Bukh V8 Series User manual

Owners Manual 1
OWNERS MANUAL
BUKH V8 SERIES ENGINE
In 2009, marine diesel engines were introduced as 6.6L V8 turbo charged, common rail,
intercooled marine engines for light duty commercial and pleasure craft applications.
The production was transferred to BUKH A/S, in 2018 and relocated to Denmark.
The lightweight and high performance 6.6L 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 BUKH V8 engine has been tested on a high power engine test bench, to assure that
torque and power is in accordance with BUKH specifications.

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Identification
BUKH V8 series engines have an engine number.
Example:
BBPS DK 00 19 1654
Where first letter is
Bfor BUKH
then
Bfor Boat engine
and
Pfor Propulsion drive
followed by
Sfor Solas marine approved.
and
DK states manufactured in DK, Denmark.
and after 00
19 for year 2019
And last
Last four digits are ID numbers
Before first engine start
Due to safety restrictions some BUKH V8 engines are shipped without oil and coolant.
Please check oil and coolant levels.
Please ensure sufficient sea water cooling flow.
Break in procedure
The BUKH V8series 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 for more than 30
minutes.
5-10hrs:
Use varied load and engine speed but do not load the engine above 60% throttle
and keep maximum engine speed below 2800 rpm. Do not stay at one load and
engine speed configuration for more than 30 minutes.
A few short wide open throttle trials up to 3600 rpm are allowed for
performance trials.

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Do oil and filter change after the engine has run a total of 10 hours.
10-30hrs: Use varied load and engine speed. The engine can be used up to 100% throttle and
3600 rpm for shorter periods.Do not stay at one load and engine speed
configuration for more than 30 minutes.
Do oil and filter change after the engine has run a total of 30 hours.
Use oil and filter as specified in BUKH V8 Maintenance book. This is highly important!
If you have any questions regarding this break-in procedure please consult the technical
department at your local BUKH dealership or BUKH.
Starting procedure
Before starting the engine always check the oil and coolant level. Also inspect that no
leaks on oil-, fuel- or cooling systems are evident.
1. Make sure gear is in neutral and that throttle is in idling position.
2. Turn ignition key to the ON position and wait for glow light to stop. This 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 not unusual with smoke from the exhaust system just after start-up but this will stop once
the engine reaches operating temperature. Glow system will automatically afterglow.
Recommended cruising engine speed for all BUKH engines is 2700-3200 rpm. although the
maximum rated effect is at a higher engine speed. It is necessary to choose a propeller that
will allow the engine to reach maximum engine speed at wide open throttle to not inflict
unnecessary load on the engine, which could effect engine lifetime and void warranty. Do
not exceed maximum recommended engine speed as the pump reduces the amount of
injected diesel after this engine speed and engine power drops quickly.

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Winter storage
•Oil system
Change oil on the supercharger. Drain the oil from the engine, either by removing the oil
plug in the oil pan or by a suction tube down the dipstick tube; remember it’s always
recommended to do this when the engine is at operating temperature. Tighten the plug, clean
the oil dipstick and reinsert it in the tube.
Then remove the oil filter and replace it with a new unit (don’t forget to pre lubricate the seal
ring on the filter and prefill the filter with oil) tighten hard with manual power.
Refill the engine with new oil according to technical maintenance specifications. Check the
oil level on the dipstick and if necessary add more oil to reach the correct oil level.
Start the engine and run it for a few minutes so that the new oil can lubricate all moving
parts.
Turn off the engine and wait for 5 minutes.
Then recheck the oil level on the dipstick, again add more oil if necessary.
•Fuel system
Check all hoses, clamps and fittings for leakage and wear, replace if necessary. Make sure
the fuel 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 freshwater cooling system. If you need to add antifreeze make
sure you allow the engine to run up to operating temperature allowing the thermostat to open
and mix the added antifreeze. Never use more than 50% antifreeze. Turn off the engine and
drain the raw-water system. At the same time remove the impeller from the impeller pump.
Check all hoses, clamps and fittings for wear and leakage, replace if necessary. The heat
exchanger, intercooler and oil cooler are exposed to raw water and should be inspected for
corrosion that could lead to engine failure. It is recommended that the raw-water cooling
system be cleaned and flushed every 500 hours or at least every second year.
•Exhaust system
When the winter service is completed make sure all exhaust outlets and the air filters are
sealed to prevent moist/salt air from entering the engine.

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•Electrical System
Remove and clean the battery/batteries. Also clean the battery cables and connecting poles.
Store battery in a cold/dry ventilated environment (never below 0ᵒC/32F) and keep it fully
charged.
Procedures after winter storage
•Exhaust System
Remove all winter-storage-seals from exhaust and intake system.
•Electrical System
Reconnect the fully charged battery/batteries and tighten/lubricate the connectors. Check the
condition of the serpentine drive system belt; replace if worn or 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 dipstick, if necessary fill up with oil. Let the engine idle up to operating
temperature before usage or shutdown. When the operating temperature is achieved, again
check for leaking fluids. It is always good to mix approx. 1% two-stroke oil into the fuel tank
once a year to give the fuel system added lubrication.

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Periodic maintenance important notes
Periodic oil change on the supercharger.
USE ONLY oil as specified in BUKH V8 Maintenance book.
Do NOT overfill. Correct oil level is crucial.
Emission control warranty statement
General statement
To retain the dependability, noise and exhaust emission control originally built into all BUKH V8
(further on referred to as BUKH or V8) engines, it is essential that the engines are installed according to
the V8 installation instructions and receive periodic maintenance according to the V8 maintenance
book.
The BUKH V8 engine is categorized as a commercial engine.
Expected useful life of 10 years or 10.000 hours.
See BUKH V8 Maintenance Book for correct service.
The warranty period shall begin:
1. On the date the machine or vessel first is delivered to the first retail purchaser or:
2. If the machine or vessel is placed in service for demonstration purposes prior to sale at retail, on the
date the engine is first placed in service. 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 systems certified by US
Environmental Protection agency performed by any repair establishment or individual and may elect to
use parts other than BUKH genuine parts for such maintenance, replacement or repair without
invalidating this warranty: the cost of such services or parts, however, will not be covered under the
warranty.
Use of replacement parts which are not of equivalent quality may impair the effectiveness of emission
control systems. If other than BUKH genuine parts are used for maintenance, the owner should obtain
assurance that such parts are warranted by their manufacturer to be equivalent to genuine BUKH parts.
However, the use of other than BUKH replacement parts does not invalidate the warranty on other
components unless such parts cause damage to warranted parts.

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Repairs and service covered by the warranty will be performed by an authorized BUKH distributor or
dealer with no charge for parts or labor, including diagnosis, using BUKH genuine parts for any part of
the emission control system covered by the warranty and found defective.
The emissions control parts covered by this Emission Control System Warranty are listed under” What
is covered by The Emission Warranty”. You are responsible for the performance of all scheduled
maintenance or repairs on your new V8 engine.
BUKH may deny a warranty claim if your failure to perform maintenance resulted in the failure of a
warranted part. Receipts covering the performance of regular maintenance should be retained in the
event questions arise concerning maintenance. The receipts should be transferred to each subsequent
owner of the machine or vessel with the emission warranted engine.
What is not covered by the emission control system warranty.
1. Malfunctions in any part caused by any of the following: misuse, abuse, improper 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 system, filters, hoses, belts, oil,
thermostat, and coolant made in connection with scheduled maintenance services once these parts have
been replaced.
4. Add on parts or modified items which are not approved by BUKH.
5. Consequential damage as loss of time, inconvenience, shipping of parts, engine or vessel, loss of use
of machine or vessel, engine or commercial loss.
6. Any machine or vessel on which the hour record has been altered so the actual usage cannot be
readily determined.
7. Damage resulting from rust or corrosion.
8. Damage caused from cooling system blockage by foreign material or from sand or debris
deterioration of water pump.
9. Cosmetic or paint changes due to exposure to the elements.
10. Product is or has been used for racing at any point, even by a prior owner.
11. Marine engines operated outside the United States or Canada.

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What is covered by the emission control system warranty.
The following is a list of items that are considered a part of the Emission Control Systems and are
covered by the Emission Warranty when installed as original equipment by BUKH on engines which
were built to conform to Environmental Protection Agency regulations.
IMPORTANT!
This may not include expendable maintenance items. Emission related parts requiring scheduled
maintenance are warranted until their first scheduled replacement point for that part.
1. Fuel System
Fuel injectors
Fuel 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 address below for assistance. If
you need additional assistance or information concerning the Emission Control System Warranty,
contact:
Your BUKH distributor.
BUKH distributors can be found at www.bukh.dk
Or
BUKH A/S
Aabenraavej 13-17
DK-6340 Krusaa
Denmark
T: [phone]
E-mail: [email protected]
Dealer & Service directory
FOR LATEST UPDATE WE REFER TO www.bukh.dk

Owners Manual 9
Exhaust manifolds
The V8 exhaust manifolds are made of high quality cast aluminium that is heat treated,
anodized, vacuum injected and powder coated for maximum corrosion resistance. Each exhaust
manifold mounts to the cylinder head with metric stainless steel hexagon socket head bolts.
Exhaust manifolds
Description
Picture show the centre exhaust manifold.
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 surrounding coolant chamber
for sea water.
Picture show the exhaust manifolds.
These stainless steel pipes lead sea water to
surrounding cooling chambers in the exhaust
manifolds.

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Turbo and intercooler system
Air induction on V8-engines includes the following parts:
•Air intake duct and air filter assembly
•Variable Geometry Turbo assembly
•Intake assembly with integrated stainless steel intercooler
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 stainless steel air filter
unit.

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Variable geometry turbo assembly
The turbocharger assembly information can be found in BUKH V8 manual. Below is an
explanation of some interacting parts.
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.

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Sea water inlet
Description
Picture of impeller pump and sea water
inlet.
Ø40 mm hose connection
IN

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Diesel fuel in/out.
Description
Picture of a diesel fuel inlet and fuel outlet.
Diesel fuel IN is Inlet from fuel tank pump.
Outside Ø12 mm tube.
Recommended 2-3 bar and max 44 ᵒC
Return Out is a Ø10 mm tube
Picture 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 connector is Ø10 mm.
IN
IN
OUT

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The return fuel must pass via the fuel cooler before returning to the tank. Raw water connection
is on the impeller pump on the lower starboard side of the 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.

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Oil hoses
Description
Picture of oil hose connections
with remote engine oil filter and
oil cooler.
1. From oil pump, out connection,
to nearest oil cooler connection.
2. From oil cooler to oil in arrow,
on remote 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
connection.
1
2
3
IN
OUT

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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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