3081 - 751 - 105b BW195 A SERVICE MANUAL

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Nachdruck 3081 751 105b

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Typ: BW (BU) 190 A (P), BW (BU) 190 A (P)

BW (BU) 190 V (P), BW (BU) 190 V (P)
Pos. In die Anleitung einlegen: nach Seite
1 Korrosionsschutz (PDF) 3070 755 101 A 13.00.00 - 01

2 Schmierstoffliste TE-ML 04 1204 754 104d A 15.00.00 - 01
3 Beschreibung (elektonisch gespeichert) 3080 758 110 B 03.00.00 - 01

4 Betriebsanleitung (elektronisch geseichert) 3081 758 102a nach Pos. 3
1-4
ZF Friedrichshafen AG ZF Friedrichshafen AG ZF Friedrichshafen AG
Workshop Workshop Workshop

Manual Manual Manual
3081 751 105b 3081 751 105b 3081 751 105b
BW 190 A (P) BW 190 A (P) BW 190 A (P)

BW 195 A (P) BW 195 A (P) BW 195 A (P)
BU 190 A (P) BU 190 A (P) BU 190 A (P)

BU 195 A (P) BU 195 A (P) BU 195 A (P)
BW 190 V (P) BW 190 V (P) BW 190 V (P)

BW 195 V (P) BW 195 V (P) BW 195 V (P)
BU 190 V (P) BU 190 V (P) BU 190 V (P)

BU 195 V (P) BU 195 V (P) BU 195 V (P)
BW (BU) 190 A (P)
BW (BU) 195 A (P)
BW (BU) 190 V (P)
BW (BU) 195 V (P)
3081 751 105b
BW (BU) 190 A (P), BW (BU) 190 V (P) Workshop
BW (BU) 195 A (P), BW (BU) 195 V (P) Manual
Service-Center
General A
Description
Operation B
Maintenance
Locating and removing faults C
Adjustment data D
50
Nm
Special tools E
Removal/installation of parts with

F
the transmission installed
Removal/installation of the
G
complete transmission
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. Any reproduction and dissemination in whatever
form Ð also in adapted, paraphrased or extracted form Ð in particular as a reprint, photomechanical or
electronic reproduction or as a storage in data-processing equipment or data networks without approval
by the holder of the copyright is prohibited and will be prosecuted under civil and criminal law.
Printed in Germany
Edition: 02.93
3081 751 105b
ZF Friedrichshafen AG 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 A (P), BW (BU) 190 V (P) Workshop manual
BW (BU) 195 A (P), BW (BU) 195 V (P) Contents
D 02.01.00 - 01
- 00.00.00 - 01 - 04 D 03.00.00 - 01
D 03.01.00 - 01
Section A D 05.00.00 - 01
D 05.01.00 - 01
A 00.00.00 - 01 D 05.02.00 - 01
A 01.00.00 - 01 D 05.03.00 - 01 - 03
A 01.01.00 - 01 D 05.04.00 - 01
A 03.00.00 - 01 D 05.05.00 - 01 - 02
A 03.01.00 - 01 D 05.06.00 - 01 - 02
A 03.02.00 - 01 D 07.00.00 - 01
A 05.00.00 - 01 D 07.01.00 - 01
A 09.00.00 - 01 D 09.00.00 - 01
A 09.01.00 - 01 - 06 D 09.01.00 - 01
A 09.02.00 - 01 - 06 D 09.02.00 - 01
A 11.00.00 - 01 D 11.00.00 - 01
A 11.01.00 - 01 D 11.01.00 - 01
A 13.00.00 - 01 D 13.00.00 - 01
A 15.00.00 - 01 D 13.01.00 - 01
A 17.00.00 - 01 D 13.02.00 - 01
A 17.01.00 - 01
A 17.01.01 - 01
A 17.01.02 - 01 Section E
E 00.00.00 - 01
Section B E 01.00.00 - 01
E 01.01.00 - 01
B 00.00.00 - 01 E 01.02.00 - 01 - 09
B 03.00.00 - 01
B 05.00.00 - 01
B 05.01.00 - 01 Section F
B 07.00.00 - 01
B 07.01.00 - 01 - 02 F 00.00.00 - 01
B 07.01.01 - 01 - 02 F 01.00.00 - 01
B 07.03.00 - 01 - 02 F 01.01.00 - 01 - 02
B 07.05.00 - 01 - 03 F 03.00.00 - 01
F 03.01.00 - 01 - 02
F 03.02.00 - 01 - 02
Section C F 03.03.00 - 01 - 02
F 03.04.00 - 01 - 02
C 00.00.00 - 01 F 05.00.00 - 01
F 05.01.00 - 01 - 03
F 05.02.00 - 01 - 02
Section D F 07.00.00 - 01
F 07.01.00 - 01
D 00.00.00 - 01 F 07.02.00 - 01
D 01.00.00 - 01 F 07.03.00 - 01 - 04
D 01.01.00 - 01 F 07.04.00 - 01 - 03
D 02.00.00 - 01
- 00.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P) Workshop manual
Section G H 31.02.00 - 01 - 08
H 32.00.00 - 01 - 03
G 00.00.00 - 01 H 32.01.00 - 01 - 09
H 32.02.00 - 01 - 08
H 33.00.00 - 01 - 04
Section H H 33.01.00 - 01 - 10
H 33.02.00 - 01 - 08
H 00.00.00 - 01 H 37.00.00 - 01 - 03
H 01.00.00 - 01 H 37.01.00 - 01 - 11
H 01.01.00 - 01 - 03 H 37.02.00 - 01 - 16
H 07.00.00 - 01 - 06
H 07.01.00 - 01 - 02
H 07.02.00 - 01 - 02 Section K
H 07.03.00 - 01
H 07.04.00 - 01 - 02 K 00.00.00 - 01
H 07.05.00 - 01 K 01.00.00 - 01
H 09.00.00 - 01 K 01.01.00 - 01
H 09.01.00 - 01 K 01.01.01 - 01
H 11.00.00 - 01 - 05 K 01.01.02 - 01
H 11.01.00 - 01 288
H 13.00.00 - 01 - 02
H 13.01.00 - 01 - 03
H 15.00.00 - 01 - 02
H 15.01.00 - 01 - 02
H 15.02.00 - 01 - 03
H 17.00.00 - 01 - 03
H 17.01.00 - 01
H 17.02.00 - 01
H 19.00.00 - 01 - 02
H 19.01.00 - 01
H 19.02.00 - 01
H 21.00.00 - 01
H 21.01.00 - 01
H 21.01.01 - 01
H 21.01.02 - 01
H 21.02.00 - 01
H 21.02.01 - 01
H 21.02.02 - 01
H 27.00.00 - 01 - 02
H 27.01.00 - 01
H 29.00.00 - 01 - 02
H 29.01.00 - 01 - 02
H 29.02.00 - 01 - 04
H 30.00.00 - 01 - 02
H 30.01.00 - 01 - 02
H 30.02.00 - 01 - 03
H 31.00.00 - 01 - 03
H 31.01.00 - 01 - 11
- 00.00.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P)
Preface
BW (BU) 195 A (P), BW (BU) 195 V (P)
This repair manual is intended for skilled personnel

trained by ZF Friedrichshafen AG to carry out mainte-
nance and repair work on ZF products.
This manual deals with the standard ZF product in

accordance with the state of development on the
date of issue.
However, due to continuing development of the

product, repair work might require work practices and
test or adjustment data not contained in this manual.
We 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 Service training
centers.
Service points equipped by ZF Friedrichshafen AG all

over the world offer you:
1. Continually trained personnel
2. Specified equipment, e.g. special tools
3. Genuine ZF spares, to our latest

specifications
All work performed at these service points is carried

out conscientiously and with utmost care.
Repair work carried out at ZF service points is

subject to the contractual conditions prevailing in
the individual case.
ZF FRIEDRICHSHAFEN AG Damage resulting from work performed by non-ZF

C.V./Special Transmissions personnel in an improper and unprofessional manner
Service Plant 2 and any consequential costs are excluded from the
Tel.: (0 75 41) 77-0 contractual liability agreement. Exclusion of liability
Fax: (0 75 41) 77-5726 also applies if genuine ZF spares are not used.
- 00.00.00 - 03
BW (BU) 190 A (P), BW (BU) 190 V (P)
Important Information
BW (BU) 195 A (P), BW (BU) 195 V (P)
SAFETY NOTICE GENERAL INFORMATION
Companies repairing ZF units are responsible for their Read this manual carefully before starting any tests or
own work safety. repair work.
To avoid injury to personnel and damage to pro-

ducts, all safety regulations and legal requirements CAUTION
which apply to repair and maintenance work must Pictures, drawings and components do not always
be adhered to. represent the original object, but are used to illustrate
Before starting work, mechanics must familiarize working procedures.
themselves with these regulations. Pictures, drawings and components are not to scale.
Conclusions about size and weight should not be
Personnel required to carry out repairs on ZF products drawn (even within a complete illustration).
must receive appropriate training in advance. It is the Always follow the working steps as described in the
responsibility of each company to ensure that their text.
repair staff is properly trained.
After completion of repair work and testing, skilled

staff must satisfy themselves that the product is
The following safety instructions appear in this functioning correctly.
manual:
NOTE
Refers to special processes, techniques, data, use of
auxiliary equipment, etc.
CAUTION
This is used when incorrect, unprofessional working
practices could damage the product.
! DANGER
This is used when lack of care could lead to
personal injury or death.
- 00.00.00- 04
BW (BU) 195 A (P), BW (BU) 195 V (P) Section A
Contents of principal groups
Section for filing Service Information Sheets......................................................................................... A 01.00.00
Layout of manual..................................................................................................................................... A 03.00.00
Service Points ......................................................................................................................................... A 05.00.00
Photographs and sectional views of gearbox and power-flow diagrams ................................................ A 09.00.00
Consumables............................................................................................................................................ A 11.00.00
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
A 00.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Please store Service Information Sheets in this section.
List of Service Information Sheets.......................................................................................................... A 01.01.00
A 01.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
List of Service Information Sheets
BW (BU) 195 A (P), BW (BU) 195 V (P)
Please fill in the relevant information on receipt of Service Information Sheets.
Date of Service No. Transmission Introduced Comments

Information type on by
A 01.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Layout of manual..................................................................................................................................... A 03.01.00
Note about the manual............................................................................................................................. A 03.02.00
A 03.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Layout of manual
BW (BU) 195 A (P), BW (BU) 195 V (P)
Layout of manual
Section
Main group
Group
Sub-assembly
Page
G 07. 03. 12 - 08
A 03.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Note about the manual
BW (BU) 195 A (P), BW (BU) 195 V (P)
NOTE: The Workshop Manual deals with all

variants of the basic gearbox version
(i.e. not just parts list versions) of the
gearbox family
BW 190 A (P)
BW 190 V (P)
BW 195 A (P)
BW 195 V (P)
BU gearbox versions are not specifically

mentioned. For BU gearboxes, proceed
according to the description for the
corresponding BW gearboxes.
If you wish to arrange the manual to deal with only

one gearbox type, remove all pages which do not list
that particular gearbox type in the header.
A 03.02.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Service Points
BW (BU) 195 A (P), BW (BU) 195 V (P)
Service Points
NOTE: You may order the ZF Company Register

(Service Points) with information on:
ZF Group
Subsidiaries
Sales / After-sales Service Points
Associated companies
Order from:
ZF FRIEDRICHSHAFEN AG
D–88038 Friedrichshafen
Please quote F 11/23 GF 91 50 08 when ordering.
A 05.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Photographs and sectional views of gearbox and power-flow diagrams ................................................. A 09.01.00
A 09.00.00 - 01
BW (BU) 190 A (P)
Photographs and diagrams of gearbox
BW (BU) 195 A (P)
000272
000273
A 09.01.00 - 01
BW (BU) 190 A (P)
BW (BU) 195 A (P)
000274
000275
A 09.01.00 - 02
BW (BU) 190 A (P)
BW (BU) 195 A (P)
Version without secondary pump
000276
000277
A 09.01.00 - 03
BW (BU) 190 A (P)
BW (BU) 195 A (P)
000284
000284
Gearbox and power-flow diagram D
A - Input shaft A
B - Change-over shaft
Gears in mesh
C - Output shaft B
D - Clutch for cntr-enginewise E

rotation
C
E - Clutch for enginewise
rotation
Power-flow for:
A Counter-enginewise rotation
B A Enginewise rotation
C
000129
A 09.01.00 - 04
BW (BU) 190 A (P)
BW (BU) 195 A (P)
I I
II II
000130
A 09.01.00 - 05
BW (BU) 190 A (P)
BW (BU) 195 A (P)
II
II
000131
A 09.01.00 - 06
BW (BU) 190 V (P)
BW (BU) 195 V (P)
000279
000280
A 09.02.00 - 01
BW (BU) 190 V (P)
BW (BU) 195 V (P)
000281
000282
A 09.02.00 - 02
BW (BU) 190 V (P)
BW (BU) 195 V (P)
000283
A 09.02.00 - 03
BW (BU) 190 V (P)
BW (BU) 195 V (P)
Gearbox and power-flow diagram, V version
A = Input shaft
B = Change-over shaft
D
C = Output shaft
A
D = Clutch for counter- Gears in
enginewise rotation mesh
B
E = Clutch for enginewise
rotation E
Power-flow for:
Counter- A
enginewise
rotation C
Enginewise A
rotation B
C-
000132
A 09.02.00 - 04
BW (BU) 190 V (P)
BW (BU) 195 V (P)
II
000133
A 09.02.00 - 05
BW (BU) 190 V (P)
BW (BU) 195 V (P)
II
II
000134
A 09.02.00 - 06
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Consumables
Sealing compounds, Loctite, lubricants, paste for recording tooth flank contact pattern ....................... A 11.01.00
A 11.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Consumables
BW (BU) 195 A (P), BW (BU) 195 V (P)
This information is given subject to alteration! Dyken-Read DX-296 / 8 oz, Helling, Sandorkai 1,
2000 Hamburg 11, Tel. (40) 376010
Sealing compound! Telex 213611 + 2165082, Fax (40) 37601100 Made in
(Extract from manufacturer's operating instructions) Germany.
Manufacturer's operating instructions are binding.
HYLOMAR (Universal compound SQ 32 M-Special, Grease

for use on sealing surfaces of housings and covers). See List of Lubricants A 15.00.00
SQ 32 M-Special, flexible universal sealing

compound (CFC-free), produced by MARSTON, Cleaner (to remove grease from tapered surfaces of
Ölchemie GmbH, 5352 Zülpich, Germany, oil press-fits).
Tel. (0 22 52) 25 66 and 27 25 Acetone, Spirits (Warning! Inflammable) or standard
non-greasy cleaner.
Instructions for use:
Ensure the joint surfaces are clean and dry. Apply
HYLOMAR to both surfaces and allow solvent to Use Glycerine to seal oil press-fits on the BW 160 to
evaporate (approx. 10 minutes). Oil, grease and BW 195 families.
previous coatings can be removed with HYLOMAR Oil or glycerine can be used for sealing other gearbox
CLEANER. types.
Temperature resistant, -50 °C to + 250 °C.
Loctite:
No. 640 for pump sealing faces
No. 241
No. 275 for valve seats
Loctite Deutschland GmbH, Munich

Loctite Europa GmbH, Vienna
Instructions for use:

Clean parts. Apply sufficient product to fill gap. Join
parts and allow product to harden.
Dyken Read DX-296 for recording tooth flank contact

patterns in gearboxes subject to Classification Society
acceptance requirements.
A 11.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
NOTE:
Instructions for corrosion-proofing, types of
packaging, storage conditions and storage periods for
marine gears are enclosed overleaf.
The instructions given in the footnote relating to

"Corrosion-proofing and Protective Treatment" are
specified in Section IV of the document "Description,
Installation, Operation and Maintenance".
This document is contained in Section
B 00.00.00 of the Workshop Manual.
A 13.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
NOTE:
The List of Lubricants for ZF Marine Gears is given
overleaf. The currency of this list depends on the date
of printing of your particular Workshop Manual.
Please request the latest issue of the ZF List of

Lubricants for Marine Gears from your nearest ZF
Service Point (the list should be replaced every 1 – 2
years).
A 15.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
General – Disassembly ............................................................................................................................ A 17.01.00
General – Testing and Reworking ........................................................................................................... A 17.02.00
General – Assembly................................................................................................................................. A 17.03.00
A 17.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
General – Disassembly
BW (BU) 195 A (P), BW (BU) 195 V (P)
This Workshop Manual deals with the ZF marine

reduction gear of the gearbox types listed above.
CAUTION
During all work, observe instructions concerning the
gearbox types in question given in the most recent
circulars and/or Service Memoranda. Contact the
specialist department of the ZF After-sales Service if
matters arise which require clarification.
Ensure an appropriate degree of cleanliness and skilled

workmanship when repairing the gearbox.
Use special tools provided for the individual steps of

the disassembly and assembly process.
After the gearbox is removed from the vessel, it should

be thoroughly cleaned with a suitable washing agent
before being opened.
Parts jointed with Loctite can be separated more easily

if they are first heated with a hot air fan.
Refer to the instructions in the section «The Oil

Injection Method» D 05.00.00 for releasing an oil
press-fit. After disassembling the gears, ensure that the
tapered parts of the oil press-fit are not damaged. This
is best done by using suitable protective sleeves or
adhesive tape.
Clean the housings and sealing covers with a suitable

washing agent, particularly in the corners and angles.
Cleaning parts:
Clean off any oil sealing compound from the contact
faces. Carefully remove any burrs or similar
irregularities with an oil stone.
Ensure lube oil bores and grooves are free from

preservative grease and foreign bodies, and check
them to ensure free passage.
Cover all gearbox apertures to prevent foreign bodies

from falling in.
A 17.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P) General – Testing
BW (BU) 195 A (P), BW (BU) 195 V (P) General – Reworking
Re-use of parts Gearboxes subject to approval by Classification

An expert must check whether parts such as roller Societies
If gears, shafts or flanges of gearboxes approved by a
bearings, discs, thrust washers etc. may be re-installed.
Parts which are damaged or severely worn should be Classification Society (recognizable by the stamp of
replaced by new ones. approval on top of the gearbox housing) have to be
replaced, only fit parts bearing the stamp of approval
of the Classification Society in question. (The name
Gaskets, tab washers of the Classification Society should be stated
Parts which are unavoidably damaged during assembly, separately when ordering spare parts). After
such as gaskets and tab washers, must be replaced by assembling the above parts, check the contact pattern
new ones. using, for example, Dyken Read DX-296.
Shaft sealing rings

Shaft sealing rings with rough, cracked or hardened Re-working
sealing lips should also be replaced. If re-working is required on spacer discs or shims, etc.
in order to adjust play, ensure that the re-worked face
does not have any runout relative to the starting face
Discs and has the same surface quality.
Check discs with a steel ruler to determine whether Sealing ring races must be clean and in perfect
they are flat or distorted. When checking the discs, condition; any defects found may only be removed by
note that some types of steel disc (see D 09.00.00) means of plunge-grinding, never using emery cloth.
have 6 wave-shaped corrugations around the Ensure no traces or scroll due to grinding remain.
circumference and these should not be confused with
distortion. Discs which have dish-shaped distortions
greater than 0.1 mm must be replaced.
Discs with fretting on the running surface or lined
discs with a damaged lining or lined discs whose
grooves are not longer visible must not be re-installed.
All discs which are to be installed must be inspected
for cracks.
Inspecting for cracks

A crack inspection must be undertaken if the propeller
is grounded or after damage to the power transmitting
components in the gearbox. Carry out the crack or
case hardness test as far as facilities allow, after
consulting the gearbox manufacturer (if necessary).
A 17.01.01 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
BW (BU) 195 A (P), BW (BU) 195 V (P) General - Assembly
Assembly of gearbox: Shaft sealing rings

The gearbox should be assembled at a clean place of a) Shaft sealing rings with steel shells: Apply a thin
work. coat of sealing compound* to the outer
Install flat gaskets without any sealing compound or circumference.
grease.
When assembling the gearbox, observe all tightening b) Shaft sealing rings with rubber shells: Moisten the
torques and adjustment data specified in the Repair outer circumference with a lubricant such as water-
Manual. Use the specifically developed special tools soluble washing-up liquid.
when required during working steps.
c) Shaft sealing rings with steel and rubber shells:
Coat the outside rubber shell with a lubrication
CAUTION agent, e.g. water-soluble washing-up liquid (Fairy
Photographs, drawings and components displayed do Liquid etc.)
not always represent the original item but are used to
illustrate a working procedure. d) The double shaft sealing ring consists of two seal
lips. The dustproof seal lip (X) must point
Photographs, drawings and components are not drawn outwards.
to scale and no conclusions about size and weight
should be inferred (even within an illustration).
Always follow the description of working steps in the

X
text. 000 102
Bearings e) Fill 60% of gap between sealing lips with

If bearings need to be heated prior to fitting, this must grease (e.g. Aral – Aralub HL2 or Texaco –
be done evenly. The temperature should be approx. Texando FO 20).
85 ¡C and must not rise to more than 120 ¡C. Oil each
assembled bearing with operating oil following f) Heat shaft sealing ring hole to 40 - 50 °C if
assembly. possible (this facilitates installation). Press shaft
sealing ring in with adapter or plane face. Ensure
correct push-on distance and that the shaft sealing
Sealing ring is evenly seated.
Use a sealing compound* for sealing. Refer to the
manufacturer's instructions for use. Apply a thin film Loctite
of sealing coumpound to the surfaces and cover When using the locking agent "Loctite", always refer
evenly. Keep oil ducts and bores free of sealing to the manufacturer's instructions for use.
compound. Sealing compound must be applied around
oil transfer duct openings or bores in the area of the Shrink-fit grommets
mating faces in such a way that no sealing compound Use a hot-air fan to shrink-fit the grommets. The ideal
enters the oil feeds when the parts are pressed shrink-fit temperature, e.g. for Thermofit grommets, is
together. + 250 to 300 °C. Shrink-fitting begins at +125 °C.
* Sealing compound Hylomar SQ 32 M-Special, see

A 11.01.00
A 17.01.02 - 01
BW (BU) 195 A (P), BW (BU) 195 V (P) Section B
Contents of main groups
NOTE:
You must follow the instructions in Section A 17.00.00 General - Disassembly, Testing, Reworking and
Assembly.
Complete manual - Description, installation, operation and maintenance (basic version) ..................... B 03.00.00
Tool set WI ............................................................................................................................................. B 05.00.00
Maintenance work ................................................................................................................................... B 07.00.00
B 00.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
NOTE:
Refer to the manual overleaf for information on
description, installation, operation and maintenance.
B 03.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Tool set WI ............................................................................................................................................. B 05.01.00
B 05.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Tool set WI
BW (BU) 195 A (P), BW (BU) 195 V (P)
Tool set WI
Tool set WI is composed of commercially available tools e.g.
General hand tools
Open-jawed spanners up to AF ...................................................................................................................... 63 mm
Straight ring spanners up to AF ..................................................................................................................... 46 mm
Offset ring spanners up to AF ........................................................................................................................ 46 mm
Socket set ................................................................................................................................................ 4 Ð 13 mm
Socket set .............................................................................................................................................. 11 Ð 32 mm
Socket set .............................................................................................................................................. 22 Ð 50 mm
Hex driver socket set .............................................................................................................................. 5 Ð 22 mm
Pair of pliers (straight) for circlips (inner locking) ................................................................................ I 1 Ð 4 (Nr.)
Pair of pliers (straight) for circlips (outer locking)............................................................................... A 1 Ð 4 (Nr.)
Screwdrivers ......................................................................................................................................... up to 13 mm
Hammers (metal + plastic), punches
Measurement and testing equipment
Torque wrench...................................................................................................................................... 10 Ð 350 Nm
Caliper gauge, depth gauge..................................................................................... Measuring range up to 350 mm
Feeler gauge .................................................................................................... Measuring range up to 0.5 Ð 1.0 mm
B 05.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Maintenance step 165:

Engine-dependent oil pump (primary oil pump) ....................................................................................B 07.01.00
Maintenance step 165:

Propeller-dependent oil pump (secondary oil pump) ............................................................................. B 07.01.01
Maintenance step 166 (test control unit) ................................................................................................ B 07.03.00
Maintenance step 169 (clean oil cooler)................................................................................................. B 07.05.00
NOTE:
The standard input direction of rotation is to the right when looking at the gearbox input flange;
= input direction I
Special gearbox versions rotate in the opposite direction, to the left when looking at the gearbox input flange;
= input direction II
The gearbox input is marked with an appropriate direction arrow.
Standard gearbox direction of rotation (I)
for engines rotating

counter-clockwise - viewed from the engine output -
viewed from the engine output -
000094
Special direction of rotation (II)

clockwise -
000095
B 07.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P) Maintenance step 165
BW (BU) 195 A (P), BW (BU) 195 V (P) Engine-dependent oil pump
2 1
2
3
4
5
6
7
8 9 10
000135 000136
Input direction I Input direction II

1 = Hex bolts 6 = Thrust washer
2 = Engine-dependent oil pump 7 = Intermediate gear
3 = Screw plug 8 = Needle sleeve
4 = O-ring 9 = Thrust ring
5 = Hex bolt 10 = Pin
B 07.01.00 Test engine-dependent oil pump, 3081 206 001/013
Removal
01 Remove pipe connections as required according to H 11.00.00.
02 Unscrew fixing bolts (1) for the oil pump.
03 Lift oil pump off cover (use assembly levers placed against housing webs if necessary).
04 For input direction II, remove intermediate gear items 3 to 10 if neccary. See Figure 000136.
2 3 4 5
1 = Tapered pin
2 = O-ring
3 = Woodruff key
4 = Input gear
5 = Retaining ring
A = End float, see D 09.00.00 A
Disassembly 1
05 Remove retaining ring (5). 000137
06 Pull off input gear (4).
B 07.01.00 - 01
BW (BU) 195 A (P), BW (BU) 195 V (P) Engine-dependent oil pump
07 Collect woodruff key (3). Assembly
NOTE: 01 Insert pump pinion into pump housing.

The oil pump is a complete component and is not
normally dismantled. However, after checking or 02 Insert O-rings (2) into pump housing.
cleaning, it may be necessary to dismantle the pump.
When checking the pump, pay particular attention that 03 Position pump cover and bolts, do not tighten
the end float is within the wear limits, see bolts.
D 09.00.00. Check the pump components for traces
of wear. 04 Drive in tapered pins (1) and tighten bolts.
08 Remove fixing bolts from the pump cover, drive 05 Insert woodruff key (3) into pump shaft.
the tapered pins (1) out in the arrowed direction
and remove the pump cover. 06 Heat input gear to approx. 85°C and push onto
pump shaft.
NOTE:
Check parts carefully and clean them. Do not use lint 07 Insert retaining ring (5) into annular groove on
cloths for cleaning. Oil movable parts lightly. pump shaft.
Installation
08 Apply a light coating of sealing compound* to

the pump cover sealing face and fit the pump.
09 Fit pipe connections according to H 11.00.00.
* Sealing compound HYLOMAR SQ 32 M-Special,

see A 11.01.00
B 07.01.00 - 02
BW (BU) 195 A (P), BW (BU) 195 V (P) Propeller-dependent oil pump
000138
000186
Pump drive ratio i = 3.44 Pump drive ratio i = 1.347
1 = O-ring a
2 = Cap screw 3
2 4 5
3 = Woodruff key
4 = Input gear
5 = Retaining ring
A = End float see D 09.00.00
Test propeller-dependent oil pump, 7631 955 120

000139
Removal and Disassembly

03 Lift oil pump off cover (use assembly levers if
necessary).
01 Remove pipe connections as required according
to H 11.00.00.
02 Remove fixing bolts for oil pump.
B 07.01.01 - 01
BW (BU) 195 A (P), BW (BU) 195 V (P) Propeller-dependent oil pump
Disassembly
04 Remove retaining ring (5).
06 Collect woodruff key (3).
NOTE:
normally dismantled. However, after checking or
cleaning, it may be necessary to dismantle the pump.
When checking the pump, pay particular attention that
the end float is within the wear limits, see
D 09.00.00. Check the pump components for traces
of wear.
07 Remove fixing bolts from the pump cover and lift

off pump cover.
NOTE:
Check parts carefully and clean them. Do not use lint
cloths for cleaning. Oil movable parts lightly.
Assembly
01 Insert eccentric ring, inner and outer rotor with

rotor shaft into the pump housing.
02 Position pump cover and screw on tightly.
03 Insert woodruff key (3) into pump shaft.
04 Heat input gear to approx. 85°C and push onto

pump shaft.
05 Insert retaining ring (5) into annular groove on

pump shaft.
Installation
06 Slide O-ring (1) onto pump housing and fit oil

pump to cover.
B 07.01.01 - 02
BW (BU) 195 A (P), BW (BU) 195 V (P) Testing control unit
1
2
3 18
4 17
5
6 16
41 42 11 15
7
8 1314 19
9
10 12
67 20
22 21
40 23
39 24
25
38 26
36 37 27
35 33 28
34 32
31
30
29
000140
1= Screw plug 15 = Rectangular ring 29 = Lever
2= Sealing ring 16 = Piston 30 = Hex bolt
3= Ball 17 = Gasket 31 = Clamping pin
4= Screw plug 18 = Cover 32 = O-ring
5= Sealing ring 19 = Hex bolt 33 = Threaded pin
6= Screw plug 20 = Screw plug 34 = Gasket
7= Sealing ring 21 = Sealing ring 35 = Screw plug
8= Pressure spring 22 = Control housing 36 = Gasket
9= Ball 23 = Rotary distributor 37 = Snap ring
10 = Nut 24 = Clamping pin 38 = Control piston
11 = Hex bolt 25 = Gasket 39 = Pressure spring
12 = Nozzle 26 = Cover 40 = Pressure spring
13 = Spacer bush 27 = Cap screw 41 = Hex bolt
14 = Washer 28 = Hex nut 42 = Hex bolt
Removal, disassembly, assembly and fitting of complete control unit
Removal
02 Unscrew hex bolts (41, 42, 11) and hex nut (10) and remove.
03 Lift off complete control unit and collect gasket (34).
B 07.03.00 - 01
BW (BU) 195 A (P), BW (BU) 195 V (P) Test control unit
Disassembly Installation
04 Remove detent elements (6, 7, 8 and 9). 07 Fit complete control unit with gasket and place in
installation position.
05 Remove lever (29) and cover (26) with gasket
(25). 08 Screw in hex bolts (41, 42, 11) and nut (10) and
tighten.
06 Pull rotary distributor (23) out of control housing.
09 Install pipe connections according to H
07 Unscrew cover (18) and remove gasket (17). 11.00.00.
08 Collect components (16, 15, 14, 13, 40, 39 and

38).
Test: Pressure spring (39) acc. to D 07.00.00

Pressure spring (40) acc. to D 07.00.00
Ensure piston, piston guide and rotary

distributor are not damaged.
NOTE:
Clean parts to remove dirt, lightly oil movable parts.
Assembly
01 Insert components (38, 39, 40, 13, 14, 15 and 16)

into control housing.
02 Fit new gasket (17) and screw on cover (18).
03 Insert rotary distributor (23) into control housing.
05 Fit lever (29).
06 Fit detent elements (9, 8, 7 and 6).
B 07.03.00 - 02
BW (BU) 195 A (P), BW (BU) 195 V (P) Clean oil cooler
1 2
3
4
000141
1 = Oil cooler 3 = Threaded pin

2 = Hex nut 4 = O-ring
Removal, cleaning and installation of oil cooler
01 Remove pipe connections as necessary according

to H 11.01.00.
Removal
02 Unscrew fixing nuts (2) from oil cooler and

remove oil cooler.
B 07.05.00 - 01
Cleaning of oil cooler
000142
In order to achieve uniform cooling capacity and an oil 02 Cleaning the water side
side pressure reduction, certain cleaning operations Before cleaning the water side, examine the dirt
must be performed at particular intervals, especially at which has accumulated. If there is a greasy lime
the oil side. layer, degrease the water side also before
proceeding. Next dissolve the lime layer by
It is not possible to specify in advance the intervals at flushing with water and with lime remover; you
which the cleaning procedure described below should may also use a 10 - 15% hydrochloric acid
be performed because the nature and extent of dirt can solution, with an inhibitor added to ensure that it
vary very greatly. Record operating periods prior to does not attack the metal surfaces.
cleaning and repair work in order to establish a After finishing cleaning, flush out the water side
schedule of operating periods and cleaning work. thoroughly with clear water and then fill the oil
side with oil of the same grade as will be used
We recommend the following cleaning for this disc- during normal operation and drain again.
type oil cooler: Cleaning will be more effective and faster if the
flushing direction at both the water and oil side is
01 Cleaning the oil side opposite to the normal flow direction during
Connect the cooler to a trichlorethane or operation.
perchloroethane unit and flush through with the
hot medium, with the flushing direction opposite Cleaning the cooler in this way ensures that full
to normal oil flow in operation. This removes cooling capacity will be available during
dirt particles, in particular abrasion, from the subsequent operation and there will be a
multi-disc clutches and from the turbulence reasonable pressure drop at the oil side.
baffles of the oil cooler plates, which are then
flushed out by the medium. Insert a suitable
filter into this main flow to remove the impurities
flushed out from the cleaning medium. Continue
cleaning until a check reveals that the purity of
the medium flowing out is equivalent to that
flowing in.
B 07.05.00 - 02
Installation
01 Insert new O-rings into the grooves in the oil

cooler legs.
02 Fit the oil cooler to the transmission housing and

screw on tightly.
03 Attach pipe connections.
B 07.05.00 - 03
BW (BU) 195 A (P), BW (BU) 195 V (P) Section C
NOTE:
You must follow the instrustions in Section A 17.00.00 General - Disassembly, Testing, Reworking and
Assembly.
See booklet - Description, Installation, Operation and

Maintenance (basic version) for maintenance intervals ......................................................................... B 03.00.00
Maintenance steps .................................................................................................................................. B 07.00.00
C 00.00.00 - 01
BW (BU) 195 A (P), BW (BU) 195 V (P) Section D
See Description, Installation, Operation and Maintenance for monitoring values ................................ B 03.00.00
Standard tightening torques for bolts and nuts ...................................................................................... D 01.00.00
Tightening torques for screw plugs and banjo bolts ............................................................................. D 02.00.00
Adjustment data and tightening torques ................................................................................................ D 03.00.00
Oil press-fits........................................................................................................................................... D 05.00.00
Table of springs ...................................................................................................................................... D 07.00.00
Oil pumps (technical data) ..................................................................................................................... D 09.00.00
Table of discs ......................................................................................................................................... D 11.00.00
Pressure relief valves.............................................................................................................................. D 13.00.00
D 00.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Standard tightening torques for bolts and nuts....................................................................................... D 01.01.00
Tightening torques for screw plugs and banjo bolts .............................................................................. D 02.01.00
D 01.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P) Tightening torques
BW (BU) 195 A (P), BW (BU) 195 V (P) for bolts and nuts
Tightening torques for bolts and nuts,

Excerpt from ZFN 148
This Standard applies for bolts to DIN 912, DIN 931, Surface condition of bolts: heat-treated blackened
DIN 933, DIN 960, DIN 961 and for nuts to DIN 934. finish and oiled or galvanized and oiled or galvanized,
chrome-plated and oiled.
This Standard contains data on tightening torques
(MA) for bolts in strength categories 8.8, 10.9 and Tighten bolts using a calibrated snap or pointer-type
12.9 and nuts in strength categories 8, 10 and 12. torque wrench.
Metric coarse thread Metric fine pitch thread
Size Tightening torque Size 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 1112.8 1114,1 1114,8 M 8x1 1124,5 1136 1143

M 5 1115.5 1118,1 1119,5 M 9x1 1136 1153 1162 1
M 6 1119.5 1114 1116,5 M 10x1 1152 1176 1189
M 7 1115.5 1123 1127 M 10x1.25 1149 1172 1184

M 8 1123 1134 1140 M 12x1.25 1187 1125 1150
M 10 1146 1168 1179 M 12x1.5 1183 1122 1145
M 12 1179 1117 1135 M 14x1.5 1135 1200 1235

M 14 1125 1185 1215 M 16x1.5 1205 1300 1360
M 16 1195 1280 1330 M 18x1.5 1310 1440 1520
M 18 1280 1390 1460 M 18x2 1290 1420 1490

M 20 1390 1560 1650 M 20x1.5 1430 1620 1720
M 22 1530 1750 1880 M 22x1.5 1580 1820 1960
M 24 1670 1960 1120 M 24x1.5 1760 1090 1270

M 27 1000 1400 1650 M 24x2 1730 1040 1220
M 30 1350 1900 2250 M 27x1.5 1110 1580 1850
M 27x2 1070 1500 1800

M 30x1.5 1540 2190 2560
M 30x2 1490 2120 2480
Issue date March 1990
D 01.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Tightening torques for screw plugs and banjo bolts .............................................................................. D 02.01.00
D 02.00.00 - 01
Tightening torques for
BW (BU) 190 A (P), BW (BU) 190 V (P)
- Banjo bolts
BW (BU) 195 A (P), BW (BU) 195 V (P)
- Screw plugs
Name Dimension Measuring device Remarks
Housing
Tightening torque for
banjo bolts DIN 7623 with CU flat gasket, screwed into silumin
Banjo bolt
M 14 x 1.5 approx. 40 Nm Torque wrench Ð

M 52 x 1.5 Experience Ð Ð
Tightening torque for

screw plugs DIN 7604 (cylindrical) with CU flat gasket, screwed into silumin
Screw plugs

D 02.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Adjustment data and tightening torques .................................................................................................. D 03.01.00
D 03.00.00 - 01
Adjustment data
BW (BU) 190 A (P), BW (BU) 190 V (P)
and
BW (BU) 195 A (P), BW (BU) 195 V (P)
Tightening torques
Name Dimension Measuring device Remarks
Input shaft:
Tightening torque approx. 550 Nm Experience Locked after tightening

of M 50 x 1.5 grooved nut
End float of pinion 0.6 to Feeler gauge Not adjustable. Measure as

on bearing bush 1.0 mm check only.
Change-over shaft:
Tightening torque approx. 550 Nm Experience Locked after tightening

of M 50 x 1.5 grooved nut
End float of pinion 0.6 to Feeler gauge Not adjustable. Measure as

on bearing bush 1.0 mm check only.
Output shaft
End float of 0.05 - 0.1 mm Measurement gauge Adjust using shim under axial
output shaft roller bearing outer ring.
(Propeller thrust bearing) Pre-load 4000 N
Tightening torque of approx. 800 Nm Experience Locked after tightening

M 90 x 1.5 grooved nut
Tightening torque of approx. 800 Nm Experience Locked after tightening

M 65 x 1.5 grooved nut
D 03.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Table of oil press-fits............................................................................................................................... D 05.01.00
Table of hydraulic nut installation forces ............................................................................................... D 05.02.00
Description of "The Oil Injection Method"............................................................................................. D 05.03.00
Test instruction:
Test that oil press-fit surfaces are free of grease .................................................................................... D 05.04.00
Assembly instruction:
Inspection of tapered oil press-fits which are pressed on fully .............................................................. D 05.05.00
Inspection of tapered oil press-fits which are set and pushed on to specified push-on distances........... D 05.06.00
D 05.00.00 - 01
Table of oil press-fits
BW (BU) 190 A (P), BW (BU) 190 V (P)
(Note on assembly:
BW (BU) 195 A (P), BW (BU) 195 V (P)
see "The Oil Injection Method")
Max. oil pressure

for expanding oil Max. installation Hydraulic nut
press-fits when force of hydr. nuts to be used
pressing on or off (pressure gauge on 1X56 137 170
Push-on distance (pressure gauge reciprocating
i Name in mm* on oil injector) pump)
Input flange 95 kN (9.5 t)

Flange and flex. torsion coupling
on 3.6 - 4.2 = 268 bar X

Input shaft
Flexible torsion 81 kN (8.1 t)

coupling on 4.0 - 4.6 = 227 bar X
input shaft
as a function of the existing axial force and cannot be exceeded because of the oil flowing out.
Note: In practice the max. expansion pressure is obtained automatically
Constant gear 4.0 - 5.3 83 kN (8.3 t) X
Input shaft
on input shaft = 230 bar

Pressure range between 1500 and 3000 bar
Change-over
Constant gear 4.0 - 5.3 83 kN (8.3 t) X

on change-over = 230 bar
shaft
shaft
1.26 Output gear 210 kN (21 t)

to on 6.6 - 8.1 = 550 bar X
2.926 output shaft
Output shaft
* Applies to new parts at room temperature, contact faces not oiled. When re-assembling, the push-on dimension may
be up to 0.15 mm smaller for each re-used part.
D 05.01.00 01
BW (BU) 190 A (P), BW (BU) 190 V (P) Table of hydraulic nut installation forces
BW (BU) 195 A (P), BW (BU) 195 V (P) 1X56 137 227
Oil pressure on Installation forces

pressure gauge of
of reciprocating pump hydraulic nut
450 bar (450 at) = 162 kN (16.2 t)
425 bar (425 at) = 153 kN (15.3 t)
400 bar (400 at) = 144 kN (14.4 t)
375 bar (375 at) = 135 kN (13.5 t)
350 bar (350 at) = 126 kN (12.6 t)
325 bar (325 at) = 117 kN (11.7 t)
300 bar (300 at) = 108 kN (10.8 t)
275 bar (275 at) = 99 kN ( 9.9 t)
250 bar (250 at) = 90 kN ( 9.0 t)
225 bar (225 at) = 81 kN ( 8,1 t)
200 bar (200 at) = 72 kN ( 7.2 t)
175 bar (175 at) = 63 kN ( 6.3 t)
150 bar (150 at) = 54 kN ( 5.4 t)
125 bar (125 at) = 45 kN ( 4.5 t)
100 bar (100 at) = 36 kN ( 3.6 t)
75 bar (75 at) = 27 kN ( 2.7 t)
50 bar (50 at) = 18 kN ( 1.8 t)
25 bar (25 at) = 9 kN ( 0.9 t)
D 05.02.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
The Oil Injection Method
BW (BU) 195 A (P), BW (BU) 195 V (P)
The Oil Injection Method fitted. Use glycerine or oil as a lubricant

(depending on gearbox type). The work is best
Operating principle: performed directly in front of a wall or a work
Tapered and cylindrical oil press-fits are released and bench. The pressurized oil used should have a
joined using this method. Pressure oil is forced viscosity of approx. 300 mm 2/s at room tempera-
through bores and distributing grooves between the ture (approx. 20°C). Should it not be possible to
mating faces and a thin film of oil is formed which produce any pressure, a thicker oil should be used.
separates the components. This greatly reduces the Do not exceed the installation forces given in the
forces required for installing and removing the tables of oil press-fits. The same tables also list the
components or, in the case of the tapered oil press-fit, specified push-on distance "a". The fixtures used
the components jump off quite suddenly when must be in perfect condition, particularly at the
released. threads. The threads must be fully screwed into the
shafts.
!ž DANGER
Special measures:
To prevent any accidents, no-one should be
positioned in front of the pressurized components
when a tapered oil press-fit is being released or
Application: Releasing oil press-fit Fixture arrangement shown for releasing oil press-fit
1 2 3
4 5 6 7
A
000103
1= Hydraulic nut 5= Pump holder

2= Supporting nut 6= Pressure gauge
3= Threaded bolt 7= Oil injector
4= High pressure pump A= Clearance (push-on distance max. +5 to 10 mm)
D 05.03.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
BW (BU) 195 A (P), BW (BU) 195 V (P)
Fit the safety device consisting of parts 1 to 3. The parts to be joined must be at the same
Connect oil injector to flange by means of high temperature, perferably room temperature. First
pressure pipe and bleed the pipe. Pump pressure oil or properly clean the tapers of the shaft and gear or
glycerine between the mating faces until it is flange, do not oil or grease them before measurement.
distributed in the oil press-fit (pressure gauge pressure Fit the gear or flange onto the taper of the shaft but
drops). Continue pumping until the oil press-fit is only until it is seated. Check the push-on distance "a"
released suddenly and with considerable force. in this position. On shafts without a stop collar, the
axial position of the gear or flange relative to the shaft
Measuring push-on distance. must be measured to check on the push-on distance
NOTE: "a" exactly. Remove parts again after meassurement.
The complete new part (replacement part), and not just See also D 05.04.00 - 01 to D 05.06.00 - 02.
the cones and oil injection bores, must be thoroughly
cleaned of any oil and grease.
1 2 3 4
5
6
7
8
A A
B B
9
14 13 12 11 10
000104
Application: Assembling oil press-fit
Arrangement of fixture shown for mounting oil press- 6 = Hydraulic nut

fit. 7 = Support
8 = Bolt
A–A = Assembling with stop collar 9 = Reduction nipple
B–B = Assembling without stop collar 10 = Reciprocating pump
1 = High pressure pipe 11 = Pressure gauge
2 = Pressure gauge 12 = Adaptor
3 = Pump holder 13 = High pressure hose
4 = Oil injector 14 = Measurement gauge with holder
5 = Bush a = Push-on distance
D 05.03.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P)
BW (BU) 195 A (P), BW (BU) 195 V (P)
Fitting:
NOTE:
Before fitting, remove every trace of grease from
injector bores and tapers because, unlike an oil or
glycerine 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 tapers and injector bores.
Connect the press-on apparatus (parts 1 to 13).

Operate both pumps approximately simultaneously
and push on the gear or flange.
When performing this operation, the hydraulic nut
must not push the gear or flange on too rapidly, i.e.
sufficient pressure oil must always be introduced
through the oil injector and distributed over the entire
fitting face to enable the gear or flange to "float" on a
film of oil which has fully spread out.
!ž DANGER
Once the specified push-on distance is reached,
release the oil pressure at the injector first. The oil
pressure in the hydraulic nut should be maintained,
however, until the film of oil in the oil press-fit has
receded and the tapers are firmly seated together.
The minimum waiting is:
a) 15 minutes for tapered oil press-fits with spiral-

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

fixtures, check whether the parts are firmly seated.
NOTE:
When pressing on components, always proceed
according to Sections D 05.04.00 to D 05.06.00.
D 05.03.00 - 03
BW (BU) 190 A (P), BW (BU) 190 V (P)
Test instructions*
BW (BU) 195 A (P), BW (BU) 195 V (P)
Sealing of tapered oil press-fits:
The following parts must be totally free of grease:

- external tapers on shafts
- internal tapers on gears and flanges
- injection holes on shafts, gears and flanges
Pre-clean:
- Pre-cleaning with cold cleaner (alphatic based
hydrocarbon)
- wipe tapered surface 5 times with disposable
paper towel
- rinse and blow out injection holes
(ensure no anti-corrosion compound and/or
grease remains).
Final cleaning:
!ž DANGER:
- Final cleaning with acetone, spirits (Warning:
Inflammable) or standard non-greasy cleaner.
- Soak disposable paper towel in cleaner and
clean tapered surface by wiping over twice.
Loosening an oil press-fit:

Always use oil to loosen oil press-fits.
CAUTION:
Sealing oil press-fits:
Oil press-fits on gearbox types
BW 160 to BW 195
must only be sealed with glycerine.
Oil press-fits on remaining gearbox types may be

sealed with oil or glycerine.
* Extract from Test Instructions 0000 701 084 with

alteration for external use.
D 05.04.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Assembly Instructions*
BW (BU) 195 A (P), BW (BU) 195 V (P)
Check of tapered oil press-fits pushed on as far as possible.
000105
Check using the following instructions to guarantee safety of oil press-fit during power transmission.
CAUTION:
Lack of care may lead to gearbox failure.
1) Take the following measurements before and during sealing.

Dimension L: Hub length
000106
Dimension B: Measured from shaft end face to locating face for hub.
000107
* Extract from Assembly Instructions 0000 701 093
D 05.05.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
BW (BU) 195 A (P), BW (BU) 195 V (P)
Push hub on until it can be moved no further by hand.
C
000108
Dimension C: Distance between shaft end face and hub end face
Press hub up against locating face
D
000109
Dimension D: Distance between shaft end face and hub end face after pressing on hub.
2) Hub is pushed on as far as possible when:
B–L–D=0
3) Calculate Dimension A.
A=D–C
(Dimension A: Calculated actual dimension of push-on distance.
Dimension A must be within the specified push-on distance range.

This means the hub is correctly sealed.
D 05.05.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P)
BW (BU) 195 A (P), BW (BU) 195 V (P)
Check of tapered oil press-fits which are installed to a previously-specified push-on distance.
Type 1 Type 2 Type 3
000111 000112
000110
Check using the following instructions to guarantee safety of oil press-fit during power transmission.
CAUTION
Lack of care can lead to total gearbox failure.
1) Take the following measurements before and during sealing.
Push hub until it cannot be moved any further by hand
C C C
000114 000115
000113
Dimension C: Distance between shaft end face and hub end face before pushing on
D 05.06.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
BW (BU) 195 A (P), BW (BU) 195 V (P)
Press on hub to specified push-on distance
D D
000116 D
000118
000117
Dimension D: Distance between shaft end face and hub end face after pressing on.
2) Calculate Dimension A
A=D–C A=C–D A=D+C
(Dimension A: Calculated actual value of push-on distance)
Dimension A must be within the given push-on distance range.

This means the hub is correctly sealed.
If the condition in 2) is not fulfilled, the complete measurement and sealing procedure must be repeated and
checked to see whether the above condition is then fulfilled.
If the condition is still not fulfilled, this could be due to defective parts.
D 05.06.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Table of springs ....................................................................................................................................... D 07.01.00
D 07.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Table of springs
BW (BU) 195 A (P), BW (BU) 195 V (P)
Part number Location No. of Wire Ø Spring Ø Untensioned

coils in mm in mm length in mm
1217 304 102 Control unit 8.5 1.0 6.0 13.8
0732 041 969 Oil jet and 15.5 3.0 27.16 113.5
flow limiting valve
in Trolling version
0732 041 256 Pressure limiting 6.5 4.0 23.8 36.1

valve (for max.
system pressure)
0732 042 037 Actuation 1 13.0 2.5 16.8 67.3

(Trolling)
0732 041 545 Actuation 110.5 1.3 7.9 22.4

(Trolling)
0732 041 198 Actuation 13.5 1.8 19.3 61.9

(Electronic)
0732 042 118 Control unit and 18.5 4.5 23.7 117.1
switchable PTO
0732 042 119 Control unit and 30.0 2.5 13.3 117.1
switchable PTO
0732 041 996 Piston prepared for 6.5 1.5 10.4 16.7
Trolling version
0732 041 655 Output shaft 5.5 2.25 13.9 19.4
D 07.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Primary oil pump (engine-dependent) .................................................................................................... D 09.01.00
Secondary oil pump (propeller-dependent) ............................................................................................ D 09.02.00
D 09.00.00 - 01
BW (BU) 190 A (P). BW (BU) 190 V (P) Primary oil pump
BW (BU) 195 A (P). BW (BU) 195 V (P) (engine-dependent)
Oil pump (primary) A = End float
3081 206 044 In new condition Wear limit
Input pinion 0.03 to 0.06 mm max. 0.08 mm
Pump gear 0.03 to 0.06 mm max. 0.08 mm
1 = Tapered pin
2 = O-ring 2 3 4 5
3 = Woodruff key
4 = Input gear
5 = Retaining ring
6 = Input pinion
7 = Pump gear
A = End float A
NOTE:
1
normally dismantled.
7 6
000278
However, after checking or cleaning, it may be
necessary to dismantle the pump.

the end float is within the wear limits. Check the
pump components for traces of wear.
Technical data 3081 206 044
cloths for cleaning. Oil movable parts lightly. Minimum delivery = 13 dm3 /min
At pump speed = 400 rpm
Pressure = 20 bar
Temperature = 90°C
Oil quality = SAE 30
Theoretical
delivery = 42.75 cm 3/rev.
Max. operating speed = 2865 rpm
D 09.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P) Secondary oil pump
BW (BU) 195 A (P),BW (BU) 195 V (P) (propeller-dependent)
Oil pump (secondary) A = End float
7631 955 120 In new condition Wear limit
Eccentric ring 0.01 to 0.095 mm max. 0.15 mm
Internal rotor 0.01 to 0.055 mm max. 0.1 mm
External rotor 0.025 to 0.055 mm max.0.1 mm
1 = O-ring 1
2 = Cap screw
3 = Woodruff key 2 3 4 5
4 = Input gear
5 = Retaining ring
6 = Internal rotor
7 = External rotor
8 = Eccentric ring
A = End float
6
NOTE: 7
normally dismantled. 8
However, after checking or cleaning, it may be

necessary to dismantle the pump.
000143
the end float is within the wear limits. Check the Technical data 7631 955 120
pump components for traces of wear.
Minim delivery = 3.7 m3/min
at pump speed = 530 rpm
Pressure = 5 bar
Temperature = 70°C
Oil quality = SAE 30
Max sped = 3600 rpm
Max. pressure = 23 bar
D 09.02.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Table of discs .......................................................................................................................................... D 11.01.00
D 11.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Table of discs
BW (BU) 195 A (P), BW (BU) 195 V (P)
Table for fitting discs to clutch

(Input or change-over shaft)
NOTE:
Outer discs are corrugated.
a) The discs must not have any severe scoring or

discolorations. The discs should not be warped.
b) The minimum depth of the profile of the
grooves on the inner discs must be ≥ 0.2 mm.
000474
Thickness of set
NOTE:
Compress set of discs (tensioned) with two U-irons by means of clamping vices and measure over the U-irons.
No. of friction No. of No. of Permissible thickness of set for re-use

faces depending inner discs outer discs
on gearbox Perm. thickness of Perm. thickness of
version set when tensioned set when tensioned
in mm in mm
12 6 6 40.7 44.3
14 7 7 (*9) 47.5 51.7
16 8 8 54.4 59.1
* Fit 2 dummy external discs for Parts List no. 3081 011 001.
The permissible disc play if the thickness of the disc set is adhered to is:
No. of friction faces Disc play (set untentioned)

min. (mm) max. (mm)
12 1.36 5.10
14 1.57 5.80
16 1.78 6.30
Exchanging individual discs is permitted.

We recommend fitting new discs to the piston side of the clutch.
CAUTION
Always maintain disc play independently of disc set thickness.
D 11.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Pressure relief valves (system pressure) ................................................................................................ D 13.01.00
Pressure relief valves (lubricating oil pressure) ..................................................................................... D 13.02.00
D 13.00.00 - 01
BW (BU) 190 A (P). BW (BU) 190 V (P)
Pressure relief valve
BW (BU) 195 A (P). BW (BU) 195 V (P)
3
1 2
000144
1 = Valve seat 3 = Pressure spring (0732 041 256)

2 = Spring cup A = Function for max. system pressure
Removal and installation of pressure relief valve Installation
01 Remove pipe connections as required according 01 Insert pressure spring (3) and spring cup (2).
to H 11.00.00.
02 Screw in valve seat (1) to the distance noted
during removal.
Removal
02 Measure screw-in depth of valve seat (1) and note

down dimension for subsequent installation.
03 Unscrew valve seat (1).
04 Collect spring cup (2) and pressure spring (3).
Test: Pressure spring (3) according to

Table of Springs D 07.00.00.
D 13.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
BW (BU) 195 A (P), BW (BU) 195 V (P)
1
2
3
4
000145
1 = Screw plug 3 = Pressure spring (0732 041 969)

2 = Sealing ring 4 = Piston
01 Unscrew screw plug (1).
02 Collect parts (2 to 4).
Test: Pressure spring (3) according to Table of Springs

D 07.00.00.
Check piston and piston guide for fretting or scoring.
NOTE:
Ensure parts are free of dirt. Lightly oil movable
parts. Fit new sealing ring.
Installation
01 Insert piston (4) and pressure spring (3).
02 Fit new CU sealing ring (2) to screw plug (1).

Screw in screw plug (1) and tighten.
D 13.02.00 - 01
BW (BU) 195 A (P), BW (BU) 195 V (P) Section E
Special tools............................................................................................................................................. E 01.00.00
E 00.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Tool set (W 1) for maintenance work ...................................................................................................... E 01.01.00
Tool set (W 2) special tools for major overhaul....................................................................................... E 01.02.00
E 01.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Tool set (W 1) for gearbox maintenance work is listed in Section B 05.00.00 .
E 01.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Special tools
BW (BU) 195 A (P), BW (BU) 195 V (P)
Fig. Quan-
Special tools Order no. Application Remarks
No. tity
1X56 130 588 1 BW (BU)

190 A (P)
High pressure hose
195 A (P)
(in connection with reciprocating
1 pump) BW (BU)
190 V (P)
195 V (P)
1X56 130 589 1 BW (BU)

190 A (P)
Reciprocating pump
195 A (P)
for hydraulic nuts
2 BW (BU)
190 V (P)
195 V (P)
1X56 130 591 1 BW (BU)

190 A (P)
Adaptor
195 A (P)
for pressure gauge R 1/2"
3 BW (BU)
190 V (P)
195 V (P)
1X56 130 592 1 BW (BU)

190 A (P)
Pressure gauge R 1/2"
195 A (P)
for checking oil pressure in
4 hydraulic nuts BW (BU)
190 V (P)
195 V (P)
1X56 130 595 1 BW (BU)

190 A (P)
Oil injector
195 A (P)
for expanding oil press-fits
-
5 BW (BU)
190 V (P)
195 V (P)
E 01.02.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Special tools
BW (BU) 195 A (P), BW (BU) 195 V (P)
Fig. Quan-
No. tity
1X56 130 597 1 BW (BU)

190 A (P)
Pump holder
195 A (P)
for oil injector
6 BW (BU)
190 V (P)
195 V (P)
1X56 130 601 1 BW (BU)

190 A (P)
High pressure line
195 A (P)
(in combination with pump holder
7 and connections for oil press-fits) BW (BU)
190 V (P)
195 V (P)
1X56 130 604 1 BW (BU)

190 A (P)
Pressure gauge
195 A (P)
for checking oil pressure in oil
8 press-fits BW (BU)
190 V (P)
195 V (P)
1X56 136 461 1 BW (BU)

190 A (P)
Bolt M 24 x 2
195 A (P)
for input flange and various removal
9 operations BW (BU)
190 V (P)
195 V (P)
1X56 136 513 1 BW (BU)

190 A (P)
Hot-air blower
195 A (P)
for heating various parts
10 BW (BU)
190 V (P)
195 V (P)
E 01.02.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P)
Special tools
BW (BU) 195 A (P), BW (BU) 195 V (P)
Fig. Quan-
No. tity
1X56 136 564 1 BW (BU)

190 A (P)
Hook
195 A (P)
for removal and installation of
11 output flange BW (BU)
190 V (P)
195 V (P)
1X56 137 030 1 BW (BU)

190 A (P)
Pipe elbow
195 A (P)
for use in connection with hydraulic
12 nut (1X56 137 227) BW (BU)
190 V (P)
195 V (P)
1X56 137 055 1 BW (BU)

190 A (P)
Socket driver
195 A (P)
for emergency control cap screws
13 (shorten if necessary) BW (BU)
190 V (P)
195 V (P)
1X56 137 450 1 BW (BU)

190 A (P)
Gearbox swivel stand
195 A (P)
14 BW (BU)
190 V (P)
195 V (P)
1X56 137 222 1 BW (BU)

190 A (P)
Ring spanner
195 A (P)
for M 50 x 1.5 grooved nut on
15 input and change-over shaft BW (BU)
190 V (P)
195 V (P)
E 01.02.00 - 03
BW (BU) 190 A (P), BW (BU) 190 V (P)
Special tools
BW (BU) 195 A (P), BW (BU) 195 V (P)
Fig. Quan-
No. tity
1X56 137 224 1 BW (BU)

190 A (P)
Ring spanner
195 A (P)
for M 90 x 1.5 grooved nut
16 on output shaft BW (BU)
190 V (P)
195 V (P)
1X56 137 225 1 BW (BU)

190 A (P)
Lifting device
195 A (P)
M 50 x 1.5 for input and change-
17 over shafts BW (BU)
190 V (P)
195 V (P)
1X56 137 226 1 BW (BU)

190 A (P)
Nut M 24 x 2
195 A (P)
for input flange or flexible coupling
18 and various removal operations BW (BU)
190 V (P)
195 V (P)
1X56 137 227 1 BW (BU)

190 A (P)
Hydraulic nut
195 A (P)
for various fitting and removal
19 operations BW (BU)
190 V (P)
195 V (P)
1X56 137 228 2 BW (BU)

190 A (P)
Adapter
195 A (P)
for clamping the gearbox in
20 connection with gearbox swivel BW (BU)
stand 190 V (P)
1X56 137 150 195 V (P)
E 01.02.00 - 04
BW (BU) 190 A (P), BW (BU) 190 V (P)
Special tools
BW (BU) 195 A (P), BW (BU) 195 V (P)
Fig. Quan-
No. tity
1X56 137 229 1 BW (BU)

190 A (P)
Removal plate
195 A (P)
21 BW (BU)
190 V (P)
195 V (P)
1X56 137 230 1 BW (BU)

190 A (P)
Pull-out ring
195 A (P)
for intermediate bush on input shaft
22 BW (BU)
190 V (P)
195 V (P)
1X56 137 231 1 BW (BU)

190 A (P)
Push-on disc
195 A (P)
for pump gear and cover of output
23 shaft BW (BU)
190 V (P)
195 V (P)
1X56 137 232 1 BW (BU)

2 190 A (P)
Set of nuts and bolts
195 A (P)
1 5 for various removal and installation
24 6
operations BW (BU)
190 V (P)
10 7
11
195 V (P)
8
1X56 137 260 1 BW (BU)

190 A (P)
Adaptor
195 A (P)
for shaft sealing ring
25 105 x 130 x 16 BW (BU)
on output for clamping self-aligning 190 V (P)
bearing on input shaft 195 V (P)
E 01.02.00 - 05
BW (BU) 190 A (P), BW (BU) 190 V (P)
Special tools
BW (BU) 195 A (P), BW (BU) 195 V (P)
Fig. Quan-
No. tity
1X56 137 277 1 BW (BU)

190 A (P)
Pressure piece
195 A (P)
for pushing on output gear
26 BW (BU)
190 V (P)
195 V (P)
1X56 137 289 1 BW (BU)

190 A (P)
Pressure piece
195 A (P)
for flexible coupling
27 BW (BU)
190 V (P)
195 V (P)
1X56 137 411 3 BW (BU)

190 A (P)
Fixing piece
195 A (P)
for output shaft of cover
28 BW (BU)
190 V (P)
195 V (P)
1X56 137 448 4 BW (BU)

190 A (P)
Removal hook
195 A (P)
for self-aligning roller bearings on
29 output shaft BW (BU)
190 V (P)
195 V (P)
1X56 137 473 1 BW (BU)

190 A (P)
Pressure piece
195 A (P)
X
for expanding and simultaneously
30 pushing shaft out of self-aligning BW (BU)
roller bearing of input and change- 190 V (P)
over shafts. Rework dimensions X 195 V (P)
and Y on old version.
Y
X = 19.5 mm / Y = Ø 24 mm
E 01.02.00 - 06
BW (BU) 190 A (P), BW (BU) 190 V (P)
Special tools
BW (BU) 195 A (P), BW (BU) 195 V (P)
Fig. Quan-
No. tity
1X56 137 574 1 BW (BU)

190 A (P)
Nipple
195 A (P)
R 1/4" x R 1/8" for expanding bush
31 of self-aligning roller bearing on BW (BU)
input shaft 190 V (P)
195 V (P)
1X56 137 922 1 BW (BU)

190 A (P)
Lifting device
195 A (P)
for input shaft
32 BW (BU)
190 V (P)
195 V (P)
1X56 137 922

1X56 137 926 1 BW (BU)
190 A (P)
Grooved nut socket
195 A (P)
for M 65 x 1.5 grooved nut
33 on output shaft BW (BU)
190 V (P)
195 V (P)
1X56 137 927 1 BW (BU)

190 A (P)
Extension piece
195 A (P)
R 1/4" x R 1/4" for sliding on output
34 gear and expanding self-aligning BW (BU)
roller bearing on input and change- 190 V (P)
over shafts 195 V (P)
1X56 137 928 1 BW (BU)

190 A (P)
Removal plate
195 A (P)
in connection with
35 1X56 137 929 BW (BU)
1X56 137 930 190 V (P)
195 V (P)
E 01.02.00 - 07
BW (BU) 190 A (P), BW (BU) 190 V (P)
Spezialwerkzeug
BW (BU) 195 A (P), BW (BU) 195 V (P)
Fig. Quan-
No. tity
1X56 137 929 1 BW (BU)

190 A (P)
Removal device
195 A (P)
for pulling out the cylinder roller
36 bearing outer ring on the output BW (BU)
shaft in connection with 190 V (P)
1X56 137 928 195 V (P)
1X56 137 930 1 BW (BU)

190 A (P)
Removal device
195 A (P)
for removing the cylinder roller
37 bearing inner ring on the output BW (BU)
shaft in connection with 190 V (P)
1X56 137 928 195 V (P)
1X56 137 931 1 BW (BU)

190 A (P)
Pressure piece
195 A (P)
for removing the self-aligning roller
38 bearings and bushes from the input BW (BU)
and change-over shafts 190 V (P)
195 V (P)
1X56 137 932 1 BW (BU)

190 A (P)
Pressure piece
195 A (P)
for releasing and pushing the
39 constant gear onto the input shaft BW (BU)
190 V (P)
195 V (P)
1X56 137 942 1 BW (BU)

190 A (P)
Pressure piece
195 A (P)
for pulling the cylinder roller
40 bearing inner ring off the output BW (BU)
shaft 190 V (P)
195 V (P)
E 01.02.00 - 08
BW (BU) 190 A (P), BW (BU) 190 V (P)
Special tools
BW (BU) 195 A (P), BW (BU) 195 V (P)
Fig. Quan-
No. tity
1X56 137 943 1 BW (BU)

190 A (P)
Support cap
195 A (P)
for removing the cylinder roller
41 bearing outer ring and the cylinder BW (BU)
roller bearing inner ring on the input 190 V (P)
shaft 195 V (P)
E 01.02.00 - 09
BW (BU) 195 A (P), BW (BU) 195 V (P) Section F
NOTE:
You must follow the instructions in Section A 17.00.00 General - Disassembly, Testing, Reworking and
Assembly.
Control unit ............................................................................................................................................. F 01.00.00
Input flange, flexible coupling, input shaft sealing ring ......................................................................... F 03.00.00
Oil pumps................................................................................................................................................ F 05.00.00
Replacing discs on the input or change-over shafts ................................................................................ F 07.00.00
F 00.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Control unit............................................................................................................................................ F 01.01.00
F 01.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Testing control unit
BW (BU) 195 A (P), BW (BU) 195 V (P)
1
2
3 18
4 17
5
6 16
41 42 11 15
7
8 1314 19
9
10 12
67 20
22 21
40 23
39 24
25
38 26
36 37 27
35 33 28
34 32
31
30
29
000140
1= Screw plug 15 = Rectangular ring 29 = Lever

2= Sealing ring 16 = Piston 30 = Hex nut
3= Ball 17 = Gasket 31 = Clamping pin
4= Screw plug 18 = Cover 32 = O-ring
5= Sealing ring 19 = Hex bolt 33 = Threaded pin
6= Screw plug 20 = Screw plug 34 = Gasket
7= Sealing ring 21 = Sealing ring 35 = Screw plug
8= Pressure spring 22 = Control housing 36 = Gasket
9= Ball 23 = Rotary distributer 37 = Circlip
14 = Washer 28 = Hex bolt 42 = Hex bolt
Removal, disassembly, assembly and fitting of Removal

complete control unit
02 Unscrew hex bolts (41, 42, 11) and hex nut (10)
01 Remove pipe connections as required according and remove.
to H 11.00.00. .
03 Lift off complete control unit and collect gasket
(34).
F 01.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Control Unit
BW (BU) 195 A (P), BW (BU) 195 V (P)
04 Remove detent elements (6, 7, 8 and 9). 07 Fit complete control unit with gasket and place in
installation position.
(25). 08 Screw in hex bolts (41, 42, 11) and nut (10) and
tighten.
06 Pull rotary distributor (23) out of control housing.
09 Install pipe connections according to H
07 Unscrew cover (18) and remove gasket (17). 11.00.00.
08 Collect components (16, 15, 14, 13, 40, 39 and

38).
Test: Pressure spring (39) 0732 042 119 acc. to

Table of Springs D 07.00.00
Pressure spring (40) 0732 042 118 acc. to
Pressure spring (8) 1217 304 102 acc. to

NOTE:
Assembly
01 Insert components (38, 39, 40, 13, 14, 15 and 16)

03 Insert rotary distributor (23) into control housing.
05 Fit lever (29).
F 01.01.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Removal and installation of input flange BW 190 V (P), BW 195 V (P) .............................................F 03.01.00
Removal and installation of input flange BW 190 V (P), BW 195 V (P) .............................................F 03.02.00
Removal and installation of flexible coupling BW 190 V (P), BW 195 V (P)......................................F 03.03.00
Input shaft sealing ring ......................................................................................................................F 03.04.00
Upper section of diagram shows

direction of rotation I
Lower section of diagram shows

direction of rotation II
000096
NOTE:
= input direction I
................................................................................................................

counter-clockwise -
000094

clockwise -
000095
F 03.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Input flange
BW (BU) 195 A (P), BW (BU) 195 V (P)
1 2 3 4
8 7 6 5
000 146
000146
1 = Oil injector 1X56 130 595 5 = Input flange
2 = Pressure gauge 1X56 130 604 6 = Hydraulic nut 1X56 130 227
3 = Pump holder 1X56 130 597 7 = Nut 1X56 130 226
4 = High pressure line 1X56 130 601 8 = Bolt 1X56 130 461
A = Distance approx.12 - 15 mm
Removal and installation of input flange
Removal
01 Set up equipment as shown in drawing.
! DANGER Once pressure is applied to conical oil press-fits,

Important information for the following procedure! they will come off automatically and abruptly.
Ensure that all equipment used is in perfect Follow the instructions in Section D 05.00.00
condition, especially the screw threads. exactly when removing and installing conical oil
Ensure that threaded connections are screwed on or press-fits.
in as far as possible. When using threaded rods for
bracing purposes, always use all available bracing Pay particular attention to the paragraphs dealing
points. with cleaning, push-on distances and pushing on
When loosening or pushing on a conical oil press- part-way and fully.
fit, ensure that no-one is standing in front of the
pressurized components. This instruction is
intended to prevent accidents. 02 Loosen input flange (5).
We strongly recommend that you perform this
procedure directly in front of a wall or workbench.
F 03.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Input flange
BW (BU) 195 A (P), BW (BU) 195 V (P)
1 2 3 4 5 6
13
12
11
000 147
10 9 8 7
1 = Oil injector 1X56 130 595 7 = High pressure hose 1X56 130 588
2 = Pressure gauge 1X56 130 604 8 = Pressure gauge 1X56 130 592
3 = Pump holder 1X56 130 597 9 = Adapter 1X56 130 591
4 = High pressure line 1X56 130 601 10 = Reciprocating pump 1X56 130 589
5 = Measurement gauge with holder 11 = Bolt 1X56 130 461
6 = Input flange 12 = Nut 1X56 130 226
13 = Hydraulic nut 1X56 130 227
Installation

in as far as possible. When using threaded rods for Pay particular attention to the paragraphs dealing
bracing purposes, always use all available bracing with cleaning, push-on distances and pushing on
points. part-way and fully.
When loosening or pushing on a conical oil press-
fit, ensure that no-one is standing in front of the 02 Push on input flange (6).
intended to prevent accidents. 03 Remove equipment.
F 03.01.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P)
Input flange
BW (BU) 195 A (P), BW (BU) 195 V (P)
1 A
3
4
I
II
8 7 6 5
000 148
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 line 1X56 130 601
Removal and installation of input flange
Removal

pressurized components. This instruction is 02 Release input flange.
intended to prevent accidents.
F 03.02.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Input flange
BW (BU) 195 A (P), BW (BU) 195 V (P)
3
4
I
5
II
6
7
13 12 11 10 9 8 000 149
1 = Input flange 8 = Adapter 1X56 130 591

2 = Measurement gauge with holder 9 = Pressure gauge 1X56 130 592
3 = Hydraulic nut 1X56 137 227 10 = High pressure line 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 pump 1X56 130 589 13 = Oil injector 1X56 130 595
7 = High pressure hose 1X56 130 588
Installation

intended to prevent accidents. 02 Push on input flange.
procedure directly in front of a wall or workbench. 03 Remove equipment.
F 03.02.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P)
Flexible coupling
BW (BU) 195 A (P), BW (BU) 195 V (P)
1 2 3 4 5
6
7
I 8
II 9
000 150
1 = Flexible coupling 6 = Pressure piece 1X56 137 289

2 = High pressure line 1X56 130 601 7 = Hydraulic nut 1X56 137 227
4 = Pressure gauge 1X56 130 604 9 = Bolt 1X56 130 461
5 = Oil injector 1X56 130 595 A = Distance approx. 12 - 15 mm
Removal and installation of flexible coupling
Removal

intended to prevent accidents. 02 Loosen flexible coupling.
F 03.03.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Flexible coupling
BW (BU) 195 A (P), BW (BU) 195 V (P)
1 2 3 4 5
6
7
I 8
II 9
10
11
000 151
14 13 12
1 = Flexible coupling 8 = Nut 1X56 130 226
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 = Adapter 1X56 130 591
6 = Pressure piece 1X56 137 289 13 = Pressure gauge 1X56 130 592
7 = Hydraulic nut 1X56 137 227 14 = Measurement gauge with holder
Installation

intended to prevent accidents. 02 Push on flexible coupling.
F 03.03.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P)
Input shaft sealing ring
BW (BU) 195 A (P), BW (BU) 195 V (P)
Version BW ... V (P) Version BW ... A (P)
1 2 3
4 5 6 7
II
3 2
000153
004 949
1 = Bush 5 = Washer
2 = Sealing ring cover or mounting cap 6 = Sealing ring bush
3 = Shaft sealing ring 7 = Washer
4 = Snap ring
Removal and installation of input shaft sealing ring Installation
Removal NOTE:
a) Apply a thin coat of sealing compound* to the
01 Remove input flange or flexible coupling external steel jacket of the shaft sealing ring.
according to F 03.00.00 . b) Moisten the outer circumference of the shaft
02 Remove mounting cap (if fitted) or sealing ring sealing ring with rubber shell with a lubricant such
cover (2). as water-soluble washing-up liquid.
c) Shaft sealing rings with steel and rubber shells
NOTE: should be coated on the outside of their rubber
Check bush (1) for traces of wear. If the bush needs to shell with a lubrication agent, e.g. water-soluble
be reworked or replaced, remove the snap ring (4) and washing-up liquid (Fairy Liquid etc.).
washer (5) in Versionn V (P). Remove the bush (6) d) The double shaft sealing ring consists of two seal
using 2-arm puller (heat bush if necessary). In Version lips. The dustproof seal lip (X) must point
A (P) remove input shaft as described in Sections outwards.
H 29.00.00 and H 31.00.00 and pull off sealing ring e) Fill 60% of gap between sealing lips with grease
bush. (e.g. Aral - Aralube HL2 or Texaco FO 20).
f) Heat shaft sealing ring hole to 40 - 50°C if possible
03 Drive shaft sealing ring out of mounting cap or (this facilitates installation). Press shaft sealing
sealing ring cover (2). ring in with adapter or plane face.
Ensure correct installation depth
and angle.
*See Comsumables A 11.00.00. X

000102
F 03.04.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Input shaft sealing ring
BW (BU) 195 A (P), BW (BU) 195 V (P)
01 Insert new shaft sealing ring (3) into cover,

according to version. Ensure sealing ring is
installed the right way round. Lightly grease
sealing lip of sealing ring.
02 For Version V (P)

If removed, heat sealing ring bush (6) to 85°C,
ensure is the right way round and sealing ring
bush (6) and push onto input shaft. Allow to
cool. Push on washer (5) and insert snap ring (4).
For Version A (P)
If removed, fit bush (1) as described in Section
H 31.00 00 .
Install input shaft as described in Sections
H 31.00 00 and H 29.00 00 .
03 Apply a thin coating of sealing compound* to

mounting cap or cover (2) sealing face and fit
onto the housing.
04 Install input flange or flexible coupling according

to F 03.00.00 .
*See Consumables A 11.00.00
F 03.04.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Primary oil pump (engine-dependent) .................................................................................................. F 05.01.00
Secondary oil pump (propeller-dependent) (BW 190 A + V) .............................................................. F 05.02.00
NOTE:
= input direction I

counter-clockwise - viewed from the engine output -
000094

clockwise -
000095
F 05.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Oil pumps
BW (BU) 195 A (P), BW (BU) 195 V (P)
000154
F 05.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P) Oil pumps
BW (BU) 195 A (P), BW (BU) 195 V (P) (engine-dependent)
2
1
2
3
4
5
6
7
8 9 10
000136
000135
Input direction I Input direction II

3 = Screw plug 8 = Needle sleeve
Oil pumps 3081 206 044 / 3081 206 046

(engine-dependent)
Removal
01 Remove pipe connections as required according 03 Lift oil pump off cover (use assembly levers
to H 11.00.00. placed against housing webs if necessary).
02 Unscrew the fixing bolts (1) for the oil pump. 04 For input direction II, remove intermediate gear
items 3 to 10 if necessary. See Figure 000136.
2 3 4 5
1 = Tapered pin
2 = O-ring
3 = Woodruff key
4 = Input gear
A 5 = Retaining ring
A = End float, see D 09.00.00
1
000137
F 05.01.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P) Oil pump
BW (BU) 195 A (P), BW (BU) 195 V (P) (engine-dependent)
Disassembly Assembly
05 Remove retaining ring (5). 01 Insert pump pinion into pump housing.
06 Pull off input gear (4). 02 Insert O-rings (2) into pump housing.
07 Collect woodruff key (3). 03 Position pump cover and bolts, do not tighten
bolts.
NOTE:
The oil pump is a complete component and is not 04 Drive in tapered pins (1) and tighten bolts.
normally dismantled. However after checking or
cleaning it may be necessary to dismantle the pump. 05 Insert woodruff key (3) into pump shaft.
When checking the pump, pay particular attention that 06 Heat input gear to approx. 85°C and push onto
the end float is within the wear limits, see pump shaft.
D 09.00.00.
Check the pump components for traces of wear. pump shaft.
08 Remove fixing bolts from the pump cover, drive

the tapered pins (1) out in the arrowed direction Installation
and remove the pump cover.
08 For gearboxes with direction of rotation II, install
NOTE: intermediate gear drive items 3 to 10, Fig.
Check parts carefully and clean them. Do not use lint 000136 if removed.
09 Apply a light coating of sealing compound* to
the pump cover sealing face and fit the pump.
* See Consumables A 11.00.00
F 05.01.00 - 03
BW (BU) 195 A (P), BW (BU) 195 V (P) (propeller-dependent)
A B
000155 000156
NOTE:
Screw a hex bolt and washer with sealing compound
into A and B in versions without oil pump.
1= Propeller-dependent oil pump 5 6

2= Screw plug 4 7
3= Hex bolt 3
4= Thrust washer 2
1
5= Intermediate gear
6 = Thrust ring
7 = Pin
8 = Needle sleeve
9 = O-ring
10 = O-ring 10 9 8
000157
Oil pump 7631 955 120 (propeller-dependent)
Removal
01 Remove pipe connections as required according

to H 11.00.00 .
02 Unscrew fixing nuts from oil pump.
03 Lift off oil pump (use assembly lever if

necessary).
F 05.02.00 - 01
BW (BU) 195 A (P), BW (BU) 195 V (P) (propeller-dependent)
NOTE:
normally dismantled.
However after checking or cleaning it may be
necessary to dismantle the pump.When checking the
pump, pay particular attention that the end float is
within the wear limits, see D 09.00.00.
Check the pump components for traces of wear.
2 3 4 5
1 = O-ring
2 = Cap screw
3 = Woodruff key
4 = Input gear
5 = Retaining ring
a = End float, see D 09.00.00
1
Assembly
000139
Disassembly
04 Unclip retaining ring (5).
pump shaft.
06 Collect woodruff key (3).
07 Remove fixing bolts from the pump cover and lift 05 Insert retaining ring (5) into annular groove on
off pump cover. pump shaft.
NOTE:
Installation
pump to cover.
F 05.02.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Replacment of input shaft and change-over shaft discs
Removal and installation of covers ......................................................................................................... F 07.01.00
Removal and installation of input shaft and change-over shaft cover ..................................................... F 07.02.00
Pressing input shaft or change-over shaft constant gear off and on ........................................................ F 07.03.00
Removal and installation of input shaft and change-over shaft disc sets ................................................ F 07.04.00
F 07.00.00 - 01
BW (BU) 190 A (P) Replacement of input shaft and
BW (BU) 195 A (P) change-over shaft discs
II
1 2 3 4 6
II
000292
1 = Cover 4 = Pressure piece

2 = Grooved nut M 50 x 1.5 5 = Cover
3 = 3-arm puller 6 = Input gear
Removal and installation of covers Installation
01 Remove pipe connections as required according 01 Heat input gear (6) to approx. 85°C and push
to H 11.00.00 . onto change-over shaft. Ensure correct
orientation of input gear (6).
02 Remove oil pump according to F 05.00.00 .
02 Screw grooved nut (2) onto change-over shaft
and tighten using socket 1X56 137 222. Lock
Removal grooved nut (2) carefully.
03 Remover covers (1 and 5). 03 Apply a thin coat of sealing compound* to the
sealing faces of covers (1 and 5) and fit.
04 Release grooved nut (2) and remove using socket
1X56 137 222. 04 Install oil pump according to F 05.00.00.
05 Pull off input gear (6) using 3-arm puller. 05 Fit pipe connections according to H 11.00.00.
06 Remove cover according to F 07.02.00.
* Sealing compound Hylomar SQ 32 M Special, see

A 11.00.00
F 07.01.00 - 01
II
2 3
2 3
II
000294
1 = Cover 3 = Cylinder roller bearing inner ring

2 = Cylinder roller bearing outer ring
Removal and installation of input shaft and change- Installation

over shaft cover
01 Heat cylinder roller bearing inner ring to 85°C
01 Remove covers according to F 07.01.00 . and push fully onto the input or change-over
shaft. Ensure correct orientation of cylinder
Removal roller bearing inner ring.
02 Unscrew fixing bolts from cover (1) and push off 02 Insert cylinder roller bearing outer rings (2) into
cover. the cover.
03 Drive cylinder roller bearing outer rings (2) out 03 Apply a thin coat of sealing compound* to the
of cover. sealing face of the cover.
04 Using 2-arm puller, pull the cylinder roller 04 Carefully position cover (1) onto the housing and
bearing inner ring (3) off the input or change-over screw tight.
shaft.
05 Install covers according to F 07.01.00.
05 Remove constant gear according to F 07.03.00.
* Sealing compound, see A 11.00.00
F 07.02.00 - 01
1 2 3 4 5 6 7 8 9 10
II
II
000293
1 = Oil injector 1X56 130 595 6 = Emergency shift device

2 = Pressure gauge 1X56 130 604 7 = Constant gear
3 = Pump holder 1X56 130 597 8 = Piston
4 = High pressure line 1X56 130 601 9 = Rectangular ring
5 = Hydraulic nut 1X56 137 227 10 = Input shaft
Pressing input shaft or change-over shaft constant condition, especially the screw threads.
gear off and on Ensure that threaded connections are screwed on or
01 Remove cover for input shaft and change-over bracing purposes, always use all available bracing
shaft according to F 07.02.00. points,
Removal fit, ensure that no-one is standing in front of the
NOTE: intended to prevent accidents.
Do not mix up input shaft and change-over shaft We strongly recommend that you perform this
constant gear. These gears are differentiated by the procedure directly in front of a wall or workbench.
direction of their helical gearing. Always refer to the Once pressure is applied to conical oil press-fits,
parts numbers. they will come off automatically and abruptly.
Gear with parts no. 3081 302 ... Follow the instructions in Section D 05.00.00
Spare parts no. 3081 202 ... for input shaft exactly when removing and installing conical oil
Gear with parts no. 3081 303 ... press-fits.
Spare parts no. 3081 203 ... for change-over shaft
Pay particular attention to the paragraphs dealing
02 Set up equipment as shown in diagram. with cleaning, push-on values and pushing on part-
way and fully.
! DANGER
Important information for the following procedure! 03 Loosen constant gear (7 ).
Ensure that all equipment used is in perfect
F 07.03.00 - 01
04 Remove piston (8) from constant gear and

remove rectangular ring.
05 Remove emergency shift device (6), if required.
06 Remove disc set according to F 07.04.00 .
F 07.03.00 - 02
1 2 3 4 5 6 7 8 9 10
II
14 13 12 11
II
000295
1 = Oil injector 1X56 130 595 8 = Piston

2 = Pressure gauge 1X56 130 604 9 = Rectangular ring
3 = Pump holder 1X56 130 597 10 = Input shaft
4 = High pressure line 1X56 130 601 11 = High pressure hose 1X56 130 588
6 = Emergency control unit 13 = Adapter 1X56 130 591
7 = Constant gear 14 = Reciprocating pump 1X56 130 589
Installation
01 Install discs according to F 07.04.00. 04 When installing constant gear (7) check correct
spare parts no. and ensure the constant gear is the
02 Check emergency shift device and install if right way round. Push on as described in Section
removed from constant gear. D 05.00.00, "The Oil Injection Method" and
measure push-on distance.
NOTE:
Stretch rectangular ring (9) well before fitting constant NOTE:
gear. Take care not to damage the rectangular ring (9) on the
piston when pushing on the constant gear.
03 Insert rectangular rings into piston (8) and place
piston in constant gear.
F 07.03.00 - 03
05 Set up equipment as shown in diagram.
! DANGER
Important information for the following procedure!
condition, especially the screw threads.
Ensure that threaded connections are screwed on or
bracing purposes, always use all available bracing
points.
Once pressure is applied to conical oil press-fits,
they will come off automatically and abruptly.
Follow the instructions in Section D 05.00.00
exactly when removing and installing conical oil
press-fits.

with cleaning, push-on values and pushing on part-
way and fully.
06 Push on constant gear.
07 Fit input shaft and change-over shaft cover

according to F 07.02.00.
F 07.03.00 - 04
1 2 3 4
II
II
000296
1 = Plate springs (6) 3 = External disc

2 = Internal disc 4 = End shim
Removal and installation of input shaft and change-

over shaft disc sets
01 Remove constant gear according to F 07.03.00 .
Removal
02 Remove 6 plate springs (1) from shaft.
03 Remove internal and external discs (2 and 3)

from disc carrier.
04 Remove end shim (4) from disc carrier.
F 07.04.00 - 01
14 15 16
II
II
000297
14 = Internal disc carrier

15 = Snap ring
16 = Input shaft 2
1
Installation
NOTE:
2
When sliding on the external discs, pay attention to the
marking on the disc driver lug. Each external disc has
a marking on two driver lugs. One marking is narrow 000101
and the other wide. Insert the outer discs as follows: 2 = Wide marking
Start with the narrow marking centered and the wide 1 = Narrow marking
marking to the right or left of the narrrow marking
when the first external disc is inserted. Insert the Example: 1. Wide marking of external disc to the
remaining external discs with the wide markings right of the narrow marking.
alternatively left and right of the narrow central 2. Wide marking of the external disc to
markings. the left of the narrow marking.
3. Wide marking of the external disc to
the right of the narrow marking, etc.
(see diagram above).
F 07.04.00 - 02
01 Push end shim (4) onto disc carrier. Ensure end

shim (4) is the right way round.
02 Assemble disc set (discs 2 and 3) according to the

Table of Discs in Section D 11.00.00 for the
gearbox type in alternative sequence - external
disc, internal disc - starting with an external disc.
Ensure compliance with the instructions above
and push the disc set into the disc carrier.
03 If disc set has been assembled correctly, it will

have the prescribed disc play.
04 Push on 6 plate springs (1) assembled correctly

(see diagram) onto the input shaft.
05 Push on constant gear according to F 07.03.00.
F 07.04.00 - 03
BW (BU) 195 A (P), BW (BU) 195 V (P) Section G
NOTE:
You must follow the instructions in Section A 17.00.00 General - Disassembly, Testing, Re-working and
Assembly.
Removal and installation of gearbox (refer to Manual - Description,

Installation, Operation and Maintenance, basic version)........................................................................ B 03.00.00
G 00.00.00 - 01
BW (BU) 195 A (P), BW (BU) 195 V (P) Section H
NOTE: You must follow the instructions in Section A 17.00.00 General - Disassembly, Testing, Re-working
and Assembly
Removal and installation sequence of main groups ............................................................................. H 01.00.00
Control unit .......................................................................................................................................... H 07.00.00
Filter ..................................................................................................................................................... H 09.00.00
Pipe connections ................................................................................................................................... H 11.00.00
Oil cooler............................................................................................................................................... H 13.00.00
Oil pumps.............................................................................................................................................. H 15.00.00
Valves .................................................................................................................................................... H 17.00.00
Gearbox mountings ............................................................................................................................... H 19.00.00
Input flange, flexible coupling .............................................................................................................. H 21.00.00
Flange-mounted bell housing................................................................................................................ H 27.00.00
Cover BW 190 A, BW 195 A .............................................................................................................. H 29.00.00
Cover BW 190 V, BW 195 V ............................................................................................................... H 30.00.00
Input shafts BW 190 A, BW 195 A ..................................................................................................... H 31.00.00
Input shafts BW 190 V, BW 195 V ...................................................................................................... H 32.00.00
Change-over shaft ................................................................................................................................. H 33.00.00
Output shaft .......................................................................................................................................... H 37.00.00
H 00.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Diagrams for removal and installation sequence of main groups ....................................................... H 01.01.00
H 01.00.00 - 01
Diagrams for removal and
BW (BU) 190 A (P), BW (BU) 190 V (P)
installation sequence of
BW (BU) 195 A (P), BW (BU) 195 V (P)
main groups
Control unit = 07 Filter = 09
000158 000159
Pipe connections = 11 Oil cooler = 13
000160 000161
Oil pumps = 15 Valves = 17
000162
000163
Numbers refer to H 00.00.00
H 01.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
BW (BU) 195 A (P), BW (BU) 195 V (P)
main groups
Transmission mountings = 19 Input flange = 21 Flexible coupling
000164 000165
Flange-mounted bell housing = 27 Housing cover = 29

30
000166 000167
Input shaft A = 31 Input shaft V = 32
000168 000169
H 01.01.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P)
BW (BU) 195 A (P), BW (BU) 195 V (P)
main groups
Change-over shaft = 33
000170
Output shaft = 37
000171
H 01.01.00 - 03
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Removal and Installation, Disassembly and Assembly of

complete control unit (basic version), mechanical operation ................................................................ H 07.01.00

electrical actuator .................................................................................................................................. H 07.02.00

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

control valve for trolling version............................................................................................................ H 07.04.00

pneumatic actuator ................................................................................................................................ H 07.05.00
H 07.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
000172
H 07.00.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Control unit +
Electrical actuator
000173
H 07.00.00 - 03
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Control unit - basic version + switchable PTO

Mechanical actuator
000175
H 07.00.00 - 04
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Control unit - Basic version + Trolling + switchable PTO

Mechanical actuator
000177
H 07.00.00 - 05
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Control unit +
Pneumatic actuator
000179
H 07.00.00 - 06
BW (BU) 190 A (P), BW (BU) 190 V (P) Control unit - Basic version
BW (BU) 195 A (P), BW (BU) 195 V (P) Operation - mechanical
1
2
3 18
4 17
5
6 16
41 42 11 15
7
8 1314 19
9
10 12
67 20
22 21
40 23
39 24
25
38 26
36 37 27
35 33 28
34 32
31
30
29
000140
1 = Screw plug 15 = Rectangular ring 29 = Lever

2 = Sealing ring 16 = Piston 30 = Hex nut
3 = Ball 17 = Gasket 31 = Clamping pin
4 = Screw plug 18 = Cover 32 = O-ring
5 = Sealing ring 19 = Hex bolt 33 = Threaded pin
6 = Screw plug 20 = Screw plug 34 = Gasket
7 = Sealing ring 21 = Sealing ring 35 = Screw plug
8 = Pressure spring 22 = Control housing 36 = Sealing ring
9 = Ball 23 = Rotary distributor 37 = Snap ring
14 = Washer 28 = Hex bolt 42 = Hex bolt
Removal, disassembly, assembly and fitting of complete control unit
Removal
02 Unscrew hex bolts (41, 42, 11) and hex nut (10).
03 Lift off complete control unit and collect gasket (34).
H 07.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P) Control unit - Basic version
BW (BU) 195 A (P), BW (BU) 195 V (P) Operation - mechanical
Disassembly Assembly
04 Remove detent elements (6, 7, 8 and 9). 01 Insert components (38, 39, 40, 13, 14, 15 and 16)
(25). 02 Fit new gasket (17) and screw on cover (18).
06 Pull rotary distributor (23) out of control housing. 03 Insert rotary distributor (23) into control housing.
07 Unscrew cover (18) and remove gasket (17). 04 Fit new gasket (25) and screw on cover (26).
08 Collect components (16, 15, 14, 13, 40, 39 and 05 Fit lever (29).
38).
Test: Pressure spring (39) acc. to D 07.00.00
Installation
07 Fit complete control unit with gasket and place in
NOTE: installation position.
08 Screw in hex bolts (41, 42, 11) and nut (10) and
tighten.
09 Install pipe connections according to

H 11.00.00.
H 07.01.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P) Control valve for electrical
BW (BU) 195 A (P), BW (BU) 195 V (P) operation
17 18 19
16 20
11 13 15
12
14
5 10
4
1 3 6 7
2
8
000174
1 = Hex bolts 11 = Hex bolt

2 = Cap screw 12 = Control piston
3 = Cover 13 = Washer
4 = Gasket 14 = Pressure spring
5 = Control housing 15 = Retaining ring
6 = Gasket 16 = Gasket
7 = Solenoid valve 17 = Cover
8 = Gasket 18 = Sealing ring
9 = Cover 19 = Hex bolt
10 = Cable harness 20 = Cap screw
H 07.02.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P) Control valve for electrical
BW (BU) 195 A (P), BW (BU) 195 V (P) operation
Disassembly Cleaning
01 Remove cover (9), loosen cable harness (10) and Clean parts and lightly oil movable parts.
remove cables.
02 Remove solenoid valve (7). Assembly
03 Unscrew cap screws (20) and take out. Remove 01 Fit cover (3) and gasket (4).
cover (17) and gasket (16).
02 Push washer (13), pressure spring (14), washer
04 Remove control piston (12) and parts (13, 14 & (13) onto control piston and clip retaining ring
15) from the control housing. into control piston.
05 Remove retaining ring (15) from control piston. 03 Insert control piston into control housing. Ensure
Take off washers (13) and pressure spring (14). control piston is the right way round.
06 Remove cover (3) and gasket (4). 04 Fit cover (17) and gasket (16) onto control
housing.
Check 05 Fit solenoid vale (7).
Pressure spring (14) acc. to D 07.00.00. 06 Connect cable harness to solenoid valve and fit
cover (a).
Inspect control piston (12) and control piston bore in
control housing (5) for damage. Prevent these parts
from being damaged.
H 07.02.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P)
Control valve for switchable PTO
BW (BU) 195 A (P), BW (BU) 195 V (P)
13
12
11
10
7
6 8 9
4
3
2
1
000176
1 = Screw plug 8 = Screw plug with sealing ring

2 = Sealing ring 9 = Screw plug with sealing ring
3 = Snap ring 10 = Screw plug
4 = Control piston 11 = Sealing ring
5 = Pressure spring 12 = Screw plug
6 = Pressure spring 13 = Screw cover
7 = Valve housing
Disassembly Cleaning: Clean parts and lightly oil movable parts.
01 Remove screw plug (1) and sealing ring (2).

Assembly
02 Remove snap ring (3) from valve housing.
01 Screw in plug (10) if removed. Observed screw-in
03 Remove control piston (4), pressure springs (5) depth (see note under disassmbly).
and (6) from valve housing.
02 Insert pressure springs (6 and 5) and control piston
Note: Measure screw-in depth of plug (10) and note (4) into valve housing.
down if plug (10) is removed.
03 Insert snap ring (3) into valve housing.
Check: Pressure springs (5) and (6) acc. to
D 07.00.00. Inspect control piston (4) and 04 Screw on screw plug (1) with sealing ring.
control piston bore in valve housing (7) for
damage. Prevent these parts from being
damaged.
H 07.03.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Control valve for trolling version
BW (BU) 195 A (P), BW (BU) 195 V (P)
24
25
26
22 23
21
20 27
19
18
17
16
13 12
15 11 28
14
10
98
7 29
6
3 5
2 4
1
000178
1 = Stop screw 16 = Ball Ø 8

2 = O-ring 17 = Valve cover
3 = Hex bolt 18 = Gasket
4 = Cam 19 = Piston
5 = Hex bolt 20 = Washer
6 = Lever 21 = Pressure spring
7 = Shaft 22 = Washers 1.0 / 0.5 / 0.4 / 0.3 / 0.2 mm
8 = Shaft sealing ring 23 = Control piston
9 = Snap ring 24 = Gasket
10 = Needle sleeve 25 = Valve housing
11 = Clamping pin 26 = Hex bolt
12 = Needle sleeve 27 = Hex bolt
13 = Dowel pin 28 = Plate
14 = Adjusting disc 29 = Plate
15 = Pressure spring
NOTE: 03 Remove piston (19), washer (20), pressure spring

Remove valve housing and hold with hex head of stop (21), washers (22) and control piston (23) from
screw (1) pointing vertically downwards before valve housing.
removing stop screw (1).
04 Unscrew stop screw (1). Collect adjusting discs
01 Unscrew hex bolts (26 and 27) and remove. (14), pressure spring (15) and ball (16).
Remove valve housing (25) and gasket (24)
05 Drive dowel pin (13) out of cover (17).
02 Unscrew hex bolts (3) from valve cover (17) and
remove. Remove cover and gasket (18).
H 07.04.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Control valve for trolling version
BW (BU) 195 A (P), BW (BU) 195 V (P)
06 Drive clamping pin (11) out of cam (4) and shaft 09 Use grease to hold ball Ø 8 (16) on the end of the
(7). spring in the stop screw (1). Hold stop screw (1)
vertically and screw into valve cover (17) from
07 Remove shaft (7) and cam (4) from cover (17). underneath.
10 Fit valve cover (17) and gasket (18) onto valve

Check: Pressure springs (5) and (6) according to housing (25).
D 07.00.00.
11 Fit valve housing (25) and gasket (24) to control
Inspect piston (19), control piston (23) and unit.
control piston bore in valve housing (25) for
damage. Prevent these parts from being
damaged.
Cleaning: Clean parts and lightly oil movable parts.
Assembly
01 Insert cam (4) in valve cover (17) and insert shaft

(7) into cam.
02 Line up the clamping pin bores in the cam and

shaft. Drive the clamping pin into the cam and
shaft until the clamping pin protrudes approx. 3
mm out of the cam.
03 Fit shaft sealing ring (8) according to

A 17.03.00 - 01
04 Install lever (6) on shaft (7).
05 Insert washers (22) into control piston (23) and

insert control piston into valve housing (25).
06 Insert pressure spring (21) into control piston

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

onto pressure spring (21).
08 Insert adjusting discs (14) and pressure spring

(15) into stop screw (1).
H 07.04.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P) Control unit +
BW (BU) 195 A (P), BW (BU) 195 V (P) pneumatic actuator
9
8
10
6
5
7
1 2 3
4 000180
1 = Joint bolt 6 = Fork head

2 = Joint head 7 = Hex bolt
3 = Washer 8 = 3-position cylinder
4 = Locking nut 9 = Block
5 = Hex nut 10 = Hex bolt
Removal Installation
01 Remove connections from 3-position cylinder. 01 Fasten 3-position cylinder to block (9) using hex
bolts (7). Slip joint head (2) onto joint bolt (1)
02 Unscrew locking nut (4) and remove washer (3). when installing 3-position cylinder.
03 Unscrew hex bolts (7) and remove. Remove NOTE:

3-position cylinder. Make sure that the joint head (2) is pushed centrally
onto the joint bolt (1) if the 3-position cylinder and
NOTE: control unit were removed in neutral position (middle
The 3-position cylinder is a complete component and position).
must not be dismantled.
02 Push on washer (3) and screw on locking nut (4).
03 Fit connections to 3-position cylinder.
H 07.05.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Removal, Cleaning and Installation of filter ........................................................................................ H 09.01.00
H 09.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Filter
BW (BU) 195 A (P), BW (BU) 195 V (P)
6
7
3
5
2 4
1
000181
1 = Hex bolt 5 = Sealing ring

2 = Filter 6 = Sealing ring
3 = Gasket 7 = Sludge drain plug
4 = Oil drain plug
Oil filter: Removal, Cleaning Cleaning
01 Unscrew sludge drain plug (7) and drain filter 06 Clean the filter cartridge using diesel or petrol for
chamber. washing.
02 Unscrew oil drain plug (4) approx. 20 - 25 mm. 07 Only use a brush for cleaning, never lint cloths or
Wait for the oil in the filter chamber to flow back implements such as screwdrivers, scrapers, etc.
into the transmission housing and then unscrew
the oil drain plug fully and remove.
Installation
Removal
01 Fit sludge drain plug (7) and oil drain plug (4)
03 Unscrew hex bolts (1) from filter and remove. with new sealing ring, screw in and tighten.
04 Pull out filter cartridge. 02 Fit filter with new gasket. Insert filter and screw
in tightly.
05 Cover filter chamber to prevent dirt from falling
in.
H 09.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Removal and installation of pipe connections ....................................................................................... H 11.01.00
H 11.00.00 - 01
BW (BU) 190 A (P)
Contents
BW (BU) 195 A (P)
000298
H 11.00.00 - 02
BW (BU) 190 A (P)
Contents
BW (BU) 195 A (P)
000299
H 11.00.00 - 03
BW (BU) 190 V (P)
Contents
BW (BU) 195 V (P)
000182
H 11.00.00 - 04
BW (BU) 190 V (P)
Contents
BW (BU) 195 V (P)
000183
H 11.00.00 - 05
BW (BU) 190 A (P), BW (BU) 190 V (P)
Pipe connections
BW (BU) 195 A (P), BW (BU) 195 V (P)
3 4
2 54 7
9 8
1 22 10
23
6
24
26 11
12
33 25
14 16
32 27 16
15
29 28
11
31 13
17
16
19 18
30 20
19
21
000184
1 = Hex bolt 8 = Connection

2 = Hex bolt 19 = Sealing ring
3 = Connection piece 20 = Lubricating oil line
4 = O-ring 21 = Hollow screw
5 = Tube 22 = O-ring
6 = Gasket 23 = Pipe connection
7 = Hollow screw 24 = Hex bolt
8 = Sealing ring 25 = Gasket
9 = Oil pipe 26 = Hex bolt
10 = Nozzle (sealing cover) 27 = Hex bolt
11 = Sealing ring 28 = O-ring
12 = Hollow screw 29 = Flange
13 = Connection 30 = Hex bolt
14 = Pressure line 31 = Suction line
15 = Hollow screw 32 = Connection
16 = Sealing ring 33 = Sealing ring
17 = Pressure line 34 = Connection
35 = Sealing ring
Removal and installation of pipe connections
The drawing shows pipe connections for the Installation

BW (BU) 190 / 195 A (P)
01 Install pipe connections, depending on gearbox
Removal version. Fit new CU sealing rings, O-rings and
gaskets.
01 Remove pipe connections as required, depending
on gearbox version.
H 11.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Removal, cleaning and installation of oil cooler ................................................................................... H 13.01.00
H 13.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
000185
H 13.00.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P)
Oil cooler
BW (BU) 195 A (P), BW (BU) 195 V (P)
1 2
3
4
000141
1 = Oil cooler 3 = Threaded pin

2 = Fixing nut 4 = O-ring
Removal, cleaning and installation of oil cooler Removal
01 Remove pipe connections, if required, according 02 Unscrew fixing nuts (2) from oil cooler and
to H 11.01.00. remove oil cooler.
H 13.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Oil cooler
BW (BU) 195 A (P), BW (BU) 195 V (P)
Cleaning oil cooler
000142
In order to achieve uniform cooling capacity and an oil 02 Cleaning the water side
side pressure reduction, certain cleaning operations Before cleaning the water side, examine the dirt
must be performed at particular intervals, especially at which has accumulated. If there is a greasy lime
the oil side. layer, degrease the water side also before
proceeding. Next dissolve the lime layer by
It is not possible to specify in advance the intervals at flushing with water and with lime remover; you
which the cleaning procedure described below should may also use a 10 - 15% hydrochloric acid
be performed because the nature and extent of dirt can solution, with an inhibitor added to ensure that it
vary very greatly. Record operating periods prior to does not attack the metal surfaces.
cleaning and repair work in order to establish a After finishing cleaning, flush out the water side
schedule of operating periods and cleaning work. thoroughly with clear water and then fill the oil
side with oil of the same grade as will be used
We recommend the following cleaning for this disc- during normal operation and drain again.
type oil cooler: Cleaning will be more effective and faster if the
flushing direction at both the water and oil side is
01 Cleaning the oil side opposite to the normal flow direction during
Connect the cooler to a trichlorethane or operation.
perchloroethane unit and flush through with the
hot medium, with the flushing direction opposite Cleaning the cooler in this way ensures that full
to normal oil flow in operation. This removes cooling capacity will be available during
dirt particles, in particular abrasion, from the subsequent operation and there will be a
multi-disc clutches and from the turbulence reasonable pressure drop at the oil side.
baffles of the oil cooler plates, which are then
flushed out by the medium. Insert a suitable
filter into this main flow to remove the impurities
flushed out from the cleaning medium. Continue
cleaning until a check reveals that the purity of
the medium flowing out is equivalent to that
flowing in.
H 13.01.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P)
Oil cooler
BW (BU) 195 A (P), BW (BU) 195 V (P)
Installation
01 Insert new O-rings into the grooves in the oil

cooler legs.
02 Fit the oil cooler to the transmission housing and

screw on tightly.
03 Fit pipe connections as required.
H 13.01.00 - 03
BW (BU) 190 A (P) BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P) BW (BU) 195 V (P)
Primary oil pump - engine-dependent .................................................................................................... H 15.01.00
Secondary oil pump - propeller-dependent ............................................................................................. H 15.02.00
NOTE:
= input direction I

counter-clockwise -
000094

clockwise -
000095
H 15.00.00 - 01
BW (BU) 190 A (P) BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P) BW (BU) 195 V (P)
000154
* = with/without secondary pump, depending on gearbox version.
H 15.00.00-02
BW (BU) 190 A (P) BW (BU) 190 V (P) Oil pump
BW (BU) 195 A (P) BW (BU) 195 V (P) (engine-dependent)
2
1
2
3
4
5
6
7
8 9 10
000135
000136
Directon of rotation I (Version A) Directon of rotation II (Version A)

Directon of rotation II (Version V) Directon of rotation I (Version V

3 = Plug 8 = Needle sleeve
Oil pumps 3081 206 044 / 3081 206 046

(engine-dependent)
Removal
01 Remove pipe connections as required according 03 Lift oil pump off cover (use assembly levers if
to H 11.00.00. necessary placed against housing webs).
02 Unscrew fixing bolts (1) for the oil pump. 04 Remove intermediate gear drive, items 3 - 10 (see
Figure 136) for Version A, direction of rotation II
or Version V, direction of rotation I.
2 3 4 5
1 = Tapered pin
2 = O-ring
3 = Woodruff key
A 4 = Input gear
5 = Retaining ring
1
000137
H 15.01.00 - 01
BW (BU) 195 A (P) BW (BU) 195 V (P) (engine-dependent)
05 Remove retaining ring (5). 08 Remove intermediate gear drive, items 3 - 10 (see
Figure 000136) for Version A, direction of
06 Pull off input gear (4). rotation II or Version V, direction of rotation I.
Insert needle sleeve (8) into intermediate gear
07 Collect woodruff key (3). (7). Insert thrust ring (9) and intermediate gear
with needle sleeve into the housing the right way
NOTE: round. Push pin (10) into intermediate gear with
The oil pump is a complete component and is not needle sleeve. Place thrust washer (6) onto
normally dismantled. However after checking or intermediate gear. Screw in hex bolt (1) and
cleaning it may be necessary to dismantle the pump. tighten. Insert plug (3) and O-ring (4).
When checking the pump, pay particular attention that 09 Apply a light coating of sealing compound* to
the end float is within the wear limits, see the pump cover sealing face and fit the pump.
D 09.00.00.
Check the pump components for traces of wear. 10 Fit pipe connections according to H 11.00.00.
08 Remove fixing bolts from the pump cover, drive

the tapered pins (1) out in the arrowed direction
and remove the pump cover.
NOTE:
Assembly
01 Insert pump pinion into pump housing.
02 Insert O-rings (2) into pump housing.
03 Position pump cover and bolts, do not tighten

bolts.
04 Drive in tapered pins (1) and tighten bolts.

pump shaft.

pump shaft.
* Sealing compound, see Consumables

A 11.00.00
H 15.01.00 - 02
BW (BU) 195 A (P) BW (BU) 195 V (P) (propeller-dependent)
B
A
000155
000156
NOTE:
Screw in hex bolt and washer into locations A and B using sealing compound on versions without oil pump.
5 6
4 7
3
2
1
10 9 8
000157
1 = Propeller-dependent oil pump 6 = Thrust ring

2 = Plug 7 = Pin
3 = Hex bolts 8 = Needle sleeve
4 = Thrust washer 9 = O-ring
5 = Intermediate gear 10 = O-ring
H 15.02.00 - 01
Oil pump 7631 955 120 (propeller-dependent) Disassembly
Removal 05 Remove retaining ring (5).
01 Remove pipe connections as required according to 06 Pull off input gear (4).
H 11.00.00.
07 Collect woodruff key (3)
02 Remove fixing bolts on oil pump.
08 Remove fixing bolts from the pump cover and lift
off pump cover.
03 Lift off oil pump (use assembly levers if
necessary).
NOTE:
04 Remove intermediate gear drive, items 2 - 9.
NOTE:
normally dissmantled. However after checking or
cleaning it may be necessary to dismantle the pump.
the end float is within the wear limits, see D 09.00.00.
Check the pump components for traces of wear.
2 3 4 5
1 = O-ring
2 = Cap screw
3 = Woodruff key
4 = Input gear
1 5 = Retaining ring
000139
H 15.02.00 - 02
Assembly

04 Heat input gear to approx. 85° and push onto

pump shaft.

pump shaft.
Installation
06 Install intermediate gear drive, (items 2 to 9). See

Fig. 000157.

pump onto cover and screw tight.
H 15.02.00 - 03
BW (BU) 190 A (P) BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P) BW (BU) 195 V (P)
Pressure relief valve ................................................................................................................................ H 17.01.00
Pressure relief valve (for max. system pressure).................................................................................... H 17.02.00
H 17.00.00 - 01
BW (BU) 190 A (P) BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P) BW (BU) 195 V (P)
000187
H 17.00.00 - 02
BW (BU) 190 A (P) BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P) BW (BU) 195 V (P)
000188
H 17.00.00 - 03
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
1
2
3
4
000145
1 = Screw plug 4 = Piston

2 = Sealing ring A = Function for oil jet line (gear tooth mesh)
3 = Pressure spring
01 Unscrew screw plug (1). 01 Insert piston (4) and pressure spring (3).
02 Collect parts (2 to 4). 02 Fit new CU sealing ring (2) to screw plug (1).
Screw in screw plug (1) and tighten.
Test:
Pressure spring (3) according to Table of Springs
D 07.00.00.
Check piston and piston guide for fretting or scoring.
NOTE:
Ensure parts are free of dirt. Lightly oil movable parts.
Fit new sealing ring.
H 17.01.00 - 01
BW (BU) 190 A (P) BW (BU) 190 V (P) Pressure relief valve
BW (BU) 195 A (P) BW (BU) 195 V (P) for max. system pressure
3
1 2
000144
1 = Valve seat 3 = Pressure spring

2 = Spring cup A = Function for max. system pressure
01 Remove pipe connections as required according to 01 Insert pressure spring (3) and spring cup (2).
H 11.00.00.
02 Screw in valve seat (1) to the distance noted
during removal.
Removal
02 Measure screw-in depth of valve seat (1) and note

down dimension for subsequent installation.
03 Unscrew valve seat (1).
04 Collect spring cup (2) and pressure spring (3).
Test: Pressure spring (3) according to Table of Springs

D 07.00.00
H 17.02.00 - 01
BW (BU) 190 A (P) BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P) BW (BU) 195 V (P)
Removal and installation of gearbox mountings .................................................................................... H 19.01.00
Removal or installation of gearbox swivel stand adapter ........................................................................H 19 02.00
H 19.00.00 - 01
BW (BU) 190 A (P) BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P) BW (BU) 195 V (P)
000189
H 19.00.00 - 02
BW (BU) 190 A (P) BW (BU) 190 V (P)
Gearbox mountings
BW (BU) 195 A (P) BW (BU) 195 V (P)
000190
1 = Gearbox mountings 2 = Fixing bolt
Removal and installation of gearbox mountings
Removal
01 Unscrew fixing bolts (2).
02 Lift off gearbox mountings (1).
Installation
01 Install gearbox mountings (1).
02 Screw in fixing bolts (2) and tighten.
H 19.01.00 - 01
BW (BU) 190 A (P) BW (BU) 190 V (P)
Gearbox mountings
BW (BU) 195 A (P) BW (BU) 195 V (P)
000191
Removal or installation of gearbox swivel stand adapter from/to gearbox housing
Installation Removal
01 Remove gearbox mountings if required as 01 Remove adapter from gearbox housing.

described in Section H 19.01.00.
02 Fit gearbox mountings if required, as described in
02 Fit adapter to gearbox housing (observe gearbox Section H 19.01.00.
type markings on the adapter).
H 19.02.00 - 01
BW (BU) 190 A (P) BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P) BW (BU) 195 V (P)
Removal of input flange (BW 190 A (P)) .............................................................................................. H 21.01.00
Removal of input flange (BW 190 V(P)) ............................................................................................... H 21.01.01
Removal of flexible coupling ................................................................................................................. H 21.01.02
Installation of input flange (BW 190 A (P) ............................................................................................ H 21.02.00
Installation of input flange BW 190 V (P) ............................................................................................. H 21.02.01
Installation of flexible coupling .............................................................................................................. H 21.02.02
H 21.00.00 - 01
BW (BU) 190 A (P)
Input flange
BW (BU) 195 A (P)
1 A
3
4
I
II
8 7 6 5
000148
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
5 = High pressure line 1X56 130 601 A = Distance approx. 12 - 15 mm
Removal and installation of input flange We strongly recommend that you perform this
Removal Once pressure is applied to conical oil press-fits,
01 Set up equipment as shown in drawing. Follow the instructions in Section D 05.00.00
! DANGER press-fits.
Ensure that all equipment used is in perfect Pay particular attention to the paragraphs dealing
condition, especially the screw threads. with cleaning, push-on distances and pushing on
Ensure that threaded connections are screwed on or part-way and fully.
points. 02 Release input flange.
H 21.01.00 - 01
BW (BU) 190 A (P) BW (BU) 190 V (P)
Input flange
BW (BU) 195 A (P) BW (BU) 195 V (P)
1 2 3 4
8 7 6 5
000146
1 = Oil injector 1X56 130 595 6 = Hydraulic nut 1X56 137 227
2 = Pressure gauge 1X56 130 604 7 = Nut 1X56 137 226
3 = Pump holder 1X56 130 597 8 = Bolt
4 = High pressure line 1X56 130 601 A = Distance approx. 12–15 mm
5 = Input flange 1X56 136 461
Removal of input flange We strongly recommend that you perform this

01 Set up equipment as shown in drawing. they will come off automatically and abruptly.
02 Release input flange.
points.
H 21.01.01 - 01
BW (BU) 190 A (P)
Flexible coupling
BW (BU) 195 A (P)
1 2 3 4 5
6
7
I 8
II 9
000150
1 = Flexible coupling 6 = Druckstück 6 = Pressure piece 1X56 137 289

5 = Oil injector 1X56 130 595 A = Clearance approx. 12–15 mm
Removal of flexible coupling We strongly recommend that you perform this

! DANGER
press-fits.
with cleaning, push-on distances and pushing on
part-way and fully.
points.
When loosening or pushing on a conical oil press- 02 Release flexible coupling.
H 21.01.02 - 01
BW (BU) 190 A (P)
Input flange
BW (BU) 195 A (P)
3
4
I
5
II
6
7
13 12 11 10 9 8
000149
1 = Input flange 8 = Adapter 1X56 130 591
2 = Measurement gauge with holder 9 = Pressure gauge 1X56 130 592
3 = Hydraulic nut 1X56 137 227 10 = High pressure line 1X56 130 601
4 = Nut 1X56 137 226 11 = Pump holder 1X56 130 597
6 = Reciprocating pump 1X56 130 589 13 = Oil injector 1X56 130 595
Installation of input flange

Installation
! DANGER
press-fits.
points. 02 Push on input flange (1).
H 21.02.00 - 01
BW (BU) 190 A (P) BW (BU) 190 V (P)
Input flange
BW (BU) 195 A (P) BW (BU) 195 V (P)
1 2 3 4 5 6
13
12
11
10 9 8 7
1 = Oil injector 1X56 130 595 8 = Pressure gauge 1X56 130 592
2 = Pressure gauge 1X56 130 604 9 = Adapter 1X56 130 591
5 = Measurement gauge with holder 12 = Nut 1X56 137 226
6 = Input flange 13 = Hydraulic nut 1X56 137 227
Installation of input flange

Installation
! DANGER
press-fits.
part-way and fully.
points. 02 Push on input flange. Do not push input flange
When loosening or pushing on a conical oil press-fit, on fully.
ensure that no-one is standing in front of the
pressurized components. This instruction is 03 Remove equipment.
H 21.02.01 - 01
BW (BU) 190 A (P)
Flexible coupling
BW (BU) 195 A (P)
1 2 3 4 5
6
7
I 8
II 9
10
11
14 13 12
000151
1 = Flexible coupling 8 = Nut 1X56 137 226

5 = Oil injector 1X56 130 595 12 = Adapter 1X56 130 591
7 = Hydraulic nut 2X56 137 227 14 = Measurement gauge with holder
Installation of flexible coupling We strongly recommend that you perform this

Installation Once pressure is applied to conical oil press-fits,
! DANGER:
press-fits.
part-way and fully.
points.
When loosening or pushing on a conical oil press- 02 Push on flexible coupling.
H 21.02.02 - 01
BW (BU) 190 A (P)
Contents
BW (BU) 195 A (P)
Removal and installation of flange-mounted bell housing ..................................................................... H 27.01.00
H 27.00.00 - 01
BW (BU) 190 A (P)
Contents
BW (BU) 195 A (P)
000192
H 27.00.00 - 02
BW (BU) 190 A (P)
Flange-mounted bell housing
BW (BU) 195 A (P)
3 5
2
1
000193
6
1 = Hex bolt 4 = Flange-mounted bell housing

2 = Cover 5 = Shaft sealing ring
3 = Hex nut 6 = Centering ring
Removal and installation of flange-mounted bell Installation

housing
NOTE:
01 Remove flexible coupling according to Fit shaft sealing ring according to
H 21.00.00. A 17.01.02.
01 Make sure shaft sealing ring

Removal (5) is pointing in the correct X
direction (depending on 000102
02 Unscrew hex nut (3). version) and apply a thin coat
of sealing compound to the
03 Remove flange-mounted bell housing. shaft sealing ring sealing lip. Insert shaft sealing
ring into bell housing.
04 Drive shaft sealing ring out of bell housing (if
required). 02 Insert centering ring (6).
05 Collect centering ring (6). 03 Fit bell housing and centering ring (6) and screw
on tightly.

A 11.00.00
H 27.01.00 - 01
BW (BU) 190 A (P)
Contents
BW (BU) 195 A (P)
Removal and installation of covers ......................................................................................................... H 29.01.00
Installation and removal of covers on pump end for input and change-over shafts .............................. H 29.02. 00
II
II
000194
Upper half of shaft shows direction of rotation I
Lower half of shaft shows direction of rotation II
H 29.00.00 - 01
BW (BU) 190 A (P)
Contents
BW (BU) 195 A (P)
* not fitted on all versions 000195
H 29.00.00 - 02
BW (BU) 190 A (P)
Covers
BW (BU) 195 A (P)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
* * *
II
* 17
18
* 19
I
II
*
6 25 24 23 3 7 22 21 20
000196
1 = Cover 15 = * O-ring
2 = * Shim 16 = Shaft sealing ring
3 = Cylinder roller bearing outer ring 17 = * O-ring
4 = Housing cover 18 = Cover
5 = Grooved nut M 50x1.5 19 = * Shim
6 = Rectangular rings 20 = Retaining ring
7 = Cylinder roller bearing inner ring 21 = Shim
8 = Bearing bush 22 = Self-aligning roller bearing
9 = Self-aligning roller bearing 23 = Pump input gear
10 = * Shim 24 = * Shim
11 = Shim 25 = Cover
12 = Retaining ring
13 = Segment (2 pcs.)
14 = Sealing ring cover
* not fitted on all versions.
H 29.01.00 - 01
BW (BU) 190 A (P)
Covers
BW (BU) 195 A (P)
Removal
01 Remove pipe connections as required acc. to

H 11.00.00 .
02 Remove oil pump acc. to H 15.00.00 .
03 Remove input flange or flexible coupling accor-

ding to H 21.00.00 .
04 Remove flange-mounted bell housing (if fitted)

acc. to H 27.00.00 .
05 Remove covers (1, 14, 18, 25), shims* (mark

shims to ensure correct assembly) and O-rings.
06 Remove retaining ring (12), shim (11) and two

segments (13).
07 Remove retaining ring (20) and shim (21).
08 Release grooved nut (6) and remove using span-

ner 1X56 137 222.
09 Using puller, pull off pump input gear (23).
10 Remove housing cover (4).
11 Remove cylinder roller bearing outer rings (3)

from housing cover.
* not fitted on all versions
H 29.01.00 - 02
BW (BU) 190 A (P)
Covers
BW (BU) 195 A (P)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
* * *
II
B
K
* 17
A
18
* 19
I
II
C
D
*
25 5 24 23 3 6 7 22 21 20
000197
1 = Cover 15 = *O-ring
2 = *Shim 16 = Shaft sealing ring
3 = Cylinder roller bearing outer ring 17 = O-ring
4 = Housing cover 18 = Cover
5 = Grooved nut M50x1.5 19 = Shim
6 = Rectangular rings 20 = Retaining ring
7 = Cylinder roller bearing inner ring 21 = Shim
8 = Bearing bush 22 = Self-aligning roller bearing
9 = Self-aligning roller bearing 23 = Pump input gear
10 = *Shim 24 = *Shim
11 = Shim 25 = Cover
12 = Retaining ring
13 = Segment (2 pcs.)
14 = Sealing ring cover
H 29.02.00 - 01
BW (BU) 190 A (P)
Covers
BW (BU) 195 A (P)
Installation For version with shim (19)

- Ensure self-aligning roller bearing is inserted
01 Install change-over shaft according to fully.
H 33.02.00 .
Insert shim (19) into cover (18). Measure clea-
02 Install input shaft according to H 31.02.00 or rance C – D (end float 0–0.55 mm). Dimension
H 32.02.00 . "D" must be
0–0.55 mm smaller than Dimension "C".
03 Install shaft sealing ring in sealing ring cover
(14) according to A 17.01.02 . When installing 07 Apply a thin coat of sealing compound* to the
shaft sealing ring (16), ensure that the shaft sea- sealing face of the cover (18). Insert O-ring in
ling ring (16) is inserted evenly and that its out- versions with O-ring and fit cover.
put end face fits snugly in the cover bore.
NOTE:
Installation of input end of input shaft:
there is a version with or without shim (10).
Observe the following.
04 For version without shim (10)

- Ensure self-aligning roller bearing outer ring
(9) is inserted fully into the housing.
- Ensure dimension K is 8.0 to 8.4 mm.
- Ensure dimension B is 7.9 to 8.0 mm.
For version with shim (10)

- Ensure self-aligning roller bearing (9) is
inserted fully.
Insert shim (10), measure clearance A and clea-
rance B (end float 0–0.55 mm).
05 Apply a thin coat of sealing compound* to the

sealing face of the cover. Insert O-ring in versi-
ons with O-ring and fit cover.
NOTE:
Installation of input end of change-over shaft:
06 For version without shim (19)

- Ensure self-aligning roller bearing outer ring is
inserted fully into the housing.
- Ensure self-aligning roller bearing (22) does
not protrude over the housing sealing face. * Sealing compoung Hylomar SQ 32 M-Special, see
- Ensure dimension C is 0.0 to 0.39 mm. A 11.01.00
H 29.02.00 - 02
BW (BU) 190 A (P)
Covers
BW (BU) 195 A (P)
25
1
2
24 N O M
L 4
F H
3
7 7
E G
000198
08 Provisionally fit cover (1) and cover (25) (only NOTE:

for version with shim 2 and 24) onto housing Installation of input end of change-over shaft:
cover (4). there is a version with or without shim (24).
09 Insert shims (2 and 24) into covers (1 and 25).
12 For version without shim (24), measure
10 Place cylinder roller bearing outer rings (3) onto clearance L. Clearance must be 9.2- 9.4 mm
the cylinder roller bearing inner rings (7).
For version with shim (24)
NOTE: Insert shim (24), measure clearance E and F (and
Installation of input end of input shaft: float 0.5–0.25 mm).
Observe the following. 13 Make corrections on shims (24 and 2). Mark
shims to denote which shaft they are from.
11 For version without shim (2), measure M.
Clearance must be 7.8 - 8.0 mm. 14 Remove covers (1 and 25) from housing cover.
For version with shim (2) 15 Insert the correct shim (24 and 2) into the rele-
Insert shim (2), measure clearance G and H (end vant cover. Measure clearance N and O and note
float 0.5–2.5 mm). down measurement.
H 29.02.00 - 03
BW (BU) 190 A (P)
Covers
BW (BU) 195 A (P)
16 Insert both cylinder roller bearing outer rings (3)

into housing cover (4) and press in until each bea-
ring protrudes by the relevant dimension N and O
over the cover sealing face.
17 Apply a thin coating of sealing compound* to the

housing cover on its sealing face which is facing
the housing. Insert O-ring.
18 Fit housing cover.
19 Heat pump input gear (23) to approx. 85°C and

push onto change-over shaft the right way around.
20 Screw grooved nut (5) onto change-over and

input shaft. Use spanner 1X56 137 222 to tighten
to 550 Nm. Lock grooved nuts.
21 Apply a thin coating of grease to rectangular

rings (6) and position centrally.
22 Apply a thin coating of sealing compound* to the

sealing faces of covers (1 and 25) . Insert O-ring
in version with O-ring. Fit cover and shims (2
and 24).
CAUTION
After fitting the housing cover, measure tooth back-
lash of reduction gears.
Refer to H 37.02.00 - 13 for backlash measurement.
* Sealing compoung Hylomar SQ 32 M-Special, see

A 11.01.00
H 29.02.00 - 04
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Removal of covers .................................................................................................................................. H 30.01.01
Installation of covers ............................................................................................................................... H 30.02.01
II
II
000199
Upper half of shaft shows direction of rotation II
Lower half of shaft shows direction of rotation I
H 30.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
000200
H 30.00.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P)
Covers
BW (BU) 195 A (P), BW (BU) 195 V (P)
11
10
8 9
*
13 12
7
6 * 14
15
2
1 4
3
16
*
17
5 000201
1 = Cover 10 = Circlip 55x3

2 = Dowel pin 11 = Cover
3 = Grooved nut M 50x 1.5 12 = Cover
4 = Pump input gear 13 = Circlip
5 = Cover 14 = Disc
6 = Housing cover 15 = *Shim
7 = Pin 16 = Cylinder roller bearing outer ring
8 = *Shim 17 = *Shim
9 = Adjusting ring * not fitted on all versions
Remove cover
01 Remove pipe connections according to H 11.00.00.
02 Remove oil pump according to H 15.00.00.
03 Remove input flange according to H 21.00.00.
H 30.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Covers
BW (BU) 195 A (P), BW (BU) 195 V (P)
Removal
04 Remove cover (1).
05 If pin (2) is firmly located, leave it in place. If pin

(2) is loose, remove it.
06 Release grooved nut (3) and remove using spanner

1X56 137 222.
07 Using puller, pull off pump input gear (4).
08 Remove cover (5).
09 Collect *shim (17) from cover and mark for

assembly.
10 Remove cover (11). Collect *shim (8) and mark

for assembly.
11 Remove circlip (10) and collect adjusting ring (9).
12 Remove cover (12). Collect *shim (15) and mark

for assembly.
13 Remove circlip (13) and collect shim (14).
14 Remove housing cover (6).
15 Press cylinder roller bearing outer shim (16) out

of housing cover.
* not fitted on all versions.
H 30.01.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P)
Covers
BW (BU) 195 A (P), BW (BU) 195 V (P)
1 2 3 4 5 C 6 7
*
P A
K
D
O
II
16*
8
15
14 9
II
11 *10
F
13 12 E
000202
1 = Shaft sealing ring 10 = *Shim

2 = Sealing ring cover 11 = Self-aligning roller bearing
3 = O-Ring 12 = Rectangular ring
4 = Cylinder roller bearing outer ring 13 = Cover
5 = Housing cover 14 = Pin
6 = *Shim 15 = Bush
7 = Cover 16 = *Shim
8 = Rectangular ring
9 = Cover
H 30.02.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Covers
BW (BU) 195 A (P), BW (BU) 195 V (P)
Installation 07 Apply a thin coat of sealing compound** to the

sealing face of cover (9). Insert O-ring in version
01 Push self-aligning roller bearing fully onto input with *O-ring and fit cover.
shaft.
08 Install shaft sealing ring in cover (2) according to
NOTE: A 17.01.02 - 01. Fit the shaft sealing ring so the
Installation of self-aligning roller bearing of input end of the shaft sealing ring is level with the cover
shaft: there is a version with or without *shim (6). bore on the output end.
02 For version without shim (6) NOTE:

Ensure self-aligning roller bearing outer ring is Installation of input end of input shaft: there is a
inserted fully into the housing. version with or without *shim (16). Observe the
Ensure Dimension K is 8.0 to 8.4 mm. following.
Ensure Dimension D is 7.9 to 8.0 mm.
09 For version without *shim (16)
For version with shim (6) Ensure self-aligning roller bearing outer ring lis
Ensure self-aligning roller bearing outer ring is inserted fully.
inserted fully. Ensure Dimension "M" is 9.3 to 9.5 mm..
Insert *shim (6) and measure Dimension C - D,
(end float 0 – 0.55 mm).
H
M
03 Lightly coat rectangular rings (8) with grease and
position centrally.
16
000203 G
04 Apply a thin coat of sealing compound** to the
sealing face of cover (7) and fit cover.
05 Push self-aligning roller bearing (11) fully onto

change-over shaft.
000204
NOTE:
Installation of self-aligning bearing on change-over For version with *shim (16).
shaft opposite input end: there is a version with or Ensure self-aligning roller bearing outer ring is
without *shim (10). Observe the following. inserted fully.
Insert *shim (16). Insert cylinder roller bearing
06 For version without shim (10) outer ring in cover (2). Measure clearance H - G,
- Ensure self-aligning roller bearing outer ring is (end float 0.5– 2.5 mm).
inserted fully into the housing. Ensure self-
aligning roller bearing (11) does not protrude Measure clearance H from front end of cylinder
over the housing sealing face. roll to sealing face of sealing ring cover.
Measure clearance G from sealing face of housing
Ensure Dimension "F" is 0.0 to 0.39 mm. cover to front face locating collar for cylinder
rollers on cylinder roller bearing inner ring.
For version with *shim (10) Clearance "G" must be 0.5–2.5 mm larger than
- Ensure self-aligning roller bearing outer ring clearance "H". Correct on shim (16).
(11) is inserted fully into the housing.
Insert shim (10) into covers (9). Measure
clearance E - F (end float 0-0.55 mm). * not fitted on all versions
** Sealing compound "Hylomar", see A 11.00.00
H 30.02.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P)
Covers
BW (BU) 195 A (P), BW (BU) 195 V (P)
10 Measure clearance "O" or clearance "P". Heat

bearing bore in housing cover (5) to approx. 50°C
and press cylinder roller bearing outer ring (4)
into housing until the cylinder roller bearing outer
ring protrudes from the housing cover by
clearance "O" (for version with shim) or
clearance "P" (for version without shim).
11 Insert O-ring in housing cover (5). Apply a thin

coat of sealing compound** to sealing face. Heat
bearing bore in housing cover (5) for self-aligning
roller bearing on the change-over shaft to approx.
50°C.
12 Place housing cover on housing and drive fixing

pins (2 pcs.) into the housing. Screw housing
cover on tightly. Move bush (15) so pin (14)
engages in the groove after the cover is fitted.
13 Check pin (14) in cover (13) or insert pin.
14 Apply a thin coating of grease to rectangular rings

(12) and position centrally.
15 Apply a thin coating of sealing compound** to

the sealing face of cover (13) and fit.
CAUTION
After fitting the housing cover, measure reduction gear
tooth backlash when meshing with output gear.
Refer to H 37.02.00 - 13 for backlash measurement.
16 Fit input flange according to H 21.00.00.
17 Fit oil pump according to H 15.00.00.
** Sealing compound "Hylomar" , see A 11.00.00
H 30.02.00 - 03
BW (BU) 190 A (P)
Contents
BW (BU) 195 A (P)
Removal and disassembly of input shaft (direction of rotation I and II .................................................. H 31.01.00
Assembly and installation of input shaft (direction of rotation I and II ................................................. H 31.02.00
NOTE:
When assembling the input shaft, pay particular attention to the direction of gearbox rotation. Depending on the
direction of rotation, the ring or supporting disc must be fitted on the input shaft to the left or right of the pinion.
The text describes fitting the ring or supporting disc for direction of rotation II.
= input direction I

counter-clockwise -
000094

clockwise -
000095
H 31.00.00 - 01
BW (BU) 190 A (P)
Contents
BW (BU) 195 A (P)
II
II
I
I
II
I
II
I
Sign denoting different layout for other direction of rotation 000205
H 31.00.00 - 02
BW (BU) 190 A (P)
Contents
BW (BU) 195 A (P)
000206
H 31.00.00 - 03
BW (BU) 190 A (P)
Input shaft
BW (BU) 195 A (P)
2
II
I
II
4
5
21 6
7
8
4
9
10
11
12
13
20 19 18 17
14
15
16
000207
1 = Lifting device 1X56 137 225 11 = Removal plate 1X56 137 229
2 = Self-aligning roller bearing 12 = Collar nut 1X56 137 232
3 = Sealing ring bush 13 = Bolt 1X56 136 461
4 = Coupling nut 1X56 137 232 14 = Segment (2 Pcs.)
5 = Extension piece 1X56 137 927 15 = Shim
6 = High pressure line 1X56 130 601 16 = Retaining ring
9 = Nut 1X56 137 226 19 = Adapter 1X56 130 591
10 = Hydraulic nut 1X56 137 227 20 = Reciprocating pump 1X56 130 589
21 = Stud screw 1X56 137 232
H 31.01.00 - 01
BW (BU) 190 A (P)
Input shaft
BW (BU) 195 A (P)
Removal
Removal of input shaft
01 Remove housing cover.
02 Remove retaining ring (16), shim (15) and 2

segments (14)
NOTE:
It is usually possible to press out the input shaft as
shown in the bottom right-hand section of drawing
000207 on the previous page. However, before
performing this operation, press oil into the fit using
the oil injector as shown in the drawing on the top
right-hand side. If the shaft still cannot be pressed out,
proceed according to the main drawing No. 000207).
03 Set up equipment as shown in the drawing.
! DANGER
points.
When loosening or pushing on oil press-fits, ensure
that no-one is standing in front of the pressurized
components. This instruction is intended to prevent
accidents.
04 Press input shaft out of self-aligning roller bearing

and lift out of housing.
H 31.01.00 - 02
BW (BU) 190 A (P)
Input shaft
BW (BU) 195 A (P)
1 2 3 4 5 6 7 8 9 10
15 11
12 13 14
I
II
000208
1 = Sealing ring bush 9 = Removal plate 1X56 137 229

2 = Self-aligning roller bearing 10 = Stud screw 1X56 137 232
3 = Housing 11 = High pressure hose 1X56 130 588
4 = Coupling nut 1X56 137 232 12 = Adapter 1X56 130 591
6 = Nut 1X56 137 226 14 = Reciprocating pump 1X56 130 589
7 = Hydraulic nut 1X56 137 227 15 = Pressure piece 1X56 137 931
8 = Collar nut 1X56 137 232
Removal of sealing ring bush for bracing purposes, always use all available
bracing points.
05 Set up equipment as shown in drawing. When loosening or pushing on oil press-fits, ensure
! DANGER components. This instruction is intended to prevent
Important information for the following procedure! accidents.
Ensure that threaded connections are screwed on or 06 Press sealing ring bush out of self-aligning
in as far as possible. When using threaded rods roller bearing.
H 31.01.00 - 03
BW (BU) 190 A (P)
Input shaft
BW (BU) 195 A (P)
1 2 3 4 5 6 7 8 9
10
11
*15
12 13 14
I
II
000209
1 = Pressure piece 1X56 137 931 9 = Stud screw 1X56 137 232
2 = Self-aligning roller bearing 10 = Bolt 1X56 136 461
3 = Pressure piece 1X56 137 931 11 = High pressure hose 1X56 130 588
5 = Collar nut 1X56 137 232 13 = Pressure gauge 1X56 130 592
6 = Removal plate 1X56 137 229 14 = Reciprocating pump 1X56 130 589
7 = Hydraulic nut 1X56 137 227 15 = * Shim
8 = Nut 1X56 137 226 * not fitted on all versions
Removal of self-aligning roller bearing bracing purposes, always use all available bracing
points.
07 Set up equipment as shown in the drawing. When loosening or pushing on oil press-fits, ensure
! DANGER components. This instruction is intended to prevent
Important information for the following procedure! accidents.
08 Pull self-aligning roller bearing out of housing.
Remove *shim (15) from bearing bore and mark
for assembly.
H 31.01.00 - 04
BW (BU) 190 A (P)
Input shaft
BW (BU) 195 A (P)
1 2 3 4 5 6 7
II
000210
1 = 3-arm puller 5 = Pinion with external disc carrier

2 = Pressure piece 6 = Thrust washer
3 = Roller bearing inner ring 7 = Sealing ring bush
4 = Input shaft
Removal of cylinder roller bearing inner ring
NOTE:
If the sealing ring bush (7) separates from the
input shaft when removing the input shaft, pull
off the pinion and the external disc carrier (5).
10 Pull off cylinder roller bearing inner ring (3).
H 31.01.00 - 05
BW (BU) 190 A (P)
Input shaft
BW (BU) 195 A (P)
5 6 7 8 9 10
II
1 2 3 4
000211
1 = Oil injector 1X56 130 595 6 = Emergency shift device

2 = Pressure gauge 1X56 130 604 7 = Constant gear
3 = Pump holder 1X56 130 597 8 = Piston
4 = High pressure line 1X56 130 601 9 = Rectangular ring
5 = Hydraulic nut 1X56 137 227 10 = Input shaft
Removal of constant gear
Important information for the following procedure! Pay particular attention to the paragraphs dealing
Ensure that all equipment used is in perfect with cleaning, push-on distances and pushing on
condition, especially the screw threads. part-way and fully.
bracing purposes, always use all available bracing 12 Release constant gear (7).
points.
When loosening or pushing on oil press-fits, ensure 13 Remove piston (8) from constant gear.
components. This instruction is intended to prevent 14 Remove emergency shift device (6), if required.
accidents.
H 31.01.00 - 06
BW (BU) 190 A (P)
Input shaft
BW (BU) 195 A (P)
4
5 6 7 8 9 10 11 12
II
000212
1 = Retaining ring 7 = Rectangular ring

2 = Pin 8 = Plate spring (6 pcs.)
3 = Pressure spring 9 = Internal disc
4 = Piston 10 = External disc
5 = Rectangular ring 11 = End shim
6 = Piston, for Trolling version 12 = Input shaft
or version prepared for Trolling
Removal of disc set from input shaft
15 Remove rectangular rings (5 and 7) from the

annular grooves on piston.
16 Remove 6 plate springs (8), from input shaft.
17 Remove inner and outer discs (9 and 10) from

the disc carrier.
H 31.01.00 - 07
BW (BU) 190 A (P)
Input shaft
BW (BU) 195 A (P)
8 9 10 11
1 2 3 4 5 6 7 12 13
II
20 19 18 17 16 15 14
000213
1 = Input shaft 11 = High pressure line 1X56 130 601

2 = Thrust washer 12 = Nut 1X56 137 226
3 = Sealing ring bush 13 = Bolt 1X56 136 461
4 = Removal plate 1X56 137 229 14 = Push-on disc 1X56 137 231
5 = Pull-out ring 1X56 137 230 15 = Hydraulic nut 1X56 137 227
6 = Retaining ring 1X56 137 230 16 = High pressure hose 1X56 130 588
7 = Stud screw 1X56 137 232 17 = Coupling nut 1X56 137 232
8 = Pressure gauge 1X56 130 604 18 = Adapter 1X56 130 591
NOTE:
The sealing ring bush usually stays in the self-aligning
roller bearing when the input shaft is removed. The
sealing ring bush is therefore usually already removed.
If only the sealing ring bush (3), pinion with disc
carrier or thrust washer (2) are to be removed, the
following steps do not have to be performed: Removal
of cylinder roller bearing inner ring and removal of
disc set from input shaft.
H 31.01.00 - 08
BW (BU) 190 A (P)
Input shaft
BW (BU) 195 A (P)
! DANGER
points.
accidents.
20 Pull off bush and collect.
H 31.01.00 - 09
BW (BU) 190 A (P)
Input shaft
BW (BU) 195 A (P)
1 4 5
II
2 3
000214
1 = Input shaft 4 = Ring

2 = Supporting disc 5 = Pinion with external disc carrier
3 = Thrust washer
Removal of pinion with external disc carrier
21 Pull off pinion with external disc carrier (5)

and collect.
H 31.01.00 - 10
BW (BU) 190 A (P)
Input shaft
BW (BU) 195 A (P)
6 5 3
II
1 2 4
000215
1 = Input shaft 4 = Bush

2 = Thrust washer 5 = Internal disc carrier
3 = Bearing bush 6 = Cylindrical roller
Removal of bearing bushes
22 Remove thrust washer (2) for version with

direction of rotation II.
NOTE:
The bearing bushes should remain on the input shaft
and not be removed. Protect the bearing bushes from
damage.
Replace the bearing bushes if necessary by breaking
open the old bushes (3) using a chisel (destructive
removal).
23 Remove bush (4).
24 Heat thrust washer or ring (depending on version)

if necessary and press off using two screwdrivers.
NOTE:
Internal disc carrier (5).
Depending on production (transition fit), the internal
disc carrier may have a press-fit, an interference-fit or
a sliding-fit.
25 Remove cylindrical roller (5).

If necessary, remove internal disc carrier
Modification index for this page: b H 31.01.00 - 11

BW (BU) 190 A (P)
Input shaft
BW (BU) 195 A (P)
1 2 3
II
7 1 6 5 4
000216
1 = Cylindrical roller 4 = Bush

2 = Ring 5 = Thrust washer
3 = Bearing bush 6 = Supporting disc
7 = Input shaft
Installation
Fitting bearing bushes.
01 Re-install internal disc carrier if removed

previously.
Fit cylindrical roller (1).
02 For direction of rotation I: heat ring (2) to

approx. 85°C and push onto input shaft.
For direction of rotation II: heat supporting disc
(6) to approx. 85°C, ensure supporting disc (6) is
the right way round and push onto input shaft.
03 Heat bearing bushes to approx. 120°C.
04 Push first bearing bush (3) fully onto input shaft.
05 Push bush (4) onto input shaft.
06 Push second bearing bush (3) onto input shaft

until snug with bush (4).

BW (BU) 190 A (P)
Input shaft
BW (BU) 195 A (P)
1 2 3 4 5 6
II
A
000217
1 = Retaining ring 5 = Input shaft

2 = Pinion with external disc carrier 6 = Segment (2 pcs.)
3 = Thrust washer (direction of rotation I) A = End float 0.6 to 1.0 mm
4 = Sealing ring bush
Fitting pinion with external disc carrier
07 Fit retaining ring (1) if removed.
08 Push on external disc carrier with pinion (2).
NOTE:
Watch out for the grooves for the segments (6) when
pushing on the sealing ring bush (4). Push on the
sealing ring bush (4), insert the segments (6) and push
the pinion towards the input end using assembly levers
(arrowed). Ensure the segments are pressed against
the edge of the segment groove.
09 Depending on version, heat thrust washer (3) and

sealing ring bush (4) or just sealing ring bush (4)
to approx. 100°C and push onto input shaft the
right way round.
10 Allow parts to cool. Measure pinion end float.

End float must be 0.6–1.0 mm.
11 Remove segments (6) again.
Modification index for this page: H 31.02.00 - 02

BW (BU) 190 A (P)
Input shaft
BW (BU) 195 A (P)
4
5 6 7 8 9 10 11 12
II
000218

6 = Piston, for Trolling versionor version 12 = Input shaft
preapred for Trolling
Fitting disc set
NOTE:
When sliding on the external discs, pay attention to the marking on the disc
driver lug. Each external disc has a marking on two driver lugs. One marking
2 is narrow and the other wide. Insert the outer discs as follows: Start with the
narrow marking centered and the wide marking (2) to the right or left of the
narrrow marking (1) when the first external disc is inserted. Insert the
remaining external discs with the wide markings alternatively left and right of
1
the narrow central markings.
Example:
2 1. Wide marking of external disc to the right of the narrow marking.
2. Wide marking of the external disc to the left of the narrow marking.
000101
3. Wide marking of the external disc to the right of the narrow marking.
H 31.02.00 - 03
BW (BU) 190 A (P)
Input shaft
BW (BU) 195 A (P)
12 Fit snap ring (see Fig. 000217) onto internal disc

carrier if not already fitted (acts as stop for end
shim (11)).
13 Slide end shim (11) onto the disc carrier the right
way round.
14 Depending on the gearbox type (see Table of

Discs D 11.00.00), insert discs (9 and 10) into the
disc carrier. Alternate external disc and internal
discs as follows: external, internal and observe the
note on the previous page. If the disc set is
assembled correctly, disc play will be as specified.
15 Push 6 plate springs (8) onto the input shaft in the

right order (see drawing).
16 Insert new rectangular rings (5 and 7) into the

annular groove on the piston.
17 Fit trolling valve (1 to 4) into the piston (6).
H 31.02.00 - 04
BW (BU) 190 A (P)
Input shaft
BW (BU) 195 A (P)
1 2 3 4 5 6 7 8 9 10
II
15 14 13 12 11
000219
1 = Oil injector 1X56 130 595 9 = Rectangular ring

2 = Pressure gauge 1X56 130 604 10 = Input shaft
3 = Pump holder 1X56 130 597 11 = High pressure hose 1X56 130 588
4 = High pressure line 1X56 130 597 12 = Pressure gauge 1X56 130 592
5 = Hydraulic nut 1X56 137 227 13 = Adapter 1X56 130 591
6 = Emergency shift device 14 = Reciprocating pump 1X56 130 589
7 = Constant gear 15 = Cylinder roller bearing inner ring
8 = Piston
Fitting constant gear

Push on constant gear to measure push-on dimension
NOTE: Do not mix up input shaft and change-over as described in Section D 05.00.00.
shaft constant gear. These gears are differentiated by Stretch rectangular ring (9) well before installation of
the direction of their helical gearing. Always refer to constant gear.
the parts numbers. When installing the constant gear, be careful not to
damage the rectangular rings on the piston.
For version BW 190, 195 A (P)
Gear with parts no. 3081 303 ...
Spare parts no. 3081 203 ... for input shaft 18 Check emergency shift device and install if
removed from constant gear.
For version BW 190, 195 A (P)
Gear with parts no. 3081 302 ... 19 Insert piston (8) into constant gear.
H 31.02.00 - 05
BW (BU) 190 A (P)
Input shaft
BW (BU) 195 A (P)
! DANGER
points.
accidents.
press-fits.
part-way and fully.
22 Heat cylinder roller bearing inner ring (15) to

approx. 85°C and push fully onto input shaft the
right way round.
H 31.02.00 - 06
BW (BU) 190 A (P)
Input shaft
BW (BU) 195 A (P)
II
*3
II
4
A
5
6
7
8
9
10
000220
2 = Input shaft 7 = Collar nut 1X56 137 232
3 = *Shim 8 = Segment (2 pcs.)
4 = Self-aligning roller bearing 9 = Shim
5 = Adapter 1X56 137 260 10 = Retaining ring
H 31.02.00 - 07
BW (BU) 190 A (P)
Input shaft
BW (BU) 195 A (P)
NOTE:
There are versions with and without shim (3).
For version without shim (3), clearance A must be 63
to 63.2 mm.
For version with *shim (3).

If fitting a new pinion, install shim (3), thickness 3.0
mm.
If the current pinion is re-used, mark the shim (3)

during disassembly and install the same shim during
assembly.
22 Depending on version, insert shim (3) into bearing

bore.
23 Heat bearing bore for input end of input shaft to

approx. 60°C.
24 Insert self-aligning roller bearing (4) into bearing

bore.
25 Fit adapter (5) and removal plate (6) to assist

assembly and clamp using collar nuts (7).
26 Heat self-aligning roller bearing inner ring (4) to

90 –100°C and insert input shaft in self-aligning
roller bearing.
27 Remove removal plate (6) and adapter (5). .
28 Insert two segments (8) into sealing ring bush.
29 Slide shim (9) over the segments.
30 Insert retaining ring (10) into sealing ring bush.
H 31.02.00 - 08
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Removal and disassembly of input shaft (direction of rotation I and II .................................................. H 32.01.00
Assembly and installation of input shaft (direction of rotation I and II ................................................. H 32.02.00
NOTE:
When assembling the input shaft, pay particular attention to the direction of gearbox rotation. Depending on the
direction of rotation, the ring or supporting disc must be fitted on the input shaft to the left or right of the pinion.
The text describes fitting the ring or supporting disc for direction of rotation II.
= input direction I

counter-clockwise -
000094

clockwise -
000095
H 32.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
II
II
I
000221
Sign denoting different layout for other directions of rotation
H 32.00.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Input shaft
000222
Change-over shaft
03.394-
03.420-
03.564-
03.254-
03.460-
03.454-
03.436-
03.480- 03.432- 03.324- 03.500-
03.470-
03.520- 03.510-
03.350-
03.530-
03.120-
03.430-
03.370-
03.450-
03.456- 03.360-
03.100-
03.090-
03.370-
03.080-
03.560- 03.406- 03.360-

02.068-
03.404-
03.274- 03.260-
03.402- 03.266-
03.568-
03.400-
03.414- 03.040-
03.408-
02.244-
02.070- 02.240-
02.230-
02.380- 03.262-
*
03.490- 03.200-
03.210-
02.390- 03.208-
03.110-
02.392-
000223
H 32.00.00 - 03
BW (BU) 190 A (P), BW (BU) 190 V (P)
Input shaft
BW (BU) 195 A (P), BW (BU) 195 V (P)
2
II
II
I
4
5
6
7
8
9
10
11
19 18 17 16 12
13
14
15
000224
2 = Input shaft 12 = Stud screw 1X56 137 232
3 = Coupling nut 1X56 137 232 13 = Bolt 1X56 136 461
4 = High pressure line 1X56 130 601 14 = Shim
5 = Pressure piece 1X56 137 473 15 = Retaining ring
8 = Pump holder 1X56 130 590 18 = Adapter 1X56 130 591
Removal
Removal of input shaft
02 Remove retaining ring (15) and take off shim (14).
H 32.01.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Input shaft
BW (BU) 195 A (P), BW (BU) 195 V (P)
NOTE:
It is usually possible to press the input shaft out of the
bearing bush after injecting oil using the oil injector
(do not press off the shaft at the same time as injecting
oil). The diagram indicates the most unfavourable
condition.
Therefore, items 4, 5, 6, 15 & 16 do not necessarily
need to be fitted.
03 Inject oil between the input shaft and bush using

the oil injector. Remove oil injector.
04 Set up equipment without items 4, 5, 6, 15 and 16.

Fit screw (13) with hex head against shaft end.
! DANGER
points.
accidents.
05 Press input shaft out of self-aligning roller bearing

and lift out of housing.
H 32.01.00 - 02
BW (BU) 190 A (P), BW (BU) 190 V (P)
Input shaft
BW (BU) 195 A (P), BW (BU) 195 V (P)
1 2 3 4 5 6 7 8 9 10
15 11
12 13 14
I
II
000225
1 = Bearing bush 9 = Removal plate 1X56 137 229

2 = Self-aligning roller bearing 10 = Stud screw 1X56 137 232
3 = Housing 11 = High pressure hose 1X56 130 588
7 = Hydraulic nut 1X56 137 227 15 = Pressure piece 1X56 137 931
8 = Collar nut 1X56 137 232
Removal of sealing ring bush
06 Set up equipment as shown in drawing. 07 Press bearing bush out of self-aligning roller
bearing.
! DANGER
points.
accidents.
H 32.01.00 - 03
BW (BU) 190 A (P), BW (BU) 190 V (P)
Input shaft
BW (BU) 195 A (P), BW (BU) 195 V (P)
1 2 3 4 5 6 7 8 9
10
11
*15 12 13 14
I
II
000226
2 = Self-aligning roller bearing 10 = Bolt 1X56 136 461
3 = Pressure piece 1X56 137 931 11 = High pressure hose 1X56 130 588
5 = Collar nut 1X56 137 232 13 = Pressure gauge 1X56 130 592
6 = Removal plate 1X56 137 229 14 = Reciprocating pump 1X56 130 589
7 = Hydraulic nut 1X56 137 227 15 = *Shim
8 = Nut 1X56 137 226 * not fitted on all versions
Removal of self-aligning roller bearing
09 Pull self-aligning roller bearing out of housing.

Remove *shim (15) from bearing bore and mark
for assembly.
H 32.01.00 - 04
BW (BU) 190 A (P), BW (BU) 190 V (P)
Input shaft
BW (BU) 195 A (P), BW (BU) 195 V (P)
1 2 3 4 5 6 7 8
II
000227
1 = 3-arm puller 5 = Sealing ring bush

2 = Pressure piece 6 = Cylinder roller bearing inner ring
3 = Snap ring 7 = Pinion with external disc carrier
4 = Shim 8 = Bearing bush
NOTE:
If the bearing bush (8) separates from the
input shaft when removing the input shaft,
pull off the pinion and the external disc carrier (7).
11 Pull off sealing ring bush (5).
H 32.01.00 - 05
BW (BU) 190 A (P), BW (BU) 190 V (P)
Input shaft
BW (BU) 195 A (P), BW (BU) 195 V (P)
12
A
II
I
1
2
3
4
6 7 8 9 10 11
000228
1 = Bolt 1X56 136 461 8 = Pump holder 1X56 130 590
2 = Nut 1X56 137 226 9 = High pressure line 1X56 130 601
3 = Hydraulic nut 1X56 137 227 10 = Constant gear
4 = Pressure piece 1X56 137 932 11 = Piston
5 = Input shaft 12 = Emergency shift device
6 = Oil injector 1X56 130 595 A = Clearance approx. 15 mm
7 = Pressure gauge 1X56 130 604
Removal of constant gear
13 Set up equipment as shown in the drawing. Pay particular attention to the paragraphs dealing
! DANGER part-way and fully.
condition, especially the screw threads. 14 Release constant gear (10).
15 Remove piston (11) from constant gear.
Remove emergency shift device (12), if
required.
points.
accidents.
press-fits.
H 32. 01.00 - 06
BW (BU) 190 A (P), BW (BU) 190 V (P)
Input shaft
BW (BU) 195 A (P), BW (BU) 195 V (P)
4
5 6 7 8 9 10 11 12
II
000229

6 = Piston, for Trolling version or 12 = Input shaft
version prepared for Trolling
Removal of disc set from input shaft
16 Remove rectangular rings (5 and 7) from the

annular grooves on piston.
17 Remove 6 plate springs (8), from input shaft.
18 Remove inner and outer discs (9 and 10) from

the disc carrier.
H 32.01.00 - 07
BW (BU) 190 A (P), BW (BU) 190 V (P)
Input shaft
BW (BU) 195 A (P), BW (BU) 195 V (P)
1 2 3 4 5 6 7 8 9 10 11
II
13 12
000230
1 = External disc carrier with pinion 8 = Pressure piece 1X56 137 473
2 = Puller 9 = Pump holder 1X56 130 590
3 = Thrust washer (depending on version) 10 = Pressure gauge 1X56 130 604
4 = Supporting disc or ring (depending on version) 11 = Oil injector 1X56 130 595
5 = Bearing bush 12 = Nipple 1X56 137 927
6 = Rectangular ring 13 = Washer
Removal of external disc carrier and pinion
NOTE:
Do not perform the working steps from removal
of sealing ring bush to removal of disc set if you
are only removing the external disc carrier and pinion.
The bearing bush (5) is usually removed when taking
out the input shaft.
20 Remove rectangular rings (6) from the annular

grooves.
21 Pull pinion and external disc carrier off as shown

in the drawing.
22 Remove washer (13) (depending on version).
H 32.01.00 - 08
BW (BU) 190 A (P), BW (BU) 190 V (P)
Input shaft
BW (BU) 195 A (P), BW (BU) 195 V (P)
1 2 3 4 5
II
8 7 6
000231
1 = Input shaft 5 = Bearing bushes

2 = Internal disc carrier 6 = Bush
3 = Snap ring 7 = Supporting disc (depending on version)
4 = Ring (depending on version) 8 = Cylindrical roller
NOTE:
The bearing bushes should remain on the input shaft
and not be removed. Protect the bearing bushes from
damage.
23 Replace the bearing bushes if necessary by

breaking open the old bushes (5) using a chisel
(destructive removal).
24 Remove bush (5).
25 Heat supporting disc (7) or ring (4) (depending on

version) if necessary and press off using two
screwdrivers.
NOTE:
a sliding-fit.
26 Remove cylindrical roller (8).

If necessary, remove internal disc carrier

BW (BU) 190 A (P), BW (BU) 190 V (P)
Input shaft
BW (BU) 195 A (P), BW (BU) 195 V (P)
1 2 3 4 5
II
8 7 6
000232
1 = Input shaft 5 = Bearing bushes

2 = Internal disc carrier 6 = Bush
3 = Snap ring 7 = Supporting disc (depending on version)
4 = Ring (depending on version) 8 = Cylinderical roller
Installation
Fitting bearing bushes.
01 Re-install internal disc carrier if removed previously.

Fit cylindrical roller (8).
02 For direction of rotation II: heat ring (4) to

approx. 85°C and push onto input shaft.
For direction of rotation I: heat supporting disc (7)
to approx. 85°C, ensure supporting disc (7) is the
right way round and push onto input shaft.
03 Heat bearing bushes to approx. 120°C.
04 Push first bearing bush (3) fully onto input shaft.
05 Push bush (6) onto input shaft.
06 Push second bearing bush (5) onto input shaft until

snug with bush (6).
07 Insert snap ring (3) into annular groove of internal

disc carrier (2).

BW (BU) 190 A (P), BW (BU) 190 V (P)
Input shaft
BW (BU) 195 A (P), BW (BU) 195 V (P)
1 2 3 4 5
II
A
8 7 6
000233
1 = Input shaft 6 = Dowel pin

2 = External disc carrier with pinion 7 = Ring
3 = Thrust washer 8 = Thrust washer
4 = Supporting disc A = End float 0.6 to 1.0 mm
5 = Bearing bush
Installation of external disc carrier with pinion
08 For direction of rotation I: fit thrust washer (8).
09 Push on external disc carrier with pinion (2).
10 Depending on direction of rotation, heat thrust

washer (3) and supporting disc (4) or ring (7) to
approx. 80°C and fit.
11 Insert dowel pin (6) into bearing bush (5).
12 Heat bearing bush (5) to approx. 80°C and push

onto input shaft so that the dowel pin (6) engages
in the groove of the ring (7) or the supporting disc
(4) depending on version.

BW (BU) 190 A (P), BW (BU) 190 V (P)
Input shaft
BW (BU) 195 A (P), BW (BU) 195 V (P)
4
5 6 7 8 9 10 11 12 13
II
000234
1 = Retaining ring 8 = Internal disc

2 = Pin 9 = External disc
3 = Pressure spring 10 = End shim
4 = Piston 11 = Input shaft
5 = Rectangular ring 12 = Plate spring (6 pcs.)
6 = Piston, for Trolling version or 13 = Snap ring
version preapred for Trolling
Fitting disc set
NOTE:
2
is narrow and the other wide. Insert the outer discs as follows: Start with the
1 narrrow marking (1) when the first external disc is inserted. Insert the
the narrow central markings.
2
000101
H 32.02.00 - 03
BW (BU) 190 A (P), BW (BU) 190 V (P)
Input shaft
BW (BU) 195 A (P), BW (BU) 195 V (P)
Example:
1. Wide marking of external disc to the right of the
narrow marking.
2. Wide marking of the external disc to the left of the

narrow marking.
3. Wide marking of the external disc to the right of the

narrow marking.
13 Fit snap ring (13) onto internal disc carrier if not

already fitted (this acts as a stop for the end shim
(10)).
way round.

16 Push 6 plate springs (12) onto the input shaft in

the right order (see drawing).

B 32.02.00 - 04
BW (BU) 190 A (P), BW (BU) 190 V (P)
Input shaft
BW (BU) 195 A (P), BW (BU) 195 V (P)
16
15
12
14 a
20 19 18 17 13
II
I
1
2
3
4
5
6 7 8 9 10 11
000235
1 = Bolt 1X56 136 461 12 = Emergency shift device

2 = Nut 1X56 137 226 13 = High pressure hose 1X56 130 588
5 = Input shaft 16 = Reciprocating pump 1X56 130 589
6 = Oil injector 1X56 130 595 17 = Cylinder roller bearing inner ring
7 = Pressure gauge 1X56 130 604 18 = Sealing ring bush
8 = Pump holder 1X56 130 597 19 = Shim
9 = High pressure line 1X56 130 601 20 = Snap ring
10 = Constant gear A = Push-on distance
11 = Piston
NOTE: 18 Push on constant gear to measure push-on

Do not mix up input shaft and change-over shaft distance as described in Section D 05.00.00.
constant gear. These gears are differentiated by the
direction of their helical gearing. Always refer to the 19 Check emergency shift device (12) and install if
parts numbers. removed from constant gear.
For version BW 190, 195 V (P) 20 Check Trolling valve in the constant gear and fit
Gear with parts no. 3081 303 ... piston (11).
Spare parts no. 3081 203 ... for input shaft
For version BW 190, 195 V (P)

H 32.02.00 - 05
BW (BU) 190 A (P), BW (BU) 190 V (P)
Input shaft
BW (BU) 195 A (P), BW (BU) 195 V (P)
NOTE:
Stretch smaller rectangular ring of constant gear well
before fitting into the piston (11).
When installing the constant gear, be careful not to
damage the rectangular rings on the piston.
21 Set up equipment as shown in drawing..
! DANGER
points.
accidents.
press-fits.
part-way and fully.
23 Heat cylinderical roller bearing inner ring (17) to

approx. 80°C and push on fully the right way
round.
24 Heat sealing ring bush (18) to approx. 80°C and

push on the right way round .
25 Push on shim (19).
26 Insert snap ring (20).
H 32.02.00 - 06
BW (BU) 190 A (P), BW (BU) 190 V (P)
Input shaft
BW (BU) 195 A (P), BW (BU) 195 V (P)
II
I
II
I
*3
4
A
5
6
7
8
9
000236
2 = Input shaft 7 = Shim
3 = *Shim 8 = Retaining ring
4 = Self-aligning roller bearing 9 = Rectangular ring (2 pcs.)
5 = Adapter 1X56 137 260 * not fitted on all versions
Installing input shaft
NOTE: If the current pinion is re-used, mark the *shim (3)

There are versions with or without shim (3). during disassembly and install the same ring during
For version without shim (3), clearance A must be 63 assembly.
to 63.2 mm.
27 Depending on version, insert the appropriate
For version with shim (3). *shim (3).
If fitting a new pinion, install *shim (3), thickness
3.0 mm.
H 32.02.00 - 07
BW (BU) 190 A (P), BW (BU) 190 V (P)
Input shaft
BW (BU) 195 A (P), BW (BU) 195 V (P)
28 Heat bearing bore to approx. 60°C and insert in

self-aligning roller bearing (4).
29 Clamp self-aligning roller bearing (4) using

adapter (5) and removal plate (6).
30 Heat self-aligning roller bearing to approx.

85–90°C.
31 Insert input shaft (2) fully into self-aligning roller

bearing.
33 Install retaining ring (8).
34 Insert two rectangular rings (9) into the annular

groove on the input shaft.
H 32.02.00 - 08
BW (BU) 190 A (P) BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P) BW (BU) 195 V (P)
Removal and disassembly of change-over shaft

(direction of rotation I and II ................................................................................................................... H 33.01.00
Assembly and installation of change-over shaft

(direction of rotation I and II .................................................................................................................. H 33.02.00
NOTE:
When assembling the change-over shaft, pay particular attention to the direction of gearbox rotation. Depending
on the direction of rotation, the ring or support disc must be fitted on the change-over shaft to the left or right of
the pinion. The text describes fitting the ring or support disc for direction of rotation II.
= input direction I

counter-clockwise -
000094

clockwise -
000095
H 33.00.00 - 01
BW (BU) 190 A (P) BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P) BW (BU) 195 V (P)
Change-over shaft: Version: BW 190/195 A (P)
II
000237

Change-over shaft: Version: BW 190/195 V (P)
II
000238

H 33.00.00 - 02
BW (BU) 190 A (P)
Contents
BW (BU) 195 A (P)
000239
H 33.00.00 - 03
BW (BU) 190 V (P)
Contents
BW (BU) 195 V (P)
000240
H 33.00.00 - 04
BW (BU) 190 A (P) BW (BU) 190 V (P)
Change-over shaft
BW (BU) 195 A (P) BW (BU) 195 V (P)
2
II
20
15 3
19 4
18 5
17 6
16
15
14
10 9 8 7
13
12
11
000241
1 = Lifting device 1X56 137 225 11 = Retaining ring

2 = Change-over shaft 12 = Shim
4 = Pump holder 1X56 130 597 14 = Removal plate 1X56 137 229
5 = Oil injector 1X56 130 595 15 = Coupling nut 1X56 137 232
7 = Reciprocating pump 1X56 130 589 17 = Nut 1X56 137 226
8 = Adapter 1X56 130 591 18 = Pressure piece 1X56 137 473
9 = Pressure gauge 1X56 130 592 19 = Extension piece 1X56 137 927
10 = High pressure hose 1X56 130 588 20 = Self-aligning roller bearing
H 33.01.00 - 01
BW 190 A (P) BW 190 V (P)
Change-over shaft
BW 195 A (P) BW 195 V (P)
Removal
Removal of change-over shaft
NOTE:
It is usually possible to remove the change-over shaft
without having to inject oil and press at the same time.
Initially inject glycerine or oil into the fit between the
bush and change-over shaft using the oil injector (see
Figure 000241, top right). Press the change-over shaft
out as shown in Figure 000241, bottom right. If the
shaft still cannot be pressed out, proceed according to
Figure 000241, left.
! DANGER
points.
accidents.
03 Press change-over shaft out of self-aligning roller

bearing and lift out of housing.
H 33.01.00 - 02
BW 190 A (P) BW 190 V (P)
Change-over shaft
BW 195 A (P) BW 195 V (P)
1 2 3 4 5 6 7 8 9
10
11 12 13
000242
1 = Bearing bush 8 = Removal plate 1X56 137 229

3 = Coupling nut 1X56 137 232 10 = High pressure hose 1X56 130 588
4 = Bolt 1X56 136 461 11 = Adapter 1X56 130 591
5 = Nut 1X56 137 226 12 = Pressure gauge 1X56 130 592
7 = Collar nut 1X56 137 232
Bearing bush ausbauen
04 Set up equipment as shown in drawing. 05 Press bearing bush (1) out of self-aligning roller
bearing.
! DANGER:
points.
accidents.
H 33.01.00 - 03
BW (BU) 190 A (P) BW (BU) 190 V (P)
Change-over shaft
BW (BU) 195 A (P) BW (BU) 195 V (P)
1 2 3 4 5 6 7 8 9
10
11
12 13 14
*
15
000243
1 = Pressure piece 1X56 137 931 10 = Bolt 1X56 136 461

2 = Self-aligning roller bearing 11 = High pressure hose 1X56 130 588
3 = Housing 12 = Adapter 1X56 130 591
4 = Coupling nut 1X56 137 232 13 = Pressure gauge 1X56 130 592
5 = Collar nut 1X56 137 232 14 = Reciprocating pump1X56 130 589
6 = Removal plate 1X56 137 229 15 = *Shim
7 = Hydraulic nut 1X56 137 227 * not fitted on all versions
8 = Nut 1X56 137 226
9 = Stud screw 1X56 137 232
Remove self-aligning roller bearing condition, especially the screw threads. Ensure that
threaded connections are screwed on or in as far as
06 Remove bearing bush. possible. When using threaded rods for bracing
purposes, always use all available bracing points.
Removal that no-one is standing in front of the pressurized
accidents.
! DANGER
Important information for the following procedure! 08 Pull self-aligning roller bearing out of housing and
Ensure that all equipment used is in perfect collect shim (15). Mark *shim (15) for assembly.
H 33.01.00 - 04
BW (BU) 190 A (P) BW (BU) 190 V (P)
Change-over shaft
BW (BU) 195 A (P) BW (BU) 195 V (P)
1 2 3 4
II
7 6
II
5
I
000244
1 = Puller 5 = BW 190 V (P)

2 = Pressure piece 6 = Self-aligning roller bearing
3 = Change-over shaft 7 = Bush
4 = Roller bearing inner ring
09 Remove change-over shaft.

For Version V (5) pull off self-aligning roller
bearing and remove bush (7) from self-aligning roller
bearing.
H 33.01.00 - 05
BW (BU) 190 A (P) BW (BU) 190 V (P)
Change-over shaft
BW (BU) 195 A (P) BW (BU) 195 V (P)
5 6 7 8 9 10
II
1 2 3 4
000245
1 = Oil injector 1X56 130 595 6 = Change-over shaft

2 = Pressure gauge 1X56 130 604 7 = Emergency shift device
3 = Pump holder 1X56 130 597 8 = Constant gear
4 = High pressure line 1X56 130 601 9 = Piston
5 = Hydraulic nut 1X56 137 227 10 = Rectangular ring
Loosening constant gear
12 Remove cylinder roller bearing inner ring or self-

aligning roller bearing.
NOTE:
Do not mix up input shaft and change-over shaft
constant gear. These gears are differentiated by the
direction of their helical gearing. Always refer to the
part numbers.

Sp a re par ts no. 3081 202 ... for change-over shaft

Sp a re par ts no. 3081 203 ... for input shaft
H 33.01.00 - 06
BW (BU) 190 A (P) BW (BU) 190 V (P)
Change-over shaft
BW (BU) 195 A (P) BW (BU) 195 V (P)
! DANGER
points.
accidents.
press-fits.
part-way and fully.
14 Release constant gear (8).
15 Remove piston (9) from constant gear.
16 Remove emergency shift device (7), if required.
H 33.01.00 - 07
BW (BU) 190 A (P) BW (BU) 190 V (P)
Change-over shaft
BW (BU) 195 A (P) BW (BU) 195 V (P)
4
5 6 7 8 9 10 11 12
II
000246

6 = Piston, for Trolling version or 12 = Change-over shaft
Removal of disc set from change-over shaft
17 Remove constant gear.
18 Remove rectangular rings (5 and 7) from annular

grooves on piston.
19 Remove 6 plate springs (8) from input shaft.
20 Remove internal and external discs (9 and 10)

from disc carrier.
H 33.01.00 - 08
BW (BU) 190 A (P) BW (BU) 190 V (P)
Change-over shaft
BW (BU) 195 A (P) BW (BU) 195 V (P)
1 2 3 4 5 6 8
9
10
I
II
11
12
16 15 14 13
000247
1 = Change-over shaft 9 = High pressure line 1X56 130 601

2 = Supporting disc 10 = Bearing bush
3 = Thrust washer 11 = Puller
4 = Pinion with external disc carrier 12 = Pressure piece 1X56 137 473
5 = Ring 13 = Cylindrical roller
6 = Oil injector 1X56 130 595 14 = Supporting disc
7 = Pressure gauge 15 = Thrust washer
8 = Pump holder 16 = Ring
Removal of outer disc carrier with pinion
NOTE:
Do not perform the working steps from removal of
cylinder roller bearing inner ring to removal of disc
set if you are only removing the external disc carrier
and pinion.
The bearing bush (10) is usually removed when
taking out the change-over shaft.
22 Remove pinion (4) with external disc carrier as

as shown in drawing.
23 Remove thrust washer (3) depending on version.
24 Remove cylindrical roller (13) from change-over shaft.
H 33.01.00 - 09
BW (BU) 190 A (P) BW (BU) 190 V (P)
Change-over shaft
BW (BU) 195 A (P) BW (BU) 195 V (P)
1 2 3 4
II
7 6 5
000248

2 = Internal disc carrier 6 = Ring
3 = Supporting disc 7 = Cylindrical roller
4 = Bearing bush
25 Remove external disc carrier with pinion.
NOTE:
If re-using the bearing bushes (4), leave them on
the shaft and make sure they are not damaged. If
renewing the bearing bushes, proceed as follows:
Heat bearing bush (4) quickly and drive off the shaft
(do not re-use bearing bush). Alternatively, remove
using a chisel (destructive removal).
NOTE:
a sliding-fit.
26 Remove bearing bushes or ensure they are

protected.
Modification index for this page: b H 33.01.00 -10

BW (BU) 190 A (P) BW (BU) 190 V (P)
Change-over shaft
BW (BU) 195 A (P) BW (BU) 195 V (P)
1 2 3 4
II
8 7 6 5
000249

2 = Internal disc carrier with pinion 6 = Ring
3 = Supporting disc 7 = Snap ring
4 = Bearing bush 8 = Cylindrical roller
Installation
Installation of bearing bushes
01 Re-install internal disc carrier if removed 02 Insert cylindrical roller (8).

previously.
If bearing bushes have been removed: 03 Push on ring or supporting disc the right way
round.
For transmission version A,
Direction of rotation I: "Supporting disc" 04 Heat bearing bushes (4) to approx. 120°C.
For transmission version A, 05 Slide on first bearing bush (4).

Direction of rotation II: "Ring"
06 Slide on bush (5).
For transmission version V,
Direction of rotation I: "Ring" 07 Slide on second bearing bush.
For transmission version V, 08 Insert snap ring (7) in annular groove of internal
Direction of rotation II: "Supporting disc" disc carrier.

BW (BU) 190 A (P) BW (BU) 190 V (P)
Change-over shaft
BW (BU) 195 A (P) BW (BU) 195 V (P)
1 2 3 4 5 6
A
II
8 7
000250
1 = Change-over shaft 6 = Bearing bush

2 = Thrust washer 7 = Supporting disc
3 = External disc carrier with pinion 8 = Thrust washer
4 = Ring A = End float 0.6 to 1.0 mm
5 = Cylindrical roller
Installation of external disc carrier with pinion
09 Install bearing bushes. For gearbox version A, direction of rotation II and

gearbox version V, direction of rotation I: push on
10 For gearbox version A, direction of rotation I and thrust washer (8) and supporting disc (7).
gearbox version V, direction of rotation II: push
on thrust washer (2).
14 Heat bearing bush (6) to approx. 80°C and push
11 Push on external disc carrier with pinion (3). on.
15 Check end float "A", 0.6 to 1.0 mm.

12 Insert cylindrical roller (5).
13 Hear ring (4) or supporting disc (7) to approx.

80°C.
For gearbox version A, direction of rotation I and

gearbox version V, direction of rotation II: push
on ring (4).

BW (BU) 190 A (P) BW (BU) 190 V (P)
Change-over shaft
BW (BU) 195 A (P) BW (BU) 195 V (P)
4
5 6 7 8 9 10 11 12 13
II
000251
1 = Retaining ring 8 = Internal disc

2 = Pin 9 = External disc
3 = Pressure spring 10 = End shim
4 = Piston 11 = Change-over shaft
5 = Rectangular ring 12 = Plate spring (6 pcs.)
6 = Piston, for Trolling version or 13 = Snap ring
Fitting disc set
2 NOTE:
1 is narrow and the other wide. Insert the outer discs as follows: Start with the
narrrow marking (1) when the first external disc is inserted. Insert the
2 the narrow central markings.
000101
H 33.02.00 - 03
BW (BU) 190 A (P) BW (BU) 190 V (P)
Change-over shaft
BW (BU) 195 A (P) BW (BU) 195 V (P)
Example:
1. Wide marking of external disc to the right of the

narrow marking.
2. Wide marking of the external disc to the left of the

narrow marking.
3. Wide marking of the external disc to the right of the

narrow marking. (See drawing on previous page).
16 Fit snap ring (13) onto internal disc carrier if not

already fitted (this is the stop for the end shim
(10).
way round.

19 Push 6 plate springs (12) onto the change-over

shaft in the right order (see drawing).

H 33.02.00 - 04
BW (BU) 190 A (P) BW (BU) 190 V (P)
Change-over shaft
BW (BU) 195 A (P) BW (BU) 195 V (P)
1 2 3 4 5 6 7 8 9 10
II
16 15
14 13 12 11
000252
1 = Oil injector 1X56 130 595 9 = Piston

2 = Pressure gauge 1X56 130 604 10 = Rectangular ring
3 = Pump holder 1X56 130 597 11 = High pressure hose 1X56 130 588
4 = High pressure line 1X56 130 601 12 = Pressure gauge 1X56 130 592
6 = Change-over shaft 14 = Reciprocating pump 1X56 130 589
7 = Emergency shift device 15 = Cylinder roller bearing inner ring
8 = Constant gear 16 = Self-aligning roller bearing
NOTE:
Do not mix up input shaft and change-over shaft 21Check emergency shift device and install if removed
constant gears. These gears are differentiated by the from constant gear. Insert piston (9) in constant gear
direction of their helical gearing. Always refer to the (8).
part numbers.
NOTE:
For Version BW 190, 195 A and V (P) Stretch rectangular ring (10) well before installation of
Gear with parts no. 3081 302 ... constant gear. When installing the constant gear, be
S p are pa r t s no. 3081 202 ... for change-over shaft careful not to damage the rectangular rings (10) on the
piston.
For Version BW 190, 195 A and V (P)
S p are pa r t s no. 3081 203 ... for input shaft
Push on constant gear to measure push-on

dimension as described in Section D 05.00.00.
H 33.02.00 - 05
BW (BU) 190 A (P) BW (BU) 190 V (P)
Change-over shaft
BW (BU) 195 A (P) BW (BU) 195 V (P)
! DANGER
points.
accidents.
press-fits.
part-way and fully.
24 For version BW 190, 195 A (P): Heat cylinder

roller bearing inner ring to approx. 85°C and push
fully onto change-over shaft the right way round.
For version BW 190, 195 V (P): Heat self-
aligning roller bearing (16) to approx. 85°C and
push fully onto change-over shaft the right way
round.
H 33.02.00 - 06
BW (BU) 190 A (P) BW (BU) 190 V (P)
Change-over shaft
BW (BU) 195 A (P) BW (BU) 195 V (P)
II
*3
5
6
7
8 000253
1 = Lifting device 1X56 137 225 6 = Shim

2 = Change-over shaft 7 = Retaining ring
3 = Shim 8 = Collar nut
4 = Self-aligning roller bearing * not fitted on all versions
5 = Removal plate 1X56 137 229
Installing change-over shaft
NOTE: If re-using the currently fitted pinion, install the *shim

There are versions with and without shim (3). (3) which was marked during removal.
For version without shim (3) ensure clearance A is
48 to 48.2 mm. 25 Depending on version, insert appropriate *shim
(3) into the bearing bore.
For version with shim (3).
If fitting a new pinion, fit 3.0 mm thick shim (3).
H 33.02.00 - 07
BW (BU) 190 A (P) BW (BU) 190 V (P)
Change-over shaft
BW (BU) 195 A (P) BW (BU) 195 V (P)
26 Clamp self-aligning roller bearing using removal

plate (5) 1X56 137 229.
27 Heat self-aligning roller bearing to approx.

85–90°C.
28 Insert change-over shaft (2) fully into self-

aligning roller bearing.
30 Install retaining ring (7).
H 33.02.00 - 08
BW (BU) 190 A (P) BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P) BW (BU) 195 V (P)
Removal and disassembly of output shaft .............................................................................................. H 37.01.00
Assembly and installation of output shaft .............................................................................................. H 37.02.00
H 37.00.00 - 01
BW (BU) 190 A (P) BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P) BW (BU) 195 V (P)
000254
H 37.00.00 - 02
BW (BU) 190 A (P) BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P) BW (BU) 195 V (P)
000255
H 37.00.00 - 03
BW (BU) 190 A (P) BW (BU) 190 V (P)
Removal and disassembly of output shaft
BW (BU) 195 A (P) BW (BU) 195 V (P)
000256
1 = Bell housing 4 = Oil tray

2 = Cover 5 = Gasket
3 = Oil level tube and dipstick 6 = Sump
H 37.01.00 - 01
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
Removal
Removal of cover, sump and oil tray
01 For version with bell housing (1):

- remove bell housing.
- remove secondary pump. If secondary pump is
not fitted, remove the cover for secondary pump
bore.
- remove input and change-over shafts.
02 Remove cover (2) for version without bell

housing.
03 Remove oil level tube and dipstick (3).
04 Remove sump (6).
05 Collect gasket (5).
06 Remove oil tray (4).
H 37.01.00 - 02
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
10 11
9
7 8
5 6
4
3
1 2
* 12
* 13
14
15
16
20 19 18 17
000257
1 = Output shaft 12 = *Shim

2 = Hex bolt 13 = *Shim
3 = Housing 14 = Bolt 1X56 136 461
4 = Output gear 15 = Nut 1X56 137 226
5 = Cylinder roller bearing outer ring 16 = Hydraulic nut 1X56 137 227
6 = Removal device 1X56 137 929 17 = Reciprocating pump 1X56 130 589
7 = Removal plate 1X56 137 928 18 = Adapter 1X56 130 591
9 = Retaining ring 20 = High pressure hose 1X56 130 588
10 = *Shim
11 = Grooved nut * not fitted on all versions
Removal of cylinder roller bearing outer ring
07 Release grooved nut (11) and remove using 09 Remove retaining ring (9).
ring spanner 1X56 137 926 .
10 Unscrew hex bolts (2).
08 Collect *shim (10).
H 37.01.00 - 03
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
11 Push output shaft (1) towards output end until the

output gear (4) is in contact with the propeller
bearing.
! DANGER
points.
accidents.
procedure in front of a wall or workbench.
13 Pull off cylinder roller bearing outer ring.
H 37.01.00 - 04
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
7 8
5 6
3 4
2
9 10 11 12
000258
1 = Output shaft 7 = Nut 1X56 137 226

2 = Cylinder roller bearing inner ring 8 = Bolt 1X56 137 461
3 = Removal device 1X56 137 930 9 = High pressure line 1X56 130 601
4 = Removal plate 1X56 137 928 10 = Adapter 1X56 130 591
14 Set up equipment as shown in drawing. 15 Pull off cylinder roller bearing inner ring.
! DANGER
points.
accidents.
H 37.01.00 - 05
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
4
2 3
8
7
5 6
9
000259
1 = Output shaft 6 = Extension piece 1X56 137 927

2 = Oil injector 1X56 130 595 7 = Pressure piece 1X56 137 277
3 = Pressure gauge 1X56 130 604 8 = Hydraulic nut 1X56 137 227
4 = Pump holder 1X56 130 597 A = Push-on distance max. +15 mm
Loosening of output gear
! DANGER
Before loosening the output gear, support the output
shaft and output gear using load slings to prevent
these components falling out of the housing.
16 Secure the output shaft using load slings.
H 37.01.00 - 06
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
! DANGER
points.
accidents.
18 Loosen output gear.
19 Remove output gear and output shaft from

housing.
H 37.01.00 - 07
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
1 2 3 4 5 6 7 8 9 10 11 12
13
14
21 20 19 18 17 16 15
000260
1 = Output shaft 12 = Removal plate 1X56 137 229

2 = Shaft sealing 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 = Axial roller bearing inner ring 16 = Adapter 1X56 130 591
6 = Ring 17 = Reciprocating pump 1X56 130 589
7 = Grooved nut 18 = Stud screw 1X56 137 232
8 = Coupling nut 1X56 137 232 19 = Push-on disc 1X56 137 231
9 = Stud screw 1X56 137 232 20 = Removal hook 1X56 137 448
10 = Nut 1X56 137 226 21 = Shim
Pulling off propeller pressure bearing
Removal
20 Release M 90x1.5 grooved nut (7) and unscrew

using ring spanner 1X56 137 224.
21 Collect ring (6) from output shaft.
H 37.01.00 - 08
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
! DANGER
points.
accidents.
23 Pull off axial roller bearing inner ring (5) as

shown in drawing. Heat bearing inner ring if
necessary.
H 37.01.00 - 09
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
1 2 3 4 5 6 7 8 9 10 11 12
13
14
18 17 16 15
000261
1 = Output shaft 10 = Nut 1X56 137 226

2 = Shaft sealing ring 11 = Hydraulic nut 1X56 137 227
3 = Cover 12 = Removal plate 1X56 137 229
4 = Tapered roller bearing 13 = Bolt 1X56 136 461
5 = Push-on disc 1X56 137 231 14 = High pressure hose 1X56 130 588
6 = Hex bolt 1X56 137 232 15 = Pressure gauge 1X56 130 592
7 = Stud screw 1X56 137 232 16 = Adapter 1X56 130 591
8 = Coupling nut 1X56 137 232 17 = Reciprocating pump 1X56 130 589
9 = Stud screw 1X56 137 232 18 = Hex bolt 1X56 137 232
Pulling off cover and tapered roller bearing
24 Remove cover bolts by tilting the cover (3). 25 Pull off cover (3) and tapered roller bearing (4) as
shown in drawing.
! DANGER
Important information for the following procedure! NOTE:
Ensure that all equipment used is in perfect Whilst pulling off the cover and tapered roller bearing,
condition, especially the screw threads. the shaft sealing ring (2) is pushed out of the cover by
Ensure that threaded connections are screwed on or the pump output gear.
points. 26 Drive tapered roller bearing outer ring out of the
When loosening or pushing on oil press-fits, ensure cover.
accidents.
H 37.01.00 - 10
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
1 2 3 4 5 6 7 8
12 11 10
000262
1 = Push-on disc 1X56 137 231 7 = Hydraulic nut 1X56 137 227
2 = Input gear 8 = Removal plate 1X56 137 229
3 = Stud screw 1X56 137 232 9 = High pressure hose 1X56 130 588
4 = Output shaft 10 = Pressure gauge 1X56 130 592
6 = Stud screw 1X56 137 232 12 = Reciprocating pump 1X56 130 589
Removal of input gear
27 Set up equipment as shown in drawing. 28 Pull off input gear as shown in drawing.
! DANGER
points.
accidents.
H 37.01.00 - 11
BW (BU) 190 A (P) BW (BU) 190 V (P)
Assembly and installation of output shaft
BW (BU) 195 A (P) BW (BU) 195 V (P)
1 2
"a"
000263
1 = Output shaft 3 = Screw clamp (fit two clamps offset at 180°)

2 = Output gear
Installation
Check push-on distance "a" 01 Measure push-on distance of output gear (2).
Install output gear as described in Section
! DANGER D 05.00.00 "The Oil Injection Method".
Important information for the following procedure! Measure push-on distance "a".
Only use lifting slings which are check and valid for At a later stage, the output gear is pushed on so
lifting > = 2000 N. Attach screw clamps to prevent that the end face (Y) is level with the output gear
and the collar (X) is level with the output shaft.
the output shaft from tipping over before
positioning the output gear.
H 37.02.00 - 01
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
1 2 3 4 5 6 7 8 9 10 11 12 13
000264
1 = Output shaft 8 = Tapered roller bearing outer ring

2 = Fixing piece 9 = Tapered roller bearing inner ring
3 = Shaft sealing ring 10 = Shim
4 = Cover 11 = Axial roller bearing outer ring
5 = Hex bolt 12 = Ring
6 = Input gear 13 = Grooved nut M 90x1.5
7 = Shim
Installation of shaft sealing ring, cover and 05 Heat input gear (6) to approx. 85°C and push onto
propeller pressure bearing output shaft the right way round.
1 2 3 4 5 6 7 06 Heat bearing bore for tapered roller bearing outer

ring (8) to approx. 60° C and insert tapered roller
x bearing outer ring into the cover the right way
round.
07 Insert the long M 10x70 hex bolts (5) into the

appropriate holes in the cover.
000265 CAUTION
Use shim (7) to position the output shaft axially and
02 Fit 3 fixing pieces (2) offset at 120° angles to set the backlash. If the input shaft or change-over
each other. shaft has insufficient backlash, adjust shim (7)
accordingly.
03 Using adapter 1X56 137 260, press shaft sealing
ring (3) in evenly accoring to Section
A 17.01.02-01. NOTE:
Select shim (7) thickness depending on gearbox
04 Push cover (4) and shaft sealing ring fully onto version. The thickness of shim (7) always depends on
the output shaft until snugly located against the the reduction pinion version on the change-over shaft.
fixing piece (2).
H 37.02.00 - 02
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
Thickness of shim (7) depending on version
BW (BU) 190 / 195 A (P)
Thickness of shim Pinion no. Spare part

(7) on i on change- number
output shaft over shaft
4.5 1.260 3081 303 082 3081 203 017
4.5 1.769 3081 303 089 3081 203 015
4.5 2.936 3081 303 086 3081 203 014
4.5 2.484 3081 303 085 3081 203 013
4.5 1.972 3081 303 084 3081 203 012
4.5 1.488 3081 303 083 3081 203 011

4.5 2.030 3081 303 148 3081 203 048
4.5 1.273 3081 303 142 3081 203 035
4.5 1.750 3081 303 141 3081 203 034
4.5 2.920 3081 303 143 3081 203 036
4.5 2.448 3081 303 140 3081 203 033
6,0 2.030 3081 303 139 3081 203 032
4.5 1.538 3081 303 138 3081 203 031
H 37.02.00 - 03
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)

4.5 1.273 3081 303 164 3081 203 066
4.5 1.750 3081 303 163 3081 203 065
4.5 2.920 3081 303 165 3081 203 067
4.5 2.448 3081 303 162 3081 203 064
4.5 2.030 3081 303 161 3081 203 063
4.5 1.538 3081 303 160 3081 203 062
H 37.02.00 - 04
BW (BU) 190 A (P) BW (BU) 190 V (P)
Assembly and installation of input shaft
BW (BU) 195 A (P) BW (BU) 195 V (P)
BW (BU) 190 / 195 V (P)

5.5 2.030 3081 303 149 3081 203 049
5.5 1.273 3081 303 135 3081 203 042
5.5 1.750 3081 303 134 3081 203 041
5.5 2.920 3081 303 136 3081 203 043
5.5 2.448 3081 303 133 3081 203 040
6.0 2.030 3081 303 132 3081 203 039
5.5 1.538 3081 303 131 3081 203 038

4.5 1.273 3081 303 157 3081 203 059
4.5 1.750 3081 303 156 3081 203 058
4.5 2.920 3081 303 158 3081 203 060
4.5 2.448 3081 303 155 3081 203 057
4.5 2.030 3081 303 154 3081 203 056
4.5 1.538 3081 303 153 3081 203 055
H 37.02.00 - 05
BW (BU) 190 A (P) BW (BU) 190 V (P)
Assembly and installation of input shaft
BW (BU) 195 A (P) BW (BU) 195 V (P)
08 Slide appropriate shim (7) up against input gear

(6).
09 Heat tapered roller bearing inner ring to approx.

85 °C and push fully onto the input shaft until
snug against the shim (7).
10 Slide shim (10) up against tapered roller bearing

inner ring.
11 Heat axial roller bearing inner ring (11) to approx.

85°C and push onto output shaft the right way
round.
12 Push ring (12) fully onto the output shaft until

snug against axial roller bearing inner ring.
13 Screw on grooved nut M 90x1.5 and tighten to

approx. 800 Nm using ring spanner 1X56 137
224.
14 Carefully secure grooved nut.
H 37.02.00 - 06
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
7 8
5 6
3 4
2
1
10
14 13 12 11
000266
1 = Output shaft 8 = Meas. gauge holder with measurement gauge

2 = Hex bolt 9 = High pressure hose 1X56 130 588
3 = Axial roller bearing outer ring 10 = Auxiliary tool
4 = Disc 11 = Pressure gauge 1X56 130 604
5 = Roll pin 12 = Adapter 1X56 130 591
6 = Threaded rod 1X56 137 232 13 = Reciprocating pump 1X56 130 589
7 = Hydraulic nut 1X56 137 227 14 = Pressure spring (4 pcs.)
Installation and adjustment of propeller pressure bearing
15 Insert roll pin (5) into disc (4) or housing if roll pin (5) has not already being fitted.
16 Insert disc (4) into bearing bore.
17 Insert 4 pressure springs (14) into disc (4).
H 37.02.00 - 07
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
18 Place axial roller bearing outer ring (3) onto the

bearing inner ring.
19 Insert output shaft (1) into housing without using

sealing compound and tighten provisionally.
20 Position output shaft until it is as vertical as

possible.
21 Rotate output shaft several times clockwise and

anti-clockwise.
23 Using measurement gauge and holder (8),

measure end float of output shaft.
The end float must be 0.05 to 0.1 mm with a
preload of 4000 N.
This preload is provided by the pressure springs
(14).
24 Make any necessary corrections using the disc (4).

Discs (4) are available in 0.2 mm steps from 16.00
mm to 14.6 mm and 14.5 mm.
H 37.02.00 - 08
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
6
4 5
9 10
8
7
2 3
1
16
17 15 14 13 12 11
18
000267
1 = Output shaft 11 = Reciprocating pump 1X56 130 589

2 = Hex bolt 12 = Adapter 1X56 130 591
3 = O-ring 13 = Pressure gauge 1X56 130 604
5 = Pressure gauge 1X56 130 604 15 = Output gear
6 = Pump holder 1X56 130 597 16 = Pressure spring (4 pcs.)
7 = Extension piece 1X56 137 927 17 = Disc
8 = High pressure line 1X56 130 601 18 = Axial roller bearing outer ring
9 = Pressure piece 1X56 137 277 X = Push-on distance (push on evenly up to shaft
10 = Hydraulic nut 1X56 137 227 shoulder)
Slide on output gear
25 Swivel housing so that output side is uppermost.
H 37.02.00 - 09
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
! DANGER Follow the instructions in Section D 05.00.00

Important information for the following procedure! exactly when removing and installing conical oil
Only use lifting slings which are check and valid for press-fits.
lifting > = 2000 N. Pay particular attention to the paragraphs dealing
26 Insert output gear (15) into the housing the right part-way and fully.
way round (e.g. with large cone diameter pointing
towards output end).
27 Check that the disc (17), four pressure springs 33 Push on output gear until level with the shaft
(16) and the axial roller bearing outer ring are collar.
inserted. If not, insert these components.
28 Insert O-ring (3) into annular groove on cover.

sealing face of the cover.
30 Insert output shaft and helical gear into the

housing.
31 Screw in hex bolts (2). Do not fully tighten these

hex bolts.
! DANGER
points.
When loosening or pushing on conical oil press-fits,
ensure that no-one is standing in front of the

A 11.01.00
H 37.02.00 - 10
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
9 10
7 8
5 6 * *
4 *
3
2
1
* 11
G
C
B
A
000268
1 = Output shaft 7 = Cylinder roller bearing outer ring

2 = Hex bolt 8 = *Adjusting shim
3 = Output gear 9 = *Shim
4 = Retaining ring 10 = Grooved nut
5 = *Adjusting shim 11 = Shim
6 = Cylinder roller bearing inner ring * not fitted on all versions
Installation of cylinder roller bearing

- Dimension "C" between 37.8 and 37.9 mm:
34 Tighten hex bolts (2). adjusting shims (5) and (9) are fitted.
NOTE: There are two versions differentiated by - Dimension "C" between 30.8 and 30.9 mm:
dimension "C". adjusting shim 8 and shims 9 and 11 are fitted.
H 37.02.00 - 11
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
CAUTION 43 Calculate thickness of shim "F" or "G", depending

Measure end float between shoulder, cylinder roller on version.
bearing inner ring and end face of cylindrical roller on
bearing outer ring. 44 Push corrected shim (5) onto the shaft.
Adjust end float using adjusting shim (5) or ring (11).
Heat cylinder roller bearing inner ring to approx.
For version with adjusting shim (5), ensure end float is 85°C and push fully onto the output shaft the right
between 0.45 to 2.25 mm. way round.
For version (without adjusting shim (5)) but with shim 45 After allowing the inner ring to cool, heat the
(11), ensure end float is between 1.0 to 1.5 mm. housing bore to approx. 60°C and insert cylinder
roller bearing outer ring (7) far enough into the
bearing bore until the retaining ring (4) can be
35 Depending on version, adjust end float using inserted.
adjusting shim (5) or, for version without
adjusting shim (5), using shim (11). For version with shim (11), push the cylinder
roller bearing outer ring in further by the
Adjustment of end float for cylinder roller bearing. thickness of the shim (11).
36 For version with adjusting shim (5) and shim 46 For version with shim (11), insert shim (11).
(9). Calculate thickness of shim "F" (adjusting For all versions, insert retaining ring (4) into the
shim 5) by subtracting end float 0.45 to 2.25 mm annular groove of the bearing bore.
from dimension "E".
47 Check: Cylinder roller bearing inner ring must
For version without adjusting shim (5) but with protrude past the shaft collar.
adjusting shim (8), shims (9) and (11).
Calculate thickness of shim "G" by subtracting 48 For version without adjusting shim (5), fit
end float 1.0 to 1.5 mm from dimension "E". adjusting shim 8 and shim 9.
For version with adjusting shim (5), fit shim (9).
37 Measure thickness of retaining ring (4) and note
down. This is dimension "B". 49 Screw on grooved nut (10) and using ring spanner
1X56 137 926, tighten grooved nut. Tightening
38 Insert retaining ring into annular groove on torque approx. 800 Nm.
housing. Ensure retaining ring is in contact with Secure grooved nut.
the upper edge of the annular groove.
39 Measure from the upper edge of the retaining ring

to the shaft and output gear end face and note
down. This is dimension "A". Remove retaining
ring after taking this measurement.
40 Dimension "A" minus dimension "B" =

dimension "C".
41 Measure dimension "D", the thickness of the

cylinder roller bearing.
42 Calculate dimension "E". E = C - D.
H 37.02.00 - 12
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
II
II
000269
II
II
000270
Measuring tooth backlash
NOTE:
Depending on direction of rotation, push the
reduction gear in the supporting direction (arrowed)
and hold firmly in this position.
H 37.02.00 - 13
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
II
005050
1 = Shim
53 Fit measurement gauge holder with measurement 56 Calculate backlash as shown in the drawing by
gauge. movement to the left and right.
54 Push the corresponding pinion in the correct axial 57 If backlash is not within the specified tolerances,
direction using an assembly lever whilst adjust by correcting shim 1.
preventing the pinion from turning.
55 Check backlash for version A or V.

Correct backlash:
Input shaft pinion 0.1–0.45 mm measured at the
output gear flank.
Change-over shaft pinion 0.1–0.45 mm measured
from the output gear flank.
H 37.02.00 - 14
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
000256
1 = Bell housing 4 = Oil tray

2 = Cover 5 = Gasket
3 = Oil level tube and dipstick 6 = Sump
H 37.02.00 - 15
BW (BU) 190 A (P) BW (BU) 190 V (P)
BW (BU) 195 A (P) BW (BU) 195 V (P)
58 Fit oil tray (4).
59 Install sump (6) and gasket (5).
60 Fit oil level tube and dipstick (3).

sealing face of cover (2) and fit cover (2).
For version with bell housing (1), fit the bell
housing after installation of the input and change-
over shafts.
* Sealing compound Hylomar SQ 32 M-Special (see

A 11.00.00)
H 37.02.00 - 16
BW (BU) 195 A (P), BW (BU) 195 V (P) Section K
Inspection sequence................................................................................................................................. K 01.00.00
K 00.00.00 - 01
BW (BU) 190 A (P), BW (BU) 190 V (P)
Contents
BW (BU) 195 A (P), BW (BU) 195 V (P)
Gearbox inspection report for the BW 190 marine gearbox family

(Sample for nominal clutch pressure17 bar) .......................................................................................... K 01.01.00

(Copy for nominal clutch pressure17 bar) .............................................................................................. K 01.01.01

(Copy for nominal clutch pressure15 bar) .............................................................................................. K 01.01.02
K 01.00.00 - 01
Topic Inspection report for Type
QA no..
BW 190 family marine gearboxes Page from Modif.
Valid for XYZ

..................................................................
Eval. mode. FKZ Group Status
Nominal pressure (*) 17 bar

ZF Friedrichshafen AG On form Replacement for
i= 2,03
.......................... A Replaced by
Gearbox operating type: mechanical, pneumatic, electronic XYZ

G/box no. ...................................................
Fast craft P/list no. .................................................

Power/speed max. .................. kW/rpm Order no. ...................................................
Test sequence Test rig no. ................................................
Input Output Input Clutch oil Oil press. Lub. oil Oil Op. Überprüfung:
speed direction torque pressure at filter pressure temp. time Mengenbegrenzungsventil at:
of n An = 2000 min-1, t = 40 °C
(Nm) PK (bar) inlet
rotation PS in Schaltstellung Neutral
(rpm) PvF (bar) PS (bar) t (°C) (Min)
Nom: < 4,5 bar Act: .............. bar
20 reversing shifts
En.-wise - 17.0 19.8 1.2 26° Min. 2 sec. gap between shifts
1000 appr. 5 Downstream section in "Neutral"
C-en.-wise - 17.0 19.2 1.1 29° position.
C-en.-wise 700 17.0 18.3 1.0 36° 10 G/box test oil: Renolin MR-40Z
1500 (corrosion protection oil)
En.-wise 700 16.9 17.8 1.0 44° 10 Check fill level using dipstick.
15 Load cycle with oil cooling

En.-wise 700 17.3 18.4 2.7 58°
Control range 75 - 85 °C
1500
C-en.-wise 700 17.2 18.1 2.6 70° 15 Fitted oil cooler
Product:
C-en.-wise 1500 16.7 17.0 1.1 75° 10
470 D 83
No. ......................................................
1500
En.-wise 1500 16.7 17.0 1.0 80° 10
See inst. dwg. for measurement pts.
Operating and lubricating oil pressures, measurements at t oil = 65 - 75 °C

Measurements with Trolling "OFF"
At n In = 2000 rpm Nom: PvF ≤ PK Act + 0.7 bar 18.1 bar
Act: ................ in enginewise or c-enginewise shift pos.
At n In = 1300 rpm Nom: PK = 17.0 - 17.5 bar 17.0
Act: ................ bar in enginewise or c-enginewise shift pos.
At n In = 400 rpm Nom: PK ≥ 16.5 bar 16.5 bar
Act: ................ in enginewise or c-enginewise shift pos.
At n In = 400 rpm Nom: PK = 3.7 - 4.5 bar 4.0 bar
Act: ................ in Neutral
Lube oil pressure:
At n In = 1300 rpm Nom: PS = 1.0 - 2.0 bar Act: ................ bar in enginewise or c-enginewise shift pos.
At n In = 400 rpm Nom: PS min. = 0.5 bar 1.5 bar in Neutral
Act: ................
0.9
Functional check of secondary pump
At n In = 1300 rpm Nom: P ≥ PvF Act Act: ................ bar in enginewise or c-enginewise shift pos.
-
Concluding test: Check gearbox for leaks at operating temperature. Check contact patterns and assess inked tooth flanks
through inspection window. Clean oil filter after test.
Crack test: All hardened shafts and gears were subjected to 100% crack tests.
Wear proportion on tooth flanks good
Assessment: ................................... Stamp:
approx. 90 %
Location: Friedrichshafen G/box test dept.:
Accepting Type of test: Tested by:
company
* see clutch nominal pressure stamped on control unit
K 01.01.00 - 01
QA no..
Valid for ..................................................................
i= .......................... A Replaced by
Gearbox operating type: mechanical, pneumatic, electronic XYZ

G/box no. ...................................................

of n An = 2000 min-1, t = 40 °C
(Nm) PK (bar) inlet
Nom: < 4,5 bar Act: .............. bar
20 reversing shifts
En.-wise - Min. 2 sec. gap between shifts
C-en.-wise - position.
C-en.-wise 700 10 G/box test oil: Renolin MR-40Z

En.-wise 700 10 Check fill level using dipstick.

En.-wise 700
1500
C-en.-wise 700 15 Fitted oil cooler
Product:
C-en.-wise 1500 10
1500 No. ......................................................
En.-wise 1500 10

At n In = 2000 rpm Nom: PvF ≤ PK Act + 0.7 bar Act: ................ bar in enginewise or c-enginewise shift pos.
At n In = 1300 rpm Nom: PK = 17.0 - 17.5 bar Act: ................ bar in enginewise or c-enginewise shift pos.
At n In = 400 rpm Nom: PK ≥ 16.5 bar Act: ................ bar in enginewise or c-enginewise shift pos.
At n In = 400 rpm Nom: PK = 3.7 - 4.5 bar Act: ................ bar in Neutral
Lube oil pressure:
At n In = 400 rpm Nom: PS min. = 0.5 bar Act: ................ bar in Neutral
Wear proportion on tooth flanks Assessment: ................................... Stamp:
approx. %
Location: G/box test dept.: FQ-A1:
company
K 01.01.01 - 01
QA no..
Valid for ..................................................................
i= .......................... A Replaced by
Gearbox operating type: mechanical, pneumatic, electronic G/box no. ...................................................

of n An = 2000 min-1, t = 40 °C
(Nm) PK (bar) inlet
Nom: < 4,5 bar Act: .............. bar
20 reversing shifts
En.-wise - Min. 2 sec. gap between shifts
C-en.-wise - position.
C-en.-wise 700 10 G/box test oil: Renolin MR-40Z

En.-wise 700 10 Check fill level using dipstick.

En.-wise 700
1500
C-en.-wise 700 15 Fitted oil cooler
Product:
C-en.-wise 1500 10
1500 No. ......................................................
En.-wise 1500 10

At n In = 2000 rpm Nom: PvF ≤ PK Act + 0.7 bar Act: ................ bar in enginewise or c-enginewise shift pos.
At n In = 1300 rpm Nom: PK = 17.0 - 15.0 bar Act: ................ bar in enginewise or c-enginewise shift pos.
At n In = 400 rpm Nom: PK ≥ 14.0 bar Act: ................ bar in enginewise or c-enginewise shift pos.
At n In = 400 rpm Nom: PK = 3.7 - 4.5 bar Act: ................ bar in Neutral
Lube oil pressure:
At n In = 400 rpm Nom: PS min. = 0.5 bar Act: ................ bar in Neutral
Wear proportion on tooth flanks Assessment: ................................... Stamp:
approx. %
Location: G/box test dept.: FQ-A1
company
K 01.01.02 - 01

3081 - 751 - 105b BW195 A SERVICE MANUAL

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Druckliste

Nachdruck 3081 751 105b

Typ: BW (BU) 190 A (P), BW (BU) 190 A (P)

Pos. In die Anleitung einlegen: nach Seite

1 Korrosionsschutz (PDF) 3070 755 101 A 13.00.00 - 01

3 Beschreibung (elektonisch gespeichert) 3080 758 110 B 03.00.00 - 01

Workshop Workshop Workshop

BW 190 A (P) BW 190 A (P) BW 190 A (P)

BU 190 A (P) BU 190 A (P) BU 190 A (P)

BW 190 V (P) BW 190 V (P) BW 190 V (P)

BU 190 V (P) BU 190 V (P) BU 190 V (P)

Locating and removing faults C

Removal/installation of parts with

3081 751 105b

ZF Friedrichshafen AG ZF Padova S.p.A. ZF-HURTH Marine S.p.A.

D-88038 Friedrichshafen I-35030 Caselle di Selvazzano I-38062 Arco (TN)

This repair manual is intended for skilled personnel

This manual deals with the standard ZF product in

However, due to continuing development of the

We recommend that work done on your ZF product is

Service points equipped by ZF Friedrichshafen AG all

1. Continually trained personnel

2. Specified equipment, e.g. special tools

3. Genuine ZF spares, to our latest

All work performed at these service points is carried

Repair work carried out at ZF service points is

ZF FRIEDRICHSHAFEN AG Damage resulting from work performed by non-ZF

SAFETY NOTICE GENERAL INFORMATION

To avoid injury to personnel and damage to pro-

After completion of repair work and testing, skilled

Contents of principal groups

Section for filing Service Information Sheets......................................................................................... A 01.00.00

Layout of manual..................................................................................................................................... A 03.00.00

Service Points ......................................................................................................................................... A 05.00.00

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

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

Please store Service Information Sheets in this section.

List of Service Information Sheets.......................................................................................................... A 01.01.00

Please fill in the relevant information on receipt of Service Information Sheets.

Date of Service No. Transmission Introduced Comments

Layout of manual..................................................................................................................................... A 03.01.00

Note about the manual............................................................................................................................. A 03.02.00

NOTE: The Workshop Manual deals with all

BU gearbox versions are not specifically

If you wish to arrange the manual to deal with only

NOTE: You may order the ZF Company Register

Please quote F 11/23 GF 91 50 08 when ordering.

Version without secondary pump

Gearbox and power-flow diagram D

D - Clutch for cntr-enginewise E

Gearbox and power-flow diagram, V version

HYLOMAR (Universal compound SQ 32 M-Special, Grease

SQ 32 M-Special, flexible universal sealing

Loctite Deutschland GmbH, Munich

Instructions for use:

Dyken Read DX-296 for recording tooth flank contact

The instructions given in the footnote relating to

Please request the latest issue of the ZF List of

General – Disassembly ............................................................................................................................ A 17.01.00