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Страница 1: ...009W2228 Publ No 009W2228 Work shop Manual for BUKH diesel engine TYPE DV10 20 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 dk...

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Страница 245: ...R1 009W2229 R01 SECTION R ZF GEAR BW7...

Страница 246: ...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 bea...

Страница 247: ...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...

Страница 248: ...R4 009W2229 R01...

Страница 249: ...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...

Страница 250: ...ar 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 D...

Страница 251: ...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...

Страница 252: ...the 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 ex...

Страница 253: ...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...

Страница 254: ...R10 009W2229 R01 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...

Страница 255: ...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...

Страница 256: ...ing 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...

Страница 257: ...009W2229 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...

Страница 258: ...and 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...

Страница 259: ...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...

Страница 260: ...e 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...

Страница 261: ...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...

Страница 262: ...springs 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...

Страница 263: ...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...

Страница 264: ...he 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 taper...

Страница 265: ...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...

Страница 266: ...ure 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 co...

Страница 267: ...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...

Страница 268: ...mediate 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...

Страница 269: ...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...

Страница 270: ...be 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...

Страница 271: ...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 stop plate see illust...

Страница 272: ...r 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 intermediat...

Страница 273: ...seal faces of the gearbox halves with 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 with...

Страница 274: ...in layer 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 th...

Страница 275: ...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...

Страница 276: ...R32 009W2229 R01 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...

Страница 277: ...ing screws hit against the walls of the gearbox because of the slots which may lead to wrong adjustments Adjustment can be carried out by axial displacement angle 90 must be maintained see picture 40...

Страница 278: ......

Страница 279: ...009W2229 R01 S1 SECTION S SAIL DRIVE TYPE Z 7...

Страница 280: ...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...

Страница 281: ...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...

Страница 282: ...009W2229 R01 S4...

Страница 283: ...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...

Страница 284: ...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...

Страница 285: ...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...

Страница 286: ...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...

Страница 287: ...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...

Страница 288: ...009W2229 R01 S10...

Страница 289: ...009W2229 R01 S11...

Страница 290: ...009W2229 R01 S12...

Страница 291: ...009W2229 R01 S13...

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