4 Maintenance
Contents
1. 456789 3 VD00630 Basic panel model 22 Fly bridge panel excl voltmeter model 21 Tachometer Operating hours counter Voltmeter Starter pre heat switch lock Warning light battery charging second alternator Warning light low oil pressure Warning light high coolant temperature Warning light battery charging Indicator light pre heating Warning light gearbox low oil pressure NANI Oo ON O This is an option not fitted as standard 15 2 Introduction Control panels optional 10 1 2 RPM 3000 START uetus d 11 4 56789 3 VD00631 Uitgebreid paneel model 34 Tachometer Operating hours counter 7 Warning light battery charging Voltmeter 8 Indicator light pre heating Starter pre heat switch lock 9 Warning light gearbox low oil pressure Warning light high raw water temperature O Temperature gauge coolant Warning light low oil pressure 1 Oil pressure gauge Warning light high coolant temperature oOoahond EE This is an option not fitted as standard 3 Use General guidelines for use Implementing the following recommenda tions will result in longer life and better performance and more economical opera tion of your engine Carry out the maintenance described regularly including the Daily proce dures before st2. Check and adjust injector pressure Bleeding fuel system 36 Check glow plugs Cleaning heat exchanger 60 Check idle rpm 59 Every 1000 hours at least once every 2 years Raw water pump inspection 52 Replace coolant 54 Replace air filter 58 Every 1000 hours Check starter motor 58 Check alternator 58 Check turbocharger Consult the service manual work to be carried out by a Vetus Mitsubishi dealer A DANGER Stop the engine before carrying out any maintenance work Only engines with intercooling 31 4 Maintenance Checking engine oil level Daily before starting 2 B i VD00155 vD01052 1 Check oil level 2 Oil level 3 Topping up oil Turn the engine off The oil level must be at or near the upper The oil filling cap is on top of the the valve The dipstick is located on the starboard mark on the dipstick If necessary top up cover side of the engine with the same brand and type of oil A second oil filling cap is located at the The difference between the two oil level distrubution cover see page 18 marks is 1 9 litres 3 3 UK pt 4 US pt 32 4 Maintenance vp01131 1cm RES 3 8 4 Checking coolant level VD00158 Check the coolant level in the header tank This has to be checked when the engine is cold Remove the cap of the filler neck on the heat exchanger The level of the coolant must be approx
3. Turn the screw that holds on the filter cover to the left and remove the filter from its housing Use an Allen key for this 4 Maintenance Changing the gearbox oil ZF Hurth Every 500 operating hours FILTERELEMENT ART CODE CT50081 m 2 1 VD00645 28 Filling with new oil Withdraw the filter element 1 Refill the gearbox to the correct level via In case your engine is equipped with the dipstick opening another brand of gearbox follow the Check the O rings 2 and 3 for damage For oil specification see page 65 instructions given in the supplied owners and replace if necessary manual for changing oil and other care and maintenance Install the new filter and mount the unit on the gearbox 45 4 Maintenance 30 Checking adjusting valve clea rance Checking the valve clearance must be done with a cold engine that is an engine which did not run for at least 6 hours 46 voot067 Checking valve clearance Every 500 operating hours Markering BDP cilinder 1 en 4 Markering motorblok Markering injectie Zr uy A 27 Markering BDP cilinder 2 en 3 VD00130 31 Remove rocker cover Remove the 5 bolts of the rocker cover Complete the following steps 32 Locating TDC Locate the Top Dead Center TDC at the end of the compression stroke for cylin der 1 by barring the engine slowly until the TDC marks of the engine block
4. 1 cm 3 8 below the lower edge of the filler neck e VD01130 If necessary top up When topping up coolant remove the bolt from the upper side of the thermostat cover so that air can escape from the cooling system N WARNING Never open the cap on the header tank when the engine is at operating tempera ture Checking coolant level Daily before starting T vD01129 5 Topping up coolant The internal cooling system can be filled with a mixture of anti freeze 40 and tap water 60 or with a special coolant For specification see page 87 AN CAUTION Never fill the cooling system with sea water or brackish water 33 4 Maintenance Checking and cleaning the raw water strainer VD00125 CT30119 6 Checking the raw water strainer Check daily whether there is any dirt in the raw water strainer 34 7 Cleaning the strainer Close the seacock before removing the lid of the water strainer Clean the raw water strainer as often as is necessary depending on the pollution of the waterways but at least once every 6 months A clogged raw water strainer will result in excessive temperatures or over heating of the engine coolant Daily before starting A NoTE Only engines with intercooling Check the sealing between the lid and housing after cleaning and re assembling the strainer An improperly sealed lid will result in air sucked in by the sea water
5. Air in fuel system Check and bleed Faulty injector injection pump Check replace if required Water in fuel system Check water separator Faulty glow plugs Check replace Incorrect valve clearance Adjust Incorrect injection timing Check adjust Wrong fuel quality or contami Check fuel Drain and flush nated fuel fuel tank Replace with new fuel Vapour in exhaust gases con denses as a result of very low ambient temperature 79 8 Technical data Model General Make Number of cylinders Based on Type Injection Aspiration Bore Stroke Total displacement Compression ratio Idling speed Max no of revolutions at no load Valve Clearances cold Weight with standard gearbox Engine installation Max installation angle Max athwartships angle 80 M4 55 Vetus Mitsubishi 4 S4L2 T 4 stroke diesel in line Indirect Turbo charged 78 mm 92mm 1758 cm 107 cu inch 22 1 900 rpm 9350 rpm Inlet 0 25 mm 0 010 Exhaust 0 25 mm 0 010 192 kg 423 lbs 15 degrees backwards 25 degrees continuously 30 degrees intermittent Maximum Output at the flywheel ISO 3046 1 at the prop shaft ISO 3046 1 at no of revolutions of Torque at no of revolutions Fuel consumption at no of revolutions Fuel System Self bleeding Injection pump Injectors Opening pressure Firing order Injection timing Fuel filter element Fuel li
6. Y START VD00105 VD00106 17 Electrical shutdown Reduce engine speed to idle and shift the gearbox to NEUTRAL Turn the key entirely to the left through the Orr position Never stop the engine immediately after it has been in operation for a long time Allow the engine to idle for a few minutes before stopping 28 When the engine has stopped turn the key to the Orr position If the engine is not to be used for some time it is recommended that the sea cock is closed and the battery main switch turned off Stopping VD01057 18 Mechanical shutdown On the engine itself stopping is possible by pressing the black button on the fuel injection pump If the fuel supply is not shut off by the elec trically operated fuel solenoid stopping of the engine can be done this way 4 Maintenance Introduction The following guidelines should be observed for daily and periodic mainte nance Perform each function at the indi cated time interval The intervals stated are for normal opera tional conditions Service the unit more frequently under severe conditions Failure to carry out maintenance can result in faults and permanent damage to the engine No claim can be made on the Guarantee if maintenance has been neglected Keep record of the following informa tion in the logbook and or the Service and Guarantee Book Total engine hours reading engine hour c
7. cally during filling of the cooling system AN NoTE B The HIGHEST point of the water heater is situated at a HIGHER level than the expansion tank for the ship s engine The water heater will Nor be filled and bled automatically during filling of the cooling system Fill the cooling system via the extra expan sion tank Open the valve during the filling and bleed ing of the system Close the valve again once the system is filled 57 4 Maintenance AIR FILTER ART CODE STM7467 VD01141 VD01135 55 Changing the air filter Loosen the hose clamp 1 Remove the filter housing 2 Remove the old filter and fit a new filter 3 Replace the unit in reverse order and tighten the hose clamp again AN WARNING Never clean the element with petrol or hot liquids 58 56 Checking the starter motor Check for visible defects Check whether the Bendix engages with the starter ring when the starter motor is activated If the Bendix does not engage properly contact your Vetus dealer Changing the air filter checking the starter motor and alternator Every 1000 operating hours VEM 57 Checking the alternator Check for visible defects Remove the alternator belt Turn the pulley by hand to check whether the alternator can be turned easily If this is not the case contact your Vetus dealer 4 Maintenance Checking engine speed YN CAUTION The maximum engi
8. If an engine is used with a broken fan belt this can lead to the engine overheat ing which in turn can cause coolant to spray out of the expansion tank 2 Introduction Dear customer Vetus diesel engines are designed both for pleasure and commercial craft Consequently a wide range of variants are offered to meet the requirements of specific cases Your engine is appropriately equipped for your vessel which means that not neces sarily all components described in this manual are mounted to your engine We have endeavoured to highlight any differences so that you will able to locate the operating and maintenance instruc tions relevant to your engine quickly and easily Please read this manual before starting your engine and always observe the operating and maintenance instructions We are available to help with any addi tional inquiries Sincerely Vetus n v 2 Introduction vets MARINE DIESEL ENGINE SCHIEDAM HOLLAND 3000 kw 38 3 PK VD01139 VD01048 1 Engine data tag The Vetus engine serial number and per formance data are printed on the engine data tag Model and engine serial number must be given when ordering spare parts 2 Engine data tag location The Vetus engine data tag is attached to the valve cover Data tag serial number VD01132 3 Engine serial number The MirsuBisHI engine serial number is stamped on the fuel injection pump arrow 2 In
9. boxes 7 YY In case your engine is equipped with f 1 another brand of gearbox follow the instructions given in the supplied own ers manual VD01024 VD01024 3 Filling gearbox with oil Fill the gearbox with oil Technodrive ZF Hurth type TM345 1 6 litres Engine oil type ZF25 2 5 litres Check the oil level with the dipstick see SAE 20W40 CD 4 4 UK pt 5 3 US pt page 42 type TM345A 1 6 litres Engine oil type ZF25A 1 8 litres SAE 20W40 CD 3 2 UK pt 3 8 US pt 2 8 UK pt 3 4 US pt ATF Automatic Transmission Fluid type type TMC60 0 8 litre Engine oil A Suffix A SAE 20 30 1 4 UK pt 1 7 US pt 19 3 Use COOLANT QUANTITY 6 5 litres 1 gal 3 4 pt UK 1 gal 5 7 pt US VASE M VD01129 VD00158 4 Filling the cooling system Remove the cap of the filler neck on the top of the heat exchanger housing Remove the bolt from the upper side of the thermostat cover so that air can escape from the cooling system Fill the cooling system Use a mixture of 4096 antifreeze ethylene glycol based and 60 tap water or use a special coolant For specifications see page 87 20 First commissioning N NoTE WATER HEATER If a water heater is connected to the engine and this heater is positioned above the upper side of the engine then bleeding of the heater will not take place automatically Follow fil
10. pump which again will result in overheat ing of the engine 4 Maintenance AN DANGER Do not smoke when draining off water and sediment Keep flame and sources of igni tion out of the area Remove spilled fuel and litter before you start the engine Draining of water from the water separator fuel filter 8 Empty fuel filter Open the drain plug at the lower side of the filter Drain the water and close the drain plug Every 100 operating hours CT30119 9 Empty water separator Empty the separately installed water sepa rator fuel filter Openthe drain plug at the lower side of the filter Drain the water and close the drain plug Note The water separator is not within the scope of supply but installation is required 35 4 Maintenance iu STOP A ON 1 N START VD00107 10 Bleeding After the water separator fuel filter has been drained the air has to be bled from the fuel system The fuel system is self bleeding Turn the key of the starter switch to posi tion ON and the fuel lift pump will feed the fuel system 36 Draining of water from the water separator fuel filter VD01133 Every 100 operating hours START VD00109 Open the bleeding nipple to speed up the bleeding process Close the bleeding nipple when all air has escaped 11 Start the engine Operate the starter switch until the engine fires
11. T6 Gulf Dextron Other brands of gearboxes See supplied owners manual for oil type and quantities 86 Lubricating oil 9 Operating media Coolant fluid The preparation and monitoring of coolant in inter cooled engines is especially important because corrosion cavitation and freezing can lead to engine damage Use as coolant a mixture of a cool ing system protective liquid anti freeze ethylene glycol based and tap water In tropical climates where anti freeze availability may be limited use a corrosion inhibitor to protect the engine cooling system The concentration of the cooling system protective liquid in the coolant should not fall below exceed the following limits Cooling system protective Water Protection against liquid Anti freeze freezing to max 45 vol 55 35 C 31 F 40 vol 60 28 C 18 F min 35 vol 65 22 C 8 F The protective liquid concentration must be maintained under all circumstances Therefor if coolant must be added always use the same mixture of anti freeze and tap water Coolant Water quality for coolant preparation Use preferably tap water If an other available fresh water is used the values given below must not be exceeded Water quality min max pH value at 20 C 68 F 6 5 8 5 Chloride ion content mg dm 100 Sulfate ion content mg dm 100 Total hardness degrees 3 12 AN CAUTION Never use sea wa
12. for oil pres sure and alternator will now light up and the alarm buzzer will sound 10 Pre heating Turn the key further clockwise to the position only the pre heating indica tor light will be lit now Hold the key in this position for about 6 seconds 11 Pre heating time The ideal pre heating time depends on ambient temperature the lower the ambi ent temperature the longer the pre heat ing time required See table AN CAUTION To prevent the glow plugs from burning out never exceed the stated maximum pre heating time 23 3 Use OFF STOP 7 ON By START VD00109 OFF STOP BON 10 START VD00110 12 Starting Now turn the key further to the sTART position 24 Release the key as soon as the engine fires the key will return to the on posi tion and throttle back Leave the key in this position while the engine is running Starting YN CAUTION Release the key if the engine does not fire within 10 seconds Let the starter motor cool for 30 seconds before turning the key to the START posi tion again 3 Use Check that the indicator lights for oil pres sure and alternator are off Cooling water should now flow out of the exhaust if this is not the case stop the engine immediately 1 Only engines with intercooling Let the engine run for 5 to 10 minutes in neutral A good warm up is essential to ensure maxi
13. starting ALways check the follow ing points Engine oil level Coolant level Sea cock open Main switch on Gearbox in NEUTRAL position After repair work Check that all guards have been replaced and that all tools have been removed from the engine When starting with pre heating do not use any other substance e g injection with Easy Start Doing so could result in an accident 22 Starting neutral gearbox reverse gearbox forward forward throttle reverse throttle VD00111 half throttle gearbox not engaged F 8 Preparation starting Before starting the engine always check that the control lever s is are in the neu tral position N WARNING Never start the engine with the fuel injection pump removed Disconnect battery 9 Control lever Set the control lever to half throttle with out engaging the gearbox 3 Use Starting TE XL sr E Ed TM ux IN FN OFF STOP ON WO N START VD00107 VIZ ye er E ES WD UK PAN OFF STOP 7 ON START VD00108 Ambient Pre heating time Temperature 9 Above 5 C 41 F about 6 seconds 5 C to 5 C 41 F to 23 F about 12 seconds Below 5 C 23 F about 18 seconds Maximum ae 1 minute pre heating time Turn the start key on the instrument panel clock wise the warning lights
14. water free fuel Collect some fuel from the return pipe while engine is running 5 Winter storage procedure 2 Lubrication system With the engine still at operating tem perature If not run the engine until warm then turn off Replace the oil filter and change the engine oil use oil with protective proper ties See page 65 VD00125 3 Raw water cooling system Close the seacock before removing the lid of the water strainer If necessary clean the raw water strainer Pour 1 litre 1 4 Imp gal of anti freeze into the water strainer and run the engine until the anti freeze has disappeared into the cooling system Take care that no anti freeze is spilled into the waterway anti freeze is poisonous Check the seal between the lid and hous ing after cleaning and re assembling the strainer An improperly sealed lid will result in air sucked in by the raw water pump which again will result in overheating of the engine AN NoTE Only engines with intercooling 65 5 Winter storage procedure VD00139 CT40063 4 Fresh water cooling system 5 Electrical system To avoid corrosion during winter storage Disconnect the battery cables Charge batteries during winter lay up reg the cooling system must be filled with an ularly if required antifreeze water mixture or a coolant For specifications see page 87 N B Replacing the coolant is only neces sary if the coolant prese
15. 1 22 O Eo Lo Model 20 21 22 Ma nih Voltmeter B 1 Tachometer D 1 1 CLO R8 17 5 4 pa 12 5 i X1 Jat 07 19 58 15 w i i i NV D1 NZ D2 Ny D3 yy D4 i Warning lights i i Q1 Red Yellow Orange Violet White Black i i BZ Rn ia m isa ng i 6911 69 2 R3 6913 6914 69 15 L6 d H R1 R2 Plug amp An Al D5 se i L AA A E EI A i D6 Gearbox Socket Al Peet as j i D7 oil press a 3 i F i D8 Al A3 A4 A2 A5 A6 i Fuse or i D9 circuit breaker Auxiliary i 7 start relay l Pre i heating AM A a Pre heating so se 902 as s iL mu 1 gt Battery i MM Socket B trem mam 87 es 87 85 peu switch Transparent Pied Green Brown Blue Gray RION 17 PHEA oH E B enn X G D Battery charging Battery BY PY Ww Starter motor Pre heating Stop solenoid ETS Fuel pump ETR Alternator Oil Coolant press temp Gearbox oil press 90 10 Wiring diagram Engine with panel model 20 21 22 engine with keel cooling A e E E30 riye L3 L4 L5 L2 L1 L6 214 Alternator Violet Fuse 5A Consumers Re
16. Oe ss M4 55 Operation manual 340402 01 Operation manual eI M4 55 Serial numbers Engine serial number Vetus Mitsubishi Gearbox serial number Please enter the serial numbers here These numbers should be quoted when inquiring about Customer Service Repairs or Spare Parts see page 6 We reserve the right to make any changes without previous notice Copyright 2007 Vetus N V Schiedam Holland Please read and observe the information given in this operation manual This will enable you to avoid accidents preserve the manufacturer s warranty and maintain the engine in peak operating condition For the Guarantee Conditions see the Vetus Diesel Service and Warrantee Manual 320199 05 This engine has been built exclusively for the application specified in the scope of supply and is to be used only for the intended purpose Any use exceeding that scope is considered to be contrary to 2 the intended purpose The manufacturer will not not assume responsibility for any damage resulting therefrom The risks involved are to be borne by the user Use in accordance with the intended purpose also implies compliance with the conditions laid down by the manufacturer for operation maintenance and servic ing The engine should only be operat ed maintained and serviced by persons which are familiar with the former and the hazards involved The relevant accident prevention guide lines and other
17. Vetus Maintenance free battery has a hydrometer 1 built into the cover Visual inspection of the hydrometer will show one of three conditions 20 Hydrometer operation Green dot visible State of charge 65 or more Dark State of charge less than 65 26 Recharge immediately Clear or light yellow Electrolyte level low In case of low level caused by over charging the battery for a long period of time with a voltage too high replace battery Check alternator and or voltage regulator 4 Maintenance Battery cables and connections Every 100 operating hours Conventional batteries Conventional batteries VD00119 VD00120 Specific State of gravity charge 1 280 100 1 200 50 recharge 1 120 10 recharge immediately 21 Checking electrolyte level For conventional batteries it is required to check the electrolyte level regularly Remove vent caps taking care no spark or open flame is nearby and inspect the level Fluid should be 10 to 15 mm 3 8 to 5 8 above top of all plates If necessary top up with distilled water Replace vent caps and charge the battery for 15 min utes at 15 25 Amps to mix electrolyte 22 Checking specific gravity Measure the electrolyte specific gravity of the individual cells with a commer cial hydrometer The hydrometer reading see table indicates the state of charge Hydrometer reading of all cells should be at leas
18. a 2 l5 13 i A PUDE heb or E i heating E Connection for B nd 30 lse 30 relay 86 Plug B 2nd alternator Ty rx H NI Violet Battery Y J y Socket B A T 8 mam Fortes far Te VD td Switch B6 B4 B3 Yellow Yellow Transparent Green Green Brown Blue Gray Green Battery charging 2nd alternator 1 4 a p HEN 517 Yellow B R B Green X G D a Battery charging Black 2 Battery SY DH WwW r Stop Exhaust Oil Coolant Gearbox Starter motor Pre heating Fuel pump ETR solenold Alternator temp press temp oll press VD00407 ETS 88 10 Wiring diagram Options 2 alternator engine with intercooling 2 d Alternator Violet Fuse 5A Consumers Red Red sE 86 30 AAA Pe 85 87 87a Battery White main switch 30 86 30 86 43 r aa x HERPES i 87a 87 85 87a 87 85 i 1N4002 5 Yellow Y B xus k Green D4 G ES Yellow 3Y w Battery i 1 Black 2nd Alternator 1 lt VD00650 89 10 Wiring diagram Engine with panel model 20 21 22 engine with keel cooling VD00651 Engine panel model Tachometer hour counter Voltmeter TE 20 2
19. ak oil pipe nut M12 1 5 18 27 25 2 75 0 25 20 2 Nozzle retaining nut M16 0 75 19 37 25 3 75 0 25 27 2 Fuel injection pipe nut M12 1 5 29 3 0 5 22 3 5 Delivery valve holder 19 44 5 45 0 5 32 3 5 Solenoid lock nut M30 1 5 36 44 5 4 5 0 5 32 3 5 Temperature switch M16 1 5 17 22 6 4 2 3 0 4 16 3 Oil filter M20 1 5 12 1 1 2 0 1 9 0 8 Oil pressure switch PT1 8 26 10 2 1 0 2 7 1 5 Pressure relief valve M22 1 5 22 49 5 5 0 5 36 3 5 Oil drain plug M14 1 5 22 39 5 4 0 5 29 3 5 Glow plug M10 1 25 12 17 2 2 5 1 75 0 25 13 2 Fly wheel housing bolt M12 1 25 17 64 10 6 5 1 47 7 82 9 Operating media Fuel Quality Grade Use commercially available diesel fuel with less than 0 5 sulfer content If the sulfur content is higher than 0 5 the intervals between oil changes should be halved e g change oil every 250 hours Don t use fuel with more than 1 sulfur The following fuel specifications standards are approved CEN EN 590 or DIN EN 590 under development DIN 51 601 Feb 1986 BS 2869 1988 A1 and A2 ASTM D975 88 D1 and D2 NATO Code F 54 and F75 The exhaust emission levels determined during certification by the supervising authority are always based on the reference fuel described by law Biodiesel A CAUTION Only use the prescribed diesel fuel Do not use biodiesel Fuel Winter grade fuel Waxing may occur at low temperatur
20. amaged sea water pump impeller Growth of algae or seaweed Cleaning the heat exchanger voo1148 m 60 Remove the drain plug e Close the seacock and detach the water inlet hose from the sea water pump Drain the coolant To do this remove the drain plug from the heat exchanger housing 4 Maintenance Remove the filler cap from the top of the heat exchanger housing to allow air into the system and check that all coolant has drained off Cleaning the heat exchanger VDO1137 61 Removal of bolts out of the end covers Take out both central bolts from the end covers and take the end covers with the O rings out of the housing A NoTE Only engines with intercooling 61 4 Maintenance 62 Revolving the alternator out 63 Remove heat exchanger wards Loosen the bolts of the adjustment bracket Slide the heat exchanger out of the hous and both the alternator mounting bolts ing Remove the belt Push the alternator outwards to have enough room to slide the heat echanger out of the housing AN NorE Only engines with intercooling 62 Cleaning the heat exchanger STM7217 64 Cleaning the heat exchanger Clean the heat exchanger Use a pipe cleaner to remove fouling in the pipes Then rinse the heat exchanger pipes with clean water Ensure that both heat exchanger end chambers are free from dirt 4 Maintenance Cleaning the heat exchange
21. and the crank pulley match Note There are two TDC s e g compres sion and suction At the TDC at the end of the compression stroke the rocker arm does not move when the crank pulley is rotated a little 4 Maintenance VALVE CLEARANCE INLET 0 25 mm 0 010 ExHAUST 0 25 mm 0 010 te VD01068 N12 w 12X65 VD00637 32 Adjusting valve clearance Check valve clearance at cylinder 1 and adjust if necessary Rotate the crankshaft 180 clockwise and check valve clearance at cylinder 3 Again rotate the crankshaft 180 and check valve clearance at cylinder 4 Finally again rotate the crankshaft 180 and check valve clearance at cylinder 2 34 Cylinder numbering Cylinders are numbered consecutively beginning at the front end Checking valve clearance Every 500 operating hours 47 4 Maintenance np VD01157 35 Fuel filter removal The fuel filter is to be replaced as a unit Close the fuel stopcock Remove the fuel filter use a filter wrench Catch any fuel AN DANGER Keep naked flames away when working on the fuel system Do not smoke 48 Fuel filter replacement Every 500 operating hours FUEL FILTER ART CODE STM3690 VD00154 VD00133 36 Fuel filter installation Clean any debris from the filter carrier rim Lubricate the rubber gasket sparingly with clean engine oil Fill the new filt
22. arting Use anti freeze in the engine coolant all year long this helps prevent corrosion as well as protecting against frost dam age For specifications see page 87 Never run the engine without a thermo stat Use a good quality lubricating oil For specifications see page 84 Use a good quality diesel fuel that is free of water and other pollutants General guidelines Always stop the engine immediately if one of the warning lamps for oil pressure high coolant temperature high raw water temperature or battery charging lights up Always follow the safety advice see page 4 Only engines with intercooling 17 3 Use Engine Oil 5 5 litres 15 W40 1 gal 1 7 pt UK 1 gal 3 6 pt US API CF CF 4 Cl 4 For example Vetus Marine Diesel Engine Oil Shell Nautilus Premium Inboard 15W 40 VDO1052 1 Commissioning the engine Before starting the engine for the first time the following procedures must be carried out 18 2 Filling with engine oil As a rule engines are delivered empty of oil Fill the engine with oil through the filler neck on top of the valve cover for quantity and specification see page 65 Check the oil level with the dipstick see page 32 First commissioning VD01142 A second oil filling cap is located at the distribution cover 3 Use First commissioning Vetus engines are normally equipped with Technodrive or ZF Hurth gear OIL
23. ater return connection 15 mm 5 8 Exhaust system Exhaust diameter Exhaust back pressure Electrical System Voltage Alternator 2nd alternator Intercooler version Keel cooler version Startmotor Capacity starter battery Protection V belt Alternator and coolant pump 2 d alternator Intercooler version Keel cooler version Gearbox Technodrive type TM345 type TM345A type TMC60 ZF Hurth type ZF25 type ZF25A Technodrive type TMC40 Engine specifications 50 mm at specified output max 150 mbar 2 2 psi 12 Volt 14 Volt 110 Amp 14 Volt 95 Amp 14 Volt 110 Amp 14 Volt 1 7 kW Fuse ATO40 Amp min 55 Ah max 108 Ah Fuse ATO 10 Amp STM7643 STM9857 STM9858 Gear ratio 1 54 2 0 2 47 1 1 54 2 0 2 47 1 1 5 2 0 2 45 1 1 97 2 8 1 1 55 1 93 2 29 2 71 1 2 05 2 60 1 81 8 Technical data Torque wrench settings Serewicennection Diameter PIGA Size Nm ian ft Ibf Cylinder head bolt M10 1 25 14 88 5 9 0 5 65 3 5 Connecting rod nut M9 1 0 14 348 2 5 3 55 0 25 26 2 Fly wheel bolt M12 1 25 19 132 5 13 5 0 5 98 3 5 Crank shaft pulley nut M18 1 5 27 172 25 17 5 2 5 127 19 Main bearing cap bolt M10 1 25 17 515 2 5 5 25 0 25 38 2 Rocker stay bolt M8 1 25 12 14 7 5 1 5 0 5 10 3 5 Valve cover bolt M8 1 25 12 11 3 x1 5 1 15 0 15 8 1 Nozzle holder M20 1 5 21 54 5 5 5 0 5 40 3 5 Fuel le
24. box oil Technodrive Every 500 operating hours VD01034 Lu VD01043 VD01042 D 25 Draining the oil 26 Filling with new oil Drain the oil with the aid of a separate Or if sufficient space below the gearbox is Refill the gearbox to the correct level via sump pump available oil can be drained by removing the filling hole the drain plug For oil specification see page 86 Insert the suction hose of the sump pump in the dipstick hole Push down the pump Collect the oil in a dripping pan In case your engine is equipped with handle quickly and pull it up slowly another brand of gearbox follow the Remove the sump pump when all the old instructions given in the supplied owners oil has been pumped out manual for changing oil and other care and maintenance 43 4 Maintenance VD01151 27 Draining the oil Drain the oil with the aid of a separate sump pump Insert the suction hose of the sump pump in the dipstick hole Push down the pump handle quickly and pull it up slowly Remove the sump pump when all the old oil has been pumped out 44 Changing the gearbox oil ZF Hurth alee VD01153 Every 500 operating hours VD00644 Or if sufficient space below the gearbox is available oil can be drained by removing the drain plug Collect the oil in a dripping pan 28 Changing the oil filter The filter element must be replaced at the same time as the oil
25. d Red g 86 30 A EAN ar Ai 85 87 87a Battery White main switch 30 86 30 86 pu m ct pob ngon tba i AA 87a 87 85 87a 87 85 1N4002 B D G mE Yellow SY BE w Battery G Black and Alternator reen Battery charging 2 alternator 91 10 Wiring diagram Options panel model 10 engine with intercooling 2 hs Engine panel model i i i T i 1 1 1l i utt 4 A i 10 i802 jy i9 18 54 Jeesziop_i c CE QN QU uM M aM CMM DE i 31 7 19 58 15 I 1 I i 1 d D1 D2 D3 D4 a 1 Wore y Y Warning lights i i i L3 L5 L1L2 i Q1 i Red Yellow Orange Violet White Black i j E ww i L1 BZ L2 R2 6913 6914 6915 Le 5 At A3 A4 A2 A5 A6 i 9 e 8913 AL 69 e rv E seep te i Ri Rs Pug w A7 LLL A Zo _ i 2 5J i D5 am i tp O n Ea Socket A Te P D7 i L4 amp L6 A A e i d A A A z s i Hu S e Y z t D8 1 A1 A3 A4 A2 A5 A6 i xe gt i Fuse or 5l D9 i circuit breaker Auxiliary i start relay i y 010 i i Pre i i heating 9 94 61 91 lez jos 95 i y y v y y wiv Pa oo mH AERE EN te imei os o es CE heating i 86 Connec
26. eck Adjust fuel Hes tank Replace with new Incorrect lube oil SAE class or Replace quality for ambient tempera ture Leak in lubricating oil system Repair replace Excessive wear of cylinder piston Check compression overhaul engine Insufficient intake air Check Engine overloaded Check size of propeller Faulty injector injector pump Check replace if necessary Incorrect injector timing Check adjust Excessive wear of cylinder piston Check compression refurbish engine Insufficient air intake Check 77 7 Troubleshooting Fault finding table 11 Blue exhaust smoke idling 12 Black exhaust smoke at load Possible fault Remedy Possible fault Remedy Oil level too high Lower level Faulty turbo compressor Check replace Excessive inclination of engine Check Adjust Insufficient intake air Check Leaking turbo compressor oil Check replace oil seal Leak in inlet manifold Check replace seal Faulty injector injection Check replace if required pump Incorrect injector timing Check adjust Incorrect valve clearance Adjust Excessive wear of cylinder Check compression refurbish piston engine Engine overloaded max rpm Check sizes of propeller is not reached 78 7 Troubleshooting Fault finding table 13 White exhaust smoke at full load Possible fault Remedy
27. ent 54 11 Overall Dimensions 94 Introduction 29 Changing the air filter 58 Maintenance schedule 30 Checking the starter motor 58 12 Index 95 Checking the oil level 32 Checking the alternator 58 1 Safety measures Warning indications The following warning indications are used in this manual in the context of safety AN DANGER Indicates that great potential danger exists that can lead to serious injury or death AN WARNING Indicates that a potential danger that can lead to injury exists AN CAUTION Indicates that the usage procedures actions etc concerned can result in serious damage to or destruction of the engine Some CAUTION indications also advise that a potential danger exists that can lead to serious injury or death A NOTE Emphasises important procedures cir cumstances etc Warning indications Symbols Es Q9 Indicates that the relevant proce dure must be carried out Indicates that a particular action is forbidden Pass the safety precautions on to other people who will use the engine General rules and laws concerning safety and accident prevention must always be observed 1 Safety measures Fire risk Do not smoke if refuelling Avoid spilling fuel on hot surfaces Spilled fuel must be cleaned up imme diately Do not use petrol or diesel to clean components but make use of good quality non inflammable non poison ous solvents that are available from dealers Always be aler
28. er with clean diesel fuel Install the filter When the rubber gasket touches the housing apply another tightening of a half to three quarters of a turn by hand Open fuel stopcock Check for leaks 4 Maintenance FUEL FILTER ART CODE STM4050 STM7220 37 Fuel lift pump Check and if necessary clean filter inside the fuel lift pump Open the fuel stop cock Check for leakage 38 Bleeding After replacing the fuel filter and cleaning the pilot filter inside the fuel lift pump the air has to be bled from the fuel system For bleeding see page 36 Cleaning fuel lift pump Every 500 operating hours OFF STOP 7 ON By START VD00109 Start the engine Operate the starter switch until the engine fires release the starter switch if the engine does not fire within 20 seconds Wait until the starter motor has stopped before mak ing a new attempt to start the engine Repeat the above if the engine cuts out after a short time 49 4 Maintenance Checking the V belt Every 500 operating hours V BELT ART CODE STM7439 SEE TECHNICAL DATA a VD00034 10 kgf WO Ibf max 12 mm 1 2 VD00128 VD00129 39 Inspection V belt Inspect the belt for wear and tear fraying and cracking Belts which are in poor condition should be replaced Check tension and change belts only w
29. es clogging the fuel system and reducing engine efficiency If the ambient temperature is less than 0 C 32 F winter grade fuel suitable down to 15 C 5 F should be used This fuel is usually available from filling stations well in advance of the cold months Diesel fuel containing additives Super Diesel is often on sale as well for use down to 20 C 4 F 83 9 Operating media Engine oil Lubricating oils are specified by perform ance and quality classes It is usual for the specifications to be indicated according to the API American Petroleum Institute Acceptable API oils CF CF 4 Cl 4 Only use oil of a recognised brand to lubri cate the engine The choice of a correct oil guarantees that the engine starts easily because an oil film remains on the cylinder walls and bearing surfaces The friction is low and so the starting rom necessary for a dependable start can be achieved with a lower starting torque An incorrect choice of oil can lead to a thickened oil layer on the cylinder walls and bearing surfaces This can in turn lead to higher frictional resistance and more effort which forms a hindrance to reaching the starting rom required for a dependable start and this results in a reduced lifespan 84 Recommended lubricating oil vis cosity There are two important considerations when it comes to ambient temperature in order to achieve satisfactory engine per formance the possibility to tu
30. ft pump Suction height max Fuel supply connection Fuel return connection 244 g kW h Engine specifications 38 3 kW 52 hp 37 1 kW 50 4 hp 3000 rom 127 Nm 13 kgm 93 7 ft Ib 3000 rpm 179 g hp h 8 6 oz hp h 1800 rpm Bosch model M Nippon Denso Plug injector 140 bar kgf cm 2030 psi 1 3 4 2 14 BTDC STM3690 max 1 5 m 5 ft for hose 8 mm 5 16 I D for hose 8 mm 5 16 I D 8 Technical data Oil lubrication system Oil capacity max without oil filter 5 5 litres 1 gal 1 7 pt UK 1 gal 3 6 pt US with oil filter 6 0 litres 1 gal 2 6 pt UK 1 gal 4 7pt US Oil Filter STMO051 Oil temperature in sump max 130 C 266 F Cooling system Capacity Intercooler version 6 5 litres 1 gal 3 4 pt UK 1 gal 5 7 pt US Keel cooler version engine only 7 2 litres 1 gal 4 7 pt UK 1 gal 7 2 pt US Thermostat opening at 71 C 1 5 C 160 F 3 F fully opened at 84 C 183 F Coolant pump Flow at max engine rpm 50 l min 11 UK Gal min 13 2 US Gal min Total head keelcooler at max flow 2 m Water 6 7 Inlet connection for hose keelcooler 28 mm 1 1 8 1 D Raw water pump Flow at max engine rpm 45 l min 9 8 UKGal min 11 9 US Gal min Total head at max flow 2 m Water 6 7 Impeller STM7463 Inlet connection for hose 20 mm 3 4 I D Heater supply connection 15 mm 5 8 He
31. g fuel supply line or fuel injection line Check replace Faulty injector injection pump Check replace if required Setting of stop valve incorrect Check adjust Oil level too high Lower level Lubricating oil incorrect SAE Replace spec or quality for ambient tem perature Incorrect valve clearance Adjust Exhaust restricted Check clean Insufficient intake air Check Wrong fuel quality or contami Check fuel Drain and flush nated fuel fuel tank Replace with new fuel Incorrect injector timing Check adjust Leak in inlet manifold Check replace Engine overloaded Check size of propeller Sea cock closed Open Raw water strainer clogged Check clean Leak in raw water feed system Check replace Faulty thermostat Check replace Faulty coolant pump Check replace Faulty raw water pump impeller Check replace Faulty injector injection pump Check replace if required Oil level too high Lower level Oil level too low Increase level Faulty oil filter Replace Faulty turbo compressor Check replace Heat exchanger dirty or clogged as a result of rubber particles from a worn impeller Check clean Insufficient intake air Check replace air intake filter Leak in inlet manifold Check replace Motor becomes apparantly o
32. generally accepted safety and industrial hygiene regulations must be observed Unauthorized engine modifications will invalidate any liability claims against the manufacturer for resultant damage Manipulations of the injection and regu lating system may also influence the performance of the engine and its emis sions Adherence to legislation on pollu tion cannot be guaranteed under such conditions Contents 1 Safety measures 4 Checking the coolant level 33 Checking engine rpm 59 Checking and cleaning the Cleaning the heat exchanger 60 2 Introduction 9 raw water strainer 34 Data tag 10 Draining water from the water 5 Winter storage procedure 64 Serial number 10 separator fuel filter 35 Cylinder numbering 11 Bleeding 36 6 Recommissioning after winter Fuel pump seal 11 Changing the oil 37 storage 67 Identification of engine parts 12 Battery cables and cable Control panels 14 connections 40 7 Troubleshooting 72 Checking the gearbox oil level 42 3 Use Changing the gearbox oil 43 8 Technical Data 80 General guidelines 17 Checking valve clearance 46 First commissioning 18 Replacing the fuel filter 48 9 Operating media Running in 21 Cleaning fuel lift pump 49 Fuel 83 Starting 22 Checking the V belt 50 Lubrication Oil 85 Pre heating 23 Checking flexible engine mounts 51 Coolant 87 Cruising 26 Checking hose connections 51 Stopping 28 Checking fastenings 51 10 Wiring Diagrams 88 Checking the raw water pump 52 4 Maintenance Coolant replacem
33. heck engine for leaks 7 Changing the gearbox oil 8 Checking instruments and remote controls Start the engine Stop the engine and change the oil of the Check the operation of the instruments Check the fuel system the cooling system gearbox page 43 and 44 the remote control and the gearbox and the exhaust for leakage 71 7 Troubleshooting Engine faults are in most cases caused by improper operation or insufficient mainte nance In case of a fault always check first that the operation and maintenance instruc tions have been followed In the following tables information is given about the possible causes of faults and suggested remedies 72 Please note that these tables can never be complete If you are unable to identify the cause of the fault or to rectify it yourself then con tact the nearest service representative General AN DANGER Before starting make sure that nobody is in the immediate vincinity of the engine When carrying out repair never start the engine with the fuel injection pump removed removed Disconnect battery 7 Troubleshooting 1 Engine will not crank 2 Engine cranks but will not start no smoke from exhaust Possible fault Remedy Faulty or discharged battery Check recharge battery and check engine alternator and or battery charger Fuse blown Replace Loose or corroded connecti ons in starting circuit Clean and tighten connections Fault fi
34. i Rt LM L3 L4 L5 L2 L1 L6 i i D6 Gearbox i i El oil press i i 5i D7 i i D8 H i i D9 i L i i D10 i i Pe lisi fs o o 93 en is c lez Nc we i heating X2M 19 92 ps3 1 xam 61 G2 NC Red Yellow Orange Violet White Black E ia ork UNE CB i Al UU aie iip Mud E Era V Puga A 1H Socket A lt a T Sy Fuse or circuit breaker Auxiliary Start relay Pre Interface cable MPVB2 heating e Connection tor B n so go ely Plug B 2nd alternator E Violet Battery Ea 4 Sooket 8 S main 7 ot switch Bs B3 Yellow Yellow Transparent Gr on Green Brown Blue Gray Goo Batey charging 2nd alternator 1 ca H Yellow wl lag Green NHS c Gi lt Battery charging Black 2 Battery YDH wW Starter motor Pre heating Fuel lift pump Stop Glow plugs ETR m VD00635 Alternator Exhaust temp Oil press Coolant temp Gearbox oil press 93 11 Overall dimensions DIESEL VD00649 M4 55 b fw zu 490 1 Exhaust 40 mm 2 Fuel return 8 mm 3 Sea water intake 20 mm 4 Fuel supply 8 mm aa MIN 62 MAX 80 94 12 Index B Battery 40 41 Bleeding 36 C Changing the gearbox oil 43 44 45 Checking engine oil level 32 Checking engine speed 59 Check
35. in battery switch turned off Satisfy yourself that everything is in order before the engine is started again Make sure that no one is working on or close to the engine before you start it Remove all foreign objects from around the engine such as litter oil tools and other components that are not part of the engine Install all protective covers To prevent injury make sure that all protective covers and cover plates are replaced over moving parts Prevention of injury Remove any tool used to turn the engine over If you leave this in position seri ous injury or damage to the equipment can result NEVER open the cap of the expansion tank when the engine is at working tem perature Only check the coolant level after the engine has been stopped and the filler cap on the heat exchanger is cool enough to be removed with bare hands Never attempt to adjust the fan belt ona running engine 1 Safety measures Prevention of injury Be careful with battery acid Make sure that you are wearing suitable If battery acid comes in contact with the eyes or skin rinse the affected part immediately with copious amounts of water If battery acid comes in contact with the eyes rinse them out immedi ately with plenty of water and consult a doctor Be careful with antifreeze If you accidentally swallow antifreeze make yourself vomit and consult a doc tor immediately If antifreeze comes in contact with your eyes
36. ing the V belt 50 Checking valve clearance 46 47 Cleaning the heat exchanger 60 62 61 63 62 64 Control panels 14 15 16 Coolant 87 Coolant fluid 87 coolant level 33 Coolant replacement 54 55 56 57 Cruising 26 27 Cylinder numbering 11 D Draining the oil 37 E Engine data tag 10 Engine Oil 18 Engine oil change 37 38 39 Engine serial number 1 10 Engine specifications 80 81 F fasteners 51 Filling gearbox 19 Filling the cooling system 20 First commissioning 18 19 21 flexible engine mounts 51 Fuel 21 83 fuel filter 35 Fuel filter replacement 48 Fuel Quality Grade 83 G Gearbox Lubricating Oil 86 Gearbox oil level check 42 H hose connections 51 l Impeller 53 Introduction 9 14 Maintenance 29 55 Maintenance schedule 30 31 O Oil level 32 Operating media 84 86 85 87 86 88 Overall dimensions 94 P Pre heating 23 R Raw water pump 52 53 raw water strainer 34 Recommissioning after winter storage 67 71 Changing the gearbox oil 71 Check engine for leaks 71 Checking instruments and remote controls 71 Electrical system 70 Fresh water cooling system 70 Fuel system 67 Lubrication system 68 Raw water cooling system 68 Removing the oil filter 38 Running in 21 S Safety measures 4 5 6 7 8 Serial numbers 1 Starting 22 24 Stopping 28 95 12 Index T Tachometer 26 Technical data 80 82 Tensioning V belt 50 Topping up coolant 33 Topping up oil 32 Torque wre
37. ith the engine off Refit belt guard if provided 50 40 Checking tension Check tension of the V belt by applying moderate finger and thumb pressure If the deflection of the belt is more than 12 mm 1 2 using about 10 kg 20 Ibs thumb pressure it should be tensioned 41 Tensioning V belt Loosen the bolt of the adjustment bracket and both the alternator mounting bolts Now push the alternator outwards until the belt tension is correct Now first re tighten the upper mounting bolt of the alternator Then re tighten the bolt of the adjustment bracket and the lower mounting bolt 4 Maintenance VD00160 Flexible engine mounts hose connections and fasteners Every 500 operating hours VD01069 42 Check flexible engine mounts Check the bolts which secure the damper element the mounting bolts to engine bed and the nuts at the adjustment spindle for tightness Inspect the rubber element of the engine support for cracks Also check the deflec tion of the damper element the deflection influences the alignment of engine and propshaft Re align engine in case of doubt 43 Inspection hose connections 44 Check fasteners Inspect all hose connections of the cool Check tightness of all fasteners bolts and ingsystem Cracked hoses loose hose nuts clamps 51 4 Maintenance AN NOTE Only engines with intercooling 45 Raw water pump inspection The rubber impeller of the outboard
38. k Svenska Norsk Suomeksi Nederlands English English French WETS mv FOKKERSTRAAT 57 3125 BD SCHIEDAM HOLLAND TEL 31 10 4377700 FAX 31 10 4372673 4621286 E MAIL sales vetus nl INTERNET http www vetus com 340402 01 12 07 Printed in the Netherlands English M4 55 Vetus Diesel
39. ling instructions on p 57 va VD01130 The level of the coolant must be approx 1 cm 3 8 below the lower edge of the filler neck Bleeding will take place automatically dur ing filling Replace the filler cap After the engine has run for the first time and has reached operating temperature and has cooled down again to ambient temperature check the coolant level in the heat exchanger housing If necessary add coolant A CAUTION Never fill the cooling system with sea water or brackish water vDo0002 5 Fuel Ensure that the fuel tank is filled with die sel fuel Use only clean water free commercial approved diesel fuel For fuel grade see page 83 Bleed the fuel system see page 36 N WARNING Never fill the fuel tank while the engine is running Do not spill fuel Prevent unnec essary pollution 6 Other preparations Check battery and cable connections Start the engine see page 22 and let it run for about 10 minutes without load Check the engine and all connections fuel cooling water and exhaust for leaks First commissioning Running in 7 Running in In order to ensure a long life for your engine please observe the following for the first 50 operating hours Allow the engine to reach operating temperature before applying a load Avoid fast acceleration Do not allow the engine to run faster than 3 4 of maximum RPM 21 3 Use Before
40. mum lifetime and good per formance NEVER turn the main switch off while the engine is running Starting OQ OFF VEM w by STOP VD00629 AN CAUTION Never turn the key to the srART position while the engine is running Doing so will damage the starter motor 25 3 Use The instrument panel is provided with the following instruments Depending of the type of panel see page 14 26 1000 RPM 3000 Q 0 wets 4000 VD00113 13 Tachometer Indicating the number of revolutions per minute of the engine Also the number of running hours is indi cated Idling speed 900 rpm Cruising AN WARNING Avoid idling for more than 10 minutes This can lead to carbon deposits in the combustion chambers and incomplete combustion of fuel 3 Use Cruising VD00114 14 Voltmeter Indicating the battery voltage When the engine is running the battery voltage should be between 12 and 14 Volts With the engine stopped and the start key in the first position the voltmeter should indicate 12 Volts 15 Warning lights None of the five warning lights should light up while the engine is running 16 Alarm buzzer Oil pressure battery charging and tem perature indicator lights are all connected to an alarm buzzer If this alarm buzzer sounds while running STOP THE ENGINE IMMEDIATELY 27 3 Use OFF
41. n the same position as removed 53 4 Maintenance 51 Coolant replacement The coolant has to be replaced every 1000 operating hours or at least once every two years N B Replacing the coolant may also be necessary as part of the winter storage procedure in case that the coolant present in the cooling system offers insufficient protection for the winter 54 NA DANGER Be aware of the risk of skin burning dur ing draining the hot coolant Used cool ant must be collected in a container for proper disposal according to laws and regulations xo Coolant replacement Every 1000 operating hours AN WARNING Cooling system protective liquids must be disposed of in accordance with environ mental regulations 4 Maintenance VD01147 52 Draining of coolant Detach the hose to the oil coller 1 and remove the drainplug from the heat exchanger 2 AN NOTE Keel cooler How the cooling system in engines with keel cooling should be drained depends on the installation of the keel cooler Refer to the keel cooler manufacturer s instructions for this Check using a coolant hydrometer whether the coolant is providing suf ficient protection against freezing if total draining off is not possible Coolant replacement Every 1000 operating hours VDO1131 Remove the filler cap to vent the cooling system and check that all the coolant has been drained After draining
42. nch settings 82 Troubleshooting 72 77 U Use 17 26 V Voltmeter 27 W Warning lights 27 water separator fuel filter 35 36 Winter grade fuel 83 Winter storage procedure 64 66 Electrical system 66 Fresh water cooling system 66 Fuel system 64 Lubrication system 65 Raw water cooling system 65 Wiring diagram 88 89 90 91 92 93 96 Manuals Art code 340401 01 340402 01 340403 01 340404 01 340405 01 340406 01 340407 01 340408 01 340409 01 340410 01 320331 01 320199 05 341831 01 342402 01 342404 01 Description Bedieningshandleiding M4 55 Operation manual M4 55 Bedienungsanleitung M4 55 Manuel d utilisation M4 55 Manual de operacion M4 55 Istruzioni per l uso M4 55 Brugsanvisning M4 55 Anv ndarmanual M4 55 Bruksanvisning M4 55 K ytt opas M4 55 STMO032 Installatiehandleiding Installation manual STMO016 Service en Garantieboek Service and Warranty Manual Service und Garantieheft Livret Garantie et Service Manual de servicio y garant a Libretto di assistenza e garanzia Service og garantibog Service och garantih fte Service og garantibok Huolto ja takuukirja Onderdelenboek Parts manual M4 55 Service manual M4 55 Service manual M4 55 Nederlands English Deutsch Francais Espanol Italiano Dansk Svenska Norsk Suomeksi Nederlands English Nederlands English Deutsch Frangais Espanol Italiano Dans
43. nding table Possible fault Remedy Fuel stop valve closed Open Nearly Empty fuel tank Refill Air in fuel system Check and bleed Fuel filter clogged with water and or contamination Check or replace Faulty starter switch or faulty starter relay Check replace Faulty starter motor or pinion does not engage Check replace starter motor Starter relay is not engaged due to a voltage too low caused by a very long inter mediate cable from engine to control panel Install an auxiliary starter relay Seized components Repair Leaking fuel supply line or fuel injection line Check replace Faulty injector injection pump Check replace if required Vent line of fuel supply tank clogged Check clean Exhaust restricted Check Electric fuel pump not working Check clean Dirt in the inlet or outlet valves of the electric fuel pump Install a strainer in the fuel line between tank and engine Electric fuel pump filter bloc ked Check clean 73 7 Troubleshooting 3 Engine cranks but will not start smoke from exhaust PY 4 Engine starts but runs unevenly rough idling or stalls Possible fault Remedy Air in fuel system Check and bleed Faulty injector injection pump Check replace if required Setting of stop valve incorrect Check adjust Faulty glow plugs Check re
44. ne speed adjust ment screw has been correctly set at the factory and sealed DO NOT attempt to remove this seal VD00134 I ci Ex Maximum ELA speed adjust Lead seal ment screw A 10 VD00145 At full load with the boat cruising the maximum engine speed should be about 3000 RPM see technical data page 80 If the engine does not reach this speed it is being overloaded If this is the case check the ship s pro peller for defects or irregularities and also to see that it is the correct pitch and diameter 58 Checking engine speed The engine 900 rpm Allow the engine to warm up normally until the coolant temperature reaches at least 60 C 140 F before checking and or adjusting the idling speed Check the engine RPM using a rev coun ter or use the rev counter fitted to the control panel idling speed should be 59 Adjusting engine idling speed If the engine speed differs from that stated above it must be adjusted The engine idling speed can be reset using the adjustment screw on the fuel pump 59 4 Maintenance YN NoTE Only engines with intercooling Only clean the heat exchanger if this is badly fouled Under normal conditions of use cleaning the heat exchanger is not necessary 60 The engine temperature will be higher than normal if the heat exchanger is fouled Possible causes of fouling are Small rubber particles from a d
45. nt in the cooling system offers insufficient protection for the winter For coolant replacement see page 54 66 6 Recommissioning after winter storage VD00027 VD00141 1 Fuel system Drain the water from the water separator Drain the water from the fuel tank Install a new fuel filter page 48 fuel filter page 35 67 6 Recommissioning after winter storage A VD01143 PM VD00137 E Open the fuel valve 68 2 Lubrication system Check the engine oil level page 32 VD00125 3 Raw water cooling system Check that the lid of the raw water strainer is reinstalled A NoTE Only engines with intercooling 6 Recommissioning after winter storage Y The lid of the raw water pump and drain Re tighten possible loose hose clamps Open the sea cock plugs are reinstalled pages 52 53 VD01138 VD00138 AN Note AN NOTE Only engines with intercooling Only engines with intercooling 69 6 Recommissioning after winter storage VDO 131 CT40063 VD00140 4 Fresh water cooling system 5 Electrical system Check the coolant level page 38 Make sure that the batteries are fully Connect the batteries charged page 40 66 70 6 Recommissioning after winter storage VD01144 VD01151 VD00581 6 C
46. ounter Amounts of oil fuel and coolant needed for topping up The dates and intervals at which the oil and coolant are changed Oil pressure and coolant temperature Introduction Parts on which maintenance is conduct ed and type of maintenance adjust ment repair or replacement and the results of each procedure Changes in operating conditions such as Exhaust gas became black etc 29 4 Maintenance Maintenance schedule Every 10 hours or daily before starting Every 100 hours at least once every year Check engine oil level 32 Drain water from fuel filter Check coolant level 33 Engine oil change 37 Check water strainer 34 Replace oil filter 38 Battery cables and cable connections 40 Check gearbox oil level 42 After the first 50 hours Drain water from fuel filter 35 Replace oil filter 38 Change gearbox oil Pee es Change gearbox oil Technodrive 43 Change gearbox oil and replace filter ZF Hurth 44 Change gearbox oil and replace filter ZF Hurth 44 Check valve clearance 46 Replace fuel filter 48 Replace fuel filter 48 Check idle rom 59 Cleaning fuel lift pump 49 Check V belt 50 Check flexible engine mounts 51 Check engine for leaks 51 Check tightness of all fasteners bolts and nuts 51 A DANGER Stop the engine before carrying out any maintenance work 30 4 Maintenance Maintenance schedule Every 500 hours When required
47. place Incorrect valve clearance Adjust Incorrect injection timing after Check adjust overhauling of engine Insufficient intake air Check Wrong fuel quality or contami nated fuel Check fuel Drain and flush fuel tank Replace with new fuel Incorrect lube oil SAE class or quality for ambient tempera ture Replace 74 Possible fault Fault finding table Remedy Nearly Empty fuel tank Refill Air in fuel system Check and bleed Fuel filter clogged with water and or contamination Check or replace Leaking fuel supply line or fuel injection line Check replace Faulty injector injection pump Check replace if required Vent line of fuel supply tank clogged Check clean Fuel supply line restricted Check clean Incorrect valve clearance Adjust Idle setting too low Check adjust Exhaust restricted Check Wrong fuel quality or contami nated fuel Check fuel Drain and flush fuel tank Replace with new fuel Clogged filter of electric fuel lift Check clean pump 7 Troubleshooting Fault finding table 5 Engine does not reach maximum rpm under load 6 Engine overheats Possible fault Remedy Possible fault Remedy Air in fuel system Check and bleed Coolant level too low Check top up Fuel filter clogged with water and or contamination Check or replace Leakin
48. r O RING ART CODE STM6113 2 x YN NoTE Only engines with intercooling VD00157 STM6202 65 Replacing heat exchanger 66 Replacing the end covers Replace the heat exchanger in the original Fit the end covers in the housing the con Tighten up the bolts when both covers are position in the heat exchanger housing nector cover is fitted with a locating pin in the correct position Use new O rings 61 x 2 5 mm which so that it can be fitted in one way only in have been greased relation to the heat exchanger Refit the drain plug This ensures the correct position of the separator baffle in the connector cover in Reconnect all hoses previously relation to the heat exchanger removed Refill the cooling system see page 56 63 5 Winter storage procedure 1 Fuel system Drain the water from the water separator fuel filter and the fuel tank Ensure that the tank is completely filled with fuel 64 VD00136 Running with protective fuel mixture Connect the fuel supply pipe to a can filled with a mixture of one 1 part of engine oil to nine 9 parts of clean fuel Use this mixture to run the engine at no load for approx 10 minutes Stop the engine AN CAUTION Never run the engine under load with this mixture of fuel and oil Engine oil with protective properties E g Vetus Marine Diesel Engine Oil 15 W 40 Shell Nautilus Premium Inboard 15W 40 Preferably
49. release the starter switch if the engine does not fire within 20 seconds Wait until the starter motor has stopped before mak ing a new attempt to start the engine Repeat the above if the engine cuts out after a short time 4 Maintenance 12 Engine oil change Change the engine oil every 100 hours of operation together with engine oil filter replacement If the engine runs less than 100 hours dur ing the year the oil should be changed at least once a year Run the engine for a few minutes before changing the oil warm oil can be pumped out more easily Change the oil with a switched off engine at operation temperature Lube oil tem perature max 80 C 176 F AN DANGER Be aware of the risk of skin burning during draining the hot oil Used oil must be col lected in a container for proper disposal according to laws and regulations Engine oil change Every 100 operating hours VD01159 13 Draining the oil Remove the dipstick insert the suction hose of the supplied sump pump in the dipstick tube Push down the pump handle quickly and pull it up slowly 37 4 Maintenance Engine oil change Every 100 operating hours yh e i OIL FILTER ART CODE STMOO51 is d ji d gt VD01155 mm VD00124 VD01156 14 Removing the oil filter 15 Oiling the oil seal 16 Oil filter installation Unscrew the oil filter with a commercially Clean the contact surface of
50. replace the drain plug 55 4 Maintenance COOLANT QUANTITY 6 5 litres 1 gal 3 4 pt UK 1 gal 5 7 pt US iV t il oi et VD01129 VD00158 53 Filling the cooling system Remove the cap of the filler neck on the top of the heat exchanger housing Remove the bolt from the upper side of the thermostat cover so that air can escape from the cooling system Fill the cooling system Use a mixture of 4096 antifreeze ethylene glycol based and 60 tap water or use a special coolant For specifications see page 87 56 VD01130 The level of the coolant must be approx 1 cm 3 8 below the lower edge of the filler neck Bleeding will take place automatically dur ing filling Replace the filler cap After the engine has run for the first time and has reached operating temperature and has cooled down again to ambient temperature check the coolant level in the Coolant replacement Every 1000 operating hours heat exchanger housing If necessary add coolant AN CAUTION Never fill the cooling system with sea water or brackish water 4 Maintenance Coolant replacement Every 1000 operating hours VD00626 VD00627 54 Filling coolant system if a water heater is connected A The HiGHEST point of the water heater is situated at a LOWER level than the expan sion tank for the ship s engine The water heater will be filled and bled automati
51. rn the engine over quickly enough to make an easy start possible and adequate lubrication of internal wear surfaces during starting and warming up By making the right choice of lubricating oil these requirements can be met The recommended oil viscosity is shown in the overview below Lubricating oil Because the viscosity runniness of lubri cating oil varies with temperature the ambient temperature in which the engine is started determines the choice of viscos ity class SAE class To avoid having to change the oil for differ ent seasons we recommend SAE 15W 40 all season motor oil For example Vetus Marine Diesel Engine Oil 15 W 40 Shell Nautilus Premium Inboard 15W 40 For oil capacity see p 81 Recommended lubricating oil viscosity Starting tempera 30 m a ture C deg F s i T Lubricating oil viscosity 0 10 20 30 40 32 50 68 86 104 SAE15W 40 SAE10W30 SAE5W 20 9 Operating media AN CAUTION Do not mix oil of different brands together Oils of different brands are mostly not com patible with each other If they are mixed the mixtures can cause components such as piston rings cylinders etc to seize up and cause wear to moving parts The best thing is to keep to one brand and one type of lubricating oil for each subsequent service Limits concerning motor oil Limits concerning motor oil If an analysis of the used lubricating oil is conduc
52. t 1 200 and show less than 0 050 between high and low If not recharge or replace battery During checking the tem perature of the electrolyte should prefer ably be 20 C 68 F YN DANGER The gases emitted by the battery are explosive Keep sparks and naked flames away from the battery Do not allow battery acid to come into contact with skin or clothing Wear protective goggles Do not rest tools on the battery 41 4 Maintenance Vetus engines are normally equipped with Technodrive or ZF Hurth gearbox es Consult the supplied Owners Manual for more details about care and mainte nance In case your engine is equipped with another brand of gearbox follow the instructions given in the supplied owners manual for changing oil and other care and maintenance 42 VD01038 23 Oil level check Technodrive The oil level must between the two marks on the dipstick If necessary top up The fillercap is on top of the gearbox housing For oil type and specification see page 86 Gearbox oil level check Every 100 operating hours 24 Oil level check ZF Hurth Unscrew the dipstick out of the gearbox housing Check the oil level by cleaning the dip stick and lowering it into the hole without screwing it in The oil level must between the two marks on the dipstick If necessary top up by pouring oil in the dipstick hole For oil type and specification see page 86 4 Maintenance Changing the gear
53. t to possible fuel or oil leakage If you discover a leak take counter measures immediately If fuel or oil is spilled on a hot engine fire can break out This can cause physical injury or damage to the equipment Do not fill the fuel tank while the engine is running Only refuel with the engine stopped Never put flammable materials in the vicinity of the engine Keep the engine and engine compart ment clean Remove all inflammable materials such as fuel oil and other litter before it builds up in the vicinity of the engine Preventing fire and explosion Connecting emergency extra starting battery Proceed as follows when an extra start ing battery is used to jump start the engine First connect the positive lead Lastly connect the earth cable nega tive pole to the engine block If this cable is connected in error to the negative pole of the engine battery a spark can occur The result of this could be that explo sive gas produced by the battery explodes Once the engine is started first remove the earth cable 1 Safety measures The moving parts of the engine are dan gerous Never touch moving parts of the engine while it is running to prevent cuts and other injuries Stop the engine before carrying out maintenance Always stop the engine before topping up or replacing fuel oil or coolant Before carrying out inspection or maintenance the ignition key must be removed and the ma
54. ted to determine its condition con sult the overview below Change the oil if one or more of the conditions is not met Lubricating oil A NoTE How often the oil has to be changed depends on the characteristics of the fuel Only use the recommended fuels The limit for the total base number is half of that of new oil in the case of an analysis method based on perchloric acid Characteristic Unit Test method Limit O 1 O Viscosity cSt 100 C JIS K 2283 Amer qe max for new oil Total base numberl HCl mgKOH g 2 0 min JIS K 2501 c Total acid number mgKOH g 3 0 max for new oil Water content 96 volume JIS K 2275 0 2 max Flash point C JIS K 2265 180 min Pentane insolubles weigth 0 5 max f ASTM D 893 Coagulated pentane insolubles 96 weight 3 0 max 85 9 Operating media Gearbox Lubricating Oil Only use a recognised brand of oil for lubricating the gearbox Technodrive type TM345 type TM345A type TMC60 ZF Hurth type ZF25 type ZF25A ATF For example 1 6 litres Motorolie SAE 20W40 CD 2 8 UK pt 3 4 US pt 1 6 litres Motorolie SAE 20W40 CD 2 8 UK pt 3 4 US pt 0 8 litres Motorolie SAE 20 30 1 4 UK pt 1 7 US pt 2 5 litres ATF 4 4 UK pt 5 3 US pt 1 8 litres ATF 3 2 UK pt 3 8 US pt AutomaticTransmission Fluid Transmissie olie type A Suffix A Vetus Marine Gearbox Oil Shell Donax
55. ter motor 25 Alternator 26 Sea water pump inlet 20 mm 27 V belt 28 Extra expansion tank connection only for keel cooling option 29 Cooling system air bleeding nipple 30 Cooling system filler cap pressure cap 31 Expansion tank 32 Heat exchanger 33 Cooling system drain plug 34 Vent connection 35 Exhaust injector elbow o 50 mm 26 25 24 23 22 21 VD01150 13 2 Introduction Control panels engines with intercooling 2000 1000 RPM pod T g34 3000 EE 456789 3 VD00576 ME VD00575 Basic panel model 22 Fly bridge panel excl voltmeter model 21 Tachometer Operating hours counter Voltmeter Starter pre heat switch lock Warning light high raw water temperature Warning light low oil pressure Warning light high coolant temperature o0 cnm Sailingboat panel model 10 Warning light battery charging Indicator light pre heating Warning light gearbox low oil pressure oO 0 Y This is an option not fitted as standard 2 Introduction Control panels engines with keelcooling 2000 1000 RPM 3000 po T e34
56. ter or brackish water AN WARNING ws Cooling system protective liquids must be disposed GR of in accordance with environmental regulations 87 10 Wiring diagram Engine with panel model 20 21 22 engine with intercooling BEA c Engine panel model Voltmeter Tachometer Mix 20 21 22 OP Ho Model 20 21 22 Ma E Voltmeter D D 1 Tachometer D 1 1 rl 4 8 T2 45 4 RA 12 78 qe Ji E AL El EE rat A a x E g M M a prs a u We PX lar H7 19 58 15 w 95 i i i i i SZ D1 Z D2 yz D3 D4 i i Ne 1 i Warning lights i i Qi Red Yellow Orange Violet White Black i i L1 BZ L2 Rs 6913 69 L4 69 L5 L6 i A1 A3 A4 A2 A5 A6 i 9 e es educ i Plugin iA qu D oa Ane NAS A TON i al os i L3 L4 L5 L2 L1 L6 Esci da td E i D6 Gearbox i Socket A i AS TI n h i D7 oil press AEREA PE pee li goes lS le 1 Ai A3 ha A3 As AG i py 08 i Fuse or i 5 D9 circuit breaker Auxiliary i i start relay i Y D10 Pre 19 94 61 91 o2 jes fw q E heating X2M y open Se i i A Y
57. the gasket Install the filter in accordance with the available tool when all the oil has been Lubricate the oil seal of the new filter ele instructions printed on the filter element pumped out ment with clean engine oil housing Catch any dripping oil AN DANGER Beware of burns from hot oil 38 4 Maintenance AMOUNT OF OIL 6 0 litres OIL FILTER INCL 1 gal 2 6 pt UK 1 gal 4 7pt US D voorosz A s 17 Refilling with oil Refill the engine with new oil for specifica tion see page 84 through the filler open ing in the valve cover Operate the engine at idling speed for a short period of time Check for oil leaks whilst the engine is running Stop the engine Allow 5 minutes for the oil to return to the sump Check the oil level with the dipstick Engine oil change Every 100 operating hours 39 4 Maintenance Battery cables and connections Every 100 operating hours Vetus maintenance free batteries VD00117 VD00118 GREEN DOT O ALL DARK e VD00122 CLEAR VD00121 18 Battery battery connections Keep battery clean and dry Remove battery cables negative first Clean battery posts and and clamps and grease with acid free and acid resist ant grease Ensure that clamps make good contact after reassembling Hand tighten the bolts only 40 19 Checking specific gravity Every
58. tion for 30 les 30 9Y ag Plug B i 2nd alternator TEESE up Aen Battery nt j ME Socket B X E Violet 3 main 710 av Tes see EOS ett switch B6 B4 B1 B2 B5 B3 Yellow E Transparent Green Green Brown Blue Gray Battery charging j m 2nd alternator 1 2d aA HER Yellow lj H B BE Green li m MC X GyD a Battery charging Black 2 dd Battery Pod Y iv Ww E Stop Starter motor Pre heating Fuel pump ETR Solenoid Alternator ETS Exhaust Oil Coolant temp press temp VD00652 92 10 Wiring diagram Options panel model 34 engine with intercooling Key switch Voltmeter Tachometer Oil pressure Temperature ES Engine panel model hour counter gauge gauge m IU ge f TEX 34 im po is 54 58 3210P_1 C Pe 8 DR 7 5 44 T8 T6 MM 2 i i Xt ar 7 9 58 15 w 95 Mi M2 i i i i i D1 YZ D2 X D D4 i Warning lights i i i i Q1 i i n3 eu BZ 412 nRs 6913 69 La 6915 L6 i
59. troduction Cylinder numbering fuel pump seal VD00637 Maximum VD00145 4 Cylinder numbering Cylinders are numbered consecutively beginning at the front end 5 Fuel pump seal AN CAUTION Breaking the seals on the regulator to alter the settings of maximum rpm and maximum injector volume may only be carried out by authorised Vetus Service personnel Breaking the seals and altering the set tings can lead to Accelerated wear of engine compo nents Increased fuel and oil consumption Incorrectly adjusted injector volume and poor engine performance Breaking emission regulations 11 2 Introduction ouahond 10 11 12 13 14 15 16 17 18 19 20 12 Oil filler cap 8 mm fuel hose connection Fuel pump Oil filter Engine oil cooler Water separator fuel filter drain plug Water separator fuel filter Gearbox Gearbox filter Air inlet Gearbox oil cooler Air filter Turbo Electrical system connector box and fuses 8 mm fuel return hose connection Water separator fuel filter bleed nipple Oil dipstick Manually operated electrical stop Push pull throttle cable connection Oil filler cap Identification of engine parts Service side VD01149 2 Introduction Identification of engine parts Starter side 21 Push pull gearbox cable connec 27 28 29 30 31 32 33 34 35 tion 22 Gearbox drain plug 23 Gearbox oil dipstick filler cap J 24 Star
60. ver heated as a result of faulty tempe rature switch sensor or meter Check replace 75 7 Troubleshooting 7 Engine not firing on all cylinders 8 Engine has little or no oil pressure Possible fault Remedy Possible fault Fault finding table Remedy Air in fuel system Check and bleed Oil level too low Increase level Fuel filter clogged with water and or contamination Check or replace Leaking fuel supply line or fuel injection line Check replace Faulty injector injection pump Check replace if required Fuel supply line restricted Check clean Blocked oil filter Replace Faulty oil pump Repair replace Excessive inclination of engine Check Adjust Incorrect lube oil SAE class or quality for ambient tempera ture Replace Faulty glow plugs Check replace Incorrect valve clearance Adjust Electric fuel pump filter bloc ked Check clean Faulty electric fuel pump Check replace 76 Oil pressure apparently too low due to faulty oil pressure switch sensor or meter Check replace 7 Troubleshooting 9 Engine oil consumption excessive 10 Fuel consumption excessive Fault finding table Possible fault Remedy Possible fault Remedy Oil level too high Lower level Incorrect fuel quality or dirty Check fuel Drain and rinse Excessive inclination of engine Ch
61. wash them out immediately with plenty of water and consult a doctor clothing before starting work For your own safety you will most likely need special equipment safety hel met eye protection safety boots safety goggles heavy gloves ear protectors etc Use them when necessary Carry out maintenance procedures safely by only using suitable tools Exhaust gases Do not start the engine if the exhaust system is not connected 1 Safety measures When the engine stops suddenly If the engine stops suddenly do not start it again immediately Track down the cause and carry out the necessary repairs before you start the engine again If you do not do this serious engine problems can develop If the oil pressure is too low Stop the engine immediately and check the lubrication system Running an engine with low oil pressure can cause bearing and other parts to seize f the engine overheats If the engine should overheat do not switch it off immediately If an overheat ed engine is stopped suddenly this can cause the coolant temperature to rise rapidly and moving parts to seize First let the engine run in neutral to allow the hot parts of the engine to cool down stop the engine and allow it to cool and then gradually top up the coolant Remember adding coolant to an over heated engine can cause damage to the cylinder head When problems occur If the fan belt is broken Immediately stop the engine
62. water pump is not proof against running dry If the water supply has been blocked it may be necessary to replace the impeller Always carry a spare impeller on board 52 VD01070 46 Pump cover removal Inspection where appropriate changing is as follows Close the sea cock Remove the cover of the pump by unscrewing the screws out of the hous ing Raw water pump inspection Every 1000 operating hours VD01071 47 Impeller removal Slide the impeller off of the shaft using a waterpump plier Mark the impeller to ensure correct re installation if it is to be re used The impeller must be installed in the same position as removed 4 Maintenance Raw water pump inspection Every 1000 operating hours IMPELLER ART CODE STM7463 VD00127 O RING ART CODE STM7686 FSF STM7696 VD00004 VD00582 48 Impeller inspection Inspect the impeller for damage Replace the impeller if necessary A NOTE Only engines with intercooling 49 Re install the impeller 50 Replacing the pump cover The impeller should be lubricated with Replace the cover with a new O ring glycerin or a non petroleum based lubri cant such as a silicone spray before fit Check the water filter and open the sea ting it into the impeller housing cock Fit the impeller to the pump shaft if an existing impeller is re used install it i
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