Bukh Marine Diesel Lifeboat Engine type DV29 RME Owner's Handbook
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OWNER'S HANDBOOK
FOR
BUKH MARINE DIESEL
LIFEBOAT ENGINE
TYPE DV29 RME
AABENRAA MOTORFABRIK
Heinrich Callesen A/S
Næstmark 30, P.O. Box 79
DK 6200 AABENRAA
Tel: +45 74 62 20 88
Fax: +45 74 62 74 07
E-mail: bukh@bukh.dk
www.bukh.dk
009W4921-R06
OPERATING MANUAL FOR BUKH DV29RME LIFEBOAT ENGINES
CONTENTS
Page
Pictures for recognition of engine....................................... 3
Introduction, 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
Electrical system ................................................................ 8
Marine gear ........................................................................ 8
Starting instructions............................................................ 8
Winter storage of the engine .............................................. 9
Hydro – and Spring Starter .............................................. 10
Lubricating oil quantities................................................... 10
Instruction for Marine Diesel Fuel in cold climates ........... 10
Lubricating oil for Spray pump ......................................... 11
Technical data for engine and gearbox ............................ 12
Recommended maintenance and checklist ..................... 13
Irregular operation ............................................................ 15
Lubricating oil chart .......................................................... 16
El-diagram ........................................................................ 17
DV29 installation .............................................................. 18
General Terms of Sale and Delivery ................................ 19
009W4921-R06 - 2 -
OPERATING MANUAL FOR BUKH DV29RME LIFEBOAT ENGINES
1. Bracket for reversing cable
2. Bleeder valve for gear
3. Reversing lever for gear
4. Lubricating oil pump
5. Electric stop solenoid
6. Bracket for control cable
7. Engine speed control lever
8. Exhaust pipe connection
9. Fuel filter
10. Lubricating oil filling plug
11. Lifting fittings
12. Cooling water filling plug
13. Air filter with noise
suppression
14. Water cooled exhaust
manifold
15. Outlet to keelcooler
16. Thermostat housing
17. Plug for hot-water take off
18. Alternator
19. Tension device for V-belt
20. Transmitter for cooling water
alarm and temperature
21. Electric starter
22. Oil pressure switch
23. Reversible engine mountings
24. Lubricating oil filter
25. Electric multi plug
26. Plug for draining off lubricating oil
27. Reverse-reduction gear
28. Coupling flange for propeller shaft
29. Cooling water expansion tank
30. Inlet from keelcooler
31. Dipstick for engine oil
32. Fuel lift pump
009W4921-R06 - 3 -
OPERATING MANUAL FOR BUKH DV29RME LIFEBOAT ENGINES
INTRODUCTION
BASIC ENGINE CONFIGURATION:
The BUKH Lifeboat 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.
All BUKH Diesel Lifeboat Engines are tested in the factory, and a test certificate according to SOLAS and ISO regulations is
issued.
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.
AABENRAA MOTORFABRIK
Heinrich Callesen A/S
As Aabenraa Motorfabrik 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 DV29RME
Reverse-reduction gear
Decompression lever
Wet sump lubrication oil system
Full-flow lubrication oil filter
Automatic injection timing
Centrifugal governor
Keel cooling with thermostat
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) Push button for start
e) Electric stop or mechanical stop
f) Audible warning
Fittings for remote control
Standard set of tools
Drain pump for lub. oil
Following documentation is delivered with the engine:
1. Operating manual with sparepart katalog
2. Test certificate
3. Declaration of conformity according to SOLAS and
IMO regulations.
Flex. engine mounts (optional)
Stern gear (optional)
Raised hand start (optional)
Spring start (optional)
2 El-start (optional)
Hydro 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?
009W4921-R06 - 4 -
OPERATING MANUAL FOR BUKH DV29RME LIFEBOAT ENGINES
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 as below:
a) Pump with the fuel lift pump handle until fuel is free from air bubbles seen
in the hose to the fuel tank. After the pumping the pump handle must be
locked in top position.
b) Loosen fuel pipe connection on the fuel valve, if neccessary.
c) Turn the engine until fuel is free from air bubbles. Retighten the pipe
connection.
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.
7. Bleed the cooling water system by removing the pressure cap. While en-
gine is idling pour water into the expansion tank until system is free of air
(loosen possible plug pos. 17 on the thermostat housing).
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 putting the switch into ”RUN” position.
4. Push the ”START” button until the engine starts. 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 clockwise as far as possible.
3. Engage starting handle and crank engine as quickly as possible. Release
decompressor by turning lever anticlockwise 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.
009W4921-R06 - 5 -
OPERATING MANUAL FOR BUKH DV29RME LIFEBOAT ENGINES
After Start
1. When the engine has started, the RPM should be 800-1000 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 goes 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. Push the ”Stop” button (or pull the mechanical stop handle) until engine stops.
4. Move the ”Off/Run” switch to the ”Off” position.
5. 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”
009W4921-R06 - 6 -
OPERATING MANUAL FOR BUKH DV29RME LIFEBOAT ENGINES
Fuel lift pump
The fuel lift pump is a sealed type 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. 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. Remove the dipstick.
2. Insert the sump pump suction hose into the hole and pump up the oil.
3. When the sump is empty reinsert dipstick and pour fresh oil.
4. If possible, drain the oil through the plug hole at the bottom of the sump.
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 system (Keel cooling)
A pump circulates the freshwater in a closed system.This circulation pump is fitted on the front end of the engine.
The freshwater circulates through the cooling jackets of the engine and through the keel cooler, fitted on the bottom of the
boat.
Too high cooling temperature will cause the blue lamp in the control panel to light up and the acoustic alarm to function.
Frost precautions
It is recommended to use 25 per cent ethylene glycol in the cooling water all the year as protection against corrosion and
freezing cooling water.
1. Cirkulating pump
2. Expansion tank
3. Thermostat 75
o
C
4. Pressure cap
5. Keel cooling pipe 2 x ø22/ø19
copper pipe
009W4921-R06 - 7 -
OPERATING MANUAL FOR BUKH DV29RME LIFEBOAT ENGINES
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 syatem 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 reduction is 3:1 for AHEAD
and 2.36:1 for REVERSE.
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 "Technical data" .
The oil change is carried out by means of the lubricating oil bilge pump.
The oil should be warm when draining.
Refill new oil to the quantity og 1.1 liters through the dipstick hole.
Check oil level on the dipstick.
Starting instructions for BUKH Diesel Engine type DV29RME
Electric start:
1. Switch on the main switch.
2. Put the gear in neutral position
3. Put the switch into ”RUN” position
4. Push the ”START” button until the engine starts
Cold Start (below minus 15
o
C if mounted):
Start pilot: Pull and push the pump (2) 2-3 times.
Stopping the engine: Push the ”STOP” button until
the engine stops.
After the engine has stopped:Put the switch
in ”OFF” 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.
Hand Start: (If mounted):
Put gear into neutral position.
Put handle into crank claw.
Lift decompression lever (1).
Cold start with hand start (below 0
o
C).
Start pilot: Pos 1 – 2 - 3
Pull and push the pump (2) 2-3 times.
Turn the start handle as quickly as possible (clockwise), release the decompression lever, but keep on turning until the
engine starts.
009W4921-R06 - 8 -
OPERATING MANUAL FOR BUKH DV29RME LIFEBOAT ENGINES
WINTER STORAGE OF THE ENGINE
1. Carry out the following whilst the boat is still in the water:
1. Run the engine until normal workingtemperature is reached.
2. Drain off engine and gear oil with the oil bilge pump.
3. Fill the engine and gearbox with preservative lubricating oil of a recognized make up to the upper mark on the dipstick.
4. Fill the fuel tank with fuel preservative oil in the rate of mixture prescribed by the oil manufacturer.
5. Start the engine and let it run for about 10 minutes to be sure that the fuel mixed with preservative oil has been flushed
through the fuel system of the engine.
6. Fill the fuel tank completely with fuel. Pay no special attention to the preservative oil previously added to the fuel as this
is consumed normally and properly when service is resumed in spring.
2. On land the following procedure has to be carried out:
1. Remove the engine cooling water drain plugs, drain off the sea water from the engine and refit plugs.
2. For direct sea water cooled engines: Remove the suction hose from the cooling water pump at the bottom cock and put
the hose into a bucket with freshwater containing preservative oil in the rate of mixture prescribed by the oil
manufacturer
3. The outlet hose for the cooling water which goes into the exhaust elbow may be removed and returned to the bucket via
a length of hose so that the freshwater is able to circulate.Start the engine and the freshwater containing preservative oil
will be flushed through the engine.
4. Stop the engine after 5 - 10 minutes and drain off the water. Ensure that after removing the drain plug (1 plug is placed
in the block, see fig. 4, pos. 24; and 1 plug in the exhaust manifold) all the water is drained off. This is done by cleaning
the drain holes with a nail,a steel wire or the like, so that any remaining water may drain out. Remove the impeller from
the cooling water pump, which will allow water in pump and pipes to be drained off. Keep the impeller separately in a dry
place during the winter.
5. A: For freshwater-cooled engines:
6. Drain the freshwater from the engine by removing the plugs as indicated for seawater cooled engines. It is not
necessary to flush this system with freshwater containing preservative oil. If the engine is to be used in period of frost, it
must be protected against frost burst with a mixture of anti-freeze solution in the freshwater system - irrespective of the
protection to the freshwater system against the risk of frost - by removing the cover of the impeller pump and turning the
engine manually or with the starter motor.
7. Remove the battery and store it separately during the winther in a dry and frost-free place. Fill up and charge the battery
before storing.
8. Remove the air filter and turn the engine manually until each inlet valve opens alternately, during which about 1/2 cup of
preservative oil is injected into each piston head. Turn the engine backwards and forwards manually in order to spread
the preservative oil.
9. Insert a clean, oil moistened rag (not cotton waste) into the inlet manifold.
10. Insert another clean, oil moisted rag into the exhaustelbow aperture.
11. Treat electrical connections with grease free from acid. Fill the multiple plugs with grease from the wire side.
The engine is now preserved for winther storage and can be futher protected by covering of polythen sheeting, under
which a bucket of silicagel should be placed.
3. Preparation of engine before launching.
1. Remove the oil moisted rags from the inlet manifold and the aperture of the exhaust elbow.
2. Fit the cooling water pump impeller.
3. Fit cooling water drain plugs.
4. Drain the preservative lubricating oil from both engine and gearbox and fill up with fresh oil to the upper mark of the
dipstick.
5. Change the lubricating oil filter.
6. Make sure - before starting up - that the oil on the piston heads is drained off. This is checked by turning the engine
manually without operating the decompression lever.
7. Examine the stern tube stuffing box and fill up with stern tube oil.
8. Fit the battery after re-charging.
9. Lubricate all moveable parts with oil.
10. Check the anode.
11. Check that there is electrical contact at the sterntube at the internal connection to the gearbox.
009W4921-R06 - 9 -
OPERATING MANUAL FOR BUKH DV29RME LIFEBOAT ENGINES
RME-ENGINES MOUNTED WITH HYDRO- OR SPRING STARTER EQUIPMENT (service info 9201)
The above mentioned type of starting method has proved to start the lifeboat engines in a very short period of time. In cold
climates a standard multigrade lubrication oil may not be sufficient for a rapid build-up of lub. oil pressure. We recommend
the following methods to prevent problems:
1. Full synthetic low friction lub. oil with a viscosity of 5W/40 or 10W/30 (e.g. Mobil No. 1 or Castrol Syntruck).
2. Cooling water jacket heater.
3. Oil sump heater.
In view of starting time the above points also increase the electrical start performance.
LUBRICATION OIL QUANTITIES FOR DV29RME (service info 9702)
When the engine is dry, you are recommended to fill up with 3.5 litres of lubricating oil (min. 3.1 litres - max. 3.9 litres).
A dip stick with standard indications of minimum (20 mm) and maximum (32 mm) oil levels for checking of the oil quantity is
located on the side of the engine.
THESE INDICATIONS APPLY WHEN THE ENGINE IS IN HORIZONTAL POSITION!
When mounted in a lifeboat, the engine is rarely in a horizontal position. Usually, it has an aft inclination of max. 12°, which
will change the oil level on the dip stick.
The following values are intended as a guide:
Oil level when 3.5 litres of oil have been added to the engine:
Horizontal engine: Oil level on dipstick= 26 mm
Engine inclination 12° aft: Oil level on dipstick= 18 mm
Engine inclination 30° forward: Oil level on dipstick= 9 mm
Irrespective of the inclination, engine running will be troublefree if the above oil quantity has been added. If more oil than
advised is added, the crank will be running submerged in oil. Consequently, the oil will get too warm and foam, and bleeding
will be inadequate.
Oil vapour will condense and in extreme cases run out of the suction filter.
Do NOT fill the engine with more oil than indicated above.
It will not be necessary to adjust the oil quantity of freefall boats, in which the engine will
be started while the boat is still in the chute at an inclination of approx 30°.
INSTRUCTION FOR MARINE DIESEL FUEL IN COLD CLIMATES
COLD FILTER PLUGGING POINT (CFPP) (service info 9301)
To ensure proper operation of the lifeboat engines in very cold climates, it is essential to ensure that the diesel fuel in the fuel
tank of the lifeboat is suitable to the lowest temperature possible in the area of operation of the ship. The temperature where
the fuel is no more filterable is called "CFPP" in the specifications for the particular fuel
To improve the CFPP-point, a dilution with kerosene is recommended. A max. dilution of 40% kerosene is possible. If 50% or
more are necessary, 2-stroke lubricating oil must be added to protect the fuel injection pump and nozzles from seizure.
If no information is available onboard the ship about the particular fuel to be diluted, it is recommended to use 2-stroke
lubricating oil in ratio 0.3 ltrs. to 100 ltrs. of fuel. This is necessary due to the fact that the diesel oil might be winter-type and
already diluted from the oil company.
The reason for the necessity of 2-stroke lub. oil is that it is self-mixing with the fuel.
Note: In ship storage tanks a max. of 25% dilution is the limit, in order to ensure that min. flame point of fuel = 55°C.
EXAMPLE:
Diesel Oil without Dilution CFPP/-18°C
90 litres diesel + 10 litres kerosene
80 litres diesel + 20 litres kerosene
70 litres diesel + 30 litres kerosene
60 litres diesel + 40 litres kerosene
50 litres diesel + 50 litres kerosene
-20°C
-22°C
-24°C
-26°C
-28°C
009W4921-R06 - 10 -
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What's Included?
Lifetime Access
Fast Download Speeds
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Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$26.99
This product is a comprehensive resource for the Bukh Marine Diesel Lifeboat Engine type DV29 RME. It includes detailed information on operation, maintenance, and repairs, making it useful for both professional mechanics and DIY enthusiasts.
The manual contains instructions for using the engine, planned maintenance, detailed illustrations, diagrams, and troubleshooting advice. It covers all models for the DV29 RME engine, including DV29 RME, DV29 ME, and DV29 M.
This Bukh Marine Diesel Lifeboat Engine type DV29 RME Owner's Handbook is essential for maximizing the engine's performance. It is available for instant download upon online purchase.
