3081 - 751 - 103 BW195 P Service Manual

ZF Friedrichshafen AG ZF Friedrichshafen AG ZF Friedrichshafen AG
Workshop Workshop Workshop

Manual Manual Manual
3081 751 103 3081 751 103 3081 751 103
BW (BU) 190 (P) BW (BU) 190 (P) BW (BU) 190 (P)

BW (BU) 195 (P) BW (BU) 195 (P) BW (BU) 195 (P)
BW (BU) 190 S (P) BW (BU) 190 S (P) BW (BU) 190 S (P)

BW (BU) 195 S (P) BW (BU) 195 S (P) BW (BU) 195 S (P)
BW 196 (P) BW 196 (P) BW 196 (P)

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P)
3081 751 103
BW (BU) 190 (P), BW (BU) 190 S (P) Workshop
BW (BU) 195 (P), BW (BU) 195 S (P), BW 196 (P) manual
Service centers
General A
Description
Operation B
Maintenance
Trouble shooting and rectification C
50 Adjustment data D
Nm
Special tools E
Changing parts on
installed gearbox F
Removal / installation of gearbox G
Major overhaul H
Installation of auxiliaries I
Test run K
Subject to alterations in design
Copyright by ZF
This workshop manual is protected by copyright. Reproduction and dissemination in any form, either wholly
or in part especially as a reproduction, photomechanical or electronic copies or stored in data processing
equipment or data networks without the approval of the legal owner is expressly prohibited and any violation
will be pursued vigorously in the civil and criminal courts.
Printed in Germany
Edition . 07.99
3081 751 103
ZF Marine GmbH ZF Padova S.p.A. ZF-HURTH Marine S.p.A.

Via Penghe 48 Via S. Andrea 16
D-88038 Friedrichshafen I-35030 Caselle di Selvazzano I-38062 Arco (TN)
Germany Padova, Italy Italy
Phone (07541) 77-0 Phone (049) 8299-311 Phone (0464) 58 05 55

Fax (07541) 77-4000 Fax (049) 8299-550 Fax (0464) 58 05 44
BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Workshop manual
BW 196 (P) Contents
00.00.00 01-04 D 02.00.00 01

D 02.01.00 01 G 00.00.00 01
D 03.00.00 01
Section A D 03.01.00 01 - 02
D 04.00.00 01 Section H
A 00.00.00 01 D 04.01.00 01
A 03.00.00 01 D 05.00.00 01 H 00.00.00 01
A 03.01.00 01 D 05.01.00 01 - 02 H 01.00.00 01
A 03.02.00 01 D 05.02.00 01 H 01.01.00 01 - 03
A 05.00.00 01 D 05.03.00 01 - 04 H 07.00.00 01 - 02
A 07.00.00 01 D 05.04.00 01 H 07.01.00 01 - 02
A 07.01.00 01 D 05.05.00 01 - 02 H 07.02.00 01 - 02
A 09.00.00 01 D 05.06.00 01 - 02 H 07.02.01 01 - 02
A 09.01.00 01 - 06 D 07.00.00 01 H 07.03.00 01 - 02
A 11.00.00 01 D 07.01.00 01 H 07.03.01 01
A 11.01.00 01 D 09.00.00 01 H 07.04.00 01 - 02
A 13.00.00 01 D 09.01.00 01 H 07.04.01 01 - 02
A 15.00.00 01 D 09.02.00 01 H 07.05.00 01 - 02
A 17.00.00 01 D 11.00.00 01 H 07.05.01 01
A 17.01.00 01 D 11.01.00 01 H 09.00.00 01
A 17.01.01 01 D 13.00.00 01 H 09.01.00 01
A 17.01.02 01 D 13.01.00 01 H 11.00.00 01 - 03
H 11.01.00 01
H 13.00.00 01 - 02
Section B Section E H 13.01.00 01 - 02
H 15.00.00 01 - 03
B 00.00.00 01 E 00.00.00 01 H 15.01.00 01 - 02
B 03.00.00 01 E 01.00.00 01 H 15.02.00 01 - 03
B 05.00.00 01 E 01.01.00 01 H 15.03.00 01 - 02
B 05.01.00 01 E 01.02.00 01 - 10 H 17.00.00 01
B 07.00.00 01 H 17.01.00 01- 02
B 07.01.00 01 - 02 H 17.02.00 01 - 02
B 07.01.01 01 - 02 Section F
B 07.03.00 01 - 02 H 19.00.00 01
B 07.05.00 01 - 03 F 00.00.00 01 H 19.01.00 01 - 02
F 01.00.00 01 H 19.02.00 01
F 01.01.00 01 - 02 H 21.00.00 01
Section C F 03.00.00 01 H 21.01.00 01
F 03.01.00 01 - 02 H.21.02.00 01
C 00.00.00 01 F 03.01.01 01 - 02 H.21.03.00 01
F 03.01.02 01 H.21.04.00 01
F 05.00.00 01 H 27.00.00 01 - 02
Section D F 05.01.00 01 - 03 H 27.01.00 01 - 02
F 05.02.00 01 - 02
D 00.00.00 01 F 05.03.00 01 - 02 H 29.00.00 01 - 02
D 01.00.00 01 F 07.00.00 01 H 29.01.00 01 - 02
D 01.01.00 01 F 07.01.00 01 H 29.02.00 01 - 02
F 07.02.00 01 H 31.00.00 01
F 07.03.00 01 - 02 H 31.01.00 01 - 02
F 07.04.00 01 - 04 H 31.01.01 01 - 03
Section G
Page index: 00.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Workshop manual
BW 196 (P) Contents
H 31.00.00 01 - 12 Section I
H 31.01.04 01 - 10
H.31.02.00 01 - 08
H.33.00.00 01 - 10 Section K
H.33.01.00 01 - 09
H.33.02.00 01 - 08 K 00.00.00 01
K 01.00.00 01
H 37.00.00 01 - 02
H 37.01.00 01 - 06
H 37.02.00 01 - 07
H 39.00.00 01 - 02
H 39.01.00 01 - 06
H 39.02.00 01 - 12
H 41.00.00 01 - 03
H 41.01.00 01 - 06
H 41.02.00 01 - 05
Page index: 00.00.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Preface
This manual is intended for skilled personnel who

have been trained by ZF Friedrichshafen AG to carry
out maintenance and repair work on ZF products.
This manual deals with a ZF volume production

product in accordance with the state of
development at issue date.
However, due to continuing development of the

product, repair work might require work practices and
test or adjustment data which are not contained in this
manual.
We therefore recommend that work done on your ZF
product is carried out only by skilled mechanics who
have had their practical and theoretical knowledge
updated on a regular basis at our after-sales training
courses.
Service points equipped by ZF Friedrichshafen AG all

over the world offer you:
1. Well-trained personnel
2. Specified equipment,
e. g: specialized tools
3. Genuine ZF spares
to our latest specifications
All work performed in these service points is carried

out conscientiously and with care.
Warranty:
Repair work carried out at ZF service points is
guaranteed in accordance with the prevailing
contractual conditions.
Damage resulting from work performed by non-ZF

ZF MARINE GmbH personnel in an improper and unprofessional manner,
together with follow-on costs caused by such work, is
Tel.: (0 75 41) 77-0 excluded from the contractual guarantee agreement.
Fax: (0 75 41) 77-4000 This also applies where ZF spares have not been used.
Page index: 00.00.00 - 03

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Work safety notice
W ORK S AF ETY N OT IC E G E NE RAL NO T E
Companies who repair ZF units are responsible for Read this manual carefully before starting any tests or
their own work safety. repair work.
To avoid injury to personnel and damage to

products, all safety regulations and legal CAUTION
requirements which apply to repair and Pictures, drawings and components do not always
maintenance must be adhered to. represent the original object, but are used to
Before starting work, mechanics must familiarize illustrate working procedures.
themselves with these regulations. Pictures, drawings and components are not to scale
and no information about size and weight should
Personnel required to carry our repairs on these ZF not be inferred (even within a complete
products must receive appropriate training in advance. illustration).
It is the responsibility of each company to ensure that Always follows the working steps as described in
their repair staff are properly trained. the text.
After completion of repair work and testing, skilled

The following safety instructions appear in this staff must satisfy themselves that the product is
manual: functioning correctly.
NOTE
Refers to special processes, techniques, data, ! ENVIRONMENTAL HAZARD
use of auxiliary equipment etc. Lubricants and cleaning agents must not be allowed
to enter the ground, the water table or the sewerage
system.
CAUTION Request safety information for the products
This is used when incorrect, unprofessional concerned from your local environmental
working practices could damage the product. protection authority, and follow any instructions
herein at all times.
Always collect used oil in a suitably large
container.
! DANGER Always dispose of used oil, clogged filters,
This is used when lack of care could lead to lubricants and cleaning agents in accordance
personal injury or death. with environmental protection laws.
Always observe manufacturer instructions
when dealing with lubricants and cleaning
agents.
CAUTION
The gearbox must NOT be suspended on the input
shaft and must NOT be suspended on the output
flange.
Page index: 00.00.00 - 04

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Table of contents
BW 196 (P) Section A
Contents of principal groups
Structure of manual .............................................................................................................................. A 03.00.00
Service centers ...................................................................................................................................... A 05.00.00
List of gearbox series ........................................................................................................................... A 07.00.00
Sectional views of gearboxes ............................................................................................................... A 09.00.00
Consumables ......................................................................................................................................... A 11.00.00
Anti-corrosion protection, types of packaging, storage conditions and storage periods ...................... A 13.00.00
List of lubricants ................................................................................................................................... A 15.00.00
General disassembly, testing, reworking and assembly .................................................................... A 17.00.00
Page index: A 00.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Table of contents
Structure of manual .............................................................................................................................. A 03.01.00
Note regarding manual .......................................................................................................................... A 03.0200
Page index: A 03.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Structure of manual
Structure of manual
Section
Principal group
Group
Sub-group
Page number
G 07. 03. 12 08
Page index: A 03.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Note regarding manual
NOTE: The workshop manual covers all types

of gears of the basic version (not parts list
version) of the following series
BW (BU) 190 (P)

BW (BU) 195 (P)
BW (BU) 190 S (P)
BW (BU) 195 S (P)
BW 196 (P)
No particular reference is made to the BU gearbox

versions. When working with these versions, proceed
in accordance with description for the corresponding
BW gearboxes.
To use the manual for one specific type of gearbox,

remove all the pages where the gearbox type in
question is not listed in the type reference.
Page index: A 03.02.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
Service centers ................................................................................................................................ A 05.00.00-01
NOTE
The ZF company directory (service centers),

incorporating
ZF Group,
subsidiaries,
sales / after-sales centres,
affiliated companies
can be ordered quoting number 0000 762 703a from

the following address:
ZF FRIEDRICHSHAFEN AG
D-88038 Friedrichshafen
Page index: A 05.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
List of gearbox series .................................................................................................................... A 07.01.00 - 01
Page index: A 07.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) List of gearbox series
Diagram Centre distance Model
220 mm BW 190
BW 195
014218
220 mm BW 190 S
BW 195 S
014222
310 mm
BW 196
014220
390 mm
BW 191
014220
Page index: A 07.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
Sectional views of gearboxes
BW 190, 195: sectional view of gearbox and powerflow diagram ............................................. A 09.01.00 - 01
Sectional view of gearbox and cut-away diagrams of

input and intermediate shaft, not P version: .............................................................................. A 09.01.00 - 02
BW 190, 195 (P): sectional view of gearbox and cut-away diagrams of output ......................... A 09.01.00 - 03
BW 190 S,195 S (P): sectional view of gearbox and cut-away diagram of output ..................... A 09.01.00 - 04
Sectional view of gearbox and cut-away diagrams of input and intermediate shaft,
P version .................................................................................................................................... A 09.01.00 - 05
BW 196 (P): sectional view of gearbox and cut-away diagrams of output ................................. A 09.01.00 - 06
Page index: A 09.00.00 - 01

BW (BU) 190 BW (BU) 190 S
BW (BU) 195 BW (BU) 195 S
View of gearbox
Gearbox and powerflow diagram

D
A - Input shaft
A
A
B - Reversing shaft
B
Gears mesh in
C - Output shaft
one another C
D - Clutch for counter-enginewise rotation B
E - Clutch for enginewise rotation E
Powerflow in:
A counter-enginewise
C rotation
B A enginewise rotation
C 012686
Page index: A 09.01.00 - 01

BW (BU) 190 BW (BU) 190 S
BW (BU) 195 BW (BU) 195 S
View of gearbox
012687
Page index: A 09.01.00 - 02

BW (BU) 190 (P)
BW (BU) 195 (P)
View of gearbox
012688
Page index: A 09.01.00 - 03

BW (BU) 190 S (P)
BW (BU) 195 S (P)
View of gearbox
012689
Page index: A 09.01.00 - 04

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) View of gearbox
013912
Page index: A 09.01.00 - 05

BW 196 (P) View of gearbox
013909
Page index: A 09.01.00 - 06

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
Consumables
Sealing compound: ............................................................................................................................... A 11.01.00
Loctite: .................................................................................................................................................. A 11.01.00
Paste for tooth flank contact pattern acceptance .................................................................................. A 11.01.00
Page index: A 11.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Consumables
Subject to change Dyken Read DX-296 for tooth flank contact pattern
acceptance for gearboxes with acceptance
Sealant specification from classification societies.
(Extract from manufacturers instructions for use)
Manufacturers instructions for use are binding in all Dyken-Read DX-296/8 oz,
cases. Helling, Sandorkai 1, 2 000 Hamburg 11,
Tel. (40) 376010 Telex 213611+2165082,
HYLOMAR (Universal sealant SQ 32 M) Fax (40) 37601100
Use on sealing faces of housing and cover. Made in Germany.
Permanent plastic universal sealant SQ 32 M special

(CFC-free), MARSTON, Ölchemie GmbH, 5352 Lubricant (grease)
Zülpich, West-Germany, Tel. (0 22 52) 25 66 and 27 Refer to list of lubricants A 15.00.00 - 01
25.
Instructions for use Cleaner (to remove grease from taper surfaces when
De-grease sealing faces before sealant application using oil press-fits)
(Hylomar cleaner) and apply HYLOMAR to both Acetone, white spirits (Caution: inflammable) or
sides. After airing (approx. 10 minutes), start putting commercially-available cleaner which does not leave
parts together. With threaded screws, wait a few greasy residue.
minutes then tighten screws down firmly.
We recommend you use HYLOMAR CLEANER for
removing oil seals and oil/grease. Glycerine for pushing on oil press-fits in BW 160 to
BW 195 families. Oil or glycerine can be used in
other gearbox types.
Teroson (Terostat-33)
Use on cover of output shaft on the thrust bearing.
Teroson, Germany
Loctite (no. 640)

Use on sealing cover housing no. 275 for threaded pin
no. 241 for orifice in control unit.
Loctite Deutschland GmbH, Munich

Loctite Europa GmbH, Vienna
Instructions for use

Clean parts. Apply enough product to fill gap. Put
parts together. Allow compound to harden.
Page index: A 11.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
Anti-corrosion protection, types of packaging, storage conditions and storage periods ...................... A 13.00.00
The guidelines for anti-corrosion protection, types of packaging, storage conditions and storage periods for
marine gears are inserted in the following section (3070 755 001).
Page index: A 13.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
List of lubricants ................................................................................................................................... A 15.00.00
NOTE
The list of lubricants for ZF marine gears is inserted in the following section (TE-ML 04 1205 754 004c)
This list corresponds to the date of printing of the particular Workshop Manual.
Please request the latest issue of the ZF list of lubricants for marine gears from your nearest ZF service center
(the list should be replaced every 1 to 2 years).
Page index: A 15.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
General - disassembly .......................................................................................................................... A 17.01.00
General - testing and reworking ........................................................................................................... A 17.01.01
General - assembly ............................................................................................................................... A 17.01.02
Page index: A 17.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) General
BW 196 (P) disassembly
This Workshop Manual deals with the marine gear CLEANING PARTS
types listed above.
Remove old sealing compound from all seal faces.
CAUTION Carefully remove burrs or similar irregularities using
When carrying out work on the above marine gears, an oil stone.
always refer to the latest circulars and service memos
which contain details of modifications. Contact the ZF Lube bores and grooves must be free of preservation
After-Sales Service Department if matters arise which grease and foreign matter. Check for unhindered
require clarification. throughflow.
Ensure all work is carried out cleanly and to a proper Carefully cover opened gearboxes to prevent foreign
professional standard. matter from entering.
Always use the tools specified when dismantling and

assembling the gearboxes.
Once the gearbox has been removed from the vessel,

clean thoroughly using a suitable product before
opening.
Parts joined with Loctite are easier to loosen if they

are heated using a hot blower beforehand.
Always refer to the guidelines in the chapter entitled

Pressurized oil procedure D 05.03.00 when
loosening pressurized oil fits. Once gears have been
removed, protect the cones (tapers) of the pressurized
oil fits from damage. This is best assured by using
suitable protective sleeves or adhesive tape.
Clean housings and output covers using suitable

product, paying particular attention to corners and
angles.
Page index: A 17.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW 196 (P) testing and reworking
REUSING PARTS CRACK TEST
An expert must decide whether parts such as ball A crack test is required if the propeller becomes
bearings, discs, thrust washers etc. can be reinstalled. grounded or the power-transmitting components in the
Replace damaged and heavily worn parts with new gearbox become damaged. If possible, a crack or
ones. surface-hardness test must be carried out, in
consultation with the gearbox manufacturer if
required.
GASKETS, TAB WASHERS

GEARBOXES SUBJECT TO ACCEPTANCE
Replace parts such as gaskets and tab washers which SPECIFICATIONS OF CLASSIFICATION
are unavoidably damaged during disassembly with SOCIETIES
new ones.
For gearboxes which have been accepted by a
classification society (recognizable by the acceptance
stamp on the gearbox housing), only parts which have
SHAFT SEALS a stamp from the relevant classification society may
be installed, if gears, shafts or flanges need replacing.
Exchange seal rings if the sealing lip has become (When ordering spare parts, the name of the
rough, ragged or hard. classification society above all should always be
quoted). Once the above parts have been installed,
carry out a pattern check using e.g. Dyken Read DX-
296.
DISCS
Check that discs are level and not distorted by using a REWORK
steel ruler. When checking discs, note that some
versions (refer to D 11.00.00) of steel disc have 6 If spacer discs and shims require rework due to play
sinusoidal corrugated waves around the edge. This adjustment, ensure that the reworked surface has no
must not be confused with distortion. Replace discs raised material and is of constant quality.
which have become dished or misshapen by more than Sealing ring faces must be completely clean and
0.1 mm. undamaged. If defects are noticed, these must be
Do not re-install discs whose faces show signs of rectified by plunge grinding only and not, under any
fretting, lined discs with damaged lining or lined discs circumstances, with an abrasive cloth. There must be
where the grooves are no longer visible. All discs no grinding traces or spirals.
which are re-installed should undergo a crack-test.
Page index: A 17.01.01 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW 196 (P) assembly
R E- AS SEMBL IN G GE A R B OX c) Shaft seals with steel and rubber surround should

be treated in the same way as the shaft seals in (b)
Re-assemble the gearbox in a clean workplace. (above).
Attach gaskets without using sealing compound or
grease. When measuring silicon coated gaskets, do d) Duo shaft seals have two sealing
not include the silicon coating in the measurement. lips. The dust-protecting lip (X)
Comply with all adjustment values and tightening must face outwards.
torques specified in the repair manual when re- 000102
assembling the gearbox. e) Fill the space between the
Use the specifically-developed special tools for all sealing lips up to 60 % with grease (e.g. Aral
work procedures. Aralub HL2 or DEA Spectron FO 20).
f) If possible, heat shaft seal bore to 40 to 50 °C

BEARINGS (this makes shaft seal mounting easier).
Press on shaft seal until flat at correct depth using
If bearings require heating before they are applied, drift or plane disc.
this must be performed evenly (e.g. heating cabinets).
Temperature should be approx. 85 °C and must not
exceed 120 °C. Once in position, apply a coating of LOCTITE
operating oil to each installed bearing.
Loctite must only be used when specified on the parts
list.
SEALING When using «Loctite», always follow the
manufacturers instructions for handling and use.
Use sealant*. Always refer to the manufacturers Comply with all specified adjustment values, test date
instructions for use. Apply a thin and even coat of and tightening torques when re-assembling.
sealant to the surface in question. Keep sealant away
from oil ducts and bores. Spread the sealant around
thinly in areas near the edge of oil bores and ducts to SHRINK-FIT GROMMETS
prevent sealant from being forced into the oil lines
when the parts are pressed together. A hot air blower is used to shrink the shrink-fit
grommets. For example, the ideal shrink temperature
for
SHAFT SEALS Termofit shrink-fit grommets is +255 to +300 °C.
Shrinking begins at +125 °C.
a) Apply a thin coat of sealant* to the outside edge of
shaft seals with «steel surround».
b) Never use sealant on shaft seals with «rubber

surround». Instead, apply a thin coat of Vaseline
8420 grease to the outer edge. Alternatively, coat
with an anti-friction agent, such as water-soluble
dish washing liquid concentrate (e.g. Pril, Coin,
Palmolive).
* «Hylomar SQ 32 M Special» sealant, refer to

A 11.01.00
Page index: A 17.01.02 -01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Contents
BW 196 (P) Section B
Contents of principal groups
NOTE
Section A 17.00.00 General
disassembly, testing, reworking and assembly must
be observed.
Publication
description, installation, operation and
maintenance compl. (basic version)
BW 190 (P), BW 195 (P)

BW 190 S (P), BW 195 S (P)
BW 196 (P)............................................................................................................................................ B 03.00.00
Tool set WI ........................................................................................................................................... B 05.00.00
Maintenance work ................................................................................................................................. B 07.00.00
Page index: B 00.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
NOTE
The publication for description, installation, operation and maintenance is inserted in the following section.
(3080 758 010 and 3081 758 002a)
Page index: B 03.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Tool set WI ........................................................................................................................................... B 05.01.00
Page index: B 05.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Tool set WI
Tool set WI
Tool set WI is composed of commercially available tools, this referring to e.g.
General hand tools
Open-ended wrench, up to width across flats ............................................................................................. 63 mm
Single-end box wrench, up to width across flats ........................................................................................ 46 mm
Deep-offset single-end box wrench, up to width across flats ..................................................................... 46 mm
Set of socket wrenches ........................................................................................................................... 4 - 13 mm
Set of socket wrenches ......................................................................................................................... 11 - 32 mm
Set of socket wrenches ......................................................................................................................... 22 - 50 mm
Set of socket wrenches for Allen screws ............................................................................................... 5 - 22 mm
Pair of pliers (straight) for circlips (inner locking) ............................................................................. I 1 - 4 (no.)
Pair of pliers (straight) for circlips (outer locking) ........................................................................... A 1 - 4 (no.)
Screwdrivers ...................................................................................................................................... up to 13 mm
Hammers (metal and plastic), punches
Measuring and test equipment
Torque wrench ................................................................................................................................... 10 - 350 Nm
Calliper gauge, depth gauge ................................................................................. Measuring range up to 300 mm
Feeler gauge ......................................................................................................... Measuring range 0.05 - 1.0 mm
Page index: B 05.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
165 Maintenance work on engine-dependent

oil pump (primary oil pump) ...................................................................................................... B 07.01.00
Maintenance work on propeller-dependent

oil pump (secondary pump) ........................................................................................................ B 07.01.01
166 Maintenance work (checking control unit) ................................................................................ B 07.03.00
169 Maintenance work (cleaning oil cooler) ..................................................................................... B 07.05.00
NOTE
The standard input direction of rotation is clockwise, An arrow indicating the appropriate direction is fitted
viewed when facing the gearbox input flange; to the gearbox input side.
In special version gearboxes, the opposite direction of

rotation (i.e. anti-clockwise) applies, viewed when
facing the gearbox input flange.
Standard gearbox input direction of rotation (I)
for engines with anti-clockwise direction of rotation

viewed when facing the power output side.
Gearbox with special input direction of rotation

(II)
for engines with clockwise direction of rotation
viewed when facing the power output side.
012691
Page index: B 07.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Maintenance work 165
BW 196 (P) Engine-dependent oil pump
Input direction of rotation I Input direction of rotation II
2
1
6
7
012692 012693
8 9 10
1 = Hex bolts 6 = Thrust washer

2 = Engine-dependent oil pump 7 = Intermediate gear
3 = Plug 8 = Needle sleeve
4 = O-ring 9 = Thrust ring
5 = Hex bolt 10 = Bolt
Checking oil pump (engine-dependent)

3081 206 001/013 2 3 4 5
Removal
01 If necessary, remove pipes as described in

H 11.00.00.
A
02 Unscrew fastening bolts (1) for oil pump.
Fig. 012693
03 Lift oil pump off cover (using assembly levers 1 012694
if necessary as an aid placed against the

recesses of the housing).
1 = Tapered pins
2 = O-ring
04 If the gearbox input direction of rotation is
3 = Woodruff key
version II, remove intermediate gear, items 3 to
4 = Input gear
10, if necessary. Fig. 012693.
5 = Circlip
A = For end float, refer to D 09.00.00
Page index: B 07.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW 196 (P) Engine-dependent oil pump
Dismantling Installation
05 Release circlip (5). 09 Apply thin coat of sealing compound* to

sealing face on pump cover and attach pump.
06 Pull off input gear (4).
10 Attach pipes in accordance with H 11.00.00.
07 Fit Woodruff key (3).
NOTE
Oil pump is a complete part and is not usually
dismantled.
It may however be necessary to disassemble the pump
for checking or cleaning purposes.
When checking the pump, pay particular attention to
ensuring that end float is within the wear limits, refer
to D 09.00.00.
The pump parts should be checked for traces of run in.
08 Remove fastening bolts on pump cover, drive

out tapered pins (1) in direction of arrow and
take off pump cover
Fig. 012694
NOTE
Carefully check and clean parts, do not use any
fibrous cloths for cleaning. Apply a thin coat of oil to
moving parts.
Assembly
01 Place pump pinion in pump housing.
02 Insert O-rings (2) in pump housing

Fig. 012694
03 Attach pump cover, insert bolts but do not

screw in.
04 Drive in tapered pins (1) and tighten bolts.
05 Insert Woodruff key (3) in pump shaft.
06 Heat input gear (4) to approx. 95 °C and slide

onto pump shaft.
07 Snap circlip (5) into annular groove of pump * Sealing compound, e.g HYLOMAR SQ 32 M,
shaft. Marston A 11.00.00
Page index: B 07.01.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Repair work 165
BW 196 (P) Propeller-dependent oil pump
012695
012696
Pump input ratio i = 3.44 Pump input ratio i = 1.347
2 3 4 5
1 = O-ring
2 = Cylindrical screw
012697
3 = Woodruff key
4 = Input gear
1
5 = Circlip
Checking oil pump (propeller-dependent) 7631 955

120
Page index: B 07.01.01 - 01

BW (BU) 190 (P)
BW (BU) 195 (P) Maintenance work 165
BW 196 (P) Propeller-dependent oil pump
(Removal and disassembly) Assembly
01 If necessary, remove pipes as is described in 01 Insert eccentric ring, inner and outer rotor and
H 11.00.00. rotor shaft in the pump housing.
02 Unscrew fastening screws for oil pump. 02 Attach pump cover and screw down.
03 Lift off oil pump from cover (using assembly 03 Insert Woodruff key (3) in pump shaft.
levers as an aid if necessary).
onto pump shaft.
Disassembly
05 Snap circlip (5) into annular groove of pump
04 Snap out circlips (5). shaft.

Installation
06 Fit Woodruff key (3).
06 Slip O-ring (1) onto pump housing and attach
NOTE oil pump to cover.
Oil pump is a complete part and is not usually
disassembled. 07 Attach pipes in accordance with H 11.00.00.
It may however be necessary to disassemble pump for
checking or cleaning purposes.
ensuring that the end float is within the wear limit,
refer to D 09.00.00.
07 Remove fastening bolts (2) on pump cover and

lift off pump cover.
NOTE
moving parts.
Page index: B 07.01.01 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW 196 (P) Checking control unit
1
2
3 4
5
6
4 7 18
5 42 8 17
9 16 19
15
41 14
10 13
11
7 12
6
20
38 40 22 21
37 39
36 23
35 24
34 25
26
33 27
32 28
31 29
30
012698
1 = Screw plug 15 = Rectangular (section) ring 29 = Lever

2 = Seal ring 16 = Piston 30 = Hex nut
3 = Ball 17 = Gasket 31 = Clamping pin
4 = Screw plug 18 = Cover 32 = O-ring
5 = Seal ring 19 = Hex bolt 33 = Stud
6 = Screw plug 20 = Screw plug 34 = Gasket
7 = Seal ring 21 = Seal ring 35 = Screw plug
8 = Compression spring 22 = Control housing 36 = Gasket
9 = Ball 23 = Valve rotor 37 = Snap ring
10 = Nut 24 = Clamping pin 38 = Control piston
11 = Hex bolt 25 = Gasket 39 = Compression spring
12 = Orifice 26 = Cover 40 = Compression spring
13 = Spacer bush 27 = Cylindrical screw 41 = Hex bolt
14 = Washer 28 = Hex bolt 42 = Hex bolt
Removal, disassembly, assembly and installation of Removal

complete control unit
02 Unscrew hex bolts (41, 42, 11) and hex nut
(10).
01 Pipes are removed, if, as is described in
H 11.00.00. 03 Lift complete control unit upwards and fit a
gasket (34).
Page index: B 07.03.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW 196 (P) Testing control unit
Disassembling Installation
04 Remove detent parts (6, 7, 8 and 9). 07 Attach complete control unit with new gasket.
05 Remove lever (29) and cover (26) with gasket 08 Screw in hex bolts (41, 42, 11) and nut (10)
(25). and tighten.
06 Pull valve rotor (23) out of control housing. 09 Attach pipes in accordance with H 11.00.00.
07 Unscrew cover (18) and take out gasket (17).
08 Fit parts (16, 15, 14, 13, 40, 39 and 38).
Checking
Compression spring (39) in accordance with D

07.00.00
07.00.00
07.00.00
Protect piston, piston guide and valve rotor from

damage.
NOTE
Keep pieces away from dirt and lightly oil moving
parts.
Assembly
01 Insert parts (38, 39, 40, 13, 14, 15 and 16) in

control housing.
02 Screw on cover (18) with new gasket (17).
03 Insert valve rotor (23) in control housing.
05 Attach lever (29).
06 Attach detent parts (9, 8, 7 and 6).
Page index: B 07.03.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW 196 (P) Cleaning oil cooler
1 2
4 3
012696
1 = Oil cooler 3 = Stud

2 = Hex nut 4 = O-ring
Removing, cleaning and installing oil cooler Removal
01 Remove pipes, if necessary. 02 Unscrew fastening nuts (2) on oil cooler and
remove oil cooler.
Page index: B 07.05.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
Extract from cooler manufacturers maintenance

instructions
012700
The requirements in terms of achieving both a If coolers cleaned in this way are put into storage as
uniform cooling capacity as well as in terms of the spare parts, i.e. are not immediately refitted and
pressure drop at the oil end, make cleaning operations flushed through with gear oil, we would recommend
necessary at particular intervals, in particular at the oil the addition of approx. 5 % oil to the
end. It is not possible to specify in advance the trichloroethylene. This ensures that the oil film
intervals at which the cleaning procedures described remaining after cleaning and subsequent drying out
below should be performed because the nature and with warm air, acts as a preservative, in particular on
extent of contamination can vary greatly. The periods the turbulence plates at the oil end .
of operation should therefore be recorded prior to
carrying out any instruction and repair work. This will
enable a suitable cleaning schedule to be drawn up,
with intervals based on an appropriate number of Cleaning water end
operating hours.
We recommend the following treatment for this plate- Cleaning at the water end requires an examination of
type oil cooler: the dirt which has accumulated. If a greasy lime layer
is determined, the water end must first be degreased.
Cleaning oil end The lime layer is then dissolved by rinsing it with
water and a lime remover; it may also be possible to
The coolers are connected to a trichloroethylene or use a 10 to 15 % hydrochloric acid solution. An
perchloroethylene unit and are rinsed with the hot inhibitor must be added to the solution to ensure that it
medium. The direction of rinsing is the reverse to that does not attack the metal surfaces.
of the normal operating oil flow. This removes dirt After completion of cleaning, the water end is
particles, especially abrasion, from the multi-disc thoroughly rinsed with clear water and the oil end is
clutches and from the turbulence baffle of the oil then best filled with the oil subsequently used during
cooler plates. They are then flushed out by the normal operation and again drained.
medium. The cleaning will be more successful and the cleaning
time shorter if the direction of flow during pumping,
Cleaning instructions for oil cooler with plate-type both at the oil and water end, is the reverse to that
structure used in normal operation.
An appropriate filter should be inserted in this main
flow to remove the impurities rinsed out from the You can be sure that coolers cleaned in this way will
cleaning medium. Cleaning should be continued until then provide the full cooling capacity in subsequent
examinations reveal that the purity of the medium operation with a reasonable pressure drop at the oil
flowing out is equivalent to that flowing in . end.
Page index: B 07.05.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
Installation
01 Attach oil cooler (1) and new O-rings (4) to

housing and screw down.
02 Attach pipes, if necessary.
Page index: B 07.05.00 - 03

BW (BU) 190 (P) BW (BU) 190 S (P)
BW 196 (P) Section C
For maintenance intervals, refer to publication - description, installation, operation and maintenance
(basic version) ....................................................................................................................................... B 03.00.00
Maintenance work ................................................................................................................................ B 07.00.00
Page index: C 00.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW 196 (P) Section D
Contents of main groups
For monitoring data, refer to

description, operation and maintenance in section ............................................................................... B 03.00.00
Tightening torques for bolts and nuts as per standard .......................................................................... D 01.00.00
Tightening torques for screw plugs and union screws ......................................................................... D 02.00.00
Adjustment data and tightening torques ................................................................................................ D 03.00.00
Assembly specification for face end and top runout variances on

shrink-fitted input and output flanges ................................................................................................... D 04.00.00
Oil press-fits .......................................................................................................................................... D 05.00.00
Spring table ............................................................................................................................................ D 07.00.00
Oil pumps (technical data) .................................................................................................................... D 09.00.00
Table for multi-disc configuration ......................................................................................................... D 11.00.00
Table for valve adjustment values ......................................................................................................... D 13.00.00
Page index: D 00.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Tightening torques for bolts and nuts as per standard ........................................................................... D 01.01.00
Page index: D 01.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Extract from ZFN 148
Tightening torques for bolts and nuts, extract from

ZFN 148
This standard applies for bolts in accordance with DIN Surface condition of bolts: heat-treated with blackened
912, DIN 931, DIN 933, DIN 960, DIN 961 as well as finish and oiled or galvanized and oiled or galvanized,
for nuts in accordance with DIN 934. chromatized and oiled.
This standard contains data on tightening torques
(MA) for bolts and nuts of strength classes 8.8, 10.9 Use a calibrated snap wrench or torque wrench with
and 12.9, as well as for nuts of strength classes 8, 10 display to tighten bolts.
and 12.
NOTE
Any tightening torques deviating from those specified
here are listed separately in the repair manual.
Coarse-pitch thread Fine-pitch thread
Dimensions Tightening torque Dimensions Tightening torque

MA (Nm) for MA (Nm) for
Bolt 8.8 10.9 12.9 Bolt 8.8 10.9 12.9
Nut 8 10 12 Nut 8 10 12
M 4 2.8 4.1 4.8 M 8x1 24 36 43

M 5 5.5 8.1 9.5 M 9x1 36 53 62
M 6 9.5 14 16.5 M 10 x 1 52 76 89
M 7 15 23 28 M 10 x 1.25 49 72 84
M 8 23 34 40 M 12 x 1.25 87 125 150
M 10 46 68 79 M 12 x 1.5 83 122 145
M 12 79 115 135 M 14 x 1.5 135 200 235

M 14 125 185 215 M 16 x 1.5 205 300 360
M 16 195 280 330 M 18 x 1.5 310 440 520
M 18 280 390 460 M 18 x 2 290 420 490

M 20 390 560 650 M 20 x 1.5 430 620 720
M 22 530 750 880 M 22 x 1.5 580 820 960
M 24 670 960 1100 M 24 x 1.5 760 1100 1250

M 27 1000 1400 1650 M 24 x 2 730 1050 1200
M 30 1350 1900 2250 M 27 x 1.5 1100 1600 1850
M 27 x 2 1050 1500 1800

M 30 x 1.5 1550 2200 2550
M 30 x 2 1500 2100 2500
Page index: D 01.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Tightening torques for screw plugs and union screws ......................................................................... D 02.01.00
Page index: D 02.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Tightening torques
Name Dimensions Measuring equipment Remarks
Tightening torque for

union screws DIN 7623 with CU gasket, screwed into Silumin
Union screw
M 14 x 1.5 approx. 40 Nm Torque wrench

M 52 x 1.5 Experience
Tightening torque for

screw plugs DIN 7604 (cylindrical) with CU gasket, screwed into Silumin
Screw plug

Page index: D 02.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Adjustment data and tightening torques ............................................................................................... D 03.01.00
Page index: D 03.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Adjustment data and
tightening torques
Description Dimension Measuring equipment Remark
Input shaft:
Tightening torque of approx. 550 Nm Experience Secured after tightening
M 50 x 1.5 grooved nut
End float of pinion 0.6 - 1.0 mm Feeler gauge Play is given,
on bearing bush check only
Reversing shaft:
Output shaft:
BW (BU) 190/195 (P) 0.05 - 0.1 mm Dial gauge Set by means of shim
End float of output shaft below axial roller
(propeller thrust bearing) outer bearing .
Preload 4 000 N
BW (BU) 190 S/195 S (P) 0.05 - 0.1 mm Dial gauge Set by means of shim
End float of output shaft on pump drive gear.
(propeller thrust bearing) Preload 2000N

Page index: D 03.01.00 - 01

Adjustment data and
BW 196 (P) tightening torques
Description Dimensions Measuring equipment Remarks
Input shaft:
Reversing shaft
Output shaft:
BW 196 (P) 0.05 - 0.1 mm Dial gauge Set by means of shim
End float of output shaft below axial rollers
(propeller thrust bearing) outer bearing race.
Preload 4 000 N
Page index: D 03.01.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Assembly specification for face end and top runout variances on

shrink-fitted input and output flanges ............................................................................................ D 04.01.00 - 01
Page index: D 04.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P) Assembly specification
BW (BU) 195 (P) BW (BU) 195 S (P) (extract from 0000 700 114
BW 196 (P) dated, 31.05.90)
Applies for checking the face end and top runout variances on shrink-fitted input and output flanges
S I
S II R I
R II
S II S I
R II R I
1 2
005 189
1 = reference area 2 = reference area
Authorized deviations
Input Output
Gearbox type FE TR FE TR
BW 160 / 190 fam. 0.03 0.04
Page index: D 04.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Oil press-fit table .................................................................................................................................. D 05.01.00
Table of press forces for hydraulic nuts ................................................................................................ D 05.02.00
Description of Oil press-fit method ................................................................................................... D 05.03.00
Test specification:
Checking that surfaces of oil press-fits are free of grease ..................................................................... D 05.04.00
Assembly specification:
Checking tapered press-fits which are pressed firmly home ................................................................. D 05.05.00
Checking tapered press-fits which are adjusted in accordance with the

specified push-on length ........................................................................................................................ D 05.06.00
Page index: D 05.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Table of oil press-fits
BW 196 (P) Assembly note:
refer to The oil press-fit method
Push-on length Max. oil pressure for Max. pull-on force of Hydraulic nut
in mm* widening oil press-fits for hydraulic nut to be used
pressing on and off (pressure gauge 1X56 137 227
(pressure gauge oil reciprocating pump)
i Description injector)
Input flange 3081 309 006 x

on input shaft 3081 302 109 4.0 - 4.6 mm
on input shaft
Input flange 3081 309 004 x
on input shaft 3081 302 109 4.0 - 4.6 mm
on input shaft
Flange and torsion coupling
Input flange
on input shaft
on input shaft
Torsion
coupling PE 42 W 0501 204 963 x
NOTE: In practice, the max. widening pressure is automatically adjusted, depending on the prevailing force,
on input shaft 3081 302 109 4.3 - 4.9 mm
on input shaft
Constant gear 3081 202 086 x

4.0 - 5.3 mm
on input shaft 3081 302 109
Input shaft

4.5 - 5.8 mm
Constant gear 3081 202 135 and cannot be exceeded due to the oil which flows out. x
4.5 - 5.8 mm
Reversing shaft

4.0 - 5.3 mm
on reversing shaft 3081 303 070
Pressure range: 1500 to 3000 bar

4.5 - 5.8 mm
4.5 - 5.8 mm
Output gear 3081 304 041 x
on output shaft 3081 304 044 5.8 - 6.4 mm
1.086 on output shaft
Output gear
on output shaft
on output shaft
1.524 on output shaft 3081 304 044
BW (BU) 190/195 (S) (P) output shaft
Output gear
on output shaft
on output shaft
2.030 on output shaft
Output gear
on output shaft
on output shaft
2.571 on output shaft 3081 304 044
Output gear
on output shaft
on output shaft
3.0 on output shaft
Output gear
on output shaft
on output shaft
* Applicable to new parts, at room temperature, contact faces not oiled.
When re-assembling, the push-on length may be a max. 0.15 mm smaller per re-used part.
Page index: D 05.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Table of oil press-fits
BW 196 (P) Assembly note:
refer to The oil press-fit method
Push-on length Max. oil pressure for Max. pull-on force of Hydraulic nut
in mm* widening oil press-fits for hydraulic nut to be used
pressing on and off (pressure gauge 1X56 137 227
(pressure gauge oil reciprocating pump)
i Description injector)
NOTE: In practice, the max. widening pressure is automatically adjusted,

depending on the prevailing force, and cannot be exceeded due to the oil
2.917 on output shaft 3081 304 222 5.8 - 6.4 mm
on output shaft
2.917 on output shaft 3081 304 170 5.8 - 6.4 mm
on output shaft
Output gear
on output shaft
Pressure range: 1500 to 3000 bar

BW 196 (P) output shaft
on output shaft
Output gear
which flows out.

on output shaft
on output shaft
3.43 to
4.036
on output shaft
3.43 to
4.036
on output shaft
3.43 to
4.036
on output shaft
3.43 to
4.036
on output shaft
* Applicable to new parts, at room temperature, contact faces not oiled.

When re-assembling, the push-on length may be a max. 0.15 mm smaller per re-used part.
Page index: D 05.01.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Table of push-on forces
BW 196 (P) for hydraulic nuts 1X56 137 227
Oil pressure on pressure gauge of Push-on force of

piston pump hydraulic nut
450 bar 162 KN (16.2 t)
425 bar 153 KN (15.3 t)
400 bar 144 KN (14.4 t)
375 bar 135 KN (13.5 t)
350 bar 126 KN (12.6 t)
325 bar 117 KN (11.7 t)
300 bar 108 KN (10.8 t)
275 bar 99 KN ( 9.9 t)
250 bar 90 KN ( 9.0 t)
225 bar 81 KN ( 8.1 t)
200 bar 72 KN ( 7.2 t)
175 bar 63 KN ( 6.3 t)
150 bar 54 KN ( 5.4 t)
125 bar 45 KN ( 4.5 t)
100 bar 36 KN ( 3.6 t)
75 bar 27 KN ( 2.7 t)
50 bar 18 KN ( 1.8 t)
25 bar 9 KN ( 0.9 t)
Page index: D 05.02.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) The pressurized oil process
The oil press-fit method
Operating principle: - Ensure that all air is removed from the pump
Tapered and cylindrical oil pressure fits are released and high pressure hose (by filling with oil).
and joined using this method. Pressure oil is forced
through bores and distributing grooves between the Follow the operating instructions at all times.
mating faces until a thin film of oil is formed which
separates the components. This greatly reduces the - Wear protective goggles.
forces for installing and removing the components, or
in the case of the tapered pressure oil fit, the - It is always advisable to use a pressure gauge
components jump off quite suddenly when released. when working with high pressures.
DANGER
Special measure:
To prevent any accidents:
for safety reasons, no one should stand in front of
the pressurized components when a tapered
pressure oil fit is being released or fitted.
The fixtures used must be in perfect condition,
particularly at the threads. The threads should be
screwed into the shafts.
The work is best performed directly in front of a
wall or a work bench.
The pressurized oil should have a viscosity of approx.

300 mm2/s at room temperature (approx. 20 °C). If oil
pressure fails to build up, a thicker oil should be used.
The values stated in the oil pressure fit tables are
permissible maximums which should not be exceeded.
The same tables also list the specified push-on lengths
"a".
DANGER
Oil injector
Use of the oil pump is not dangerous if the
operating instructions are followed correctly.
Accessories used must be in perfect condition. Note
the following
NOTES:
- Carefully check the pump, high pressure hose
and all accessories before use. Also, never use
pump components that are even slightly
damaged or accessories that are not designed
for a pressure of 3000 bar (300 MPa).
Page index: D 05.03.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
The figure shows the fixture layout for loosening

an oil press-fit.
005190
1 = Hydraulic nut 7 = Alternating reciprocating pump

2 = Supported nut 8 = High pressure pipe
3 = Threaded bolt 9 = Pump holder
4 = High pressure hose 10 = Pressure gauge
5 = Intermediate piece 11 = Oil injector
6 = Pressure gauge A = Max. piston travel
NOTE
Push out piston of hydraulic nut (1) to limit of travel
and move fixture with hydraulic nut so that it touches
the part to be loosened. Press-on the hydraulic nut
using approx. 50 bar of pressure.
Page index: D 05.03.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
Attach the collecting equipment, comprising parts 1 Application: Assembling oil press-fit
to 11. Bring the piston of the hydraulic nut into
contact (observe note under figure 005190). Connect The parts to be joined must be at the same
oil injector to flange using high pressure pipe and temperature, preferably ambient temperature. First of
remove air. Pump pressurized oil between the pressing all, properly clean the tapers of shaft and gear or
surfaces until the oil is distributed around the oil flange. Do not oil or grease them.
press-fit (pressure drop on pressure gauge). Continue Fit gear or flange onto the taper of the shaft but only
pumping (pressure gauge reading on reciprocating until it is firmly seated. Check the push-on length "a"
pump rises erratically). Quickly open the valve on the in this position. On shafts without a stop collar, the
reciprocating pump. The piston of the hydraulic nut is axial position of the gear or flange relative to the shaft
pushed back to its starting position. The oil press-fit is must be measured so that you can accurately check
now loose. the push-on length "a". Remove parts once the push-
on dimension has been measured.
Measuring push-on length:
Also refer to D 05.05.00 - 01 to D 05.06.00 - 02.
NOTE: When using new parts (replacement parts), all
of the parts, and not just the tapers and oil injection
bores, must be thoroughly cleaned, i.e. they should be
free of any oil and grease.
The figure 000104 shows the fixture arrangement for
the push-on action.
AA = Assembly with stop collar 5 = Bush 11 = Pressure gauge

BB = Assembly w/o stop collar 6 = Hydraulic nut 12 = Intermediate piece
1 = High pressure pipe 7 = Support 13 = High pressure hose
2 = Pressure gauge 8 = Bolt 14 = Dial gauge with holder
3 = Pump holder 9 = Reduction nipple a = Push-on dimension
4 = Oil injector 10 = Reciprocating pump
Page index: D 05.03.00 - 03

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
Driving up:
NOTE
Before fitting, remove all traces of grease from oil
injector bores and tapers because, unlike an oil film,
grease cannot be forced out of the mating joint.
CAUTION
The gears and flanges cannot be tightened down
firmly (thus ensuring full torque transmission) until
every last trace of dirt and grease has been cleaned
off the taper and oil injector bores.
Connect the press-on equipment, consisting of parts 1

to 13. Operate both pumps almost simultaneously and
thereby slide on the gear or flange.
When performing this operation, the hydraulic nut
must not be slid on too rapidly, i.e. sufficient
pressurized oil or glycerine must always be introduced
through the oil injector and distributed over the entire
fitting face to enable the gear or flange to float on
fully extended film of oil.
DANGER
Once the specified push-on length has been
reached, first release the oil pressure at the oil
injector. The oil pressure should however be
maintained in the hydraulic nut until the film of oil
in the oil pressure fit has receded and the tapers are
firmly seated together.
The minimum waiting time is:
a) 15 minutes for tapered oil pressure fits with

spiral-shaped oil distribution grooves.
b) 60 minutes for tapered oil pressure fits without
spiral-shaped oil distribution grooves.
After this waiting period and before removing the

fixtures, check whether the parts are firmly sealed.
NOTE: When driving-up, it is important to note

Sections D 05.05.00 to D 05.06.00.
Page index: D 05.03.00 - 04

BW (BU) 190 (P) BW (BU) 190 S (P) Test specification
BW (BU) 195 (P) BW (BU) 195 S (P) Extract from 0000 701 084 with
BW 196 (P) amendments for external application
With regard to joining tapered oil-press fits
The following components must be absolutely free of

grease:
outer tapers of shafts
inner tapers of gears and flange
shaft, gear and flange injection holes
Pre-cleaning
Pre-clean using cold cleaner (aliphatic

hydrocarbon based)
Wipe taper surfaces 5 times using a disposable
paper towel.
Rinse and blow out injection bores (until no
preservative and/or grease residues remain).
Final cleaning
DANGER
Use acetone, spirits (caution: flammable)
or commercially-available cleaner which leaves
no trace or grease for the final cleaning.
Soak disposable paper towel in appropriate
cleaner and finally clean the tapered surfaces by
wiping them twice.
Loosening oil press-fits
You will usually have to use oil to loosen the oil

press-fits.
The oil press-fits can be slid on using oil or glycerine.
Page index: D 05.04.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW 196 (P) Extract from 0000 701 093
Checking tapered press-fits which are pressed

firmly home.
000 105
To ensure that the press-fit transmits torque reliably,

run a check in accordance with the following
specification.
CAUTION
Failure to comply with this rule may result in total
gearbox failure.
01 Measure the following before and during the ....

joining procedure.
000 106
Length L = hub length
000 107
Length B = the length between the shaft end face and

the hub stop face
Page index: D 05.05.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW 196 (P) Extract from 0000 701 093
Slide on hub until it cannot be pushed any further.
000 108
Length C = distance between shaft face end and hub

side
Push-on hub against stop
000 109
Length D = distance between shaft face end and hub

face end after pressing on
02 The hub has been pushed up to the stop when
WLH=0
03 The hub is joined correctly when
A=DC
(length A = calculated actual length of push-on

dimension)
is within the specified push-on range.
Page index: D 05.05.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW 196 (P) Extract from 0000 701 095
Checking tapered press-fits which are adjusted in 01 Measure the following lengths before and
accordance with the specified push-on length. during the joining procedure.
Slide on hub until it cannot be pushed on any ...

further.
000 110 000 113
Case 1 Case 1
000 111 000 114
Case 2 Case 2
000 112 000 115
Case 3 Case 3
To ensure that press-fits transmit torque reliably, run a Length C = distance between shaft face end and hub
check in accordance with the following specification. face end before pressing on
CAUTION
Failure to comply with this rule may result in total
gearbox failure.
Page index: D 05.06.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW 196 (P) Extract from 0000 701 095
Press on hub as far as specified 02 The hub is joined correctly when
A=DC
000 116
Case 1 Case 1
A=CD
000 117
Case 2 Case 2
A=D+C
000 118
Case 3 Case 3
Length D = distance between shaft face end and hub Length A = calculated actual length of push-on
face end after pressing on. dimension
lies within the specified push-on length range.
If the conditions under 02 are not satisfied, repeat the

entire measuring and joining procedure. Then, recheck
to see whether the above conditions are satisfied.
If after repeating the joining procedure, the

conditions are still not satisfied, some of the parts
may have become defective.
Page index: D 05.06.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Spring table ........................................................................................................................................... D 07.01.00
Page index: D 07.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Spring table
Order no. Installation location No. of Wire diam. Spring diam. Untensioned
coils in mm in mm length in mm
1204 304 116 Output shaft 6.0 1.8 11.0 17.3
1217 304 102 Control unit 8.5 1.0 6.0 13.8
0732 040 598 Flow limiting valve 10.5 2.5 21.5 62.6
0732 041 412 Control unit 17.5 4.5 23.75 106.4
0732 041 969 Injection line and 15.5 3.0 27.16 113.5
flow limiting valve
for trolling version
0732 041 067 Injection line valve 25.0 1.6 11.63 84.8
0732 041 256 Pressure limiting valve 6.5 4.0 23.5 36.1
(for max. system pressure)
0732 041 411 Control unit 30.5 2.5 13.35 106.7
0732 042 037 Actuation 13.0 2.5 16.8 67.3

(trolling)
0732 042 036 Actuation 15.0 2.8 16.8 65.6

(trolling)
0732 041 545 Actuation 10.5 1.3 7.9 22.4

(trolling)
0732 041 198 Actuation 13.5 1.8 19.3 61.9

(electrical)
0732 042 118 Control unit and 18.5 4.5 23.7 117.1
engageable PTO
0732 042 119 Control unit and 30.0 2.5 13.3 117.1
engageable PTO
0732 041 996 Piston for trolling 6.5 1.5 10.4 16.7
version and version
prepared for trolling refit
0732 041 655 Output shaft 5.5 2.25 13.9 19.4
0732 042 577 Control unit and trolling 17.0 5.0 23.5 115.0
0732 040 486 Control unit on for PTO 9.5 1.8 8.5 37.0
Page index: D 07.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Primary oil pump (engine-dependent) ................................................................................................... D 09.01.00
Secondary oil pump (propeller-dependent) ........................................................................................... D 09.02.00
Page index: D 09.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Primary oil pump
BW 196 (P) (engine-dependent)
Oil pump (primary) A = end float
3081 206 001

When new Wear limit
3081 206 013
Input pinion 0.03 to 0.06 mm max. 0.08 mm
Pump gear 0.03 to 0.06 mm max. 0.08 mm
2 3 4 5 The oil pump is a complete part and is not usually

dismantled.
ensuring that end float is within the wear limit.
A The pump parts should be checked for traces of run in.
NOTE
1
6
moving parts.
7
012703
1 = Tapered pin
2 = O-ring
3 = Woodruff key
4 = Input gear
5 = Circlip
6 = Input pinion
7 = Pump gear
A = End float
Technical data 3081 206 001
3081 206 013
Minimum displacement = 8 dm3/min
at pump speed = 400 rpm
Pressure = 20 bar
Temperature = 90 °C
Oil grade = SAE 30
Theoretical displacement = 31.6 cm3/rev.
Maximum operating speed = 2 660 rpm
Page index: D 09.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Secondary oil pump
BW 196 (P) (propeller-dependent)
Oil pump (secondary) A = end float
7631 955 120 When new Wear limit
Eccentric ring 0.01 to 0.095 mm max. 0.15 mm
Inner rotor 0.01 to 0.055 mm max. 0.1 mm
Outer rotor 0.025 to 0.055 mm max. 0.1 mm
A The oil pump is a complete part and is not usually

dismantled.
1 It may however be necessary to disassemble the pump
2 3 4 5 for checking or cleaning purposes.
ensuring that end float is within the wear limit.
NOTE
6
moving parts.
000143
1 = O-ring
2 = Cylindrical screw Technical data 7631 955 120
3 = Woodruff key
4 = Input gear Minimum displacement = 3.7 m3/min
5 = Circlip
6 = Inner rotor at pump speed = 530 rpm
7 = Outer rotor
8 = Eccentric ring Pressure = 5 bar
A = End float
Temperature = 70 °C
Oil grade = SAE 30
nmax = 3 600 rpm
Pmax = 23 bar
Page index: D 09.02.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Table for disc configuration ................................................................................................................... D 11.01.00
Page index: D 11.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Table for disc configuration
Table for clutch disc configuration

(input and reversing shaft)
NOTE
Outer discs are corrugated.
a) The discs must not be heavily scored or
discoloured.
The discs must not be dished.
b) The minimum profile depth of the groove on
the inner discs must be greater than or equal to
0.2 mm.
Pack thickness
000474
000474
NOTE
Use two U clamps to clamp disc pack together and
measure thickness above U clamps.
Permissible pack thickness for re-use

No. of friction No. of No.of
surfaces inner discs outer discs
depending Min. permissible Max. permissible
on gearbox type clamped pack unclamped
thickness in mm thickness in mm
12 6 6 40.7 44.3
14 7 7 47.5 51.7
16 8 8 54.4 59.1
If the pack thickness is as specified, the permissible
disc play is as follows
Disc play (unclamped pack)

No. of friction surfaces
min. in mm max. in mm
12 1.36 5.10
14 1.57 5.80
16 1.78 6.30
Individual discs can be changed.

New parts should preferably be installed on the piston
end of the clutch.
Page index: D 11.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Table for valve adjustment values ........................................................................................................ D 13.01.00
Page index: D 13.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Table for
BW 196 (P) valve adjustment values
Pressure limiting valve (refer to Page H 17.01.00 - 01, Figure 012 765)
Stage 1 Compression spring 0732 041 067 (function: oil injection line)
0.8 + 0.2 bar = spring force 49.3 + 12.3 N
Stage 2 Compression spring 0732 040 598 (function: lubricating pressure return suction line)
2.3 + 1 bar = spring force 142 + 61 N
Pressure limiting valve (refer to Page H 17.02.00 - 01, Figure 012769 for max. system pressure)
Compression spring 0732 041 256, spring preload = 580 + 20 N

= opening pressure = 26.1 + 0.9 bar
closing pressure = 25.2 + 0.9 bar
Page index: D 13.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW 196 (P) Section E
Contents of main group
Special tools .......................................................................................................................................... E 01.00.00
NOTE:
Operating manual for lifting tackle
- Normal conditions for use

- Instructions for use, assembly and maintenance
- Limitations on use
- Conditions for use:
(1) Lifting tackle should only be used as shown in the diagrams.
(2) Only load up to the maximum specified load bearing capacity.
- Safety checks:
(1) Keep a look out for visible defects during usage.
(2) Trained staff must conduct visual and function inspections before commissioning and at regular
intervals thereafter. These should take place at lease once a year.
(3) Lifting chains should be subjected to an additional crack inspection every three years.
- Faults:
(1) If faults are established, the lifting tackle equipment should not be withdrawn from use.
- Storage:
(1) Lifting tackle should be stored somewhere where it is protected from climatic influences and
aggressive materials.
Page index: E 00.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Tool set (W1) for maintenance work ..................................................................................................... E 01.01.00
Tool set (W2) special tools for major overhaul ..................................................................................... E 01.02.00
Page index: E 01.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Special tools
Tool set W1 for the gearbox maintenance work listed in Section B 05.00.00.
Page index: E 01.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
Fig. Diagram Order no. Application Quan- Remarks

no. tity
Complete oil injector 1 BW (P)

consisting of: 190, 190 S
195, 195 S
1 1 = 1X56 130 601 196
2 = 1X56 130 604 BU (P)
3 = 1X56 130 597 190, 190 S
4 = 1X56 130 595 195, 195 S
010919
Cpl. reciprocating piston pump

consisting of: 1 BW (P)
1 = 1X56 112 774 190, 190 S
2 = 1X56 130 588 195, 195 S
2 3 = 1X56 130 591 196
4 = 1X56 130 592 BU (P)
5 = 1X56 136 493 or 190, 190 S
1X56 130 598 or 195, 195 S
010920 1X56 130 590
1X56 130 588 1 BW (P)

190, 190 S
High pressure hose 195, 195 S
3 (used in conjunction with 196
reciprocating piston pump) BU (P)
190, 190 S
195, 195 S
1X56 130 589 1 BW (P)

190, 190 S
Reciprocating piston pump 195, 195 S
4 for hydraulic nuts 196
BU (P)
190, 190 S
195, 195 S
1X56 130 591 1 BW (P)

190, 190 S
Intermediate piece 195, 195 S
5 for R1/2 pressure gauge 196
BU (P)
190, 190 S
195, 195 S
Page index: E 01.02.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)

no. tity
1X56 130 592 1 BW (P)

190, 190 S
R1/2 pressure gauge 195, 195 S
6 for checking oil pressure in 196
hydraulic nut BU (P)
190, 190 S
195, 195 S
1X56 130 595 1 BW (P)

190, 190 S
Oil injector 195, 195 S
7 for widening oil press-fits 196
BU (P)
190, 190 S
195, 195 S
1X56 130 597 1 BW (P)

190, 190 S
Pump holder 195, 195 S
8 for oil injector 196
BU (P)
190, 190 S
195, 195 S
1X56 130 601 1 BW (P)

190, 190 S
High pressure pipe 195, 195 S
9 (used in conjunction with pump 196
holder and connections of oil press- BU (P)
fits) 190, 190 S
195, 195 S
1X56 130 604 1 BW (P)

190, 190 S
Pressure gauge 195, 195 S
10 for checking oil pressure of oil press- 196
fits BU (P)
190, 190 S
195, 195 S
Page index: E 01.02.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)

no. tity
1X56 136 461 1 BW (P)

190, 190 S
M24x2 bolt 195, 195 S
11 for input flange 196
BU (P)
190, 190 S
195, 195 S
1X56 136 513 1 BW (P)

190, 190 S
Hot-air blower 195, 195 S
12 for heating various parts 196
BU (P)
190, 190 S
195, 195 S
1X56 136 564 1 BW (P)

190, 190 S
Hook 195, 195 S
13 for removing and installing output 196
shaft BU (P)
190, 190 S
195, 195 S
1X56 137 030 1 BW (P)

190, 190 S
Pipe elbow 195, 195 S
14 used in conjunction with hydraulic 196
nut (1X56 137 227) BU (P)
190, 190 S
195, 195 S
1X56 137 055 1 BW (P)

190, 190 S
Wrench 195, 195 S
15 for cylindrical bolts of the 196
emergency control BU (P)
190, 190 S
195, 195 S
Page index: E 01.02.00 - 03

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)

no. tity
1X56 137 091 1 BW (P)

190, 190 S
Cross beam 195, 195 S
16 for removing the outer race of the 196
cylinder roller bearing on the output BU (P)
shaft 190, 190 S
195, 195 S
1X56 137 150 1 BW (P)

190, 190 S
Gearbox swivel stand 195, 195 S
17 196
BU (P)
190, 190 S
195, 195 S
1X56 137 220 1 BW (P)

190, 190 S
Extractor plate 195, 195 S
18 split for inner disc carrier 196
BU (P)
190, 190 S
195, 195 S
1X56 137 222 1 BW (P)

190, 190 S
Wrench 195, 195 S
19 for M50x1.5 grooved nut 196
on input shaft and intermediate shaft BU (P)
190, 190 S
195, 195 S
1X56 137 223 1 BW (P)

190, 190 S
Wrench 195, 195 S
20 for M65x1.5 grooved nut
on input shaft BU (P)
190, 190 S
195, 195 S
Page index: E 01.02.00 - 04

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)

no. tity
1X56 137 224 1 BW (P)

190
Wrench 195
21 for M90x1.5 grooved nut
on output shaft BU (P)
190
195
1X56 137 225 1 BW (P)

190, 190 S
Lifting device 195, 195 S
22 for input and intermediate shaft 196
M50x1.5 BU (P)
190, 190 S
195, 195 S
1X56 137 226 1 BW (P)

190, 190 S
M24x2 nut 195, 195 S
23 for input flange or torsion coupling 196
BU (P)
190, 190 S
195, 195 S
1X56 137 227 1 BW (P)

190, 190 S
Hydraulic nut 195, 195 S
24 196
BU (P)
190, 190 S
195, 195 S
1X56 137 228 2 BW (P)

190, 190 S
Adapter 195, 195 S
25 for clamping gearbox, used in 196
conjunction with gearbox swivel BU (P)
stand 1X56 137 150 190, 190 S
195, 195 S
Page index: E 01.02.00 - 05

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)

no. tity
1X56 137 229 1 BW (P)

190, 190 S
Extractor plate 195, 195 S
26 196
BU (P)
190, 190 S
195, 195 S
1X56 137 230 1 BW (P)

190, 190 S
Extractor ring 195, 195 S
27 for intermediate bush on input shaft 196
BU (P)
190, 190 S
195, 195 S
1X56 137 231 1 BW (P)

190, 190 S
Plug-in disc 195, 195 S
28 for pump gear and cover of input 196
shaft BU (P)
190, 190 S
195, 195 S
2 1X56 137 232 1 BW (P)

190, 190 S
1 5 Set of screws 195, 195 S
29 6 for various removal processes 196
7
BU (P)
11
10
190, 190 S
8
195, 195 S
1X56 137 233 1 BW (P)

190, 190 S
Extractor disc 195, 195 S
30 for bearing bush on output shaft
BU (P)
190, 190 S
195, 195 S
Page index: E 01.02.00 - 06

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)

no. tity
1X56 137 234 1 BW (P)

190, 190 S
Pipe 195, 195 S
31 for output gear on output shaft
BU (P)
190, 190 S
195, 195 S
1X56 137 260 1 BW (P)

190, 190 S
Special tool 195, 195 S
32 105x130x16 for shaft seal ring on
output BU (P)
190, 190 S
(rework if necessary)
195, 195 S
H 38.02.00 - 01
1X56 137 277 1 BW (P)

190
Pressure piece 195
33 for sliding on output gear
BU (P)
190
195
1X56 137 278 1 BW (P)

190, 190 S
Insert 195, 195 S
34 for pulling self-aligning roller 196
bearing off input and reversing shaft BU (P)
190, 190 S
195, 195 S
1X56 137 289 1 BW (P)

190
Pressure piece 195
35 for torsion coupling 196
BU (P)
190
195
Page index: E 01.02.00 - 07

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)

no. tity
1X56 137 290 1 BW (P)

190
Set of screws 195
36 for various removal processes 196
BU (P)
190
195
1X56 137 291 1 BW (P)

190
Threaded dowel 195
37 for tensioning the output shaft (used
in conjunction with 1X56 137 091) BU (P)
190
195
1X56 137 411 1 BW (BU)

190 A (P)
Locating piece 195 A (P)
38 for output shaft relative to cover 196 (P)
BW (BU)
190 V (P)
195 V (P)
1X56 137 448 1 BW (P)

190
Extractor hook 195
39 for self-aligning roller thrust bearing 196
on output shaft BU (P)
190
195
1X56 137 473

1 BW (P)
X
Pressure piece 190
for widening self-aligning roller 195
40 bearing on input and reversing shaft 196
(not available in all versions) BU (P)
Y X = 19.5 mm 190
Y = 24.5 mm 195
Page index: E 01.02.00 - 08

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)

no. tity
1X56 137 474 1 BW (P)

190, 190 S
Extension
195, 195 S
41 R 1/4 x R 1/4 for sliding on output
196
gear and for widening self-aligning
BU (P)
roller bearing on input and reversing
190, 190 S
shaft (not available in all versions)
195, 195 S
1X56 137 536 1
Support rod
42 for sliding on the output gear (for
output shaft 3081 304 074) BU (P)
190 S
195 S
1X56 137 292 1 BW (P)
M 100 x 1.5 wrench

43 for slotted nut 0737 502 084 on 196
output shaft
1X56 138 042 1
Repair kit
44 for hydraulic nut 1X56 137 227
(2 O-rings, 4 recoil springs and

18x
8 needle rollers)
1X56 184 153 1 BW (P)
Extractor plate
45 for moving output shaft and pressing 196
onto housing
Page index: E 01.02.00 - 09

BW 196 Special tools

no. tity
1X56 184 154 1 BW (P)
M 80x1.5 X M 50x1.5 threaded

46 ring 196
for sliding on output gear
1X56 184 155 1 BW (P)
Bush
47 for sliding on output gear 196
1X56 184 156 1 BW (P)
Extractor plate
48 for pulling pump gear off output 196
shaft
1X56 184 157 1 BW (P)
Plate
49 for removing output-end cover off 196
output shaft
Page index: E 01.02.00 - 10

BW (BU) 190 (P) BW (BU) 190 S (P)
BW 196 (P) Section F
NOTE
Section A 17.00.00 General disassembly, testing,
reworking and assembly must be observed.
Control unit, activation ......................................................................................................................... F 01.00.00
Input flange or torsion coupling, shaft seals ......................................................................................... F 03.00.00
Oil pumps .............................................................................................................................................. F 05.00.00
Changing multi-discs ............................................................................................................................ F 07.00.00
Page index: F 00.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Control unit ........................................................................................................................................... F 01.01.00
Page index: F 01.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Control unit
1
2
3
4
5
6
4 7 18
5 42 8 17
9 16 19
15
41 14
10 13
11
7 12
6
20
38 40 22 21
37 39
36 23
35 24
34 25
26
33 27
32 28
31 29
30
012705
1 = Screw plug 15 = Rectangular section ring 29 = Lever

3 = Ball 17 = Gasket 31 = Slotted pin
5 = Seal 19 = Hex bolt 33 = Stud
7 = Seal 21 = Seal ring 35 = Screw plug
8 = Compression spring 22 = Control housing 36 = Gasket
10 = Nut 24 = Slotted pin 38 = Control piston
12 = Finisher 26 = Cover 40 = Compression spring
13 = Spacer bush 27 = Cylindrical bolt 41 = Hex bolt
14 = Washer 28 = Hex bolts 42 = Hex bolt
Removing, disassembling, assembling and Removal

installing complete control unit
01 If necessary, remove pipes in accordance with (10).
H 11.00.00.
03 Lift complete control unit in upwards direction
and remove gasket (34).
Page index: F 01.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Control unit
Disassembly Installation
04 Remove detent parts (6, 7, 8 and 9). 07 Attach complete control unit with new gasket.
05 Remove lever (29) and cover (26) with gasket 08 Screw in hex bolts (41, 42, 11) and nut (10) and
(25). tighten.
06 Pull valve rotor (23) out of control housing. 09 Fit pipes in accordance with H 11.00.00.
07 Unscrew cover (18) and lift off gasket (17).
08 Remove parts (16, 15, 14, 13, 40, 39 and 38).
Check
Compression spring (39) 0732 041 411 in accordance

with D 07.00.00
Compression spring (40) 0732 041 412 in accordance
with D 07.00.00
Compression spring ( 8) 1217 304 102 in accordance
with D 07.00.00
Check piston, piston guide and valve rotor for

damage.
NOTE
Remove any dirt from the parts and lightly oil moving
parts.
Assembly

control housing.
Page index: F 01.01.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Input flange ........................................................................................................................................... F 03.01.00
Torsion coupling ................................................................................................................................... F 03.01.01
Input shaft seal ...................................................................................................................................... F 03.01.02
Page index: F 03.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Input flange
2
3
A
7 6 5
013816
1 = Input flange 6 = Pump holder 1X56 130 597

2 = Hydraulic nut 1X56 137 227 7 = Pressure gauge 1X56 130 604
3 = Nut 1X56 137 226 8 = Oil injector 1X56 130 595
4 = Bolt 1X56 136 461 A = Distance approx. 12 -15 mm
5 = High pressure pipe 1X56 130 601
Removing and installing input flange
Removal
01 Arrangement of fixture, as shown in above

figure.
! DANGER
Pull of input flange as described in Oil press-fit
method Section D 05.00.00.
Page index: F 03.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1
2
3
4
8 6
13 12 11 10
7
012707
1 = Input flange 8 = Intermediate piece 1X56 130 591

2 = Dial gauge with holder 9 = Pressure gauge 1X56 130 592
3 = Hydraulic nut 1X56 137 227 10 = High pressure pipe 1X56 130 601
4 = Nut 1X56 137 226 11 = Pump holder 1X56 130 597
5 = Bolt 1X56 136 461 12 = Pressure gauge 1X56 130 604
6 = Reciprocating piston pump 1X56 130 589 13 = Oil injector 1X56 130 595
7 = High pressure hose 1X56 130 588
Installation

diagram.
! DANGER
Pull on input flange as described in Oil press-fit
Observe push-on values in oil press-fit table D
05.00.00.
Page index: F 03.01.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Torsion coupling
1 2 3 4 5
6
7
8
9
013817
1 = Torsion coupling 7 = Hydraulic nut 1X56 137 227

2 = High pressure pipe 1X56 130 601 8 = Nut 1X56 137 226
3 = Pump holder 1X56 130 597 9 = Bolt 1X56 136 461
4 = Pressure gauge 1X56 130 604 A = Distance approx. 12 -15 mm
5 = Oil injector 1X56 130 595
6 = Pressure piece 1X56 137 289
Removing and installing torsion coupling
Removal

diagram.
! DANGER
Pull off torsion coupling as described in Oil press-
fit method Section D 05.00.00.
Page index: F 03.01.01 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2 3 4 5
6
7
8
11
10
12
14 13
012709
1 = Torsion coupling 8 = Nut 1X56 137 226

2 = High pressure pipe 1X56 130 601 9 = Bolt 1X56 136 461
3 = Pump holder 1X56 130 597 10 = Reciprocating pump 1X56 130 589
4 = Pressure gauge 1X56 130 604 11 = High pressure hose 1X56 130 588
5 = Oil injector 1X56 130 595 12 = Intermediate piece 1X56 130 591
6 = Pressure piece 1X56 137 289 13 = Pressure gauge 1X56 130 592
7 = Hydraulic nut 1X56 137 227 14 = Dial gauge with holder
Installation
01 Arrangement of fixtures as shown in above

diagram.
! DANGER
Pull on torsion coupling as described in Oil press-
fit method Section D 05.00.00. Observe push-on
values in oil press-fit table D 05.00.00.
Page index: F 03.01.01 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Input shaft seal
c) Spray outside rubber surround section of shaft

1 2 3 4 seal with steel or rubber surround with an anti-
friction agent, such as water-soluble, liquid
washing-up detergent (e.g. Pril).
d) The duo shaft seal has two
sealing lips. The dust protection
lip (X) must face outwards.
X
012710
e) Fill 60 % of the gap between 000102
the sealing lips with grease (e.g. Aral
Aralub HL2 or Texaco Texando FO 20).
1 = Sealing ring bush
2 = Seal cover or flange-mounted bell housing
3 = Shaft seal
01 Insert correct side of new shaft seal (3) into
4 = M65x1.5 grooved nut
of cover (depending on version). Thinly grease
sealing lip of shaft seal.
Removing and installing input shaft seal
02 If removed, heat sealing ring bush (1) to
approx. 85 °C and slide correct side onto input
Removal
shaft and leave to cool. Screw M65x1.5
grooved nut (4) into input shaft and use wrench
01 Input flange or torsion coupling is
1X56 137 223 to tighten (tightening torque
removed in accordance with F 03.00.00.
approx. 800 Nm) and carefully secure.
02 Remove flange-mounted bell housing (if fitted)
03 Thinly coat sealing surfaces of flange-mounted
or seal cover (2).
bell housing or cover (2) with sealing
compound* and attach to housing.
NOTE
Check sealing ring bush (1) for signs of run in. If the
04 Attach input flange or torsion coupling in
sealing ring bush is to be reworked or changed, use
accordance with F 03.00.00.
wrench 1X56 137 223 to remove grooved nut (4) and
use two-armed extractor to pull off sealing ring bush
(heat up sealing ring bush if necessary).
03 Drive shaft seal out of flange-mounted bell

housing or seal cover (2).
Installation
NOTE
a) Thinly coat outside section of shaft seal with
steel surround with sealing compound*.
b) Spray outside section of shaft seal with rubber
surround with an anti-friction agent such as a
water-soluble, liquid washing-up detergent (e.g. * Sealing compound, Hylomar SQ 32 M,
Pril). produced by Marston A 11.00.00
Page index: F 03.01.02 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Oil pump (primary) engine-dependent................................................................................................... F 05.01.00
Oil pump (secondary) propeller-dependent (BW 190/195) .................................................................. F 05.02.00
Oil pump (secondary) propeller-dependent (BW 190 S/195 S) ............................................................ F 05.03.00
NOTE
The standard input direction of rotation is clockwise,
when facing the gearbox input flange. In special
version gearboxes, the opposite direction of rotation
applies (i.e. anti-clockwise when facing the gearbox
input flange). An arrow is fitted to the gearbox input
side indicating the relevant direction.
Standard gearbox direction of rotation (I)
for engines with an anti-clockwise direction of

rotation viewed when facing the power output end.
Gearbox with special input rotation of direction

(II)

viewed when facing the power output end.
012712
Page index: F 05.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
A A
012713
A = depending on version
Page index: F 05.00.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Oil pump
Input direction of rotation I Input direction of rotation II
2
1
6
7
012714
012715
8 9 10
1 = Hex bolts 6 = Thrust washer

3 = Screw plug 8 = Needle sleeve
Checking oil pump 3081 206 001/ 3081 206 013

(engine-dependent) 2 3 4 5
Removal
01 If necessary, remove pipes in accordance with

H 11.00.00.
A
Figure 012715
03 Lift oil pump off cover (using assembly levers 1 012716
as an aid placed against the recesses of the

housing).
1 = Tapered pin
04 In gearboxes with input direction of rotation II, 2 = O-ring
if necessary, remove intermediate gear drive, 3 = Woodruff key
items 3 to 10, Figure 012715. 4 = Input gear
5 = Circlip
Page index: F 05.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
05 Snap out circlip (5). 09 When using gearboxes with direction of

rotation II (if removed), install intermediate
06 Pull off input gear (4). gear drive, items 3 to 10, Figure 012715.
07 Remove Woodruff key (3) 10 Apply thin coat of compound sealing* to

sealing faces of pump cover and attach oil;
NOTE pump and screw into place.
The oil pump is a complete part and is not usually
disassembled. 11 Fit pipes in accordance with H 11.00.00.
It may however be necessary to disassemble the
pump for checking or cleaning purposes.

take off pump cover.
NOTE
Carefully check and clean parts. Do not fibrous cloths
for cleaning. Apply a thin coat of oil to moving parts.
Assembly
01 Insert pump pinion in pump housing.
02 Place O-ring (2) in pump housing.

Figure 012716
03 Attach pump cover, fit bolts but do not tighten.
04 Drive in tapered pins (1) and tighten bolts.

onto pump shaft.
07 Snap circlip (5) in annular groove of pump

shaft.
* Sealing compound, Hylomar SQ 32 M,
produced by Marston A 11.00.00
Page index: F 05.01.00 - 02

BW (BU) 190 (P)
BW (BU) 195 (P) Oil pump
A
B
012717
012718
NOTE
In versions without oil pump, use sealing compound
when screwing hex bolt + washer (without
intermediate gear) into position A or B.
5 6 7
10 9 8
012719
1 = propeller-dependent oil pump 6 = Thrust ring

2 = Screw plugs 7 = Bolt
3 = Hex bolt 8 = Needle sleeve
4 = Thrust washer 9 = O-ring
5 = Intermediate gear 10 = O-ring
Oil pump 7631 955 120 (propeller-dependent)
Page index: F 05.02.00 - 01

BW (BU) 190 (P)
Removal Disassembly
01 If necessary, remove pipes in accordance with 04 Snap out circlip (5).

H 11.00.00.
02 Unscrew fastening bolts on oil pump.
06 Remove Woodruff key (3).
03 Lift off oil pump (using assembly levers if
necessary as an aid). 07 Remove fastening bolts (2) on pump cover and
NOTE
The oil pump is a complete part and is not usually NOTE
disassembled. It may however be necessary to Carefully check and clean parts. Do not use any
disassemble the pump for checking or cleaning fibrous cloths for cleaning. Apply a thin coat of oil to
purposes. moving parts.

ensuring that the end float is within the wear limit, Assembly
The pump parts should be checked for traces of run in. 01 Insert eccentric ring, inner and outer rotor and
rotor shaft in pump housing.
a
02 Attach pump cover and screw down.
2 3 4 5

onto pump shaft.

shaft.
Installation
012720
06 Slide O-ring (1) onto pump housing and attach
1
oil pump to cover.
07 Fit pipes in accordance with H 11.00.00.
1 = O-ring
2 = Cylindrical bolt
3 = Woodruff key
4 = Input gear
5 = Circlip
Page index: F 05.02.00 - 02

BW (BU) 190 S (P)
BW (BU) 195 S (P) Oil pump
(propeller- dependent)
012721
012722
NOTE
In version without oil pump, use sealing compound
when screwing hex bolt + washer (without
intermediate gear) into pos. (3).
5 6 7
4
012723
10 9 8
1 = propeller-dependent oil pump 6 = Thrust ring

2 = Screw plugs 7 = Bolt
Oil pump 7631 955 120 (propeller-dependent)
Page index: F 05.03.00 - 01

BW (BU) 190 S (P)
(propeller-dependent)
Removal Disassembly

H 11.00.00.
03 Lift off oil pump (using assembly levers as an
aid if necessary). 07 Remove fastening bolts (2) on pump cover and
NOTE
The oil pump is a complete part and is not usually NOTE
disassembled. Carefully check and clean parts. Do not use any
It may however be necessary to disassemble the fibrous cloths for cleaning. Apply a thin coat of oil to
pump for checking or cleaning purposes. moving parts.

ensuring that the end float is within the wear limit, Assembly
The pump parts should be checked for traces of run in. 01 Insert eccentric ring, inner and outer rotor and
rotor shaft in pump housing.

a
2 3 4 5 03 Insert Woodruff key (3) in pump shaft.

onto pump shaft.

shaft.
Installation

1 oil pump to cover.

012724
1 = O-ring
3 = Woodruff key
4 = Input gear
5 = Circlip
Page index: F 05.03.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Changing multi-discs of input or reversing shaft
Removing and installing cover ............................................................................................................. F 07.01.00
Removing and installing cover for input and reversing shaft ............................................................... F 07 .02.00
Removing and fitting constant gear of input or reversing shaft ............................................................ F 07.03.00
Removing and installing multi-disc pack of input or reversing shaft ................................................... F 07.04.00
Page index: F 07.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Changing multi-discs of
BW 196 (P) input or reversing shaft
3
2
1
012725
1 = Cover 4 = Pressure piece

2 = M50x1.5 grooved nut 5 = Cover
3 = Three-armed extractor 6 = Input gear
Removing and installing cover Installation
01 If necessary, pipes are removed in accordance 01 Heat input gear (6) to approx. 85 °C and slide
with H 11.00.00. correct side onto reversing shaft.
02 Oil pump is removed in accordance with F 02 Screw grooved nut (2) onto reversing shaft and
05.00.00. use wrench 1X56 137 222 to tighten and
carefully lock.
Removal 03 Apply thin coat of compound sealing* to sealing

faces of cover (1 + 5) and attach.
03 Remove covers (1 + 5).
04 Attach oil pump in accordance with
04 Unlock grooved nut (2) and use wrench F 05.00.00.
1X56 137 222 to remove.
05 Use three-armed extractor to pull of input gear
(6).
06 Remove cover in accordance with F 07.02.00. * Sealing compound, Hylomar SQ 32 M,

Page index: F 07.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
3
2
012726
1 = Cover 3 = Inner race of cylinder roller bearing

2 = Outer race of cylinder roller bearing
Removing and installing cover for input and Installation

reversing shaft
01 Heater inner race of cylinder roller bearing to
01 Covers are removed in accordance with approx. 85 °C and slide correct side onto shaft
F 07.01.00. to be fitted until firmly home.
02 Insert outer races of cylinder roller bearing (2)

Removal in cover.
02 Unscrew fastening bolts from cover (1) 03 Apply thin coat of sealing compound* to
and press off cover. sealing faces of cover.
03 Drive outer races of cylinder roller bearing (2) 04 Carefully place cover (1) on housing and screw
out of cover. down.
04 Use two-arm-ed extractor to pull inner race of 05 Attach cover in accordance with F 07.01.00.
cylinder roller bearing (3) off the shaft to be
disassembled.
05 Remove constant gear in accordance with

F 07.03.00. * Sealing compound, Hylomar SQ 32 M,
Page index: F 07.02.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
1 2 3 4 5 6 7 8 9 10
012727
1 = Oil injector 1X56 130 595 6 = Emergency control equipment

2 = Pressure gauge 1X56 130 604 7 = Constant gear
3 = Pump holder 1X56 130 597 8 = Piston
4 = High pressure pipe 1X56 130 601 9 = Rectangular section ring
5 = Hydraulic nut 1X56 137 227 10 = Input shaft
Removing and fitting constant gear of input and

reversing shaft
01 Cover for input and reversing shaft is removed 02 Fixture arrangement as shown in above diagram.
in accordance with F 07.02.00.
! DANGER
Removal Pull off constant gear (7) as described in Oil press-
fits method Section D 05.00.00.
NOTE
The constant gears of the input and reversing shaft
must not be confused. A distinction can be made 03 Take piston (8) out of constant gear and remove
between the gears by looking at the helical angle of the rectangular section ring.
gear teeth. Always note the part number.
04 If necessary, remove emergency control
Gear with part no. 3081 302 equipment (6).
Spare part no. 3081 202 for input shaft
Gear with part no. 3081 303 05 Remove multi-disc pack in accordance with
Spare part no. 3081 203 for reversing shaft F 07.04.00.
Page index: F 07.03.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
8 9 10
1 2 3 4 5 6 7
14 13 12 11
012728
1 = Oil injector 1X56 130 595 8 = Piston

2 = Pressure gauge 1X56 130 604 9 = Rectangular section ring
3 = Pump holder 1X56 130 597 10 = Input shaft
4 = High pressure pipe 1X56 130 601 11 = High pressure hose 1X56 130 588
6 = Emergency control equipment 13 = Intermediate piece 1X56 130 591
7 = Constant gear 14 = Reciprocating piston pump 1X56 130 589
Installation NOTE
Take care when sliding constant gear onto rectangular
01 Multi-discs are inserted in accordance with section ring (9) of piston.
F 07.04.00. It must not be damaged.
02 Check emergency control equipment, if removed 05 Fixture arrangement as shown in above diagram.
from constant gear, and install.
NOTE ! DANGER
Stretch rectangular section ring (9) well before Slide on constant gear as described in Oil press-fit
attaching constant gear. method Section D 05.00.00. Observe push-on
values in oil press-fit table D 05.00.00.
03 Insert rectangular section ring in piston (8) and
insert piston in constant gear.
06 Attach cover for input and reversing shaft in
04 Slide in correct side of constant gear (7) (with accordance with F 07.02.00.
correct spare parts number) as described in Oil
press-fit method Section D 05.00.00 and
measure push-on length.
Page index: F 07.03.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Changing multi-discs for
1 2 3 4
1 = Cup springs (6)

2 = Inner disc
3 = Outer disc
4 = Thrust washer
5 = Slide-on washer 1X56 137 231
6 = Stud 1X56 137 232
7 = Hydraulic nut 1X56 137 227
8 = Extractor plate 1X56 137 229
9 = Driven extractor plate 1X56 137 220
11 = Pressure gauge 1X56 130 592 012729
12 = Intermediate piece 1X56 130 591
13 = Reciproc. piston pump 1X56 130 589
5 6 7 8 9
13 12 11 10
012730
NOTE Figure 012730 shows multi-disc pack removal for

Figure 012729 shows multi-disc pack removal for whenever multi-disc packs cannot be removed by
whenever multi-disc packs can be removed by hand. hand.
Page index: F 07.04.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
Removing and installing multi-disc pack of input

or reversing shaft
01 Constant gear is removed in accordance with

F 07.03.00.
Removal
02 Remove all 6 cup springs (1) from shaft.
! DANGER
Only remove disc carrier in cases of extreme
emergency.
If the multi-discs cannot be removed, the complete
clutch pack can be pulled out with the inner disc
carrier (refer to Figure no. 012 730).
Fixture arrangement as shown in the diagram.
03 Remove inner and outer discs (2 + 3) from disc

carrier.
04 Remove thrust washer (4) from disc carrier.
Page index: F 07.04.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
14 15 16
012731
14 = Inner disc carrier 16 = Input shaft

15 = Snap ring
Installation driver lugs. One marking is narrow and the other is

wide. The outer discs should be inserted as follows:
01 Heat inner disc carrier (if removed, not in
version P) to approx. 140 - 150 °C and slide on The starting point for insertion is the narrow marking
correct side until firmly home. and is always superimposed. When inserting the first
outer disc, the wide marking is either to the right or
17 left of the narrow marking. When inserting the next
outer disc, the wide marking must be offset to the
right or left of the outer disc previously inserted.
18
Example:
17 1. Outer disc wide marking to the right of the

012732 narrow marking.
17 = Wide marking 2. Outer disc wide marking to the left of the
18 = Narrow marking narrow marking.
3. Outer disc wide marking to the right of the
NOTE narrow marking etc. (see left-hand figure)
When sliding on the outer discs, note the marking on
the driving lug. Each outer disc is marked on two
Page index: F 07.04.00 - 03

BW (BU) 190 (P) BW (BU) 190 S (P)
02 Slide correct side of thrust washer (4) onto disc

carrier.
03 Insert discs (2 + 3) in disc carrier in accordance

with gearbox type (in accordance with table for
multi-disc configuration D 11.00.00). Outer and
inner discs should be inserted alternatively,
starting with an outer disc. The notes described
above should be observed.
04 The multi-disc pack will have the specified disc

clearance if it has the correct multi-disc
configuration.
05 Slide all 6 cup plates (1) onto input shaft, in the

correct order (refer to figure).
06 Slide on constant gear in accordance with

F 07.03.00.
Page index: F 07.04.00 - 04

BW (BU) 190 (P) BW (BU) 190 S (P)
BW 196 (P) Section G
Removal and installation of gearbox (refer to operating manual) ........................................................ B 03.00.00
1. Operating manual (basic version) no. 3081 758 002

2. Installation manual no. 3000 765 001
Items 1 and 2 can be requested from the gearbox manufacturer.
Page index: G 00.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW 196 (P) Section H
NOTE
Section A 17.00.00 General disassembly, testing,
reworking and assembly must be observed.
Removal and installation sequence of main groups ............................................................................ H 01.00.00
Control unit ........................................................................................................................................... H 07.00.00
Filter ..................................................................................................................................................... H 09.00.00
Pipes ..................................................................................................................................................... H 11.00.00
Oil cooler .............................................................................................................................................. H 13.00.00
Oil pumps ............................................................................................................................................. H 15.00.00
Valves ................................................................................................................................................... H 17.00.00
Gearbox mounting ................................................................................................................................ H 19.00.00
Input flange, torsion coupling .............................................................................................................. H 21.00.00
Flange-mounted bell housing ............................................................................................................... H 27.00.00
Cover .................................................................................................................................................... H 29.00.00
Input shaft ............................................................................................................................................. H 31.00.00
Reversing shaft ..................................................................................................................................... H 33.00.00
BW (BU) 190, 195 (P) output shaft ..................................................................................................... H 37.00.00
BW (BU) 190 S, 195 S (P) output shaft ............................................................................................... H 39.00.00
BW 196 (P) output shaft ....................................................................................................................... H 41.00.00
Page index: H 00.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Diagram of
installation and removal sequence of main groups .............................................................................. H 01.01.00
Page index: H 01.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Diagram of installation and
BW 196 (P) removal sequence of main groups
07 09
11 13
17
15
012733
Reference numbers refer to H 00.00.00
Page index: H 01.01.00 - 01

BW (BU) 190 (P) Diagram of installation and
BW (BU) 195 (P) BW 196 (P) removal sequence of main groups
19 21
27 29
31 33
012734
Page index: H 01.01.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Diagram of installation and
BW 196 (P) removal sequence of main groups
39
37
013910 013911
41
013909
Page index: H 01.01.00 - 03

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Removal and installation, disassembly and assembly of

complete control unit (basic version with mechanical actuation) ........................................................ H 07.01.00

control valve (electrical actuation version) .......................................................................................... H 07.02.00

control valve for engageable PTO version ........................................................................................... H 07.03.00

control valve for trolling version .......................................................................................................... H 07.04.00
Removal and installation of

control unit (pneumatic actuation version) ........................................................................................... H 07.05.00
Page index: H 07.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Control unit basic version

Actuation mechanical
012736
Page index: H 07.00.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Control unit basic version
BW 196 (P) Actuation mechanical
1
2
3 4
5
6
7 18
4 17
5 1 8
9 16 19
15
1 14
10 13
11
7 12
6
20
38 40 22 21
37 39 23
36 24
35
34 25
26
27
33
32 28
31 29
30
012737
1 = Screw plug 15 = Rectangular section ring 29 = Lever

3 = Ball 17 = Gasket 31 = Slotted pin
5 = Seal ring 19 = Hex bolt 33 = Stud
7 = Seal ring 21 = Seal ring 35 = Screw plug
8 = Compression spring 22 = Control housing 36 = Seal ring
10 = Nut 24 = Slotted pin 38 = Control piston
12 = Finisher 26 = Cover 40 = Compression spring
13 = Spacer bush 27 = Cylindrical bolt 41 = Hex bolt
14 = Washer 28 = Hex bolts 42 = Hex bolt
Removing, disassembling, assembling and Removal

installing complete control unit
01 If necessary, pipes are removed in accordance (10).
with H 11.00.00.
03 Lift complete control unit up and remove gasket
(34).
Page index: H 07.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Control unit basic version
BW 196 (P) Actuation mechanical
04 Remove detent parts (6, 7, 8 and 9). 07 Fit complete control unit with new gasket.
05 Remove lever (29) and cover (26) with gasket 08 Screw in hex bolts (41, 42, 11) and nut (10) and
(25). tighten.
06 Pull valve rotor (23) out of control housing. 09 Fit pipes in accordance with H 11.00.00.
07 Unscrew cover (18) and remove gasket 17.
08 Remove parts (16, 15, 14, 13, 40, 39 and 38).
Checking
Compression spring (39) in accordance with

D 07.00.00
D 07.00.00
Compression spring ( 8 ) in accordance with
D 07.00.00
Protect piston, piston guide and valve rotor from

damage.
NOTE
Keep parts clean. Apply thin coat of oil to moving
parts.
Assembly

control housing.
Page index: H 07.01.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents

control valve (electrical actuation version) .......................................................................................... H 07.02.00
Page index: H 07.02.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Control unit +
Actuation electrical
012738
Page index: H 07.02.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Control valve
BW 196 (P) for electrical actuation
16 17 18 19
11 12 13 15 20
14
10
7
1 2 3 4 5 6
8
9
012739
1 = Hex bolts 11 = Hex bolt

2 = Cylindrical bolt 12 = Control piston
3 = Cover 13 = Washer
4 = Gasket 14 = Compression spring
5 = Control housing 15 = Circlip
6 = Gasket 16 = Gasket
7 = Solenoid valve 17 = Cover
8 = Gasket 18 = Seal ring
9 = Cover 19 = Hex bolt
10 = Wiring harness 20 = Cylindrical bolt
Page index: H 07.02.01 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW 196 (P) for electrical actuation
Disassembly Assembly
01 Remove cover (9), unfasten cable lugs (10) and 01 Attach cover (3) and gasket (4).
lift off cable.
02 Slide washer (13), compression spring (14)
02 Take off solenoid valve (7). andwasher (13) onto control piston and snap
circlip into control piston.
03 Unscrew cylindrical bolts (20) and lift off cover
(17) with gasket (16). 03 Insert correct side of control piston into control
housing.
04 Take control piston (12) and parts (13, 14 and
15) out of control housing. 04 Attach cover (17) and gasket (16) to control
housing.
05 Remove circlip (15) from control piston, lift off
washers (13) and compression spring (14). 05 Attach solenoid valve (7).
06 Lift off cover (3) and remove gasket (4). 06 Screw cable lugs onto solenoid valve and attach
cover (9).
Checking

D 07.00.00
Check control piston (12) and control piston bore in

control housing (5) for damage and protect from
possible damage.
Cleaning
Clean parts and apply thin coat of oil to moving parts.
Page index: H 07.02.01 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents

control valve for engageable PTO version ........................................................................................... H 07.03.00
Page index: H07.03.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Control unit basic version + trolling + engageable PTO

012740
Page index: H 07.03.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Control valve for PTO
BW 196 (P) engageable
13
12
11
10
9
6 7
8
4
3
2 012741
1
1 = Screw plug 8 = Screw plug with seal ring

2 = Seal ring 9 = Screw plug with seal ring
3 = Snap ring 10 = Plug
4 = Control piston 11 = Seal ring
5 = Compression spring 12 = Screw plug
6 = Compression spring 13 = Sealing cap
7 = Valve housing
Disassembly Cleaning
01 Remove screw plug (1) and seal ring (2). Clean parts and apply a thin coat of oil to moving
parts.
02 Remove snap ring (3) from valve housing.
Assembly
03 Take control piston (4), compression springs (5)
and (6) out of valve housing. 01 If removed, screw in plugs (10). In so doing,
observe the installation dimensions (refer to
removal).
Checking
02 Insert compression springs (6) and (5) and
Check compression springs (5) and (6) in accordance control piston (4) in valve housing.
with D 07.00.00
Check control piston (4) and control piston bore in 03 Insert snap ring (3) in valve housing.
valve housing (7) for damage and protect against
possible damage. 04 Screw in screw plug (1) and seal ring.
Page index: H 07.03.01 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents

control valve for trolling version .......................................................................................................... H 07.04.00
Page index: H 07.04.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Control unit basic version + trolling + engageable PTO

012742
Page index: H 07.04.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW 196 (P) for version with trolling
24
25
26
22
21 23
19 20 27
18
17
16
15 13
14 12
11
10 28
9 8
7 29
16
3 5
2 4
1 012743
1 = Collar screw 16 = Ball (diameter 8)

2 = O-ring 17 = Valve cover
3 = Hex bolt 18 = Gasket
4 = Cam 19 = Piston
5 = Hex bolt 20 = Washer
6 = Lever 21 = Compression spring
7 = Shaft 22 = 1.0/0.5/0.4/0.3/0.2 mm washers
8 = Shaft seal 23 = Control piston
9 = Snap ring 24 = Gasket
10 = Needle sleeve 25 = Valve housing
11 = Slotted pin 26 = Hex bolt
12 = Needle sleeve 27 = Hex bolt
13 = Cylindrical pin 28 = Sign
14 = Shim ring 29 = Sign
15 = Compression spring
NOTE 02 Unscrew hex bolt (3) on valve cover (17) and

Only unscrew collar screw (1) if the valve housing has remove cover and gasket (18).
been removed and the hex of the collar screw is
pointing downwards. 03 Take piston (19), washer (20), compression
spring (21), washers (22) and control piston
01 Unscrew hex bolts (26) and (27) and remove (23) out of valve housing.
valve housing (25) and gasket (24).
04 Unscrew collar screw (1), remove shim ring
(14), compression spring (15) and ball (16).
Page index: H 07.04.01 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW 196 (P) for version with trolling
05 Drive cylindrical pin (13) out of cover (17). 08 Insert shim ring (14) and compression spring
(15) in collar screw (1).
06 Drive slotted pin (11) out of cam (4) and shaft
(7). 09 Place ball (16) (diameter 8) and grease on
spring in collar screw and vertically screw
07 Take shaft (7) and cam (4) out of cover (17). collar screw into valve cover (17). (Screw in
from below).
Checking
10 Fit valve cover (17) and gasket (18) onto valve
Compression springs (15) and (21) in accordance housing (25).
with D 07.00.00
11 Attach complete valve housing (25) and gasket
Check piston (19), control piston (23) and control (24) to control unit.
piston bore in valve housing (25) for damage and
protect against possible damage.
Cleaning
Clean parts and apply a thin coat of oil to moving

parts.
Assembly
01 Insert cam (4) in valve cover (17) and insert

shaft (7) in cam.
02 Align cam and shaft ensuring that the bores for

the slotted pin match in the cam and shaft.
Drive slotted pin into cam and shaft until slotted
pin protrudes approx. 3 mm beyond the cam.
03 If removed, fit shaft seal (8) in accordance

with A 17.03.00 - 01.
04 Fit lever (6) on shaft (7).
05 Place washers (22) in control piston (23) and

insert control piston in valve housing (25).
06 Insert compression spring (21) in control piston

(23).
07 Insert washer (20) in piston (19) and slide

piston onto compression spring (21).
Page index: H 07.04.01 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Removal and installation of

control unit (pneumatic actuation version) ........................................................................................... H 07.05.00
Page index: H 07.05.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Control unit +
Actuation pneumatic
012744
Page index: H 07.05.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Control unit with actuation
BW 196 (P) pneumatic
9 8
10
1 2 3 4 5 6
012745
1 = Articulated bolt 6 = Yoke head

2 = Joint head 7 = Hex bolt
3 = Washer 8 = 3 position cylinder
4 = Locking nut 9 = Console
5 = Hex nut 10 = Hex bolt
Removal Installation
01 Remove lines from 3 position cylinder. 01 Use hex bolts (7) to attach 3 position cylinder to
console (9). When installing, slide the joint
02 Unscrew locking nut (4) and remove washer head onto the articulated pin.
(3).
NOTE
03 Unscrew hex bolts (7), lift off 3 position If the 3 position cylinder and the control unit are fitted
cylinder. and in the neutral setting (central setting), the joint
head (2) must be slid onto the centre of the articulated
NOTE shaft (1).
The 3 position cylinder is a complete part and is not
disassembled. 02 Slide on washer (3) and screw on locking nut
(4).
03 Install lines to 3 position cylinder.
Page index: H 07.05.01 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Removal, cleaning and installation of filter .......................................................................................... H 09.01.00
Page index: H 09.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Filter
4 5 6 7
1 2 3
012746
1 = Hex bolt 5 = Seal ring

2 = Filter 6 = Seal ring
3 = Gasket 7 = Sludge drain screw
4 = Screw for oil pocket drainage
Oil filter: removal, cleaning Cleaning
01 Unscrew sludge drain screw (7) and drain filter 06 Clean filter element with diesel oil or suitable
compartment. petroleum agent.
02 Unscrew screw (4) for oil pocket drainage by 07 Only use brush for cleaning, never fluffing
approx. 20 - 25. This allows oil to flow into the cloths or mechanical devices such as
filter compartment in the gearbox housing. screwdrivers, scrapers etc.
Then unscrew screw all the way
Installation
Disassembly
01 Screw in sludge drain screw (7) and screw (4)
03 Remove hex bolts (1) from filter. with new gasket and tighten.
04 Take out filter element (2). 02 Insert filter (2) with new gasket (3) and screw
down.
05 Protect filter chamber to prevent dirt entering.
Page index: H 09.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Removal and installation of pipes in

BW 190/195 (S), 196 (P) versions ...................................................................................................... H 11.01.00
Page index: H 11.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
pipes
012747
Page index: H 11.00.00 - 02

Contents
BW 196 (P) pipes
013 814
Page index: H 11.00.00 - 03

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Pipes
7
8
9
3 8
4
2 10
5
6 11
22 12
1 23
14 16
11
13 15
24
26
25 16
35 18 17
34 27
30a
33 30
31 28 19
32 29 20
19
21
A
30a
30
30b
A
A
012748
30c 30b
1 = Hex bolt 14 = Pressure line 27 = Hex bolt

2 = Hex bolt 15 = Union screw 28 = Seal ring
3 = Intermediate neck 16 = Seal ring 29 = Screw plug
4 = O-ring 17 = Pressure line 30 = 34x4 O-ring
5 = Tube 18 = Neck 30 a = 40x3 O-ring
6 = Gasket 19 = Seal ring 30 b = Washer
7 = Union screw 20 = Lub. oil line 30 c = 35x5.5 O-ring
8 = Seal ring 21 = Union screw 31 = Flange
9 = Oil pipe 22 = O-ring 32 = Hex bolt
10 = Finisher (sealing cap) 23 = Pipe neck 33 = Suction line
11 = Seal ring 24 = Hex bolt 34 = Neck
12 = Union screw 25 = Gasket 35 = Seal ring
13 = Neck 26 = Hex bolt A = depending on version
Removing and installing pipes
Removal Installation
01 Remove pipes if necessary. 01 Fit pipes and replace CU seal rings, O-rings and
gaskets.
NOTE
For BW 196 version, note Figure on
Page H 11.00.00 - 03.
Page index: H 11.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Removal, cleaning and installation of oil cooler ................................................................................. H 13.01.00
Page index: H 13.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW 196 (P) oil cooler
012749
Page index: H 13.00.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Oil cooler
1 2
4 3
012750
1 = Oil cooler 3 = Stud

2 = Hex nut 4 = O-ring
Removal, cleaning and installation of oil cooler
01 If necessary, remove pipes.
Removal
02 Unscrew fastening nuts (2) on oil cooler and lift

off oil cooler.
Page index: H 13.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Oil cooler
Cleaning instructions for plate-type oil cooler flushed through with gear oil, we would recommend
the addition of approx. 5 % oil to the trichloroethy-
lene. This ensures that the oil film remaining after
cleaning and subsequent drying out with warm air,
acts as a preservative, in particular on the turbulence
plates at the oil end.
Cleaning water end
Cleaning at the water end requires an examination of

012751 the dirt which has accumulated. If a greasy lime layer
is determined, the water end must first be degreased.
The lime layer is then dissolved by rinsing it with
The requirements in terms of achieving both a uni- water and a lime remover; it may also be possible to
form cooling capacity as well as in terms of the pres- use a 10 to 15 % hydrochloric acid solution. An
sure drop at the oil end, make cleaning operations nec- inhibitor must be added to the solution to ensure that it
essary at particular intervals, in particular at the end does not attack the metal surfaces.
end.
After completion of cleaning, the water end is thor-
It is not possible to specify in advance the intervals at oughly rinsed with clear water and the oil end is then
which the cleaning procedures described below should best filled with the oil subsequently used during nor-
be performed because the nature and extent of con- mal operation and again drained. The cleaning will be
tamination can vary greatly. The periods of operation more successful and the cleaning time shorter if the
should therefore be recorded prior to carrying out any direction of flow during pumping, both at the oil and
instruction and repair work. This will enable a suitable water end, is the reverse to that used in normal opera-
cleaning schedule to be drawn up, with intervals based tion.
on an appropriate number of operating hours.
You can be sure that coolers cleaned in this way will
We recommend the following treatment for this plate- then provide the full cooling capacity in subsequent
type oil cooler: operation with a reasonable pressure drop at the oil
end.
Cleaning oil end

Installation
The coolers are connected to a trichloroethylene or
perchloroethylene unit and are rinsed with the hot 01 Place oil cooler and new O-rings on housing
medium. The direction of rinsing is the reverse to that and screw down.
of the normal operating oil flow. This removes dirt
particles, especially abrasion, from the multi-disc 02 If necessary, attach pipes.
clutches and from the turbulence baffle of the oil cooler
plates. They are then flushed out by the medium. An
appropriate filter should be inserted in this main flow
to remove the impurities rinsed out from the cleaning
medium. Cleaning should be continued until examina-
tions reveal that the purity of the medium flowing out
is equivalent to that flowing in.
If coolers cleaned in this way are put into storage as

spare parts, i.e. are not immediately refitted and
Page index: H 13.01.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Engine-dependent oil pump (primary) ................................................................................................ H 15.01.00
Propeller-dependent oil pump (secondary) (BW 190/195/196) (P) .................................................... H 15.02.00
Propeller-dependent oil pump (secondary) (BW 190 S/195 S) ........................................................... H 15.03.00
NOTE
The standard input direction of rotation is clockwise,
viewed when facing the gearbox input flange.
In special version gearboxes, the opposite direction of

rotation applies, i.e anti-clockwise, viewed when fac-
ing the gearbox input flange.
An arrow is fitted to the gearbox input side indicating

the relevant direction.
Standard input direction of rotation (I)

Gearboxes with special input direction of rotation

(II)

012756
Page index: H 15.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
oil pumps
012752
Page index: H 15.00.00 - 02

Contents
BW 196 (P) oil pumps
013 815
Page index: H 15.00.00 - 03

BW (BU) 190 (P) BW (BU) 190 S (P)
Input direction of rotation (I) Input direction of rotation (II)
2
1
6
7
012753 012754 8 9 10
1 = Hex bolt 6 = Thrust water

3 = Plugs 8 = Needle sleeve
Oil pump 3081 206 001/013 (engine-dependent)
Removal 2 3 4 5
01 If necessary, remove pipes in accordance with

H 11.01.00.

Figure 012754 A
03 Lift oil pump off cover (using assembly levers

if necessary as an aid placed against the recess-
es of the housing).
1
04 With gearbox input direction of rotation II, 012755

remove intermediate gear drive, items 3 to 10,
Figure 012754. 1 = Tapered pin
2 = O-ring
3 = Woodruff key
4 = Input gear
5 = Circlip
A = Refer to end float, refer to D 09.00.00
Page index: H 15.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
04 Snap out circlip (5). 08 For gearbox input direction of rotation II, install
intermediate gear drive, items 3 to 10,
05 Pull off input gear (4). Figure 012754.
06 Remove Woodruff key (3). 09 Apply thin coat of sealing compound* to seal-
ing races on pump cover and attach oil pump
NOTE and tighten.
The oil pump is a complete part and is not usually dis-
assembled. It may however be necessary to disassem- 10 Fit pipes in accordance with H 11.00.00.
ble the pump for checking or cleaning purposes.


Figure 012755
NOTE
Carefully check and clean parts. Do not use any
moving parts.
Assembly
01 Insert pump pinion in pump housing.
02 Insert new O-ring (2) in pump housing.
03 Attach pump cover, attach screws but do not

screw in.
04 Drive in tapered pins (1) and tighten screws.

onto pump shaft.
07 Drive circlip (5) into annular groove of pump

shaft.
* Sealing compound, Hylomar SQ 32M,
Page index: H 15.01.00 - 02

BW (BU) 190 (P)
BW 196 (P) (Propeller-dependent)
A B
012757
012758
NOTE
In the version without an oil pump, use sealing com-
pound to screw hex bolt + washer (without intermedi-
ate gear) into pos. A or B.
5 6 7
10 9 8
012759
1 = Propeller-dependent oil pump 6 = Thrust ring

2 = Plug 7 = Bolt
3 = Hex bolts 8 = Needle sleeve
Oil pump 7631 955 120 (Propeller-dependent)
Page index: H 15.02.00 - 01

BW (BU) 190 (P)
Removal Disassembly

H 11.00.00.
03 Lift off oil pump (using assembly levers if nec-
essary as an aid). 08 Remove fastening bolts (2) on pump over and
04 Remove intermediate gear drive, items 2 to 9.
NOTE
NOTE Carefully check and clean parts. Do not use fibrous
The oil pump is a complete part and is not usually dis- cloths for cleaning. Apply a thin coat of oil to moving
assembled. parts.
Assembly
ensuring that the end float is within the wear limit, 01 Insert eccentric ring, inner and outer rotor and
refer to D 09.00.00. rotor shaft in pump housing.

a
2 3 4 5 04 Heat input gear (4) to approx. 85 °C and slide

onto pump shaft.

shaft.
012760
1 = O-ring
3 = Woodruff key
4 = Input gear
5 = Circlip
Page index: H 15.02.00 - 02

BW (BU) 190 (P)
Installation
06 Install intermediate gear drive, items 2 to 9,

Figure 012759.

oil pump to cover and screw down.
Page index: H 15.02.00 - 03

BW (BU) 190 S (P)
(Propeller-dependent)
012761
012762
NOTE
In the version without an oil pump, use sealing com-
pound to screw hex bolt + washer (without intermedi-
ate gear) into pos.A or B.
5 6 7
4
10 9 8
012763
1 = Propeller-dependent oil pump 6 = Thrust ring

2 = Plug 7 = Bolt
Oil pump 7631 955 120 (Propeller-dependent)
Page index: H 15.03.00 - 01

BW (BU) 190 S (P)
(Propeller-dependent)
Removal Disassembly

H 11.00.00.
02 Unscrew fastening screws on oil pump.
03 Lift off oil pump (using assembly levers if nec-
essary as an aid). 07 Remove fastening bolts (2) on pump cover and
remove pump cover.
04 Remove intermediate gear drive, items 2 to 9.
NOTE
NOTE Carefully check and clean parts. Do not use any
The oil pump is a complete part and is not usually dis- fibrous cloths for cleaning. Apply a thin coat of oil to
assembled. It may however be necessary to disassem- moving parts.
ble the pump for checking or cleaning purposes.
Assembly
ensuring that the end float is within the wear limit, 01 Insert eccentric ring, inner and outer rotor and
refer to D 09.00.00. rotor shaft in pump housing.

a
2 3 4 5 onto pump shaft.

shaft.
Installation
06 Install intermediate gear drive, items 2 to 9,

Figure 012763.
07 Slide O-ring (1) onto pump housing and fit oil

1 pump on cover.
012764 08 Fit pipes in accordance with H 11.00.00.
1 = O-ring
3 = Woodruff ley
4 = Input gear
5 = Circlip
a = For end float, refer to D 09.00.00
Page index: H 15.03.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Pressure limiting valve ......................................................................................................................... H 17.01.00
Pressure limiting valve (for max. system pressure) ............................................................................. H 17.02.00
Page index: H 17.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Pressure limiting valve
012765
012766
Page index: H 17.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1
2
3
4
5
6
7
012767
012768
1 = Screw plug 6 = Compression spring

2 = Seal ring 7 = Piston
3 = Compression spring A = Function for oil injection line (gear meshing)
4 = Snap ring B = Function for lub. oil pressure (return in suction
5 = Piston line)
Removing and installing pressure limiting valve NOTE

Clean parts. Apply thin coat of oil to moving parts.
01 Unscrew screw plug (1). Replace seal ring.
02 Remove parts (2 to 7). Adjustment values for pressure limiting valve (dual
function) are in accordance with adjustment value
table D 13.00.00.
Checking
Compression spring (3) in accordance with spring Installation

table D 07.00.00
Compression spring (6) in accordance with spring 01 Insert piston (7), compression spring (6), piston
table D 07.00.00 (5), snap ring (4), compression spring (3).
Check piston and piston guide for fretting traces 02 Screw in screw plug (1) and new CU seal ring
(grooves). (2) and tighten.
Page index: H 17.01.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Pressure limiting valve
BW 196 (P) (for max. system pressure)
012769
Page index: H 17.02.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
3
2
1
012770
1 = Valve seat 3 = Compression spring

2 = Spring cup A = Function for max. system pressure
Removing and installing pressure limiting valve Installation
01 If necessary, remove pipes in accordance with 01 Insert compression spring (3) and spring (2).
H 11.00.00.
02 Screw in valve seat to ensure adequate spring
NOTE preload (refer to adjustment values).
Before removing the pressure limiting valve, measure
the installation dimension between valve seat (1) and
housing plane face. Note down this dimension.
Removal
02 Unscrew valve seat (1).
03 Remove spring cup (2) and compression spring

(3).
Checking
Compression spring (3) in accordance with spring

table D 07.00.00.
Adjustment values for pressure limiting valve are as

in accordance with valve adjustment value table
D 13.00.00.
Page index: H 17.02.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Removal and installation of gearbox mounting ................................................................................... H 19.01.00
Fitting or removing adapter from gearbox swivel stand ...................................................................... H 19.02.00
Page index: H 19.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
012771
Page index: H 19.00.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Gearbox mounting
012772
1 = Gearbox mounting 2 = Fastening bolt
Removing and installing gearbox mounting
Removal
01 Unscrew fastening bolts (2).
02 Lift off gearbox mounting (1).
Installation
01 Fit gearbox mounting (1).
02 Screw in fastening bolts (2) and tighten.
Page index: H 19.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Gearbox mounting
012773.eps
Fitting or removing adapter from gearbox swivel

stand on gearbox housing
Installation Removal
01 If fitted, remove gearbox mounting as described 01 Remove adapter from gearbox housing.
in Section H 19.01.00.
02 If available, fit gearbox mounting as described
02 Fit adapter to gearbox housing (note type in Section H 19.01.00.
designation on adapter).
Page index: H 19.02.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Removing input flange .......................................................................................................................... H 21.01.00
Installing input flange ............................................................................................................................ H 21.02.00
Removing torsion coupling ................................................................................................................... H 21.03.00
Installing torsion coupling ..................................................................................................................... H 21.04.00
Page index: H 21.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
2
3
A
7 6 5
013816
1 = Input flange 6 = Pump holder 1X56 130 597

3 = Nut 1X56 137 226 8 = Oil injector 1X56 130 595
4 = Bolt 1X56 136 461 A = Distance approx. 12 - 15 mm
5 = High pressure pipe 1X56 130 601
Removing input flange
Removal
01 Arrangement of fixture as shown in diagram
! DANGER
Pull off input flange as described in Oil press-fit
Page index: H 21.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1
2
3
4
8 6
13 12 11 10
7
012776
1 = Input flange 8 = Intermediate piece 1X56 130 591

2 = Dial gauge with holder 9 = Pressure gauge 1X56 130 592
4 = Nut 1X56 137 226 11 = Pump holder 1X56 130 597
5 = Bolt 1X56 136 461 12 = Pressure gauge 1X56 130 604
6 = Reciprocating piston pump 1X56 130 589 13 = Oil injector 1X56 130 595
7 = Maximum pressure hose 1X56 130 588
Installing input flange
Installation
01 Arrangement of fixture as shown in diagram.
! DANGER
Pull off input flange as described in Oil press-fit
Observe push-on values in oil press-fit table
D 05.00.00.
Page index: H 21.02.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2 3 4 5
6
7
8
9
013817
1 = Torsion coupling 6 = Pressure piece 1X56 137 289

2 = High pressure pipe 1X56 130 601 7 = Hydraulic nut 1X56 137 227
3 = Pump holder 1X56 130 597 8 = Nut 1X56 137 226
4 = Pressure gauge 1X56 130 604 9 = Bolt 1X56 136 461
5 = Oil injector 1X56 130 595 A = Distance approx. 12 - 15 mm
Removing torsion coupling
Removal
! DANGER
Pull off torsion coupling as described in Oil press-
fit method Section D 05.00.00.
Page index: H 21.03.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2 3 4 5
6
7
8
11
10
12
14 13
012709
1 = Torsion coupling 8 = Nut 1X56 137 226

2 = High pressure pipe 1X56 130 601 9 = Screw 1X56 136 461
3 = Pump holder 1X56 130 597 10 = Reciprocating piston pump 1X56 130 589
4 = Pressure gauge 1X56 130 604 11 = Maximum pressure hose 1X56 130 588
5 = Oil injector 1X56 130 595 12 = Intermediate piece 1X56 130 591
6 = Pressure piece 1X56 137 289 13 = Pressure gauge 1X56 130 592
7 = Hydraulic nut 1X56 137 227 14 = Dial gauge with holder
Installing torsion coupling
Installation
! DANGER
Slide on torsion coupling as described in Oil
press-fit method Section D 05.00.00 .
D 05.00.00.
Page index: H 21.04.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Removing and installing flange-mounted bell housing ........................................................................ H 27.01.00
Page index: H 27.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
012778
Page index: H 27.00.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Flange-mounted bell
BW 196 (P) housing
1 2 3 4 5
6
7 012779
1 = Hex bolt 5 = Shaft seal

2 = Cover 6 = Stud
3 = Hex nut 7 = Bush
4 = Flange-mounted bell housing
Removing and installing flange-mounted bell

housing
01 The torsion coupling is removed in accordance

with H 21.00.00.
Removal
02 Unscrew fastening nut (3).
03 Lift off flange-mounted bell housing.
04 Drive shaft seal out of flange-mounted bell

housing (if necessary).
Page index: H 27.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P) Flange-mounted bell
BW 196 (P) housing
Installation
Shaft seals
a) Apply thin coat of sealing compound* to

outside of shaft seal with steel surround.
b) Apply coat of anti-friction agent such as water

soluble, fluid washing-up detergent (e.g. Pril) to
outside of shaft seal with rubber surround.
c) Apply coat of anti-friction agent such as water

soluble, fluid washing-up detergent (e.g Pril) to
outer rubber section of shaft seals with steel and
rubber surrounds.

sealing lips. The dust
protection lip (X) must face
X
outwards.
000102
e) 60 % of the intermediate gap between the two

dust protection lips should be filled with grease
(e.g. Aral Aralub HL2 or Texaco Texando FO
20).
01 Insert correct side of shaft seal (5) (depending

on version a or b) into flange-mounted bell
housing.
Lightly grease sealing lip of shaft seal.
02 If removed, insert bush (7) and stud (6).
03 Attach flange-mounted bell housing and screw

down.

produced by Marston
Page index: H 27.01.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Removing cover ................................................................................................................................... H 29.01.00
Installing cover ..................................................................................................................................... H 29.02.00
Page index: H 29.00.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
013818
Page index: H 29.00.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Cover
7 8
6
5 9 10
3
2
11
1
12 *
13
14
012783
1 = Cover 8 = M65x1.5 grooved nut * = P version

2 = M50x1.5 grooved nut 9 = Washer
3 = Three-armed extractor 10 = Segment (2 pieces)
4 = Pressure piece 11 = Circlip
5 = Cover 12 = Circlip
6 = Input gear 13 = Washer
7 = Cover 14 = Cover
Removing cover Removal
01 If necessary, remove pipes in accordance with NOTE

H 11.00.00. When using the P version, remove circlip (11 + 12),
washers (9 +13) and two segments.
02 Oil pump is removed in accordance with
H 15.01.00 05 Unlock grooved nut (8) and use wrench
1X56 137 223 to remove.
03 Input flange is removed in accordance with
H 21.01.00. 06 Remove cover (7).
04 Flange-mounted bell housing is removed (if 07 Remove covers (1, 5 + 14).

fitted) in accordance with H 27.01.00.
08 Unlock grooved nut (2) and use wrench
1X56 137 222 to remove.
09 Use three-armed extractor to pull off input gear

(6).
* Upper half of shaft illustrates Version P in

direction of rotation II; lower half of shaft illustrates
Version P in direction of rotation I
Page index: H 29.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Cover
1 2 3
1 = Cover
012785 2 = Outer race of cylinder roller
bearing
NOTE
Swivel gearbox so that the pump side is facing
upwards.
10 Unscrew fastening bolts of cover (1) and push

off cover.
11 Drive outer faces of cylinder roller bearing (2 +

3) out of cover.
Page index: H 29.01.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Cover
1 2 3
1 = Cover
2 = Outer face of cylinder roller
012785
bearing
Installation
- Reversing shaft is installed in accordance with

H 33.02.00.
- Input shaft is installed in accordance with

H 31.02.00.
- Insert outer races of cylinder roller bearing (2 +

3) in cover.
01 Apply thin coat of sealing compound* to

sealing faces on cover.
02 Carefully attach cover (1) to housing and screw

down.

Page index: H 29.02.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Cover
3 4 5 6
8 7
013819
03 Heat input gear (4) to approx. 85 °C and slide Shaft seals

correct side onto intermediate shaft.
a) Apply thin coat of sealing compound* to
04 Screw grooved nut (3) onto pump side of outside of shaft seal with steel surround.
reversing shaft and use wrench 1X56 137 222
to tighten and carefully secure in place. b) Apply coat of anti-friction agent such as water
05 Apply thin coat of sealing compound* to outside of shaft seal with rubber surround.
sealing faces of cover (1, 2 + 8) and install
cover. c) Apply coat of anti-friction agent such as water
soluble, fluid washing-up detergent (e.g Pril) to
06 Insert correct side of shaft seal (6) into cover outer rubber section of shaft seals with steel and
(5), depending on version. Lightly grease rubber surrounds.
sealing lip of shaft seal,
07 Apply thin coat of sealing compound* to sealing lips. The dust
sealing faces of cover (5) and attach to the protection lip (X) must face
X
housing. outwards.
000102
08 Depending on version, screw grooved nut (7) e) 60 % of the intermediate gap between the two
onto input shaft and use wrench 1X56 137 223 dust protection lips should be filled with grease
to tighten and carefully secure in place. (e.g. Aral Aralub HL2 or Texaco Texando FO
20).
09 Install flange-mounted bell housing (if
available) in accordance with H 27.00.00.
Page index: H 29.02.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Removing and disassembling input shaft ............................................................................................. H 31.01.00
Assembling and installing input shaft ................................................................................................... H 31.02.00
NOTE NOTE
When installing the input shaft, it is essential that the The standard gearbox input direction of rotation is
gearbox input direction of rotation is observed. clockwise, viewed when facing the gearbox input
Depending on the input direction of rotation, the ring flange.
and/or support shim (located to the left or right of the In special version gearboxes, the opposite direction of
pinion) must be installed. The diagrams in this manual rotation applies, i.e anti-clockwise, viewed when fac-
show direction of rotation I. ing the gearbox input flange.
There are no diagrams of the installation of the ring An arrow is attached to the input side of the gearbox
and/or support shim for direction of rotation II. There indicating the relevant direction of rotation.
are only text descriptions.


(II)

012786
Page index: H 31.00.00 - 01

BU 190
BU 195 (A)
Contents
013820
* depending on parts list

Parts lists: 3081 102 062, 075, 076
Page index: H 31.00.00 - 02

BU 190
Contents
013821
Parts list: 3081 102 058
Page index: H 31.00.00 - 03

BU 190
Contents
013822
* depending on parts list

Parts lists: 3081 102 032 , 088, 089, 092
Page index: H 31.00.00 - 04

BU 190
Contents
013823
Parts list: 3081 102 073
Page index: H 31.00.00 - 05

BW (BU) 190
Contents
Direction of rotation I without trolling
013824
Parts list: 3081 102 066
Page index: H 31.00.00 - 06

BW (BU) 190 S (P)
BW (BU) 195 S (P)
BW 196 (P) Contents
Direction of rotation I with trolling or prepared for trolling equipment
013825
Parts lists: 3081 102 043, 047, 051, 055, 074, 087, 093
Page index: H 31.00.00 - 07

BW 190 BW 190 S
BW 195 BW 195 S
Contents
013826
Parts lists: 3081 102 069, 071
Page index: H 31.00.00 - 08

BW 190
BU 195
Contents
Direction of rotation I with trolling or prepared for trolling equipment and PTO connection
013827
Parts lists: 3081 102 060, 075
Page index: H 31.00.00 - 09

BW 190
BW 195
Contents
Direction of rotation II with trolling or prepared for trolling equipment
013828
Parts lists: 3081 102 070, 072
Page index: H 31.00.00 - 10

BW 190 BW 190 S
BW 195 BW 195 S
Contents
Direction of rotation II without trolling
013829
Parts lists: 3081 102 065, 068
Page index: H 31.00.00 - 11

BW (BU) 190
BW 195 (P) BW 195 S
BW 196 (P) Contents
013824
Parts lists: 3081 102 064, 067
Page index: H 31.00.00 - 12

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Input shaft
*
Y X
14
2
15
3
7
19 20
16
13 12 11 10 9 8
17
18
012789
1 = Lifting device 1X56 137 225 13 = Reciprocating piston pump 1X56 130 589
2 = Self-aligning roller bearing 14 = Extension 1X56 137 474
3 = Seal ring bush 15 = Pressure piece 1X56 137 473
4 = Union nut 1X56 137 232 16 = Segment (2 pieces)
5 = Stud 1X56 137 232 17 = Washer
6 = Hydraulic nut 1X56 137 227 18 = Circlip
7 = Extractor plate 1X56 137 229 19 = High pressure pipe 1X56 130 601
8 = Bolt 1X56 136 461 20 = Oil injector 1X56 130 595
9 = Nut 1X56 137 226 X = Half-shaft, direction of rotation II
10 = High pressure hose 1X56 130 588 * = P version
11 = Pressure gauge 1X56 130 592 Y = Half-shaft, direction of rotation I
Page index: H 31.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
Removing and disassembling input shaft
NOTE
When using version P, once circlip (18) and washer
(17) have been removed, take both parts of segment
(16) out of bush.
02 Press input shaft out of self-aligning roller bear-

ing and lift out of housing.
03 Remove seal ring bush (3).
Page index: H 31.01.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2 3 4
012792
1 = Three-armed extractor 3 = Inner race of roller bearing

2 = Pressure piece 4 = Input shaft
Removing inner race of cylinder roller bearing
05 Pull out inner race of cylinder roller bearing (3).
Page index: H 31.01.00 - 03

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2 3 4 5 6 7 8 9 10
012793
1 = Oil injector 1X56 130 595 6 = Emergency control equipment

2 = Pressure gauge 1X56 130 604 7 = Constant gear
3 = Pump holder 1X56 130 597 8 = Piston
4 = High pressure pipe 1X56 130 601 9 = Rectangular section ring
5 = Hydraulic nut 1X56 137 227 10 = Input shaft
Removing constant gear
NOTE
The constant gears on the input and reversing shafts
must not be confused. A distinction can be made
between them by looking at the helical angle of the
gear teeth. The part number should always be
observed.
Gear with part no. 3081 302

Spare part no. 3081 202 for input shaft

Spare part no. 3081 203 for reversing shaft
06 Fixture arrangement as shown in diagram.
07 Pull off constant gear (7) as described in Oil

press-fit method Section D 05.00.00.
08 Take piston (8) out of constant gear.
09 If necessary, remove emergency control equip-

ment (6).
Page index: H 31.01.00 - 04

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2 3 4 5 6 7 8
9
012810
10
11
12
13
14
1 = Rectangular section ring 7 = Thrust washer

2 = Piston 8 = Input shaft
*2 = Piston for trolling or prepared for trolling equip- 9 = Circlip
ment version 10 = Bolt
3 = Rectangular section ring 11 = Compression spring
4 = Cup spring (6 pieces) 12 = Piston
5 = Inner disc 13 = Thread pin
6 = Outer disc 14 = Thread pin
08 Take rectangular section rings (1 + 3) out of

piston.
09 Remove 6 cup springs (4) from input shaft.
10 Lift inner and outer discs (5 + 6) of disc carrier.
11 Lift thrust washer (7) of disc carrier.
Page index: H 31.01.00 - 05

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
5 6 7 8 9
014825
13 12 11 10
5 = Slide-on disc 1X56 137 231

6 = Stud 1X56 137 232
11 = Pressure gauge 1X56 130 592
13 = Reciprocating piston pump 1X56 130 589
13 Arrangement of fixture as in diagram and pull

off inner disc carrier.
Page index: H 31.01.00 - 06

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2 3 4 5 6 7 8 9
10
012798
012798
14 13 12 11
1 = Input shaft 8 = Hydraulic nut 1X56 137 227

2 = Ring 9 = Slide-on disc 1X56 137 231
3 = Extractor plate 1X56 137 229 10 = Bolt 1X56 136 461
4 = Extractor ring 1X56 137 230 11 = High pressure hose 1X56 130 588
5 = Bush 12 = Pressure gauge 1X56 130 592
6 = Stud 1X56 137 232 13 = Intermediate piece 1X56 130 591
7 = Nut 1X56 137 226 14 = Reciprocating piston pump 1X56 130 589
* = P version A = End float 0.6 -1.0 mm
Pulling off bush
NOTE
In order to remove bush (5) and, depending on ver-
sion, ring (2), pinion with disc carrier or thrust washer,
groups H 31.01.00 - 03 to H 31.01.00 - 06 should not
be removed.
Removal
14 Arrangement of fixture as shown in diagram

and pull off bush (5) and remove.
Page index: H 31.01.00 - 07

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2 3 4 5 6 7
012799
1 = Input shaft 5 = Ring

2 = Support shim 6 = Three-armed extractor
3 = Thrust washer 7 = Pressure piece
4 = Pinion with outer disc carrier
Removing pinion with outer disc carrier
16 Pull off pinion with outer disc carrier (4) and,

depending on version, ring (5) and remove
NOTE
The figure shows input shaft version for gearbox input
direction of rotation I.
When using gearbox input direction of rotation II, ring
(5) is fitted in place of item 2 and 3 and support shim
(2) and thrust washer (3) are fitted in place of item 5.
Page index: H 31.01.00 - 08

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
5
X
1 2 3 4 3 Y
013832
1 = Input shaft X = Half-shaft, direction of rotation II

2 = Thrust washer * = P version
3 = Bearing bush Y = Half-shaft, direction of rotation I
4 = Bush
5 = Cylinder roller
Removing bearing bushes
17 When using gearbox input direction of rotation I,

remove thrust washer (2).
NOTE
The bearing bushes remain on the input shaft and are
not removed. They should however be protected from
possible damage.
If the bearing bushes are renewed, the bearing bushes
(3) should destroyed and removed (by breaking open
with a chisel).
18 Lift off bush (4).
19 If necessary heat support shim and/or ring

(depending on version) and use two screw-
drivers to press off from interference fit. When
using P version, lift off cylinder roller (5).
Page index: H 31.01.00 - 09

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2 3 4 5 6 7 8 9
10
11
12 13 14
012791
1 = Insert 1X56 137 278 8 = Nut 1X56 137 226

2 = Self-aligning roller bearing 9 = Stud 1X56 137 232
3 = Insert 1X56 137 278 10 = Bolt 1X56 136 461
4 = Union nut 1X56 137 232 11 = High pressure hose 1X56 130 588
5 = Collar nut 1X56 137 232 12 = Intermediate piece 1X56 130 591
6 = Extractor plate 1X56 137 229 13 = Pressure gauge 1X56 130 592
7 = Hydraulic nut 1X56 137 227 14 = Reciprocating piston pump 1X56 130 589
Removing self-aligning roller bearing
21 Take self-aligning roller bearing out of housing.
Page index: H 31.01.00 - 10

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
5
X
1 2 3 4 3 Y
013832
1 = Input shaft X = Half-shaft, direction of rotation II

4 = Bush
5 = Cylinder roller
Assembling and installing input shaft
01 When working with gearbox with input direc- CAUTION

tion of rotation I, heat support shim to approx. Slide bush (4) onto input shaft ensuring that the
85 °C and slide correct side onto input shaft. grooved nut in the inner diameter of the bush is on
When working with gearbox with input direc- the same side as the slid-on bearing bush.
tion of rotation II, heat ring to approx. 85 °C The grooved nut of bush (4) must be aligned the
(with the P version, fit cylinder roller (5) before right way round relative to the lube bore in the
sliding on ring) and slide onto input shaft. input shaft (for the P version, the grooved nut
should be in the centre of the bush).
02 Heat bearing bushes to approx. 120 °C.
04 Slide bearing bush (3) onto input shaft until
03 Slide bearing bush (3) onto input shaft until firmly home on the bush.
firmly home.
NOTE
Observe the figures in H 31.00.00 - 02 to
H 31.00.00 - 12 for the relevant version.
Page index: H 31.02.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2
013833
Installing inner disc carrier
NOTE
If the input shaft or inner disc carrier are needed
again, provided you have a suitable version, the inner
disc carrier can be fitted back on the input shaft.
05 Heat inner disc carrier (2) to max. 170 °C and

slide onto input shaft (1) until firmly home.
Page index: H 31.02.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2 3 4 5 5
013834
1 = Input shaft
2 = Support shim
3 = Thrust shim
4 = Pinion with outer disc carrier
5 = Support shim or bush
Installing pinion with outer disc carrier
06 Slide on thrust disc (3) depending on version. 09 Check end float of piston from outer disc carrier
(4). The end float must be between 0.6 and
07 Slide pinion and outer disc carrier (4) onto input 1.0 mm.
shaft.
10 Depending on the parts list, heat bush (5) to
NOTE approx. 100 °C and slide onto input shaft (1)
Depending on version, fit bush or ring (5) or support until firmly home.
shim (2) and thrust washer (3).
08 When working with gearbox with input direc-

tion of rotation I, heat bush or ring (5) to 85 °C
and slide onto input shaft.
When working with gearbox with input direc-
tion of rotation II, heat support shim (5) to
approx. 85 °C and slide onto input shaft with
thrust washer (thrust washer faces pinion).
Page index: H 31.02.00 - 03

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2 3 4 5 6 7 8
012795
9
10
11
12
13
14
1 = Rectangular section ring 8 = Input shaft

2 = Piston 9 = Circlip
*2 = Piston for trolling or prepared for trolling equip- 10 = Bolt
ment version 11 = Compression spring
3 = Rectangular section ring 12 = Piston
4 = Cup spring (6 parts) 13 = Threaded pin
5 = Inner disc 14 = Threaded pin
6 = Outer disc
7 = Thrust washer
Page index: H 31.02.00 - 04

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
Installing multi-disc pack
NOTE 11 Slide thrust washer (7) onto multi-disc carrier.

When sliding on the outer discs, note
the marking on the driving lugs. 12 Insert discs (5 + 6) in multi-disc carrier in
Each outer disc is marked on two accordance with gearbox type (in accordance
driving lugs. One mark is narrow with table for multi-disc configuration
and the other is wide. Insert the D 11.00.00). Discs should be inserted alternate-
outer discs as follows: ly as follows outer disc, inner disc. The first
the starting point for the insertion is disc should always be an outer disc and the
012796 the narrow mark and is always above instructions should be observed. When
superimposed. When inserting the using the correct multi-disc configuration, the
first disc, the wide mark is either to the right or left of multi-disc pack has the specified disc clearance.
the narrow mark. When inserting the next outer disc,
the wide mark must be offset to the right or left of the 13 Slide all 6 cup springs (4) onto input shaft in the
outer disc just inserted. correct order (see figure).
14 Insert new rectangular section rings (1 + 3) in

Example: annular groove of piston.
1 Outer disc, wide mark to the right of the narrow

mark.
2 Outer disc, wide mark to the left of the narrow

mark.
3 Outer disc, wide mark to the right of the narrow

mark etc. (see figure above).
Page index: H 31.02.00 - 05

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2 3 4 5 6 7 8 9 10
012794
14 13 12 11
1 = Oil injector 1X56 130 595 8 = Piston

2 = Pressure gauge 1X56 130 604 9 = Rectangular section ring
3 = Pump holder 1X56 130 597 10 = Input shaft
4 = High pressure pipe 1X56 130 597 11 = High pressure hose 1X56 130 588
6 = Emergency control equipment 13 = Intermediate piece 1X56 130 591
7 = Constant gear 14 = Reciprocating piston pump 1X56 130 589
Installing constant gear
15 Check emergency control equipment (6). If 18 Arrangement of fixture as shown in diagram.

removed from constant gear, install.
16 Insert piston (8) in constant gear. ! DANGER

Pull on constant gear as described in Oil press-fit
NOTE method Section D 05.00.00.
Stretch rectangular section ring (9) well before Observe push-on values in oil press-fit table
installing constant gear. D 05.00.00.
17 Slide on constant gear (7) with part no.

3081 202 , as described in Oil press-fit
method Section D 05.00.00 and measure push-
on dimension.
NOTE
Take care when pulling constant gear onto rectangular
section ring of piston. They must not be damaged.
Page index: H 31.02.00 - 06

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
013835
19 Heat inner race of cylinder roller bearing (1) to

approx. 85 °C and slide correct side onto input
shaft until firmly home.
1 2
013836
Installing self-aligning roller bearing
20 Heat output side of bearing bore (1) for self-

aligning roller bearing to approx. 60 °C.
21 Insert self-aligning roller bearing (2) in bearing

bore.
Page index: H 31.02.00 - 07

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
4 8
7
5
6
012790
1 = Lifting device 1X56 137 225 7 = Washer

2 = Input shaft 8 = Segment (2 pieces)
3 = Self-aligning roller bearing X = Half-shaft, direction of rotation II
4 = Extractor plate 1X56 137 229 * = P version
5 = Collar nut 1X56 137 232 Y = Half-shaft, direction of rotation I
6 = Circlip
Installing input shaft
22 Fit extractor plate (4) 1X56 137 229 as an 25 Heat seal ring bush to approx. 85 °C and slide
assembly aid and clamp with collar nuts (5). correct side onto input shaft.
23 Heat inner race of self-aligning roller bearing 26 Depending on version, fit grooved nut or two
(3) to approx. 85 °C and insert input shaft in segments (8), washer (7) and circlip.
self-aligning roller bearing.
27 Fit cover in accordance with H 29.02.00.
24 Remove extractor plate (4) (assembly aid).
Page index: H 31.02.00 - 08

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Removing and disassembling reversing shaft ....................................................................................... H 33.01.00
Assembling and installing reversing shaft ............................................................................................ H 33.02.00
NOTE NOTE
When installing the reversing shaft, it is essential that The standard gearbox input direction of rotation is
the gearbox input direction of rotation is observed. clockwise, viewed when facing the gearbox input
Depending on the input direction of rotation, the ring flange.
and/or support shim (located to the left or right of the In special version gearboxes, the opposite direction of
pinion) must be installed. The diagrams in this manual rotation applies, i.e. anti-clockwise, viewed when
show direction of rotation I. facing the gearbox input flange.
There are no diagrams of the installation of the ring An arrow is attached to the input side of the gearbox
and/or support shim for direction of rotation II. There indicating the relevant direction of rotation.
are only text descriptions.


(II)

012801
Page index: H 33.00.00 - 01

BU 190
Contents
013837
Parts list: 3081 103 049
Page index: H 33.00.00 - 02

BU 190
BU 195 (S) (A)
Contents
013838
Parts lists: 3081 103 031, 048, 050, 056, 075, 076
Page index: H 33.00.00 - 03

BU 190
BU 195 (S)
Contents
013839
Parts lists: 3081 103 065, 072
Page index: H 33.00.00 - 04

BW (BU) 190 (S)
BW 195 (S)
Contents
013840
Parts lists: 3081 103 058, 059, 060
Page index: H 33.00.00 - 05

BW 190
Contents
013841
Parts list: 3081 103 061
Page index: H 33.00.00 - 06

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Contents
Direction of rotation with trolling or prepared for trolling equipment
013842
Parts lists: 3081 103 035, 036, 037, 038, 041, 045
Page index: H 33.00.00 - 07

BW 195 BW 195 S
Contents
013843
Parts list: 3081 103 068
Page index: H 33.00.00 - 08

BW 190 BW 190 S
BW 195 BW 195 S
Contents
Direction of rotation II without trolling
013844
Parts lists: 3081 103 062, 063
Page index: H 33.00.00 - 09

BW 190 BW 190 S
BW 195
Contents
Direction of rotation II with trolling or prepared for trolling equipment
013845
Parts lists: 3081 103 066, 067, 069
Page index: H 33.00.00 - 10

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
BW 196 (P) Reversing shaft
Y X
13
17
7
16
14
6 5 4 3 15 012804
12 11 10 9 8
1 = Lifting device 1X56 137 225 11 = Hydraulic nut 1X56 137 227
2 = Reversing shaft 12 = Self-aligning roller bearing
3 = Reciprocating piston pump 1X56 130 589 13 = Pressure piece 1X56 137 473
4 = Intermediate piece 1X56 130 591 14 = Washer
5 = Pressure gauge 1X56 130 592 15 = Circlip
6 = High pressure hose 1X56 130 588 16 = High pressure pipe 1X56 130 601
7 = Union nut 1X56 137 232 17 = Oil injector 1X56 130 595
8 = Extractor plate 1X56 137 229 X = Half-shaft, direction of rotation II
9 = Bolt 1X56 136 461 * = P version
10 = Nut 1X56 137 226 Y = Half-shaft, direction of rotation I
Removing and disassembling reversing shaft
NOTE 01 Depending on version, arrangement of fixture

The input shaft does not have to be removed, for the as shown in diagram.
reversing shaft to be removed.
02 Press reversing shaft out of self-aligning roller
bearing and lift out of housing.
Page index: H 33.01.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2 3 4
012807
1 = Three-armed extractor 3 = Reversing shaft

2 = Pressure piece 4 = Inner race of roller bearing
Removing inner race of cylinder roller bearing
04 Pull out inner race of cylinder roller bearing (4).
Page index: H 33.01.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2 3 4 5 6 7 8 9 10
012808
1 = Oil injector 1X56 130 595 6 = Reversing shaft

2 = Pressure gauge 1X56 130 604 7 = Emergency control equipment
3 = Pump holder 1X56 130 597 8 = Constant gear
4 = High pressure pipe 1X56 130 601 9 = Piston
5 = Hydraulic nut 1X56 137 227 10 = Rectangular section ring
Removing constant gear
NOTE 05 Fixture arrangement as shown in diagram.

The constant gears on the input and reversing shaft
must not be confused. A distinction can be made
between them by looking at the helical angle of the ! DANGER
gear teeth. The part number should always be Pull off constant gear (8) as described in Oil
observed. press-fit method Section D 05.00.00.

Spare part no. 3081 202 for input shaft 06 Take piston (9) out of constant gear.
Gear with part no. 3081 303 07 If necessary, remove emergency control
Spare part no. 3081 203 for reversing shaft equipment (7).
Page index: H 33.01.00 - 03

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2 3 4 5 6 7 8
9
012810
10
11
12
13
14

2 = Piston 8 = Reversing shaft
*2 = Piston for trolling or prepared for trolling 9 = Circlip
equipment version 10 = Bolt
4 = Cup spring (6 pieces) 12 = Piston
5 = Inner disc 13 = Thread pin
6 = Outer disc 14 = Thread pin
08 Take rectangular section rings (1 + 3) out of

piston.
09 Remove 6 cup springs (4) from reversing shaft.
10 Lift inner and outer discs (5 + 6) of disc carrier.
11 Lift thrust washer (7) of disc carrier.
Page index: H 33.01.00 - 04

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
5 6 7 8 9
13 12 11 10
014825
5 = Slide-on disc 1X56 137 231 10 = High pressure hose 1X56 130 588
6 = Stud 1X56 137 232 11 = Pressure gauge 1X56 130 592
7 = Hydraulic nut 1X56 137 227 12 = Intermediate piece 1X56 130 591
8 = Extractor plate 1X56 137 229 13 = Reciprocating piston pump 1X56 130 589
15 Pull off inner disc carrier.
Page index: H 33.01.00 - 05

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2 3 4 5 6 7
8
012813
10
11
A
1 = Reversing shaft 8 = High pressure pipe 1X56 130 601

2 = Ring 9 = Pressure piece 1X56 137 473
3 = Pinion with outer disc carrier 10 = Bush
4 = Thrust washer 11 = Cylinder roller
5 = Support shim * = P version
6 = Three-armed extractor A = End float 0.6 -1.0 mm
7 = Oil injector 1X56 130 595
Removing pinion and outer disc carrier
NOTE NOTE
In order to remove support shim (5), thrust washer (4) In the P version, bush (10) generally remains in the
or pinion and outer disc carrier (3), groups H 33.01.00 self-aligning roller bearing (refer to H 33.01.00 - 01),
- 02 to H 33.01.00 - 06 should not be removed. and the bush must be removed, the oil injector (7) and
pressure piece (9) must be fitted and the pinion pulled
NOTE off with the two-armed extractor.
The figure shows the reversing shaft version fitted in
gearbox input direction of rotation I. For gearbox 16 Arrangement of fixture as shown in diagram.
input direction of rotation II, support shim (5) and
thrust washer (4) should be fitted in place of ring (2). 17 Depending on the version, pull off pinion with
outer disc carrier (3) and support shim (5) with
thrust washer (4) and remove. Depending on
version, take cylinder roller (11) out of
reversing shaft.
Page index: H 33.01.00 - 06

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 3 4 5 4
Y
2 012814
6
1 = Reversing shaft 6 = Cylinder roller

2 = Ring X = Half-shaft, direction of rotation II
5 = Bush
Removing bearing bushes
18 When using gearbox input direction of rotation

II, remove thrust washer (3).
NOTE
The bearing bushes remain on the reversing shaft and
are not removed. They should however be protected
from possible damage. If the bearing bushes are
renewed, the bearing bushes should be destroyed and
removed (by breaking open with a chisel).
19 Lift off bush (5).
20 If necessary, heat support shim and/or ring

(depending on version) and use two screw-
drivers to press off from interference fit. When
using (P) version, lift off cylinder roller (6).
Page index: H 33.01.00 - 07

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2 3 4 5 6 7 8 9
10
13 14
11 12
012806
1 = Insert 1X56 137 278 8 = Nut 1X56 137 226

2 = Self-aligning roller bearing 9 = Stud 1X56 137 232
3 = Housing 10 = Bolt 1X56 136 461
4 = Union nut 1X56 137 232 11 = High pressure hose 1X56 130 588
5 = Collar nut 1X56 137 232 12 = Intermediate piece 1X56 130 591
Removing self-aligning roller bearing
22 Take self-aligning roller bearing out of housing.
Page index: H 33.01.00 - 08

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 3 4 5 4
Y
2 012814
6
1 = Reversing shaft 6 = Cylinder roller

2 = Ring X = Half-shaft, direction of rotation II
5 = Bush
Assembling and installing reversing shaft
NOTE CAUTION
Observe figures H 33.00.00 - 02 to H 33.00.00 - 10 Slide bush (5) onto input shaft ensuring that
for the relevant version. grooved nut in the inner diameter of the bush is on
the same side as the slid-on bearing bush.
01 When working with gearbox with input The grooved nut of bush (5) must be aligned the
direction of rotation I, heat ring (2) to approx. right way round relative to the lube bore in the
85 °C and slide onto reversing shaft. input shaft (for version (P), the grooved nut should
When working with gearbox with input be in the centre of the bush).
direction of rotation II, heat support shim to
approx. 85 °C (with version (P), fit cylinder 04 Slide bearing bush (4) onto reversing shaft until
roller (6) before sliding onto ring (2)) and slide firmly home on the bush (5).
onto reversing shaft.
02 Heat bearing bush (4) to approx. 120 °C.
03 Slide bearing bush (4) onto reversing shaft until

firmly home.
Page index: H 33.02.00 - 01

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2
013846
Installing inner disc carrier
NOTE
If the reversing shaft or inner disc carrier are needed
again, provided you have a suitable version, the inner
disc carrier can be fitted back on the input shaft.
Heat inner disc carrier (2) to max. 170 °C and slide
correct side onto reversing shaft (1) until firmly home.
Page index: H 33.02.00 - 02

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2 3 4
5 013847
Installing pinion with outer disc carrier
05 Slide pinion (5) onto reversing shaft (1).
06 Slide on thrust washer (2) depending on

version.
NOTE
Depending on version, fit bush (4) or support shim (3)
and thrust washer (2). (Figure shows direction of
rotation I.)
07 Check end float of piston. The end float must be

between 0.6 - 1.0 mm.
Page index: H 33.02.00 - 03

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2 3 4 5 6 7 8
9
012810
10
11
12
13
14

2 = Piston 8 = Reversing shaft
*2 = Piston for trolling or prepared for trolling 9 = Circlip
equipment 10 = Bolt
4 = Cup spring (6 parts) 12 = Bolt
5 = Inner disc 13 = Threaded pin
6 = Outer disc 14 = Threaded pin
Page index: H 33.02.00 - 04

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
Installing multi-disc pack 08 Slide thrust washer (7) onto multi-disc carrier.
NOTE 09 Insert discs (5 + 6) in multi-disc carrier in

When sliding on the outer discs, note accordance with gearbox type (in accordance
the marking on the driving lugs. with table for multi-disc configuration
Each outer disc is marked on two D 11.00.00). Discs should be inserted
driving lugs. One mark is narrow and alternately as follows outer disc, inner disc.
the other is wide. Insert the outer The first disc should always be an outer disc
discs as follows: and the above instructions should be observed.
the starting point for the insertion is When using the correct multi-disc
012811 the narrow mark and is always configuration, the multi-disc pack has the
superimposed. When inserting the specified disc clearance.
first disc, the wide mark is either to the right or left of
the narrow mark. When inserting the next outer disc, 10 Slide all 6 cup springs (4) onto input shaft in the
the wide mark must be offset to the right or left of the correct order (see figure).
outer disc just inserted.
11 Insert new rectangular section rings (1 + 3) in
annular groove of piston.
Example:
a) Outer disc, wide mark to the right of the narrow

mark.
b) Outer disc, wide mark to the left of the narrow

mark.
c) Outer disc, wide mark to the right of the narrow

mark etc. (see figure above).
Page index: H 33.02.00 - 05

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2 3 4 5 6 7 8 9 10
012809
14 13 12 11
1 = Oil injector 1X56 130 595 8 = Constant gear

2 = Pressure gauge 1X56 130 604 9 = Piston
3 = Pump holder 1X56 130 597 10 = Rectangular section ring
4 = High pressure tube 1X56 130 601 11 = High pressure hose 1X56 130 588
6 = Reversing shaft 13 = Intermediate piece 1X56 130 591
7 = Emergency control equipment 14 = Reciprocating piston pump 1X56 130 589
Installing constant gear
12 Check emergency control equipment, if 15 Arrangement of fixture as shown in diagram.

removed from constant gear, install.
13 Insert piston (9) in constant gear (8). ! DANGER

Pull on constant gear as described in Oil press-fit
NOTE method Section D 05.00.00.
Stretch rectangular section ring (10) well before Observe push-on values in oil press-fit table
installing constant gear. D 05.00.00.
14 Slide on constant gear (8) with part no. 3081

203 , as described in Oil press-fit method
Section D 05.00.00 and measure push-on
dimension.
NOTE
Take care when pulling constant gear onto rectangular
section ring. They must not be damaged.
Page index: H 33.02.00 - 06

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
1 2
013848
1 = Reversing shaft
2 = Inner race of roller bearing
16 Heat inner race of cylinder roller bearing (2) to

approx. 85 °C and slide correct side onto
reversing shaft until firmly home.
1 2
10
13
11 12
013849
1 = Self-aligning roller bearing
2 = Housing
Installing self-aligning roller bearing
17 Heat bearing bore for reversing shaft to approx.

60 °C.
18 Insert self-aligning roller bearing (1) in bearing

bore (2).
Page index: H 33.02.00 - 07

BW (BU) 190 (P) BW (BU) 190 S (P)
BW (BU) 195 (P) BW (BU) 195 S (P)
3
Y X
4
7 6 5 012805
1 = Lifting device 1X56 137 225 6 = Washer

2 = Reversing shaft 7 = Circlip
3 = Self-aligning roller bearing X = Half-shaft, direction of rotation II
4 = Extractor plate 1X56 137 229 * = P version
5 = Union nut 1X56 137 232 Y = Half-shaft, direction of rotation I
Installing reversing shaft
19 Fit extractor plate (4) 1X56 137 229 to input 21 Fit extractor plate (4) (assembly aid) again.
side as an assembly aid.
22 Depending on version, fit grooved nut or
20 Heat inner race of self-aligning roller bearing washer (6) and circlip (7).
(3) to approx. 85 °C and insert reversing shaft
in self-aligning roller bearing.
Page index: H 33.02.00 - 08

BW (BU) 190 (P)
BW (BU) 195 (P)
Contents
Removing and dismantling output shaft ............................................................................................... H 37.01.00
Assembling and installing output shaft ................................................................................................ H 37.02.00
Page index: H 37.00.00 - 01

BW (BU) 190 (P)
BW (BU) 195 (P)
Contents
012815
Page index: H 37.00.00 - 02

BW (BU) 190 (P)
BW (BU) 195 (P)
Output shaft
1 2 3 4 5 6 7 8 9
A
13 10
11
12
012816
1 = Cover 8 = Outer race of cylinder roller bearing

2 = Oil injector 1X56 130 595 9 = Cover
3 = Pressure gauge 1X56 130 592 10 = Oil tray
4 = Pump holder 1X56 130 597 11 = Gasket
5 = High pressure pipe 1X56 130 601 12 = Cover
6 = Helical gear 13 = Hex bolt
7 = Inner race of cylinder roller bearing A = Distance approx. 10 mm
Removing cover, pulling off helical gear
- Oil pump is removed in accordance with 02 Remove cover (9).

H 15.02.00.
03 Remove cover (12) and take off gasket (11).
- Input shaft is removed in accordance with
H 31.00.00. 04 Unscrew fastening bolts (13) from oil tray and
take off oil tray (10).
- Reversing shaft is removed in accordance with
H 33.00.00. 05 Move output shaft by dimension A.

Removal
07 Pull off helical gear as described in Oil press-
01 Unscrew fastening bolts from cover (1). fit method Section D 05.00.00.
Page index: H 37.01.00 - 01

BW (BU) 190 (P)
BW (BU) 195 (P)
Output shaft
11 12 13 14 15
10
9
8
6 16
5
4
3
17
1 012817
1 = Output shaft 10 = Set of screws 1X56 137 232

2 = Cover 11 = Bolt 1X56 136 461
3 = Output gear 12 = High pressure hose 1X56 130 588
4 = Inner race of cylinder roller bearing 13 = Intermediate piece 1X56 130 591
5 = Outer race of cylinder roller bearing 14 = Pressure gauge 1X56 130 592
7 = Insert 1X56 137 278 16 = Union nut 1X56 137 232
8 = Hydraulic nut 1X56 137 227 17 = Set of screws 1X56 137 232
Removing output shaft
08 Push output shaft towards side of pump and

push as far as possible.
09 Swivel gearbox through 90°, output flange

should be pointing downward.
Page index: H 37.01.00 - 02

BW (BU) 190 (P)
BW (BU) 195 (P)
Output shaft
NOTE
Fit chocks under or screw 3 studs (17),
and collar nuts into fastening points on cover to
ensure that the output shaft cannot fall out.
10 Use mandrel to drive outer race of cylinder

roller bearing (5) out of housing.
11 Push out output shaft, as shown in the diagram.
12 Remove inner race of cylinder roller bearing.
13 Once fixtures have been removed, take out

output shaft.
14 Take output gear out of housing.
Page index: H 37.01.00 - 03

BW (BU) 190 (P)
BW (BU) 195 (P)
Output shaft
1 2 3 4 5 6 7 8 9 10 11 12
13
14
012818
21 20 19 18 17 16 15
1 = Output shaft 12 = Extractor plate 1X56 137 229

2 = Seal ring 13 = Bolt 1X56 136 461
3 = Cover 14 = High pressure hose 1X56 130 588
4 = Tapered roller bearing 15 = Pressure gauge 1X56 130 592
5 = Inner race of axial roller bearing 16 = Intermediate piece 1X56 130 591
6 = Ring 17 = Reciprocating piston pump 1X56 130 589
7 = Grooved nut 18 = Stud 1X56 137 232
8 = Union nut 1X56 137 232 19 = Slide-on washer 1X56 137 231
9 = Stud 1X56 137 232 20 = Extractor hook 1X56 137 448
10 = Nut 1X56 137 226 21 = Washer
Removing propeller thrust bearing
15 Unlock M90x1.5 grooved nut (7) and use 17 Arrangement of fixture as shown in diagram.
wrench 1X56 137 224 to unscrew.
18 Pull off inner race of axial roller bearing (5), as
16 Lift ring (6) off output shaft. shown in the diagram (heat inner race of
bearing if necessary).
Page index: H 37.01.00 - 04

BW (BU) 190 (P)
BW (BU) 195 (P)
Output shaft
1 2 3 4 5 6 7 8 9
10
11
012820
14 13 12
1 = Slide-on washer 1X56 137 231 8 = Hydraulic nut 1X56 137 227
2 = Input gear 9 = Extractor plate 1X56 137 229
3 = Stud 1X56 137 232 10 = Bolt 1X56 136 461
4 = Output shaft 11 = High pressure hose 1X56 130 588
5 = Union nut 1X56 137 232 12 = Pressure gauge 1X56 130 592
Removing input gear
23 Pull off input gear, as shown in diagram.
Page index: H 37.01.00 - 06

BW (BU) 190 (P)
BW (BU) 195 (P)
Output shaft
1 2 3 4 5 6 7 8 9 10 11 12
13
14
18
012819
17 16 15
1 = Output shaft 10 = Nut 1X56 137 226

2 = Shaft seal 11 = Hydraulic nut 1X56 137 227
3 = Cover 12 = Extractor plate 1X56 137 229
4 = Tapered roller bearing 13 = Bolt 1X56 136 461
5 = Slide-on washer 1X56 137 231 14 = High pressure hose 1X56 130 588
6 = Hex bolt 1X56 137 232 15 = Pressure gauge 1X56 130 592
8 = Union nut 1X56 137 232 17 = Reciprocating piston pump 1X56 130 589
9 = Stud 1X56 137 232 18 = Hex bolt 1X56 137 232
19 Tilt the cover to remove cover bolts.
20 Pull off cover (3) and tapered roller bearing (4)

as shown in the diagram.
NOTE
When pulling cover off, the input gear pushes the
shaft seals out of the cover.
21 Drive outer race of tapered roller bearing out of

the cover.
Page index: H 37.01.00 - 05

BW (BU) 190 (P)
BW (BU) 195 (P)
Output shaft
1 2
012821
1 = 60 % of the gap between the two sealing lips is 2 = Input gear

filled with DIN 51502 multigrade grease. A = Distance approx. 4 mm
Assembling and installing output shaft d) The duo shaft seal has two
sealing lips. The dust
NOTE protection sealing lip (X)
Shaft seals should generally be changed during a must face outwards. X
major overhaul.
000102
When using the version with two shaft seals, a duo e) 60 % of the gap between the sealing lips should
shaft seal is usually fitted. be filled with grease (e.g. Aral Aralub HL2, or
Texaco Texando FO 20).
Shaft seals
01 Use special tool 1X56 137 260 to insert correct
a) Apply thin coat of sealing compound* to side of duo shaft seal into cover (if necessary,
outside of shaft seal with steel surround. rework special tool 1X56 137 260).
b) Apply anti-friction agent such as a water- 02 Check distance A.

outside of shaft seal with rubber surround. 03 60 % of the gap (1) between the two sealing lips
should be filled with grease DIN 51502.
c) Apply anti-friction agent such as a water-
soluble, fluid washing-up detergent (e.g.Pril) to 04 Slide cover onto output shaft.
outside of rubber surround of shaft seals with
steel and rubber surrounds. 05 Heat input gear (2) to approx. 85 °C and slide
correct side onto output shaft.
Page index: H 37.02.00 - 01

BW (BU) 190 (P)
BW (BU) 195 (P)
Output shaft
6
5
4
3
1
012823
1 = Output shaft 5 = Washer

2 = Cover 6 = Inner race of axial roller bearing
3 = Outer race of tapered roller bearing 7 = Ring
4 = Inner race of tapered roller bearing 8 = Grooved nut
06 Heat bearing bore for outer race of tapered 10 Heat inner race of axial roller bearing (6) to
roller bearing in cover (2) to approx. 60 °C and approx. 85 °C and slide correct side onto output
insert correct side of outer race of tapered roller shaft.
bearing into cover.
11 Slide ring (7) onto inner race of axial roller
07 Insert the M12x70 hex bolts for the cover bearing until firmly home.
fastening into the relevant cover bores.
12 Screw on M90x1.5 grooved nut and use wrench
08 Heat inner race of tapered roller bearing to 1X56 137 224 to tighten to approx. 800 Nm.
approx. 85 °C and slide onto input gear until Carefully lock grooved nut.
firmly home.
09 Place washer (5) on inner race of tapered roller

bearing.
Page index: H 37.02.00 - 02

BW (BU) 190 (P)
BW (BU) 195 (P)
Output shaft
1 2 3 4 5 6
12 11 10
012824
1 = Output shaft 7 = Dial gauge

2 = Washer 8 = Dial gauge holder
3 = Compression spring (4 pieces) 9 = High pressure hose 1X56 130 588
4 = Union nut 1X56 137 232 10 = Pressure gauge 1X56 130 604
NOTE 16 Insert output shaft (as vertical as possible) into

The end float of the propeller thrust bearing must be housing.
between 0.05 and 0.1 mm at a preload of approx.
4 000 N. This preload is ensured by compression 17 Screw in fastening bolts of cover and fasten.
springs.
18 Rotate output shaft to left and right several
times.
13 Insert 4 compression springs (3) in blind bores
in the housing bore for propeller thrust bearing. 19 Arrangement of fixture as shown in diagram.
14 Insert washer (2) in housing bore for propeller 20 Attach dial gauge to output shaft and measure
thrust bearing. end float.
15 Insert outer race of axial bearing for propeller

thrust bearing.
Page index: H 37.02.00 - 03

BW (BU) 190 (P)
BW (BU) 195 (P)
Output shaft
NOTE
The compression springs push the output shaft
towards the output flange (1st measurement, set dial
gauge to 0). If you wish to pressure the output shaft
towards the input side, the pressure (resistance) of the
compression springs has to be overcome, approx.
4 000 N (pressurize hydraulic nut, pressure gauge of
reciprocating piston pump should not indicate more
than 25 bar). Check dial gauge reading in this
position, variation of dial gauge = end float
21 Remove output shaft again.
22 Correct washer (2) ahead of outer race of axial

roller bearing according to the end float
measurement.
23 Repeat measurement if possible and remove

output shaft.
Page index: H 37.02.00 - 04

BW (BU) 190 (P)
BW (BU) 195 (P)
Output shaft
1 2 3 4 5 6 7 8 9 10
11
14 15 16
12
13
012825
18 17
1 = O-ring 10 = Pressure piece 1X56 137 277

2 = Outer race of axial bearing 11 = Hydraulic nut 1X56 137 227
3 = Washer 12 = Output shaft
4 = Compression spring (4 pieces) 13 = High pressure hose 1X56 130 588
5 = High pressure pipe 1X56 130 601 14 = Pressure gauge 1X56 130 592
6 = Pressure gauge 1X56 130 604 15 = Intermediate piece 1X56 130 591
7 = Pump holder 1X56 130 597 16 = Reciprocating piston pump 1X56 130 589
8 = Oil injector 1X56 130 595 17 = Extractor plate 1X56 137 229
9 = Output gear 18 = Dial gauge holder with dial gauge
24 Swivel housing through 90° (output side faces 27 Place corrected washer (3) on axial roller
upwards). bearing.
25 Place correct side of output gear (9) in the 28 Apply thin coat of sealing compound* to cover.
housing (small diameter of cone faces input
side). 29 Insert O-ring in annular groove of cover.
26 Insert 4 compression springs (4).
Page index: H 37.02.00 - 05

BW (BU) 190 (P)
BW (BU) 195 (P)
Output shaft
XX
012826
NOTE NOTE
Sealing compound** applied to the XX area of the The push-on length of the helical gear must be
cover during assembly. observed (check with dial gauge while pulling on).
30 Insert output shaft in housing and helical gear.

Apply sealing compound** to the XX position ! DANGER
when attaching. Pull on helical gear as described in Oil press-fits
method Section D 05.00.00. Observe push-on
31 Screw fastening bolts into cover and tighten. values in oil press-fit table D 05.00.00.
32 Swivel gearbox through 90° (output shaft is

horizontal).
* Sealing compound Hylomar SQ 32 M,

** Sealing compound Terostat-33, produced by

Teroson
Page index: H 37.02.00 - 06

BW (BU) 190 (P)
BW (BU) 195 (P)
Output shaft
1 2 3
6 4
5
7
012827
1 = Inner race of cylinder roller bearing 5 = Gasket

2 = Outer race of cylinder roller bearing 6 = Hex bolts
3 = Cover 7 = Cover
4 = Oil tray
34 Heat inner face of cylinder roller bearing (1) to 36 Insert oil tray (4) and screw down.
approx. 85 °C and slide correct side onto output
shaft and leave to cool. 37 Fit cover (7) and gasket (5).
35 Insert outer race of cylinder roller bearing (2) 38 Apply thin coat of sealing compound to sealing
(once housing bore has been heated to approx. faces on cover (3) and attach to housing (in so
60 °C) into housing bore. Observe distance B doing, outer race of cylinder roller bearing is
when inserting. Distance B should be approx. pushed into correct installation position).
0.5 mm smaller than distance A.
* Sealing compound Hylomar SQ 32 M,

Page index: H 37.02.00 - 07

BW (BU) 190 S (P)
BW (BU) 195 S (P)
Contents
Removing and dismantling output shaft ............................................................................................... H 39.01.00
Installing output shaft ........................................................................................................................... H 39.02.00
Page index: H 39.00.00 - 01

BW (BU) 190 S (P)
BW (BU) 195 S (P)
Contents
012828
Page index: H 39.00.00 - 02

BW (BU) 190 S (P)
BW (BU) 195 S (P)
Output shaft
1 2 3 4
8 5
6
7
012829
1 = Cover 5 = Oil tray

2 = O-ring 6 = Gasket
3 = Circlip 7 = Cover
4 = Washer 8 = Hex bolt
Removing and dismantling output shaft
- Input shaft is removed in accordance with 01 Remove cover (1).

H 31.01.00.
02 Lift off O-ring (2).
H 33.01.00. 03 Snap circlip (3) out of annular groove of input
shaft.
- Oil pump is removed in accordance with
H 15.03.00. 04 Lift off washer (4).
05 Remove cover (7).
06 Lift off (6) gasket.
07 Remove oil tray (5).
Page index: H 39.01.00 - 01

BW (BU) 190 S (P)
BW (BU) 195 S (P)
Output shaft
1 2 3 4 5 6 7 8
12
9
11
10
13
012830
1 = Bolt 1X56 136 461 8 = Input gear

2 = Slide-on washer 1X56 137 231 9 = Reciprocating piston pump 1X56 130 589
3 = Set of screws 1X56 137 232 10 = High pressure hose 1X56 130 588
5 = Nut 1X56 137 226 12 = Pressure gauge 1X56 130 592
6 = Extractor plate 1X56 137 229 * = BU 190 S, BU 195 S
7 = Hex bolt (3) 1X56 137 233 13 = Support rod 1X56 137 536
10 Once input gear (8) is removed, take Woodruff

key out of input shaft.
Page index: H 39.01.00 - 02

BW (BU) 190 S (P)
BW (BU) 195 S (P)
Output shaft
1 2 3 4 5 6 7 8 9
13
10
12
11 012831
1 = Bolt 1X56 136 461 8 = O-ring

2 = Slide-on washer 1X56 137 231 9 = Compression spring
3 = Set of screws 1X56 137 290 10 = Reciprocating piston pump 1X56 130 589
4 = Hydraulic nut 1X56 137 227 11 = High pressure hose 1X56 130 588
5 = Nut 1X56 137 226 12 = Intermediate piece 1X56 130 591
6 = Cover 13 = Pressure gauge
7 = Tapered roller bearing
12 Pull off cover (6) and tapered roller bearing (7).
13 Remove compression springs (9).
14 Remove O-ring (8).
Page index: H 39.01.00 - 03

BW (BU) 190 S (P)
BW (BU) 195 S (P)
Output shaft
1 2 3 4 5 6 7 8
12
9 012832
11
10
1 = Bolt 1X56 136 461 7 = Extracting disc 1X56 137 233

2 = Slide-on washer 1X56 137 231 8 = Bearing bush & axial roller bearing
3 = Set of screws 1X56 137 232 9 = Reciprocating piston pump 1X56 130 589
4 = Hydraulic nut 1X56 137 227 10 = High pressure hose 1X56 130 588
5 = Nut 1X56 137 226 11 = Intermediate piece 1X56 130 591
16 Pull off bearing bush (8) and axial roller

bearing.
17 Use load sling to hold output shaft in

installation position.
18 Pull axial roller bearing and bearing bush (8)

off output shaft.
19 Continue holding output shaft in installation

position.
Page index: H 39.01.00 - 04

BW (BU) 190 S (P)
BW (BU) 195 S (P)
Output shaft
8 9 10 11 12 13
1 2 3 4 5 6 7
012833
1 = Bolt 1X56 136 461 8 = Angle ring

2 = Nut 1X56 137 226 9 = Extension 1X56 137 082
4 = Pipe 1X56 137 234 11 = Pump holder 1X56 130 597
5 = Output shaft 12 = Pressure gauge 1X56 130 592
6 = Slide-on washer 1X56 137 231 13 = Oil injector 1X56 130 595
7 = Output gear A = Distance approx. 15 mm
NOTE 20 Arrangement of fixture as shown in diagram.

Note sequence of fixture installation. Fit pipe (observe distance A)
1X56 137 334 and slide-on washer 1X56 137 231.
Remove load sling, then move output shaft to install
extension 1X56 137 082. ! DANGER
Pull off output gear as described in Oil press-fit
21 Dismantle all of fixture apart from pipe and

slide-on washer.
Page index: H 39.01.00 - 05

BW (BU) 190 S (P)
BW (BU) 195 S (P)
Output shaft
012834
1 = Pipe 1X56 137 234 6 = Outer race of cylinder roller bearing

2 = Slide-on washer 1X56 137 231 7 = Seal ring cover
3 = Output gear 8 = Collar nut 1X56 137 232
4 = Angle ring 9 = Hook 1X56 136 564
5 = Output shaft
22 Swivel gearbox through 90° (output side faces 27 Remove seal ring cover (7) from housing.
upwards).
28 Drive outer race of cylinder roller bearing (6)
23 Lift output shaft out of housing as shown in out of housing.
diagram.
29 Drive seal rings out of seal ring cover.
24 Take angle ring (4) off output gear.
30 If necessary, driver inner race of cylinder roller
25 Take output gear (3) out of housing. bearing off output shaft once inner race has
been heated.
26 Remove fixture (1) and (2).
Page index: H 39.01.00 - 06

BW (BU) 190 S (P)
BW (BU) 195 S (P)
Output shaft
1
2
3
6
5 4
012835
1 = Duo shaft seal 5 = Pipe 1X56 137 234

2 = Gap (filled 60 % with multi-grade grease) 6 = Slide-on washer 1X56 137 231
3 = Seal ring cover B = Distance approx. 4 mm
4 = Outer race of cylinder roller bearing
NOTE 03 Fill 60 % of gap (2) between the two sealing

- Shaft seals should generally be changed during lips with grease DIN 51502.
major overhauls.
When using the version with two shaft seals, a duo 04 Insert outer race of cylinder roller bearing (4)
shaft seal is generally fitted. into housing bore (once housing bore has been
- Observe assembly note on page A 17.01.02. heated to approx. 60 °C). Observe distance A
during the insertion. Distance A between
sealing faces of housing and face end of outer
01 Use special tool 1X56 137 260 to insert correct bearing race must the less than or equal to
side of duo shaft seal (1) in cover (if necessary, dimension A measured on seal ring cover.
rework special tool 1X56 137 260,
refer to special tools E 01.02.00 - 05, item 32). 05 Fit pipe (5), 1X56 137 234, and slide-on washer
(6), 1X56 137 231.
02 Check distance B.
Page index: H 39.02.00 - 01

BW (BU) 190 S (P)
BW (BU) 195 S (P)
Output shaft
1
012837
1 = Output shaft a = Push-on length

2 = Inner race of cylinder roller bearing
3 = Angle ring
4 = Output gear
06 If removed, heat inner race of cylinder roller 09 If necessary, perform correction for push-on
bearing (2) to approx. 100 °C and slide onto length on face side of angle ring.
output shaft until firmly home.
10 Take output gear and angle ring off output shaft.
07 Slide correct side of angle ring (3) onto output
shaft until firmly home against inner race of
cylinder roller bearing.
08 Slide on output gear (4) as described in Oil

press-fit method Section D 05.00.00 and
measure push-on length a (refer to oil press-
fit table D 05.00.00).
Page index: H 39.02.00 - 02

BW (BU) 190 S (P)
BW (BU) 195 S (P)
Output shaft
6
5
4
1 012834
1 = Pipe 1X56 137 234 6 = Cylinder roller bearing

2 = Slide-on washer 1X56 137 231 7 = Seal ring cover
3 = Output gear 8 = Collar nut 1X56 137 232
4 = Angle ring 9 = Hook 1X56 136 564
5 = Output shaft
11 Swivel housing through 90° (output side faces 13 Place correct side of angle ring (4) on output
upwards). gear.
12 Place correct side of output gear (3) in housing 14 Insert output shaft in housing, angle ring and
(small diameter of cone faces propeller thrust output gear as shown in diagram.
bearing).
Page index: H 39.02.00 - 03

BW (BU) 190 S (P)
BW (BU) 195 S (P)
Output shaft
7 8 9 10 11 12
13
1 2 3 4 5 6
17 16 15 14
18
012839
1 = Bolt 1X56 136 461 11 = Pump holder 1X56 130 597

2 = Nut 1X56 137 226 12 = Pressure gauge 1X56 130 592
3 = Hydraulic nut 1X56 137 227 13 = Oil injector 1X56 130 595
4 = Pipe 1X56 137 234 14 = High pressure hose 1X56 130 588
5 = Output shaft 15 = Intermediate piece 1X56 130 591
6 = Slide-on washer 1X56 137 231 16 = Pressure gauge 1X56 130 592
7 = Output gear 17 = Reciprocating piston pump 1X56 130 589
8 = Angle ring a = Push-on length
9 = Extension 1X56 137 474 * = BU 190 S, BU 195 S
10 = High pressure pipe 1X56 130 604 18 = Support rod 1X56 137 536
15 Swivel gearbox through 90° (output shaft is NOTE

horizontal). Remove extension (9) and hydraulic nut (3). Move
output shaft towards output side until inner race of
16 Arrangement of fixture as shown in diagram. cylinder roller bearing is in its installation position.
Use load sling to hold output shaft behind output gear
! DANGER in its installation position. Remove the remaining the
Pull on helical gear as described in Oil press-fit fixtures.
D 05.00.00.
Page index: H 39.02.00 - 04

BW (BU) 190 S (P)
BW (BU) 195 S (P)
Output shaft
4
3
2
012840
1 = Output shaft 5 = Load sling

2 = Bearing bush
3 = Inner race of axial roller bearing
4 = Outer race of axial roller bearing
17 Heater inner race of axial roller bearing to

approx. 85 °C and slide correct side onto
bearing bush.
18 Heat bearing bush (2) and inner race of axial

roller bearing (3) to approx. 100 °C and slide
correct side onto output shaft until firmly home.
19 Insert outer race of axial roller bearing (4) in

bearing bore.
Page index: H 39.02.00 - 05

BW (BU) 190 S (P)
BW (BU) 195 S (P)
Output shaft
1 2 3 4 5 6
012841
1 = Cover 4 = Compresssion spring (4 pieces)

2 = Outer race of tapered roller bearing 5 = Outer race of axial roller bearing
3 = O-ring 6 = Load sling
20 Heat bearing bore for outer race of tapered 23 Apply thin coat of sealing compound* to
roller bearing in cover (1) to approx. 60 °C and sealing faces of cover (1) and fit to housing.
insert outer race of tapered roller bearing (2) When attaching, apply sealing compound** to
until firmly home. position XX and tighten cover.
21 Insert 4 compression springs (4) into cover. * Sealing compound Hylomar SQ 32 M,

22 Insert O-ring (3) in annular groove of cover. ** Sealing compound Terostat-33, produced by
Teroson in accordance with A 11.00.00
NOTE
Sealing compound** is applied to area XX on the
cover during assembly.
XX
012842
Page index: H 39.02.00 - 06

BW (BU) 190 S (P)
BW (BU) 195 S (P)
Output shaft
1 2 3 4 5 6 7 8 9 10 11 12 13
14
012843
1 = Circlip 8 = Outer race of axial roller bearing

3 = Input gear 10 = Bolt seat 1X56 137 232
4 = 8x9 Woodruff key 11 = Cross beam 1X56 137 091
5 = Inner race of tapered roller bearing 12 = Washer 1X56 137 290
6 = Outer race of tapered roller bearing 13 = Collar but 1X56 137 232
7 = Cover 14 = Threaded spindle 1X56 137 291
24 Arrangement of fixture as shown in diagram. 28 Heat input gear (3) to approx. 85 °C and slide
correct side onto inner race of tapered roller
25 Clamp output shaft ensuring that outer race of bearing (5) until firmly home.
axial roller bearing (8) is on cover (7).
29 Slide on washer (2).
26 Heater inner race of tapered roller bearing (5) to
approx. 85 °C and slide onto outer race of 30 Snap circlip (1) into annular groove.
tapered roller bearing (6) until firmly home.
27 Insert Woodruff key (4) in output shaft.
Page index: H 39.02.00 - 07

BW (BU) 190 S (P)
BW (BU) 195 S (P)
Output shaft
1 2 3 4 5 6 7
11 10 9
A 8
012844
1 = Reciprocating piston pump 1X56 130 589 7 = Output shaft

2 = Pressure gauge 1X56 130 592 8 = Input gear
3 = Intermediate piece 1X56 130 591 9 = Nut 1X56 137 226
4 = High pressure hose 1X56 130 588 10 = Bolt 1X56 136 461
5 = Hydraulic nut 1X56 137 227 11 = Washer
6 = Hex bolt 1X56 137 233 A = Distance for end float setting
NOTE NOTE
The end float of the propeller thrust bearing must be Pressurize hydraulic nut, pressure gauge of
between 0.05 and 0.1 mm with a preload of 2 000 N. reciprocating piston pump (2) must not indicate more
This preload is ensured by compression springs. than 25 bar (9 kN = 0.9 t). During the press process,
the output shaft must be rotated forwards and
31 Arrangement of fixture as shown in diagram. backwards continuously.
32 Relieve end float in bearing.
Page index: H 39.02.00 - 08

BW (BU) 190 S (P)
BW (BU) 195 S (P)
Output shaft
1 2 3 4
A
012845
1 = Circlip 3 = Input gear

33 Measure distance A between circlip (1) and

washer (2) and note down length
34 Distance A must be between 0.03 to

0.05 mm.
35 Washers (2) are available with the following

gauges:
0730 002 089 = 4.6 mm

0730 002 090 = 4.4 mm
0730 002 091 = 4.2 mm
0730 002 092 = 4.0 mm
0730 002 093 = 3.8 mm
0730 002 094 = 3.6 mm
0730 002 095 = 3.4 mm
0730 002 096 = 3.2 mm
0730 002 097 = 3.0 mm
0730 003 281 = 2.9 mm
0730 003 282 = 2.8 mm
0730 003 283 = 2.7 mm
0730 003 284 = 2.6 mm
36 Fit corrected washer (2).
Page index: H 39.02.00 - 09

BW (BU) 190 S (P)
BW (BU) 195 S (P)
Output shaft
1 2 3 4 5 6 7 8
012846
10
11 9
12
1 = Bolt 1X56 136 461 8 = Output shaft

2 = Hex bolt 1X56 137 290 (5) 9 = Reciprocating piston pump 1X56 130 589
3 = Slide-on washer 1X56 137 231 10 = Pressure gauge 1X56 130 592
5 = Nut 1X56 137 226 12 = High pressure hose 1X56 130 588
6 = Circlip
7 = Washer
37 Relocate end float from circlip to bearing. 40 Circlip (6) must be slightly tensioned.
38 Arrangement of fixture as shown in diagram. 41 Dismantle fixture.
39 Apply pressure of max. 150 bar to hydraulic nut 42 Screw in remaining 3 fastening bolts of cover
(4) (note pressure gauge on reciprocating piston and tighten.
pump).
Page index: H 39.02.00 - 10

BW (BU) 190 S (P)
BW (BU) 195 S (P)
Output shaft
1 = Dial gauge with holder 4 = Washer 1X56 137 290

2 = Stud 1X56 137 232 5 = Threaded spindle 1X56 137 291
3 = Cross beam 1X56 137 091 A = Tightening torque 30 Nm
Checking end float
43 Rotate output shaft to left and right several 47 Read end float off dial gauge. End float must be
time. between 0.05 and 0.1 mm.
44 Attach dial gauge and holder (1) to cover and 48 If the end float is not between 0.05 and 0.1 mm,
set to 0. the washer behind the circlip should be
corrected by the variance required, refer to
45 Arrangement of fixture as shown in diagram. Figure 012845.
46 Clamp output shaft by tightening the threaded

spindle with 30 Nm. Turn clamped output shaft
to the left and to the right (and note dial gauge).
Page index: H 39.02.00 - 11

BW (BU) 190 S (P)
BW (BU) 195 S (P)
Output shaft
1 = Cover 4 = Gasket
2 = O-ring 5 = Cover
3 = Oil tray 6 = Hex bolt
49 Insert oil tray (3) and screw down.
50 Fit cover (5) and gasket (4).
51 Insert O-ring (2) in cover.
52 Fit cover (1).
Page index: H 39.02.00 - 12

BW 196 Contents
Removing and dismantling output shaft ............................................................................................. H 41.01.00
Assembling and installing output shaft .............................................................................................. H 41.02.00
Page index: H 41.00.00 - 01

BW 196 Contents
1 5
013581
Page index: H 41.00.00 - 02

BW 196 Contents
* depending on parts list version
013582
Page index: H 41.00.00 - 03

Removing and dismantling
BW 196 output shaft
1 5
013581
* Depending on parts list version Removal
- Pipes are removed in accordance with H 11.00.00. ! DANGER

Secure cover (5) before releasing cover fastening to
- Flange-mounted bell housing is removed in ensure that it cannot fall out.
accordance with H 27.00.00.
- Input shaft is removed in accordance with 01 Unscrew fastening bolts (1).

H 31.00.00
02 Lift off cover (5).
H 33.00.00. 03 Lift off gasket (4).
04 Unscrew fastening bolts (2) and lift off gear

shells (3).
Page index: H 41.01.00 - 01

BW 196 output shaft
*05 Unscrew fastening bolts (1) on cover (2). ! DANGER

When output gear springs off output shaft, make
06 Unfasten seal ring cover (2) from sealing faces on sure that no one is standing in front of the output
housing. shaft.
07 Depending on parts list version, unscrew
fastening bolts (4) and lift off cover (3). 10 Pull off output gear as described in Oil press-fit
09 Move output shaft by dimension A.

Dimension A = approx. 15 mm
* depending on parts list version
Page index: H 41.01.00 - 02

BW 196 output shaft
11 Push output shaft (1) as far as possible towards the 15 Take output gear out of housing.
pump. Output gear touches housing panel for
propeller bearing. 16 Take compression springs (4) and ring (5) out of
housing bore of propeller bearing.
12 Use load sling to secure output gear (2) centrally
in its installation position.
13 Press inner race of cylinder roller bearing (3) in

front of output gear off by pressing out the output
shaft (refer to figure) and force the race off the
shaft.
14 Take output shaft out of housing.
Page index: H 41.01.00 - 03

BW 196 output shaft
17 Unlock M100x1.5 grooved nut (on output shaft in

front of axial roller bearing) and use grooved nut
wrench 1X56 137 292 to remove
18 Lift off ring in front of axial roller bearing
20 Pull off axial roller bearing (heat inner bearing

race if necessary), remove inner race and
intermediate race of roller bearing.
Page index: H 41.01.00 - 04

BW 196 output shaft
22 Pull off cover and tapered roller bearing as shown

in diagram.
NOTE
When pulling these off, the input gear will press
the shaft seals out of the cover.
23 Drive outer race of tapered roller bearing out of

cover.
Page index: H 41.01.00 - 05

BW 196 output shaft
25 Pull off input gear (1) (pump drive) as is shown in

the diagram.
Page index: H 41.01.00 - 06

Assembling and installing
BW 196 output shaft
Assembly 04 Slide cover (2) onto correct side of output shaft

(1) until firmly home on the fixing pieces.
NOTE:
Shaft seals are generally replaced once removed 05 Heat correct side of input gear (3) (for pump
from the output shaft. drive) to approx. 85 °C and slide onto output shaft
(1).
01 Note installation instructions on page A 17.01.02
when assembling shaft seals (4).
02 Insert correct side of shaft seals (4) so that they

are flush in cover (2).
03 Insert fixing piece 1X56 137 411 (offset 3x120°)

in output flange bore.
Page index: H 41.02.00 - 01

BW 196 output shaft
06 Insert correct side of outer race of tapered roller 09 Heat correct side of inner race of axial roller
bearing (6) into bearing bore on cover (7). bearing (3) to approx. 85 °C and slide onto output
shaft.
NOTE
Use fixing pieces 1X56 137 411 to adjust cover 10 Slide ring (2) onto inner race of axial roller
(7) ensuring that the cover is adjusted so far bearing (3) until firmly home.
downwards that when inner race of tapered roller
bearing (5) is slid on, it comes into contact with 11 Screw on M 10x1.5 grooved nut (1) and use
input gear (8). wrench 1X56 137 292 to tighten to approx.
800 Nm.
07 Heat inner race of tapered roller bearing (5) to Carefully secure grooved nut.
approx. 85 °C and slide onto correct slide of input
gear (8) until firmly home.
08 Place intermediate ring (4) on inner race of

tapered roller bearing (5).
Page index: H 41.02.00 - 02

BW 196 output shaft
12 If removed, insert stud (3) in bearing bore. NOTE

Measure end float of propeller bearing. The end
13 Insert original washer (2) in housing bearing bore. float must be between 0.05 and 0.1 mm with a
Washers (2) are available in 0.20 mm grades preload of 4000 N.
between 14.8 and 16.4 mm. The preload is specified by the compression
springs.
14 Insert 10 compression springs (4) through the
washer (2) into bearing bore. 20 Set dial gauge with holder (6 + 7) on output
flange with pretension (3 to 4 mm) to 0.
15 Insert correct side outer race of axial roller
bearing (1) into bearing bore until firmly home 21 The compression springs press the output shaft
and against the compression springs (4). towards the output flange.
1st measurement, dial gauge is set to 0.
16 Do not apply sealing compound to cover (5) and
insert output shaft (from above if possible) into 22 For the 2nd measurement, press output shaft
housing. towards input (refer to arrangement of fixture).
Pressurize hydraulic nut 1X56 137 227 to
17 Screw in fastening bolts (8) of cover (5) and max. 25 to 30 bar.
tighten. Take reading from dial gauge with this pretension.
Dial gauge variance = end float.
18 Turn output shaft to left and right several times.
23 Remove output shaft again.
Set distance A equally around the 24 Correct washer (2) in front of outer race of axial
circumference. bearing in accordance with end float
Rotate housing, if possible, the housing should measurement.
face downwards.
25 Repeat measurement and remove output shaft
again.
Page index: H 41.02.00 - 03

BW 196 output shaft
26 Place correct side of output gear (8) in housing. NOTE

(small diameter of cone faces input side). Do not press output gear up against taper by
Move output gear into installation position. tightening down cover screws.
27 Insert corrected washer (2) (for end float setting) 32 Arrangement of fixture as shown in diagram.
and compression springs (4) in bearing bore.
NOTE
28 Insert correct side of outer race of axial roller The push-on length of the output gear must be
bearing (1) in bearing bore. observed. Use dial gauge to monitor the push-on
length while pushing on parts. Set dial gauge to 0
29 Apply thin coat of sealing compound** to sealing with 10 mm pretension.
faces of cover (5).
! DANGER
30 Insert output shaft in housing and in output gear Pull on output gear as described in Oil press-fit
(8). method Section D 05.00.00.
Observe push-on values in oil press-fits table
31 Screw in fastening bolts (9) of cover (5) but do D 05.00.00.
not tighten. Only screw in bolts until the output
gear (8) touches the housing. 33 Slide on output gear (8) and screw down cover
(5).
** Sealing compound, Terostat-33, produced by

Teroson
Page index: H 41.02.00 - 04

BW 196 output shaft
34 Heat correct side of inner race of cylinder roller 38 Apply thin coat of sealing compound* to sealing
bearing (1) to approx. 85 °C and slide onto output faces of cover (4) and fit to housing.
shaft (3) and leave to cool. When fitting the cover, the outer race of the
cylinder roller bearing is shifted into the correct
35 Insert outer race of cylinder roller bearing (2) in installation position.
housing bore.
Observe dimension B during the insertion. 39 Fit blind cover or secondary pump (8) in
Distance B should be approx. 0.5 mm smaller accordance with the oil pumps Section
than distance A. H 15.00.00.
36 Install oil tray (5) in cover (7) and screw down. 40 Fit pipes in accordance with H 11.00.00.
37 Attach cover (7) and gasket (6). * Hylomar SQ 32 M
Page index: H 41.02.00 - 05

BW (BU) 190 (P) BW (BU) 190 S (P)
BW 196 (P) Section K
Test run - refer to monitoring data ........................................................................................................ K 01.00.00
Page index: K 00.00.00 - 01

12.3 Monitoring data of BW 190 family
Page index:
Filter Clutch oil pressure Lubricating Oil temperature for
contamination oil pressure P, L, M applic. C application P, L, M, C appl.
BW 196 (P)
BW 195 (P)
BW 190 (P)
Measuring point 1) 5 2 22 11, 12, 41

Operating mode Neutral 9) Shift position 9) Shift position 9) Driving mode Trailing
Enginewise/counter Enginewise/counter Neutral mode 8)
enginewise rotation enginewise rotation
Rated value PKN 7)
Nom. display min PK = PKN 0.5 bar 4) 7.5 bar 0.4 bar 30 °C 30 °C
BW 195 S (P)
BW 190 S (P)
value
max PVF = PK + 4 bar PK = PKN + 1 bar 4) 10 bar 5 bar 90 °C 100 °C 75 °C 8) 11)
105 °C 8) 12)
Warning 24 bar s 2) 15) PK = 0.25 bar t 2) 95 °C s 2) 105 °C s 2)
26 bar s 2) 13) PKN 3 bar t 2) 5) 6)
Minimum monitoring 14) Pressure switch Pressure gauge 0 to 25 bar Thermometer 0 to 120 °C
Additional Pressure gauge Pressure switch 3) 6) or Pressure with Temperature switch 2) or
K 01.00.00 - 01
monitoring 14) 0 to 40 bar 3) Pressure gauge 16) 0 to 25 bar or pressure gauge Temperature sensor 16) 0 to 120 °C
0 to 6 bar
Refer to Section 12.2 for more information 7) The rated clutch pressure is specified in the 13) If PKN > 19 bar
1) Refer to monitoring plan in installation binding technical documents (order-specific)
14) Not within the standard ZF scope of supply
manual for schematic arrangement; refer to and also stamped on the type plate and in the
control housing. 15) If PKN 19 bar
installation drawing or operating instructions
or Description of basic gearbox Section for 8) For operation with stationary engine and 16) For remote display
arrangement on gearbox current-driven propeller (also refer to Usage
17) Not included in table above
2) For optical and acoustic warning and Maintenance Manual)
s Increasing
3) Use distributor piece 9) For normal operation without trolling
t Decreasing
4) 60 °C to 80 °C oil temperature 10) Not included in table above
PK = Clutch oil pressure
5) Warning with time delay of between 3 and 10 s 11) Without trailing pump
PKN = Rated clutch oil pressure
(provided by the shipyard) 12) With trailing pump
6) Warning must be set to no function when PVF = Pressure before filter
in shift positions Trolling on or Neutral
Issue date 99.07.01
Monitoring data

3081 - 751 - 103 BW195 P Service Manual

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ZF Friedrichshafen AG ZF Friedrichshafen AG ZF Friedrichshafen AG

Workshop Workshop Workshop

BW (BU) 190 (P) BW (BU) 190 (P) BW (BU) 190 (P)

BW (BU) 190 S (P) BW (BU) 190 S (P) BW (BU) 190 S (P)

BW 196 (P) BW 196 (P) BW 196 (P)

Trouble shooting and rectification C

Removal / installation of gearbox G

3081 751 103

ZF Marine GmbH ZF Padova S.p.A. ZF-HURTH Marine S.p.A.

Phone (07541) 77-0 Phone (049) 8299-311 Phone (0464) 58 05 55

00.00.00 01-04 D 02.00.00 01

Page index: 00.00.00 - 01

Page index: 00.00.00 - 02

This manual is intended for skilled personnel who

This manual deals with a ZF volume production

However, due to continuing development of the

Service points equipped by ZF Friedrichshafen AG all

All work performed in these service points is carried

Damage resulting from work performed by non-ZF

Page index: 00.00.00 - 03

W ORK S AF ETY N OT IC E G E NE RAL NO T E

To avoid injury to personnel and damage to

After completion of repair work and testing, skilled

Page index: 00.00.00 - 04

Contents of principal groups

Structure of manual .............................................................................................................................. A 03.00.00

Service centers ...................................................................................................................................... A 05.00.00

List of gearbox series ........................................................................................................................... A 07.00.00

Sectional views of gearboxes ............................................................................................................... A 09.00.00

Consumables ......................................................................................................................................... A 11.00.00

List of lubricants ................................................................................................................................... A 15.00.00

General  disassembly, testing, reworking and assembly .................................................................... A 17.00.00

Page index: A 00.00.00 - 01

Structure of manual .............................................................................................................................. A 03.01.00

Note regarding manual .......................................................................................................................... A 03.0200

Page index: A 03.00.00 - 01

Page index: A 03.01.00 - 01

NOTE: The workshop manual covers all types

BW (BU) 190 (P)

No particular reference is made to the BU gearbox

To use the manual for one specific type of gearbox,

Page index: A 03.02.00 - 01

Service centers ................................................................................................................................ A 05.00.00-01

The ZF company directory (service centers),

can be ordered quoting number 0000 762 703a from

Page index: A 05.00.00 - 01

List of gearbox series .................................................................................................................... A 07.01.00 - 01

Page index: A 07.00.00 - 01

Diagram Centre distance Model

Page index: A 07.01.00 - 01

Sectional views of gearboxes

Sectional view of gearbox and cut-away diagrams of

Page index: A 09.00.00 - 01

Gearbox and powerflow diagram

Page index: A 09.01.00 - 01

Page index: A 09.01.00 - 02

Page index: A 09.01.00 - 03

Page index: A 09.01.00 - 04

Page index: A 09.01.00 - 05

Page index: A 09.01.00 - 06

Sealing compound: ............................................................................................................................... A 11.01.00

Loctite: .................................................................................................................................................. A 11.01.00

Paste for tooth flank contact pattern acceptance .................................................................................. A 11.01.00

General disassembly, testing, reworking and assembly .................................................................... A 17.00.00