Publ. No. Aabenraavej 13-17, DK - 6340 Krusaa, Denmark Tel: +45 74 62 20 88 Fax +45 74 62 74 07 E-mail: bukh@bukh.dk – Internet: www.bukh.
Contents Section A … Introduction and technical data Section B … List of tools Section C … Cylinder head Section D … Flywheel Section E … Front end cover Section G … Rear end cover and hand start Section H … Fuel system Section IJ … Piston, connecting rod and cylinder liner Section L … Crankcase, crankshaft, main bearings and oil sump Section M … Camshaft Section N … Lubricating oil system Section O … Cooling water system Section P … Electrical system Section R … Gearbox ZF, BW7 Section S … Sail drive Secti
A1 SECTION A INTRODUCTION AND TECHNICAL DATA 009W2329
A2 CONTENTS Introduction ................................................................................ page A 3 Technical Data ........................................................................... page A 4 Torques ..................................................................................... page A 5 Spare Part Nos. for Service Parts .............................................. page A 6 Torque and Rating Curves.........................................................
A3 Introduction BUKH DV36 is a 3-cylinder, water cooled, 4-stroke diesel engine with direct injection, giving an easy start at low temperatures, a low consumption of fuel and a low thermic load of the cylinder head. The engines are specially designed to comply with the heavy demands made on stability, safety and environment now.
A4 TECHNICAL MAIN DATA WORKING PRINCIPLE……………………………………………………… ... 4-STROKE BORE/STROKE ...................... ................................ ................................... 85 mm / 85 mm CYLINDER VOLUME ............. ................................ ................................... 1.447 Litres COMPRESSION RATIO ......... ................................ ................................... 18,5:1 COMPRESSION PRESSURE …. ................. at 1800-3600 rpm………… .. 46 Bar OUTPUT, CONTINOUS RATING.…. ..
A5 BAYSAN M60 MARINEGEAR LUBRICATING OIL QUALITY ................................ ................................... Automatic Transmission Fluid (ATF) LUBRICATING OIL TEMPERATURE...................... ................................... MAX. 120oC LUBRICATING OIL CONTENT ............................... ................................... 0.5 Litres STERN TUBE (FLEXIBLE) LUBRICANT ................ ...................................
A6 Spare Part Numbers for Service Parts In this manual we have maintained on the drawings some numbers which are also spare part numbers. However, this manual is not to be regarded as a spare parts catalogue but only as helping guidance for correct identification of parts.
A7 009W2329
A8 Results of Measurement The below curves indicate results of measurements at 762 mm Hg and a room temperature of 26 °C.
A9 Longitudinal Section of DV36 009W2329
A10 Cross Section of DV36 009W2329
A11 Diagram of the Relation between the Total Weight, Speed and Horse Power of the boat The below diagram is normative and not binding in any way as many different circumstances influence the result, especially the type and shape of the boat, the propeller and its placing as well as the horse power of the engine. Seek the scheme to the right of the intersection between the actual length in the waterline of the ship and the total weight.
B1 SECTION B LIST OF TOOLS 009W2329-R01
B2 CONTENTS Tools for repairs on DV36.......................................................... page B 3 Dimensions of mounting punches .............................................
B3 Tools for repairs on DV36 The below mentioned tools are necessary to make the engine repairs described in this manual. Part of the tools are special tools which can be ordered from the spare parts department at BUKH. We have indicated the fields of application for the special tools in this manual. Designation of tools Fields of application Spare part No.
B4 Designation of tools Fields of application Spare part No. 36 mm socket spanner 19 mm socket spanner for fastening of cylinder head Section C 19 mm crowfoot wrench for tightening up of cyl.
B5 Designation of tools Fields of application Spare part No. Flanging tools for nozzle holder insert Section C 009P2565 Torque wrench (Stahlwille 73/6 1.5-6.
B6 009W2329-R01
C1 SECTION C CYLINDER HEAD 009W2329-R01
C2 CONTENTS Exploded view of cylinder head complete ................................. page C 3 Valve adjustment ...................................................................... page C 4 Removal and refitment of cylinder head ................................... page C 5 Replacement of rocker arm or rocker shaft .............................. page C 6 Adjustment of valve lifter arrangement ..................................... page C 6 Replacement of rocker arm bushing .................................
Exploded view of cylinder head 009W2329-R01 C3
C4 Valve adjustment The clearance of the inlet and exha ust valves should be adjusted at 0.3 mm w hen the engine is cold and the clearance of the valves should always be checked after tighteningup of the c ylinder head. The valv es are adj usted when the pisto ns are alternately at their highest point in the working stroke. Adjust the valves by loosening the counter nut A which makes it possible to adjust the clearance by means of the adjusting screw B. Measure the clearance with a feeler gauge at C.
C5 Removal and refitment of cylinder head 1. Drain off the cooling water. 2. Remove the top cover. 3. Remove valve rocker arms. 4. Remove the inlet and return pipes of the fuel valves. 5. Remove the charging alternator. 6. Remove the exhaust and inlet manifold. 7. Loosen the top bolts, after which the cylinder head can be lifted out of the engine block. 8. Refitment of the cylinder head is made in reverse order and the bolts are tightened evenly at a torque of 118±5 Nm (12±0.5 kpm).
C6 Replacement of rocker arm or rocker shaft For each cylinder, a rocker arm column wit h two rocker arms for inlet valve and exhaust valve, respectively, is fitted on a common shaft with corresponding rocker arm columns and rocker arms for the two other cylinders. 1. Remove the top cover. 2. Unscrew the three central nuts on the rocker arm columns. 3. Lift off the shaft arrangement. 4. Knock out the tube pin and washer in one of the shaft ends. 5.
C7 Replacement of rocker arm bushing 1. Remove the rocker arm as indicated on page C5 and check it as to wear and tear as well as fracture. 2. Press out the defective bushing with an adequate tool. 3. Fit the new bushing as shown below paying special attention to the position of the bearing joint and the oil grooves. 4. When fitted, calibrate the bearing bush so that the tolerance ø19-R7 is observed. Do this either with a calibration ball or with a reamer having the mentioned tolerance. 5.
C8 Removal of fuel valves The fuel valves are removed by loosening the clamping nuts for the flanges A as indicated on the sketch below after removal of the inlet and return pipes of the fuel valves. The drawing at the bottom right-hand side indicates the placing of the fuel valve in proportion to the piston. For repair of the fuel valves, we refer to section H.
C9 Nozzle holder insert The nozzle holder inserts are placed in the cylinder head and form – a the name indicates – an insert for the placing of the fuel valves in the cylinder head. The nozzle holder ins erts can be replace d, which demands that the sp ecial tools below for flanging (piston and backstop) are used and that t he surfaces are treated as indicated on the drawing.
C10 Fitting measurements for the fuel nozzle into insert.
C11 Valve springs Six identical springs for inlet and exhaust valves, respectively, are fitted in the cylinder head. The springs are identical in both ends, and therefore fitting up or down is of no importance. The springs are locked in their position in proportion to the valve stems by means of two conical halves for each valve spring and guided by a guide for valve spring and a corresponding disc, respectively.
C12 Replacement of valve guides Replace the valve guides whic h are pressed into the cylinder head if the tolerance is exceeded because of wear and tear by 0.05 mm. Check the measure with a ø9 – H7 internal gauge according to the drawing below of the valve guide. Fit new valve guides according t o the drawing on page C13. Before fitment, heat the cylinder head in an oven or heat it in boiling water and cool down t he valve guides in a deep freezer or otherwise.
C13 Pressing-in dimensions for valve guide.
C14 Valve guide stuffing box In order to avoid lubricating oil consumption because of lubricating oil passing between valve guide and valve stem causing the valves to be burnt or to be carbonized, a stuffing box has been mounted on the upper end of the valve guides.
C15 Repair or replacement of inlet and exhaust valves 1. Remove the cylinder head from the engine (page C5). 2. Then place the cylinder head on a file bench or the like with the valve seats at the bottom. 3. Compress the valve springs with a special tool or the like and remove the conical valve locking halves. 4. Then place the cylinder head upright and remove the valves from the cylinder head. Refitment is a reversal of removal procedure. Note! Refit the valves in the same valve guides again.
C16 Exhaust valve Tolerances and repair measures.
C17 Inlet valve Tolerances and repair measures.
C18 Grinding of valves 1. Place the cylinder head with the valve seats upwards. Block the cylinder head so that the valves fit tightly against the seats and can be turned freely by means of a rubber suction disc or the like. 2. Apply abrasive compound to valve and seat, after w hich grinding can tak e place. 3. When grinding, turn the valve by means of the rubber suction disc in various directions while fitting it at the same time with an equal pressure against the seat.
C19 Replacement of valve seats The valve seat rings should be replaced when, after repeated millings and grindings, they have been milled so far down that the valv e heads are more than 0.3 mm belo w the face of joint of the cylinder head (see the sketch below). 1. Remove the valve springs an d valves as indicated previously in this section. 2.
C20 Cylinder head gasket The cylinder head gasket is made from “Grafos eal” (Asbestos free) which is an expanded graphite which is strengthened with a special 0.2 mm carbon steel inlay. When replacing the cylinder head gasket, the grooves in the cylinder completely clean to obtain tightness. head must be If the cylinder head has been removed several time s, the metal around the studs may have risen which can be checked by m eans of a straight-edge. If the me tal has risen, it must be planned. Drwg.
C21 Air inlet manifold arrangement. Pos. Part No. Qty.
C22 Exhaust manifold arrangement. Pos. Part No. Qty.
D1 SECTION D FLYWHEEL 009W2329-R01
D2 CONTENTS Removal and refitment of flywheel ............................................ page D 3 V-belt pulley fitted on flywheel ................................................... page D 3 Replacement of gear rim ...........................................................
D3 Removal and refitment of flywheel 1. Mark the flywheel in propor tion to the crankshaft out of consideration for the other marking of the outer diameter of the flywheel. 2. Slacken the V-belt for the charging alternat or and take it clear of the V-belt pulley of the flywheel. 3. Remove the six bolts securing the flywheel to the crankshaft. 4. Lift off the flywheel. Refitment is to be carried out in reverse or der.
D4 Replacement of gear rim 1. Remove the flywheel. 2. Saw with a hacksaw as far int flywheel. o the gear rim as possible without damaging the 3. Split the gear rim in the sawed slot with a chisel. 4. Clean the recess on the flywheel. 5. Heat the new gear rim gradually to about 225°C (dark blue) and fit it. Make sure at the fitting that the gear rim lies true against th e recess and that the chamfered edge turns towards the starter engine. Drwg.
E1 SECTION E FRONT END COVER 009W2329-R01
E2 CONTENTS Dismounting of front end cover.................................................. page E 3 Mounting of front end cover ....................................................... page E 3 Front rotating weight .................................................................. page E 3 Replacement of front oil seal ring .............................................. page E 4 Replacement of bushes in the front rotating weight...................
E3 Dismounting of front end cover 1. Dismount the flywheel (see page D3). 2. Slacken the attachment of the end cover in engine block as well as in oil sump. 3. Dismount the tightening arrangement for shaft for rotating weight. The tightening consists of two washers of different thickness and a fibre washer assembled by a 8 mm screw. 4. Remove the end cover considering the guide spindles of the cover. . Mounting of front end cover The mounting is carried out in reverse order of the dismounting, i.
E4 Replacement of front seal ring A seal ring is mounted in the front end cover in order to avoid lubricating oil waste at the end of the crank through the front end cover. The seal ring can be replaced without dismounting the front end cover. It is, however, necessary to dismount the flywheel.
G1 SECTION G REAR END COVER AND HAND START 009W2329-R01
G2 CONTENTS Rear end cover .......................................................................... page G 3 Dismounting of rear end cover .................................................. page G 3 Mounting of intermediate wheel and chain wheel ...................... page G 4 Tightening for shaft for intermediate wheel................................ page G 4 Intermediate wheel .................................................................... page G 5 Rear of rotating weight (drawing) ...............
G3 Rear end cover The rear end cover contains gear-wheel for crank, cam shaft, fuel pump,hand start, lubricating oil pump, cooling water pump and rear rotating weight. The gear-wheels are in the gear with each other through an intermediate wheel. The sketch below indicates the marking of the gear-wheels which have been marked in relation to each other so that their position to each other may easily be observed when being repared. Dismounting of rear end cover 1. Dismount the gear from the engine. 2.
G4 Mounting of intermediate wheel and chain wheel After the intermediate wheel has been placed on the shaft, and after the timing marks – as indicated overleaf – have been adapted for the corresponding marks, the chain wheel for hand start should be mounted on the same shaft. The two thrust collars shown form part of the arrangement.
G5 009W2329-R01
G6 009W2329-R01
G7 Mounting of the rear rotating weight Mount the rotating weight on the shaft pressed into the engine block and the tooth marking in relation to the intermediate wheel should be observed. After the end cover has been mounted, the tightening for shaft should be mounted in accordance with the drawing below. The tightening consists of two washers of different thickness and a fibre ring.
G8 Replacement of bush in the rear rotating weight and intermediate wheel Bushes have been mounted in both rear rotating weights as well as in the intermediate wheel. These bushes can be replaced in case of wear and tear. After the new bushes have been pressed in these should be calibrated with a ball or be reamed with the correct measures and clearances as indicated on the drawings on page G5 and G6 for rear rotating weight and intermediate wheel respectively.
G9 Chain adjuster The chain adjuster is mounted on two pins in the engine block. The chain adjuster is self-adjusting and thus it does not require any adjustments in connection with repairs in the end cover during which the chain is to be dismounted.
G10 Hand start The chain case is bolted on to the rear end cover, as indicated on the drawing below. When dismounting remove the covers “A”, and this results in the chain being slackened and then the chain wheel and shaft can be taken out. Mounting is carried out in reverse order and it should be taken care that the O-rings for oiltightness are correctly placed in the grooves on the chain wheel shaft. Dismount the chain case from the end cover by removing the bolts “B”.
H1 SECTION H FUEL SYSTEM 009W2329.
H2 CONTENTS: Dismounting of the fuel pump ......................................................... page H 3 Mounting and Adjustment for fuel pump ......................................... page H 4 Specification of Numbers to Fig. 1 and 2 ........................................ page H 6 Fuel System ................................................................................... page H 7 Centrifugal Governor ......................................................................
H3 Dismounting of the fuel pump 1. Dismount the bilge pump for lubricating oil from engine and gear. 2. Dismount the flange opposite of the fuel pump. 3. Take off the gear-wheel of the pump by slackening the clamping nut on the shaft of the pump and pull off the gear-wheel. 4. Slacken the nuts in the flange of the pump and take out the pump. REPAIRS OF THE PUMP SHOULD ONLY BE CARRIED OUT BY AUTHORIZED BOSCH WORKSHOPS 009W2329.
H4 1. Turn piston No. 3 (rear) to TOP in the working stroke. 2. Mark the flywheel in this position in relation to the arrow mounted on the front edge of the engine. 3. Measure 86 mm. arc measure from the TOP mark (to the right, when the flywheel faces you). 009W2329.
H5 4. The pump should be adjusted for correct injection timing: a. Adjust the key on the conical shaft of the pump so that it flushes with the outlet hole B to the fuel valve for cylinder No. 3. b. Remove the screw X and mount a dial indicator with a special sensing element instead by means of a special holder for dial indicator. c. Push in the dial indicator 2.0 mm. d.
H6 Specification of Numbers to Fig. 1 and 2 1. Feed pump 2. Drive shaft 3. Gear-wheel 4. Thrust washer 5. Governor shaft 6. Governor bush 7. Holder 8. Governor weight 9. Governor spring 10. Timing lever 11. Adjusting screw (idling) 12. Adjusting screw (max. r.p.m.) 13. Stop lever 14. Overflow throttle 15. Correcting lever 16. Bolt 17. Adjusting screw (full load) 18. Idle spring 19. Clamping arm 20. Starter spring 21. Starting lever 22. Delivery valve holder 23. Distributor piston 24. Governor slide 25.
H7 Fuel System The fuel is pumped by a lift pump (29 from the tank via a fine filter (30) to the internal wing feed pump. This feed pump gives a constant quantity/revolution. Through the pressure control valve (31), after the feed pump, a pressure is produced. Most of the fuel flows through the pressure control valve back to the suction side.
H8 The centrifugal governor is placed in the upper part of the fuel pump. The holder (7) with gear-wheel is placed on the governor shaft (5) and is driven by the drive shaft (2) via the gear-wheel (3) and a rubber shock absorber (vibration damper). Four weights (8) are mounted in the centrifugal weight holder. They press on the axially displaceable governor bush (6) via a thrust washer (4) with their pressure arms.
H9 Function of the Centrifugal Governor The revolutions of the engine are transmitted by the drive shaft (2) through gear-wheel to the governor weights (8) and are transformed into centrifugal force there. With stopped fuel pump, the starting lever (21) and the governor slide (24) are pressed into start position by the starter spring (20). Through this automatic ful volume, when starting, is obtained. When the r.p.m.
H10 Fuel Lift Pump The fuel lift pump is a diaphragm type and is placed at the upper side of the rear end cover. The pump is sealed and cannot be dismantled for repair or cleaning. It is driven by the camshaft. Workpressure is 35 – 55 kPa. A hand pump is fitted, which can be used for priming and bleeding by standing engine. After priming the lever must be put in neutral position, where it is locked. If priming not is effective, it may be caused by the driving cam being in top position.
H11 Fuel Filter The fuel filter used is a Bosch disposable one mounted to the port side on the front of the engine. The filter cannot be cleaned, but has to be changed every 300 operating hours, or if water contamination is suspected. Unscrew the filter casing by hand after the filter casing has been emtied for fuel via the drain screw in the bottom of the filter casing. Before fitting of a new filter the sealing surface of the filter casing should be cleaned.
H12 The fuel valves are mounted in the cylinder head and are secured here with tightening bars which are loosened when dismounting the fuel valves. Disassemble the fuel valves after the sketch beside and so the nozzle can be exchanged and the pressure can be adjusted at the washers (541). Adjust the fuel valves by means of a pressure test apparatus at 184 Kp/cm² *) opening pressure. When using Bosch pressure testapparatus for nozzles you are referred to Bosch infor-mation WPP 320/2 DK (500.8.
H13 Causes and Remedies of the Fuel Pump 009W2329.
IJ1 SECTION IJ PISTON, CONNECTING ROD AND CYLINDER LINER 009W2329-R01
IJ2 CONTENTS Disassembling of pistons and connecting rods.......................... page IJ 3 Assembling of pistons and connecting rods .............................. page IJ 3 Exchange of pistons .................................................................. page IJ 4 Measurement of piston .............................................................. page IJ 5-6 Piston rings................................................................................ page IJ 7-8 Exchange of piston rings ..........
IJ3 Disassembling of Pistons and Connecting Rods 1. Drain off the cooling water and the lubricating oil from the engine. 2. Dismount the cylinder head (see section C). 3. Remove any wear or soot edge which may be at the top of the cylinder liner with a scraper. 4. Turn the engine “upside down”. 5. Remove the oil pan. 6. Unscrew the connecting rod nuts and remove the bearing cap from the connecting rod. 7.
IJ4 Exchange of Pistons If the pistons are scored or very worn, exchange them for new ones. This is carried out as follows: 1. Remove the pistons with connecting rods as stated on page IJ 3. 2. Take off one of the locking rings at the gudgeon pin. 3. Knock out the gudgeon pin with a punch. 4. Place the new pistons upside down. Pour a little spirit into them and light it. The heating can also take place on a boiling plate. 5. When the piston has reached a temperature of about 100°C, smother the fire.
Measurements for Piston 009W2329-R01 IJ5
IJ6 009W2329-R01
Piston Ring 1 (Please note page IJ4) 009W2329-R01 IJ7
IJ8 Piston Ring 3 (Please note page IJ4) 009W2329-R01
IJ9 Exchange of Piston Rings The piston ring gap is 0.3 – 0.45 mm (0.0118 - 0.0177 inch) in a new engine. The wear of the piston rings ca n be seen by measuring the piston ring gap, and the piston rings must be changed when this is max. 2.0 mm (0.0787 inch). This is done as follows: 1. Take out the piston with connecting rod as stated on page IJ 3. 2. Remove the piston rings either by a spec ial pair of tongs or by m eans of two piec es of string which have been folded.
IJ10 009W2329-R01 Arrangement of Connecting Rod
IJ11 Connecting Rod Bearings The connecting rod bearings are in two parts and consists of two steel shells in which a thin layer of bearing metal is cast. The connecting rod bearings must be exchanged if they are scratched or if the “red” layer between the bearing metal and the steel shell can be seen faintly. When grinding the crank journal, connecting rod bearings can be supplied in following undersize: 0.6 mm (0.02362inch) (see section L).
IJ12 Cylinder liner The bore of the cylinder liner is 85.000 – 85.020 mm (3.3464 – 3.3472 inch). The cylinder liner must be exchanged when it is worn max. 0.3 mm (0.012 inch). Measuring of Cylinder Wear Place a new piston ring in the upper end of the liner where this is not worn. Measure the piston ring gap with a feeler gauge. This will be e.g. 0.3 mm (0.012 inch). Place the piston ring lower in the liner where it is worn and measure the piston ring gap again which is now e.g. 0.9 mm (0.0354 inch).
IJ13 Test Measurements of Cylinder Liner 009W2329-R01
L1 SECTION L CRANKCASE, CRANKSHAFT, MAIN BEARINGS AND OIL SUMP 009W2329-R01
L2 CONTENTS Dismounting of crankshaft ......................................................... page L 3 Change of main bearings .......................................................... page L 3 Rear part of crank ...................................................................... page L 4 Rear gear-wheel and rear part of crank ..................................... page L 5 Marking of front gear-wheel on crank ........................................ page L 6 Front part of crank ......................
L3 Dismounting of crankshaft 1. Remove the cylinder head with manifold (see section C page 4). 2. Dismount the flywheel (see section D page 3). 3. Dismount the gear (see section R page 3). 4. Dismount the rear end cover (see section G page 3). 5. Turn the engine upside down. 6. Remove the oil sump. 7. Dismount the pistons and the connecting rods (see section IJ page 3). 8. Dismount the front end cover (see section E page 3). 9. Remove the bearing caps and lift out the crank.
L4 Rear part of crank The drawing below shows the rear part of the crank with screwing-on of the counter weights of the crankshaft. Drwg. No.
L5 Rear gear-wheel and rear part of crank 009W2329-R01
L6 Marking of front gear-wheel on crank The front gear-wheel on the crank drives the front rotating weight and is marked in proportion to this and in accordance with the drawing below. The gear-wheel has been shrinked on the shaft. When shrinking on a new gear-wheel there should be a difference of temperature between the crankshaft and the gear-wheel of 231 C. Further see the drawing overleaf.
L7 Front part of crank 009W2329-R01
L8 Repair dimensions of crankshaft The crankshaft is made of drop-forged, heat-treated steel. Thus it is possible to gring the crankshaft without subsequent surface treatment. The crankshaft must never be repaired with hard chromium-plate or metal feeding, but only by grinding in accordance with the below mentioned measures and tolerances to which we supply undersize bearings. The crankshaft should be ground, if it is oval and the smallest diameter is 0.05 mm (0.
L9 Oil Sump The engine is fitted with an oil sump of cast iron. The oil sump is fixed to the crankcase and is ensured correct position to this by means of guide pins. Under the oil sump the suction strainer for the lubricating oil system is placed and pipe connections for it. The oil sump with pipe arrangement for lubricating oil system is shown on the drawing below.
M1 SECTION M CAMSHAFT, COMPLETE 009W2329-R01
M2 CONTENTS Camshaft ................................................................................... page M 3 Valve timings ............................................................................. page M 4 Guide for push rod ..................................................................... page M 4 Gear-wheel of camshaft ............................................................ page M 5 Drawing of push rod ..................................................................
M3 Camshaft The camshaft runs in borings in the engine block, and it has been forced-lubricated through grooves bored in the engine block. A bush for the camshaft is fitted in the front end of the engine block. There is a hole for lubricating oil inlets in this bush. The camshaft is fixed on to the engine block at the flange “A” on the sketch below. The cams which are casted together with the camshaft are made of hardened steel. The camshaft is driven via a gear-wheel from the crankshaft.
M4 Valve timings and injection point Flywheel diameter ........................................... 370 mm Inlet valve opens ......................... before TDC: 32° (arc measure: 103 mm (4.07”)) Inlet valve closes......................... after BDC: 64° (arc measure: 207 mm (8.14”)) Exhaust valve opens ................... before BDC: 64° (arc measure: 207 mm (8.14”)) Exhaust valve closes................... after TDC: 32° (arc measure: 103 mm (4.07”)) Injection starts ............................
M5 Gear-wheeI of camshaft The camshaft gear-wheel is equipped with a single mark for its correct position in relation to the rear rotating weight and a double mark in relation to intermediate wheel (see instructions in section G page 3).
M6 Drawing of pushrod Drwg. No.
M7 Drawing of push rod guide 009W2329-R01
N1 SECTION N LUBRICATING OIL SYSTEM 009W2329-R01
N2 CONTENTS Lubricating oil system ................................................................ page N 3 Pressure relief valve .................................................................. page N 3 Fitting of dip stick ....................................................................... page N 4 Pipe connections in oil sump ..................................................... page N 5 Lubricating oil pump ..................................................................
N3 Lubricating oil system The engine is lubricated through a pressure l ubrication system. The lubricating pump driven by the camshaft sucks oil from the oil sump th rough a strainer. From the lubricating pump the oil is pressed through a fine filter to the respective lubr icating points through oil ducts bored in the goods. A reduction valve in the lubric ating system secures that the oil pres sure is kept between 2.0 and 4.0 Bar at hot engine and max. revolutions.
N4 Fitting of dip stick 009W2329-R01
N5 Pipe connections in oil sump 009W2329-R01
N6 Lubricating oil pump The lubricating oil pump is placed below the rear end cover and actuated via the rear gear-wheel of the crank and a gear-wheel fixed to the shaft of the pump. The pump is an Eaton pump with star rotor and life ring. When the engine runs at full speed, the pump runs 4000 r.p.m. and thus supplies 33.15 litres lubricating oil per minute to the lubricating oil system. Removal of lubricating oil pump 1. Remove the gear (see section R page 8). 2.
N7 Lubricating oil cooler The standard engine is equipped with a lubricating oil cooler, fitted as shown on the drawing below. On the water side the cooler is connected between the cooling water pump and the cooling water suction hose, and on the oil side it is connected to the outlet of the lubricating oil pump to the lubricating oil system. The end pieces “A” of the cooler consists of two profile-cast rubber tubes fastened to the cooler and the cooling water pipes with clips “B”.
N8 Change and quality of lubricating oil Exchange the lub. oil every 150 operating hours or once a year. This is done with a bilge pump, fitted on the engine. This pump can be set for emptying the engine or gearbox of lub. oil by means of the three-way cock. Lub. oil content inclusive of filter is 4.9 Litres. Pour fresh oil through the filling hole in the top cover. Normally a lubricating oil quality mark “Service CC” must be used, but for operation under difficult conditions, i.e.
N9 Lubricating oil filter The lubricating oil filter is a disposable one which cannot be cleaned. Exchange the filter every 150 operating hours or once a year. Remove the filter by hand and discard it. Tighten the new filter by hand too. When changing the filter clean the sealing surface on the engine block, if necessary, and lubricate the rubber gasket of the filter with a little clean oil. After changing the filter start up and check that the filter and the sealing surface towards the engine are tight.
O1 SECTION O COOLING WATER SYSTEM 009W2329-R01
O2 CONTENTS Cooling water systems .............................................................. page O 3 Johnson cooling-water pump type F5B9 ................................... page O 4 Removal of pump ...................................................................... page O 4 Dismantling of pump .................................................................. page O 4 Dismantling of intermediate housing ......................................... page O 4 Reassembly of pump .........................
O3 The engine can be c ooled by direct seawater cooling which is supplied as standard cooling system. Alternatively freshwater cooling can be supplied as extra equipment and this c an be arranged in three different ways: either with heat exchanger, keel cooler or with radiator cooling. However, the latter will n ot be of i mmediate importance when using the engine as marine engine and therefore it is not dealt with separately in this section.
O4 Johnson cooling water pump type F5B9 The cooling water pump is used for direct s eawater cooling with a cam heigh t 0f 2.0 mm and for freshwater cooling with heat exchanger to the seawater si de with a cam height of 3.1 mm (see technical data page A5). Removal of the pump 1. Loosen the three screws in the flange marked A. 2. Remove the cooling water pipes going to and from the pump. 3. Lift the pump free in one piece from its attachment in the engine block. Dismantling of the pump 1.
O5 Reassembly of pump The pump should be assembled in the reverse order of the dismantling. Observe that the ball bearings of the intermediate housing are filled with grease free from acid. Refitment of the pump Fit the pump in the reverse order of the removal and check that the rubber gasket ring marked H fits tightly.
O5A Johnson cooling water pump: After DV36 serial No. 1051 the outer dimensi ons of the Johnson cooling water pump have been changed and the pump has been par tly simplified at the same ti me, as e.g. the carbon ring stuffing box has been left out. The type and the technical data of the pum p and height of the cam in ca se of direct seawater cooling and indirect freshwater cooling respectively are the same for the new pump as for the one previously used.
O5B Removal of the pump 4. Loosen the three screws in the flange marked 20. 5. Remove the cooling water pipes going to and from the pump. 6. Lift the pump free in one piece from its attachment in the engine block. Dismantling of the pump 5. Loosen the three screws marked 12 in the front cover and remove the front cover marked 3. 6. Withdraw the neoprene impeller which is mounted on a multiple spline shaft. 7.
O6 Circulation pump for freshwater The circulation pump shown on page O7 is used for freshwater cooling, both when cooled by heat exchanger and by keel cooling. Removal of circulation pump 1. Remove the inlet and outlet pipes from the pump. 2. Loosen the pump from its fixing on the rear end cover and lift it out. Dismantling of circulation pump 1. Loosen the screws 500C2363 in the cover 000E4934 of the pump and remove the cover and gasket 560K1119. 2.
O7 Circulation pump 009W2329-R01
O8 Zinc rod protection For seawater-cooled engines it is necessary to fit zinc anodes in the cooling water system in order to protect against corrosion of the engine block. On the starboard side of the engine under the exhaust manifold there therefore are three mounting holes for zinc anodes. As standard for seawater cooling zinc anodes have been screwed into the two back holes as shown on the drawing below.
Thermostate O9 For controlling the cooling water temperature the cooling water system is fitted with a thermostate. Dependent on the cooling principle the thermostate has different opening temperatures. In case of direct seawater cooling the thermostate has an opening temperature of 50°C. In case of freshwater cooling the thermostate has an opening temperature of 80°C. In case of freshwater cooling with keel cooler the thermostate has an opening temperature of 80°C. Direct seawater cooling thermostate No.
O10 Header tank and heat exchanger The arrangement of header tank and heat exchanger fitted on the top of the water cooled exhaust manifold is shown on page O11.
O11 009W2329-R01
O12 009W2329-R01
P1 SECTION P ELECTRICAL SYSTEM 009W2329-R01
P2 CONTENTS Wiring diagram (key switch) ...................................................... page P 3 Wiring diagram (key switch) – 2 battery starting system............ page P 4 Wiring diagram (push button) .................................................... page P 5 Wiring diagram (push button) – 2 battery starting system ......... page P 6 Generator with double charging diodes ..................................... page P 7 Key switch start panel .......................................................
P3 009W2329-R01
P4 009W2329-R01
P5 009W2329-R01
P6 009W2329-R01
P7 Generator with double charging diodes Drg.no.
P8 009W2329-R01
P9 009W2329-R01
P10 009W2329-R01
R1 SECTION R ZF GEAR – BW7 009W2329-R01
R2 CONTENTS Gear ratio .................................................................................. page R 3 Oil change ................................................................................. page R 3 Special tools .............................................................................. page R 5 Adjusting measures and torques for BW7 ................................. page R 6 General information for work with the gear ................................
R3 Gear Ratio The BW7 gear which is used on DV36 has normally a reduction ratio of 3.0:1 for AHEAD and 2.36:1 for REVERSE. For special purposes it can be delivered with a reduction ratio of 2.47:1 for AHEAD and 2.36:1 for REVERSE. Oil Change The gear will need no other attendance than regular change of oil. This to be carried out after the first 25 hours of operation and then every 150 hours or once a year.
R4 009W2229
Special Tools Order No. 009P3187 Mounting punch for seal ring 25x33x6 at input shaft Order No. 009P3188 Internal puller for tapered roller bearings / outer ring Order No. 009P3189 For fitting of tapered roller bearings / outer ring in connection with 009P3188 Order No. 009P3190 Measuring instrument for adjustment of tapered roller bearings Order No. 009P3191 Protective sleeve for seal ring 25x33x6 at input shaft Order No. 009P3192 Mounting punch for seal ring 32x45x7 at output shaft Order No.
R6 Adjusting Measures and Torques for BW7 Designition Statement of dimensions Gauge Remarks Axial tightening of tapered roller bearings on input and output shafts 0.03 – 0.08 mm With a load of 30 N (3 Kp) Dial indicator or Depth micrometer Adjusted by means of washer (s) under bearing outer ring in the housing. The bearings are fitted with Loctite 601 Axial clearance Sliding sleeve in shifting fork 0.1 – 0.4 mm Feeler gauge New gear Axial clearance Sliding sleeve in shifting fork incl.
R7 Adjusting Measures and Torques for BW7 Designition Statement of dimensions Gauge Remarks Testing indication for pressure spring 0732 041 008 for shift pins L = 11.4 mm P = 46±5 N (4.6±0.5 Kp) Depth measure L = length of loaded spring Torque of hexagon nut M20x1.5 on output shaft on the output side 100 Nm (10 Kpm) Torque wrench Secure after having packed with liquid jointing on the contact face Torque of hexagon nut M20x1.
R8 General Information for Work with the Gear Show cleanliness when repairing the gear and before the gear is opened it must be carefully cleaned. Use special tools as stated earlier in this section when removing and fitting the gear. The seal face between the two parts of the housing is tightened with liquid jointing. When dismantling the halves of the gearbox from each other, loosen the screws in the flanged joint first and push/press back the fitting pins.
R9 Dismantling of BW7 Gear Pull the dip stick of the housing. Remove the locking ring on the input shaft. Remove the shifting arrangement with gasket. There are two different shifting levers which, however, can be built in without any problems in either cases. Press the shifting lever out of the shifter shaft and take out the O-ring 12x2.4 and the pin and the pressure spring.
R10 Unscrew the nut of the output shaft flange. Pull off the output shaft flange. Screw off the fixing screws which hold the halves of the gearbox together.
R11 Drive back the fitting pins 2 – 3 mm in the gearbox and lift one gearbox half with reversing shaft, input and output shafts free of the other gearbox half. Protective sleeve 1 x 56 136 992 may be fitted on the input shaft before the dismantling. Removal of Input and Output Shaft ProTake out the screws M8x25 and the gearwheel bolts and remove the washer plate. At the fitting the screws have been smeared with Loctite and consequently it may be necessary to heat before they are loosened. Loctite No.
R12 Dismantling of Shifting Fork Screw out the pin M6x12 of the shifting fork and press out the reversing shaft of the shifting fork. At the fitting the threaded pin has been smeared with Loctite No. 241 and so it may be necessary to heat. 1. Shifting fork 2. Threaded pin 3. Reversing shaft Dismantling of Output Shaft Remove nut with washer “ASTERN” Pull off the wheel “ASTERN” with a special tool and take up washer, disc springs and tapered roller bearing inner collar.
R13 Remove the thrust collar wuth bolts and washers together wuth needle bearing bushing, sliding sleeve and pressure spring. Remove the wheel “AHEAD” with a special tool and take off all parts “AHEAD”.
R14 Dismantling of Input Shaft Squeeze off the tapered roller bearing inner collar. Dismantling of Lower Gearbox Half Pull out the tapered roller bearing outer collars of the lower gearbox with an inner puller No. 1 x 56 122 208 and auxiliary tool No. 1 x 56 122 227 and take up the washers. At the fitting the tapered roller bearing outer collars have been smeared with Loctite 601 and so heating may be necessary.
R15 Refitment of BW7 Gear Before refitment of the gear examine the different components for cracks and wear. In the following description only the fitting of output shaft for “AHEAD” is described as the fitting for “ASTERN” is chiefly corresponding. If it is necessary reference will be made to the paragraph marked “Note”. Picture 19 Insert the sliding sleeve in the shifting fork and measure the axial clearance of the sliding sleeve. The axial clearance below the wear limit must be 0.1 – 0.4 mm.
R16 Fit the tension rollers on the shafts for suspension by rollers. “Note”: The tension rollers must be placed so that the big surface lies outwards. Fit the pressure springs in the check bolts. Fit the check bolts in the corresponding bores. The point of the check bolts should turn so that it is horizontal. Press the sliding sleeve from the bottom against the check bolts. Press the check bolts back with a screwdriver and at the same time press the sliding sleeve upwards.
R17 Fit needle bearing housing, wheel for “AHEAD” and washer. Check the axial clearance of wheel for “AHEAD”. It should be 0.1 – 0.4 mm. “Note”: For “ASTERN” the axial clearance can be adjusted by fitting an intermediate washer (thrust washer). First fit a washer. Then fit an inner disc and the an outer disc. Fit 4 inner and 3 outer discs in this order. Fit wheel for “AHEAD” with clutch discs on the thrust collar.
R18 Fit thrust washer, the oil pockets of which should turn towards the wheel for “AHEAD”. Fit the disc springs which should touch with the outside diameter. Check the tightening of the disc springs. The inside diameter of the disc springs must, when slack, in proportion to the front be min. 1.1 mm (measure A). Tighten the disc springs with bush 1 x 56 136 994. Measure disc clearance between inner disc and washer with a feeler gauge in two places which are opposite one another. The disc clearance to be 0.
R19 Heat the tapered roller bearing inner collar to about 85°C and fit it with the thin end of the taper roller facing the shaft end of the output shaft until it fits tightly against the disc springs. Tighten the tapered roller bearing with bush No. 1 x 56 136 995 and original hexagon nut until it fits tightly against the shaft assembly. See picture No. 33 overleaf too). “Note”: Fix the tapered roller bearing for “ASTERN” with supporting washer and original hexagon nut.
R20 The picture shows the ready-mounted output shaft. Fitting of Input Shaft Heat the tapered roller bearing inner collars to about 85°C and fit it with the thin end of the bearings towards the shaft ends. “NOTE”: Fit wide tapered roller bearing on the input side.
R21 Measuring of Tightening of Tapered Roller Bearing on Input and Output Shafts with Measuring Gauge. 1 = Housing 2 = Input shaft 3 = Depth micrometer 4 = Measuring gauge 1 x 56 136 978 5 = Output shaft Heat the bearing bores in the housing to about 85°C and fit the tapered bearing outer collars with Loctite No. 601. Build in the tapered roller bearings of input and output shafts with the tightening of 0.03 to 0.08 mm after the cooling.
R22 1 = Bearing bushing 2 = Measuring gauge 3 = Depth micrometer Fit the measuring gauge on lower gearbox half. Calculate the thickness of the intermediate washer G as follows: Establish measure E as D minus B (thickness of measuring gauge). Calculate the difference measure F as E minus A (See picture No. 35 on last page). Calculate intermediate washer G for the input shaft as F plus tightening 0.03 – 0.08 mm.
R23 Measuring of Tapered Roller Bearing tightening on Input and Output Shafts without Measuring Gauge. 1 = Dial indicator holder 2 = Input shaft 3 = Dial indicator 4 = Driving arrangement It would be an advantage, if the input shaft and the output shaft are measured individually for the adjusting of the tapered roll er bearing tightening. The measur ing procedure is the same both for input as well as for output. Howeve r, only the procedure for the input sh aft is described here.
R24 Picture No. 37 continued Measuring example: Thickness of intermediate washer during the measuring procedure: Measured axial clearance of shaft: Correct tightening 0.03 – 0.08 mm (average value): Thickness of compressed liquid jointing: 0.60 mm 0.08 mm 0.055 mm 0.02 mm Theoretical thickness of intermediate washer: 0.755 mm In practice the intermediate washer will be 0.73 – 0.78 mm. Then insert the correct intermediate washers in the bores (max.
R25 1 = Shifter shaft 2 = Shift pin 3 = Pressure spring 4 = Gearbox 5 = O-ring 6 = Shift control lever 7 = Grease lubrication 8 = Screw cap Insert pressure spring, shift pin, oiled shifter shaft and O-ring in the gearbox. Press the shift control lever on to theshifter shaft so tha t shift control leveris placed in neutral position at 90°±30’to the gear shaft length. Fit the screw cap with grease lubrica-ting after the pressing on.
R26 Fitting of Bolts in Gearbox Drive in t he slotted pins 4x16 in thebolts and fit the washers on the bolts so that the lubricating groove in them point to the wheel. “NOTE”: The bolt must be fitted in pos. 1 or 2 all depending on the transmission. Transmission: GLL = AHEAD GGL = ASTERN Heat the gearbox and fit the bolts with slotted pins in pos. 1 or 2 all depending on the transmission. Fit the hexagon nut and tight en it with 100 Nm (10 kpm).
R27 Fitting of Input and Output Shafts with Shifting Fork in Gearbox Place the shaft arrangement as shown on the picture. “NOTE”: The long side of the reversing shaft faces the input side. Fit the intermediate wheel and needle bearing. Lift intermediate wheel with s plate (see illustration). top The intermediate wheel should be lifted about 25 mm, otherwise fitting is not possible.
R28 Place the housing so that the opening of it turns upwards. Oil the roller bearings and reversing shaft and fit them together in the housing. Remove the stop plate. “NOTE”: The long side of the reversing shaft points upwards to the input side. Fit retaining plate for intermediate wheel and before that smear the screws M8x25 with Loctite No. 241. Torque: 17 Nm (1.7 Kpm).
R29 Smear the seal f aces of the gearbox halves wit h permanently plastic liquid jointing. Oil the bearings on the input and output shafts. Assemble the gearbox and drive in the guide pins. Tighten the screws M8x25 with a torque of 17 Nm (1.7 Kpm).
R30 Fitting of Shaft Seal Rings Fit the protective cap No. 1 x 56 136 992 over the input shaft. Smear the seal ring 25 x 33 x 6 with a thin layer of grease on the lip ring and smear with a thin lay er of plastic liquid jointing on the outside. Fit the seal ring with punch No. 1 x 56 199 916 so that it fits tightly against the bore of the housing. Smear the similar seal ring 32 x 45 x 7 for the output shaf t in the same way as the seal ring for the input shaft and fit it by means of punch No.
Supplement to Fitting of Shaft Seal Rings A = Distance to shaft seal ring: 22.5 ±0.5 mm. B = Shaft seal ring binding with surface of casting on the lower gearbox half. The picture shows the necessary mounting dimensions for the shaft seal rings on the input and output shafts.
R32 Heat the output flange to about 85°C and fit it on the output shaft. Smear the nut with permanently plastic liquid jointing and secure it with a torque of 100 Nm ( 10 Kpm).
Picture 55 Fit the screws M8x25 with washers in the gearbox. Put the gear shift lever in “neutral” (the sliding sleev e is also in “neutral” position). Place the gearbox with gask et in the opening of the housing and pr ess the shifting eccentric down into the shifting fork. In connection with this check at the same time with a ligh t pressure of the eccentric pointing to the assembly the axial clearance between the sliding sleeve and the shifting fork. Secure the shifter housing in this position.
S1 SECTION S SAIL DRIVE TYPE Z-7 009W2329-R01
S2 CONTENTS Oil change and gear ratio .......................................................... page S 3 Zinc anode................................................................................. page S 3 Outside maintenance ................................................................ page S 3 Removal of sail drive from engine and boat .............................. page S 3 Alarm function of double membrane ..........................................
S3 Oil Change and Gear Ratio As an alternative to the BW7 gear the DV36 can be equipped with a sail drive. The reduction ratio is 2.25:1 for “AHEAD” and 2.25:1 for “REVERSE”. The sail drive will need no other attendance than regular change of oil. This to be carried out after the first 25 hours of operation and then every 150 hours or once a year. Carry out the oil change when the boat is on land by loosening the drain screw in the bottom of the sail drive enabling the oil to run out.
S4 009W2329-R01
S5 ‘ Alarm Function of Double Membrane A sensing element is fitted in the double membrane. The element is shown on the diagram below. The sensing element is connected to the the operating panel and if water penetrates into the double membrane it will release an acoustic alarm. As a precaution the alarm function should be checked once or twice a year by short-circuiting the connections 1 and 2 on the plastic box No. 008E5840 placed on the engine next to the multiple plugs.
S6 The instruction below is stated for assembling of sail drives as broadly the disassembly procedure is to be carried out in reverse order noting the thickness and the placing of the different intermediate washers. General At the assembly all parts must be clear, burred and free from grease. In order to prevent wrong measuring when adjusting, the parts should normally not be oiled when being assembled.
S7 Assembling Procedure for Sail Drive 1. Measure the intermediate piece (between engine and clutch housing), the clutch housing and the end cover for the same, and then the “K” measure can be worked out. 2. Up-end the clutch shaft so that any clearance is equalized. (about 2 kg compression, if it is not possible to up-end the shaft). At the same time the gear-wheel should be engaged. Measure the “J” measure now. Measure the “C” measure for use later on under point 10. 3.
S8 Measure on the intermediate wheel as follows: 7. 1.0 mm is chosen as thickness of the intermediate washer “III” as starting point. 8. Freeze the gear-wheel and measure the stagger between the inner collar and outer collar of the bearing. Fit the bearing with the ball filler hole facing the adjusting washer “IV”. Fit the next bearing correspondingly. Punch the inner collar when fitting it to secure that the two inner collars touch each other.
S9 21. Calculate the “T” measure. The “S” measure is stamped on the gear-wheel whereas the “R” measure has to measure. “T” measure = “S” measure minus “R” measure. 22. The intermediate washer ”VIIIB” should be: the sum of “T” measure and “Q” measure minus the difference of “U” measure and “O” measure. 23.
S10 009W2329-R01
S11 009W2329-R01
S12 009W2329-R01
S13 009W2329-R01
T1 SECTION T IRREGULAR OPERATION, CAUSES AND REMEDIES 009W2329.
T2 CONTENTS Engine does not start ................................................................ page T 3 The engine starts, but stops soon after ..................................... page T 3 The engine does not reach maximum output ............................ page T 3 Knocking operation of engine .................................................... page T 3 Engine speed too high ............................................................... page T 3 The engine knocks .................................
T3 1.
V1 SECTION V MAINTENANCE 009W2329-R01
V2 CONTENTS Recommended maintenance and check list ..............................
V3 RECOMMENDED MAINTENANCE AND A CHECK LIST FOR BUKH ENGINES CHECK RECTIFY IF NEEDED W E E K L Y M O N T H L Y Y E A R L Y EVERY 5 YEARS 1. 1.1 Tightness of connections through hull: stern tube hull connection change sealing 2. 2.1 a 2.1.b 2.2.a 2.2.b 2.3 Check of lubricating oil: engine engine gearbox gearbox lubricating oil filter change oil check oil level change oil check oil level change - system to be full check for minus 25°C.
