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Bukh 427 Service Manual

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Service Manual
Service Manual
S
Aabenraavej 13 - 17, DK 6340 Kruså - Denmark
Aabenraavej 13 - 17, DK 6340 Kruså - Denmark
Tel: +45 74 62 20 88
Tel: +45 74 62 20 88
i
M
Type 427
Type 427
T
yp
427
Fax: +45 74 62 74 07
Fax: +45 74 62 74 07
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E mail: bukh@bukh.dk
E-mail: bukh@bukh.dk

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Summary of Contents for Bukh 427

  • Page 1 Service Manual Service Manual Type 427 Type 427 Aabenraavej 13 - 17, DK 6340 Kruså - Denmark Aabenraavej 13 - 17, DK 6340 Kruså - Denmark Tel: +45 74 62 20 88 Tel: +45 74 62 20 88 Fax: +45 74 62 74 07 Fax: +45 74 62 74 07 E-mail: bukh@bukh.dk...

  • Page 2: Cylinder Cover

    INDEX FOR TYPE 427 C-F OPERATION AND MAINTENANCE OF ENGINE 7 - 94 Directions for use of Callesen Diesel 7 - 95 Maintenance of Callesen Diesel 7 - 16 Things to remember when engine is inspected 4 - 68 Technical data of Callesen Diesel...
  • Page 3 9 - 77 Alarm device MISCELLANEOUS 7 - 113 Checking the adjustment of the fuel pumps 7 - 75 Adjusting the revolutions of type 427 C-E 4 - 90 Woodward governor 7 - 120 Hydraulic mounting of hubs 9 - 31...
  • Page 4 FIRST START AND TRIAL RUN When the engine has been installed and everything has been properly checked, the engine is ready for trial run. Before the engine is started for the first time, proceed as follows: Oil level Check the existing quantity of lubricating oil; the oil level should be seen on the oil gauge (or dip stick) on the side of the oil container, which is cast together with the starboard side of the crankcase (below the exhaust pipe).
  • Page 5 In case the unions in the top of the fuel pumps have been loosened, these should not be retightened too hard as the pumps may hereby be deformed, with the result that the regulating rods will go too tight and the engine will not regulate very well. Open the decompression cocks on the cylinder heads and turn the engine to top dead centre 1 (foremost cylinder);...
  • Page 6 The alarm device should be connected to generator (not to the batteries with handswitch) by a contact relay which will cause only a faint current to pass through the contacts of the pressure control and the thermostat, as otherwise the contacts here would soon be destroyed. If the alarm device is giving signal the engine must of course be stopped immediately and the fault must be found and corrected.
  • Page 7 Never alter the blocking of the governor and the toothed rods of the fuel pumps. In case the lead seals are broken, the factory's guarantee will cease to be valid. The adjustment has been made so by the factory that the output of the engine can be about 5% above normal full load. When the engine is working at full load, and the governor rod is free, as described above, the ex- haust should be nearly smokeless.
  • Page 8 outboard does not exceed a temperature of about 30-40ºC (under tropical conditions a little higher, which is about 25ºC above the inlet water temperature). During the first trial run, the sterntube must be lubricated sufficiently (apply a not too heavy "sterntube grease", better too thin than too thick), and the stuffing box frequently checked for heating;...
  • Page 9 the cooling water temperature. As described above, it must be about 65-70ºC. If this level is exceeded, the alarm device will give a warning. The oil pressure can be checked in the wheelhouse where manometers for lubricating oil and clutch oil pressure are fitted.
  • Page 10 As mentioned before, the engine has been adjusted by the factory to be able to yield about 5% above the stated output. This overloading possibility is intended as a reserve for a few very special occasions, and it is not wise to make use of it under normal conditions! It is therefore recommended never to load the engine plant more than always to leave about 1-2 mm free before the toothed rods of the fuel pumps are fully against the blocking piece of the governor.
  • Page 11 Normally, the valves should not be interfered with until they are no longer completely tight. Usually, this can be heard in the exhaust when the engine is idling, or when starting difficulties appear. Turn the pistons against top with closed compression cocks. If the valves can be heard blowing in the exhaust or suction channels, they need grinding.
  • Page 12 The fuel filters should be cleaned at suitable intervals, about every six months or when necessary, and when the inserts are too poor they should be replaced. A set of filters should always be kept in reserve. This is very important as poor filters may damage pumps and injectors. Normally, the injectors are checked once a year (provided that the engine is running satisfactorily) and the pressure adjusted at the same time.
  • Page 13 1. That there is no fuel supply, either because the fuel tank is empty, the fuel filter clogged, or the overflow valve not in order; when the outlet pipe on the filter has been removed it should be possible to pump the oil through in full jet by means of the feed pump. There may be air in the fuel feed pipes.
  • Page 14 Too low charging pressure. Filter for turbocharger or the turbocharger itself should perhaps be cleaned. The fuel pumps are not equally adjusted (see adjustment under "Idling"), or they might be worn. The delivery valve spring of the fuel pump may be broken. Leaky valves.
  • Page 15 OIL LUBRICATED STERNTUBE WITH "SUBLIME" PACKING GLANDS Same oil as engine. GREASE FOR AUTOMATIC GREASE GUN (DE LIMON) As stated below. THE FOLLOWING OILS CAN BE USED FOR CALLESEN MARINE DIESEL ENGINES 4-STROKE, TYPES 422, 425 AND 427 MAKE ENGINE/OIL LUBRICATED CLUTCH STERNTUBE...
  • Page 16 MAINTENANCE OF CALLESEN DIESEL ENGINES Before start Check oil level in engine, turbocharger and clutch as well as water level in freshwater tank. Open the seawater and fuel valves. Pump pressure on the lubricating oil system by means of the hand pump. Turn the engine 1 turn - if necessary, in starting position.
  • Page 17 Check (and exchange, if necessary) all corrosion anodes. If corroded away, the anodes must be checked and exchanged at shorter intervals. Empty the starting air bottles of water. Clean the fuel filters at the front of the engine at suitable intervals. Exchange the inserts if they are in a poor state.
  • Page 18 TO BE REMEMBERED WHEN ENGINE IS INSPECTED Cylinder Covers and Cover Fittings If the covers have been dismounted, it must always be checked whether they are leaking. Press the fuel pumps to the bottom when engine is idling; if there are any leakages, a whistling sound will be heard which is caused by the explosions going through the copper packings.
  • Page 19 Water Pumps Check the valves of the cooling and bilge pump (see mounting instructions 7-62). Circulation Pump Check the circulation pump. On the lower side of the bracket are two holes. One of them is con- nected to the shaft packing ring which is blocking the engine oil, and the other is connected to the carbon ring packing gland which is blocking the water.
  • Page 20 TECHNICAL DETAILS FOR CALLESEN DIESEL TYPE 427 AND 427 T Engine type Lubricating oil filling liter Hydraulic oil filling liter Freshwater filling liter Capacity: Lubricating oil pump m³/h Return oil pump m³/h 2.45 2.45 4.25 4.25 Clutch oil pump m³/h 2 x 3.5...
  • Page 21 OPERATION OF RELIEF VALVE FOR LUBRICATION OF PULL ROD AND PROPELLER HEAD After having stopped the engine, pump grease in with closed cock until resistance is felt. To increase the flow of the grease you might oprerate the reversal to ahead and astern pumping. The grease must draw out into the propeller head and the cock should be kept closed for about 20 minutes.
  • Page 22 DESCRIPTION OF "SUBLIME" STERNTUBE SEALING AFT SEALING The aft sealing consists of: an inner casing (9 and 14) with chromium steel bush (5) an outer casing (1 and 13) Inner casing The inner casing consists of two rings (9 and 14) which are exactly centered to each other. The bronze ring (9) is supplied with 3 rubber sealing rings.
  • Page 23 7-93-2A Callesen Diesel Page 2 af 6 Sheet No.
  • Page 24 FORWARD SEALING The forward sealing has the same construction as the aft sealing, however, instead of the rubber sleeve, simple sealing rings are used as it is known from experience that the front end bearing is never worn worth mentioning. The forward sealing consists of a casing (1).
  • Page 25 7-93-2A Callesen Diesel Page 4 af 6 Sheet No.

  • Page 26: Mounting Instructions

    MOUNTING INSTRUCTIONS Mounting of the seals takes place as a whole unit. The seals are built together in the work shop and the bushes mounted. All you have to do at dock or slip, is to push the bushes with the seals over the shaft.
  • Page 27 OPERATION INSTRUCTIONS Starting By means of a handpump the oil has to be pumped out of the tank into the sterntube and overhead tank. While filling the sterntube the air escape valve (10) of the aft sealing has to be open. The sterntube is fully filled if the oil in the overhead tank and the gauge glass does not drop but flows back through the overflow pipe to the tank.
  • Page 28 DISMANTLING AND ASSEMBLING OF PROPELLER BLADES AND HEAD Before stopping the engine, set the propeller pitch at zero position. When dismounting the propeller head cover, take care that the joint surface is not damaged. When the joint bolts have been unscrewed, the cover can be loosened by turning the blades. When the cover has been removed, the blades can be taken out by turning them around the sliding journal.
  • Page 30 3. In case of fastening by means of a torque wrench, the direction indicated under item 1 should also be observed. Torque: Type 427 = 300 kpm. – Type 425 = 255 kpm. 4. In case of hydraulic fastening the manometer should indicate a pressure of approx. 250 Bar (Type 427) and approx.
  • Page 31 Please observe: when grinding valves you must only grind one way. The valve should be lifted at return. Having finished the grinding and having cleaned the valve carefully, MOLYKOTE should be applied to the valve shaft before mounting. 427 TK-G Inlet valve 20700 16700...
  • Page 32 DRAWING OF NOZZLE HOLDER First you have to remove the cap nut on the nozzle holder. Thereafter the drawing tool (16978) for the nozzle holder should be mounted as shown on the drawing and by means of the drawing tool you can draw the nozzle holder.
  • Page 33 GRINDING OF CYLINDER COVER The cylinder head is placed with the bottom upwards. The seal face of the cylinder head is lubricated with carborundum. The grinding ring is placed as illustrated on the drawing. The ring is turned backwards and forwards while at suitable intervals the ring is moved ¼...
  • Page 34 1160 1000 Suction opens before top (15 mm Exhaust closes after top element) Fuel pump with drip pipe Valve 427 T Suction opens before top clear- (17 mm Exhaust closes after top ance element) Fuel pump with drip pipe at cam Suction opens before top 0.45...
  • Page 35 DISMOUNTING OF CRANK BEARING AND MOUNTING OF PISTON SUPPORT The crank covers are dismounted. The slotted nut on the operating side is to be loosened while the slotted nut on the opposite side is dismounted. The crank should be turned to top for the cylinder in question. The remaining slotted nut is removed and the base of the bearing is lowered down into the oil pan.
  • Page 36 The lifting tool is fastened to the piston - see drawing (on recent engines type 427, use an M 12 eye bolt). The crank covers are dismounted. The forelocks in the connecting rod studs are removed and the slotted nuts are loosened.
  • Page 37 REPAIR OF GROOVES FOR PISTON RINGS 1) Compression ring (chromium plated) 2) Compression ring 3) Compression ring 4) Oil control ring (chamfer facing upwards) 5) Oil control ring (chamfer facing downwards) Acceptable wear of grooves for compression rings: 6 + 0,4 mm + 0.16 + 0.16 Oversize for chromium ring:...
  • Page 38 Distance from piston to cylinder head: 2.2 - 2.4 mm. Distance from upper edge of liner to piston: 1.8 - 2.0 mm (applies to type 427 only - see also 7-45). Mounting of piston: See 7-14 and 7-14a.
  • Page 40 OPERATION AND MAINTENANCE OF FRESHWATER AND OIL COOLER Structure The cooler is made up of two parts - an oil cooler and a freshwater cooler. As shown on the sketch, (sheet No. 7-11) the seawater is led through the pipes in the cooling element. The freshwater is led around the pipes in the cooling element.
  • Page 42 REPAIR OF CIRCULATION PUMP Dismounting The rotor is dismounted by means of the puller (16986) as shown on the drawing. The keyway in the rotor should be in top position during the pulling; otherwise the disc key could fall down into the spiral case. For dismounting of gearwheel (18561), apply puller (16986) as well.
  • Page 43 DISMOUNTING OF BALL VALVE IN THE PISTON WATER PUMP Dismounting Remove air vessel (17503-1) Distance piece (17509) is set free by putting a wrench over the ribs and turning it round. The distance piece can then be removed. The valve tappets (17525) and the ø 60 rubber ball are removed.
  • Page 44 120 litres 422 - 425 D approx 155 litres 422 CT approx 145 litres 422 DT approx 180 litres 427 B-BT approx 170 litres 427 C-CT approx 230 litres 427 D-DT approx 290 litres 427 E-ET approx 350 litres...
  • Page 45 FROST PROTECTION OF CALLESEN DIESEL ENGINES Data for ESSO and BP anti-freeeze mixture • The anti-freeze mixture is an etylenglykol product mixed with special additives which can prevent the cooling water from freezing and reduce rust, corrosion and foam formation in the cooling system.
  • Page 46 ADJUSTMENT OF TOOTH CLEARANCE FOR CIRCULATION PUMP TYPE 427 E-F The bearing housing (15504) can rotate and is provided with an eccentric recess for guiding of the pump. Adjustment of tooth clearance The four unbraco screws 3/8 x 1½" are tightened loosely so that the bearing housing (15504) can be turned on the bracket (15503) by hand.
  • Page 56 REPAIR OF STARTING AIR DISTRIBUTOR TYPE 427 H (RUNNING CLOCKWISE) For maintenance of the starting air distributor, the cover (16155) has to be dismounted and the disc valve (17132) to be lubricated on the sealing face. Mounting of new disc valve or journal On the sketch the position of the disc valve is shown with cylinder 7 in start position.
  • Page 57 REPAIR OF STARTING AIR DISTRIBUTOR TYPE 427 H (RUNNING ANTI-CLOCKWISE) For maintenance of the starting air distributor, the cover (16155) has to be dismounted and the disc valve (17132) to be lubricated on the sealing face. Mounting of new disc valve or journal On the sketch the position of the disc valve is shown with cylinder 1 in start position.
  • Page 58 DESCRIPTION OF CHARGING VALVE For charging of the starting air receivers there is usually placed a charging valve on each engine. Mode of operation The valve is opened by turning the handle (16728) 3/8 turn to the left. Thereby the spindle (16716) is lifted so that the ball can move up and down, and at the same time the air supply upwards is closed as the upper breast of the spindle is pressed up...
  • Page 59 OPERATING INSTRUCTIONS FOR DELIMON GREASE LUBRICATING PUMP The Delimon grease lubricating pump type FZ-A is a single plunger pump with 8 outlets. The pump is driven by means of an oscillating lever via an intermediate driver, whereby the transmission between the drive shaft and the pumps will be 50:1.
  • Page 60 Pump body The pump body contains a control sleeve (14) to guide the plunger and for each outlet an adjustable spindle (27) to preset the stroke of the plunger and consequently the quantity delivered. The allowable number of revolutions of the feed piston is max 6 rpm when it is oscillatting lever driven. Driving power The piston water pump of the main engine is provided with a rocking lever which actuates the oscillating lever (39).
  • Page 61 By changing the drive speed or the internal transmission ratio of the pump, or by changing the angle of the oscillating lever, the quantity by each outlet - and consequently the total quantity - can be varied. 4. MAINTENANCE Filling the grease reservoir As soon as about three quarters of the contents of the reservoir have been used up, the reservoir should be refilled.
  • Page 62 7-102-2A Callesen Diesel Page 4 of 4 Sheet No.
  • Page 63 ANBEFALEDE SMØREMIDLER FOR DELIMON FEDTSMØREPUMPE TYPE FZ RECOMMENDED LUBRICANTS FOR DELIMON GREASE LUBRICATION PUMP TYPE FZ EMPFEHLENSWERTE SCHMIERMITTEL FÜR DELIMON FETTSCHMIERPUMPE TYP FZ FABRIKAT / FEDTTYPE / GREASE TYPE / BASE PENETRATION MAKE FETT TYP NLGI/ASTM Energrease LS2 Lithium 265 - 295 CASTROL Spheerol AP3 Lithium...
  • Page 64 LUBRICATING OIL DIAGRAMME TYPE 427 C - D E - F Forward pump - capacity m³/h Return oil pump - capacity m³/h 2.45 4.25 Hand pump - capacity m³/h Normal drive Usually, the engine has dry sump, and the 3 three-way cocks A, B and C must be in the positions shown in the diagramme.
  • Page 65 OIL LUBRICATED STERNTUBE WITH "SUBLIME" PACKING GLANDS: Same oil as the engine. GREASE FOR AUTOMATIC GREASE GUN (DE LIMON): As stated below. THE FOLLOWING OILS CAN BE USED FOR CALLESEN MARINE DIESEL ENGINES (4-STROKE) TYPES 422, 425 AND 427: MAKE ENGINE AND CLUTCH OIL LUBRICATED STERNTUBE...
  • Page 66 REPLACING WORN OUT CATCH BOLTS IN CLUTCH If the catch bolts (1) and the holes, respectively, are worn out to such an extent that the oil leakage is becoming to large, the bolts have to be replaced by new oversize bolts. The following procedure must be used: Cover (2), reversing cylinder (5) and clutch shaft (4) are bolted together by means of the studs (3), and the clutch cones (6) and (7) are unbolted by means of the blocking bolts (8) after having...
  • Page 67 BLOCKING INSTRUCTIONS FOR CLUTCH AND REVERSAL In case of failure of the oil pressure system in the clutch and reversal, the clutch as well as the reversal can be blocked as an emergency arrangement. The 6 blocking screws are to be mounted as shown on the drawing and must be tightened simultaneously to avoid jam-...
  • Page 68 TWO-STEP OVERFLOW VALVE Mode of Operation The valve is a two-step overflow valve. It is functioning by means of the pressure available in the hydraulic system which rises when the oil is fed into the cylinder head. This is done during the reversing manoeuvre.
  • Page 69 9-068-2A Callesen Diesel Page 1 of 1 Sheet No.
  • Page 70 9-172-2A Callesen Diesel Page 1 of 1 Sheet No.
  • Page 71 9-169-2A Callesen Diesel Page 1 of 1 Sheet No.
  • Page 72 9-168-2A Callesen Diesel Page 1 of 1 Sheet No.
  • Page 73 Alarm device 9-077-2A Callesen Diesel Page 1 of 1 Sheet No.
  • Page 74 CHECKING THE ADJUSTMENT OF THE FUEL PUMPS 1. Dismount the Bosch pumps and the pump lever guide (18101) with lever (17190). Check the Ona bearing 3264-1; It must be absolutely without backlash. At the same time, check the cam face while the engine is turned.
  • Page 75 ADJUSTMENT OF REVOLUTIONS FOR TYPE 427 C-E See fig. 8 page 11 in the spareparts manual showing a sectional drawing of the hydraulic governor. The engine is adjusted to run 225 r.p.m. at idle speed by means of the ¼" x 75 mm screw which pushes against the end of the piston (17115).
  • Page 76 WOODWARD GOVERNOR Description The Woodward UG8L governor is a mechanical-hydraulic governor for controlling diesel engines. The governor is mechanically linked through a damper to the fuel racks. The maximum work output of the governor is 1.1 kpm over the full 42° travel of its output shaft; however, recommended travel of the output shaft is 30°.
  • Page 77 Mounting instructions Make sure the governor drift shaft rotates freely before installing the governor. Mount and fasten the governor squarely on its mounting pad on top of the gearbox, taking care that the connection between the governor and the prime mover drive is in order. It is most important to make sure that there is no binding, excessive side loading of the drive shaft or looseness in the coupling.
  • Page 78 1. Loosen the nut holding the compensation adjusting pointer enough to set the pointer at its extreme upward position for maximum compensation. 2. Remove the plug and open the compensating needle valve 3 to 5 turns anti-clockwise with a screw driver. Be sure that the screw driver fits into the shallow slot of the compensating needle valve - not into the deep slot - located at right angles to the shallow screw driver slot.
  • Page 79 HYDRAULIC MOUNTING OF HUBS In principle the method is as follows: At a very high oil pressure, approx 3000 atm, the hub is expanded so that the hub can be drawn up on a conical shaft with a slim cone (1:50) by a small axial pull .
  • Page 80 FUEL OIL SYSTEM TYPE 427 C-F 9-31-2A Callesen Diesel Page 1 af 1 Sheet No.

This manual is also suitable for:

427 t