Bukh DV10 – DV20 Diesel Engine Service Workshop Manual

Workshop Service and Repair Manual for the Bukh DV10/DV20 diesel engine, an absolute must for any boat owner. This full workshop manual covers every component, service and repair procedure in full Bukh factory specification, fully indexed with clear step by step technical drawings for the DV10 & DV20 with torque setting values, this is the most comprehensive service manual available as used by boatyards and independent marine engineers the world over.

Chapters covered within this manual:

.General Description And Technical Data
2.Cylinder Head
3.Crankcase
4.Crankshaft
5.Flywheel
6.Connecting Rod
6.Piston And Cylinder Liner
7.Camshaft
8.Lubricating Oil System
9.Cooling Water System
10.Fuel System
11.Two-stage Combustion
12.Vibration Damping
13.Automatic Injection Timing
14.Sectional Drawing Of DV20SME
15.Technical Data For DVl0
16.Torque, Rating
17.Consumption Curve For DVl0
18.Technical Data For DV20
19.Torque, Rating
20.Consumption Curve For DV20
21.Torques In Kgm (Fl.Lbf)

List Of Tools For Dv Engines:
Installation Tools
Service Tools
Installation Dummy For Dvlo And Dv20 With Bw6 Gear
Installation Dummy For Dvlo And Dv20 With Bw7 Gear
Repair Tools

Cylinder Head:
Cylinder Head DVl0 (Drawing)
Cylinder Head DV20 (Drawing)
Change Of Rocker Arm & Rocker Shaft
Exchange Of Bushing In Rocker Arm
Dismounting Of Cylinder Head
Mounting Of Cylinder Head
Valve Adjustments
Dismounting Of Fuel Valves
Mounting Of Fuel Valves
Exhaust Valve – Machining Dimensions And Tolerances
Inlet Valve – Machining And Tolerances
Minimum Repair Measures For Inlet Valve And Exhaust Valve
Repair Or Change Of Exhaust And Inlet Valves
Grinding Takes Place As Follows Measures For New Valves
Change Of Valve Guides
Pressing-in Measures For Valve Guides Dvlo And DV20
Changing Of Valve Seats
Mounting Of Valve Seat Rings
Measures For Bores For Valve Seats
Machining And Mounting Dimensions For Inlet And Exhaust Valve Seat
Cylinder Head Gasket
Mounting Of Valve Springs
Adjustment Of Decompression Lever Vacuum Valve For Dvl0 And Dv20
Surfacing Of Cylinder Precombustion Chamber
Compression Gauging
Operating Instructions

Flywheel:
Mounting And Dismounting Of Flywheel
Adjustment Of V-belt
Replacement Of Gear Rim

Front End Cover:
Front End Cover
Dismounting Of Counterweights
Mounting Of Counterweights
Tightening Of Shafts For Counterweights
Arrangement Of Counterweight
Replacement Of Oil Seal Ring In Guard
Replacement Of Front End Cover
Replacement Of Axle Journals For Counter-weights
Replacement Of Front Main Bearing Lining

Raised Hand Start:
Raised Hand Start On Front Edge
Checking Of Chain For Raised Hand Start Dismounting Of Raised Hand Start On Front Edge
Arrangement Of Raised Hand Start On Front Edge (Drawing)
Dismounting Of Raised Hand Start On
Rear Edge
Arrangement Of Raised Hand Start On Rear Edge (Drawing)

Rear End Cover:
Dismounting Of Rear End Cover
Removal Of Rear Counterweights
Exchange Of Bearings For Counterweights.
Fitting Of Counterweights
Tightening Of Shafts For Rotating Weights
Arrangement Of Rotating Weights (Drawing)
Tightening Of Pipe Plugs In Rear End Cover
Governor System Dismounting Of Centrifugal Governor Fitting Of Centrifugal Governor Dismounting Of Manual Governor Mounting Of Manual Governor Characteristic For Governor Spring Adjustment Of Governor System
Dismounting And Adjustment Of Stop Button

Fuel System:
Bleeding Of The Fuel System
Fuel Lift Pump
Fuel Filter
Fuel Pump
Adjustment Of Injection Timing (Spill Point) …..
Fuel Valve
Nozzle Tester
Operating Instructions For Bosch Nozzle Tester
Warning

Piston, Connecting Rod, And Cylinder Liner:
Piston And Connecting Rod
Dismounting Of Pistons And Connecting Rods
Change Of Pistons
Test Measurement Of Piston DV10
DV10 Change Of Piston Rings
Exchange Of Connecting Rod
Exchange Of Piston Pin Bearing
Arrangement Of Connecting Rod (Drawing)
Mounting Of Pistons And Connecting Rods
Connecting Rod Bearings
Cylinder Liner
Measuring Of Cylinder Wear
Dismounting Of Cylinder Liner
Mounting Of Cylinder Liner
Arrangement Of Cylinder Liner (Drawing)
Test Measurement Of Cylinder Liner(Drawing)

Crankcase:
Fitting Of Oil Dip Stick
Fitting Of Oil Dip Stick For DVl0 And DV20 (Drawing)
Fitting Of Inlet Connecting Piece
Tightening Of Lubricating Oil Grooves
Crankshaft, Intermediate Bearing, And Rear
Repair Dimensions Of Crank Shaft
Dismantling Of Crank Shaft
Replacement Of Rear Main Bearing Bush And Intermediate Bearing

Camshaft Complete:
Camshaft
Dismounting Of The Camshaft
Change Of Front Bearing Bush For Camshaft
Check Of Camshaft
Valve Times
Injection Timer
Dismounting
Mounting
Check Of Injection Timer
Arrangement Of Automatic Injection Timer

Lubricating System:
Lubrication System
Excess-pressure Valve
Lubricating Oil Filter
Arrangement Drawing Of Lubricating Oil Reduction Valve
Lubricating Pump – Old Type Dismounting – Mounting
Lubricating Oil Pump In Old Execution
Lubricating Oil Pump In New Execution
Lubricating Oil Pump – New Type
Lubricating Oil Quality

Cooling System:
Direct Cooling (Seawater Cooling)
Dismounting
Technical Data
Technical Data – Pump For Dv20 Dismantling Of Cooling Water Pump
Thermostat Dismounting
Thermostat Mounting
Fitting Of Double Transmitter
Zinc Rod
Indirect Cooling (Freshwater Cooling)
Heat Exchanger System DV20 Engines
Dismantling, Cleaning And Reassembly Of Heat Exchanger For Dv10 And Dv20
Exchange Of Thermostat Dvlo Engines
Cooling Water System For DV10 And DV20
Thermostat Housing
Header Tank
Keel Cooling
Common Components
Freshwater Circulating Pump
Dismantling Of Circulating Pump
Reassembly Of Circulating Gump
Expansion Cover
Protection Against Frost Arrangement Of Circulating Pump (Drawing)
Arrangement Of Heat Exchanger DV20 (Drawing)
Arrangement Of Keel Cooling DV10 (Drawing)
Arrangement Of Keel Cooling DV20 (Drawing)

Electrical System:
Dynastarter
Supervisory Relay
Dimensioning Of Starter Cables And Tech
Data For The Electrical System
Starter Motor
Stop Magnet
Safety Regulations
Battery
Electrical System
Charging System
Starter System
Consumers Of Current
Battery
Group A: Alternator
Maintenance Instructions For Motorola Alternator
Alternator Type A 14/30
Fault Localisation
Checking And Testing Of Alternator And Voltage Relay
Voltage Relay
Checking Of Voltage Relay
Checking Of Alternator
Examination Of Insulating Diode Bridge
Exciting Circuit
Examination Of Rotor Windings And Brush Holder
Two-pole Insulated Type
One-pole Insulated Type
Checking Of Rectifier Diodes
Alternator Type 14/35 A
Fault Localization Of Alternator
Checking And Testing Of Alternator And Voltage Relay Voltage Relay – Type Tl4V
Checking Of Rotor Windings
Checking Of Magnetizing (Trio) Diodes
Checking Of Trio Diodes
Checking Of Rectifier Diodes
Removal Of Diode Set
Reassembly Of Alternator
Fitting Of Voltage Regulator
Checking At Starting-up
Change Of Starter Motor Into Two-wire Execution
Change Of Alternator Into Two-wire Execution
Wiring Diagram. F. Dynastarter With Therrrostart And Inst.Panel
Wiring Diagram. F. Dynastarter With Therrrostart And Operating And Instrument Panel
Wiring Diagram. F. Dynastarter With Oper. And Instr. Panel
Wiring Diagram. F. Dynastarter With Instrument Panel
Wiring Diagram. F. Dynastarter With Operating Panel
Wiring Diagram. F. Dynastarter With Thermostart
Wiring Diagram. F. Dynastarter With Thermostart And Operation Panel
Wiring Diagram. F. Dynastarter
Wiring Diagram. F. Alternator
Diagram For Standard Electrical System
Diagram For Fully Developed Electrical System
Explanation To The Wiring Diagrams Pages
Standard Operating Panel W. Warning Lamps, Acoustic Alarm & Key Switch

Marine Reduction Gear Zf Gear Bw6:
Technical Characteristics
Input Rotation Sense
Power Flow
Operating Conditions Service
Repairs
Reassembly
Pinions Axial Setting
Slip Sleeve Fitting
Lapping Of The Movable Cones
Lapping Method
Setting (Regulation) Of The Cone Bearings
Setting Of The Shifting Yoke Lining Up Of Intermediate Housing

Marine Reduction Gear Zf Gear Bw7:
Gear Ratio Oil Change
Special Tools
Adjusting Measures And Torques For Bw7
Adjusting Measures And Torques For Bw7- General Information For Gear Work
Removal Of Gear From Engine
Dismantling Of Bw7 Gear
Removal Of Input And Output Shafts
Dismantling Of Shifting Fork
Dismantling Of Output Shaft
Dismantling Of Input Shaft
Dismantling Of Lower Gearbox Half
Dismantling Of Upper Gearbox Half
Refitment Of Bw7 Gear
Fitting Of Input Shaft
Measuring Of Tightening Of Tapered Roller Bearing On Input And Output Shafts With Measuring Gauge
Measuring Of Tapered Roller Bearing Tightening On Input And Output Shafts Without Measuring Gauge
Pre-mounting Of Shifting Fork
Fitting Of Bolts In Gearbox
Fitting Of Input And Output Shafts With Shifting Fork In Gearbox
Fitting Of Shaft Seal Rings – Supplement To Fitting Of Shaft Seal Rings

Sail Drive:
Oil Change And Gear Ratio
Zinc Anode
Outside Maintenance
Removal Of Sail Drive From Engine And Boat
Alarm Function Of Double Membrane
General (For Assembly And Dismantling Of Sail Drive)
Assembling Procedure For Sail Drive
Intermediate Housing And Intermediate Shaft (Drawing)

Irregularities In Operation For The Electrical System And For The Engine:
Engine Does Not Start Or Is Difficult To Start
Engine Starts But Stops Shortly After
Engine Does Not Reach Maximum Capacity
Knocking Operation Of Engine
Engine Speed Too High
Engine Knocks
Engine Has Black Exhaust Smoke
Engine Has Bluish Exhaust Smoke
Excessive Lubricating Oil Consumption
Excessive Fuel Oil Consumption
Engine Runs Hot
Engine Does Not Reach Normal Operating Temperature
The Electrical System
Causes To Irregularities In The Electric Starter
Maintenance Check
Maintenance Schedule Storage
Preparation For Use After Storage
Storage Of Fuel