Bukh DV36, DV48 Workshop Manual

Name: Bukh DV36
Brand: Bukh
SKU: 1968134
Rating: 4.3 (6 reviews)

4.3 (6)

				Publ. No.
				009W2329
		Aabenraavej 13-17, DK - 6340 Krusaa, Denmark		009W2329
		Tel: +45 74 62 20 88
		Fax +45 74 62 74 07
		E-mail: bukh@bukh.dk – Internet: www.bukh.dk

Work shop Manual

for

BUKH diesel engine

TYPE DV36/48

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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

Section T … Irregularities in operation - causes and remedies

Section V … Maintenance

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SECTION A

INTRODUCTION AND TECHNICAL DATA

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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.........................................................	page A 7
Results of Measurement............................................................	page A 8
Longitudinal Section of DV36 ....................................................	page A 9
Cross Section of DV36 ..............................................................	page A 10
Diagram of the Relation between the Total Weight,
Speed and Horse Power of the Boat .........................................	page A 11

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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.

The technical structure of the engine with components and systems appears from the individual sections of this workshop manual and therefore this introduction contains no descriptions of this.

DV36 is designed with small installation dimensions compared to corresponding engine outputs on the market. This applies to both height, length and width. At the same time the weight of the engine is comparatively low and the proportion weight/horse power is in fact only

7.36 compared to corresponding engine outputs on the market with a corresponding factor of

8.28 and 8.48.

Being a 3-cylinder engine, DV36 is a naturally low level of vibration compared to 1- and 2- cylinder engines, but in order to obtain a further improvement of the vibration level, the rotating weight system has been continued on DV36 as it is known with great success from DV10 and DV20. DV36 with the anti-vibration system is thus free from unpleasant vibrations and may correctly be described as the less vibrating engine on the market.

DV36 is supplied either with sail-drive (type DV36SME) or with BW7 gear (type DV36ME). The type description S = saildrive, M = marine gear and E = with electric start.

The temperature of the exhaust gas is for DV36 max. 550°C, which is about 100°C below corresponding engine outputs on the market.

DV36 is delivered as standard with direct seawater cooling but may be alternatively be delivered with heat exchanger built integral with water cooled exhaust, keel cooler or radiator cooler.

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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.…. ............at 2400 rpm………..……… ..		29.8 BHP - 21.9 kW
ACCORDING TO ISO 3046……. ..................at 3000 rpm…………………..34.5 BHP – 25.4 kW
	..............at 3600 rpm…………………. 36.0 BHP - 26.5 kW
OUTPUT, INTERMITENT RATING BHP.......at 4000 rpm.........................		39.3 BHP – 28.9 kW
MAX. TORQUE Kp*m............. ......................	at 1800 rpm..........................	9.2 Kpm – 90 Nm
MAX. AIR CONSUMPTION .... ................................	...................................	2214 Litres/min.
ENGINE ROTATING, LOOKING AT FLYWHEEL .. ...................................		CLOCWISE
IDLING SPEED....................... ................................	...................................	800 – 1000 RPM
MAX INCLINATION, FORE AND AFT..................... ...................................		15o
HEEL, MAX. CONTINOUS ..... ................................	...................................	30o
NET WEIGHT INCL. ZF MARINEGEAR ................. ...................................		265 Kg
NET WEIGHT INCL. SAILDRIVE ............................	...................................	290 Kg
LOCATION OF ENGINE SERIAL NUMBER ........... ...................................		ON CRANKCASE NEAR FUEL THE PUMP
EXHAUST TEMP. MAX / NORMAL......................... ...................................		600oC – 580oC
VALVE TIMING AND INJECTION POINT
FLYWHEEL DIAMETER......... ................................	...................................	370 mm
INLET VALVE OPENS ..................	BEFORE TDC . ...................................	32o (arc measure: 103 mm)
INLET VALVE CLOSES ...............	AFTER BDC .... ...................................	64o (arc measure: 207 mm)
EXHAUST VALVE OPENS............	BEFORE BDC . ...................................	64o (arc measure: 207 mm)
EXHAUST VALVE CLOSES .........	AFTER TDC .... ...................................	32o (arc measure: 103 mm)
INJECTION STARTS………..........	BEFORE TDC……………………….....	6.2o (arc measure: 20 mm)
VALVE CLEARANCES (COLD ENGINE) INLET/EXHAUST ......................		0.30 mm
FUEL SYSTEM ...................... ................................	...................................	DIRECT INJECTION
INJECTOR OPENING PRESSURE ........................ ...................................		210 Bar
INJECTION TIMING .............. ................................	...................................	AUTOMATIC VARIABLE
FUEL LIFT PUMP................... ................................	...................................	CAM SHAFT DRIVEN DIAPHRAGM PUMP
STATIC PRESSURE OF FUEL LIFT PUMP ........... ...................................		153 - 285 mBar
FUEL FILTER ......................... ................................	...................................	THROW AWAY FILTER INSERT
FUEL QUALITY GAS OIL....... ................................	...................................	BS 2869 CLASS A
LUBRICATING SYSTEM
TYPE OF LUBRICATING OIL PUMP...................... ...................................		ROTARY VANE PUMP
LUBRICATING OIL PRESSURE: WARM ENGINE / MINIMUM .................		2-4.5 Bar / 1 Bar
LUBRICATING OIL QUALITY ................................	BELOW +5oC ...................................	SERVICE CC or CD
LUBRICATING OIL VISCOSITY....	BELOW +5oC ...................................	SAE 10 or SAE 10W-30
	BETWEEN +5oc and +25oC ................	SAE 20 or SAE 15W-40
	ABOVE +25oC . ...................................	SAE 30 or SAE 15W-40
LUBRICATING OIL CONTENT INCL. FILTER........ ...................................		4.9 Litres
LUBRICATING OIL FILTER .. ................................	...................................	THROW AWAY FILTER INSERT
ZF BW7 MARINEGEAR
LUBRICATING OIL QUALITY ................................	...................................	API CC or CD, MILL-L-46152
LUBRICATING OIL VISCOSITY..............................	...................................	SAE 30 or SAE 15W-40
LUBRICATING OIL TEMPERATURE...................... ...................................		MAX. 120oC
LUBRICATING OIL CONTENT ...............................	...................................	1.1 Litres
NEWAGE PRM120 MARINEGEAR
LUBRICATING OIL QUALITY ................................	...................................	Automatic Transmission Fluid (ATF)
LUBRICATING OIL TEMPERATURE...................... ...................................		MAX. 120oC
LUBRICATING OIL CONTENT ...............................	...................................	0.8 Litres

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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 ................ ...................................	OUTBOARD GEAR OIL
COOLING WATER SYSTEM – DIRECT SEAWATER COOLING	50 – 65oC
COOLING WATER TEMPERATURE...................... ...................................	50 – 65oC
TYPE OF CIRCULATING PUMP / CAPACITY AT 3600 rpm .....................	CENTRIFUGAL / 24-30 Litres/min
CAM HEIGHT ......................... ................................ ...................................	2.0 mm
MAX. PUMP COUNTER PRESSURE..................... ...................................	0.6 Bar
MAX. PUMP SUCTION PRESSURE....................... ...................................	0.3 Bar
COOLING WATER SYSTEM – INDIRECT COOLING WITH FRESHWATER
COOLING WATER TEMPERATURE...................... ...................................	70 – 95oC
TYPE OF FRESHWATER PUMP / CAPACITY AT 3600 rpm.....................	CENTRIFUGAL / 135 Litres/min
PUMP PRESSURE................. ................................ ...................................	1.1 Bar
TYPE OF SEAWTAER PUMP / CAPACITY AT 3600 rpm..........................	CENTRIFUGAL / 36-42 Litres/min
CAM HEIGHT ......................... ................................ ...................................	3.1 mm
MAX. PUMP COUNTER PRESSURE..................... ...................................	0.6 Bar
MAX. PUMP SUCTION PRESSURE....................... ...................................	0.3 Bar
ELECTRICAL SYSTEM
BATTERY VOLTAGE / CAPACITY ............................................................	12 VOLT / 88 Ah
STARTER TYPE / OUTPUT .......................................................................	GEAR DRIVEN / 1.0 KW
ALTERNATOR TYPE/ OUTPUT ................................................................	BELT DRIVEN / 700 W
ENGINE STOP ...........................................................................................	SOLONOID / MANUAL
RELAY ........................................................................................................	ELECTRONIC, BUILT ON
TORQUES
CYLINDER HEAD BOLTS/BEARING TOP SECTION................................	118 +/- 5 Nm (12 +/- 0.5 Kpm)
CONNECTING ROD BOLTS . ....................................................................	69 +/- 3 Nm (7 +/- 0.3 Kpm)
FLYWHEEL/COUNTERWEIGHTS... ..........................................................	147 +/- 7 Nm (15 +/- 0.7 Kpm)
FLEX. COUPLING .................. ....................................................................	61 +/- 3 Nm (6.3 +/- 0.3 Kpm)
ASSEMBLY OF FUEL VALVE ....................................................................	59 +/- 3 Nm (6.0 +/- 0.3 Kpm)
BRACKET FOR ENGINE SUPPORTS .......................................................	69 +/- 3 Nm (7 +/- 0.3 Kpm)
GEARBOX .............................. ....................................................................	25 +/- 5 Nm (2.5 +/- 0.5 Kpm)

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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.

In the daily service work, some of the parts must be replaced after the number of hours stated in the owner´s manual and in this book, and therefore we have made the following table:

610J0200	Lubricating oil filter
610D0201	Fuel filter
020D4326	Air filter
000E0450	Sacrificial zinc anode
610G0506	Impeller
542A0602	V-belt 10*1035 (seawater cooling)
542A0609	V-belt 10*1100 (freshwater cooling)

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Results of Measurement

The below curves indicate results of measurements at 762 mm Hg and a room temperature of 26 °C.

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Longitudinal Section of DV36

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A10

Cross Section of DV36

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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.

Draw a straight line between this point (the intersection) and the fixed point in the bottom left corner.

Where the line of the desired speed crosses the straight line, you can read the required horse power vertically below.

If you know three of the specifications, you can by means of these schemes find the fourth one.

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SECTION B

LIST OF TOOLS

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CONTENTS

Tools for repairs on DV36..........................................................	page B 3
Dimensions of mounting punches .............................................	page B 6

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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.

Slip-on ring for mounting of	Section IJ
pistons

Puller for cylinder liner	Section IJ	009P2235

Punch for rear seal ring	Section G	009P3177

Punch for front seal ring	Section E	009P3178

Punch for mounting of	Section M and L	009P3179
camshaft bearing in block

Punch for journal for	Section G	009P3180
intermediate wheel

Punch for journal for front and	Section E and G	009P3181
rear rotating weight

Punch for mounting of valve	Section C	009P3175
guide

Punch for mounting of inlet	Section C	009P3173
valve seat

Punch for mounting of exhaust	Section C	009P3174
valve seat

Punch for mounting of expan-	Section C	009P3176
sion discs in the cylinder head

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Designation of tools

Fields of application

Spare part No.

36 mm socket spanner

19 mm socket spanner for	Section C
fastening of cylinder head

19 mm crowfoot wrench for	Section C	009P3225
tightening up of cyl. head

10 mm Allen top for faste-ning of	Section L
bearing top section

5 mm Allen key	-

6 mm Allen key	-

7 mm Allen key	-

Open-end spanner/ring spanner,	-
8/10/12/13/14/15/17/19/22/24/27
30 and 32 mm

Dismantling tool for valve	Section C	009P3115
springs

Tachometer	Generally	009P3106

Testing set for fuel nozzles	Section H	009P3100

Cleaning for fuel nozzles	Section H	009P3101

Bosch dial indicator for	Section H
adjustment of fuel pump

Bosch dial indicator “holder with	Section H	529W0002
extension” for adjustment of the
fuel pump (KDEP1085)

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Designation of tools	Fields of application	Spare part No.

Flanging tools for nozzle holder	Section C	009P2565
insert

Torque wrench	Generally	009P3108
(Stahlwille 73/6 1.5-6.5)

Torque wrench	Generally Section C, D,	009P3109
(Stahlwille 73/25 8-26)	IJ and L

Circlip tongs (external)	-
A1, 10-28 mm

Circlip tongs (internal)	-
J2, 19-75 mm

Puller for gear wheel	Generally
(Kukko 20/10)

Puller for flexible coupling	Section R	T 41069

Compression gauge	Section C	529W0000

Adapter for compression gauge	Section C	009P3123

Part of the mentioned special tools can be manufactured without too much trouble at the dealer´s workshopin periods outside the boat season. Therefore we have made sketches at page B6 of each individual mounting punch with dimensions.

Slip-on ring for mounting of pistons is not illustrated but is manufactured of a worn out cylinder liner or another piece of work pipe. Cut the cylinder liner so that you get a piece being about 100 mm high, the turn it conical inside the liner or pipe.

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SECTION C

CYLINDER HEAD

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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 .........................................	page C 7
Removal of fuel valves .............................................................	page C 8
Nozzle holder insert ..................................................................	page C 9
Fitting measures for fuel nozzle insert ......................................	page C 10
Valve springs.............................................................................	page C 11
Replacement of valve guides ....................................................	page C 12
Pressing-in dimensions for valve guide .....................................	page C 13
Valve guide stuffing box ............................................................	page C 14
Repair or replacement of inlet and exhaust valves....................	page C 15
Exhaust valve ............................................................................	page C 16
Inlet valve ..................................................................................	page C 17
Grinding of valves......................................................................	p age C 18
Measures for new valves...........................................................	p age C 18
Replacement of valve seats .....................................................	page C 19
Cylinder head gasket ................................................................	page C 20
Air inlet manifold arrangement...................................................	page C 21
Exhaust manifold arrangement..................................................	page C 22

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Exploded view of cylinder head

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Valve adjustment

The clearance of the inlet and exhaust valves should be adjusted at 0.3 mm when 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 adjusted 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.

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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). Tighten in the order shown on the skeleton diagram below.

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Replacement of rocker arm or rocker shaft

For each cylinder, a rocker arm column wit htwo 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.Then the rocker arms and the intermediate springs can be taken out.

Reassembly is a reversal of the dismantling procedure.

Adjustment of valve lifter arrangement

Furthermore, a common shaft for decompression is fitted on the three rocker arm columns.

For a possible removal of the shaft, remove first the pins going down on the rocker arms at decompression, after which the shaft can be pulled out.

When adjusting, adjust the pins so that you faintly see a single groove of the pin thread (about 1.5 mm free pin) just on the side facing the rocker arms.

When fitting the top cover, ensure that the slot in the decompression handle in the top cover mesh with the corresponding pin on the decompression shaft.

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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.After refitting the rocker arm, check the axial play with a feeler gauge. The axial play may be 0.1 – 0.2 mm.

6.Finish refitting the rocker arm arrangement.

drwg. No. 008E4893

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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.

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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 inserts can be replace d, whic demands that the special tools below for flanging (piston and backstop) are used and that the surfaces are treated as indicated on the drawing.

Remove the old nozz le holder inserts by boring-up the flanged endof the nozzle holder inserts with a ø8 – ø9 mm drill, and then k nockout the nozzle h older inserts with a 10 mm punch.

After having fitted the new nozz le holder inserts, test the cylinder head for pressure with water in order to check the flanged seals.

drwg. No. 008E4881

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C10

Fitting measurements for the fuel nozzle into insert.

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Bukh DV36, DV48 Workshop Manual

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