.

•

Simple to handle Ideal solutions are always simple. This statement also particularly applies to tools. For that reason BPW tools are designed strictly to the necessary technical requirements. Solutions that do not meet practical requirements are rigorously weeded out at the development stage. The following pages show a representative range of the tools available. For complete details please contact your local BPW Transpec Office or BPW distributor. SPECIAL TOOLS FOR KNORR DISC BRAKE CALIPERS Tool Purpose

Tool Name

Caliper A & B

Caliper C

Disassembling thrust pieces with bellows

Tool Fork Thrust Pad

0201304200

0201304200

Fitting thrust pieces with bellows

Tool Thrust Pad Boot

0201303900

0201306200

Pressing in inner secondary seal

Tool Thrust Pad Seal

Replacing brake caliper. Fitting fixed bearing cover cap

Tool Slide Pin Cap

0201305700

0201306500

Inserting inner bellow, fixed bearing

Tool Slide Pin Boot

0201304000

0201306300

Extracting and inserting brass bush, fixed bearing

Tool Slide Pin Bush

0201304100

Caulking brass bush

Tool Caulking Slide Pin Bush

0201305200

Extracting and inserting bush, movable bearing

Tool Second Slide Pin

0201305900

0201305900

Replacing brake caliper, fitting cover cap movable bearing

Tool Punch Second Slide Pin

02010305800

0201305800

Assembly aid to fit calipers to axle brackets

Caliper alignment bolt

TL-0044

Assembly aid to fit calipers to axle brackets

Caliper offset bolt

TL-0045

0201306600

0201306400

0201304200

0201309300 0201206200

0201306600

0201305700

0201306500

0201304000 0201306300

0201304100

0201305200

0201306400

0201305900

TL-0044

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

0201305800

TL-0045

29

NOTES

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

30

NOTES

BPW Transpec Knorr Disc Brake Axle Parts Catalogue 3/2013

31

STATE BRANCHES VICTORIA (Head Office) 1 - 11 Cherry Lane, North Laverton VIC 3026 Phone: (03) 9267 2444 Fax: (03) 9369 4826 Internet: www.bpwtranspec.com.au e-mail: [email protected] NEW SOUTH WALES 10 Squill Place, Arndell Park, NSW 2148 Phone: (02) 8811 7000 Fax: (02) 8811 7050 QUEENSLAND Cnr Archerfield Road & Bernoulli Street, Darra, QLD 4076 Phone: (07) 3217 0877 Fax: (07) 3217 0230 WESTERN AUSTRALIA 20 Brennan Way, Belmont, WA 6104 Phone: (08) 9479 5822 Fax: (08) 9479 6922

FREE CALL: 1300 651 652