Bukh DV24 Diesel Engine Service Workshop Manual

Workshop Service and Repair Manual for the Bukh DV24 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 photographs and technical drawings for the DV24 this also covers the Bukh DV20 unit but with much greater detail than the original DV20 workshop manual with torque setting values throughout each chapter, this is the most comprehensive service manual available as used by boatyards and independent marine engineers the world over.

Detailed Procedures For Engine Types: DV24M, DV24ME, DV24SME, DV24RM, DV24RME and DV24ST

Chapters covered within this manual:

1 LIST OF TOOLS:
Definition Of This Section
Standard Tools
Additional Tools For Rm / Rme
Special Tools

2 TECHNICAL DATA

3 CYLINDER HEAD:
Exploded View Of Cylinder Head Complete
Valve Adjustment
Removal And Refitment Of Cylinder Head
Replacement Of Rocker Arm Or Rocker Shaft
Adjustment Of Valve Lifter Arrangement
Replacement Of Rocker Arm Bushing
Removal Of Fuel Valves
Nozzle Holder Insert
Fitting Measures For Fuel Nozzle Insert
Valve Springs
Replacement Of Valve Guides
Pressing-in Dimensions For Valve Guide
Valve Guide Stuffing Box
Repair Or Replacement Of Inlet And Exhaust Valves
Exhaust Valve
Inlet Valve
Grinding Of Valves
Measures For New Valves
Replacement Of Valve Seats
Cylinder Head Gasket
Air Inlet Manifold Arrangement
Exhaust Manifold Arrangement

4 FLYWHEEL:
Removal And Refitment Of Flywheel
V-belt Pulley Fitted On Flywheel
Replacement Of Gear Rim

5 FRONT END COVER:
Front End Cover
Dismounting Of Counterweights
Mounting Of Counterweights
Arrangement Of Counterweights
Replacement Of Oil Seal Ring
Replacement Of Front End Cover
Replacement Of Journals For Counterweights
Replacement Of Front Main Bearing Lining

6 RAISED HAND START & COLD START ARRANGEMENTS (RME):
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)
Cold Start Arrangement

7 REAR END COVER:
Dismounting Of Rear End Cover
Removal Of Rear Counterweights
Exchange Of Bearings For Counterweights
Fitting Of Counterweights
Arrangement Of Rotating Weights (Drawing)
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
Stop Button For Engines Without Electric Stop Solenoid

8 FUEL SYSTEM:
Fuel System
Bleeding Of The Fuel System
Fuel Lift Pump
Fuel Filter
Fuel Valve
Adjustment Of Injection Timing (Spill Point) H8
Fuel Adjustment

9 PISTON,CONNECTING ROD & CYLINDER LINER:
Dismounting Of Piston And Connecting Rod
Exchange Of Piston
Measurement Of Piston
Piston Rings
Exchange Of Piston Rings
Exchange Of Piston Pin Bearing
Arrangement Of Connecting Rod (Drawing)
Mounting Of Piston And Connecting Rod
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)

10 ENGINE BLOCK & OIL SUMP:
Crankcase And Oil Sump
Fitting Of Oil Dip Stick
Fitting Of Connecting Piece
Tightening Of Lubricating Oil Grooves
Upside Down Valve For Inverting Running (Capsizing Rme)

11 CRANKSHAFT, INTERMEDIATE BEARING & REAR MAIN BEARING SHELL:
Repair Dimensions Of Crankshaft
Dismounting Of Crankshaft
Rear End Main Bearing Bush And Intermediate Bearing
Exchange Of Intermediate Bearing

12 CAMSHAFT:
Camshaft
Dismounting Of Camshaft
Change Of Front Bearing Bush For Camshaft
Check Of Camshaft
Valve Timings
Injection Timer
Dismounting Of Injection Timer
Mounting Of Injection Timer
Check Of Injection Timer
Drawing Of Camshaft
Drawing Of Push Rod
Drawing Of Push Rod Guide

13 LUBRICATION SYSTEM:
Lubricating System
Excess-pressure Valve
Lubricating Oil Filter
Arrangement Drawing Of Lubricating Oil Reduction Valve
Lubricating Oil Pump
Lubricating Oil

14 COOLING WATER SYSTEM:
Direct Cooling With Seawater
Indirect Cooling With Heat Exchanger
Indirect Cooling With Keel Cooling
Direct Cooling
Impeller Pump
Thermostat
Circulation Pump
Heat Exchanger
Keel Cooling
Zinc Rod Protection
Dismantling, Cleaning Heat Exchanger
Exchange Of Thermostat (Heat Exchanger)
Freshwater Circulating Pump
Expansion Cover
Protection Against Frost

15 ELECTRICAL SYSTEM:
Wiring Diagram (Key Switch)
Wiring Diagram (Key Switch) – 2 Battery Starting System
Wiring Diagram (Push Button)
Wiring Diagram (Push Button) – 2 Battery Starting System
Generator With Double Charging Diodes
Key Switch Start Panel
Push Button Start Panel
Instrument Panel

16 GEARBOX ZF. BW7:
Gear Ratio
Oil Change
Special Tools
Adjusting Measures And Torques For Bw7
General Information For Work With The Gear
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 Part
Dismantling Of Upper Gearbox Part
Refitment Of Bw7 Gear
Fitting Of Input Shaft
Measuring Of Tightening And Tapered Roller Bearing On Input
And Output Shafts With Measuring Gauge
Measuring Of Tightening And Tapered Roller Bearing On Input
And Output Shafts Without Measuring Gauge
Premounting 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

17 SAILDRIVE:
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)

18 IRREGULARITIES IN OPERATION FOR THE ELECTRICAL SYSTEM & ENGINE:
Engine Does Not Start
The Engine Starts But Stops Soon After
The Engine Does Not Reach Maximum Output
The Engine Knocks
The Engine Smokes
Excessive Consumption Of Lubricating Oil
The Engine Gets Too Warm Or Too Cold
Insufficient Or No Lube Oil Pressure

19 MAINTENANCE PROCEDURES:
The Tightness Of Connections Through-hull:
Check Of Lubricating Oil
Check Of Cooling Water System
Check Of The Fuel System
Check Of Remote Control Cables:
Check Of Propeller Shaft Arrangement
Engine Maintenance
Running With Engine – Checks
Air Supply
Batteries