Bukh DV36 – DV38 Diesel Engine Service Workshop Manual

Workshop Service and Repair Manual for the Bukh DV36 / DV38 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 DV36 – DV38 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: DV36 – DV38

Chapters covered within this manual:

1 LIST OF TOOLS:
Tools For Repairs On DV36
Dimensions Of Mounting Punches

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:
Dismounting Of The Front End Cover
Front Rotating Weight
Replacement Of Bushes In The Front Rotating Weight
Mounting Of The Front End Cover

6 REAR END COVER & HND START:
Dismounting Of Rear End Cover
Mounting Of Intermediate Wheel & Chain Wheel
Tightening For Shaft For Intermediate Wheel
Intermediate Wheel
Rear Of Rotating Weight (Drawing)
Replacement Of Bush In Rear Rotating Weight & Intermediate Wheel
Replacement Of Seal Ring In Rear End Cover
Mounting Of Rear Rotating Weight
Mounting Of Rear End Cover
Chain Adjuster
Hand Start

7 FUEL SYSTEM:
Dismounting Of The Fuel Pump
Fuel System
Mounting & Adjustment Of The Fuel Pump
Specifications Of Fig Numbers
Centrifugal Governor
Function Of The Centrifugal Governor
Fuel Lift Pump
Fuel Filter
Fuel Valve
Causes & Remedies Of The Fuel Pump

8 PISTON, CONNECTING ROD & CYLINDER LINER:
Disassembling Of Piston And Connecting Rods
Exchange Of Piston
Assembling Pistons & Connecting Rods
Measurement Of Piston
Piston Rings
Exchange Of Piston Rings
Exchange Of Piston Pin Bearing In Connecting Rod
Arrangement Of Connecting Rod (Drawing)
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)

9 CRANKCASE, CRANKSHAFT & OIL SUMP:
Dismounting Of Crankshaft
Change of Main Bearings
Rear Part Of Crank
Rear Gear Wheel & Rear Part Of Crank
Marking on Front Gear Wheel Of Crank
Front Part Of Crank
Rear Dimensions Of Crankshaft
Connecting Rod Journals
Main Bearing Journals
Oil Sump

10 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

11 CAMSHAFT:
Camshaft
Gear Wheel Of Camshaft
Valve Timings
Drawing Of Camshaft
Drawing Of Push Rod
Drawing Of Push Rod Guide

12 LUBRICATION SYSTEM:
Lubricating Oil System
Pressure Relief Valve
Lubricating Oil Filter
Fitting Of Dipstick
Pipe Connections In Oil Sump
Lubricating Oil Pump
Change & Quality Of Lubricating Oil
Removal Of Lubricating Oil Pump
Lubricating Oil Cooler
Removal Of Lubricating Oil Cooler

14 COOLING WATER SYSTEM:
Cooling water systems
Johnson cooling-water pump type F5B9
Removal of pump
Dismantling of pump
Dismantling of intermediate housing
Reassembly of pump
Refitment of pump
Circulation pump for freshwater
Removal of pump
Dismantling of pump
Reassembly of pump
Circulation pump
Zinc rod protection
Thermostat
Header tank and heat exchanger
Dismantling of heat exchanger
Filling up of anti freeze solution
Keel cooler arrangement

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