Bukh DV36/48 Instruction manual

009W2329-R01
Publ. No.
009W2329
Work shop Manual
for
BUKH diesel engine
TYPE DV36/48
Aabenraavej 13-17, DK - 6340 Krusaa, Denmark
Tel: [phone]
Fax [phone]
E-mail: [email protected] – Internet: www.bukh.dk

009W2329-R01
Contents
Section A … Introduction and technical data
Section B … List of tools
Section C … Cylinder head
Section D … Flywheel
Section E … Front end cover
Section G … Rear end cover and hand start
Section H … Fuel system
Section IJ … Piston, connecting rod and cylinder liner
Section L … Crankcase, crankshaft, main bearings and oil sump
Section M … Camshaft
Section N … Lubricating oil system
Section O … Cooling water system
Section P … Electrical system
Section R … Gearbox ZF, BW7
Section S … Sail drive
Section T … Irregularities in operation - causes and remedies
Section V … Maintenance

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SECTION A
INTRODUCTION AND TECHNICAL DATA

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CONTENTS
Introduction................................................................................page A 3
Technical Data...........................................................................page A 4
Torques .....................................................................................page A 5
Spare Part Nos. for Service Parts..............................................page A 6
Torque and Rating Curves......................................................... page A 7
Results of Measurement............................................................page A 8
Longitudinal Section of DV36 ....................................................page A 9
Cross Section of DV36 ..............................................................page A 10
Diagram of the Relation between the Total Weight,
Speed and Horse Power of the Boat.........................................page A 11

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Introduction
The engines are specially designed to comply with the heavy demands made on stability,
safety and environment now.
The technical structure of the engine with components and systems appears from the
individual sections of this workshop manual and therefore this introduction contains no
descriptions of this.
DV36 is designed with small installation dimensions compared to corresponding engine
outputs on the market. This applies to both height, length and width. At the same time the
weight of the engine is comparatively low and the proportion weight/horse power is in fact only
7.36 compared to corresponding engine outputs on the market with a corresponding factor of
8.28 and 8.48.
Being a 3-cylinder engine, DV36 is a naturally low level of vibration compared to 1- and 2-
cylinder engines, but in order to obtain a further improvement of the vibration level, the rotating
weight system has been continued on DV36 as it is known with great success from DV10 and
DV20. DV36 with the anti-vibration system is thus free from unpleasant vibrations and may
correctly be described as the less vibrating engine on the market.
DV36 is supplied either with sail-drive (type DV36SME) or with BW7 gear (type DV36ME). The
type description S = saildrive, M = marine gear and E = with electric start.
The temperature of the exhaust gas is for DV36 max. 550°C, which is about 100°C below
corresponding engine outputs on the market.
DV36 is delivered as standard with direct seawater cooling but may be alternatively be
delivered with heat exchanger built integral with water cooled exhaust, keel cooler or radiator
cooler.
BUKH DV36 is a 3-cylinder, water cooled, 4-stroke diesel engine with direct injection, giving
an easy start at low temperatures, a low consumption of fuel and a low thermic load of the
cylinder head.

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TECHNICAL MAIN DATA
WORKING PRINCIPLE………………………………………………………...4-STROKE
BORE/STROKE...................... ................................ ...................................85 mm / 85 mm
CYLINDER VOLUME ............. ................................ ...................................1.447 Litres
COMPRESSION RATIO......... ................................ ...................................18,5:1
COMPRESSION PRESSURE …. .................at 1800-3600 rpm…………..46 Bar
OUTPUT, CONTINOUS RATING.….............at 2400 rpm………..………..29.8 BHP - 21.9 kW
ACCORDING TO ISO 3046……. ..................at 3000 rpm…………………..34.5 BHP – 25.4 kW
..............at 3600 rpm………………….36.0 BHP - 26.5 kW
OUTPUT, INTERMITENT RATING BHP.......at 4000 rpm.........................39.3 BHP – 28.9 kW
MAX. TORQUE Kp*m............. ......................at 1800 rpm..........................9.2 Kpm – 90 Nm
MAX. AIR CONSUMPTION.... ................................ ...................................2214 Litres/min.
ENGINE ROTATING, LOOKING AT FLYWHEEL .. ...................................CLOCWISE
IDLING SPEED....................... ................................ ...................................800 – 1000 RPM
MAX INCLINATION, FORE AND AFT..................... ...................................15o
HEEL, MAX. CONTINOUS..... ................................ ...................................30o
NET WEIGHT INCL. ZF MARINEGEAR ................. ...................................265 Kg
NET WEIGHT INCL. SAILDRIVE............................ ...................................290 Kg
LOCATION OF ENGINE SERIAL NUMBER........... ...................................ON CRANKCASE NEAR FUEL THE PUMP
EXHAUST TEMP. MAX / NORMAL......................... ...................................600oC – 580oC
VALVE TIMING AND INJECTION POINT
FLYWHEEL DIAMETER......... ................................ ...................................370 mm
INLET VALVE OPENS .................. BEFORE TDC . ...................................32o(arc measure: 103 mm)
INLET VALVE CLOSES ............... AFTER BDC.... ...................................64o(arc measure: 207 mm)
EXHAUST VALVE OPENS............ BEFORE BDC. ...................................64o(arc measure: 207 mm)
EXHAUST VALVE CLOSES ......... AFTER TDC .... ...................................32o(arc measure: 103 mm)
INJECTION STARTS……….......... BEFORE TDC……………………….....6.2o(arc measure: 20 mm)
VALVE CLEARANCES (COLD ENGINE) INLET/EXHAUST......................0.30 mm
FUEL SYSTEM ...................... ................................ ...................................DIRECT INJECTION
INJECTOR OPENING PRESSURE ........................ ...................................210 Bar
INJECTION TIMING .............. ................................ ...................................AUTOMATIC VARIABLE
FUEL LIFT PUMP................... ................................ ...................................CAM SHAFT DRIVEN DIAPHRAGM PUMP
STATIC PRESSURE OF FUEL LIFT PUMP........... ...................................153 - 285 mBar
FUEL FILTER ......................... ................................ ...................................THROW AWAY FILTER INSERT
FUEL QUALITY GAS OIL....... ................................ ...................................BS 2869 CLASS A
LUBRICATING SYSTEM
TYPE OF LUBRICATING OIL PUMP...................... ...................................ROTARY VANE PUMP
LUBRICATING OIL PRESSURE: WARM ENGINE / MINIMUM.................2-4.5 Bar / 1 Bar
LUBRICATING OIL QUALITY ................................ ...................................SERVICE CC or CD
LUBRICATING OIL VISCOSITY.... BELOW +5oC ......................................SAE 10 or SAE 10W-30
BETWEEN +5oc and +25oC ................SAE 20 or SAE 15W-40
ABOVE +25oC. ...................................SAE 30 or SAE 15W-40
LUBRICATING OIL CONTENT INCL. FILTER........ ...................................4.9 Litres
LUBRICATING OIL FILTER .. ................................ ...................................THROW AWAY FILTER INSERT
ZF BW7 MARINEGEAR
LUBRICATING OIL QUALITY ................................ ...................................API CC or CD, MILL-L-46152
LUBRICATING OIL VISCOSITY.............................. ...................................SAE 30 or SAE 15W-40
LUBRICATING OIL TEMPERATURE...................... ...................................MAX. 120oC
LUBRICATING OIL CONTENT ............................... ...................................1.1 Litres
NEWAGE PRM120 MARINEGEAR
LUBRICATING OIL QUALITY ................................ ...................................Automatic Transmission Fluid (ATF)
LUBRICATING OIL TEMPERATURE...................... ...................................MAX. 120oC
LUBRICATING OIL CONTENT ............................... ...................................0.8 Litres

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BAYSAN M60 MARINEGEAR
LUBRICATING OIL QUALITY ................................ ...................................Automatic Transmission Fluid (ATF)
LUBRICATING OIL TEMPERATURE...................... ...................................MAX. 120oC
LUBRICATING OIL CONTENT ............................... ...................................0.5 Litres
STERN TUBE (FLEXIBLE) LUBRICANT................ ...................................OUTBOARD GEAR OIL
COOLING WATER SYSTEM – DIRECT SEAWATER COOLING
COOLING WATER TEMPERATURE...................... ...................................50 – 65oC
TYPE OF CIRCULATING PUMP / CAPACITY AT 3600 rpm .....................CENTRIFUGAL / 24-30 Litres/min
CAM HEIGHT ......................... ................................ ...................................2.0 mm
MAX. PUMP COUNTER PRESSURE..................... ...................................0.6 Bar
MAX. PUMP SUCTION PRESSURE....................... ...................................0.3 Bar
COOLING WATER SYSTEM – INDIRECT COOLING WITH FRESHWATER
COOLING WATER TEMPERATURE...................... ...................................70 – 95oC
TYPE OF FRESHWATER PUMP / CAPACITY AT 3600 rpm.....................CENTRIFUGAL / 135 Litres/min
PUMP PRESSURE................. ................................ ...................................1.1 Bar
TYPE OF SEAWTAER PUMP / CAPACITY AT 3600 rpm..........................CENTRIFUGAL / 36-42 Litres/min
CAM HEIGHT ......................... ................................ ...................................3.1 mm
MAX. PUMP COUNTER PRESSURE..................... ...................................0.6 Bar
MAX. PUMP SUCTION PRESSURE....................... ...................................0.3 Bar
ELECTRICAL SYSTEM
BATTERY VOLTAGE / CAPACITY ............................................................12 VOLT / 88 Ah
STARTER TYPE / OUTPUT .......................................................................GEAR DRIVEN / 1.0 KW
ALTERNATOR TYPE/ OUTPUT ................................................................BELT DRIVEN / 700 W
ENGINE STOP ...........................................................................................SOLONOID / MANUAL
RELAY ........................................................................................................ELECTRONIC, BUILT ON
TORQUES
CYLINDER HEAD BOLTS/BEARING TOP SECTION................................118 +/- 5 Nm (12 +/- 0.5 Kpm)
CONNECTING ROD BOLTS . ....................................................................69 +/- 3 Nm (7 +/- 0.3 Kpm)
FLYWHEEL/COUNTERWEIGHTS... ..........................................................147 +/- 7 Nm (15 +/- 0.7 Kpm)
FLEX. COUPLING.................. ....................................................................61 +/- 3 Nm (6.3 +/- 0.3 Kpm)
ASSEMBLY OF FUEL VALVE ....................................................................59 +/- 3 Nm (6.0 +/- 0.3 Kpm)
BRACKET FOR ENGINE SUPPORTS .......................................................69 +/- 3 Nm (7 +/- 0.3 Kpm)
GEARBOX.............................. ....................................................................25 +/- 5 Nm (2.5 +/- 0.5 Kpm)

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Spare Part Numbers for Service Parts
In this manual we have maintained on the drawings some numbers which are also spare part
numbers. However, this manual is not to be regarded as a spare parts catalogue but only as
helping guidance for correct identification of parts.
In the daily service work, some of the parts must be replaced after the number of hours stated
in the owner´s manual and in this book, and therefore we have made the following table:
610J0200 Lubricating oil filter
610D0201 Fuel filter
020D4326 Air filter
000E0450 Sacrificial zinc anode
610G0506 Impeller
542A0602 V-belt 10*1035 (seawater cooling)
542A0609 V-belt 10*1100 (freshwater cooling)

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Results of Measurement
The below curves indicate results of measurements at 762 mm Hg and a room temperature of 26 °C.

A9
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Longitudinal Section of DV36

A10
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Cross Section of DV36

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Diagram of the Relation between the Total Weight,
Speed and Horse Power of the boat
The below diagram is normative and not binding in any way as many different circumstances
influence the result, especially the type and shape of the boat, the propeller and its placing as
well as the horse power of the engine.
Seek the scheme to the right of the intersection between the actual length in the waterline of the
ship and the total weight.
Draw a straight line between this point (the intersection) and the fixed point in the bottom left corner.
Where the line of the desired speed crosses the straight line, you can read the required horse
power vertically below.
If you know three of the specifications, you can by means of these schemes find the fourth one.

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SECTION B
LIST OF TOOLS

B2
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CONTENTS
Tools for repairs on DV36 .......................................................... page B 3
Dimensions of mounting punches ............................................. page B 6

B3
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Tools for repairs on DV36
The below mentioned tools are necessary to make the engine repairs described in this
manual.
Part of the tools are special tools which can be ordered from the spare parts department at
BUKH.
We have indicated the fields of application for the special tools in this manual.
Designation of tools Fields of application Spare part No.
Slip-on ring for mounting of
pistons
Section IJ
Puller for cylinder liner Section IJ 009P2235
Punch for rear seal ring Section G 009P3177
Punch for front seal ring Section E 009P3178
Punch for mounting of
camshaft bearing in block
Section M and L 009P3179
Punch for journal for
intermediate wheel
Section G 009P3180
Punch for journal for front and
rear rotating weight
Section E and G 009P3181
Punch for mounting of valve
guide
Section C 009P3175
Punch for mounting of inlet
valve seat
Section C 009P3173
Punch for mounting of exhaust
valve seat
Section C 009P3174
Punch for mounting of expan-
sion discs in the cylinder head
Section C 009P3176

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Designation of tools Fields of application Spare part No.
36 mm socket spanner
19 mm socket spanner for
fastening of cylinder head
Section C
19 mm crowfoot wrench for
tightening up of cyl. head
Section C 009P3225
10 mm Allen top for faste-ning of
bearing top section
Section L
5 mm Allen key -
6 mm Allen key -
7 mm Allen key -
Open-end spanner/ring spanner,
8/10/12/13/14/15/17/19/22/24/27
30 and 32 mm
-
Dismantling tool for valve
springs
Section C 009P3115
Tachometer Generally 009P3106
Testing set for fuel nozzles Section H 009P3100
Cleaning for fuel nozzles Section H 009P3101
Bosch dial indicator for
adjustment of fuel pump
Section H
Bosch dial indicator “holder with
extension” for adjustment of the
fuel pump (KDEP1085)
Section H 529W0002

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Designation of tools Fields of application Spare part No.
Flanging tools for nozzle holder
insert
Section C 009P2565
Torque wrench
(Stahlwille 73/6 1.5-6.5)
Generally 009P3108
Torque wrench
(Stahlwille 73/25 8-26)
Generally Section C, D,
IJ and L
009P3109
Circlip tongs (external)
A1, 10-28 mm
-
Circlip tongs (internal)
J2, 19-75 mm
-
Puller for gear wheel
(Kukko 20/10)
Generally
Puller for flexible coupling Section R T 41069
Compression gauge Section C 529W0000
Adapter for compression gauge Section C 009P3123
Part of the mentioned special tools can be manufactured without too much trouble at the
dealer´s workshopin periods outside the boat season. Therefore we have made sketches at
page B6 of each individual mounting punch with dimensions.
Slip-on ring for mounting of pistons is not illustrated but is manufactured of a worn out
cylinder liner or another piece of work pipe. Cut the cylinder liner so that you get a piece
being about 100 mm high, the turn it conical inside the liner or pipe.

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