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Bukh V8 Series, Owner'S Manual

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Bukh V8 Series Owner'S Manual Download Page 363

 

 

 

Owners Manual   

 

363

 

 
Section 5 – BATTERY and CONTROL

 

  

 

 

Battery  

 

 

Battery Cables  

 

 

Accessories  

 

 

ECU and Relay Box 

 

 

Warnings System and Alarms  

 

 

Control Panel 

 

 

 

 

 

 

Summary of Contents for V8 Series

Page 1: ...base engine is upgraded with high quality BUKH marine parts The BUKH V8 is a marine certified SOLAS engine built for optimal marine safety BUKH is ISO 9001 2015 certified which allows us to produce high quality marine engines BUKH V8 engines are built by trained personnel according to our quality specifications BUKH V8 engines are quality inspected and tested before they leave the BUKH factory The...

Page 2: ...ing flow Break in procedure The BUKH V8 series engines need break in time before being operating to its full potential This is due to the design characteristics of the base engine Follow the recommendations below 0 5hrs Use varied load and engine speed but do not load the engine above 50 throttle and keep engine speed below 2500 rpm 2500 1 min Do not stay at one load and engine speed configuration...

Page 3: ...his allows the automatic glow system to glow its first sequence DO NOT USE STARTING AIDS SUCH AS STARTING GAS ETHER OR OTHER This will void any warranty 3 Turn the ignition key to the CRANK position to start the engine If the engine doesn t start in 15 seconds wait for 30 seconds and go back to step 2 As soon as the engine starts let it run at idle while checking oil pressure and volt reading It s...

Page 4: ...el tank is full to prevent water contamination Add water repellent isopropanol to the fuel system Remove and replace the fuel filter remember to prefill the filter with fuel as you otherwise will have issues with bleeding all the trapped air from the fuel system Cooling system Start the engine and run antifreeze mix through the raw water system Check the freeze protection of antifreeze in the fres...

Page 5: ... dry Cooling system Recheck that all hoses and fittings in the raw water system are connected and replace the impeller be careful not to scuff the impeller use grease Prime the raw water system to prevent overheating of the impeller at start up Air filter Replace with new filter unit Start up See starting procedures on page 3 Check for leakage of oil fuel and water Also check the oil level on the ...

Page 6: ... Maximum demonstration period is 50h The emission control systems of your new V8 engine were designed built and tested using BUKH genuine parts accordingly it is recommended that any replacement parts used for maintenance repair or replacement of emission control systems be BUKH genuine parts The owner may elect to have maintenance replacement or repair of the emission control components and syste...

Page 7: ...adjustments modifications alteration tampering disconnection improper or inadequate maintenance improper installation and or rigging or use of fuels not recommended for the engine as described in the User s Manual 2 Damage resulting from accident acts of nature or other events beyond the control of BUKH or any of its representatives 3 The replacement of expendable maintenance items such as exhaust...

Page 8: ...uel injection pump 2 Air Induction System Turbocharger Intercooler 3 Miscellaneous Items ECU Software calibration Customer assistance BUKH wishes to help assure that the Emission Control System Warranty is properly administered In the event that you do not receive the warranty service to which you believe you are entitled under the Emission Control Systems Warranty you should contact BUKH at the a...

Page 9: ...ifold The centre exhaust manifold is high quality cast aluminium Vacuum injected and powder coated The center exhaust has one inner exhaust chamber and a surrounding coolant chamber for sea water Exhaust and sea water exits the BUKH V8 engine through 2 outlets and mixes into an Ø120 mm outlet Picture show the exhaust manifolds These exhaust manifolds has one inner exhaust chamber and one surroundi...

Page 10: ...ooler Air intake duct and air filter assembly Outside air enters the induction system through a filter located on the front of the engine This is a bonded stainless steel mesh filter material and should be cleaned and replaced according to service intervals See BUKH V8 MAINTENANCE BOOK The air filter element mounts to the intake runner inlet with a clamp Air filter unit Description Picture of the ...

Page 11: ...arts Turbo charger Description Picture of the turbo charger The charger is a high quality turbo charger in stainless steel Intake assembly with integrated stainless steel intercooler Intercooler assembly Description Picture of the stainless steel intercooler core with aluminium housing Compressed air and coolant connections Ø40 mm hoses are sea water coolant hoses ...

Page 12: ...Owners Manual 12 Sea water inlet Description Picture of impeller pump and sea water inlet Ø40 mm hose connection IN ...

Page 13: ...e of inlet fuel cooler Some configurations make use of the inlet fuel cooler option Fuel cooler is sea water cooled Is such case the inlet fuel can be connected to the IN connection This connection is a hydraulic connection Guide 3 8 inch straight ISO 228 1 G Some configurations with outlet fuel cooler Fuel out is after the fuel cooler Fuel cooler is sea water cooled Return hose to fuel tank Hose ...

Page 14: ...engine Please see appropriate sections for further information Oil filter It is essential that the oil lines and oil filter are prefilled with oil before starting the engine The lines should be connected as shown below Remote engine oil filter Description Picture of a remote engine oil filter Engine oil in and oil out are marked with arrows on top of the oil filter house ...

Page 15: ...ote oil filter house 3 From oil out arrow connection on oil filter house to oil pump in connection Oil pump connections Description Picture of oil hose connections with remote engine oil filter and oil cooler See IN and OUT mark OUT and hose 1 From oil pump out connection to nearest oil cooler connection IN and hose 3 From oil out arrow connection on remote engine oil filter house to oil pump IN c...

Page 16: ...Owners Manual 16 WARNING BEFORE MOUNTING THE OIL FILTER FILL THE OIL FILTER COMPLETELY WITH OIL THIS IS TO ENSURE THAT THE ENGINE GETS LUBRICATED DIRECT FROM START UP ...

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Page 338: ...s Manual 338 Section 1 ENGINE MOUNTING Engine Mounting Flexible Engine Mounting Engine Mounts Engine Alignment Checking Stringer Height Suspending the Engine Power Steering Hose Routing Exhaust Hose Routing ...

Page 339: ...e bed or stringers should be constructed in such way as to allow even weight distribution and load transfer Cross braces on the engine bed or stringers may be desired in certain applications to prevent lateral movement of the engine This bracing limits hull vibration and reduces stress on engine casting such as mounts Please mount the engine with possibility for future adjustments ...

Page 340: ...ngine vibrations The rear of the engine mounts to the stern drive transom plate or transmission IMPORTANT do NOT use solid engine mounts doing so will cause severe engine damage and void warranty Engine Mounts Engine mount Description BUKH offers heavy duty SOLAS flexible mounting as an option for BUKH V8 series engines Engines mount Drawing Description Drawing shows key measures ...

Page 341: ...arboard front to port rear The strings should lightly touch where they cross If not corrections should be made to the engine bed Suspending the Engine Lifting bracket Lifting bracket Description Picture of engine lifting brackets Front and rear lifting brackets on the engine are provided to allow attachment of a suitable sling The engine can then be lifted into position in boat using an overhead h...

Page 342: ...over tighten fittings Power steering fluid hoses must be purchased separately Proper routing and installation of the hoses is required to avoid problems related to power steering system Observe the following Hoses must be secured to avoid contact with moving components Torque both power steering hose fittings to 15 Nm after connecting to control valve Avoid stress on the hose fittings and avoid be...

Page 343: ...n engine is directly related to the amount of exhaust that can flow out of the exhaust system For example engines will generally suffer approximately a 10 horsepower loss for the first 1 psi 7 kPa of exhaust back pressure Exhaust Elbow Height A Measurement Between Straight Edge And Top Of Exhaust Elbow B Measurement Between Straight Edge And Water Line Measurement Raiser to waterline B A Minimum 3...

Page 344: ...be continuously sloping so that a low spot does not exist at any point in the exhaust hose or pipe The exhaust system on V8 engines must have a minimum of 6 downward slope between the exhaust elbow outlet and the exhaust outlet of the boat The exhaust system on V8 engines must have a minimum of 130 mm of vertical drop between the exhaust elbow outlet and the exhaust outlet of the boat Minimum exha...

Page 345: ...Owners Manual 345 Section 2 ENGINE COMPARTMENT Engine Compartment Engine Compartment Ventilation Combustion Air Requirements ...

Page 346: ...on air Maintain a low temperature in the engine compartment Sufficient Ventilation of air and fumes in the engine compartment Fresh air should enter the engine compartment as low as possible and the heated air should be discharged from the highest point When sufficient ventilation is not provided too much heat can build up inside the engine compartment and cause vapor locking The engine will not r...

Page 347: ...s lighter than cold air and will exit at the top of the compartment Once the engine is shut down such a system will auto ventilate until the engine bay temperature is at ambient level Combustion Air Requirements Engine compartments with natural draft ventilation must have vent openings of sufficient size and location to accomplish the tasks previously outlined A B ...

Page 348: ...factor from HP to KW is 0 735 Example for BUKH V8 500 Recommended open ventilation area for combustion air only is 1 7 x 500 HP x 0 735 620 cm2 For engine combustion air only NOT total engine compartment ventilation requirement IMPORTANT The amount of vent area required according to boating standards NMMA ABYC etc and Coast Guard regulations for complete total engine compartment ventilation must i...

Page 349: ...3 FUEL DELIVERY SYSTEM Fuel Delivery System Fuel Tank Fuel Lines Additional Fuel Filter Usage Fuel Line Fitting Installation Fuel Return Fitting Requirements Water Separating Fuel Filter Fuel System Temperature and Pressure Drop ...

Page 350: ... of the fuel tank in the boat due to the broad range of possible configurations Refer to information from the tank manufacturer as well as boating standards NMMA ABYC etc and Coast Guard regulations for complete guidelines Only a few points related to function and safety are listed here All connections should be on the upper side of the tank The tank ventilation pipe must have an inner diameter of...

Page 351: ...e following additional fuel connection related points applying to all engines unless otherwise stated must be considered Refer to boating standards NMMA ABYC etc Coast Guard regulations and or your countries regulatory agency for complete guidelines Fuel lines must be Coast Guard approved USCG Type A1 All fuel lines to engine shall be at least Ø12 mm inner diameter All fuel return lines from engin...

Page 352: ...oast Guard The maximum measured vacuum at the engine s fuel inlet must not exceed 2 inch Hg 6 8 kPa at idle engine speed and full throttle engine speed Additional Fuel Filter Usage CAUTION The engine fuel pump and factory installed water separating fuel filter have been carefully designed to function properly together Do not install additional fuel filters and or water separating fuel filters betw...

Page 353: ...nch DO NOT OVER TIGHTEN To prevent over tightening when installing a fuel line the brass fittings should be held with a suitable wrench as fuel line connectors are tightened securely Fuel Return Fitting Requirements Return fuel line is recommended to be Ø10 mm and must end in the top of the fuel tank There must be no restrictions on the fuel return system Water Separating Fuel Filter The engine mu...

Page 354: ... and therefore cause a greater fuel pressure drop The design of the fuel system should always take into account the highest engine output offered in the boat Doing this will help prevent performance problems related to fuel supply Air temperature and the RVP Reid Vapor Pressure of the fuel also play an important role in fuel system performance Higher air temperature can cause higher fuel line temp...

Page 355: ...ners Manual 355 Section 4 COOLING SYSTEM Cooling System Seawater Supply and Hose Connections Through The Hull or Transom Seacock Seawater Filter Seawater Pump and Bracket Drive Belt Routing Water Heaters ...

Page 356: ...priately to supply the engine with sufficient sea water under all operating conditions Observe the following information Seawater Supply and Hose Connections Seawater Supply Specifications Seawater Pickup through the hull or transom Minimum Flow Rate 230 liters per minute Seawater Pickup Hose Wire Reinforced Inner Diameter Ø40 mm Seacock Size Ø40 mm Seawater Strainer Minimum Flow 230 liters per mi...

Page 357: ...al area equal to or greater than seawater inlet hose to prevent restricting water flow Pickup must be located on the boat in an area that permits an uninterrupted flow of water to the pickup Be sure to make hose connections with double hose clamps Typical Through the Hull Pickup Typical Through the Transom Pick up a Through the Hull Pickup b Seacock c Through the Transom Pickup d Water Flow IMPORT...

Page 358: ...n Be sure to make hose connections with double hose clamps Secure hose to prevent contact with any moving parts Seacock Seacock seawater inlet valve if used must be installed between seawater pickup and seawater pickup pump or sea strainer to allow operator to shut off the seawater to flush or drain the engine or clean the sea strainer while boat is in the water Valve used must have an internal cr...

Page 359: ...e it will be easily accessible for inspection and cleaning Strainer must be installed in water inlet hose after the seacock water inlet valve to allow operator to shut off water when cleaning strainer Hose connections must be made with double hose clamps Secure hose to prevent contact with any moving parts Seawater Pump and Bracket Seawater pump and bracket Description The seawater pump is install...

Page 360: ...Owners Manual 360 Drive Belt Routing Drive belt routing Description The drive belt routing on one configuration of a BUKH V8 series engine ...

Page 361: ...Owners Manual 361 Drive Belt Routing Configurations BUKH V8 without Power Steering BUKH V8 with Power Steering ...

Page 362: ... with the supply and return connections CAUTION Avoid engine overheating which could result in engine damage On models equipped with Closed Cooling an air pocket may form in the closed cooling system if some coolant is lost from the system and the cabin heater or hot water is mounted higher than the fill cap on the heat exchanger Heater must be mounted lower than the fill cap of the heat exchanger...

Page 363: ...Owners Manual 363 Section 5 BATTERY and CONTROL Battery Battery Cables Accessories ECU and Relay Box Warnings System and Alarms Control Panel ...

Page 364: ...e located as close to the engine as possible Each engine requires its own battery for normal operation Failure to do so will lead to an unstable voltage source The alternator may not charge the battery properly if two engines are connected to a single battery Battery leads should not be reversed for example positive to negative Battery minimum rating requirements depend on boat configuration and a...

Page 365: ...d flux solder as it may cause corrosion and a subsequent failure Starter cable The positive battery cable is connected to the battery positive terminal on the starter motor Charging and control power cable The positive battery pole is connected directly to the black terminal box on the engine This is done to ensure sufficient power to the engine control and to ensure charging of the battery Please...

Page 366: ...n the starter motor These leads must be equipped with the appropriate current overload protection Refer to the ABYC standards or applicable industry standards for more information Do not attach any accessory ground wires to engine block Accessory ground wires should only be attached to ground terminal on battery ...

Page 367: ...rness Picture of relay box Relay box Description Picture of relay box after black cap is removed Note position and color of fuses and pay attention to position of relays To ensure correct function of engine relays are not to be turned Fuse 3 is 20 A for the starter Fuse 4 is 10 A for the display Fuse space 7 is free Fuse 9 is 10 A for the fuel pump at tank Other fuses are for the engine Center rel...

Page 368: ...d immediately shut down the engine by turning the key to off position Control Panel Control panel Description Picture of control panel Panel with red emergency stop Ignition key and engine data display screen Please mount control panel covered from rain and vapour ...

Page 369: ...PREPARATION Pre Delivery Preparation Battery Connection Power Steering Boat in the Water Test Engine Idle Speed Wide Open Throttle Test Important Installation Notes Pre Delivery Checklist Cold Weather or Extended Storage Draining Instructions ...

Page 370: ...ures completed Battery Connection 1 Connect engine positive battery cable from the starter motor usually RED to positive battery terminal 2 Connect engine positive charging and control power cable from the connecter box to positive battery terminal 3 Connect engine negative battery cable from engine block usually BLACK to negative battery terminal 4 Ensure that all battery terminal connections are...

Page 371: ...ng unit or sterndrive unit turns the correct way 6 Inspect engine compartment for water oil fuel and exhaust leaks 7 Check power steering oil level 8 Turn steering wheel left port until it stops and continue to apply pressure If pump lugs engine speed drops and or power steering pump tone changes check the following a Check for an obstruction between gimbal ring and gimbal housing and all moving s...

Page 372: ...With engine shut off 3 Check lever positions and adjust the external lever cable Please do not adjust screws on engine lever 4 Still ensure engine is shut off 5 External throttle lever is set to full engine speed With engine shut off 6 Check lever positions and adjust the external lever cable Please do not adjust screws on engine lever Wide Open Throttle Test IMPORTANT To operate engine at full th...

Page 373: ... pump suction If the fuel feed hose line get flat from suction the engine will lose engine speed and performance instantly even if it may not run rough You MUST use double hose clamps on all fuel line fittings to prevent air penetrating into the fuel system Do NOT use Teflon tape or other to seal fuel or oil fitting use only Loctite 518 and use it on ALL fuel and oil fittings to prevent leakage or...

Page 374: ...ve inlets We have found that adding the through hull inlet ensures adequate water flow to the engine and prevents issues arising in the future The BUKH warranty does NOT cover engine overheat related problems It is HIGHLY recommended that the engine exhaust be run through the transom and NOT run exhaust through the sterndrive as this will lead to excessive back pressure It is MANDATORY that all V8...

Page 375: ...Owners Manual 375 Please see BUKH V8 Official Warranty Information and hand in a warranty registration form on www bukh dk ...

Page 376: ...ed must remain closed until engine is to be restarted to prevent water from flowing back into seawater cooling system If boat is not fitted with a seacock water inlet hose must be disconnected and plugged to prevent water from flowing into cooling system and or boat As a precautionary measure attach a tag to the ignition switch or steering wheel with the warning that the seacock must be opened or ...

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