BPW Brake Cylinders

for disc and drum brake axles

Technical data - Valid June 2015 - Version 1.6

BPW-BZ 39131502e
Page 2 BPW-BZ 39131502e - Version 1.6

1 General description

Contents
1. General description ......................................................................................................................... Page 2
2. Brake cylinder for axles with disc brakes ..................................................................................... Page 4
2.1 Diaphragm cylinder Page 4
2.2 Diaphragm-diaphragm cylinder Page 6
2.3 Diaphragm-piston cylinder Page 8
3. Brake cylinder for axles with drum brakes .................................................................................. Page 10
3.1 Diaphragm cylinder Page 10
3.2 Diaphragm-diaphragm cylinder Page 12

The power plant for your brake system.

Brake cylinders from BPW.
In a brake system, it is of the utmost importance to achieve an optimum interface between the individual components.
The brake cylinders have a decisive role to play in this, because they have to provide a perfectly modulated force
transfer within the brake system. BPW develops and produces its own brake cylinders for drum and disc brakes –
further proof of our extensive expertise when it comes to brakes. As a system supplier, our product range includes
diaphragm and spring-type cylinders.

Variants of BPW brake cylinders

Diaphragm cylinders Diaphragm-diaphragm (M-M) Diaphragm-piston (M-K) cylinders

cylinders
They act as a service brake and are They have the same function as
characterised by their compact ex- They act both as a service brake a diaphragm-diaphragm cylinder.
ternal dimensions and low weight. as well as an auxiliary and parking Their greater spring-type accumula-
brake. They are lighter than the dia- tor force means they are suited abo-
phragm-piston cylinder. ve all for vehicles with higher axle
loads and limited installation space.
BPW-BZ 39131502e - Version 1.6 Page 3

For axles with disc brakes For axles with drum brakes
Diaphragm cylinder Diaphragm-diaphragm Diaphragm-piston Diaphragm cylinder Diaphragm-diaphragm
cylinder cylinder cylinder

14" 14/24" 12"

15" 15/24" 16" 16/24"
16" 16/24" 16/16" 20" 20/30"
18" 18/24" 24" 24/30"
20" 20/24" 20/24" 30" 30/30"
22" 22/24" 36"
24" 24/24"

BPW Original Equipment axles can be delivered complete with brake cylinders. (Foundation brake adjustment
necessary). If the lever length is > 150 mm, make sure that only long-stroke diaphragm cylinders are used.
Always use long-stroke cylinders with automatic slack adjusters.

BPW brake cylinders – Features and benefits

• Sustained high quality assured by testing and continuous quality checks (FMEA, dimension test, release pressure
test, functional test on the vehicle, vibration test, dirt test, fatique strength test with one million braking cycles,
hot and cold test (80° C, -40° C), force output check)
• Improved sealing using innovative flanging technique
• Optimum corrosion protection for the housing components by means of various high-quality coating procedures
• Optimum corrosion protection for the springs by means of double coating
• Inch and metric connections available
• BPW brake cylinders have long stroke capability as standard
• Easy to install because of extended compressed air connection (standard in spring-type cylinders for disc brakes)
• In drum brakes, there is no need for an external return spring between the slack adjuster and air cylinder bracket
(precondition: mounting on BPW axles, round hole yoke end and lever length > 100 mm)
• Brake cylinder sizes / brake cylinder configurations are calculated using BPW brake calculations for each vehicle
type. (For a questionnaire to establish the vehicle data see www.bpw.de)
• New ECE certificates and test reports are available on the BPW website
Page 4 BPW-BZ 39131502e - Version 1.6

2 BPW Brake cylinder for axles with disc brakes

2.1 Diaphragm cylinder









 




Version A Version B
05.444.xx.02.0    05.444.xx.01.0




Installation dimensions BPW brake cylinder

Cylinder size L D1 D3 R1*
mm mm mm mm
14" 101 143 165 101.5
15" 101 143 165 101.5
16" 101 145 165 101.5
18" 108 150 176 107
20" 108 150 176 107
22" 110 160 186 112
24" 110 160 186 112
* Applies only to cylinders with a clamp lock. Current cylinder versions are beaded.

Versions of BPW brake cylinder

Version BPW brake cylinder Test report BC 0055.2
Compressed air cylinder
Cylinder size BPW Code number BPW Code number Maximum stroke Average thrust- Effective stroke
Version A Version B smax (mm) ThA (N) sp (mm)

14" 05.444.30.02.0 05.444.30.01.0 62 865p - 300 1.45p + 43

15" 05.444.31.02.0 05.444.31.01.0 60 958p - 372 0.78p + 51
16" 05.444.32.02.0 05.444.32.01.0 60 1062p - 320 0.89p + 47
18" 05.444.33.02.0 05.444.33.01.0 65 1088p - 218 1.14p + 52
20" 05.444.34.02.0 05.444.34.01.0 65 1199p - 239 0.85p + 57
22" 05.444.35.02.0 05.444.35.01.0 69 1297p -259 0.39p + 60
24" 05.444.36.02.0 05.444.36.01.0 66 1404p - 281 0.42p + 62
BPW-BZ 39131502e - Version 1.6 Page 5

Characteristic line of diaphragm cylinder 14 - 24" for disc brakes

12000
[N]
Kraft [N]
Force

10000

8000

6000

4000

2000

0
0 1 2 3 4 5 6 7 8
Pressure
Druck[bar]
[bar]

14" 15" 16" 18" 20" 22" 24"

Page 6 BPW-BZ 39131502e - Version 1.6

2 BPW Brake cylinder for axles with disc brakes

2.2 Diaphragm-diaphragm (M-M) cylinders

 


 

 







 

 
  

Version A Version B
05.444.xx.02.0 05.444.xx.01.0
Brake cylinder kit with compressed
air connection mounted
 05.444.xx.xx.3





BPW Code no.: 05.001.00.05.0

Installation dimensions BPW brake cylinder

Cylinder size Ø D1 Ø D2 Ø D3 Ø D4 R1 L1 L2 L3 L4
mm mm mm mm mm mm mm mm mm
14/24" 145 161 165 186 100 95 235 92 85.5
15/24" 145 161 165 186 100 95 235 92 85.5
16/24" 145 161 165 186 100 95 235 92 85.5
18/24" 145 161 176 186 106 103 257 92 85.5
20/24" 145 161 176 186 106 103 257 92 85.5

Versions of BPW brake cylinder

Version BPW brake cylinder Test report BC 0056.2
Compressed air cylinder Spring-type cylinder
Max. Average Effective Max. Average Release
BPW BPW stroke thrust stroke stroke thrust pressure
Cylinder Code number Code number smax ThA sp smax Ths pL10
size Version A Version B Mounting kit (mm) (N) (mm) (mm) (N) (bar)
14/24" 05.444.38.02.0 05.444.38.01.0 05.801.21.50.0 61 858p - 300 1.45p + 42 61 7939 - 71s 5.15
15/24" 05.444.39.02.0 05.444.39.01.0 05.801.21.51.0 57 921p - 280 0.57p + 50 56 7939 - 71s 5.2
16/24" 05.444.40.02.0 05.444.40.01.0 05.801.21.52.0 56 1062p - 320 0.89p + 47 56 7939 - 71s 5.0
05.444.40.08.0 05.444.40.07.0 -- *
18/24" 05.444.42.02.0 05.444.42.01.0 05.801.21.53.0 63 1088p - 218 1.14p + 52 63 7850 - 68s 5.2
05.444.42.04.0 05.444.42.03.0 -- *
20/24" 05.444.44.02.0 05.444.44.01.0 05.801.21.54.0 64 1199p - 239 0.85p + 57 63.5 7850 - 68s 5.2
05.444.44.04.0 05.444.44.03.0 -- *
* for ECO Air COMPACT (air connection rotated by 30 degrees)
BPW-BZ 39131502e - Version 1.6 Page 7

Spring type characteristic line of diaphragm - diaphragm cylinder 14 - 20" for disc brakes
9000
[N]
Kraft[N]
Force

8000

7000

6000

5000

4000

3000

2000

1000

0
0 10 20 30 40 50 60

Stroke [mm]
Hub [mm]

14/24" 15/24" 16/24" 18/24" 20/24"

Diaphragm - diaphragm cylinder 14 - 20" for disc brakes

10000
Kraft[N]
Force [N]

9000

8000

7000

6000

5000

4000

3000

2000

1000

0
0 1 2 3 4 5 6 7 8
Pressure
Druck[bar]
[bar]

14/24" 15/24" 16/24" 18/24" 20/24"

Page 8 BPW-BZ 39131502e - Version 1.6

2 BPW Brake cylinder for axles with disc brakes

2.3 Diaphragm-piston (M-K) cylinders










 





 

  Diaphragm piston-type cylinders
Version A   Version B
 are not suitable for use with LL
axles!


Brake cylinder kit with compressed



air connection mounted

05.444.xx.xx.3



     

 
 ! "
! BPW Code no.: 05.001.00.06.0

Installation dimensions BPW brake cylinder

Cylinder size Ø D1 Ø D2 Ø D3 R1 L1 L2 L3 L4 L5
mm mm mm mm mm mm mm mm mm
16/16" 145 161,6 177 104 88 230 78 90 90
20/24" 152 174 188 110 96 246 86 97 93
22/24" 163 174 188 115 99 249 86 100 95
24/24" 163 174 188 115 99 249 86 100 95

Versions of BPW brake cylinder

Version BPW brake cylinder Test report BC 0077.1
Compressed air cylinder Spring-type cylinder
Max. Average Effective Max. Average Release
BPW BPW stroke thrust stroke stroke thrust pressure
Cylinder Code number Code number smax ThA sp smax Ths pL10
size Version A Version B Mounting kit (mm) (N) (mm) (mm) (N) (bar)
16/16" 05.444.41.02.0 05.444.41.01.0 05.801.21.55.0 60 1062p - 320 0.84p + 49 79 9408 - 96s 5.0
05.444.41.04.0 05.444.41.03.0 05.801.21.59.0 *
20/24" 05.444.43.02.0 05.444.43.01.0 05.801.21.56.0 68 1199p - 239 0.80p + 53 67 10775 - 91s 5.0
05.444.43.04.0 05.444.43.03.0 05.801.21.60.0 *
05.444.43.06.0 05.444.43.05.0 -- *1
22/24" 05.444.45.02.0 05.444.45.01.0 05.801.21.57.0 65 1297p - 259 1.06p + 49 65 10775 - 91s 4.7
05.444.45.04.0 05.444.45.03.0 05.801.21.61.0 *
24/24" 05.444.46.02.0 05.444.46.01.0 05.801.21.58.0 65 1404p - 281 0.72p + 53 64.5 10775 - 91s 4.8
05.444.46.04.0 05.444.46.03.0 05.801.21.62.0 *
* for top trailing arm (vent rotated 180º)
*1 for ECO Air COMPACT (air connection rotated by 30 degrees)
BPW-BZ 39131502e - Version 1.6 Page 9

Spring type characteristic line of diaphragm - piston cylinder 16 - 24" for disc brakes
12000
Kraft[N]
Force [N]

10000

8000

6000

4000

2000

0
0 10 20 30 40 50 60

Hub [mm]
Stroke [mm]
16/16" 20/24" 22/24" 24/24"

Diaphragm - piston cylinder 16 - 24" for disc brakes

12000
[N]
Kraft[N]
Force

10000

8000

6000

4000

2000

0
0 1 2 3 4 5 6 7 8
Pressure
Druck[bar]
[bar]

16/16" 20/24" 22/24" 24/24"

Page 10 BPW-BZ 39131502e - Version 1.6

3 BPW Brake cylinder for axles with drum brakes

3.1 Diaphragm cylinders













 


!  








 





Brake cylinder kit with mounted round hole yoke Brake cylinder kit with mounted slotted yoke
Threaded connection M 16 : 05.171.03.34.0 Threaded connection M 16 : 05.171.04.10.0
Threaded connection 5/8" : 05.171.03.37.0 BPW Code no.: 05.444.xx.xx.2
BPW Code no.: 05.444.xx.xx.1 (Application for manual parking brake system (FBA))

Installation dimensions BPW brake cylinder

Cylinder size L D1
mm mm
12" 116 122.5
16" 115 145
20" 111.5 151
24" 118.5 161
30" 121.5 183
36" 131 201
Some brake cylinders are available with shorter pushrods. Alternative versions on request.

Versions of BPW brake cylinder

Version BPW brake cylinder Test report BC 0069.1
Compressed air cylinder
Cylinder size BPW Code number Threaded connection Maximum stroke Average thrust Effective stroke
Smax (mm) ThA (N) SP (mm)

12" 05.444.12.01.0 M 12 x 1.5 78 760p - 352 1.28p + 57

16" 05.444.13.01.0 M 16 x 1.5 80 1060p - 330 1.40p + 57
20" 05.444.14.01.0 M 16 x 1.5 75 1261p - 349 0.85p + 62
24" 05.444.15.01.0 M 16 x 1.5 75 1509p - 423 0.74p + 69
30" 05.444.16.01.0 M 16 x 1.5 79 1977p - 556 0.63p + 73
36" 05.444.17.01.0 M 16 x 1.5 75 2362p - 365 0.98p + 58
24" and 30" diaphragm cylinder with air connection 3/8" NTPF and 5/8"-18UNF available. Alternative versions on request.
BPW-BZ 39131502e - Version 1.6 Page 11

Characteristic line of diaphragm cylinders 12 - 36" for drum brakes

[N]

20000
Kraft [N]
Force

18000

16000

14000

12000

10000

8000

6000

4000

2000

0
0 1 2 3 4 5 6 7 8
Pressure
Druck[bar]
[bar]

12" 16" 20" 24" 30" 36"

Page 12 BPW-BZ 39131502e - Version 1.6

3 BPW Brake cylinder for axles with drum brakes

3.2 Diaphragm-diaphragm (M-M) cylinders













   






 



 Brake cylinder kit with mounted round hole yoke

BPW Code No. 05.444.xx.xx.1
Spring-type cylinder assembled ready for installation.

Installation dimensions BPW brake cylinder

Cylinder size Ø D1 Ø D2 Ø D3 Ø D4 R1 L1 L2 L3 L4
mm mm mm mm mm mm mm mm mm
16/24" 145 162 165 186 101,5 105 268 110.5 80
20/30" 163 183 186 210 112 102 274 112.5 91.5
24/30" 163 183 186 210 112 102 274 112.5 91.5
30/30" 185 183 210 212 125 102 274 112.5 98
Some brake cylinders are available with shorter pushrods. Alternative versions on request.

Versions of BPW brake cylinder

Version BPW brake cylinder Test report BC 0070.1
Compressed air cylinder Spring-type cylinder
Cylinder BPW Threaded Maximum Average Effective Maximum Average Release
size Code number connection stroke thrust stroke stroke thrust pressure
smax ThA sp smax Ths pL10
(mm) (N) (mm) (mm) (N) (bar)
16/24" 05.444.18.01.0 M 16 x 1.5 74 1071p - 403 0.70p + 56 70,5 7852 - 75s 5.0
20/30" 05.444.19.01.0 M 16 x 1.5 75 1261p - 349 1.34p + 62 75 8625 - 63s 5.0
24/30" 05.444.20.01.0 M 16 x 1.5 75 1457p - 464 0.74p + 69 75 8625 - 63s 4.7
30/30" 05.444.21.01.0 M 16 x 1.5 80 1977p - 556 0.43p + 73 79 9040 - 67s 4.6
30/30" diaphragm cylinder with air connection 3/8" NPTF and 5/8"-18 UNF, as well as short-stroke version with stroke Smax = 64 mm available.
Alternative versions on request..
BPW-BZ 39131502e - Version 1.6 Page 13

Spring-type characteristic line of diaphragm - diaphragm cylinder 16 - 30" for drum brakes
10000
Kraft[N]
Force [N]

9000

8000

7000

6000

5000

4000

3000

2000

1000

0
0 10 20 30 40 50 60 70 80

Stroke
Hub [mm]
[mm]
16/24" 20/30" 24/30" 30/30"

Diaphragm - diaphragm cylinder 16 - 30“ for drum brakes

18000
[N]
Kraft[N]
Force

16000

14000

12000

10000

8000

6000

4000

2000

0
0 1 2 3 4 5 6 7 8
Pressure
Druck[bar]
[bar]

16/24" 20/30" 24/30" 30/30"

 BPW-BZ 39131502e

Your partner on the path

to economic viability

BPW Bergische Achsen Kommanditgesellschaft

Postbox 12 80 · 51656 Wiehl, Germany · Phone +49 (0) 2262 78-0
[email protected] · www.bpw.de