BUKH DV10 WORKSHOP MANUAL Pdf Download

4
Contents
5
List of Tools for DV Engines
7
Installation Tools
7
Service Tools
8
Installation Dummy for DV10 and DV20 With BW6 Gear
9
Installation Dummy for DV10 and DV20 With BW7 Gear
10
Repair Tools
17
General Description and Technical Data
19
Cylinder Head
19
Crankcase
20
Crankshaft
20
Flywheel
20
Connecting Rod
21
Piston and Cylinder Liner
21
Camshaft
21
Lubricating Oil System
22
Cooling Water System
22
Fuel System
22
Two-Stage Combustion
22
Vibration Damping
23
Sectional Drawing of DV20SME
24
Technical Data for DV10
25
Torque, Rating, Consumption Curve for DV10
26
Technical Data for DV20
27
Torque, Rating, Consumption Curve for DV20
28
Torque in KGM (Ft.lbf)
31
Cylinder Head DV10
32
Cylinder Head DV20
33
Change of Rocker Arm or Rocker Shaft
34
Exchange of Bushing in Rocker Arm
35
Dismounting of Cylinder Head
35
Mounting of Cylinder Head
36
Valve Adjustments
37
Dismounting of Fuel Valves
37
Mounting of Fuel Valves
38
Inlet Valve - Machining Dimensions and Tolerances
39
Exhaust Valve - Mounting and Tolerances
40
Minimum Repair Measures for Inlet Valve and Exhaust Valve
41
Repair or Change of Exhaust and Inlet Valves
42
Grinding Takes Place As Follows
43
Change of Valve Guides
44
Pressing-In Measures for Valve Guides - DV 10 and DV 20
45
Changing of Valve Seats
45
Mounting of Valve Seat Rings
45
Measures for Bores for Valve Seats
46
Machining and Mounting Dimensions for Inlet and Exhaust Valve Seat
47
Cylinder Head Gasket
48
Mounting of Valve Springs
49
Adjustment of Decompression Lever
50
Vacuum Valve for DV 10 and DV 20
51
Surfacing of Cylinder Head
51
Packing Grooves
51
Precombustion Chamber
52
Compression Gauging
53
Operation Instruction
57
Dismounting of Flywheel
57
Mounting of Flywheel
58
Adjustment of V-Belt
59
Replacement of Gear Rim
61
Front End Cover
63
Dismounting of Counterweights
64
Mounting of Counterweights
65
New Marking
65
Tightening of Shafts for Counterweights
66
Arrangement of Counterweight
67
Replacement of Oil Seal Ring in Guard
68
Replacement of Front End Cover
68
Replacement of Axle Journals for Counterweights
68
Replacement of Front Main Bearing Lining
69
Raised Hand Start
71
Raised Hand Start On Front Edge
71
Checking of Chain for Raised Hand Start
72
Dismounting of Raised Hand Start On Front Edge
74
Dismounting of Raised Hand Start On Rear Edge
77
Rear End Cover
79
Dismounting of Rear End Cover
80
Removal of Rear Counterweights
80
Exchange of Bearings for Counterweights
80
Fitting of Counterweights
81
Tightening of Shafts for Rotating Weights
82
Arrangement of Rotating Weights
83
Tightening of Pipe Plugs in Rear End Cover
84
Governor System
85
Dismounting of Centrifugal Governor
86
Fitting of Centrifugal Governor
87
Dismounting of Manual Governor
88
Mounting of Manual Governor
89
Characteristic for Governor Spring
90
Adjustment of Governor System
91
Dismounting and Adjustment of Stop Button
95
The Fuel System
96
Bleeding of the Fuel System
97
Fuel Lift Pump
97
Dismounting and Mounting of the Fuel Lift Pump
98
Repair of Fuel Lift Pump Type AC-DELCO
98
Remedy of Leaks
100
Technical Data of the Fuel Lift Pump
100
Counter Pressure
100
Disassembly of Fuel Lift Pump
100
Cleaning of Suction Filter
101
Exchange Diaphragm As Follows
102
Fuel Lift Pump S.E.V. Marchal Type 70 BA
103
Fuel Filter
103
Fuel Filter Element: BOSCH No. 04500 15014
103
Exchange of Fuel Filter Element
107
Dismounting of the Fuel Pump
107
Dismantling of the Fuel Pump
109
Assembling of the Pump
110
Capacity of the Fuel Pump
111
Fuel Pump Type BRYCE
111
Disassembly of Fuel Pumps
111
Disassembly of the Roller Section
112
Disassembly of the Pressure Valve Section
113
Checking of the Control Sleeve
113
Reassembly of Fuel Pumps
113
Testing of BRYCE Fuel Pumps
117
Adjustment of Injection Timing (Spill Point)
117
Data for Injection Timing
117
Adjustment of Injection Timing
120
Fuel Valve
121
Dismounting and Dismantling of the Fuel Valve
123
Adjustment of Opening Pressure
124
Nozzle Tester
125
Operating Instructions for Bosch Nozzle Tester
125
Cleaning of Nozzles
125
Preliminary Testing
126
Testing With Nozzle Tester
127
Testing of Tightness
127
Snarl Test and Injection Angle
128
Maintenance
129
Piston, Connecting Rod, and Cylinder Liners
131
Dismounting of Pistons and Connecting Rods
132
Change of Pistons
133
Test Measurement of Piston DV10-DV20
134
Change of Piston Rings
135
Exchange of Piston Pin Bearing
136
Arrangement of Connecting Rod
137
Mounting of Pistons and Connecting Rods
137
Connecting Rod Bearings
138
Cylinder Liner
138
Measuring of Cylinder Wear
138
Dismounting of Cylinder Liner
138
Mounting of Cylinder Liner
139
Arrangement of Cylinder Linear
140
Test Equipment of Cylinder Liner
143
Fitting of Oil Dip Stick
144
Fitting of Oil Dip Stick for DV10 and DV20
145
Fitting of Inlet Connecting Piece
145
Tightening of Lubricating Oil Grooves
147
Crank Shaft, Intermediate Bearing and Rear Main Bearing Bush
149
Repair Dimensions of Crank Shaft
149
Front Main Bearing Journal
149
Rear Main Bearing Journal
149
Intermediate Bearing Journal
150
Connecting Rod Journals
150
Exchange of Crank
151
Dismounting of Crank Shaft
152
Change of Intermediate Bearing
153
Camshaft, Complete
155
Dismounting of the Camshaft
156
Change of Front Bearing Bush for Camshaft
157
Check of Camshaft
157
Valve Times
158
Injection Timer
158
Dismounting
158
Mounting
159
Check of Injection Timer
160
Arrangement of Automatic Injection Timer
161
Lubricating System
163
Excess-Pressure Valve
163
Lubricating Filter
164
Arrangement Drawing of Lubricating Oil Reduction Valve
165
Lubricating Pump - Old Type
166
Lubricating Oil Pump in Old Execution
166
Lubricating Oil Pump in New Execution
167
Lubricating Oil Pump - New Type
167
Lubricating Oil Quality
171
Direct Cooling (Seawater Cooling Water Pump)
172
Technical Data
172
Technical Data - Pump for DV20
173
Dismantling of Cooling Water Pump
174
Thermostat
176
Fitting of Double Transmitter
177
Zinc Rod
178
Indirect Cooling (Freshwater Cooling)
178
Heat Exchanger System
178
DV20 Engines
178
DV10 Engines
179
Cooling Water System for DV10 and DV20
179
Thermostat Housing
179
Header Tank
180
Keel Cooling
180
Common Components
180
Freshwater Circulating Pump
180
Dismantling of Circulating Pump
181
Expansion Cover
181
Type of Cover
181
Protection against Front
182
Arrangement of Circulating Pump
183
Arrangement of Heat Exchanger DV20
184
Arrangement of Keel Cooling DV10
185
Arrangement of Keel Cooling DV20
187
The Electrical System
189
Dynastarter
190
Supervisory Relay
191
Dimensions of Starter Cables and Technical Data for the Electrical System
194
Stop Magnet
195
Safety Regulations
195
Battery
197
Electrical System
198
Alternator
203
Maintenance Instructions for Motorola Alternator
204
Alternator Type a 14/30
204
Fault Localization
205
Checking and Testing of Alternator and Voltage Relay
206
Voltage Relay
206
Checking of Voltage Relay
207
Checking of Alternator
207
Examination of Insulating Diode Bridge
207
Exciting Circuit
209
Checking of Rectifier Diodes
210
Alternator Type 14/35 a
210
Fault Localization of Alternator
211
Voltage Relay - Type T14V
211
Checking of Rotor Windings
212
Checking of Magnetizing (Trio) Diodes
212
Check the Diode Connection
212
Checking of Trio Diodes
213
Removal of Diode Set
213
Reassembly of Alternator
214
Fitting of Voltage Regulator
214
Checking at Starting-Up
215
Change of Starter Motor Into Two-Wire Execution
216
Change of Alternator Into Two-Wire Execution
222
Wiring Diagram for Dynastarter With Instrument Panel
223
Wiring Diagram for Dynastarter With Operating Panel
224
Wiring Diagram for Dynastarter With Thermostat
225
Wiring Diagram for Dynastarter With Thermostat and Operating Panel
226
Wiring Diagram for Dynastarter
227
Wiring Diagram for Alternator
228
Diagram for Standard Electrical System
229
Diagram for Fully Developed Electrical System
233
Standard Operating Panel With Warning Lamps, Key Switch and Acoustic Alarm
235
Marine Reduction Gear ZF - BW6
247
ZF Gear - BW7
249
Gear Ratio
249
Oil Change
251
Special Tools
252
Adjusting Measures and Torques for BW7
254
General Information for Work With the Gear
254
Removal of Gear From Engine
255
Dismantling of BW7 Gear
258
Dismantling of Shifting Fork
258
Dismantling of Output Shaft
260
Dismantling of Input Shaft
260
Dismantling of Lower Gearbox Half
260
Dismantling of Upper Gearbox Half
261
Refitment of BW7 Gear
267
Measuring of Tightening of Tapered Roller Bearing On Input and Output Shafts With Measuring Gauge
269
Measuring of Tapered Roller Bearing Tightening On Input and Output Shafts Without Measuring Gauge
270
Pre-Mounting of Shifting Fork
272
Fitting of Bolts in Gearbox
272
Transmission
273
Fitting of Input and Output Shafts With Shifting Fork in Gearbox
276
Fitting of Shaft Seal Rings
277
Supplement to Fitting of Shaft Seal Rings
281
Sail Drive Type Z-7
283
Oil Change and Gear Ratio
283
Zinc Anode
283
Outside Maintenance
283
Removal of Sail Drive From Engine and Boat
285
Alarm Function of Double Membrane
287
Assembling Procedure for Sail Drive
292
Intermediate Housing and Intermediate Shaft
297
Irregularities in Operation
297
Causes and Remedies for the Engine and the Electrical System
301
The Engine Does Not Start or Is Difficult to Start
303
Engine Starts, but Stops Shortly After
303
Engine Does Not Reach Maximum Capacity
303
Knocking Operation of Engine
303
Engine Speed Too High
305
Engine Knocks
305
Engine Had Black Exhaust Smoke
305
Engine Has Bluish Exhaust Smoke
305
Excessive Lubricating Oil Consumption
307
Engine Run Hot
309
Causes to Irregularities in the Electric Starter
319
Maintenance Schedule
321
Storage

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