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instructions ECO
Maintenance

BPW BERGISCHE ACHSEN

ECOPlus Axle system

Only limited warranty without registration

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WARRANTY DOCUMENTS / SERVICE AND REQUIREMENTS

ECOPlus Warranty and Service Instructions

Table of contents: Pages

Warranty statement and service requirements 2  10
Maintenance instructions 11  31

Service checks to qualify for the ECOPlus warranty:

5 year warranty (on$road use only)

BPW$AIRLIGHT II (70 mm wide trailing arms):
Zero maintenance $ visual checks within the scope of the statutory
check (see page 8).
Other BPW air suspension types:
Torque tightening after commissioning (see pages 4 and 7) as well as visual
checks within the scope of the statutory check (see page 8).

5 + 3 year warranty (on$road use only)

BPW$AIRLIGHT II (70 mm wide trailing arms):
Zero maintenance $ visual checks within the scope of the statutory
check as well as a full service after 60 months (see pages 8 and 9).
Other BPW air suspension types:
Torque tightening after commissioning (see pages 4 and 7), visual checks
within the scope of the statutory check as well as a full service after
60 months (see pages 8 and 9).

3 year warranty (off$road use)

BPW$AIRLIGHT II and other BPW air suspension types:
Tightening after commissioning (see pages 4 and 7) as well as visual
checks and, if appropriate, tightening of bolted connections within the
scope of the statutory annual check (see page 8).

On-rroad/off-rroad definition:
On$road is defined as a sealed and metalled surface, i.e. asphalt or concrete surfaces.
Gravel roads are taken as being off$road. Off$road operation also applies when the
vehicle departs from metalled surfaces even for only short periods during the course
of its operation. Off$road use is assumed for all cases in the CIS, BG, RO and other
similar countries.

2
 BPWRegistration No.: __ __ __ __ __ __ __ __ __ __

Chassis number: __ __ __ __ __ __ __ __ __ __

1. Warranty statement:
BPW Bergische Achsen Kommanditgesellschaft, 51674 Wiehl, Germany, referred to below
as BPW, hereby extends a warranty to the owner, in addition to the existing statutory and
contractual provisions, for the defect free manufacture and performance of the complete
ECOPlus air$spring axle system.
This warranty applies:
– Without a mileage limit
– From the date of first registration or the date when the vehicle is taken into service,
for a period of five years in on$road operation or three years in off$road operation
(see 7.)
– Only to registered vehicles (see 4.)
– for operation throughout all of Europe (including Turkey) as far as the Urals.
– Only for ECOPlus complete air$sprung axle systems which have been selected
as appropriate for the particular application. Please refer to the current BPW
recommendations. BPW recommends a heavy duty package for vehicles operating
in countries with poor road conditions such as the CIS, BG, RO and other
similar countries.

Additional warranty
In addition to the aforementioned ECOPlus warranty, BPW also offers to extend this warran$
ty by 3 years $ subject to agreement $ for all vehicles which were previously covered by the
five year ECOPlus warranty and which have had a full service carried out by a BPW Direct
Service Partner after 5 years of operation.
2. Scope of warranty
BPW will pay for the materials needed and for removal and installation work according to
BPW reference times, providing this is agreed with BPW (or the BPW representative in
a particular country) in advance and the work is performed by an authorised workshop.
The defective parts which are removed must be retained and sent to BPW if requested,
with the costs being borne by the warranty client. All other additional warranty claims and
claims for compensation for damage of any kind shall be excluded. Only warranty claims
received during the warranty period by the vehicle manufacturer, BPW, one of its agencies
or a service workshop shall be considered.

3. Exclusion from warranty

This warranty does not extend to natural wear and tear, the relevant parts subject to wear
(in particular brake linings, brake drums, brake discs, shock absorbers and air bags), parts
requiring maintenance in the brake callipers of axles with disc brakes and environmental
effects such as noise or odour emissions. These items are subject to a one year warranty
covering mechanical defects only.
The ECOPlus warranty does not apply to damage caused by force majeure, operating
errors, failure to adhere to BPW installation instructions and maintenance regulations or
if parts other than genuine BPW parts are used.
3
ECOPlus Warranty and Service Instructions

4. Registration
The ECOPlus warranty only covers registered vehicles:
Registration involves returning the enclosed warranty registration form for each vehicle.
The warranty form must be completed in full after Check 1 has been performed (see the
service instructions) by the vehicle owner / warranty client. They must then sign the form
and send it to the appropriate registration address. BPW will then send the warranty client
a registration number for the vehicle in question in order to confirm that the company
accepts its warranty obligation.

5. Conditions for obtaining the ECOPlus warranty

In order to obtain and receive the ECOPlus warranty and, if appropriate, the additional
warranty, the warranty client undertakes to perform or have performed all measures in
accordance with the BPW service instructions.

Period of warranty Service

On$road Off$road Time Measures Service provider
Entry into Tighten all bolted BPW service centre
service connections or vehicle owner
(not applicable for Airlight II
in on$road applications)
BPW registration Vehicle owner
/national representative
3 years 12 months Check/visual check BPW service centre
5 years 36 months Check/visual check BPW service centre
60 months Full service BPW Direct Service Partner
5+3 years 72 months Check/visual check BPW service centre

6. Repairs whilst under warranty:

If repairs are performed during the warranty period, then the warranty period for any
replaced components expires at the same time as the axle system warranty expires.

7. Onroad/offroad definition:
On$road is defined as a sealed and metalled surface, i.e. asphalt or concrete surfaces.
Gravel roads are taken as being off$road. Off$road operation also applies when the
vehicle departs from metalled surfaces even for only short periods during the course
of its operation. Off$road use is assumed for all cases in the CIS, BG, RO and other
similar countries.
The warranty period is reduced to 3 years for off$road service and there is no additional
warranty available.

4
Retention of value through preventive
maintenance
The visual inspections after 12, 36 and 72 months should take place within
the framework of any statutory inspections.

2 Visual check after 12 months

(As described on page 8)

Date:
Stamp and signature of the BPW service
centre performing the work

Visual check after 36 months

(As described on page 8)

Date:
Stamp and signature of the BPW service
centre performing the work

3 Full service after 60 months

(As described on pages 8 and 9)

Date:
Stamp of the BPW Direct Service Partner
4 Check after 72 months
(As described on page 8)

Date:
Stamp and signature of the BPW service
centre performing the work

5
Service instructions

It is essential that all maintenance work is carried out in accordance with the prescribed
intervals in order to maintain the safe operation and roadworthiness of the trailer. The
relevant operation and service regulations of the vehicle manufacturer and of the manu$
facturers of other vehicle parts must also be adhered to.

Rectification of any defects which are discovered or replacement of worn parts should be
carried out by a BPW service centre unless the vehicle owner has the appropriate person$
nel facilities and equipment available and possesses an official certificate to perform
interim inspections or special brake inspections.

We strongly recommend that only genuine BPW parts be used when fitting
spare parts. Parts authorised by BPW for trailer axles and axle units are
regularly subjected to special inspections. BPW accepts product liability
for them.

BPW is unable to determine whether all third party product can be used
with BPW trailer axles and axle units without any safety risk; this also
applies even if an authorised testing organisation has accepted the product.

Our warranty shall be rendered null and void if spare parts other than
genuine BPW parts are used.

The warranty shall also be rendered null and void if the BPW axle systems are not
installed in accordance with the technical guidelines given in the current BPW installation
instructions.

Brake linings
Brake lining qualities authorised by BPW are matched to each other and their
performance is confirmed in the assessment reports and the general certification
of the components. These brake linings are subject to continual monitoring by our
quality assurance department, so that we, independent of the lining manufacturer,
are able to guarantee consistent quality. BPW cannot verify the performance of the
braking system should other types of lining be used. Our guarantee is therefore void
if other brake linings are used.

6
1 Checks to be performed shortly after the vehicle goes
into service –
(within 2 weeks of the first journey under load)

ECOPlus units with Airlight II air suspension (70 mm wide trailing arms) are
maintenancefree in onroad applications and do not need to be retightened.

Service instructions
It is essential for the specified bolted connections to be retightened on all other
BPW air suspension systems, as well as Airlight II when used offroad.

1 Tighten the spring mounting assembly (U$bolts) with a torque wrench.

Tightening torque: M 22 M = 550 Nm (510 $ 605 Nm)
M 24 M = 650 Nm (605 $ 715 Nm)
2 Tighten the spring pivot bolt with a torque wrench.
Tightening torque:
hanger brackets up to 07/2001: M 30 M = 750 Nm (700 $ 825 Nm)
hanger brackets from 08/2001: M 30 M = 900 Nm (840 $ 990 Nm)
channel cross member: M 30 M = 900 Nm (840 $ 990 Nm)
3 Tighten the shock absorber fastening with a torque wrench.
Tightening torque: M 24 M = 420 Nm (390 $ 460 Nm)
for aluminium hanger brackets M 24 M = 320 Nm (300 $ 350 Nm)
4 Tighten the air bag fastenings with a torque wrench.
Tightening torque: M 12 M = 66 Nm
M 16 M = 230 Nm
5 Tighten the axle lift device with a torque wrench.
Tightening torque:
supporting arm M 16 M = 230 Nm
cylinder M 16 M = 180 $ 210 Nm

7
Service instructions

2 Visual inspection to be carried out within the framework

of the statutory annual inspection
– Description of inspection after 12, 36 and, if appropriate, 60 months –
4 – Description of inspection after 72 months –

after 12 months

after 36 months

after 60 months

after 72 months
– Visual inspection
Check all component parts for damage and wear.
1 Check condition of air bags.
2 Check air suspension level valves for condition,
seal integrity and tightness.
3 Visual inspection $ Check shock absorber fastening for
tightness. M 24 M = 420 Nm (390$460 Nm)
for alloy hanger brackets M = 320 Nm (300$350 Nm)
4 Visual inspection $ Check spring mounting assembly for
tightness. M 22 M = 550 Nm (510$605 Nm)
M 24 M = 650 Nm (605$715 Nm)
5 Visual inspection $ Check air bag fastening for tightness.
M 12 M = 66 Nm
M 16 M = 230 Nm
6 Visual inspection $ Check spring pivot bolts for tightness.
hanger brackets
up to 07/2001: M 30 M = 750 Nm (700$825 Nm)
from 08/2001: M 30 M = 900 Nm (840$990 Nm)
channel cross member: M 30 M = 900 Nm (840$990 Nm)
7 Visual inspection $ Check axle lift for tightness.
supporting arm M 16 M = 230 Nm
cylinder M 16 M = 180 $ 210 Nm
8 Check strap. Check condition and fastening.
A visual check is sufficient for these checks. Tighten any screw connections as required to
the specified tightening torques. Tightening may be charged to the vehicle owner.
8
3 Full service after 60 months at the
BPW Direct Service Partner
(for additional warranty qualification)

– The extension of the warranty for a further 3 years applies to the hub, the hub
bearings, the axle beam, the air spring mounting kit, the air suspension hanger
brackets and all parts which must to be replaced as part of the relevant warranty
requirement. It is essential for the prescribed inspections to have been performed
 with full documentation  starting from when the vehicle was first taken into
service.
If the warranty period has elapsed for a certain defective part, e.g. an air bag or
a trailing arm, then the part shall be replaced subject to a charge following
consultation with the customer.
In all cases, replacement of components as part of the warranty provision shall
be agreed with BPW or the relevant BPW representative prior to the start of work..

Service instructions

Work to be performed
1 Hub bearings: Completely re$grease, assess bearings and change if necessary
2 Hub seals: replace all seals
1 Spring mounting kits: Use a torque wrench to check the spring mounting kit is firmly
seated. Tightening torques: M 22 M = 550 Nm (510$600 Nm)
M 24 M = 650 Nm (605$715 Nm)
2 Spring pivot bolts: Use a torque wrench to check the spring pivot bolts are firmly
seated and check them for wear. Tightening torques:
hanger brackets up to 07/2001: M 30 M = 750 Nm (700$825 Nm)
hanger brackets from 08/2001:M 30 M = 900 Nm (840$990 Nm)
channel cross members: M 30 M = 900 Nm (840$990 Nm)
The necessary maintenance and lubrication requirements should be performed as part of
the Full Service in accordance with information provided by BPW.
Parts subject to wear which the BPW Direct Service Partner assesses as defective should
be replaced subject to a charge.
9
BPW Trailer axles / lubrication

Lubrication requirements

Valid: 01.01.2002

at every brake lining

every 26 weeks 2)

replacement, 2)
latest annually
every 6 weeks

every 3 years

every 5 years
Lubrication work
Overview

For detailed description see pages 12 - 13

Lubrication of ECOPlus axle systems

with BPW special longlife grease ECOLi Plus:
1 Steering knuckle bearing, top and bottom 1
2 Low$maintenance camshaft bearing: 1)
short$distance haulage 2 1)
long$distance haulage 2
3 Slack adjuster ECO$Master: short$distance haulage 3
long$distance haulage 3
4 ECOPlus hub system Off$road$conditions 4
On$road$conditions 4

For the positions 1 to 3 the use of a high$pressure central lubrication system which
is capable of feeding special longlife grease of viscosity class 2$3 is permissible.
The use of liquid lubricants is not permitted!
1) after a long idle period, prior to initial operation actuate the brake lever and lubricate
the brake camshaft bearing.
2) under extreme conditions, lubricate more frequently (Heavy Duty).

10
Series H / KH / NH

Series ...LL
Maintenance instructions

Series SH / SKH

11
BPW Trailer axles / lubrication

Lubrication requirements

Note: After cleaning the vehicle with high$

pressure cleaners, all lubrication points
must be relubricated.

1 Steering knuckle bearing,

top and bottom
– every 6 weeks –
Grease lubrication nipple with BPW
special longlife grease ECOLi Plus until
fresh grease emerges from the bearing
points.

2 Lowmaintenance brake camshaft

bearing
– every 6 months for short$distance traffic –
– every year and with each brake lining
change for long$distance haulage –
use only BPW special longlife grease
ECOLi Plus.

3 Automatic slack adjusters ECO-M Master

– every 6 months for short$distance traffic –
– every year and with each brake lining
change for long$distance haulage –
Remove rubber seal cap. Grease with
BPW special longlife grease ECOLi Plus
(approx. 80 g) until sufficient new grease
emerges from the adjustment screw.
Turn back adjustment screw by approx.
one turn using a ring spanner. Actuate the
brake lever several times by hand.
After this automatic adjustment must
take place smoothly. If necessary, repeat
several times.
Replace seal cap. Once again only use
BPW special longlife grease ECOLi Plus.

12
4 The ECOPlus hub system is designed for
longlife lubrication.
– up to every 3 years with off$road$conditions –
– up to every 5 years with on$road$conditions –
Thereafter clean taper roller bearings and
seals (using e.g. diesel oil) thoroughly, dry
and check for re$ useability.
Work BPW special longlife grease
ECOLi Plus thoroughly into the cavities
between the taper rollers and the cage in
both taper roller bearings. (For grease
quantity see illustration below). Smear any
residual grease into the hub's outer bearing
race. Smear the lip of the new seal all round
with BPW special longlife grease ECOLi Plus.
Clean the bearing seats of the axle stub
(metal must be bright, dry and free from
grease). Spray with BPW ECO Assembly
and Protection Spray.
Fit the wheel hub, 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.) Fit the retain$
ing key in the groove between the axle
stub and the nut (no need to back$off the
axle nut).
Insert the hooked spring ring, depending
on the version, behind the flange on the
Maintenance instructions

axle nut or in the thread on the axle stub.

Tighten the hub cap to 800 Nm.

ECOPlus hub system

13
BPW Trailer axles / maintenance

Valid: 01.01.2002

at every brake lining

every 26 weeks 2)
every 12 weeks

replacement, 2)
latest annually
Maintenance work and visual inspection
Overview

initially
For detailed description see pages 16 - 24
Suspension see pages 26 - 31

Maintenance work  Drum brakes 1)

1 Check wheel nuts for tightness. 1
2 Check brake lining thickness. Brake lining thickness at 2
least 5 mm or check wear indicator.
$ Visual inspection of all component parts for damage $
and wear.
3 Check operation of automatic slack adjusters. 3
Maintenance work  Disc brakes
1)
1 Check wheel nuts for tightness. 1
2 Check brake pad thickness. The thickness of the 2
remaining pad can be detected by the position of the
brake caliper in relation to the stationary guide sleeve.
3 Check brake disc for cracks. 3
4 Check brake adjustment. 4
5 Check caliper guide system. 5
6 Check bellows on the guide pins. 6
7 Check caliper unit. 7

1) after the first run under load conditions and likewise after each wheel change.
2) under extreme conditions, increase frequency (e.g. construction sites and
poor roads)

14
Series H
Series LL

Maintenance instructions
Series SH
15
BPW Trailer axles / maintenance

Drum brake maintenance and visual inspection

1 Check wheel nuts for tightness

– after the first run under load conditions,
likewise after each wheel change –
Tighten wheel nuts crosswise using a
torque wrench to the tightening torque
shown in the table.

Wheel contact surfaces should not have

additional coats of paint (risk of the
wheels becoming detached!)

Tightening torques for wheel nuts

Wheel stud arrangement Tightening torque

M 20 x 1,5 3 8 0 N m (360 $ 400 Nm)

M 22 x 1,5 5 1 0 N m (485 $ 535 Nm)
M 22 x 2 4 6 0 N m (435 $ 485 Nm)

Spigot arrangement Wheel nut with collar

M 18 x 1,5 350 N m (330 $ 370 Nm)

M 20 x 1,5 480 N m (455 $ 505 Nm)
M 22 x 1,5 630 N m (600 $ 660 Nm)
M 22 x 1,5 alloy wheels 630 N m (600 $ 660 Nm)
M 24 x 1,5 860 N m (820 $ 900 Nm)

16
 The torque values shown below can be
achieved using a normal wheel nut
spanner (vehicle tool kit) and a length of
tubing.
However always check with a torque
wrench as soon as possible afterwards.

To achieve tightening torques with

on-b
board tools

Tightening torque Tubing length ”A” Physical weight ”B”

320 $ 350 Nm 350 mm 91 $ 99 kg
400 mm 80 $ 88 kg
450 mm 71 $ 78 kg
500 mm 64 $ 70 kg
360 $ 400 Nm 400 mm 90 $ 99 kg
450 mm 80 $ 89 kg
500 mm 72 $ 80 kg
600 mm 60 $ 67 kg
440 $ 480 Nm 500 mm 88 $ 96 kg
600 mm 73 $ 80 kg
Maintenance instructions

700 mm 63 $ 69 kg
480 $ 540 Nm 600 mm 80 $ 90 kg
700 mm 67 $ 77 kg
800 mm 60 $ 67 kg
600 $ 660 Nm 700 mm 85 $ 95 kg
800 mm 75 $ 83 kg
900 mm 67 $ 73 kg
1000 mm 60 $ 66 kg
820 $ 900 Nm 1000 mm 82 $ 90 kg

17
BPW Trailer axles / maintenance

Drum brake maintenance and visual inspection

2 Check brake lining thickness

– quarterly –
Open inspection hole by folding back the
rubber flap. The brake lining should be
replaced at a residual lining thickness
of 5 mm or on reaching the bottom of the
indicator machined into the edge of the
lining. Re$insert the rubber flap.

If brake lining wear indicators are fitted to

the slack adjusters, the minimum thickness
of the brake linings is indicated by the
horizontal position of the lever (when the
brake is released).

In certain cases the slack adjusters may

not be fitted in the normal (i.e. vertical)
position. In such instances, the position of
the wear indicator will also be different.
Linings should be changed when the wear
indicator is approximately at right angles to
the brake lever.

– Visual inspection
– every six months –
Check all components for damage
and wear.

18
3 Check operation of the automatic
slack adjuster
– six$monthly and / or as part of any other
service inspection –
Remove rubber seal cap. Turn back
adjustment screw by approx. 3/4 of a
turn in a counterclockwise direction using
a ring spanner. A play of at least 50 mm
with a lever length of 150 mm must be
available.
Actuate the brake lever several times by
hand. When this is done automatic adjust$
ment must take place smoothly.
Engagement of the clutch coupling is
audible and on the return stroke the
adjustment screw turns slightly in a
clockwise direction. Fit seal cap.
Grease with ECO$Li Plus, see also 3 on
page 12.

Maintenance instructions

19
BPW Trailer axles / maintenance

Disc brake maintenance and visual inspection

Premature brake pad wear on the disc brake

Even at high temperatures, disc brakes display stable braking properties and
a high level of safety. In contrast to the situation with drum brakes, excessive
thermal stress is not indicated by brake fade. Though positive in itself, this
characteristic of the disc brake leads to increased levels of wear when they
are used in a particular way.

All the brakes on a tractor/trailer unit must be balanced to ensure the braking
effort is distributed evenly throughout the vehicle. Tractor units with EBS
cannot have their brakes adjusted in the normal manner. As a result, the trailer
or semi$trailer merely has to be checked for compliance with the EC tolerance
bands. Always check the tractor vehicle if the trailer is in the EC band despite
premature brake pad wear. The EBS parameters in the tractor unit must be
modified in order to improve compatibility. Failure to do so will invalidate the
warranty.

The response of the disc brake is so good that there is no need to have any
predominance or at least the predominance can be restricted to max. 0.2 bar.

Other possible solutions to premature brake pad wear:

$ Prescribed maintenance work must be performed at regular intervals.
$ Use the retarder or engine brake to adjust the vehicle’s speed
$ Think ahead when driving
$ Drop down to a lower gear in good time

20
1 Check wheel nuts for tightness
– after the first loaded journey or
after a wheel change –
Tighten wheel nuts crosswise using a
torque wrench to the correct tightening
torque.
Tightening torques for wheel nuts
M 22 x 1,5:
Wheel stud alignment:
510 Nm (485 $ 535 Nm)
Spigot alignment:
630 Nm (600 $ 660 Nm)

Warning: Do not exceed specified settings!

Wheel contact surface should not have
additional coats of paint (risk of the wheels
becoming detached)!

2 Check brake pad thickness

– quarterly –
The brake pad thickness must be checked
regularly, e.g. during the tyre inflation
pressure check. The intervals must not be
more than 3 months.
The thickness of the remaining pad must
not be less than 2 mm.
Open bearing:
The thickness of the brake pad can be
Maintenance instructions

checked by the position of the brake

caliper (1) in relation to the guide rod (2) New condition
(rough indication of wear). open bearing sealed bearing
If the end of the guide sleeve (3) is level
with the fixed guide rod, the pad thickness
must be checked again after the wheels 1
have been removed.
+ Sealed bearing:
The sealed bearing has a ridged rubber 2
seal which is fitted over the guide pin. 3
Pad wear should be checked when the
wear mark (see diagram) has moved to Wear mark
the end of the guide pin.

21
BPW Trailer axles / maintenance

Disc brake maintenance and visual inspection

3 Brake disc
(Checking the condition of the brake disc)
– every 6 months – A B

a
Sections A $ D (see fig.) show the possible max. 0.75 x a
conditions of the disc surface: max. 1.5 mm
A: Network$type tears = permissible
B: Radial cracks
up to max. 1.5 mm
width and depth = permissible D C
C: Uneven disc surface less
than 1.5 mm = permissible
D: continuous cracks = not permissible

Technical details:
• disc thickness, new = 45 mm
• minimum permissible
disc thickness = 37 mm

In the case of surface conditions A  C,

the brake disc can be used until the
minimum permissible disc thickness
has been reached.

+ IMPORTANT!
To prevent damage to the brake discs,
the brake pads should be replaced when
their thickness (excluding 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.

22
4 Checking adjustment
– every 6 months –
Prevent the vehicle from rolling away.
Release the service brakes and the
handbrake.
Remove cap.
Place a size 8 ring spanner on the
hexagonal profile of the adjuster, or a
size 10 spanner on the adjuster adapter.
Turn anticlockwise until the ratchets
click 3 or 4 times.
+ Important!
If the version has an adjustment adapter,
never turn without the adapter. Exceeding
the specified break$off torque of the
adapter will cause the adapter to break.
Repeat with a new adapter. Fit a new
brake calliper if the adapter shears off
again $ this is an indication of internal
damage.
Do not use an open$ended spanner.
Max. torque: approx. 25 Nm
Apply brake 5 to 10 times (approximately
2 bar). If the adjustment is correct, the
ring spanner will turn back in a clockwise
direction (make sure the ring spanner can
rotate freely).
Note:
As the cycle rate increases, the movement
of the ring spanner, becomes smaller.
Maintenance instructions

If the ring spanner moves as described,

the adjustment is OK.
Remove ring spanner.
Wet the cap with Renolit HLT2 and re$fit.
For the version with the adapter, fit the lug
on the cap pointing towards the axle beam.
If the following faults occur:
The adjuster, or the ring spanner
a) does not turn,
b) turns only upon initial application,
c) turns forward and back again upon
each application,
The adjustment is not correct and the
brake caliper must be replaced.
23
BPW Trailer axles / maintenance

Disc brake maintenance and visual inspection

5 Checking the brake caliper guide system

– every 6 months –
(e.g. within the scope of the statutory
checks)
Prevent the vehicle from rolling away.
Release the service brakes and the hand$
brake.
Apply considerable pressure to the sliding
calliper in the direction of the guide bear$
ing. It should be possible to move it by
about 0.5 to 1 mm (play).
Check the brake calliper guide if this is not
the case.

The guide bush (1a) is sealed by the

bellows (2) and the sheet metal cap (3)
with the sealing ring (4).
Parts (2) and (3) must not be split or
damaged in any way. Check for correct
fitting.
If the version has a guide sleeve (5),
check it for damage and to make sure
it is correctly seated.

6 Bellows on the thrust tappets

– at every brake lining replacement,
latest annually –
The bellows on the tappets (arrow)
must have no splits or damage.
Check for correct fitting.
Advice:
Penetrating dirt and damp cause
corrosion and affect the operation
of the clamping mechanism and
adjustment.
If water has penetrated or rusting has
been detected, replace the brake caliper.

24
7 Checking the caliper
– at every brake lining replacement,
latest annually –
If damage to the parts becomes visible on
the thrust tappet when the bellows are
checked, both bellows must be dismantled.
The parts which have been removed must
be replaced by new ones.
Before the new parts are fitted check that
the adjusting unit is free of corrosion and
operates smoothly.
To check the parts, turn the threaded
tubes (1) on the hexagon nut (size 8 or size
10 with an adapter) of the adjuster clock$
wise onto the brake disc (2).
The threads of the threaded tubes (1) can
be checked during the turning process for
corrosion damage.
If the threads are rusted, the brake caliper
must be replaced.

+ Advice:
To prevent the threaded tubes (1) being
turned completely out of the caliper, insert
a new brake pad (3) into the caliper in the
outboard brake pad position.

+ To prevent the threaded tubes being

Maintenance instructions

wound completely out of the caliper when

working on a work bench, insert a separator
(approximately 75 mm) between the tubes
and the caliper housing.
If the threaded tubes are wound
completely out of the caliper, the
brake caliper must be replaced.

25
BPW Air suspensions

Valid: 01.01.2002

expires, 3 years off$road,

after the warranty period
recommended annually

5 or 8 years on$road 1)
Maintenance work after expiry of the warranty period
Overview
For detailed description see pages 28 - 31
Visual checks or maintenance work
during the warranty period, see pages 7 $ 9

Maintenance

– Visual inspection. Check all component parts for damage and wear.
1 Check condition of air bags.
2 Check air suspension level valves for condition,
seal$tightness and general tightness.
3 Check shock absorber fastening for tightness.
Tightening torques with a torque wrench:
M 24 M = 420 Nm (390$460 Nm)
for aluminium hanger brackets M = 320 Nm (300$350 Nm)
4 Check spring mounting kit for tightness.
Tightening torques with a torque wrench:
M 22 M = 550 Nm (510$600 Nm) 2)
M 24 M = 650 Nm (605$715 Nm)
5 Check air bag fastening for tightness.
Tightening torques with a torque wrench:
M 12 M = 66 Nm
M 16 M = 230 Nm
6 Check spring pivot bolts for tightness.
Tightening torques with a torque wrench:
hanger brackets up to 07/2001: M 30 M = 750 Nm (700$825 Nm)
hanger brackets from 08/2001: M 30 M = 900 Nm (840$990 Nm)
channel cross member: M 30 M = 900 Nm (840$990 Nm)
7 Check axle lift for tightness.
Tightening torques with a torque wrench:
supporting arm M 16 M = 230 Nm
cylinder M 16 M = 180 $ 210 Nm
8 Check strap. Check condition and fastening.
1)
under extreme conditions, more frequently.
2)
When mounting new spring mounting kit components for Airlight II:
Tightening torque: M 22 M = 550 Nm + 90° angle tightening
26
 7

Series ALO/SLO Series ALO/SLO with two-s

sided axle lift

2 1 3 8 5

6 4 5
Maintenance instructions

Series ALM/SLM Series ALM/SLM with Kombi-A

Air Bag II

Series ALU/SLU

27
BPW Air suspensions

Maintenance work after expiry of the warranty period

Visual checks or maintenance work during the warranty period, see pages 7 $ 9

– Visual inspection
– recommended annually after the
warranty period expires,
3 years off$road, 5 or 8 years on$road –
Check all component parts for wear
and damage.
1 Air bags
– recommended annually after the
warranty period expires,
3 years off$road, 5 or 8 years on$road –
Check air bags for external damage (sur$
face cracking, abrasion, crease
formation, trapped foreign bodies etc.).
Replace air bags in the event of damage.
Safety notice
No welding should be carried out to steel
parts of air bags and pressure vessel! The
air suspension should only be filled with
compressed air when mounted or when the
mechanical height limit has been reached!
Danger of injury!
2 Air installation circuit
– recommended annually after the
warranty period expires,
3 years off$road, 5 or 8 years on$road –
Check air installation valves and line con$
nections for firm seating, damage and seal$
tightness. Check valve linkage and fasten$
ings (arrows) for damage and tightness.
The length of the valve lever and permis$
sible angular positions on the valve linkage
are shown in the illustration on page 31.
3 Shock absorber fastening
– recommended annually after the
warranty period expires,
3 years off$road, 5 or 8 years on$road –
Check lower and upper shock absorber
fastening for tightness.
Tightening torques with a torque wrench:
M 24 M = 420 Nm (390$460 Nm)
In the case of alloy hanger bracket
M 24 M = 320 Nm (300$350 Nm)
28
4 Spring mounting kit
– recommended annually after the
warranty period expires,
3 years off$road, 5 or 8 years on$road –
Check lock nuts of spring U$bolts for tight$
ness. If loose, tighten nuts alternately a little
at a time. No welding should be performed
on the trailing arm spring!
Tightening torques with a torque wrench:
M 22 M = 550 Nm (510$605 Nm)
M 24 M = 650 Nm (605$715 Nm)

5 Air bag fastenings

– recommended annually after the
warranty period expires,
3 years off$road, 5 or 8 years on$road –
Check air bag fixing screws or nuts for
tightness.
Tightening torques with a torque wrench:
M8 M= 19 Nm
M 12 M= 66 Nm
M 16 M= 230 Nm

6 Spring pivot bolts

– recommended annually after the
warranty period expires,
3 years off$road, 5 or 8 years on$road –
Check bushes $ move vehicle backward
and forward slightly with the brake applied,
or move rolled spring ends with the aid of a
lever. No play should be present in the
rolled spring end when doing so. If the
Maintenance instructions

fastening is loose the spring pivot bolt

may be damaged.
$ Check the wear washers in the
hanger bracket.
$ Check the M 30 lock nut on the spring
pivot bolt for tightness.
Tightening torque with a torque wrench:
Air suspension hanger brackets
up to 07/2001 M 30 M = 750 Nm (700$825 Nm)
from 08/2001 M 30 M = 900 Nm (840$990 Nm)
Channel cross member
M 30 M = 900 Nm (840$990 Nm)
The serviceable life of the rubber/ steel
bush is dependent on the tightness of the
inner steel bushing.
29
BPW Air suspensions

Maintenance work after expiry of the warranty period

Visual checks or maintenance work during the warranty period, see pages 7 $ 9

7 Axle lift
– recommended annually after the
warranty period expires,
3 years off$road, 5 or 8 years on$road –
Check the M16 lock nuts on the lever arm
fixing and diaphragm cylinder to make sure
they are tight. Tighten with a torque
wrench if necessary.
Tightening torques with a torque wrench:
supporting arm M 16 M= 230 Nm
cylinder M 16 M= 180 $ 210 Nm
Check for wear on the bump stop on the
lever arm or the stop for the double$sided
lift. Make sure they are secure.
M 12 M= 66 Nm

8 Check straps
– recommended annually after the
warranty period expires,
3 years off$road, 5 or 8 years on$road –
Examine check straps and attachment.
Replace if necessary.

30
Spring pivot bolt bearing with axle lift

Single$sided lift Two$sided lift

Air levelling valve

Maintenance instructions

31
 BPW-W-ECOPlus - 02/1e

BPW Bergische Achsen Kommanditgesellschaft, Postfach 12 80, D-51656 Wiehl,

Tel. ++49 (0 ) 22 62/78-0, info@bpw.de, www.bpw.de