MMaaiinntteennaannccee aanndd sseerrvviiccee iinnssttrruuccttiioonnss ffoorr BBPPWW cchhaassssiiss
ZAF-1 ZAF-2
Drawbar forcePull rod (thrust force)
Brake lever Brake lever
Tensile force
Wheel brake
DIRECTION OF TRAVEL
Ø 48 mm
10,5
mm
105 mm
CChheecckk wwhheeeell bboollttss ffoorr ffiirrmm sseeaattiinngg– after each wheel change –
Tighten wheel bolts crosswise using atorque wrench to the tightening torque forwheel bolts 8.8 (spanner widths 19)
M 12 x 1,5 M = 92 Nm ± 10%
Refer to BPW and manufacturershandbook for correct torque!
Heavy dutycranked support
Cranked support
Locking nuts
Locking nutsLocking nuts
Linkage rod
Linkage rod
Brakecompensator
Brakecompensator
Brakecompensator
Brakecompensator
SL-Lock
SL-Lock
SL-Lock
Turn buckle
Turn buckleTurn buckle
Adjustment nut
Adjustment nut
Adjustment nut
Remove the transportcover
Lift off the upper cablehose support
Insert the brake cable withits nipple into the expanderlock tension bolt.Replace the cable hosesupport.Slide on the cable sleeve.
Wheel stud Wheel stud
Roller bearing
Roller bearing
Seal
Roller bearing
Locking ring
Lock nut
Lock nutSplit pin
Cap
Cap
Drum hub Drum hub
Cable guidePlug
Circlip
Return spring
Brake plate
Reversing cam
BoltExpander
Return spring
Retaining pin
Retaining clip
Brake shoe kit
Screw
Adjusting nut
Spring clip
Cable link
Adjusting bolt
1600 kg axle
Check brake lining wear- every 5000 kilometres -The brake lining wear is dependent on thestyle of driving. Careful driving saves brakelinings and tyres. As soon as a brake lininghas been worn to a thickness of 2 mm, the brake shoe must be replaced. Stiff orstretched brake springs, the coils of whichare no longer closed tightly together, mustalso be replaced. For visual check remove the plug (arrow) from the brake plate. RReeppllaacceemmeenntt bbrraakkee ppaadd aasssseemmbblliieess mmuusstt bbee rreeppllaacceedd aass aa sseett ffoorr tthhee iinnddiivviidduuaall aaxxlleess..
Re�adjustment of the brake system- every 2000 - 3000 kilometers of travel -
Jack up the trailer. Release the towingequipment and handbrake lever and brakelinkage (free from tension).
Lock the reversing cam of the wheel brakefrom the outside by means of a locking pin(item A, pin Ø 4 mm) through the backplate.
Tighten the adjustment nut on the wheel brake with a spanner turn hex adjuster until the wheel will not rotate in the direction of travel.Centre the brake shoes by applying theparking brake several times.
Turn back the adjustment bolt by approx.one turn, until no braking effectcan be feltwhen the wheel is turned in a forwarddirection.
With parking brake activated check equaliser bar is at right angles to brakerod. It may be necessary to readjust thebrakes or adjust length of brake cables(screw clevis in/out as required).
Remove 4 mm locking pin from reversing cam.
To test, partially apply parking brake andcheck for similar brake torque on all wheels (in forward direction of travel).
BBrraakkee LLiinnkkaaggee ((sseeee ffiigg.. EE))With the parking brake off and all brakes correctly set, readjust brake rod length with turnbuckle nut or equaliser until there is neither free play or tension. If necessary, adjust the nut of the brake cables. Tightenall lock nuts after adjustment.
Note: Excessive travel on the handbrake lever or failure of the handbraketo operate properly may be due to brake wear or a poorly adjusted linkage.
EEXXPPLLOODDEEDD VVIIEEWW -- WWhheeeell bbrraakkee
FFUUNNCCTTIIOONNAALL CCHHAARRAACCTTEERRIISSTTIICCSS -- OOvveerrrruunn bbrraakkee ssyysstteemmss
MMAAIINNTTEENNAANNCCEE WWOORRKK OOFF TTHHEE BBRRAAKKEE SSYYSSTTEEMM
WWHHEEEELL SSTTUUDD
EEXXPPLLOODDEEDD VVIIEEWW -- OOvveerrrruunn hhiittcchhIINNSSTTAALLLLAATTIIOONN -- BBrraakkee ccaabbllee
BBRRAAKKEE LLIINNKKAAGGEE -- SSiinnggllee aaxxlleeCCOORRNNEERR SSTTEEAADDIIEESS JJOOCCKKEEYY WWHHEEEELLCCLLAAMMPPIINNGG
BPW Bergische Achsen Kommanditgesellschaft, P.O. Box 12 80, D�51656 Wiehl, Phone +49 2262 78�0, [email protected], www.bpw.de
TTYYPPEE PPLLAATTEE -- AAxxllee
TTYYPPEE PPLLAATTEE -- OOvveerrrruunn hhiittcchh // ttooww ssyysstteemm
A
B
A
loose
fixed
B
left and rightwheel side
BBOOLLTTEEDD JJOOIINNTT CChhaassssiiss rraaiill // AAxxllee ffllaannggeessBBOOLLTTEEDD JJOOIINNTT AAnnggllee ffllaannggee // DDrraawwbbaarr BBOOLLTTEEDD JJOOIINNTT DDrraawwbbaarr // CChhaassssiiss rraaiill
BA C DF
H
IK
J
E
M
L
RUNNING WELL FOR YOU. BPW BERGISCHE ACHSEN
Lmin=
237
Lmax =337
max. 65° BPWorder no.
05.803.00.60.005.803.00.61.005.803.00.63.0
Identification
redblueblack
Weight ranges(Axle load)
550 - 1050 kg1050 - 1350 kg1350 - 1800 kg
SSHHOOCCKK AABBSSOORRBBEERRSS
G
MMAAIINNTTEENNAANNCCEE SSCCHHEEDDUULLEE -- AAxxllee
LLuubbrriiccaattiioonn aanndd mmaaiinntteennaannccee wwoorrkk initi
ally
ever
y 2,
000
-3,
000
kilo
met
res
or
ann
ual
lye
very
5,0
00
ki
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10,0
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In case of torsion bar axles: lubricate thetrailing arm bearing via the grease nipple.Check wheel bolts for firm seating
Check brake play, if necessary, readjust
Check hub caps for firm seating
Check tyres for uneven wear
Check brake lining wearCheck bearing end float, replace bearing ifnecessary.
1
2 2
3
-
4
5
MMAAIINNTTEENNAANNCCEE SSCCHHEEDDUULLEE -- DDrraawwbbaarr
LLuubbrriiccaattee initi
ally
ZZAA
FF--11
ever
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res
or
ann
ual
lyZZ
AAFF--
11ev
ery
5,00
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lyZZ
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22ev
ery
10,0
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2,00
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so
r an
nu
ally
Drawbar bearings at the housing of theoverrun hitchOil or grease brake leverGrease sliding points on the height-adjustingdeviceMMaaiinntteennaannccee wwoorrkk
Check coupling head
Check all movabel parts for ease of movement.
Check safety cable for damage
2
1
2
3
1
3
1 1
2 2
33
1
2
Chassis specifications may vary according to market requirements. BPW’s policy of continuously improving their product may involve major or minor changes on the chassis or accessories. The manufacturer reservesthe right to alter specification, with or without prior notice, at any time.
Refer to BPW maintenance and operating instructions
51)
1) 1600 kg axle
BBRRAAKKEE LLIINNKKAAGGEE -- TTaannddeemm aaxxllee
ZZAAFF--11 ZZAAFF--22
1
2) and after 500 kilometres
2)
3
1
2
BPW-PW-Caravan 05/1e
