BUKH Diesel Engine OWNER USER OPERATOR Manual

009W0327-R03 OWNER'S HANDBOOK FOR BUKH MARINE DIESEL LIFEBOAT ENGINE TYPE DV36 ME BUKH A/S Aabenraavej 13 - 17 DK - 6340 Krusaa Tel: +45 74 62 20 88 Fax: +45 74 62 74 07 E-mail: bukh@bukh.dk www.bukh.dk

OPERATING MANUAL FOR BUKH DV36ME ENGINES 009W0327-R03 - 2 - CONTENTS Page Pictures for recognition of engine ................................................ 3 Introduction .................................................................................. 4 Standard equipment ..................................................................... 4 Operating manual ......................................................................... 4 Preparation for the first start......................................................... 5 Before start ................................................................................... 5 Electric start ................................................................................. 5 Hand start ..................................................................................... 5 After start…………………………………………………….…… ..... 6 Maneuvering ................................................................................ 6 Stopping the engine ..................................................................... 6 Running in .................................................................................... 6 Maintenance ................................................................................. 6 Belt for alternator .......................................................................... 6 Air inlet filter ................................................................................. 6 Fuel filter....................................................................................... 6 Fuel lift pump ................................................................................ 7 Lubricating oil system................................................................... 7 Change of oil ................................................................................ 7 Recommended lubricating oil ...................................................... 7 Change of lubricating oil filter ....................................................... 7 Cooling water system ................................................................... 7 Seawater cooling.......................................................................... 7 Exchange of zinc anode ............................................................... 7 Exchange of impeller.................................................................... 7 Freshwater cooling ....................................................................... 8 Frost precautions ......................................................................... 8 Electrical system .......................................................................... 8 Marine gear .................................................................................. 8 Propeller equipment ..................................................................... 9 Sail drive....................................................................................... 9 Galvanic corrosion ..................................................................... .10 Starting instructions.................................................................... .10 Winter storage of the engine ...................................................... .11 Technical data for engine and gearbox...................................... .12 Recommended maintenance and checklist ............................... .13 Irregular operation ...................................................................... .14 Lubricating oil chart .................................................................... .15 El-diagram .................................................................................. .16 DV36 installation.. ....................................................................... 17 List of representatives ................................................................. 18 General Terms of Sale and Delivery .......................................... .22

OPERATING MANUAL FOR BUKH DV36ME ENGINES 009W0327-R03 - 3 - 1. Lubricating oil filling plug 2. Valve cover 3. Electric stop solenoid 4. Air filter with noise suppression 5. Fuel filter 6. Cooling water drain plug 7. Dipstick for engine oil 8. Oil pressure switch 9. Lubricating oil filter 10. Fuel pump 11. Control lever 12. Cock 13. Reversing lever for gear 14. Bracket for reversing cable 15. Coupling flange for propeller shaft 16. Reverse-reduction gear 17. Housing for vacuum valve 18. Bilge pump for change of lub. oil 19. Bracket for control cable 20. Electric multi plug 21. Fuel lift pump 22. Lifting fittings 23. Water cooled exhaust manifold 24. Zinc anode 25. Cooling water expansion tank 26. Cooling water filling plug 27. Identification label 28. Water drain plug for exhaust manifold 29. Thermostat housing 30. Cooling water temperature transmitter 31. Exhaust 32. Outlet to keelcooler 33. Circulation pump 34. Dip stick for gear oil 35. Reversible engine mountings 36. Lubricating oil cooler 37. Electric starter 38. Inlet from keel cooler 39. Flywheel 40. Tension device for V-belt 41. Alternator

OPERATING MANUAL FOR BUKH DV36ME ENGINES 009W0327-R03 - 4 - INTRODUCTION BASIC ENGINE CONFIGURATION: The BUKH Marine Diesel engine is a four-stroke marine diesel engine with direct fuel injection and the following basic equipment: Crankcase with oil pan, one-piece cylinder head with 2 valves per cylinder, forged crankshaft with counterweights, balance weights, cast iron connecting rods, light metal pistons, water-cooled exhaust manifold; all necessary pipework for exhaust, coolant, fuel and lubricating oil are fitted on engine. A reverse/reduction gearbox with integrated thrust bearing is fitted on the engine. No BUKH Diesel Engine is sent from the factory without having been thoroughly tested. The tests have shown that the engine in all aspects is working satisfactorily and is generating its full power. You will expect the engine to work reliably witout giving any problems, and to achieve this you are asked to follow the instructions in this manual. By so doing, you will get the best from your BUKH engine. If a problem with the engine should arise, we ask you to apply to one of our distributors, who will always be ready to help you, having skilled personnel, necessary tools etc., and at the same time you will be sure that only original BUKH spare parts are used. Do always use original BUKH spare parts. When ordering spare parts from the distributor please state: Engine type and serial number, description and number of parts. BUKH A/S Powering Marine Safety As BUKH A/S is always endeavouring to improve the engines, the specifications mentioned are subject to alterations without previous notice. Read this instruction book thoroughly before starting your new BUKH Diesel Engine. STANDARD EQUIPMENT for DV36ME Reverse-reduction gear Decompression lever Wet sump lubrication oil system Full-flow lubrication oil filter Automatic injection timing Centrifugal governor Watercooled exhaust manifold Air inlet filter and silencer Fuel lift pump Electric start Charging alternator Operating remote panel with: a) Charging light b) Lub. oil pressure warning light c) Cooling water temp. warning light d) Key switch for start and stop e) Audible warning Fittings for remote control Standard set of tools Drain pump for lub. oil (built on engine) Following documentation is delivered with the engine: 1. Operating manual with sparepart katalog 2. Test certificate Flex. engine mounts (optional) Stern gear (optional) Raised hand start (optional) OPERATING MANUAL Before the engine is put into use you are recommended to get familiar with the placing of the following components of engine and gear: Fuel oil filter, lub oil filter and air intake filter, fuel lift pump with handle, zincrod in the crankcase and water-separator in the fuel pipe (if mounted). Where is lub oil poured into engine and gear and where are the dipsticks placed? Where is fuel oil filled into the fuel tank and where is the drain plug placed? Where is the main switch?

OPERATING MANUAL FOR BUKH DV36ME ENGINES 009W0327-R03 - 5 - Preparation before first start 1. Pour lubricating oil through filling hole on top of valve cover. Check that oil level is between the marks on the dipstick, placed at the port side of the engine. Check oil level as mentioned below: a) remove and wipe dipstick b) reinsert dipstick in the pipe c) withdraw dipstick, check oil level. 2. Pour lubricating oil through dipstick hole on the top of reverse- and reduction gear and check oil level as described in pos 1. 3. Flexible sterntube: Lubricate the stuffing box with sterntube oil (outboard). Unscrew the filler plug and pour in oil until the bearing is full. Important:The stuffing box shall under no circumstances be force-lubricated. These instructions are only valid for propeller equipment supplied by BUKH. If other equipment is mounted, we refer to the instructions given for this. 4. We always recommend checking of oil level before start. 5. Fill the fuel tank. 6. Bleed the fuel system in the following way: a) Loosen the slotted screw B on the fuel filter and pump with the handle A on the fuel lift pump until the fuel is free from air bubbles and runs out at the slotted screw. b) Tighten the slotted screw B and continue pumping with the handle A until fuel, free from bubbles, runs through the transperent hose from fuel pump to tank. You must lock the pumping handle in the upper position when you have finished pumping. c) Loosen the fuel pressure pipes at their connection on the fuel valves and turn the engine by the starter motor until fuel, free from bubbles, runs out from the fuel pressure pipes. Finally tighten the pipes and the engine fuel system is ready for use. Normally it will not be necessary to bleed the fuel system before starting but after changing the fuel filter element or carrying out any work on the fuel system it should be bled in the following way: Loosen the bleed screw and operate the hand priming lever on the fuel lift pump until air-free fuel discharges from screw. Tighten bleed screw. Loosen high pressure pipe unions to injectors and turn engine until fuel discharges from pipes. Reconnect pipes to injectors. The engine will start in the normal way. AFTER THE ENGINE HAS BEEN TAKEN INTO USE Before start 1. The oil level of the engine should be checked every 14 days or every 25 hours of running as described in ”Preparation before first start”. It is not necessary to refill oil if the level is between the two marks on the dipstick. 2. The oil level of the reduction gear should be checked every 14 days or every 25 hours of running as described in ”Preparation before first start”. 3. The sterntube stuffing box should be lubricated every 14 days or every 25 hours of running. 4. Check the quantity of fuel in the tank. Electric start with remote control and instrument panel 1. Switch on the main switch. 2. Put the marine gear in neutral position by means of the control handle. 3. The engine is started by pushing the key and turning it to the right. The starter should not work for more than 10-15 secs. continuously. Hand start (optional) 1. Put the gear lever in neutral position. 2. Turn decompression lever on valve cover anti-clockwise as far as possible. 3. Engage starting handle and crank engine as quickly as possible. Release decompression lever quickly by turning lever clockwise while cranking and engine will start. 4. By hand start in cold weather you may achieve an easier start after having cranked the engine with activated decompression lever before the starting procedure. Never accelerate a cold engine. Let it get warm first.

OPERATING MANUAL FOR BUKH DV36ME ENGINES 009W0327-R03 - 6 - After Start 1. When the engine has started, the RPM should be 900-1000 RPM when idling. 2. Check the oil pressure. Normally this should be 2-4.5 bar. With cold engine the RPM should be kept down so that the oil pressure does not exceed 4.5 bar. When idling at warm engine the oil pressure must not be below 1 bar. 3. Immediately after start the oil pressure warning lamp should go out. During normal operation the lamp should stay off. 4. Make sure that the charging control lamp goes out after the engine has started. 5. Check the cooling water temperature frequently. The temperature should be in the area of 70 – 95 o C when engine is warm. Manoeuvering 1. With the control lever in central position the engine is idling, and the marine gear is in neutral (pos. 0). When the lever is moved forward in range 1, the marine gear is engaged to "Ahead” first, and then in range 2 the engine R.P.M. is increased. When the lever is moved from the central position to range 3, the marine gear is engaged to "Astern” first, and then in range 4 the engine R.P.M. is increased. 2. Only engage "Ahead” or "Astern” when the engine is idling. 3. To accelerate engine without engaging gear, operate gear release button 5 and move control handle in either direction. 4. Increase the load gradually from idling in the course of the first 15-20 minutes shortly after the start of the engine. Stopping the engine 1. Reduce the load gradually in the course of 15-20 minutes before stop. 2. Reduce the engine to idling and put the gear in neutral position. 3. Turn the ignition key left to stop position, pushing it slightly inwards. The key must not be left in this position after the engine has stopped due to the large current consumption of the stop solonoid. In this position the acoustic alarm will function, when the engine has stopped. 4. Turn off the battery main switch. Running in To secure long life and maximum power it is recommended to run the engine for the first 25 hours at not more than 80 pct. of the maximum output (about 3200 r.p.m.) You should avoid slow hauling as for instance towage. After the first 25 hours it is recommended to change engine and gear oil and to tighten up the cylinder head and to check or to possibly adjust the tension of the V-belt. Besides, it is recommended to let an authorized service dealer go over engine and installation. MAINTENANCE Belt for alternator To be adjusted every 150 hours by turning the alternator round the centres of suspension. Tensioning should be so as to allow 8 - 10 mm deflection of the belt under firm thumb pressure. Air inlet filter This is a wire gauze filter to be rinsed in petrol and cleaned by a blast of compressed air after 300 hours' operating. Fuel filter A fuel filter is fitted between the fuel lift pump and the H.P. fuel pump. The filter is a disposable one which cannot be cleaned. It should be changed every 300 operating hours or if water contamination is suspected. Change the filter as follows: 1. Drain off the fuel from the filter by slackening drain screw A in the bottom of the filter casing B. 2. Remove by hand or by means of a pair of tongs the filter casing and discard it. 3. Clean the sealing surface of the filter holder C if necessary. 4. Fill the new filter casing with clean fuel through the holes at the top of same. 5. Screw on the filter casing and tighten it by hand about half a turn after the gasket fits tightly. 6. After changing the filter, bleed the fuel system as stated under ”Preparation for first start”

OPERATING MANUAL FOR BUKH DV36ME ENGINES 009W0327-R03 - 7 - Fuel lift pump The fuel lift pump is a cam shaft driven sealed type diaphragm pump, which cannot be dismantled for repair or cleaning. It is recommended to install a water/dirt accumulating filter in the suction line to the pump. After repairs the fuel system must be bled as described under ”Preparation for the first start” if necessary. Lubricating Oil System The engine is pressure lubricated and the oil system has a built-in relief valve for controlling the oil pressure. A lubricating oil cooler is also fitted. The oil level is checked as mentioned before. Change of Oil Lubricating oil should be changed for the first time after 25 hours of running, later for every 150 hours or at least once a year. It is recommended to change the oil when engine is warm, and the procedure is as follows: 1. Turn the left cock below oil bilge pump 90°. 2. Pump up the oil from the sump by means of the bilge pump. 3. When the sump is empty pour fresh oil. 4. Check oil level on dipstick. Recommended Lubricating Oil Modern diesel engines demand heavy-duty oils with additives securing best operation conditions and longest life time of the engine under various conditions. Therefore use a first class HD-oil from a recognized oil company. Oil specifications as mentioned in ”LUBRICATION OIL CHART”. When operating under difficult conditions, i.e. frequent cold starting, short operation periods, greatly varying loads, use quality ”Service CD” and also use quality "Service CD" in case the sulphur content of fuel is higher than 1 %. Change of Lubricating Oil Filter Lubricating oil filter cannot be cleaned, but should be changed every 150 hours or once a year. To change the filter proceed as follows : 1. Unscrew filter A and discard it. 2. Clean the sealing surface of the engine B, and remove old gasket C if any from old filter 3. Mount new filter at once under clean conditions. 4. Screw on filter until gasket fits tightly, tighten a further half turn. 5. Fill with oil until normal level is reached. 6. Start the engine and check that the filter is tight. Cooling water system Normally the engine is direct seawater-cooled, however, alternatively it can be delivered with freshwater-cooling, or it may be fitted with this later on. Freshwater-cooling is particularly used in boats running more than 500 hours a year. Seawater cooling From external strainer the cooling water is drawn through the lubricating oil cooler to the pump from where the water is fed through the cooling jackets up to the cylinder head and from there, via the watercooled exhaust manifold and thermostat overboard, through the exhaust pipe. A thermostat is fitted in the watercooled exhaust manifold. This ensures a constant cooling-water temperature between 50-75°C Exchange of zinc anode In order to protect against corrosion in the engine cooling-water system, there is one zinc anode fitted on the starboard side of the crankcase under the water-cooled exhaust manifold. The zinc anode must be checked 2-3 times during the season, dependent on the waters you are sailing in. If the zinc anode is corroded away it must be replaced. Exchange of impeller in cooling-water pump The cooling-water pump is a rotary pump with a neoprene impeller. The impeller cannot stand up to dry running for more than 20 sec., and this is why you must make sure before starting the engine that the sea-cock is open. When building the boat or during winter storage of the engine, you must not put water pressure to the seawater in-take, as this may fill the engine cylinders with water. Due to varying temperatures and the one-sided deformation during the winter storage, the impeller should be taken out and kept separately during this period. Change the impeller by slackening the six screws in the cover of the pump, remove the cover and withdraw the impeller which is fitted on a multi spline shaft. Too high cooling temperature (defective pump impeller) or defects on thermostat will cause the blue lamp in the control panel to light up and the acoustic alarm to function. If the thermostat is removed, the by-pass for cooling water has to be closed.

OPERATING MANUAL FOR BUKH DV36ME ENGINES 009W0327-R03 - 8 - Freshwater cooling When using freshwater cooling it will be possible to reach a higher operating temperature of 70-95°C which will prolong the life of the engine. This cooling system is recommended for engines operating for more than 500 hours a year. A pump circulates the freshwater in a closed system. This circulation pump is fitted on the back end of the engine. The fresh water circulates through the cooling jackets of the engine and through the heat exchanger fitted on the water-cooled exhaust manifold. The freshwater is cooled in the heat exchanger by seawater which is pumped through by a big impeller pump like the one used for direct seawater-cooling. The seawater leaves the heat exchanger via the exhaust system as in the case of seawater cooling. Frost precautions To avoid damaging the engine, drain the cooling water during frosty periods. To protect the engine against damage caused by frost, proceed as follows: 1. Turn off the cock on the cooling water inlet skin fitting. 2. Drain the cooling water off the engine by removing the plug above the lubricating oil filter on starboard side and under the exhaust manifold, respectively. 3. Clean up the drain holes with a nail, a steel wire or the like, so that any remaining water may drain out. 4. Start the engine and let it run for 30 seconds to remove all the water from engine and exhaust manifold. Running for that short time will cause no damage to the impeller of the pump. On engines fitted with heat exchanger cooling it is recommended to use a mixture of min. 30% antifreeze liquid and 70% water and max. 50% antifreeze and 50% water as protection against corrosion and to secure the cooling water freezing temperature to min. minus 15° Celsius or lower if required from climate conditions. However please also note when doing service on the boat that the mix of water and antifreeze can get aggressive and start corrosion. If corrosion is found in the cooling system it can be caused by one of two conditions: 1. The anti corrosion additives in the anti freezing liquid are exhausted and have evaporated. 2. Oxidation due to incoming air causing an acid which is lowering the PH value. Therefore and also to keep the anti freezing properties it is recommended to change the cooling water and antifreeze every 3 years min. Please also note the details provided by your supplier of antifreeze liquid normally stated on the can. Heat exchanger freshwater capacity for DV36 is approx. 7.0 litres. Drain the raw water from the heat exchanger cooled engines by taking off the seawater pump cover. Electrical System The engine is equipped with a 12 volt electrical system consisting of a starter motor and an alternator, the max. charging current of which is 50 Amp. Electrical wiring diagram for the engine with control and instrument panels is shown later in this instruction. The level of the electrolyte in the battery should be checked every 14 days or every 25 operating hours. The level should be 5-6 mm above the plates, if this is not the case top up as required with destilled or demineralized water. The battery must never be isolated from the alternator, when the engine is running. Warning! It is not allowed to connect additional equipment to the wiring system on the engine. Possible additional equipment has to be connected directly to the terminals of the battery. NOTE! The starter must not be operated for more than 10 sec. If further operation is necessary, a pause of at least half a minute before starting attempt is repeated. Marine Gear The engine is equipped with a reverse-reduction gear. The standard reduction is 3:1 for AHEAD and 2.5:1 for REVERSE (but also available as 2.5:1 for special purposes). The marine gear will need no other attendance than regular change of oil. This to be carried out after 25 hours of operation, and then every 150 hours or once a year. See oil quality under "Technical data" . The oil change is carried out by means of the lubricating oil bilge pump fitted on the engine. The oil should be warm when draining. Refill new oil to the quantity of 0.8 liters through the dipstick hole. Check oil level on the dipstick. Don’t forget to close the cock before starting up. 28. Cooling water filling plug 31. Zinc anode 33. Thermostat housing 34. Temperature transmitter 37. Lubricating oil cooler 42. Heat exchanger 43. Cooling water pump

OPERATING MANUAL FOR BUKH DV36ME ENGINES 009W0327-R03 - 9 - Propeller equipment (As supplied by BUKH – for other types consult individual manufacturer’s instructions) Flexible stern tube: Every three years replace the three seal rings in the stuffing box “A” and the rubber hose “B” connecting stuffing boxand inter- mediate tube “C” . Fill the flexible stuffing box “A” with Out-board gear oil through the filler hole in this or via the automatic stern tube lubrication “D” supplied as extra equipment to the stern tube arrangement. Normally the consumption of Out-board gear oil is not considerable, and therefore, a sudden increase indicates defectivesealing rings. The container “D” should be mounted about 0.25 m above the water line. Sail drive As an alternative to the marine gear, the engine can be equipped with a sail drive. The sail drive has the same function as the reverse-reduction gear. The reduction is 2.25:1 for AHEAD and for REVERSE. The sail drive will need no other attention than regular change of oil. Change of oil should be carried out after the first 25 hours of operation, then every 150 hours or once a year. Carry out the oil change when the boat is on land by loosening the screw ”D” in the bottom of the drive, enabling the oil to run out. Refill the fresh oil to a quantity of 3.3 ltr. through the filter hole “B” at the top of the drive corresponding to the upper mark on the dipstick “A”. Use the same quality of oil as indicated iunder “Technical Data” for the marine gear. A replaceable zinc anode “C” is fitted on the sail drive. Check this anode once a year, replace it in case of considerable corrosion. Only use a propeller which is insulated from the shaft and the leg!. Check that there is good electrical connection between the zinc anode and the bearing hub through the two mounting screws. The sail drive is equipped with a double diaphragm “F” preventing penetration of seawater. In the double diaphragm a sensor “E” is fitted which releases an acoustic alarm if water penetrates between the two diaphragms. It is important for the sake of safety that this alarm is always serviceable. It should be checked twice a year by short-circuiting the connections 1 and 2 on the plastic box next to the multiple plugs. When short-circuiting here by means of a piece of wire or a screw-driver, the buzzer should give alarm. The aluminium housing of the sail drive has been specially treated on the outside. Damage to surface treatment should be treated as soon as possible with special BUKH paint. The sail drive should be coated with the same paint as the rest of bottom of the boat. This paint must not contain copper.

OPERATING MANUAL FOR BUKH DV36ME ENGINES 009W0327-R03 - 10 - Galvanic corrosion To avoid corrosion of the propeller due to galvanic action it is advisable to fit a sacrificial zinc anode on the outside of the hull. To obtain a high degree of protection, electrical contact between sacrificial zinc (anode) and propeller (cathode) has to be established. This is obtained by fitting the sacrifial zinc and connecting electrically, as shown on the sketch. For the DV36 a sacrificial zinc of BERA 2B type is recommended. The sacrificial zinc must not be painted or be otherwise insulated, as this will prevent the zinc from corroding. The sacrificial zinc must be checked everytime the boat is ashore, or at least twice a year. If the corrosion turns out to be very heavy, bigger anodes, e.g. 2 pcs. BERA 2B or 1 pc. BERA 1, should be fitted. If there is no corrosion, check the electrical connections. A good way of fitting the sacrificial zinc is to fold down one of its flaps and to clamp it to thestern bearing by means of a rustproof clip as shown on the sketch. Starting instructions for BUKH Diesel Engine type DV36ME Electric start: 1. Switch on the main switch. 2. Put the gear into neutral position 3. Turn the start switch to the right until the engine starts Hand start (Emergency start): a. Put the gear into neutral position b. Put the handle into the crank claw c. Lift the decompression lever (1) Only for cold start (below 0 o C, if mounted): Start pilot: Pull and push the pump (2) 2-3 times. d. Turn the starting handle counter-clockwise as quickly as possible, release the decompression lever but keep on turning until the engine starts. Stopping the engine: Turn the start switch to the left. After the engine has stopped: Turn the switch right to neutral position. Filling the pressure tank (3) (if mounted): 1. Open the cover. 2. Put the gas cylinder on top of the valve and fill up the tank to max. marking.

BUKH Diesel Engine OWNER USER OPERATOR Manual

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