Bukh DV36/48 Workshop Manual Download Page 28

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009W2329-R01

Removal of fuel valves

The fuel valves are removed by loosening the clamping nuts for the flanges

as indicated on

the sketch below after removal of the inlet and return pipes of the fuel valves.

The drawing at the bottom right-hand side indicates the placing of the fuel valve in proportion

to the piston.

For repair of the fuel valves, we refer to section H.

Summary of Contents for DV36/48

Page 1: ...09W2329 R01 Publ No 009W2329 Work shop Manual for BUKH diesel engine TYPE DV36 48 Aabenraavej 13 17 DK 6340 Krusaa Denmark Tel 45 74 62 20 88 Fax 45 74 62 74 07 E mail bukh bukh dk Internet www bukh d...

Page 2: ...nd 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 Se...

Page 3: ...A1 009W2329 SECTION A INTRODUCTION AND TECHNICAL DATA...

Page 4: ...ge 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...

Page 5: ...r 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 a...

Page 6: ...m 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 OPEN...

Page 7: ...YPE 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...

Page 8: ...g 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 hav...

Page 9: ...A7 009W2329...

Page 10: ...A8 009W2329 Results of Measurement The below curves indicate results of measurements at 762 mm Hg and a room temperature of 26 C...

Page 11: ...A9 009W2329 Longitudinal Section of DV36...

Page 12: ...A10 009W2329 Cross Section of DV36...

Page 13: ...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...

Page 14: ......

Page 15: ...B1 009W2329 R01 SECTION B LIST OF TOOLS...

Page 16: ...B2 009W2329 R01 CONTENTS Tools for repairs on DV36 page B 3 Dimensions of mounting punches page B 6...

Page 17: ...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 Sectio...

Page 18: ...ction 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...

Page 19: ...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 th...

Page 20: ...B6 009W2329 R01...

Page 21: ...009W2329 R01 C1 SECTION C CYLINDER HEAD...

Page 22: ...der insert page C 9 Fitting measures for fuel nozzle insert page C 10 Valve springs page C 11 Replacement of valve guides page C 12 Pressing in dimensions for valve guide page C 13 Valve guide stuffin...

Page 23: ...009W2329 R01 C3 Exploded view of cylinder head...

Page 24: ...crew B Measure the clearance with a feeler gauge at C The clearance of the inlet and exha ust valves should be adjusted at 0 3 mm when the engine is cold and the clearance of the valves should always...

Page 25: ...s of the fuel valves 5 Remove the charging alternator 6 Remove the exhaust and inlet manifold 7 Loosen the top bolts after which the cylinder head can be lifted out of the engine block 8 Refitment of...

Page 26: ...and the intermediate springs can be taken out Reassembly is a reversal of the dismantling procedure Adjustment of valve lifter arrangement Furthermore a common shaft for decompression is fitted on the...

Page 27: ...shown below paying special attention to the position of the bearing joint and the oil grooves 4 When fitted calibrate the bearing bush so that the tolerance 19 R7 is observed Do this either with a cal...

Page 28: ...mping nuts for the flanges A as indicated on the sketch below after removal of the inlet and return pipes of the fuel valves The drawing at the bottom right hand side indicates the placing of the fuel...

Page 29: ...ecial tools below for flanging piston and backstop are used and that t he surfaces are treated as indicated on the drawing Remove the old nozz le holder inserts by bor ing up the flanged end of the n...

Page 30: ...009W2329 R01 C10 Fitting measurements for the fuel nozzle into insert...

Page 31: ...and a corresponding disc respectively The valve springs are removed by compressi ng the valve springs and removing the c onical locking halves with s pecial tools or the like so the valves are cut off...

Page 32: ...cording to the drawing below of the valve guide Fit new valve guides according to the drawing on page C13 Before fitment heat the cylinder head in an oven or heat it in boiling water and cool down t h...

Page 33: ...009W2329 R01 C13 Pressing in dimensions for valve guide...

Page 34: ...ox has been mounted on the upper end of the valve guides The stuffing box is as shown schematically on the drawing below and consists of A Metal spring coat B Plastic bushing C Spring wire The stuffin...

Page 35: ...edure Note Refit the valves in the same valve guides again Replace the valves if they are so damaged that a refacing with special tools and subsequent grinding are impossible without exceeding the tol...

Page 36: ...009W2329 R01 C16 Exhaust valve Tolerances and repair measures...

Page 37: ...009W2329 R01 C17 Inlet valve Tolerances and repair measures...

Page 38: ...eat the abrasive compound applied 4 You can c heck whether the valve is ti ght by cleaning off the abrasive compound carefully by for exam ple cleaning liquid Then make 4 pencil m arks staggered 90 de...

Page 39: ...der the rear edge of the valve seat ring IT IS IMPORTANT THAT THE FILLING PIECE IS USED BETWEEN CYLINDER HEAD AND CHISEL IN ORDER TO AVOID DAMAGING THE CYLINDER HEAD Before fitting new valve seat ring...

Page 40: ...a special 0 2 mm carbon steel inlay When replacing the cylinder head gasket the grooves in the cylinder head must be completely clean to obtain tightness If the cylinder head has been removed several...

Page 41: ...Beskrivelse Description Benennung 3 000E4923 1 Indsugningsmanifold Inlet manifold Einlasssammelrohr 4 008E7310 1 Luftfilter Air filter Luftfilter 5 501A2363 12 Cylinderskrue Unbraco screw Unbracoschr...

Page 42: ...exhaust manifold Dichtung f r Auspuffsammelrohr 3 008E9239 1 Flange Flange Flansch 4 560F1031 1 O ring O ring Abdichtung 5 500C2363 2 S tskrue M8x20 Set screw M8x20 Setzschraube M8x20 6 503N2367 2 Tap...

Page 43: ...009W2329 R01 D1 SECTION D FLYWHEEL...

Page 44: ...009W2329 R01 D2 CONTENTS Removal and refitment of flywheel page D 3 V belt pulley fitted on flywheel page D 3 Replacement of gear rim page D 4...

Page 45: ...te or something similar and tighten them with a torque of 147 7 Nm 15 0 0 7 kpm When dismounting the flywheel please note to fit the flywheel in the same position as before This only due to the timing...

Page 46: ...damaging the flywheel 3 Split the gear rim in the sawed slot with a chisel 4 Clean the recess on the flywheel 5 Heat the new gear rim gradually to about 225 C dark blue and fit it Make sure at the fi...

Page 47: ...009W2329 R01 E1 SECTION E FRONT END COVER...

Page 48: ...NTENTS Dismounting of front end cover page E 3 Mounting of front end cover page E 3 Front rotating weight page E 3 Replacement of front oil seal ring page E 4 Replacement of bushes in the front rotati...

Page 49: ...led by a 8 mm screw 4 Remove the end cover considering the guide spindles of the cover Mounting of front end cover The mounting is carried out in reverse order of the dismounting i e the tightening ar...

Page 50: ...ugh the front end cover The seal ring can be replaced without dismounting the front end cover It is however necessary to dismount the flywheel Replacement of bushes in the front rotating weight When r...

Page 51: ...G1 009W2329 R01 SECTION G REAR END COVER AND HAND START...

Page 52: ...for intermediate wheel page G 4 Intermediate wheel page G 5 Rear of rotating weight drawing page G 6 Mounting of rear of rotating weight page G 7 Replacement of bush in the rear rotating weight and i...

Page 53: ...wheels which have been marked in relation to each other so that their position to each other may easily be observed when being repared Dismounting of rear end cover 1 Dismount the gear from the engine...

Page 54: ...eel for hand start should be mounted on the same shaft The two thrust collars shown form part of the arrangement It is necessary when mounting to lubricate the washer between block and thrust washers...

Page 55: ...G5 009W2329 R01...

Page 56: ...G6 009W2329 R01...

Page 57: ...d into the engine block and the tooth marking in relation to the intermediate wheel should be observed After the end cover has been mounted the tightening for shaft should be mounted in accordance wit...

Page 58: ...diate wheel respectively Replacement of seal ring in rear end cover A seal ring is mounted in the rear end cover in order to avoid leak of lubricating oil at the outlet of the crank through the rear e...

Page 59: ...The chain adjuster is mounted on two pins in the engine block The chain adjuster is self adjusting and thus it does not require any adjustments in connection with repairs in the end cover during which...

Page 60: ...covers A and this results in the chain being slackened and then the chain wheel and shaft can be taken out Mounting is carried out in reverse order and it should be taken care that the O rings for oi...

Page 61: ...009W2329 XLS H1 SECTION H FUEL SYSTEM...

Page 62: ...ent for fuel pump page H 4 Specification of Numbers to Fig 1 and 2 page H 6 Fuel System page H 7 Centrifugal Governor page H 8 Function of the Centrifugal Governor page H 9 Fuel Lift Pump page H10 Fue...

Page 63: ...Dismount the flange opposite of the fuel pump 3 Take off the gear wheel of the pump by slackening the clamping nut on the shaft of the pump and pull off the gear wheel 4 Slacken the nuts in the flang...

Page 64: ...No 3 rear to TOP in the working stroke 2 Mark the flywheel in this position in relation to the arrow mounted on the front edge of the engine 3 Measure 86 mm arc measure from the TOP mark to the right...

Page 65: ...the flange of the pump 6 Mount the gear wheel for the pump through the hole on the opposite side of the pump Fasten the gear wheel on the conical pump shaft by means of a nut 7 Mount the flange above...

Page 66: ...11 Adjusting screw idling 12 Adjusting screw max r p m 13 Stop lever 14 Overflow throttle 15 Correcting lever 16 Bolt 17 Adjusting screw full load 18 Idle spring 19 Clamping arm 20 Starter spring 21...

Page 67: ...d and then it is led to cooling and bleeding and then back to the tank through the overflow throttle 14 The distributor piston 23 is activated by the drive shaft 2 By means of the cam disc 26 and the...

Page 68: ...st the full load quantity by the adjusting screw 17 without influencing th adjustment of the revolutions A leaf spring is placed on the starting lever 21 and it works as a starter spring An axially di...

Page 69: ...r 21 is pressed against the clamping arm 19 and the starting volume is automatically declutched as the governor slide 24 is displaced At low idling the governor spring 9 is not working The regulation...

Page 70: ...ir or cleaning It is driven by the camshaft Workpressure is 35 55 kPa A hand pump is fitted which can be used for priming and bleeding by standing engine After priming the lever must be put in neutral...

Page 71: ...ter the sealing surface of the filter casing should be cleaned The filter casing should now be filled with clea fuel before it is screwed on and tightened about half a turn after the sealing surface f...

Page 72: ...e DLLA 150P 34 combined with a nozzle holder KBEL 78P 10 13 and this combination makes the fuel valve Item no 610B9120 The adjusting filling pieces for injection pressure are obtainable from 1 mm to 1...

Page 73: ...009W2329 XLS H13 Causes and Remedies of the Fuel Pump...

Page 74: ......

Page 75: ...IJ1 009W2329 R01 SECTION IJ PISTON CONNECTING ROD AND CYLINDER LINER...

Page 76: ...iston rings page IJ 7 8 Exchange of piston rings page IJ 9 Exchange of piston pin bearing in connecting rod page IJ 9 Arrangement of connecting rod drawing page IJ 10 Connecting rod bearings page IJ 1...

Page 77: ...2 3 should be re moved and the remaining 1 3 should be turned weakly conical in the top end wanted 2 Place the crank in the top position 3 Fit the connecting rod bolts with protective caps 4 Lower th...

Page 78: ...hem and light it The heating can also take place on a boiling plate 5 When the piston has reached a temperature of about 100 C smother the fire Place the connecting rod in the piston before the oiled...

Page 79: ...IJ5 009W2329 R01 Measurements for Piston...

Page 80: ...IJ6 009W2329 R01...

Page 81: ...IJ7 009W2329 R01 Piston Ring 1 Please note page IJ4...

Page 82: ...IJ8 009W2329 R01 Piston Ring 3 Please note page IJ4...

Page 83: ...t in the reverse order after the piston ring grooves have been cleaned Rotary steel brushes or a steel scrapers should not be used as cleaning tools Each piston has three piston rings two compre ssion...

Page 84: ...IJ10 009W2329 R01 Arrangement of Connecting Rod...

Page 85: ...hich a thin layer of bearing metal is cast The connecting rod bearings must be exchanged if they are scratched or if the red layer between the bearing metal and the steel shell can be seen faintly Whe...

Page 86: ...see page IJ 3 3 Cover the connecting rod journals with a piece of oil paper or plastic 4 Pull out the cylinder liners with a special tool or place the engine block on the side and knock out the cylind...

Page 87: ...IJ13 009W2329 R01 Test Measurements of Cylinder Liner...

Page 88: ......

Page 89: ...L1 009W2329 R01 SECTION L CRANKCASE CRANKSHAFT MAIN BEARINGS AND OIL SUMP...

Page 90: ...ear part of crank page L 4 Rear gear wheel and rear part of crank page L 5 Marking of front gear wheel on crank page L 6 Front part of crank page L 7 Repair dimensions of crakshaft page L 8 Connecting...

Page 91: ...ismount the front end cover see section E page 3 9 Remove the bearing caps and lift out the crank The mounting of the crankshaft takes place in reverse order the bearing caps being fastened at a torqu...

Page 92: ...L4 009W2329 R01 Rear part of crank The drawing below shows the rear part of the crank with screwing on of the counter weights of the crankshaft Drwg No 008E4757...

Page 93: ...L5 009W2329 R01 Rear gear wheel and rear part of crank...

Page 94: ...rotating weight and is marked in proportion to this and in accordance with the drawing below The gear wheel has been shrinked on the shaft When shrinking on a new gear wheel there should be a differe...

Page 95: ...L7 009W2329 R01 Front part of crank...

Page 96: ...g the factory Connecting rod journals Standard 53 987 54 000 mm 2 1255 2 1260 0 6 mm undersize 53 387 53 400 mm 2 1019 2 1024 Clearance between bearing and journal 0 028 0 068 mm 0 0011 0 0027 Main be...

Page 97: ...is fixed to the crankcase and is ensured correct position to this by means of guide pins Under the oil sump the suction strainer for the lubricating oil system is placed and pipe connections for it Th...

Page 98: ......

Page 99: ...M1 009W2329 R01 SECTION M CAMSHAFT COMPLETE...

Page 100: ...M2 009W2329 R01 CONTENTS Camshaft page M 3 Valve timings page M 4 Guide for push rod page M 4 Gear wheel of camshaft page M 5 Drawing of push rod page M 6 Drawing of push rod guide page M 7...

Page 101: ...ole for lubricating oil inlets in this bush The camshaft is fixed on to the engine block at the flange A on the sketch below The cams which are casted together with the camshaft are made of hardened s...

Page 102: ...arc measure 103 mm 4 07 Injection starts before TDC 6 2 arc measure 20 mm 0 79 Valve clearances cold engine inlet 0 30 mm 0 01180 exhaust 0 30 mm 0 01180 Guide for push rod On the picture below the gu...

Page 103: ...eI of camshaft The camshaft gear wheel is equipped with a single mark for its correct position in relation to the rear rotating weight and a double mark in relation to intermediate wheel see instructi...

Page 104: ...M6 009W2329 R01 Drawing of pushrod Drwg No 000E9455...

Page 105: ...M7 009W2329 R01 Drawing of push rod guide...

Page 106: ......

Page 107: ...N1 009W2329 R01 SECTION N LUBRICATING OIL SYSTEM...

Page 108: ...tting of dip stick page N 4 Pipe connections in oil sump page N 5 Lubricating oil pump page N 6 Removal of lubricating oil pump page N 6 Lubricating oil cooler page N 7 Removal of lubricating oil cool...

Page 109: ...ssure relief valve is fitted on the front of the engine in bore in the engine block in vertical position in the same side as the lubricating oil filter The valve is built up as shown on the drawing be...

Page 110: ...N4 009W2329 R01 Fitting of dip stick...

Page 111: ...N5 009W2329 R01 Pipe connections in oil sump...

Page 112: ...the pump runs 4000 r p m and thus supplies 33 15 litres lubricating oil per minute to the lubricating oil system Removal of lubricating oil pump 1 Remove the gear see section R page 8 2 Remove the re...

Page 113: ...pes with clips B The cooler C consists of a nest of pipes through which the cooling water passes whereas the lubricating oil runs round the pipes As the lubricating oil pressure is higher than the coo...

Page 114: ...be used Besides quality marked Service CD must be used if the sulphur content of the fuel is higher than 1 per cent The chosen viscosity of oil depends on the air temperature at the engine In air temp...

Page 115: ...the rubber gasket of the filter with a little clean oil After changing the filter start up and check that the filter and the sealing surface towards the engine are tight A difference valve is fitted...

Page 116: ......

Page 117: ...009W2329 R01 O1 SECTION O COOLING WATER SYSTEM...

Page 118: ...mbly of pump page O 5 Refitment of pump page O 5 Circulation pump for freshwater page O 6 Removal of pump page O 6 Dismantling of pump page O 6 Reassembly of pump page O 6 Circulation pump page O 7 Zi...

Page 119: ...ith heat exchanger it is necessary out of considerationfor the capacity of the seawater pump to equip the exhaust system with a by pass hose as stated in section Y pages 8 and 9 In case of freshwater...

Page 120: ...hanged now by loosening the screw marked C 4 Take out the washer and locking ring behind the impeller Then loosen the bolt D in the mounting flange 5 Press the pump free of the cast intermediate housi...

Page 121: ...the reverse order of the dismantling Observe that the ball bearings of the intermediate housing are filled with grease free from acid Refitment of the pump Fit the pump in the reverse order of the re...

Page 122: ...r cooling and indirect freshwater cooling respectively are the same for the new pump as for the one previously used Further the impeller is the same as that used on the previous pu mp The new pump can...

Page 123: ...shaft marked 2 of the pump housing with ball bearings marked 16 and gear wheel 11 Now the sealing rings marked 17 and the O ring marked 18 and the washer marked 11 can be exchanged removed Dismantling...

Page 124: ...72 can be changed The flexible stuffing box cannot be repaired but has to be exchanged if the contact face shows signs of scratches or fractures 3 Remove the locking ring 522A0042 4 Take out the washe...

Page 125: ...009W2329 R01 O7 Circulation pump...

Page 126: ...inc anodes As standard for seawater cooling zinc anodes have been screwed into the two back holes as shown on the drawing below There is no zinc anode in the third hole as due to the placing of the st...

Page 127: ...temperature of 50 C In case of freshwater cooling the thermostate has an opening temperature of 80 C In case of freshwater cooling with keel cooler the thermostate has an opening temperature of 80 C...

Page 128: ...urpose Dismantling of heat exchanger In order to clean the heat exchanger element or in order to test it for pressure remove the profile cast rubber tubes on the inlet and outlet side of the seawater...

Page 129: ...009W2329 R01 O11...

Page 130: ...009W2329 R01 O12...

Page 131: ...P1 009W2329 R01 SECTION P ELECTRICAL SYSTEM...

Page 132: ...switch 2 battery starting system page P 4 Wiring diagram push button page P 5 Wiring diagram push button 2 battery starting system page P 6 Generator with double charging diodes page P 7 Key switch st...

Page 133: ...P3 009W2329 R01...

Page 134: ...P4 009W2329 R01...

Page 135: ...P5 009W2329 R01...

Page 136: ...P6 009W2329 R01...

Page 137: ...P7 009W2329 R01 Generator with double charging diodes Drg no 009V0053...

Page 138: ...P8 009W2329 R01...

Page 139: ...P9 009W2329 R01...

Page 140: ...P10 009W2329 R01...

Page 141: ...R1 009W2329 R01 SECTION R ZF GEAR BW7...

Page 142: ...Dismantling of lower gearbox part page R 14 Dismantling of upper gearbox part page R 14 Refitment of BW7 gear page R 15 Fitting of input shaft page R 20 Measuring of tightening and tapered roller bear...

Page 143: ...d no other attendance than regular change of oil This to be carried out after the first 25 hours of operation and then every 150 hours or once a year The oil change is carried out by means of the hand...

Page 144: ...R4 009W2229...

Page 145: ...apered roller bearings outer ring in connection with 009P3188 Order No 009P3190 Measuring instrument for adjustment of tapered roller bearings Order No 009P3191 Protective sleeve for seal ring 25x33x6...

Page 146: ...limit Axial clearance AHEAD and ASTERN wheels 0 1 0 4 mm Depth measure AHEAD Clearance appears when fitting and is examined at control ASTERN Clearance can be Adjusted by means of a thrust washer Dis...

Page 147: ...orque of hexagon nut M20x1 5 on the gear wheel bolts 50 Nm 5 Kpm Torque wrench Secure after having packed with liquid jointing on the contact face Torque of M8 screws in the halves of the gearbox 17 N...

Page 148: ...he shafts such as bearings gear wheels etc When assembling the gear and fitting the bearings it is necessary to heat the cylinder bearings in oil bath before fitting them The temperature must not exce...

Page 149: ...in without any problems in either cases Press the shifting lever out of the shifter shaft and take out the O ring 12x2 4 and the pin and the pressure spring Before the shifting lever is pressed out it...

Page 150: ...R10 009W2229 Unscrew the nut of the output shaft flange Pull off the output shaft flange Screw off the fixing screws which hold the halves of the gearbox together...

Page 151: ...oval of Input and Output Shaft ProTake out the screws M8x25 and the gear wheel bolts and remove the washer plate At the fitting the screws have been smeared with Loctite and consequently it may be nec...

Page 152: ...g fork At the fitting the threaded pin has been smeared with Loctite No 241 and so it may be necessary to heat 1 Shifting fork 2 Threaded pin 3 Reversing shaft Dismantling of Output Shaft Remove nut w...

Page 153: ...009W2329 R01 Remove the thrust collar wuth bolts and washers together wuth needle bearing bushing sliding sleeve and pressure spring Remove the wheel AHEAD with a special tool and take off all parts A...

Page 154: ...nd take up the washers At the fitting the tapered roller bearing outer collars have been smeared with Loctite 601 and so heating may be necessary At the dismantling Mark the adjusting washer s which l...

Page 155: ...rked Note Picture 19 Insert the sliding sleeve in the shifting fork and measure the axial clearance of the sliding sleeve The axial clearance below the wear limit must be 0 1 0 4 mm Picture 20 Insert...

Page 156: ...springs in the check bolts Fit the check bolts in the corresponding bores The point of the check bolts should turn so that it is horizontal Press the sliding sleeve from the bottom against the check b...

Page 157: ...fitting an intermediate washer thrust washer First fit a washer Then fit an inner disc and the an outer disc Fit 4 inner and 3 outer discs in this order Fit wheel for AHEAD with clutch discs on the th...

Page 158: ...rings must when slack in proportion to the front be min 1 1 mm measure A Tighten the disc springs with bush 1 x 56 136 994 Measure disc clearance between inner disc and washer with a feeler gauge in t...

Page 159: ...until it fits tightly against the disc springs Tighten the tapered roller bearing with bush No 1 x 56 136 995 and original hexagon nut until it fits tightly against the shaft assembly See picture No 3...

Page 160: ...ready mounted output shaft Fitting of Input Shaft Heat the tapered roller bearing inner collars to about 85 C and fit it with the thin end of the bearings towards the shaft ends NOTE Fit wide tapered...

Page 161: ...mm after the cooling Measure the tightening as shown on the pictures 35 36 and 37 and adjust it with adjusting washers measure G Measure G measure F difference measure plus tightening Fit the input a...

Page 162: ...e F as E minus A See picture No 35 on last page Calculate intermediate washer G for the input shaft as F plus tightening 0 03 0 08 mm At the calculations the thickness of the liquid jointing when comp...

Page 163: ...he tapered roller bearing with Loctite no 601 In order to be able to adjust the tightening of the roller bearing it is necessary that the shafts show axial clearance This is obtained by fitting interm...

Page 164: ...diate washer 0 755 mm In practice the intermediate washer will be 0 73 0 78 mm Then insert the correct intermediate washers in the bores max 2 washers in each bore and fit the bearing outer collars af...

Page 165: ...lubrication 8 Screw cap Insert pressure spring shift pin oiled shifter shaft and O ring in the gearbox Press the shift control lever on to theshifter shaft so that shift control leveris placed in neu...

Page 166: ...fitted in pos 1 or 2 all depending on the transmission Transmission GLL AHEAD GGL ASTERN Heat the gearbox and fit the bolts with slotted pins in pos 1 or 2 all depending on the transmission Fit the he...

Page 167: ...haft arrangement as shown on the picture NOTE The long side of the reversing shaft faces the input side Fit the intermediate wheel and needle bearing Lift intermediate wheel with s top plate see illus...

Page 168: ...bearings and reversing shaft and fit them together in the housing Remove the stop plate NOTE The long side of the reversing shaft points upwards to the input side Fit retaining plate for intermediate...

Page 169: ...eal f aces of the gearbox halves wit h permanently plastic liquid jointing Oil the bearings on the input and output shafts Assemble the gearbox and drive in the guide pins Tighten the screws M8x25 wit...

Page 170: ...lay er of plastic liquid jointing on the outside Fit the seal ring with punch No 1 x 56 199 916 so that it fits tightly against the bore of the housing Smear the similar seal ring 32 x 45 x 7 for the...

Page 171: ...Shaft Seal Rings A Distance to shaft seal ring 22 5 0 5 mm B Shaft seal ring binding with surface of casting on the lower gearbox half The picture shows the necessary mounting dimensions for the shaft...

Page 172: ...R32 009W2229 Heat the output flange to about 85 C and fit it on the output shaft Smear the nut with permanently plastic liquid jointing and secure it with a torque of 100 Nm 10 Kpm...

Page 173: ...g screws hit against the walls of the gearbo x because of the slots which may lead to wrong adjustments Adjustment can be c arried out by axial displacement angle 90 m ust be maintained see picture 40...

Page 174: ......

Page 175: ...009W2329 R01 S1 SECTION S SAIL DRIVE TYPE Z 7...

Page 176: ...de maintenance page S 3 Removal of sail drive from engine and boat page S 3 Alarm function of double membrane page S 5 General for assembly and dismantling of sail drive page S 6 Assembling procedure...

Page 177: ...Zinc Anode A replaceable zinc anode is fitted at the propeller Check this anode twice a year or as required all depending on the waters you are sailing in Outside Maintenance Do not grind thoroughly...

Page 178: ...009W2329 R01 S4...

Page 179: ...w The sensing element is connected to the the operating panel and if water penetrates into the double membrane it will release an acoustic alarm As a precaution the alarm function should be checked on...

Page 180: ...nge them two and two i e do not change one single gear wheel but one connected set of gear wheels When replacing the coupling arrangement at the top of the sail drive replace the whole arrangement wit...

Page 181: ...pipe collar too b Lead the reversing house with gasket into the opening of the clutch housing and press the shifting eccentric into the wedge shaped groove of the shifting fork In order to equalize t...

Page 182: ...he shifting fork arrangement for the test described in the next point 15 to be carried out 15 Mount the clamping tools for fixing of the big gear wheel Mount a dial indicator on the gear wheel of the...

Page 183: ...usted with the fitted washers T measure with special tools 28 Measure the V measure 29 Heat the bearing housing and fit the bearing with the ball filling opening facing the gear wheel side 30 Measure...

Page 184: ...009W2329 R01 S10...

Page 185: ...009W2329 R01 S11...

Page 186: ...009W2329 R01 S12...

Page 187: ...009W2329 R01 S13...

Page 188: ......

Page 189: ...009W2329 R01 T1 SECTION T IRREGULAR OPERATION CAUSES AND REMEDIES...

Page 190: ...maximum output page T 3 Knocking operation of engine page T 3 Engine speed too high page T 3 The engine knocks page T 3 The engine smokes page T 3 Excessive consumption of lubricating oil page T 3 Ex...

Page 191: ...gine speed too high Governor not working properly Governor spindle is bent or works sluggish Repair or replace spindle Governor not properly adjusted Governor arm has turned on the spindle Adjust arm...

Page 192: ......

Page 193: ...009W2329 R01 V1 SECTION V MAINTENANCE...

Page 194: ...009W2329 R01 V2 CONTENTS Recommended maintenance and check list page V 3...

Page 195: ...6 2 sufficient water flow to rear stern tube bearing check that water holes in bearing housing are not blocked clean holes X 6 3 alignment of gear flange and prop shaft flange alignment to be within 0...

Page 196: ......

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