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3081 - 751 - 103 BW195 P Service Manual
3081 - 751 - 103 BW195 P Service Manual
Service centers
General A
Description
Operation B
Maintenance
50 Adjustment data D
Nm
Special tools E
Changing parts on
installed gearbox F
Major overhaul H
Installation of auxiliaries I
Test run K
Subject to alterations in design
Copyright by ZF
This workshop manual is protected by copyright. Reproduction and dissemination in any form, either wholly
or in part especially as a reproduction, photomechanical or electronic copies or stored in data processing
equipment or data networks without the approval of the legal owner is expressly prohibited and any violation
will be pursued vigorously in the civil and criminal courts.
Printed in Germany
Edition . 07.99
H 31.00.00 01 - 12 Section I
H 31.01.04 01 - 10
H.31.02.00 01 - 08
H.33.00.00 01 - 10 Section K
H.33.01.00 01 - 09
H.33.02.00 01 - 08 K 00.00.00 01
K 01.00.00 01
H 37.00.00 01 - 02
H 37.01.00 01 - 06
H 37.02.00 01 - 07
H 39.00.00 01 - 02
H 39.01.00 01 - 06
H 39.02.00 01 - 12
H 41.00.00 01 - 03
H 41.01.00 01 - 06
H 41.02.00 01 - 05
1. Well-trained personnel
2. Specified equipment,
e. g: specialized tools
3. Genuine ZF spares
to our latest specifications
Warranty:
Repair work carried out at ZF service points is
guaranteed in accordance with the prevailing
contractual conditions.
Companies who repair ZF units are responsible for Read this manual carefully before starting any tests or
their own work safety. repair work.
NOTE
Refers to special processes, techniques, data, ! ENVIRONMENTAL HAZARD
use of auxiliary equipment etc. Lubricants and cleaning agents must not be allowed
to enter the ground, the water table or the sewerage
system.
CAUTION Request safety information for the products
This is used when incorrect, unprofessional concerned from your local environmental
working practices could damage the product. protection authority, and follow any instructions
herein at all times.
Always collect used oil in a suitably large
container.
! DANGER Always dispose of used oil, clogged filters,
This is used when lack of care could lead to lubricants and cleaning agents in accordance
personal injury or death. with environmental protection laws.
Always observe manufacturer instructions
when dealing with lubricants and cleaning
agents.
CAUTION
The gearbox must NOT be suspended on the input
shaft and must NOT be suspended on the output
flange.
Anti-corrosion protection, types of packaging, storage conditions and storage periods ...................... A 13.00.00
Structure of manual
Section
Principal group
Group
Sub-group
Page number
G 07. 03. 12 08
NOTE
ZF Group,
subsidiaries,
sales / after-sales centres,
affiliated companies
ZF FRIEDRICHSHAFEN AG
D-88038 Friedrichshafen
220 mm BW 190
BW 195
014218
220 mm BW 190 S
BW 195 S
014222
310 mm
BW 196
014220
390 mm
BW 191
014220
BW 190, 195: sectional view of gearbox and powerflow diagram ............................................. A 09.01.00 - 01
BW 190, 195 (P): sectional view of gearbox and cut-away diagrams of output ......................... A 09.01.00 - 03
BW 190 S,195 S (P): sectional view of gearbox and cut-away diagram of output ..................... A 09.01.00 - 04
Sectional view of gearbox and cut-away diagrams of input and intermediate shaft,
P version .................................................................................................................................... A 09.01.00 - 05
BW 196 (P): sectional view of gearbox and cut-away diagrams of output ................................. A 09.01.00 - 06
Powerflow in:
A counter-enginewise
C rotation
B A enginewise rotation
C 012686
012687
012688
012689
013912
013909
Consumables
Subject to change Dyken Read DX-296 for tooth flank contact pattern
acceptance for gearboxes with acceptance
Sealant specification from classification societies.
(Extract from manufacturers instructions for use)
Manufacturers instructions for use are binding in all Dyken-Read DX-296/8 oz,
cases. Helling, Sandorkai 1, 2 000 Hamburg 11,
Tel. (40) 376010 Telex 213611+2165082,
HYLOMAR (Universal sealant SQ 32 M) Fax (40) 37601100
Use on sealing faces of housing and cover. Made in Germany.
Instructions for use Cleaner (to remove grease from taper surfaces when
De-grease sealing faces before sealant application using oil press-fits)
(Hylomar cleaner) and apply HYLOMAR to both Acetone, white spirits (Caution: inflammable) or
sides. After airing (approx. 10 minutes), start putting commercially-available cleaner which does not leave
parts together. With threaded screws, wait a few greasy residue.
minutes then tighten screws down firmly.
We recommend you use HYLOMAR CLEANER for
removing oil seals and oil/grease. Glycerine for pushing on oil press-fits in BW 160 to
BW 195 families. Oil or glycerine can be used in
other gearbox types.
Teroson (Terostat-33)
Use on cover of output shaft on the thrust bearing.
Teroson, Germany
Anti-corrosion protection, types of packaging, storage conditions and storage periods ...................... A 13.00.00
The guidelines for anti-corrosion protection, types of packaging, storage conditions and storage periods for
marine gears are inserted in the following section (3070 755 001).
NOTE
The list of lubricants for ZF marine gears is inserted in the following section (TE-ML 04 1205 754 004c)
This list corresponds to the date of printing of the particular Workshop Manual.
Please request the latest issue of the ZF list of lubricants for marine gears from your nearest ZF service center
(the list should be replaced every 1 to 2 years).
This Workshop Manual deals with the marine gear CLEANING PARTS
types listed above.
Remove old sealing compound from all seal faces.
CAUTION Carefully remove burrs or similar irregularities using
When carrying out work on the above marine gears, an oil stone.
always refer to the latest circulars and service memos
which contain details of modifications. Contact the ZF Lube bores and grooves must be free of preservation
After-Sales Service Department if matters arise which grease and foreign matter. Check for unhindered
require clarification. throughflow.
Ensure all work is carried out cleanly and to a proper Carefully cover opened gearboxes to prevent foreign
professional standard. matter from entering.
An expert must decide whether parts such as ball A crack test is required if the propeller becomes
bearings, discs, thrust washers etc. can be reinstalled. grounded or the power-transmitting components in the
Replace damaged and heavily worn parts with new gearbox become damaged. If possible, a crack or
ones. surface-hardness test must be carried out, in
consultation with the gearbox manufacturer if
required.
Check that discs are level and not distorted by using a REWORK
steel ruler. When checking discs, note that some
versions (refer to D 11.00.00) of steel disc have 6 If spacer discs and shims require rework due to play
sinusoidal corrugated waves around the edge. This adjustment, ensure that the reworked surface has no
must not be confused with distortion. Replace discs raised material and is of constant quality.
which have become dished or misshapen by more than Sealing ring faces must be completely clean and
0.1 mm. undamaged. If defects are noticed, these must be
Do not re-install discs whose faces show signs of rectified by plunge grinding only and not, under any
fretting, lined discs with damaged lining or lined discs circumstances, with an abrasive cloth. There must be
where the grooves are no longer visible. All discs no grinding traces or spirals.
which are re-installed should undergo a crack-test.
NOTE
Section A 17.00.00 General
disassembly, testing, reworking and assembly must
be observed.
Publication
description, installation, operation and
maintenance compl. (basic version)
NOTE
The publication for description, installation, operation and maintenance is inserted in the following section.
(3080 758 010 and 3081 758 002a)
Tool set WI
Screwdrivers ...................................................................................................................................... up to 13 mm
NOTE
The standard input direction of rotation is clockwise, An arrow indicating the appropriate direction is fitted
viewed when facing the gearbox input flange; to the gearbox input side.
012691
2
1
6
7
012692 012693
8 9 10
Removal
Dismantling Installation
NOTE
Oil pump is a complete part and is not usually
dismantled.
It may however be necessary to disassemble the pump
for checking or cleaning purposes.
When checking the pump, pay particular attention to
ensuring that end float is within the wear limits, refer
to D 09.00.00.
The pump parts should be checked for traces of run in.
NOTE
Carefully check and clean parts, do not use any
fibrous cloths for cleaning. Apply a thin coat of oil to
moving parts.
Assembly
07 Snap circlip (5) into annular groove of pump * Sealing compound, e.g HYLOMAR SQ 32 M,
shaft. Marston A 11.00.00
012695
012696
2 3 4 5
1 = O-ring
2 = Cylindrical screw
012697
3 = Woodruff key
4 = Input gear
1
5 = Circlip
A = For end float, refer to D 09.00.00
01 If necessary, remove pipes as is described in 01 Insert eccentric ring, inner and outer rotor and
H 11.00.00. rotor shaft in the pump housing.
02 Unscrew fastening screws for oil pump. 02 Attach pump cover and screw down.
03 Lift off oil pump from cover (using assembly 03 Insert Woodruff key (3) in pump shaft.
levers as an aid if necessary).
04 Heat input gear (4) to approx. 85 °C and slide
onto pump shaft.
Disassembly
05 Snap circlip (5) into annular groove of pump
04 Snap out circlips (5). shaft.
NOTE
Carefully check and clean parts, do not use any
fibrous cloths for cleaning. Apply a thin coat of oil to
moving parts.
1
2
3 4
5
6
4 7 18
5 42 8 17
9 16 19
15
41 14
10 13
11
7 12
6
20
38 40 22 21
37 39
36 23
35 24
34 25
26
33 27
32 28
31 29
30
012698
Disassembling Installation
04 Remove detent parts (6, 7, 8 and 9). 07 Attach complete control unit with new gasket.
05 Remove lever (29) and cover (26) with gasket 08 Screw in hex bolts (41, 42, 11) and nut (10)
(25). and tighten.
06 Pull valve rotor (23) out of control housing. 09 Attach pipes in accordance with H 11.00.00.
Checking
NOTE
Keep pieces away from dirt and lightly oil moving
parts.
Assembly
1 2
4 3
012696
01 Remove pipes, if necessary. 02 Unscrew fastening nuts (2) on oil cooler and
remove oil cooler.
012700
The requirements in terms of achieving both a If coolers cleaned in this way are put into storage as
uniform cooling capacity as well as in terms of the spare parts, i.e. are not immediately refitted and
pressure drop at the oil end, make cleaning operations flushed through with gear oil, we would recommend
necessary at particular intervals, in particular at the oil the addition of approx. 5 % oil to the
end. It is not possible to specify in advance the trichloroethylene. This ensures that the oil film
intervals at which the cleaning procedures described remaining after cleaning and subsequent drying out
below should be performed because the nature and with warm air, acts as a preservative, in particular on
extent of contamination can vary greatly. The periods the turbulence plates at the oil end .
of operation should therefore be recorded prior to
carrying out any instruction and repair work. This will
enable a suitable cleaning schedule to be drawn up,
with intervals based on an appropriate number of Cleaning water end
operating hours.
We recommend the following treatment for this plate- Cleaning at the water end requires an examination of
type oil cooler: the dirt which has accumulated. If a greasy lime layer
is determined, the water end must first be degreased.
Cleaning oil end The lime layer is then dissolved by rinsing it with
water and a lime remover; it may also be possible to
The coolers are connected to a trichloroethylene or use a 10 to 15 % hydrochloric acid solution. An
perchloroethylene unit and are rinsed with the hot inhibitor must be added to the solution to ensure that it
medium. The direction of rinsing is the reverse to that does not attack the metal surfaces.
of the normal operating oil flow. This removes dirt After completion of cleaning, the water end is
particles, especially abrasion, from the multi-disc thoroughly rinsed with clear water and the oil end is
clutches and from the turbulence baffle of the oil then best filled with the oil subsequently used during
cooler plates. They are then flushed out by the normal operation and again drained.
medium. The cleaning will be more successful and the cleaning
time shorter if the direction of flow during pumping,
Cleaning instructions for oil cooler with plate-type both at the oil and water end, is the reverse to that
structure used in normal operation.
An appropriate filter should be inserted in this main
flow to remove the impurities rinsed out from the You can be sure that coolers cleaned in this way will
cleaning medium. Cleaning should be continued until then provide the full cooling capacity in subsequent
examinations reveal that the purity of the medium operation with a reasonable pressure drop at the oil
flowing out is equivalent to that flowing in . end.
Installation
For maintenance intervals, refer to publication - description, installation, operation and maintenance
(basic version) ....................................................................................................................................... B 03.00.00
Tightening torques for bolts and nuts as per standard .......................................................................... D 01.00.00
Tightening torques for screw plugs and union screws ......................................................................... D 02.00.00
Tightening torques for bolts and nuts as per standard ........................................................................... D 01.01.00
This standard applies for bolts in accordance with DIN Surface condition of bolts: heat-treated with blackened
912, DIN 931, DIN 933, DIN 960, DIN 961 as well as finish and oiled or galvanized and oiled or galvanized,
for nuts in accordance with DIN 934. chromatized and oiled.
This standard contains data on tightening torques
(MA) for bolts and nuts of strength classes 8.8, 10.9 Use a calibrated snap wrench or torque wrench with
and 12.9, as well as for nuts of strength classes 8, 10 display to tighten bolts.
and 12.
NOTE
Any tightening torques deviating from those specified
here are listed separately in the repair manual.
M 7 15 23 28 M 10 x 1.25 49 72 84
M 8 23 34 40 M 12 x 1.25 87 125 150
M 10 46 68 79 M 12 x 1.5 83 122 145
Tightening torques for screw plugs and union screws ......................................................................... D 02.01.00
Union screw
Screw plug
Input shaft:
Tightening torque of approx. 550 Nm Experience Secured after tightening
M 50 x 1.5 grooved nut
Tightening torque of approx. 800 Nm Experience Secured after tightening
M 65 x 1.5 grooved nut
End float of pinion 0.6 - 1.0 mm Feeler gauge Play is given,
on bearing bush check only
Reversing shaft:
Tightening torque of approx. 550 Nm Experience Secured after tightening
M 50 x 1.5 grooved nut
End float of pinion 0.6 - 1.0 mm Feeler gauge Play is given,
on bearing bush check only
Output shaft:
BW (BU) 190/195 (P) 0.05 - 0.1 mm Dial gauge Set by means of shim
End float of output shaft below axial roller
(propeller thrust bearing) outer bearing .
Preload 4 000 N
BW (BU) 190 S/195 S (P) 0.05 - 0.1 mm Dial gauge Set by means of shim
End float of output shaft on pump drive gear.
(propeller thrust bearing) Preload 2000N
Input shaft:
Tightening torque of approx. 550 Nm Experience Secured after tightening
M 50 x 1.5 grooved nut
End float of pinion 0.6 - 1.0 mm Feeler gauge Play is given,
on bearing bush check only
Reversing shaft
Tightening torque of approx. 550 Nm Experience Secured after tightening
M 50 x 1.5 grooved nut
End float of pinion 0.6 - 1.0 mm Feeler gauge Play is given,
on bearing bush check only
Output shaft:
BW 196 (P) 0.05 - 0.1 mm Dial gauge Set by means of shim
End float of output shaft below axial rollers
(propeller thrust bearing) outer bearing race.
Preload 4 000 N
Tightening torque of approx. 900 Nm Experience Secured after tightening
M 100 x 1.5 grooved nut
Applies for checking the face end and top runout variances on shrink-fitted input and output flanges
S I
S II R I
R II
S II S I
R II R I
1 2
005 189
Authorized deviations
Input Output
Gearbox type FE TR FE TR
Test specification:
Checking that surfaces of oil press-fits are free of grease ..................................................................... D 05.04.00
Assembly specification:
Checking tapered press-fits which are pressed firmly home ................................................................. D 05.05.00
Push-on length Max. oil pressure for Max. pull-on force of Hydraulic nut
in mm* widening oil press-fits for hydraulic nut to be used
pressing on and off (pressure gauge 1X56 137 227
(pressure gauge oil reciprocating pump)
i Description injector)
Input flange
on input shaft
on input shaft
Torsion
coupling PE 42 W 0501 204 963 x
NOTE: In practice, the max. widening pressure is automatically adjusted, depending on the prevailing force,
on input shaft 3081 302 109 4.3 - 4.9 mm
on input shaft
Output gear
on output shaft
on output shaft
Output gear 3081 304 192 x
on output shaft 3081 304 041 5.8 - 6.4 mm
2.030 on output shaft
Output gear
on output shaft
on output shaft
Output gear 3081 304 015 x
on output shaft 3081 304 041 6.2 - 6.8 mm
2.571 on output shaft 3081 304 044
Output gear
on output shaft
on output shaft
Output gear 3081 304 193 x
on output shaft 3081 304 080 7.8 - 8.4 mm
3.0 on output shaft
Output gear
on output shaft
on output shaft
* Applicable to new parts, at room temperature, contact faces not oiled.
When re-assembling, the push-on length may be a max. 0.15 mm smaller per re-used part.
Push-on length Max. oil pressure for Max. pull-on force of Hydraulic nut
in mm* widening oil press-fits for hydraulic nut to be used
pressing on and off (pressure gauge 1X56 137 227
(pressure gauge oil reciprocating pump)
i Description injector)
on output shaft
Output gear
75 bar 27 KN ( 2.7 t)
50 bar 18 KN ( 1.8 t)
25 bar 9 KN ( 0.9 t)
Operating principle: - Ensure that all air is removed from the pump
Tapered and cylindrical oil pressure fits are released and high pressure hose (by filling with oil).
and joined using this method. Pressure oil is forced
through bores and distributing grooves between the Follow the operating instructions at all times.
mating faces until a thin film of oil is formed which
separates the components. This greatly reduces the - Wear protective goggles.
forces for installing and removing the components, or
in the case of the tapered pressure oil fit, the - It is always advisable to use a pressure gauge
components jump off quite suddenly when released. when working with high pressures.
DANGER
Special measure:
To prevent any accidents:
for safety reasons, no one should stand in front of
the pressurized components when a tapered
pressure oil fit is being released or fitted.
The fixtures used must be in perfect condition,
particularly at the threads. The threads should be
screwed into the shafts.
The work is best performed directly in front of a
wall or a work bench.
DANGER
Oil injector
Use of the oil pump is not dangerous if the
operating instructions are followed correctly.
Accessories used must be in perfect condition. Note
the following
NOTES:
- Carefully check the pump, high pressure hose
and all accessories before use. Also, never use
pump components that are even slightly
damaged or accessories that are not designed
for a pressure of 3000 bar (300 MPa).
005190
NOTE
Push out piston of hydraulic nut (1) to limit of travel
and move fixture with hydraulic nut so that it touches
the part to be loosened. Press-on the hydraulic nut
using approx. 50 bar of pressure.
Attach the collecting equipment, comprising parts 1 Application: Assembling oil press-fit
to 11. Bring the piston of the hydraulic nut into
contact (observe note under figure 005190). Connect The parts to be joined must be at the same
oil injector to flange using high pressure pipe and temperature, preferably ambient temperature. First of
remove air. Pump pressurized oil between the pressing all, properly clean the tapers of shaft and gear or
surfaces until the oil is distributed around the oil flange. Do not oil or grease them.
press-fit (pressure drop on pressure gauge). Continue Fit gear or flange onto the taper of the shaft but only
pumping (pressure gauge reading on reciprocating until it is firmly seated. Check the push-on length "a"
pump rises erratically). Quickly open the valve on the in this position. On shafts without a stop collar, the
reciprocating pump. The piston of the hydraulic nut is axial position of the gear or flange relative to the shaft
pushed back to its starting position. The oil press-fit is must be measured so that you can accurately check
now loose. the push-on length "a". Remove parts once the push-
on dimension has been measured.
Measuring push-on length:
Also refer to D 05.05.00 - 01 to D 05.06.00 - 02.
NOTE: When using new parts (replacement parts), all
of the parts, and not just the tapers and oil injection
bores, must be thoroughly cleaned, i.e. they should be
free of any oil and grease.
The figure 000104 shows the fixture arrangement for
the push-on action.
Driving up:
NOTE
Before fitting, remove all traces of grease from oil
injector bores and tapers because, unlike an oil film,
grease cannot be forced out of the mating joint.
CAUTION
The gears and flanges cannot be tightened down
firmly (thus ensuring full torque transmission) until
every last trace of dirt and grease has been cleaned
off the taper and oil injector bores.
DANGER
Once the specified push-on length has been
reached, first release the oil pressure at the oil
injector. The oil pressure should however be
maintained in the hydraulic nut until the film of oil
in the oil pressure fit has receded and the tapers are
firmly seated together.
The minimum waiting time is:
Pre-cleaning
Final cleaning
DANGER
Use acetone, spirits (caution: flammable)
or commercially-available cleaner which leaves
no trace or grease for the final cleaning.
Soak disposable paper towel in appropriate
cleaner and finally clean the tapered surfaces by
wiping them twice.
000 105
CAUTION
Failure to comply with this rule may result in total
gearbox failure.
000 106
000 107
000 108
000 109
WLH=0
A=DC
Checking tapered press-fits which are adjusted in 01 Measure the following lengths before and
accordance with the specified push-on length. during the joining procedure.
Case 1 Case 1
Case 2 Case 2
Case 3 Case 3
To ensure that press-fits transmit torque reliably, run a Length C = distance between shaft face end and hub
check in accordance with the following specification. face end before pressing on
CAUTION
Failure to comply with this rule may result in total
gearbox failure.
A=DC
000 116
Case 1 Case 1
A=CD
000 117
Case 2 Case 2
A=D+C
000 118
Case 3 Case 3
Length D = distance between shaft face end and hub Length A = calculated actual length of push-on
face end after pressing on. dimension
Order no. Installation location No. of Wire diam. Spring diam. Untensioned
coils in mm in mm length in mm
1204 304 116 Output shaft 6.0 1.8 11.0 17.3
0732 040 598 Flow limiting valve 10.5 2.5 21.5 62.6
0732 041 969 Injection line and 15.5 3.0 27.16 113.5
flow limiting valve
for trolling version
0732 041 067 Injection line valve 25.0 1.6 11.63 84.8
0732 041 256 Pressure limiting valve 6.5 4.0 23.5 36.1
(for max. system pressure)
0732 042 118 Control unit and 18.5 4.5 23.7 117.1
engageable PTO
0732 042 119 Control unit and 30.0 2.5 13.3 117.1
engageable PTO
0732 041 996 Piston for trolling 6.5 1.5 10.4 16.7
version and version
prepared for trolling refit
0732 042 577 Control unit and trolling 17.0 5.0 23.5 115.0
0732 040 486 Control unit on for PTO 9.5 1.8 8.5 37.0
NOTE
Carefully check and clean parts, do not use any
fibrous cloths for cleaning. Apply a thin coat of oil to
1
6
moving parts.
7
012703
1 = Tapered pin
2 = O-ring
3 = Woodruff key
4 = Input gear
5 = Circlip
6 = Input pinion
7 = Pump gear
A = End float
Technical data 3081 206 001
3081 206 013
Pressure = 20 bar
Temperature = 90 °C
NOTE
Carefully check and clean parts, do not use any
fibrous cloths for cleaning. Apply a thin coat of oil to
6
moving parts.
000143
1 = O-ring
2 = Cylindrical screw Technical data 7631 955 120
3 = Woodruff key
4 = Input gear Minimum displacement = 3.7 m3/min
5 = Circlip
6 = Inner rotor at pump speed = 530 rpm
7 = Outer rotor
8 = Eccentric ring Pressure = 5 bar
A = End float
Temperature = 70 °C
Pmax = 23 bar
NOTE
Outer discs are corrugated.
a) The discs must not be heavily scored or
discoloured.
The discs must not be dished.
b) The minimum profile depth of the groove on
the inner discs must be greater than or equal to
0.2 mm.
Pack thickness
000474
000474
NOTE
Use two U clamps to clamp disc pack together and
measure thickness above U clamps.
12 6 6 40.7 44.3
14 7 7 47.5 51.7
16 8 8 54.4 59.1
If the pack thickness is as specified, the permissible
disc play is as follows
12 1.36 5.10
14 1.57 5.80
16 1.78 6.30
Pressure limiting valve (refer to Page H 17.01.00 - 01, Figure 012 765)
Stage 1 Compression spring 0732 041 067 (function: oil injection line)
0.8 + 0.2 bar = spring force 49.3 + 12.3 N
Stage 2 Compression spring 0732 040 598 (function: lubricating pressure return suction line)
2.3 + 1 bar = spring force 142 + 61 N
Pressure limiting valve (refer to Page H 17.02.00 - 01, Figure 012769 for max. system pressure)
NOTE:
- Safety checks:
(2) Trained staff must conduct visual and function inspections before commissioning and at regular
intervals thereafter. These should take place at lease once a year.
(3) Lifting chains should be subjected to an additional crack inspection every three years.
- Faults:
(1) If faults are established, the lifting tackle equipment should not be withdrawn from use.
- Storage:
(1) Lifting tackle should be stored somewhere where it is protected from climatic influences and
aggressive materials.
Tool set (W2) special tools for major overhaul ..................................................................................... E 01.02.00
Tool set W1 for the gearbox maintenance work listed in Section B 05.00.00.
Support rod
42 for sliding on the output gear (for
output shaft 3081 304 074) BU (P)
190 S
195 S
Repair kit
44 for hydraulic nut 1X56 137 227
Extractor plate
45 for moving output shaft and pressing 196
onto housing
Bush
47 for sliding on output gear 196
Extractor plate
48 for pulling pump gear off output 196
shaft
Plate
49 for removing output-end cover off 196
output shaft
NOTE
Section A 17.00.00 General disassembly, testing,
reworking and assembly must be observed.
1
2
3
4
5
6
4 7 18
5 42 8 17
9 16 19
15
41 14
10 13
11
7 12
6
20
38 40 22 21
37 39
36 23
35 24
34 25
26
33 27
32 28
31 29
30
012705
Disassembly Installation
04 Remove detent parts (6, 7, 8 and 9). 07 Attach complete control unit with new gasket.
05 Remove lever (29) and cover (26) with gasket 08 Screw in hex bolts (41, 42, 11) and nut (10) and
(25). tighten.
06 Pull valve rotor (23) out of control housing. 09 Fit pipes in accordance with H 11.00.00.
Check
NOTE
Remove any dirt from the parts and lightly oil moving
parts.
Assembly
2
3
A
7 6 5
013816
Removal
! DANGER
Pull of input flange as described in Oil press-fit
method Section D 05.00.00.
1
2
3
4
8 6
13 12 11 10
7
012707
Installation
! DANGER
Pull on input flange as described in Oil press-fit
method Section D 05.00.00.
Observe push-on values in oil press-fit table D
05.00.00.
1 2 3 4 5
6
7
8
9
013817
Removal
! DANGER
Pull off torsion coupling as described in Oil press-
fit method Section D 05.00.00.
1 2 3 4 5
6
7
8
11
10
12
14 13
012709
Installation
! DANGER
Pull on torsion coupling as described in Oil press-
fit method Section D 05.00.00. Observe push-on
values in oil press-fit table D 05.00.00.
Installation
NOTE
a) Thinly coat outside section of shaft seal with
steel surround with sealing compound*.
b) Spray outside section of shaft seal with rubber
surround with an anti-friction agent such as a
water-soluble, liquid washing-up detergent (e.g. * Sealing compound, Hylomar SQ 32 M,
Pril). produced by Marston A 11.00.00
NOTE
The standard input direction of rotation is clockwise,
when facing the gearbox input flange. In special
version gearboxes, the opposite direction of rotation
applies (i.e. anti-clockwise when facing the gearbox
input flange). An arrow is fitted to the gearbox input
side indicating the relevant direction.
012712
A A
012713
A = depending on version
2
1
6
7
012714
012715
8 9 10
Removal
Disassembly Installation
NOTE
Carefully check and clean parts. Do not fibrous cloths
for cleaning. Apply a thin coat of oil to moving parts.
Assembly
A
B
012717
012718
NOTE
In versions without oil pump, use sealing compound
when screwing hex bolt + washer (without
intermediate gear) into position A or B.
5 6 7
10 9 8
012719
Removal Disassembly
Installation
012720
06 Slide O-ring (1) onto pump housing and attach
1
oil pump to cover.
1 = O-ring
2 = Cylindrical bolt
3 = Woodruff key
4 = Input gear
5 = Circlip
A = For end float, refer to D 09.00.00
012721
012722
NOTE
In version without oil pump, use sealing compound
when screwing hex bolt + washer (without
intermediate gear) into pos. (3).
5 6 7
4
012723
10 9 8
Removal Disassembly
Installation
1 = O-ring
2 = Cylindrical bolt
3 = Woodruff key
4 = Input gear
5 = Circlip
A = For end float, refer to D 09.00.00
Removing and installing cover for input and reversing shaft ............................................................... F 07 .02.00
Removing and fitting constant gear of input or reversing shaft ............................................................ F 07.03.00
Removing and installing multi-disc pack of input or reversing shaft ................................................... F 07.04.00
3
2
1
012725
01 If necessary, pipes are removed in accordance 01 Heat input gear (6) to approx. 85 °C and slide
with H 11.00.00. correct side onto reversing shaft.
02 Oil pump is removed in accordance with F 02 Screw grooved nut (2) onto reversing shaft and
05.00.00. use wrench 1X56 137 222 to tighten and
carefully lock.
3
2
012726
02 Unscrew fastening bolts from cover (1) 03 Apply thin coat of sealing compound* to
and press off cover. sealing faces of cover.
03 Drive outer races of cylinder roller bearing (2) 04 Carefully place cover (1) on housing and screw
out of cover. down.
04 Use two-arm-ed extractor to pull inner race of 05 Attach cover in accordance with F 07.01.00.
cylinder roller bearing (3) off the shaft to be
disassembled.
1 2 3 4 5 6 7 8 9 10
012727
01 Cover for input and reversing shaft is removed 02 Fixture arrangement as shown in above diagram.
in accordance with F 07.02.00.
! DANGER
Removal Pull off constant gear (7) as described in Oil press-
fits method Section D 05.00.00.
NOTE
The constant gears of the input and reversing shaft
must not be confused. A distinction can be made 03 Take piston (8) out of constant gear and remove
between the gears by looking at the helical angle of the rectangular section ring.
gear teeth. Always note the part number.
04 If necessary, remove emergency control
Gear with part no. 3081 302
equipment (6).
Spare part no. 3081 202
for input shaft
Gear with part no. 3081 303
05 Remove multi-disc pack in accordance with
Spare part no. 3081 203
for reversing shaft F 07.04.00.
8 9 10
1 2 3 4 5 6 7
14 13 12 11
012728
Installation NOTE
Take care when sliding constant gear onto rectangular
01 Multi-discs are inserted in accordance with section ring (9) of piston.
F 07.04.00. It must not be damaged.
02 Check emergency control equipment, if removed 05 Fixture arrangement as shown in above diagram.
from constant gear, and install.
NOTE ! DANGER
Stretch rectangular section ring (9) well before Slide on constant gear as described in Oil press-fit
attaching constant gear. method Section D 05.00.00. Observe push-on
values in oil press-fit table D 05.00.00.
03 Insert rectangular section ring in piston (8) and
insert piston in constant gear.
06 Attach cover for input and reversing shaft in
04 Slide in correct side of constant gear (7) (with accordance with F 07.02.00.
correct spare parts number) as described in Oil
press-fit method Section D 05.00.00 and
measure push-on length.
1 2 3 4
5 6 7 8 9
13 12 11 10
012730
Removal
! DANGER
Only remove disc carrier in cases of extreme
emergency.
If the multi-discs cannot be removed, the complete
clutch pack can be pulled out with the inner disc
carrier (refer to Figure no. 012 730).
Fixture arrangement as shown in the diagram.
14 15 16
012731
Example:
NOTE
Section A 17.00.00 General disassembly, testing,
reworking and assembly must be observed.
Diagram of
installation and removal sequence of main groups .............................................................................. H 01.01.00
07 09
11 13
17
15
012733
19 21
27 29
31 33
012734
39
37
013910 013911
41
013909
012736
1
2
3 4
5
6
7 18
4 17
5 1 8
9 16 19
15
1 14
10 13
11
7 12
6
20
38 40 22 21
37 39 23
36 24
35
34 25
26
27
33
32 28
31 29
30
012737
Disassembly Installation
04 Remove detent parts (6, 7, 8 and 9). 07 Fit complete control unit with new gasket.
05 Remove lever (29) and cover (26) with gasket 08 Screw in hex bolts (41, 42, 11) and nut (10) and
(25). tighten.
06 Pull valve rotor (23) out of control housing. 09 Fit pipes in accordance with H 11.00.00.
Checking
NOTE
Keep parts clean. Apply thin coat of oil to moving
parts.
Assembly
Control unit +
Actuation electrical
012738
16 17 18 19
11 12 13 15 20
14
10
7
1 2 3 4 5 6
8
9
012739
Disassembly Assembly
01 Remove cover (9), unfasten cable lugs (10) and 01 Attach cover (3) and gasket (4).
lift off cable.
02 Slide washer (13), compression spring (14)
02 Take off solenoid valve (7). andwasher (13) onto control piston and snap
circlip into control piston.
03 Unscrew cylindrical bolts (20) and lift off cover
(17) with gasket (16). 03 Insert correct side of control piston into control
housing.
04 Take control piston (12) and parts (13, 14 and
15) out of control housing. 04 Attach cover (17) and gasket (16) to control
housing.
05 Remove circlip (15) from control piston, lift off
washers (13) and compression spring (14). 05 Attach solenoid valve (7).
06 Lift off cover (3) and remove gasket (4). 06 Screw cable lugs onto solenoid valve and attach
cover (9).
Checking
Cleaning
012740
13
12
11
10
9
6 7
8
4
3
2 012741
1
Disassembly Cleaning
01 Remove screw plug (1) and seal ring (2). Clean parts and apply a thin coat of oil to moving
parts.
02 Remove snap ring (3) from valve housing.
Assembly
03 Take control piston (4), compression springs (5)
and (6) out of valve housing. 01 If removed, screw in plugs (10). In so doing,
observe the installation dimensions (refer to
removal).
Checking
02 Insert compression springs (6) and (5) and
Check compression springs (5) and (6) in accordance control piston (4) in valve housing.
with D 07.00.00
Check control piston (4) and control piston bore in 03 Insert snap ring (3) in valve housing.
valve housing (7) for damage and protect against
possible damage. 04 Screw in screw plug (1) and seal ring.
012742
24
25
26
22
21 23
19 20 27
18
17
16
15 13
14 12
11
10 28
9 8
7 29
16
3 5
2 4
1 012743
05 Drive cylindrical pin (13) out of cover (17). 08 Insert shim ring (14) and compression spring
(15) in collar screw (1).
06 Drive slotted pin (11) out of cam (4) and shaft
(7). 09 Place ball (16) (diameter 8) and grease on
spring in collar screw and vertically screw
07 Take shaft (7) and cam (4) out of cover (17). collar screw into valve cover (17). (Screw in
from below).
Checking
10 Fit valve cover (17) and gasket (18) onto valve
Compression springs (15) and (21) in accordance housing (25).
with D 07.00.00
11 Attach complete valve housing (25) and gasket
Check piston (19), control piston (23) and control (24) to control unit.
piston bore in valve housing (25) for damage and
protect against possible damage.
Cleaning
Assembly
Control unit +
Actuation pneumatic
012744
9 8
10
1 2 3 4 5 6
012745
Removal Installation
01 Remove lines from 3 position cylinder. 01 Use hex bolts (7) to attach 3 position cylinder to
console (9). When installing, slide the joint
02 Unscrew locking nut (4) and remove washer head onto the articulated pin.
(3).
NOTE
03 Unscrew hex bolts (7), lift off 3 position If the 3 position cylinder and the control unit are fitted
cylinder. and in the neutral setting (central setting), the joint
head (2) must be slid onto the centre of the articulated
NOTE shaft (1).
The 3 position cylinder is a complete part and is not
disassembled. 02 Slide on washer (3) and screw on locking nut
(4).
4 5 6 7
1 2 3
012746
01 Unscrew sludge drain screw (7) and drain filter 06 Clean filter element with diesel oil or suitable
compartment. petroleum agent.
02 Unscrew screw (4) for oil pocket drainage by 07 Only use brush for cleaning, never fluffing
approx. 20 - 25. This allows oil to flow into the cloths or mechanical devices such as
filter compartment in the gearbox housing. screwdrivers, scrapers etc.
Then unscrew screw all the way
Installation
Disassembly
01 Screw in sludge drain screw (7) and screw (4)
03 Remove hex bolts (1) from filter. with new gasket and tighten.
04 Take out filter element (2). 02 Insert filter (2) with new gasket (3) and screw
down.
05 Protect filter chamber to prevent dirt entering.
012747
A = depending on version
013 814
7
8
9
3 8
4
2 10
5
6 11
22 12
1 23
14 16
11
13 15
24
26
25 16
35 18 17
34 27
30a
33 30
31 28 19
32 29 20
19
21
A
30a
30
30b
A
A
012748
30c 30b
Removal Installation
01 Remove pipes if necessary. 01 Fit pipes and replace CU seal rings, O-rings and
gaskets.
NOTE
For BW 196 version, note Figure on
Page H 11.00.00 - 03.
012749
1 2
4 3
012750
Removal
Cleaning instructions for plate-type oil cooler flushed through with gear oil, we would recommend
the addition of approx. 5 % oil to the trichloroethy-
lene. This ensures that the oil film remaining after
cleaning and subsequent drying out with warm air,
acts as a preservative, in particular on the turbulence
plates at the oil end.
NOTE
The standard input direction of rotation is clockwise,
viewed when facing the gearbox input flange.
012756
012752
A = depending on version
013 815
2
1
6
7
012753 012754 8 9 10
Removal 2 3 4 5
Disassembly Installation
04 Snap out circlip (5). 08 For gearbox input direction of rotation II, install
intermediate gear drive, items 3 to 10,
05 Pull off input gear (4). Figure 012754.
06 Remove Woodruff key (3). 09 Apply thin coat of sealing compound* to seal-
ing races on pump cover and attach oil pump
NOTE and tighten.
The oil pump is a complete part and is not usually dis-
assembled. It may however be necessary to disassem- 10 Fit pipes in accordance with H 11.00.00.
ble the pump for checking or cleaning purposes.
NOTE
Carefully check and clean parts. Do not use any
fibrous cloths for cleaning. Apply a thin coat of oil to
moving parts.
Assembly
A B
012757
012758
NOTE
In the version without an oil pump, use sealing com-
pound to screw hex bolt + washer (without intermedi-
ate gear) into pos. A or B.
5 6 7
10 9 8
012759
Removal Disassembly
012760
1 = O-ring
2 = Cylindrical bolt
3 = Woodruff key
4 = Input gear
5 = Circlip
A = For end float, refer to D 09.00.00
Installation
012761
012762
NOTE
In the version without an oil pump, use sealing com-
pound to screw hex bolt + washer (without intermedi-
ate gear) into pos.A or B.
5 6 7
4
10 9 8
012763
Removal Disassembly
Installation
1 = O-ring
2 = Cylindrical bolt
3 = Woodruff ley
4 = Input gear
5 = Circlip
a = For end float, refer to D 09.00.00
012765
012766
1
2
3
4
5
6
7
012767
012768
02 Remove parts (2 to 7). Adjustment values for pressure limiting valve (dual
function) are in accordance with adjustment value
table D 13.00.00.
Checking
Check piston and piston guide for fretting traces 02 Screw in screw plug (1) and new CU seal ring
(grooves). (2) and tighten.
012769
3
2
1
012770
01 If necessary, remove pipes in accordance with 01 Insert compression spring (3) and spring (2).
H 11.00.00.
02 Screw in valve seat to ensure adequate spring
NOTE preload (refer to adjustment values).
Before removing the pressure limiting valve, measure
the installation dimension between valve seat (1) and
housing plane face. Note down this dimension.
Removal
Checking
012771
012772
Removal
Installation
012773.eps
Installation Removal
01 If fitted, remove gearbox mounting as described 01 Remove adapter from gearbox housing.
in Section H 19.01.00.
02 If available, fit gearbox mounting as described
02 Fit adapter to gearbox housing (note type in Section H 19.01.00.
designation on adapter).
2
3
A
7 6 5
013816
Removal
! DANGER
Pull off input flange as described in Oil press-fit
method Section D 05.00.00.
1
2
3
4
8 6
13 12 11 10
7
012776
Installation
! DANGER
Pull off input flange as described in Oil press-fit
method Section D 05.00.00.
Observe push-on values in oil press-fit table
D 05.00.00.
1 2 3 4 5
6
7
8
9
013817
Removal
! DANGER
Pull off torsion coupling as described in Oil press-
fit method Section D 05.00.00.
1 2 3 4 5
6
7
8
11
10
12
14 13
012709
Installation
! DANGER
Slide on torsion coupling as described in Oil
press-fit method Section D 05.00.00 .
Observe push-on values in oil press-fit table
D 05.00.00.
012778
1 2 3 4 5
6
7 012779
Removal
Installation
Shaft seals
013818
7 8
6
5 9 10
3
2
11
1
12 *
13
14
012783
1 2 3
1 = Cover
012785 2 = Outer race of cylinder roller
bearing
NOTE
Swivel gearbox so that the pump side is facing
upwards.
1 2 3
1 = Cover
2 = Outer face of cylinder roller
012785
bearing
Installation
3 4 5 6
8 7
013819
08 Depending on version, screw grooved nut (7) e) 60 % of the intermediate gap between the two
onto input shaft and use wrench 1X56 137 223 dust protection lips should be filled with grease
to tighten and carefully secure in place. (e.g. Aral Aralub HL2 or Texaco Texando FO
20).
09 Install flange-mounted bell housing (if
available) in accordance with H 27.00.00.
* Sealing compound, Hylomar SQ 32 M,
produced by Marston A 11.00.00
NOTE NOTE
When installing the input shaft, it is essential that the The standard gearbox input direction of rotation is
gearbox input direction of rotation is observed. clockwise, viewed when facing the gearbox input
Depending on the input direction of rotation, the ring flange.
and/or support shim (located to the left or right of the In special version gearboxes, the opposite direction of
pinion) must be installed. The diagrams in this manual rotation applies, i.e anti-clockwise, viewed when fac-
show direction of rotation I. ing the gearbox input flange.
There are no diagrams of the installation of the ring An arrow is attached to the input side of the gearbox
and/or support shim for direction of rotation II. There indicating the relevant direction of rotation.
are only text descriptions.
012786
013820
Contents
013821
013822
Contents
013823
Contents
013824
013825
Parts lists: 3081 102 043, 047, 051, 055, 074, 087, 093
013826
Direction of rotation I with trolling or prepared for trolling equipment and PTO connection
013827
013828
013829
013824
*
Y X
14
2
15
3
7
19 20
16
13 12 11 10 9 8
17
18
012789
1 = Lifting device 1X56 137 225 13 = Reciprocating piston pump 1X56 130 589
2 = Self-aligning roller bearing 14 = Extension 1X56 137 474
3 = Seal ring bush 15 = Pressure piece 1X56 137 473
4 = Union nut 1X56 137 232 16 = Segment (2 pieces)
5 = Stud 1X56 137 232 17 = Washer
6 = Hydraulic nut 1X56 137 227 18 = Circlip
7 = Extractor plate 1X56 137 229 19 = High pressure pipe 1X56 130 601
8 = Bolt 1X56 136 461 20 = Oil injector 1X56 130 595
9 = Nut 1X56 137 226 X = Half-shaft, direction of rotation II
10 = High pressure hose 1X56 130 588 * = P version
11 = Pressure gauge 1X56 130 592 Y = Half-shaft, direction of rotation I
12 = Intermediate piece 1X56 130 591
NOTE
When using version P, once circlip (18) and washer
(17) have been removed, take both parts of segment
(16) out of bush.
1 2 3 4
012792
1 2 3 4 5 6 7 8 9 10
012793
NOTE
The constant gears on the input and reversing shafts
must not be confused. A distinction can be made
between them by looking at the helical angle of the
gear teeth. The part number should always be
observed.
1 2 3 4 5 6 7 8
9
012810
10
11
12
13
14
5 6 7 8 9
014825
13 12 11 10
1 2 3 4 5 6 7 8 9
10
012798
012798
14 13 12 11
NOTE
In order to remove bush (5) and, depending on ver-
sion, ring (2), pinion with disc carrier or thrust washer,
groups H 31.01.00 - 03 to H 31.01.00 - 06 should not
be removed.
Removal
1 2 3 4 5 6 7
012799
NOTE
The figure shows input shaft version for gearbox input
direction of rotation I.
When using gearbox input direction of rotation II, ring
(5) is fitted in place of item 2 and 3 and support shim
(2) and thrust washer (3) are fitted in place of item 5.
5
X
1 2 3 4 3 Y
013832
NOTE
The bearing bushes remain on the input shaft and are
not removed. They should however be protected from
possible damage.
If the bearing bushes are renewed, the bearing bushes
(3) should destroyed and removed (by breaking open
with a chisel).
1 2 3 4 5 6 7 8 9
10
11
12 13 14
012791
5
X
1 2 3 4 3 Y
013832
1 2
013833
NOTE
If the input shaft or inner disc carrier are needed
again, provided you have a suitable version, the inner
disc carrier can be fitted back on the input shaft.
1 2 3 4 5 5
013834
1 = Input shaft
2 = Support shim
3 = Thrust shim
4 = Pinion with outer disc carrier
5 = Support shim or bush
06 Slide on thrust disc (3) depending on version. 09 Check end float of piston from outer disc carrier
(4). The end float must be between 0.6 and
07 Slide pinion and outer disc carrier (4) onto input 1.0 mm.
shaft.
10 Depending on the parts list, heat bush (5) to
NOTE approx. 100 °C and slide onto input shaft (1)
Depending on version, fit bush or ring (5) or support until firmly home.
shim (2) and thrust washer (3).
1 2 3 4 5 6 7 8
012795
9
10
11
12
13
14
1 2 3 4 5 6 7 8 9 10
012794
14 13 12 11
NOTE
Take care when pulling constant gear onto rectangular
section ring of piston. They must not be damaged.
013835
1 2
013836
4 8
7
5
6
012790
22 Fit extractor plate (4) 1X56 137 229 as an 25 Heat seal ring bush to approx. 85 °C and slide
assembly aid and clamp with collar nuts (5). correct side onto input shaft.
23 Heat inner race of self-aligning roller bearing 26 Depending on version, fit grooved nut or two
(3) to approx. 85 °C and insert input shaft in segments (8), washer (7) and circlip.
self-aligning roller bearing.
27 Fit cover in accordance with H 29.02.00.
24 Remove extractor plate (4) (assembly aid).
NOTE NOTE
When installing the reversing shaft, it is essential that The standard gearbox input direction of rotation is
the gearbox input direction of rotation is observed. clockwise, viewed when facing the gearbox input
Depending on the input direction of rotation, the ring flange.
and/or support shim (located to the left or right of the In special version gearboxes, the opposite direction of
pinion) must be installed. The diagrams in this manual rotation applies, i.e. anti-clockwise, viewed when
show direction of rotation I. facing the gearbox input flange.
There are no diagrams of the installation of the ring An arrow is attached to the input side of the gearbox
and/or support shim for direction of rotation II. There indicating the relevant direction of rotation.
are only text descriptions.
Contents
013837
013838
Parts lists: 3081 103 031, 048, 050, 056, 075, 076
013839
013840
Contents
013841
013842
Parts lists: 3081 103 035, 036, 037, 038, 041, 045
013843
013844
013845
Y X
13
17
7
16
14
6 5 4 3 15 012804
12 11 10 9 8
1 = Lifting device 1X56 137 225 11 = Hydraulic nut 1X56 137 227
2 = Reversing shaft 12 = Self-aligning roller bearing
3 = Reciprocating piston pump 1X56 130 589 13 = Pressure piece 1X56 137 473
4 = Intermediate piece 1X56 130 591 14 = Washer
5 = Pressure gauge 1X56 130 592 15 = Circlip
6 = High pressure hose 1X56 130 588 16 = High pressure pipe 1X56 130 601
7 = Union nut 1X56 137 232 17 = Oil injector 1X56 130 595
8 = Extractor plate 1X56 137 229 X = Half-shaft, direction of rotation II
9 = Bolt 1X56 136 461 * = P version
10 = Nut 1X56 137 226 Y = Half-shaft, direction of rotation I
1 2 3 4
012807
1 2 3 4 5 6 7 8 9 10
012808
Gear with part no. 3081 303
07 If necessary, remove emergency control
Spare part no. 3081 203
for reversing shaft equipment (7).
1 2 3 4 5 6 7 8
9
012810
10
11
12
13
14
5 6 7 8 9
13 12 11 10
014825
5 = Slide-on disc 1X56 137 231 10 = High pressure hose 1X56 130 588
6 = Stud 1X56 137 232 11 = Pressure gauge 1X56 130 592
7 = Hydraulic nut 1X56 137 227 12 = Intermediate piece 1X56 130 591
8 = Extractor plate 1X56 137 229 13 = Reciprocating piston pump 1X56 130 589
9 = Driven extractor plate 1X56 137 220
1 2 3 4 5 6 7
8
012813
10
11
A
NOTE NOTE
In order to remove support shim (5), thrust washer (4) In the P version, bush (10) generally remains in the
or pinion and outer disc carrier (3), groups H 33.01.00 self-aligning roller bearing (refer to H 33.01.00 - 01),
- 02 to H 33.01.00 - 06 should not be removed. and the bush must be removed, the oil injector (7) and
pressure piece (9) must be fitted and the pinion pulled
NOTE off with the two-armed extractor.
The figure shows the reversing shaft version fitted in
gearbox input direction of rotation I. For gearbox 16 Arrangement of fixture as shown in diagram.
input direction of rotation II, support shim (5) and
thrust washer (4) should be fitted in place of ring (2). 17 Depending on the version, pull off pinion with
outer disc carrier (3) and support shim (5) with
thrust washer (4) and remove. Depending on
version, take cylinder roller (11) out of
reversing shaft.
1 3 4 5 4
Y
2 012814
6
NOTE
The bearing bushes remain on the reversing shaft and
are not removed. They should however be protected
from possible damage. If the bearing bushes are
renewed, the bearing bushes should be destroyed and
removed (by breaking open with a chisel).
1 2 3 4 5 6 7 8 9
10
13 14
11 12
012806
1 3 4 5 4
Y
2 012814
6
NOTE CAUTION
Observe figures H 33.00.00 - 02 to H 33.00.00 - 10 Slide bush (5) onto input shaft ensuring that
for the relevant version. grooved nut in the inner diameter of the bush is on
the same side as the slid-on bearing bush.
01 When working with gearbox with input The grooved nut of bush (5) must be aligned the
direction of rotation I, heat ring (2) to approx. right way round relative to the lube bore in the
85 °C and slide onto reversing shaft. input shaft (for version (P), the grooved nut should
When working with gearbox with input be in the centre of the bush).
direction of rotation II, heat support shim to
approx. 85 °C (with version (P), fit cylinder 04 Slide bearing bush (4) onto reversing shaft until
roller (6) before sliding onto ring (2)) and slide firmly home on the bush (5).
onto reversing shaft.
1 2
013846
NOTE
If the reversing shaft or inner disc carrier are needed
again, provided you have a suitable version, the inner
disc carrier can be fitted back on the input shaft.
Heat inner disc carrier (2) to max. 170 °C and slide
correct side onto reversing shaft (1) until firmly home.
1 2 3 4
5 013847
NOTE
Depending on version, fit bush (4) or support shim (3)
and thrust washer (2). (Figure shows direction of
rotation I.)
1 2 3 4 5 6 7 8
9
012810
10
11
12
13
14
Installing multi-disc pack 08 Slide thrust washer (7) onto multi-disc carrier.
Example:
1 2 3 4 5 6 7 8 9 10
012809
14 13 12 11
NOTE
Take care when pulling constant gear onto rectangular
section ring. They must not be damaged.
1 2
013848
1 = Reversing shaft
2 = Inner race of roller bearing
1 2
10
13
11 12
013849
1 = Self-aligning roller bearing
2 = Housing
3
Y X
4
7 6 5 012805
19 Fit extractor plate (4) 1X56 137 229 to input 21 Fit extractor plate (4) (assembly aid) again.
side as an assembly aid.
22 Depending on version, fit grooved nut or
20 Heat inner race of self-aligning roller bearing washer (6) and circlip (7).
(3) to approx. 85 °C and insert reversing shaft
in self-aligning roller bearing.
012815
1 2 3 4 5 6 7 8 9
A
13 10
11
12
012816
11 12 13 14 15
10
9
8
6 16
5
4
3
17
1 012817
NOTE
Fit chocks under or screw 3 studs (17),
and collar nuts into fastening points on cover to
ensure that the output shaft cannot fall out.
1 2 3 4 5 6 7 8 9 10 11 12
13
14
012818
21 20 19 18 17 16 15
15 Unlock M90x1.5 grooved nut (7) and use 17 Arrangement of fixture as shown in diagram.
wrench 1X56 137 224 to unscrew.
18 Pull off inner race of axial roller bearing (5), as
16 Lift ring (6) off output shaft. shown in the diagram (heat inner race of
bearing if necessary).
1 2 3 4 5 6 7 8 9
10
11
012820
14 13 12
1 = Slide-on washer 1X56 137 231 8 = Hydraulic nut 1X56 137 227
2 = Input gear 9 = Extractor plate 1X56 137 229
3 = Stud 1X56 137 232 10 = Bolt 1X56 136 461
4 = Output shaft 11 = High pressure hose 1X56 130 588
5 = Union nut 1X56 137 232 12 = Pressure gauge 1X56 130 592
6 = Stud 1X56 137 232 13 = Intermediate piece 1X56 130 591
7 = Nut 1X56 137 226 14 = Reciprocating piston pump 1X56 130 589
1 2 3 4 5 6 7 8 9 10 11 12
13
14
18
012819
17 16 15
NOTE
When pulling cover off, the input gear pushes the
shaft seals out of the cover.
1 2
012821
Assembling and installing output shaft d) The duo shaft seal has two
sealing lips. The dust
NOTE protection sealing lip (X)
Shaft seals should generally be changed during a must face outwards. X
major overhaul.
000102
When using the version with two shaft seals, a duo e) 60 % of the gap between the sealing lips should
shaft seal is usually fitted. be filled with grease (e.g. Aral Aralub HL2, or
Texaco Texando FO 20).
Shaft seals
01 Use special tool 1X56 137 260 to insert correct
a) Apply thin coat of sealing compound* to side of duo shaft seal into cover (if necessary,
outside of shaft seal with steel surround. rework special tool 1X56 137 260).
6
5
4
3
1
012823
06 Heat bearing bore for outer race of tapered 10 Heat inner race of axial roller bearing (6) to
roller bearing in cover (2) to approx. 60 °C and approx. 85 °C and slide correct side onto output
insert correct side of outer race of tapered roller shaft.
bearing into cover.
11 Slide ring (7) onto inner race of axial roller
07 Insert the M12x70 hex bolts for the cover bearing until firmly home.
fastening into the relevant cover bores.
12 Screw on M90x1.5 grooved nut and use wrench
08 Heat inner race of tapered roller bearing to 1X56 137 224 to tighten to approx. 800 Nm.
approx. 85 °C and slide onto input gear until Carefully lock grooved nut.
firmly home.
1 2 3 4 5 6
12 11 10
012824
14 Insert washer (2) in housing bore for propeller 20 Attach dial gauge to output shaft and measure
thrust bearing. end float.
NOTE
The compression springs push the output shaft
towards the output flange (1st measurement, set dial
gauge to 0). If you wish to pressure the output shaft
towards the input side, the pressure (resistance) of the
compression springs has to be overcome, approx.
4 000 N (pressurize hydraulic nut, pressure gauge of
reciprocating piston pump should not indicate more
than 25 bar). Check dial gauge reading in this
position, variation of dial gauge = end float
1 2 3 4 5 6 7 8 9 10
11
14 15 16
12
13
012825
18 17
24 Swivel housing through 90° (output side faces 27 Place corrected washer (3) on axial roller
upwards). bearing.
25 Place correct side of output gear (9) in the 28 Apply thin coat of sealing compound* to cover.
housing (small diameter of cone faces input
side). 29 Insert O-ring in annular groove of cover.
XX
012826
NOTE NOTE
Sealing compound** applied to the XX area of the The push-on length of the helical gear must be
cover during assembly. observed (check with dial gauge while pulling on).
1 2 3
6 4
5
7
012827
34 Heat inner face of cylinder roller bearing (1) to 36 Insert oil tray (4) and screw down.
approx. 85 °C and slide correct side onto output
shaft and leave to cool. 37 Fit cover (7) and gasket (5).
35 Insert outer race of cylinder roller bearing (2) 38 Apply thin coat of sealing compound to sealing
(once housing bore has been heated to approx. faces on cover (3) and attach to housing (in so
60 °C) into housing bore. Observe distance B doing, outer race of cylinder roller bearing is
when inserting. Distance B should be approx. pushed into correct installation position).
0.5 mm smaller than distance A.
012828
1 2 3 4
8 5
6
7
012829
1 2 3 4 5 6 7 8
12
9
11
10
13
012830
1 2 3 4 5 6 7 8 9
13
10
12
11 012831
1 2 3 4 5 6 7 8
12
9 012832
11
10
8 9 10 11 12 13
1 2 3 4 5 6 7
012833
012834
22 Swivel gearbox through 90° (output side faces 27 Remove seal ring cover (7) from housing.
upwards).
28 Drive outer race of cylinder roller bearing (6)
23 Lift output shaft out of housing as shown in out of housing.
diagram.
29 Drive seal rings out of seal ring cover.
24 Take angle ring (4) off output gear.
30 If necessary, driver inner race of cylinder roller
25 Take output gear (3) out of housing. bearing off output shaft once inner race has
been heated.
26 Remove fixture (1) and (2).
1
2
3
6
5 4
012835
1
012837
06 If removed, heat inner race of cylinder roller 09 If necessary, perform correction for push-on
bearing (2) to approx. 100 °C and slide onto length on face side of angle ring.
output shaft until firmly home.
10 Take output gear and angle ring off output shaft.
07 Slide correct side of angle ring (3) onto output
shaft until firmly home against inner race of
cylinder roller bearing.
6
5
4
1 012834
11 Swivel housing through 90° (output side faces 13 Place correct side of angle ring (4) on output
upwards). gear.
12 Place correct side of output gear (3) in housing 14 Insert output shaft in housing, angle ring and
(small diameter of cone faces propeller thrust output gear as shown in diagram.
bearing).
7 8 9 10 11 12
13
1 2 3 4 5 6
17 16 15 14
18
012839
4
3
2
012840
1 2 3 4 5 6
012841
20 Heat bearing bore for outer race of tapered 23 Apply thin coat of sealing compound* to
roller bearing in cover (1) to approx. 60 °C and sealing faces of cover (1) and fit to housing.
insert outer race of tapered roller bearing (2) When attaching, apply sealing compound** to
until firmly home. position XX and tighten cover.
XX
012842
1 2 3 4 5 6 7 8 9 10 11 12 13
14
012843
24 Arrangement of fixture as shown in diagram. 28 Heat input gear (3) to approx. 85 °C and slide
correct side onto inner race of tapered roller
25 Clamp output shaft ensuring that outer race of bearing (5) until firmly home.
axial roller bearing (8) is on cover (7).
29 Slide on washer (2).
26 Heater inner race of tapered roller bearing (5) to
approx. 85 °C and slide onto outer race of 30 Snap circlip (1) into annular groove.
tapered roller bearing (6) until firmly home.
1 2 3 4 5 6 7
11 10 9
A 8
012844
NOTE NOTE
The end float of the propeller thrust bearing must be Pressurize hydraulic nut, pressure gauge of
between 0.05 and 0.1 mm with a preload of 2 000 N. reciprocating piston pump (2) must not indicate more
This preload is ensured by compression springs. than 25 bar (9 kN = 0.9 t). During the press process,
the output shaft must be rotated forwards and
31 Arrangement of fixture as shown in diagram. backwards continuously.
1 2 3 4
A
012845
1 2 3 4 5 6 7 8
012846
10
11 9
12
37 Relocate end float from circlip to bearing. 40 Circlip (6) must be slightly tensioned.
39 Apply pressure of max. 150 bar to hydraulic nut 42 Screw in remaining 3 fastening bolts of cover
(4) (note pressure gauge on reciprocating piston and tighten.
pump).
43 Rotate output shaft to left and right several 47 Read end float off dial gauge. End float must be
time. between 0.05 and 0.1 mm.
44 Attach dial gauge and holder (1) to cover and 48 If the end float is not between 0.05 and 0.1 mm,
set to 0. the washer behind the circlip should be
corrected by the variance required, refer to
45 Arrangement of fixture as shown in diagram. Figure 012845.
1 = Cover 4 = Gasket
2 = O-ring 5 = Cover
3 = Oil tray 6 = Hex bolt
1 5
013581
013582
1 5
013581
11 Push output shaft (1) as far as possible towards the 15 Take output gear out of housing.
pump. Output gear touches housing panel for
propeller bearing. 16 Take compression springs (4) and ring (5) out of
housing bore of propeller bearing.
12 Use load sling to secure output gear (2) centrally
in its installation position.
NOTE
When pulling these off, the input gear will press
the shaft seals out of the cover.
06 Insert correct side of outer race of tapered roller 09 Heat correct side of inner race of axial roller
bearing (6) into bearing bore on cover (7). bearing (3) to approx. 85 °C and slide onto output
shaft.
NOTE
Use fixing pieces 1X56 137 411 to adjust cover 10 Slide ring (2) onto inner race of axial roller
(7) ensuring that the cover is adjusted so far bearing (3) until firmly home.
downwards that when inner race of tapered roller
bearing (5) is slid on, it comes into contact with 11 Screw on M 10x1.5 grooved nut (1) and use
input gear (8). wrench 1X56 137 292 to tighten to approx.
800 Nm.
07 Heat inner race of tapered roller bearing (5) to Carefully secure grooved nut.
approx. 85 °C and slide onto correct slide of input
gear (8) until firmly home.
27 Insert corrected washer (2) (for end float setting) 32 Arrangement of fixture as shown in diagram.
and compression springs (4) in bearing bore.
NOTE
28 Insert correct side of outer race of axial roller The push-on length of the output gear must be
bearing (1) in bearing bore. observed. Use dial gauge to monitor the push-on
length while pushing on parts. Set dial gauge to 0
29 Apply thin coat of sealing compound** to sealing with 10 mm pretension.
faces of cover (5).
! DANGER
30 Insert output shaft in housing and in output gear Pull on output gear as described in Oil press-fit
(8). method Section D 05.00.00.
Observe push-on values in oil press-fits table
31 Screw in fastening bolts (9) of cover (5) but do D 05.00.00.
not tighten. Only screw in bolts until the output
gear (8) touches the housing. 33 Slide on output gear (8) and screw down cover
(5).
34 Heat correct side of inner race of cylinder roller 38 Apply thin coat of sealing compound* to sealing
bearing (1) to approx. 85 °C and slide onto output faces of cover (4) and fit to housing.
shaft (3) and leave to cool. When fitting the cover, the outer race of the
cylinder roller bearing is shifted into the correct
35 Insert outer race of cylinder roller bearing (2) in installation position.
housing bore.
Observe dimension B during the insertion. 39 Fit blind cover or secondary pump (8) in
Distance B should be approx. 0.5 mm smaller accordance with the oil pumps Section
than distance A. H 15.00.00.
36 Install oil tray (5) in cover (7) and screw down. 40 Fit pipes in accordance with H 11.00.00.
Page index:
Filter Clutch oil pressure Lubricating Oil temperature for
contamination oil pressure P, L, M applic. C application P, L, M, C appl.
BW 196 (P)
BW 195 (P)
BW 190 (P)
Nom. display min PK = PKN 0.5 bar 4) 7.5 bar 0.4 bar 30 °C 30 °C
BW 195 S (P)
BW 190 S (P)
value
max PVF = PK + 4 bar PK = PKN + 1 bar 4) 10 bar 5 bar 90 °C 100 °C 75 °C 8) 11)
105 °C 8) 12)
Warning 24 bar s 2) 15) PK = 0.25 bar t 2) 95 °C s 2) 105 °C s 2)
26 bar s 2) 13) PKN 3 bar t 2) 5) 6)
Minimum monitoring 14) Pressure switch Pressure gauge 0 to 25 bar Thermometer 0 to 120 °C
Additional Pressure gauge Pressure switch 3) 6) or Pressure with Temperature switch 2) or
K 01.00.00 - 01
monitoring 14) 0 to 40 bar 3) Pressure gauge 16) 0 to 25 bar or pressure gauge Temperature sensor 16) 0 to 120 °C
0 to 6 bar
Refer to Section 12.2 for more information 7) The rated clutch pressure is specified in the 13) If PKN > 19 bar
1) Refer to monitoring plan in installation binding technical documents (order-specific)
14) Not within the standard ZF scope of supply
manual for schematic arrangement; refer to and also stamped on the type plate and in the
control housing. 15) If PKN 19 bar
installation drawing or operating instructions
or Description of basic gearbox Section for 8) For operation with stationary engine and 16) For remote display
arrangement on gearbox current-driven propeller (also refer to Usage
17) Not included in table above
2) For optical and acoustic warning and Maintenance Manual)
s Increasing
3) Use distributor piece 9) For normal operation without trolling
t Decreasing
4) 60 °C to 80 °C oil temperature 10) Not included in table above
PK = Clutch oil pressure
5) Warning with time delay of between 3 and 10 s 11) Without trailing pump
PKN = Rated clutch oil pressure
(provided by the shipyard) 12) With trailing pump
6) Warning must be set to no function when PVF = Pressure before filter
in shift positions Trolling on or Neutral
Issue date 99.07.01
Monitoring data