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BPW AirSave Operating And Installation Instruction

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Operating and Installation Instruction
AirSave
BPW-EA-AS 37882402e

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Summary of Contents for BPW AirSave

  • Page 1 Operating and Installation Instruction AirSave BPW-EA-AS 37882402e...
  • Page 2 3.4.1 AirSave Control Box 141 Page 29 3.4.2 AirSave Control Box Page 31 Installation of the cables on the AirSave Control Box 141 Page 32 Installation of the AirSave LED display and adhesive label Page 34 Installation of the pressure lines Page 35 3.7.1 Tubeless round axles Ø...
  • Page 3 10.2 Axles with R1 / RT / RY code Page 58 10.3 Redrilled axles with a BPW-approved drilling device Page 58 10.4 Explanation of AirSave axle identifi cation marks Page 58 Drilling template ..........................Page 59 11.1 AirSave Control Box Page 59 11.2 AirSave LED display...
  • Page 4 A damaged valve hose can cause the tyre to defl ate completely. • Make sure that you only use the AirSave rotor from BPW (grey cap & white PTFE sealing ring), as this is the only way to ensure tightness.
  • Page 5 Rectifi cation of any defects which are discovered or replacement of worn parts should be carried out by a BPW Service Centre or BPW Direct Service Partner, unless the vehicle owner has the required specialist personnel, the required technical facilities and workshop manuals or possesses an offi cial certifi...
  • Page 6 Page 6 BPW-EA-AS 37882402e Component overview Technical data – AirSave Technical data – AirSave Control Box and Control Box 141 Para- preset Comment meters Control Box Control Box 141 min. inlet pressure 6,0 bar invariable variably adjustable > 6 bar...
  • Page 7 10 t - ECO Plus 05.801.47.18.0 Oil seal Ø 24, Ø 16 x 4 BPW AirSave hub cap adapter O-ring Ø 32 x 3 (=> 17.08.2023) Ø 33 x 3.5 (18.08.2023 =>) Hub cap with O-ring for ECO Plus 3...
  • Page 8 Page 8 BPW-EA-AS 37882402e Component overview System components Rigid axles Cable connection to EBS, see overview in Chapter 3.5 Air pipe Ø 8 mm is not included in the scope of supply 120 x 10 Ø 146 x 10 until 07.2022 120 x 10 as of 08.2022...
  • Page 9 02.3510.04.10 axle beam Steering axles 6 x 1 mm black, L = 1555 mm 02.3510.13.10 AirSave T-piece (connector for air hoses 3 x Ø 6 mm 02.4319.45.00 => 09.12.2020) of the axle sides) 2 x Ø 6 mm / 1 x Ø 8 mm ( 02.4319.46.00...
  • Page 10 Page 10 BPW-EA-AS 37882402e Component overview System components Steering axles Cable connection to EBS, see overview in Chapter 3.5 Air pipe Ø 8 mm is not included in the scope of supply Series N...LL / N...L Series (S)H...LL / (S)K...LL...
  • Page 11 02.0130.98.20 Polyamid tube in the axle beam 6 x 1 mm black, L = 1555 mm 02.3510.13.10 AirSave T-piece (connector for air hoses 2 x Ø 6 mm / 1 x Ø 8 mm 02.4319.46.00 of the axle sides) Dummy plug for AirSave T-piece Ø...
  • Page 12 Control unit vents 50 mm clearance to the nearest component Drill template for the assembly of the AirSave Control Box - see page 59 AirSave Control Box 141 Connection of connecting cable to EBS Test connection LED light...
  • Page 13 BPW-EA-AS 37882402e Page 13 System overview System components BPW LED light for assembly on the vehicle chassis Note: When using the Control Box 141, the installation of the LED light is optional.
  • Page 14 The safety valve allows and stops the air supply to the system. AirSave is a pneumatic system that operates autonomously and does not require a power supply.
  • Page 15 In the event of a system malfunction, the solenoid valves close automatically when the pressure exceeds 10.5 bar (variable settings), to prevent excess pressure in the tyre/system. AirSave Control Box - Communication The measured data is compared with the preset data. Based on the results, the following warning or fault messages are forwarded via the CAN network: •...
  • Page 16 Page 16 BPW-EA-AS 37882402e Component overview Component descriptions AirSave connecting cable (Item 850) The connecting cables connect the control unit to the EBS units. Depending on the EBS manufacturer, there are various options for connecting the control unit. Wabco connecting cable Wabco (from TEBS E6.5)
  • Page 17 For G2.2 4pol. HDSCS Control unit 4 pol. HDSCS 4pol. HDSCS Control unit open end IDEM telematics connecting cable AirSave in combination with iC Plus BPW item number EBS connection Comment 02.1819.42.10 Gateway (HDSCS-Port) AirSave iC Plus Y-cable 4pol. HDSCS Control unit 4pol.
  • Page 18 The stator is located within the axle stub and the rotor is fastened to the wheel Stators hub cap. Compressed air fl ows through a polyamid tube from the AirSave Control Box via a T-piece and through the inside of the axle to the rotating hub via a needle, which extends from the rotor into the stator.
  • Page 19 Designation Quantity BPW item number BPW item number Axle line kit AirSave rotor, single wheels 02.0130.00.30 8 - 9 t AirSave valve hose ET 0 02.3510.05.10 05.801.47.74.0 AirSave angle piece 02.4502.21.00 AirSave rotor, single wheels 02.0130.00.30 8 - 9 t AirSave valve hose ET 120 02.3510.06.10...
  • Page 20 Item Designation Quantity Note BPW item number AirSave rotor, single wheels 02.0130.00.30 BPW AirSave hub cap 10 - 12 t 05.801.47.18.0 AirSave stator for air hose 02.0130.99.20 AirSave valve hose ET 120 02.3510.06.10 Kink protection - spiral & kink protection 02.0130.98.20...
  • Page 21 BPW-EA-AS 37882402e Page 21 Component overview AirSave basic kits (item 838) AirSave basic system kit for 1 - 2 axle vehicles Item Designation Quantity Note BPW item number Dummy plug for AirSave 02.3704.99.00 Control Box Ø 8 mm Control 05.801.47.19.0 AirSave LED display CMP5 02.0130.01.30...
  • Page 22 ECO Plus 3 05.801.47.17.0 05.801.47.86.0 BPW AirSave hub cap ECO Plus 05.801.47.18.0 BPW repair kit for axles up to 07.2022 and all steering axles (S)H...LL / (S)K...LL (Pos. 830) Item Designation Quantity BPW item number AirSave stator for air hose Kink protection - spiral &...
  • Page 23 05.801.47.17.0 ECO Plus 3 05.801.47.25.0 AirSave valve hose ET 120 02.3510.06.10 AirSave rotor, single wheels 02.0130.00.30 BPW AirSave hub cap 10 - 12 t 05.801.47.86.0 ECO Plus 3 05.801.47.93.0 AirSave valve hose ET 0 02.3510.05.10 10 - 12 t AirSave rotor, single wheels 02.0130.00.30...
  • Page 24 AirSave Control Box 02.0130.02.30 842b AirSave Control Box 141 02.0130.67.30 EBS connecting cable AirSave Knorr / 4pol. HDSCS 02.1819.37.10 AirSave Knorr / G2.2 (open end) 02.1819.38.10 AirSave Knorr / G2.2 (Y-cable) 02.1819.45.10 AirSave Wabco / SUB 02.1819.39.10 AirSave Wabco / GIO5 02.1819.40.10 AirSave Wabco / SUB (Y-cable) 02.1819.44.10...
  • Page 25 Version as of 08.2022 – original equipment Remove the transport protection from the fi tted hub cap. Check the AirSave hub cap adapter (814) for da- mage and cracks. Clean the face-side contact surface of the AirSave hub cap adapter.
  • Page 26 When fi tting the rotor, hold the hub cap adapter (817) to make sure that the rotor is Figure 4 screwed in as far as it will go. The valve connection is aligned afterwards by rotating the hub cap adapter (SW 55). AirSave on youtube...
  • Page 27 BPW Bergische Achsen KG. (Control box connections for the connecting lines Figure 5 Ø = 8 x 1 mm) Push the stator all the way into into the axle stub together with the air pipe.
  • Page 28 (SW 55) or spring pliers until the screwed joint of the rotor can be connected to the valve hose (see Figure 9). Do not turn back the rotor!! Hand-tighten the valve hose on the AirSave rotor (811 or 811a). Check valve hose for untightness. Figure 9...
  • Page 29 Screw the exhaust into the lower hole of the AirSave Control Box 141 (842b). Hold the AirSave Control Box 141 (842b) in the required installation position. Figure 12 Mark positions for the fi xing holes.
  • Page 30 Installation of the AirSave Control-Box 3.4.1 AirSave Control Box 141 Insert the AirSave Control Box into the bore holes on the frame with the fi xing screws and the spacer. Make sure that the control box is correctly aligned, see Figure 12.
  • Page 31 There must be a clearance of min. 50 mm in front of the vent. Hold the AirSave Control Box (842) in the required installation position. Mark positions for the fi xing holes. Drill Ø 9 mm holes and deburr slightly.
  • Page 32 Page 32 BPW-EA-AS 37882402e Installation Installation of the cables on the AirSave Control Box 141 Installation and repair guide!! General information: Do not use any tools when assembling or disassembling the connection cable. The cable ties for the installation of the connection cables are not included in the scope of delivery.
  • Page 33 Idem. For this purpose, the telematics gateway is connected to the AirSave Control Box as shown in Figure 21 using the AirSave Y-cable (AirSave Y-cable iC Plus BPW, part no.: 02.1819.42.10).
  • Page 34 (arrow) and vent some air. When the AirSave LED display installation or connection is correct the AirSave LED black + display starts to fl ash and the AirSave Control Box equalises the pressure. Finally assembly the cover plate. white -...
  • Page 35 Cut off the air pipe Ø 8 x 1 mm at the end with a straight cut. Push the air pipe into the AirSave angle piece (835) as far as it will go. You will feel resistance at two points. The insertion length is approx. 20 mm.
  • Page 36 Page 36 BPW-EA-AS 37882402e Installation Installation of the pressure lines 3.7.2 Axles with tube system as of 08.2022 3.7.2 Axles with tube system as of 08.2022 Remove the plug (840) from the angle piece (835). To do this, press the face-side ring into the angle piece while removing the plug.
  • Page 37 Figure 29 For axles with air suspension, connect supply lines Suspension with one axle (Ø 8 x 1 mm PA line) to the AirSave Control Box 141 (Figure 29) directly at the air tank of the trailer Right axle side air suspension.
  • Page 38 Figure 31 For axles with air suspension, connect supply lines Suspension with one axle (Ø 8 x 1 mm PA line) to the AirSave Control Box Right axle side (Figure 31) directly at the air tank of the trailer air suspension.
  • Page 39 3.7.5 For assembly, the knurled nuts must be unscrewed and slid over the relevant air pipe. Push the air pipe onto the AirSave T-piece as far as it will go (arrow) and screw hand-tight with the knurled nuts. Figure 33...
  • Page 40 The Ø 8 mm air pipes are connected to the AirSave T-piece (833a) on the vehicle frame and routed to the control box. The axles are only equipped with AirSave up to the angled piece in the steering arm groups.
  • Page 41 BPW-EA-AS 37882402e Page 41 Installation instructions Installation in air-sprung axles: The control box is connected to the air suspension storage tank. If there are several reservoirs, the replacement reservoir or the accessory reservoir is used. Installation in mechanically sprung axles: It is permissible to connect the control box to the brake reservoir, if an additional pressure limit valve is connected between them.
  • Page 42 A service kit is required for the commissioning of the Control Box 141: AirSave ECE R 141 cable (laptop) kit (BPW item number 02.1819.43.10) With the help of a laptop, a CAN reader and the soft- ware for the Control Box 141, the CAN data can be read out and the system parameter input can be confi...
  • Page 43 BPW-EA-AS 37882402e Page 43 Setting into operation AirSave Control Box 141 Software confi guration 5.1.2 Figure 38 Open the software and in the „Setup COM“ tab, select the port „COM3“. Click on „OK“ to confi rm the selection. Click on the „Connect“ tab to connect with the Control Box 141.
  • Page 44 Read the pressure on the pressure gauge. Remove pressure gauge. Relieve pressure at the valve. Wait for the AirSave Control Box 141 pumping process and then reassemble the pressure gauge. Figure 41 Repeat the test procedure twice.
  • Page 45 BPW-EA-AS 37882402e Page 45 Setting into operation AirSave Control Box 141 Checking and adjusting the outlet pressure 5.1.3 5.1.3.2 Adjusting the outlet pressure Adjusting the pressure using the software Read the current parameters, see Chapter 5.1.3.1. Enter the desired parameters.
  • Page 46 Communication is established (the traffi c light changes to red) f) The set outlet pressure is reached (the AirSave Control Box 141 stops pumping and the traffi c light changes to green) g) The external warning light fl ashes (optional).
  • Page 47 The outlet pressure must be 0.1 to 0.2 bar over the manufacturer's recommended tyre pressure in order to equalise the opening pressure of the downstream components. The outlet pressure is preset (see AirSave Con- trol Box cover plate) and must be checked before commissioning. Figure 47 Remove cap on the pressure connection (arrow, Figure 47).
  • Page 48 Wait for the pumping process, re-connect the pressure gauge and read-off the outlet pressure on the pressure gauge. Repair note! Before opening the AirSave Control Box, always close the shut-off valve and relieve the air on the excess pressure valve. Figure 50 Detach the fi...
  • Page 49 Visual inspection Inspect all components for damage and untightness Check whether the shut-off valve on the AirSave Control Box is opened Check connection lines, valve hoses and rotors Check electrical and pneumatic lines Check the stator with fi lter element (RX axles) for dirt...
  • Page 50 Check that the air can penetrate by pushing the Figure 54 valve needle in the valve hose. Hand-tighten the valve hose on the AirSave rotor (811 or 811a). Check the valve hose and the connections for untightness.
  • Page 51 Loosen valve hoses (825, 826, 827 - depending on Figure 55 version) from the rotor (811 or 811a). Screw rotor out of the AirSave hub cap adapter (817) and pull out. Screw hub caps (819, SW 110) off the wheel hub.
  • Page 52 Use a tube connector to connect the new polyamide tube (832, Ø 6 mm) to the tube being replaced. Tube connector BPW item number: 02.2012.06.00 Figure 58 [10] Unscrew stator (821) from the axle stub using a box spanner (SW 16).
  • Page 53 [23] Cut off the air pipe Ø 8 x 1 mm at the end with a straight cut. [24] Push the air pipe into the AirSave angle piece (835) as far as it will go. You will feel resistance at two points.
  • Page 54 [19] Cut off the polyamide line Ø 6 x 1 mm at the end with a straight cut. [20] Push it all the way into the AirSave T-piece (833). Figure 64 Continue with work step [25] on page 55.
  • Page 55 BPW-EA-AS 37882402e Page 55 Repairs to the stator and internal tube [18] Fasten the AirSave T-piece (833) to the long cable tie (849) with a short cable tie (850). [19] Using the cable tie, fasten the pre-assembled T-piece to the axle beam near the shaped plate for the steering lock.
  • Page 56 The thread of the lengthwise stator is Seal the stator thread with Tefl on tape not leak-proof (or similar) and screw it back in The AirSave LED display is out of Replace the AirSave LED display. operation. The AirSave LED display is switched off during system The generator is out of operation.
  • Page 57 --> a garage/service station must be pump incessantly, despite there not consulted immediately being a tyre leak, AirSave can be swit- ched off until repairs are carried out. The ball valve on the ControlBox must be closed for this purpose...
  • Page 58 Retrofi tting axles to the BPW AirSave system is only permitted using a BPW-certifi ed drilling device. For damages that occur as a result of any other kind of retrofi tting, no claims can be made under the BPW ECO Plus Warranty.
  • Page 59 BPW-EA-AS 37882402e Page 59 Drilling template AirSave Control Box 11.1 Ø 9 Ø 9 ca. 90 ca. 30 ca. 60 ca. 75 Minimum distances to the nearest components. There must be unrestricted access to the air connection. Ø 9 Ø 9 125.4...
  • Page 60 Page 60 BPW-EA-AS 37882402e Drilling template 11.2 AirSave LED display 26.5 Ø 2.5 Ø 2.5 Drilling template 1:1 - Select “Actual size” or “Scale to fi t” printing setting...
  • Page 61 BPW-EA-AS 37882402e Page 61...
  • Page 62 Your partner on the path to economic viability BPW Bergische Achsen Kommanditgesellschaft Postbox 12 80 · 51656 Wiehl, Germany · Phone +49 (0) 2262 78-0 info@bpw.de · www.bpw.de...