Bukh D4 User manual

009U4421-R01 08-03-2017
OPERATOR´S MANUAL
FOR
BUKH MARINE DIESEL
LIFEBOAT ENGINE
TYPE D4 & D6
BUKH A/S
Aabenraavej 13-17
DK- 6340 Krusaa
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
www.bukh.dk

Table of Content
Foreword ...................................................................................................... 4
Safety Information ...................................................................................... 5
Introduction ................................................................................................. 8
Instruments and Controls ........................................................................ 12
Ignition Lock .......................................................................................... 12
e-Key panel .......................................................................................... 12
e-Key Remote ...................................................................................... 13
Control Panels ....................................................................................... 14
Start/Stop Panel ................................................................................... 14
Station Panel ........................................................................................ 14
Cruise Control ...................................................................................... 16
Docking Panel ...................................................................................... 16
Power Trim panel ................................................................................. 17
Gauges ................................................................................................ 18
Displays ................................................................................................. 19
Information Display .............................................................................. 19
4" Display ............................................................................................. 21
Glass Cockpit Display .......................................................................... 28
Power Trim ............................................................................................. 30
Trim Ranges ........................................................................................ 30
Trim Controls ....................................................................................... 31
Power Trim Assistant ........................................................................... 32
Trim Instruments .................................................................................. 32
Maneuvering ........................................................................................ 33
Controls ................................................................................................. 35
Side mounted levers ............................................................................ 36
Disengaging the Shift Function ............................................................ 38
Adjusting the friction brake ................................................................... 38
Joystick ................................................................................................ 39
Optional ..................................................................................................... 40
Lowspeed ............................................................................................... 40
Joystick .................................................................................................. 41
Joystick for Docking ............................................................................. 41
High Mode ............................................................................................ 43
High Mode ............................................................................................ 44
Thruster Mode ...................................................................................... 44
Joystick Driving .................................................................................... 46
Autopilot ................................................................................................ 47
Battery Management System ............................................................... 48
Local Control ........................................................................................ 48
Battery Management display ............................................................... 48
Bukh Interceptor System .......................................................... 52
Operation ............................................................................................. 53
Screen Display ..................................................................................... 54
Cleaning ............................................................................................... 54
Swim platform Interface ....................................................................... 55
Starting ...................................................................................................... 56
Before Starting ...................................................................................... 56
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Starting the Engine ............................................................................... 57
Read the instruments and warm the engine up ................................... 58
Operation ................................................................................................... 59
Reading the Instruments ...................................................................... 59
Alarms .................................................................................................... 59
Maneuvering .......................................................................................... 60
Cruising Speed .................................................................................... 62
Synchronizing Engine Speed ............................................................... 62
Engine Shutdown ...................................................................................... 63
Stop the Engine ..................................................................................... 63
Auxiliary stop ........................................................................................ 64
After Engine Shutdown ........................................................................ 64
Operation Break ................................................................................... 65
Laying Up and Launching .................................................................... 65
Trailering Your Boat ............................................................................. 66
Cold Weather Precautions ................................................................... 66
Fault Handling ........................................................................................... 67
Alarm Handling ........................................................................................ 67
Acknowledge message ........................................................................... 68
Faults List ................................................................................................ 69
Fault Tracing .......................................................................................... 70
Fault Code Register .................................................................................. 71
In Case of Emergency .............................................................................. 78
Running Aground .................................................................................. 78
Starting Using Auxiliary Batteries ....................................................... 79
Emergency Shifting .............................................................................. 80
Emergency Shifting, Drive ................................................................... 80
Emergency Steering ............................................................................. 81
Emergency Alignment, Electrical Rudder Actuator .............................. 81
Emergency steering with control levers ............................................... 84
Emergency Trimming ........................................................................... 85
Start after crash-stop ............................................................................ 85
Maintenance Schedule ............................................................................. 86
Maintenance .............................................................................................. 87
Maintenance Safety Information .......................................................... 90
Engine, General ..................................................................................... 92
Drive Belt, Check and Change ............................................................. 92
Lubrication System ............................................................................... 93
Oil level, checking and topping up ....................................................... 94
Fuel System ........................................................................................... 95
Fuel system, bleeding .......................................................................... 96
Water in Fuel ........................................................................................ 96
Freshwater System ............................................................................... 97
Coolant Level, Checking and Topping Up ........................................... 98
Seawater System ................................................................................... 98
Seawater System, Draining ................................................................. 99
Impeller, Check and Change ............................................................. 100
Seawater System, Cleaning and Inhibiting ........................................ 100
Seawater Filter, Check and Cleaning ................................................ 102
Electrical System ................................................................................ 103
Fuses ................................................................................................. 103
Electrical Connections ....................................................................... 104
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Battery ................................................................................................ 105
Reverse Gear ....................................................................................... 107
Oil level, checking and topping up ..................................................... 107
Drive ..................................................................................................... 108
Transmission lubricant, checking and topping up .............................. 108
Steering ................................................................................................ 109
Hydraulic hoses ................................................................................. 109
Storage ..................................................................................................... 110
Calibration and Settings ......................................................................... 111
Settings Menu ....................................................................................... 111
My View ................................................................................................. 111
Neutral Beep ......................................................................................... 111
Information Beep ................................................................................... 112
Trip Reset .............................................................................................. 112
Depth Alarm .......................................................................................... 112
Display Contrast .................................................................................... 114
Side Selection ....................................................................................... 114
Units ...................................................................................................... 114
Language .............................................................................................. 115
EVC Info ................................................................................................ 115
PTA Calibration ..................................................................................... 116
Fuel Tank .............................................................................................. 117
Speed Factor ......................................................................................... 118
Key Management .................................................................................. 118
Joystick ................................................................................................. 122
Joystick Docking calibration .................................................................. 123
Joystick Inboard Docking calibration ..................................................... 125
Drive Straight calibration ....................................................................... 127
Technical Data ......................................................................................... 128
Viscosity ................................................................................................ 129
Cooling System ................................................................................... 135
Coolant, Mixing .................................................................................. 135
Identification Numbers ....................................................................... 136
Index ......................................................................................................... 139
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Foreword
Welcome!
Congratulations on your new boat equipped with a Bukh marine engine. Bukh engines are designed to fulfill
Bukh’s core values; quality, safety and environmental care. And after more than 100 years as an engine
manufacturer, the Bukh brand has also become a symbol of reliability, technical innovation, top-of-the-range
performance and long service life. Bukh marine engines are used all over the world, in all possible operating
conditions for professional as well as leisure purposes.
Make sure to thoroughly read through this Operator’s Manual and take necessary actions regarding running and
maintenance before your maiden voyage. It contains the information you need to be able to operate and maintain
the engine safely and correctly. Pay careful attention to the safety instructions included in the manual.
As the owner of a Bukh marine engine, you become part of a worldwide network of dealers and service
workshops that assist you with technical advice, service requirements and replacement parts. Contact your
nearest authorized Bukh dealer for assistance.
Information about your closest Bukh dealer and other useful information can be found at
www.bukh.dk
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Safety Information
Read this chapter very carefully. It concerns your safety. This chapter describes how safety information is
presented in the operator’s manual and on the product. It also provides you with an introduction to the basic safety
rules for using and looking after the engine.
!
This symbol is used in the operator’s manual and on the product to call your attention
to the fact that this is safety information. Always read such information very carefully.
Safety texts in the operator’s manual have the following order of priority:
DANGER!
Indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING!
Indicates a hazardous situation which, if not avoided, could result in death or serious
personal injury.
CAUTION!
Indicates a hazardous situation which, if not avoided, could result in minor or moderate
personal injury.
IMPORTANT:
Indicates a situation which, if not avoided, could result in property damage.
NOTICE! Used to draw attention to important information that will facilitate work or
operations.
In some cases, this symbol is used on our products and refers to important information
in the operator’s manual. Make sure that warning and information symbols on the
engine are clearly visible and legible. Replace symbols that have been damaged or
have been painted over.
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Daily Checks
Make a habit of giving the engine and engine bay a
visual check before driving (before starting the
engine) and after operation (when you have stopped
the engine). This will help you to quickly discover
whether there is any leakage of fuel, coolant, oil or any
other abnormal event has occurred, or is about to
occur.
WARNING!
Do not start the engine if there is reason to suspect
fuel and/or propane leaks, or if there is explosive
material nearby.
Maneuvering
To avoid passengers falling overboard, refrain from
extreme and sudden rudder movements and ahead/
astern movements.
A rotating propeller can cause severe injuries. Make
sure that there is nobody in the water before engaging
ahead/astern drive. Never drive close to bathers or in
areas where it can be expected that people are in the
water.
Lanyard Switch
We recommend installing and using a lanyard switch
(optional), especially if the boat is capable of high
speeds. The lanyard switch stops the engine if the
driver looses control of the boat.
Fuel Filling
There is always a risk of fire and explosion during
fueling. Smoking is forbidden and the engine must be
stopped during fueling.
Never overfill the tank. Close the fuel filler cap
securely.
Only use fuel recommended in the Technical
Data, page 130. The wrong grade of fuel can cause
serious malfunctions, power loss or stop the engine.
In diesel engines, fuel of poor quality can cause
damage to the fuel system or cause the engine to
over-speed, with risk of personal injury.
Accidents at Sea
Maritime rescue statistics show that a large number
of boat accidents are caused by inadequate engine
and boat maintenance and the lack of safety
equipment.
Make sure that the boat engine is properly maintained
by making sure that the recommended service is
performed, and that necessary safety equipment is
available and functional.
Safety Information
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Carbon Monoxide Poisoning
When the boat moves forward, an area of lower
pressure air is formed behind the boat — so-called
turbulence. In certain conditions, this turbulence can
be powerful enough to draw the exhaust fumes into
the cockpit or cabin, creating a risk of carbon
monoxide poisoning to people on board.
The turbulence problem is most pronounced on tall,
broad-beamed boats with a transom stern. But even
for other boat types, low-pressure suction can be a
problem in certain conditions, such as driving with
cockpit awnings rigged. Other factors that can
increase the effect of turbulence are wind conditions,
load distribution, swell, trim, open hatches and
ventilators etc.
Most modern boats are, however, designed so that
the problem of low-pressure suction is very rare.
Should turbulence nevertheless occur, hatches or
ventilators must not be opened since this might
exacerbate the problem. Instead, try to change the
speed, trim or load distribution. If possible, take down
or open the cockpit awning. Contact your boat dealer
for the best solution for your boat.
P0003073
Remember
The list below includes some tips on what to remember to bring on any boat trip. The list can be extended since
the need for safety equipment varies with the boat type and where or how it is used etc. We recommend you
ask a regional boat or sea safety organization for more detailed maritime safety information.
Safety Equipment:
•life jackets
• communication equipment
• emergency rockets
• approved fire extinguisher
• first aid kit
• life buoy
• anchor
• paddle
• flashlights
Spare Parts and Tools:
• impeller
• fuel filters
• fuses
• tape
• hose clamps
• engine oil
• other tools that may be required
• Take your chart out and study your planned route. Calculate distance and fuel consumption. Listen to
weather reports.
• Tell your friends/relatives about route plans if you undertake a long journey. Remember to notify changed
plans or delays.
• Inform everybody aboard about where the safety equipment is located, and how it works. Make sure that
there is more than one person aboard who can start and operate the boat safely.
Safety Information
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Introduction
Check that you heave received the correct operator’s manual before continuing reading. If not, please
contact your Bukh dealer.
For engine designations, refer to Technical Data, page 128. The designation is stated on the engine plate, refer
to Technical Data, page 136.
About this manual
This Operator's Manual has been prepared to give
you the greatest possible benefit from your Bukh
marine engine. It contains necessary information
regarding safe and correct engine operation and
maintenance. Read the Operator's Manual carefully
and learn to handle the engine, controls and other
equipment in a safe manner before you cast off on
your maiden voyage.
Always have the Operator's Manual available. Store
it safely and do not forget to hand it over to the next
owner if you sell your boat.
The Operator’s Manual describes the engine and
equipment sold by Bukh. The illustrations in this
book may cover several product types, which means
that there may be slight differences between the
illustrations and the purchased product. This does,
however, not affect the validity of the information
and/or instructions in the manual. Bukh reserves the
right to make alterations to specifications, design
features, and illustrations without prior notice.
Your New Boat
Carefully read through the instructions and other
information that is delivered with the new boat. Learn
to handle the engine, controls and other equipment in
a safe and proper manner. If this is your first boat or
if the boat type is unfamiliar to you, we recommend
that you practice maneuvering the boat before casting
off on the maiden voyage. Make yourself familiar with
the boat's seakeeping and maneuvering qualities at
different speeds, sea states and load conditions.
Bear in mind that a person in charge of a boat under
way bears the legal responsibility of knowing and
following the regulations for passage and safety
afloat. Learn which regulations apply to you and your
waters by contacting the relevant authorities or
maritime safety organization. We recommend that
you complete a boat driver’s course.
Warranty
Your new Bukh marine engine is covered by a limited
warranty, subject to the conditions compiled in the
6.4-F2 Rev. 30.05.11 General Terms of Sale and
Delivery
Read the information carefully, the information can
be found on www.bukh.dk
Environmental Care
Bukh has special responsibility as an engine
manufacturer, and for this reason environmental care
is a natural cornerstone of our product development.
Bukh currently has a broad engine program in which
great advances have been made in reducing
exhaust emissions, fuel consumption and engine
noise etc. We hope that you will be keen to preserve
these qualities. Always follow the directions in the
Operator's Manual regarding fuel grades, operation
and maintenance to avoid unnecessary
environmental impact. Contact your Bukh dealer if
you notice any changes such as increased fuel
consumption or increased exhaust smoke.
Remember always to hand in environmentally
hazardous waste such as drained oil, coolant, old
batteries, etc. for treatment at a recycling facility.
Our united efforts can make a valuable contribution to
the environment.
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Running In
The engine must be run in during the first 10 hours of
operation. Do this by using the engine in normal
operation, where full load is only applied for short
periods of time. Never run the engine at constant
speed for any longer periods of time.
Since oil consumption is higher during the running in
period, be sure to control the oil level more frequently
than normally recommended.
Refer to Maintenance, page 87 for more
information.
Fuel, Oils and Coolant
Only use the fuels and oils recommended in the
Technical Data, page 129, since other grades may
cause malfunctions, increased fuel consumption, and
possibly shorten the life of the engine.
Always change the oil, oil filters, and fuel filter at the
specified maintenance intervals.
Make sure to always use suitable and correctly mixed
coolant.
Future warranty claims related to engine and
accessories may be denied if an unsuitable coolant
has been used, or if the instructions for coolant
mixture have not been followed.
Maintenance and replacement parts
Bukh engines are designed for maximum reliability
and long life. They are not only built to withstand a
demanding environment, but also to have the
smallest possible environmental impact. These
qualities will be maintained through regular servicing
and the use of spare parts with the same quality as
Bukh original spare parts. If reliable and purpose-
built parts are not used, your safety, health, and the
machine's function may be compromised. Bukh has
a world-wide network of authorized dealers.
They are Bukh product specialists, and have the
accessories, genuine parts, test equipment and
special tools needed for high quality service and
repair work. Always observe the maintenance
intervals in the manual, the complete Service Protocol
can be found at volvopenta.com. Remember to note
the engine / transmission identification number when
you order service and spare parts.
Excessive Strain On a Product and
Components
Bukh products and their components are not
dimensioned for external loads. Never stand or step
onto an engine, transmission or its components.
Loads can bring about damage and the malfunction
of a product or property.
Introduction
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Instruments and Controls
This chapter describes the instruments, panels and controls Bukh sells for your engine.
If you would like to complement your instrumentation, or if your boat is equipped with instruments not described
here, we ask that you contact your Bukh dealer.
Ignition Lock
There is always a helm station with an e-Key panel on
a boat. The ignition must be switched on here in order
to use other helm stations.
Read the starting instructions in Starting, page 56 to
make sure you use the correct start procedure.
e-Key panel
The Bukh e-Key consists of a panel and a key fob.
Hold the key fob in front of the symbol on the panel
to unlock the EVC system. A sound confirms the
system is unlocked.
When the electrical system is locked, a red light will
flash under the symbol. The lamp goes out to indicate
the system is unlocked.
Key Management
Two key fobs are provided at the time of delivery. It is
possible to add additional keys; the system allows up
to four keys. With a key already registered to the
system other keys can be added or removed, see Key
Management, page 118.
Safety Lanyard
A safety lanyard (optional extra) can be connected to
the panel. Should the safety lanyard be removed, the
engines will stop, the system alerts and a warning
message will be displayed in the Information Panel.
IGNITION IGNITION
START/STOP START/STOP
P0016313
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e-Key Remote
e-Key Remote Sender locks and unlocks the boat's
electrical system and starts the engine's ignition via the
e-Key Remote Receiver.
On the key there are also two buttons that control
relays to optional functions such as deck light or anchor
winches.
ON – turns on the start switch and other selected
switches.
OFF – turns off the start switch and other selected
switches.
1 and 2 – the buttons are used to turn optional boat
functions off and on.
Battery replacement
Undo the screw on the battery cover and replace the
battery. Battery types: CR2032.
Battery installation
Place the battery cover back fasteners and secure the
gasket by pressing on the cover. Install the screw to
secure the cover placement.
NOTICE! The e-Key remote can still be used as a
regular key fob even if the battery is discharged, refer
to e-Key panel, page 12.
ON OFF
1 2
P0015214
P0016498
Instruments and Controls
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Control Panels
Bukh control panels can be installed in different
combinations. The panels all look the same but are
configured to handle different functionality. The
number of available panels and their function depend
on the boat’s functionality setup.
Start/Stop Panel
The Start/Stop panel is used for starting and stopping
the engine.
To start the engine, the ignition must be switched on
at the main helm station.
Read the starting instructions in the chapter
Starting, page 56 to make sure the correct start
procedure is used.
Station Panel
Activation
Activate the helm station with a single press of the
button.
Further pressure locks the helm station.
To render the helm station inactive, hold the button
down for 3 seconds.
Inactive helm station
Active helm station
Locked helm station
Lowspeed and Power Trim Assistant (PTA)
Depending on the installation the optional functions
lowspeed or Power Trim Assistant are engaged with
the button.
Lowspeed
For further information about the function, refer to
Optional, page 40.
Power Trim Assistant (PTA)
For further information about the function, refer to
Instruments and Controls, page 30.
P0012495
Instruments and Controls
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Neutral button
The gearshift function can be disconnected so that the
control lever only operates the throttle. The neutral
button disengages the drive/reverse gear so that
engine speed may be increased without driving the
boat; (warm-up mode).
The drive is disengaged.
Drive engaged for movement ahead/astern.
Single lever
When the single-lever function is activated, the lever
that is moved from its position first becomes the control
lever for both engines. The other control lever has no
function as long as the single-lever function is
activated.
In order to activate the single-lever function, the control
levers must in be roughly the same position, max 10%
difference.
Instruments and Controls
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Cruise Control
Switch on cruise control by pressing the button.
Make fine adjustments to the locked engine speed by
pressing the + or – buttons to increase or reduce the
speed.
Docking Panel
When the boat is operated from a docking station,
engines can be stopped and started and messages
can be managed using the docking panel.
The joystick can be used for maneuvering when the
docking station is activated; refer to the Instruments
and Controls, page 35 section for further information.
Activation
Activate the helm station by depressing the on/off
button. Further pressure on the button locks the helm
station.
To switch off the function, hold the button down for 3
seconds.
Twin installation
Both engines in a twin installation must be running
before the docking station can be activated.
The helm station is inactive.
The helm station is active and the docking
function is switched on.
The helm station is locked.
Start/Stop
Press the STOP and START buttons to stop and start
all engines.
The circles above the engine symbols show which
engines are running. An empty circle means an engine
is running.
P0001259
Instruments and Controls
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Contrast and backlighting
The button on the far right is used to adjust contrast
and panel backlighting. The button is also used to
confirm fault messages.
Backlighting
Contrast
Press the button to adjust the contrast and the
backlighting.
Use + and – to increase or reduce the contrast or
backlighting.
Adjustments affect all screens in the system.
Fault message
is displayed on the screen when the system
discovers a fault.
All fault messages must be acknowledged.
Acknowledge by pressing the button; if the fault is
accompanied by an audible signal, the signal will be
silenced. Go to the information display to obtain
information regarding the alarm.
Contact a Bukh workshop for a complete readout of
all fault messages.
For further information on how to handle fault
messages and recommended actions, refer to the
Fault Handling, page 67 and Fault Code
Register, page 71 chapters.
Power Trim panel
The Power Trim panel allows you to adjust the angle
of the drive with respect to the transom.
For twin engine installations, the control panel can be
used to make individual or simultaneous adjustments
to the drives.
By trimming out the drive away from the transom, the
bow will be ”raised” in relation to the horizontal axis and
trimming in the drive will ”lower” the bow of the boat
+Will trim the drive away from the transom, the bow
will be ”raised” in relation to the horizontal axis.
–Will trim the drive away towards the transom, ”lower”
the bow of the boat.
For further information on Power Trim refer to
Instruments and Controls, page 30.
P0001308
Instruments and Controls
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Gauges
These instruments are sold as engine options by Bukh.
Tachometer
The tachometer displays engine speed; multiply the
value shown on the dial by 1,000 to get the number of
engine revolutions per minute.
Engine hours are displayed in the tachometer window.
When a function is activated a symbol is shown briefly
on the display.
1 Fuel level gauge
The fuel level gauge shows the quantity of
remaining fuel.
2Voltmeter, battery charging
The meter shows the alternator charge current.
During operations the charge voltage should be
around 14 V. When the engine is stopped and
electrical power switched on the battery voltage
should be around 12 V.
If a 24 V system is installed, the charge voltage
should be around 28 V during operations.
3Coolant temperature gauge
The instrument shows engine coolant temperature.
During operations coolant temperature should
normally be between 75-95°C (167-203°F).
4Oil pressure gauge
The oil pressure gauge displays engine oil
pressure. During operations the oil pressure gauge
should normally show 3-5 bar. At idle, lower values
are normal.
5Fresh water level sensor
Freshwater tank level gauge.
6Rudder position indicator
The instrument shows rudder position.
7Trim indicator, analog, for Aquamatic engines
The analog indicator shows the position of the stern
drive in relation to the transom shield.
8Trim indicator, digital, for Aquamatic engines
The digital indicator shows the position of the stern
drive in relation to the transom shield.
9Alarm monitor
The alarm monitor gives a visual warning to call
attention to any alarms that occur.
0
3
2
1
4
RPMX1000
P0012490
351
h
Instruments and Controls
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Displays
Information Display
The information display shows engine and operational
information, messages and alarms.
There is one information display per driveline and helm
station if no 7" or larger screen is installed.
The information shown can be set up according to
personal preferences. The basic settings show:
•Engine speed
•Oil pressure
•Coolant temp
•Battery voltage
Press this button to return to the previous menu.
To navigate back to the main menu, hold the button
down for more than three seconds or press the button
repeatedly.
Press these buttons to navigate backwards and
forwards in the menus.
Hold down a button to scroll through a menu.
Press this button to confirm a selection.
Settings
Browse to the settings menu and press the OK button
to proceed to the submenu.
For further information about settings, refer to Settings
Menu, page 111.
P0001306
Instruments and Controls
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Fault Messages
If the system discovers a fault, the word Fault and the
number of discovered faults, are shown on the display.
To see the what faults have been detected, press the
OK button.
For further information on how to handle fault
messages and recommended actions, refer to Fault
Handling, page 67.
Backlighting
Display backlighting can be adjusted by pressing the
buttons simultaneously.
Instruments and Controls
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4" Display
The 4” display is an optional supplement to the Bukh
control system. Via the display it is possible to view
and control all installed functions in the system.
IMPORTANT:
Prolonged exposure to strong sunlight may damage
the screen and cause functional faults.
Make a habit of protecting the screen by using the
protective cover when the boat is not in use.
The Bukh 4" screen is controlled using the panel
buttons as follows:
Return to the previous menu.
P0001101
Adjust display contrast. If contrast changes are
not confirmed, display contrast will automatically
revert to its former state shortly after the button is
released.
The button functions are shown on the
display. Navigate back or forth or confirm a selection
by pressing the appropriate button.
View Selection
When starting up the system, the last selected view is
shown. To return to the main menu, press the
button. Use the arrow buttons to navigate to the
desired screen.
The following screens are available in the 4” display:
•My View shows operating information.
•Engine View shows engine information.
•Fuel Economy shows the trip computer.
•Vessel shows information regarding the boat
installation
•Settings shows display settings and installed
functions.
•Warning Manager shows detected faults and their
corrective actions.
•Battery View shows battery information.
View Selection
Instruments and Controls
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