Vetus D-LINE VD4.120 Operation Manual Download Page 41

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6 Maintenance

Introduction

Keep record of the following information
in the logbook and/or the ‘Service and War-
ranty Manual’:

- Total engine hours (reading engine hour

counter).

- 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.

- Parts on which maintenance is conduct-

ed and type of maintenance (adjustment,
repair or replacement), and the results of
each procedure.

- Changes in operating conditions, such as

‘Exhaust gas became black’, etc.

Summary of Contents for D-LINE VD4.120

Page 1: ...Operation manual D LINE Marine Diesel Engines 360602 01 VD6 210 VD4 120 VD4 140 VD6 170 VD6 210 ...

Page 2: ...ii ...

Page 3: ...ice Repairs or Spare Parts see page 10 We reserve the right to make any changes without previous notice Images shown in this manual may be different Copyright 2017 Vetus B V Schiedam Holland Serial numbers Engine serial number Vetus Engine serial number Deutz Gearbox serial number 360602 01 VD4 120 VD6 170 VD4 140 VD6 210 ...

Page 4: ... is considered to be contrary to the intended purpose The manufacturer will not not as sume responsibility for any damage resulting therefrom The risks involved are to be borne by the user Use in accordance with the intended pur pose also implies compliance with the con ditions laid down by the manufacturer for operation maintenance and servicing The engine should only be operated maintained and s...

Page 5: ...arator fuel filter 45 Engine oil change 47 Battery cables and connections 52 Gearbox oil level check 56 Changing the gearbox oil 57 Fuel filter replacement 58 Flexible engine mounts hose connections and fasteners 59 Checking the V belts 60 Raw water pump inspection 62 Air filter replacement 65 Checking the starter motor and alternator 66 Checking valve clearance 67 Coolant replacement 70 Cleaning ...

Page 6: ... also advise that a potential danger exists that can lead to serious injury or death Note Emphasises important procedures circum stances etc Symbols Indicates that the relevant procedure must be carried out Indicates that a particular action is for bidden Pass the safety precautions on to other peo ple who will use the engine General rules and laws concerning safety and accident prevention must al...

Page 7: ... Only refuel with the engine stopped Never put flammable materials in the vicin ity of the engine Keep the engine and engine compartment clean Remove all inflammable materials such as fuel oil and other litter before it builds up in the vicinity of the engine Connecting emergency extra starting bat tery Proceed as follows when an extra starting battery is used to jump start the engine First connec...

Page 8: ...king on or close to the engine before you start it Re move 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 protec tive covers and cover plates are replaced over moving parts Remove any tool used to turn the engine over If you leave this in position serious inj...

Page 9: ...freeze make yourself vomit and consult a doctor imme diately If antifreeze comes in contact with your eyes wash them out immediately with plenty of water and consult a doctor Make sure that you are wearing suitable clothing before starting work For your own safety you will most likely need special equipment safety helmet eye protection safety boots safety gog gles heavy gloves ear protectors etc U...

Page 10: ... suddenly this can cause the coolant temperature to rise rapidly and moving parts to seize First let the engine run in neutral to al low 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 overheated engine can cause damage to the cylinder head If the fan belt is broken Immediately stop the engine If an e...

Page 11: ...rily all components described in this manual are mounted to your engine We have endeavoured to highlight any differ ences so that you will able to locate the oper ating and maintenance instructions 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 additional ...

Page 12: ...XXX XX XX XX XXXX D XXXXXXXXXXXX XXX XXXXXXXX A B D C 2 Introduction Data tag Serial number 1 Engine data tag Model A Deutz engine serial number B and performance data are stamped on the engine data tag Model and engine serial number must be given when ordering spare parts 2 Engine data tag location The Deutz engine data tag C is attached to the crank case TheVetus engine nameplate D is attached t...

Page 13: ...eutz engine serial number is stamped at the indicated spot 4 Cylinder numbering and direction of rotation Cilinder numbering Cylinders are numbered consecutively begin ning at the flywheel end Direction of rotation The direction of rotation is viewed towards the flywheel counter clockwise Motor sides Seen from the flywheel side ...

Page 14: ...plug heat exchanger cover raw water 7 Heat exchanger 8 Filler cap pressure cap for cooling system 9 Cooling system drain plug heat exchanger 10 P T O Mounting facility for hydraulic pumps 11 Oil cooler 12 Fuel filter 13 Oil filter 14 Alternator 15 Fuel supply pipe connection ø 12 mm 16 V belt alternator 17 Fuel lift pump 18 V belt alternator fuel pump coolant pump 19 P T O Mounting facility for ex...

Page 15: ...prop shaft lubrication 26 Connection airvent 27 Exhaust insulator 28 Lifting eye 29 Relays and fusses 30 Gearbox lube oil cooler 31 Raw water pump 32 Raw water inlet ø 32 mm 33 Cooling system drain plug block 34 Flexible engine mounts 35 Aftercooler 36 Oil sump drain pump 37 Drain plug after cooler condens water 38 Drain plug after cooler raw water 39 Starter motor 40 Gearbox filler cap oil dipsti...

Page 16: ...plug heat exchanger cover raw water 7 Heat exchanger 8 Filler cap pressure cap for cooling system 9 Cooling system drain plug heat exchanger 10 P T O Mounting facility for hydraulic pumps 11 Fuel filter 12 Oil cooler 13 Alternator 14 V belt alternator 15 Oil filter 16 Fuel supply pipe connection ø 12 mm 17 Fuel lift pump 18 V belt alternator fuel pump coolant pump 19 P T O Mounting facility for ex...

Page 17: ...prop shaft lubrication 26 Connection airvent 27 Exhaust insulator 28 Lifting eye 29 Relays and fusses 30 Gearbox lube oil cooler 31 Raw water pump 32 Raw water inlet ø 32 mm 33 Cooling system drain plug block 34 Flexible engine mounts 35 Aftercooler 36 Oil sump drain pump 37 Drain plug after cooler condens water 38 Drain plug after cooler raw water 39 Starter motor 40 Gearbox filler cap oil dipsti...

Page 18: ...2 3 1 6 5 4 16 1 Temperature gauge coolant 2 Tachometer Operating hours counter 3 Voltmeter 4 Oil pressure gauge 5 Display 6 Starter pre heat switch lock 2 Introduction Control panels Panel model MPA34 ...

Page 19: ...typically controlled with a single lever Depending on the brand and type mechani cal or electronic there may be minor diffe rences in the mode of operation Please refer to the engine manual for details However the principle is always as indicated above The control lever works as shown in the dia gram Starting from neutral put the engine in ahead or astern by moving the lever 35 forwards or backwar...

Page 20: ...are delivered empty of oil Fill the engine with oil through the filler neck on top of the valve cover For quantity and oil specification see page 108 and 116 Check the oil level with the dipstick see page 42 Engine Oil 10W40 of 15W40 API CD CE CF of CF4 ACEA D4 D5 For example Vetus Marine Diesel Engine Oil 15W40 Shell Rimula R4 L 15W40 litres Imp pt US pt 4 cyl 8 5 15 18 6 cyl 14 24 6 29 6 ...

Page 21: ...l specification see page 118 Check the oil level with the dipstick see page 56 Vetus engines are normally equipped with ZF Hurth gearboxes In case your engine is equipped with another brand of gearbox follow the instructions given in the supplied own ers manual for changing oil and other care and maintenance ...

Page 22: ... a mixture of 40 antifreeze ethylene gly col based and 60 tap water or use a special coolant For specifications see page 119 Fill until the coolant is level with the bottom of the filler neck Bleeding will take place automatically during filling Coolant quantity litres Imp pt US pt 4 cyl 8 14 1 16 9 6 cyl 11 19 4 23 2 Note If a water heater is connected to the engine see page 22 and 23 Caution Nev...

Page 23: ...iller cap 2 on the expansion tank After the first 3 times that the engine has been in operation such that the operating temperature has been reached and the en gine has cooled back to the ambient tem perature the coolant level in the expansion tank must be checked If necessary add coolant Caution Never fill the cooling system with sea water or brackish water ...

Page 24: ...he expansion tank for the ship s engine The water heater will be filled and bled auto matically during filling of the cooling system Follow the filling instructions as shown on pages 20 and 21 Use a mixture of 40 antifreeze ethylene gly col based and 60 tap water or use a special coolant For specifications see page 119 Caution Never fill the cooling system with sea water or brackish water ...

Page 25: ...er will not be filled and bled automatically during filling of the cooling system Open valve 3 during filling and bleeding the system Follow the filling instructions as shown on pages 20 and 21 Use a mixture of 40 antifreeze ethylene gly col based and 60 tap water or use a special coolant For specifications see page 119 Note Remember to close valve 3 after filling the system Caution Never fill the...

Page 26: ...sel fuel For fuel grade see page 114 The fuel system is self bleeding 8 Other preparations Check that the battery is charged and check the battery cable connections Set the main switch to position on Open the sea cock Check that the gearbox control lever is set to neutral Warning Never fill the fuel tank while the engine is running Do not spill fuel Prevent unnec essary pollution ...

Page 27: ...bout 2 minutes at idling speed Stop the engine Check the oil level If necessary top up to the indicated level Start the engine Allow the engine to test run for about 10 minutes at idling speed Stop the engine Check that the engine and all connections fuel coolant and exhaust for leaks Caution Stop the engine immediately if it makes any strange noises vibrates excessively or if black smoke comes ou...

Page 28: ...rm engine the level will be slightly higher as indicated Check the coolant temperature 11 Sea trial Check the operation of the remote control Carry out a sea trial At full load when the vessel is in motion the maximum RPM must correspond to the value specified in the technical data The engine can become overloaded if it doesn t reach this RPM In this case check the propeller for irre gularities an...

Page 29: ...ine to run faster than 3 4 of maximum RPM After the first 50 operation hours carry out the following maintenance Drain water from fuel filter see page 45 Engine oil change see page 47 Replace oil filter see page 49 Change gearbox oil see page 56 Replace fuel filter see page 58 Check flexible engine mounts see page 59 Check engine for leaks see page 59 Check tightness of all fasteners bolts and nut...

Page 30: ... larly including the Daily procedures before starting Use anti freeze in the engine coolant all year long this helps prevent corrosion as well as protecting against frost damage For specifications see page 119 Never run the engine without a thermostat Use a good quality lubricating oil For spec ifications see page 116 Use a good quality diesel fuel that is free of water and other pollutants Always...

Page 31: ...ge 18 and further if the en gine is being commissioned for the first time After repair work Check that all guards have been replaced and that all tools have been removed from the en gine When starting with pre heating do not use any other substance e g injection with Easy Start Doing so could result in an accident ...

Page 32: ... Engine oil level Coolant level Sea cock open Main switch on Gearbox in neutral position 1 Control lever Before starting the engine always check that the control lever s is are in the neutral position Leave the control lever in position neutral 2 Control panel The control panel is equipped with a starter key ...

Page 33: ...h a pre heat supply the pre heat switch lock position on the operator panel can therefore be ignored Turn the start key on the instrument panel clock wise the warning lights for oil pres sure and alternator will now light up and the alarm buzzer will sound 3 Switching on ...

Page 34: ...n as the engine fires the key will return to the on position and throttle back Leave the key in this position while the engine is running Caution Release the key if the engine does not fire within 10 seconds Let the starter motor cool for 30 seconds be fore turning the key to the start position again ...

Page 35: ...e immediately Before fully loading the engine it should be brought up to temperature with about 3 4 of the maximum load as quickly as possible A good warming up is essential to ensure maximum life and performance Caution Never turn the main switch off while the engine is running Caution Never turn the key to the start position while the engine is running Doing so will damage the starter motor ...

Page 36: ...struments 5 Tachometer Indicating the number of revolutions per min ute of the engine Also the number of running hours is indicat ed Warning Avoid idling for more than 10 minutes This can lead to carbon deposits in the com bustion chambers and incomplete combus tion of fuel ...

Page 37: ...uge Indicating the temperature of the internal cooling system Fot the operating temperature see technical data page 109 In case the engine is overheated turn off the engine and establish the cause see fault find ing table page 96 105 8 Oil pressure gauge With the engine at operating temperature the oil pressure is When idling at least 1 bar 7 psi In case the oil pressure is too low turn off the en...

Page 38: ...e engine is running no warnings should be displayed 10 Alarm buzzer Oil pressure battery charging and temper ature indicator lights are all connected to an alarm buzzer If this alarm buzzer sounds while running Stop the engine immediately ...

Page 39: ...of the key on the other panel Note 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 Note 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 Note Never switch off the battery main switch di rectly after the engine has stopped Wait...

Page 40: ...orm each function at the indicated time interval The intervals stated are for normal operation al conditions Service the unit more frequent ly 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 ...

Page 41: ... counter 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 Parts on which maintenance is conduct ed and type of maintenance adjustment repair or replacement and the results of each procedure Changes in operating conditions such as Exhaust gas became black etc ...

Page 42: ...ter 58 Check flexible engine mounts 59 Check engine for leaks 59 Check tightness of all fasteners bolts and nuts 59 Check V belt 60 Every 100 hours at least once every year page Drain water from fuel filter 45 Engine oil change 47 Replace oil filter 49 Draining the charge air cooler 51 Battery cables and cable connections 52 Check gearbox oil level 56 Every 500 hours at least once every year page ...

Page 43: ...rs at least once every 2 years page Raw water pump inspection 62 Replace air filter 65 Every 1000 hours page Check starter motor 66 Check alternator 66 Every 1500 hours page Checking valve clearance 67 Every 2000 hours page Replace coolant 70 When required page Cleaning heat exchanger 73 Cleaning the after cooler 78 ...

Page 44: ...e starboard side of the engine 2 Oil level The oil level must be at or near the upper mark on the dipstick 1 If necessary top up with the same brand and type of oil 3 Topping up oil The oil filling cap is on top of the the valve cover 1 The difference be tween the two oil level marks is litres Imp pt US pt 4 cyl 1 5 2 6 3 2 6 cyl 2 3 5 4 2 ...

Page 45: ...el The coolant must be at the minimum level 6 Topping up coolant If necessary top up 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 119 Warning Never open the cap on the header tank when the engine is at operating temperature Note If a water heater is connected see page 22 and 23 Caution Never fill th...

Page 46: ...rainer 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 Check the sealing between the lid and housing after cleaning and re assembling the strainer An improperly sealed lid will re sult in air sucked in by the sea...

Page 47: ...fuel and litter before you start the engine 9 Waterafscheider aftappen Empty the separately installed water separa tor Disconnect the sensor connector plug con nection Unscrew the drain plug sensor on the under side of the filter Allow the water to drain out and close the drain plug sensor Reconnect the sensor connector The water separator is not engined mounted but installed is required and the s...

Page 48: ...e the starter switch if the engine does not fire within 20 seconds Wait until the starter motor has stopped before making a new attempt to start the engine Repeat the above if the engine cuts out af ter a short time 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 11 Start the engine ...

Page 49: ...ar 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 temperature approx 80 C 176 F Danger Be aware of the risk of skin burning during draining the hot oil Used oil must be collect ed in a container for proper disposal accord ing to laws and regulations Warning Never use additiv...

Page 50: ...he control panel must be in the OFF position Connect a Ø 10 mm hose to the crankcase oil change pump as shown Open the shut off valve A Turn on the oil change pump with the switch S Turn off the pump when all the oil is pumped out of the crankcase Warning The engine oil must be disposed in accord ance with the applicable environmental reg ulations Danger Beware of burns from hot oil ...

Page 51: ...er ele ment with clean engine oil For oil filter art code see page 124 16 Oil filter installation Install the filter in accordance with the in structions printed on the filter element housing Tightening torque 11 13 Nm 8 10 ft lbf 14 Removing the oil filter Unscrew the oil filter with a commercially available tool Catch any dripping oil Danger Beware of burns from hot oil ...

Page 52: ...through the filler open ing in the valve cover Amount of oil oil filter incl litres Imp pt US pt 4 cil 8 5 15 18 6 cil 14 24 6 29 6 Operate the engine at idling speed for a short period of time Check for oil leaks whilst the engine is running Stop the en gine Allow 5 minutes for the oil to return to the sump Check the oil level with the dipstick ...

Page 53: ...ng the charge air cooler The condensate water collected in the char ge air cooler must be drained every 100 hours or at least 1 x per year Remove the drain plug from the charge air cooler housing and check that all conden sate water is running out After drainage replace the drain plug ...

Page 54: ...ry acid can escape from the degassing openings or vents First aid Rinse off acid splashed in the eyes immediately for several minutes with fresh water Then consult a doctor immediately Neutralize acid splash on skin or clothes immediately with acid neu tralizer soda or soap suds and rinse with plenty of water If acid is consumed consult a doc tor immediately Warning note Do not place batteries in ...

Page 55: ...ours 19 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 resistant grease Ensure that clamps make good contact after reassembling Hand tighten the bolts only ...

Page 56: ...ilt into the cover Visual inspection of the hydrometer will show one of three conditions 21 Hydrometer operation Green dot visible State of charge 65 or more Dark State of charge less than 65 Recharge im mediately Clear or light yellow Electrolyte level low In case of low level caused by overcharging the battery for a long period of time with a voltage too high replace battery Check alter nator an...

Page 57: ... to mix electrolyte 23 Checking specific gravity Measure the electrolyte specific gravity of the individual cells with a commercial hydrome ter The hydrometer reading see table indi cates the state of charge Hydrometer reading of all cells should be at least 1 200 and show less than 0 050 between high and low If not recharge or replace battery Specific gravity State of charge 1 8 kg l 100 1 20 kg ...

Page 58: ...ust between the end and the mark on the dipstick If necessary top up by pouring oil in the dipstick hole For oil type and specification see page 118 Remember to replace the dipstick 24 Oil level check Vetus engines are normally equipped with ZF Hurth gearboxes In case your engine is equipped with another brand of gearbox follow the instructions given in the supplied own ers manual for changing oil...

Page 59: ... has been pumped out Or if sufficient space below the gearbox is available oil can be drained by removing the drain plug Remove the fillercap to vent the gearbox and check if all oil has been drained Collect the oil in a dripping pan 26 Filling with new oil Refill the gearbox to the correct level via the dipstick opening For oil specification see page 118 In case your engine is equipped with anoth...

Page 60: ...e filter carrier rim Lubricate the rubber gasket sparingly with clean motor oil Fill the new filter with clean diesel oil For fuel filter art code see page 124 N B 4 cylinder engine has 1 filter element instead of 2 28 Installing the fuel filter s Install the filters Turn the filter an additi onal one half to three quarters of a turn by hand after the rubber seal touches the housing Open the fuel ...

Page 61: ...t 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 Inspect all hose connections of the cool ingsystem Cracked hoses loose hose clamps 31 Check fasteners Check tightness of all fasteners bolts and nuts 30 In...

Page 62: ...sion Inspect the belts for wear and tear fraying and cracking Belts which are in poor con dition should be replaced For V belt art code see page 124 Check tension of the V belt by applying moderate finger and thumb pressure If the deflection of the belt is more than 9 3 8 12 mm 1 2 using about 10 kg 20 lbs thumb pressure it should be tensioned Danger Check tension and change belts only with the en...

Page 63: ...of the arrow using a square 1 2 key a until the tension of the belt is correct Tighten the bolts 1 and 2 Unscrew the mounting bracket bolts and both of the alternator mounting bolts Now push the alternator outwards until the belt has the desired tension Tighten the bolts in the order shown 37 Reinstall the protection cover Always reinstall the V belt cover and tigh ten the screws 36 Tensioning V b...

Page 64: ... the impeller Always carry a spare impeller on board 39 Pump cover removal Inspection where appropriate changing is as follows Close the sea cock Remove the cover of the pump by unscrew ing the screws out of the housing 40 Impeller removal Slide the impeller off of the shaft using a waterpump plier Mark the impeller to ensure correct re in stallation if it is to be re used The impeller must be ins...

Page 65: ... 41 Impeller inspection Inspect the impeller for damage Replace the impeller if necessary 42 Pump housing inspection Check the inside of the pump housing for damage Pay special attention to wear of the cam 1 Replace the cam and or the pump housing in case of excessive wear ...

Page 66: ...on petroleum based lubri cant such as a silicone spray before fitting it into the impeller housing Fit the impeller to the pump shaft if an existing impeller is re used install it in the same position as removed 44 Reinstall the pump cover Replace the cover with a new O ring Check the water filter and open the sea cock For O ring art code see page 124 ...

Page 67: ... tighten the hose clamp and fit a new Ty rap For air filter art code see page 124 Warning Never clean the element with petrol or hot liquids Never apply any oil to the air filter Never start the engine without the air filter in place 45 Vervangen luchtfilter Cut the Ty rap 1 Loosen the hose clamp 2 Remove the filter housing 3 ...

Page 68: ...lternator 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 46 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 ...

Page 69: ...6 hours 49 Remove upper cover Close the sea cock Disconnect the hoses 1 and 2 Remove the 4 bolts and remove the upper cover 50 Remove the V belt protection cover Loosen the the screws the screws can be loosened without tools and they have an ti loss rings and remove the V belt protec tion Note After checking adjusting the valve clearance re install the V belt protection and the upper cover and re ...

Page 70: ...ve clearance lube oil temperature less than 80 C Loosen the screws Remove the valve cover Remove the gasket The turning tool is placed on the mounting screws of the pulleys Rotate the crankshaft until the valves over lap Exhaust valve is not yet closed inlet valve starts opening 1 Lock nut 2 Adjusting screw 3 Angle gauge 4 Key socket for socket wrench 5 Magnet 51 Adjusting the valve clearance ...

Page 71: ...recti on until it is seated rocker arm has no play and turn the scale to zero Determine which cylinders should be adjus ted from the setup chart Valve overlap Setting the cylinder 1 4 3 2 4 1 2 3 Valve overlap Setting the cylinder 1 6 5 2 3 4 6 1 2 5 4 3 VD4 VD6 Valve clearance IN Inlet valve 75 10 EX Exhaust valve 120 10 Rotate the angle gauge anticlockwise until you reach the specified rotationa...

Page 72: ...hours or at least once every two years N B Replacing the coolant may also be neces sary as part of the winter storage procedure in case that the coolant present in the cooling system offers insufficient protection for the winter 52 Coolant replacement Danger Be aware of the risk of skin burning during draining the hot coolant Used coolant must be collected in a container for proper disposal accord...

Page 73: ...and check that all the fluid is run ning out Refit the drain plug after all the liquid has run out N B A small part of the coolant will remain in the engine block If necessary remove the drain plug 2 from the engine block to fully drain the engine Remove the drain plug from the heat ex changer housing 1 53 Draining of coolant ...

Page 74: ...e engine has first been in ope ration such that the operating tempera ture has been reached and the engine has cooled back to the ambient temperature Top up if necessary Caution Never fill the cooling system with sea water or brackish water Fill the cooling system as indicated on pa ges 20 to 23 Use a mixture of 40 antifreeze ethylene gly col based and 60 tap water or use a special coolant For spe...

Page 75: ...an the heat exchanger if this is badly fouled Under normal conditions of use cleaning the heat exchanger is not necessary The engine temperature will be higher than normal if the heat exchanger is fouled Possible causes of fouling are Small rubber particles from a damaged sea water pump impeller Growth of algae or seaweed ...

Page 76: ...ug in the heat exchan ger housing to drain the coolant Remove the filler cap to bleed the cooling system and check that all the fluid is run ning out Refit the drain plug after all the liquid has run out 56 Disconnecting raw water hoses Close the tap of the raw water supply Disconnect both raw water hoses ...

Page 77: ...e end covers Remove the 3 nuts from both end covers Take off the end cover 1 with the O ring from the housing Take off the connector cover 2 with the gasket from the housing Slidetheheatexchangeroutofthehousing Remove the gasket from the heat exchan ger 58 Remove heat exchanger ...

Page 78: ... exchanger Clean the heat exchanger Use a pipe clean er to remove fouling in the pipes Then rinse the heat exchanger pipes with clean water Clean the contact surfaces of the O ring and gaskets Ensure that both contact surfaces of the heat exchanger are free from dirt ...

Page 79: ...with a new gasket 1 in the heat exchanger housing Refit all the disconnected hoses Refill the cooling system see pg 72 Open the tap of the raw water supply 61 Replacing the end covers Refit the connector cover with a new gasket 2 to the housing Refit the end cover with a new O ring 3 For gasket set art code see pg 124 ...

Page 80: ...ne decreases this can be caused by a dirty heat exchanger in the after cooler The heat exchanger must then be cleaned Possible causes of fouling of the tubes of the after cooler are Small rubber particles from a damaged raw water pump impeller Growth of algae or seaweed 62 Removing the raw water hoses Close the sea cock Remove both the raw water hoses ...

Page 81: ...d covers Remove the 3 nuts from both end covers Take off the end cover 1 with the O ring from the housing Take off the connector cover 2 with the gasket from the housing 64 Removing the heat exchanger Slidetheheatexchangeroutofthehousing Remove the gasket from the heat exchan ger ...

Page 82: ... tube of the heat exchanger use a pipe brush and fresh water to remove any growth in the pipes Then rinse the heat exchanger tubes with clean water Make sure that both surfaces of the after cooler housing are free from dirt residues Clean the contact surfaces of the O ring and gaskets ...

Page 83: ... the after cooler Place the heat exchanger with a new gasket 1 in the charge air cooler housing Refit the connector cover with a new gasket 2 to the housing Refit the end cover with a new O ring 3 For gasket set art code see pg 124 Refit all the disconnected hoses Open the tap of the raw water supply ...

Page 84: ...r peri od Make sure that the engine compartment is well ventilated during the winter period Good ventilation prevents damp in the en gine compartment thus preventing corrosion of the engine from occurring The engine should be inspected at the start of the storage period and any necessary repairs should be carried out Consult a Vetus Dealer if help is required with this Inspections and maintenance ...

Page 85: ... tank 84 3 Make sure that the engine fuel system is filled with a fuel mixture with protective properties 85 4 Flush out the raw water circuit with fresh water and if necessary fill with antifreeze Clean the heat exchanger if necessary 86 5 Make sure that the cooling system is filled with a suitable anti freeze 87 6 Change the oil filter and the engine oil 88 7 Change the oil in the gearbox 88 8 D...

Page 86: ...der to prevent corrosion the engine should be rinsed off to remove any salt residues If there is any corrosion the paint should be touched up Engine parts that become hot must be touched up with heat resistant paint 2 Fuel system Drain the water from the water separator fuel filter and the fuel tank Ensure that the tank is completely filled with fuel Install a new fuel filter page 58 ...

Page 87: ...ox 5 minutes Stop the engine 2 Only use CEN EN 590 Diesel fuel Preferably water free fuel Collect some fuel from the return pipe while engine is running Tip Combine running the engine with the protective fuel mixture with flushing the raw water circuit with fresh water see Winter storage procedure Raw water cooling system Caution Never run the engine under load with this mixture of fuel and oil 1 ...

Page 88: ... raw water system must be protected in areas where the temperature drops to be low zero during the winter Pour 1 litre 1 4 gallon of anti freeze preferably a non toxic biodegradable an ti freeze into the water strainer and run the engine until the anti freeze has disap peared into the cooling system Tip Combine flushing the raw water circuit with fresh water with running the en gine with the prote...

Page 89: ...uring winter storage the cooling system must be filled with an anti freeze water mixture or a coolant For specifications see page 119 N B Replacing the coolant is only necessary if the coolant present in the cooling system offers insufficient protection against temper atures below 0 C 32 F For coolant replacement see page 70 Tip Protect the sea cock as follows With the motor stopped Place the sea ...

Page 90: ...rain the oil see page 48 Replace the oil filter and change the engine oil use oil with protective properties See page 47 49 For quantity and oil specification see page 108 and 116 7 Changing the gearbox oil Stop the engine and change the oil of the gearbox page 57 ...

Page 91: ...ter lay up regu larly if required Follow the recommendations given on pages 52 to 55 or consult the recommen dations given by the battery supplier for in spection and maintenance of the batteries Note Never switch off the battery main switch di rectly after the engine has stopped Wait at least 2 minutes See page 37 ...

Page 92: ...s and maintenance work to be car ried out are Inspections and maintenance work to be carried out are page 1 Drain the water from the fuel system 91 2 Check the raw water system 92 3 Check the coolant level in the internal cooling system 93 4 Check the oil level 93 5 Check the batteries and reconnect these 94 6 Check the operation of the engine 94 7 Check all hose connections for leaks 95 8 Check t...

Page 93: ...91 8 Recommissioning after lay up or winter storage 1 Fuel system Drain the water from the water separator fuel filter page 45 Drain the water from the fuel tank Open the fuel valve ...

Page 94: ...winter storage 2 Raw water cooling system Check that the lid of the raw water strainer is reinstalled Check whether the lid of the raw water pump and drain plugs are reinstalled pag es 62 64 Re tighten possible loose hose clamps 1 6 x 6 3 ...

Page 95: ...OIL 93 8 Recommissioning after lay up or winter storage Open the sea cock 3 Fresh water cooling system Check the coolant level page 43 4 Lubrication system Check the engine oil level page 42 ...

Page 96: ...mmissioning after lay up or winter storage 5 Electrical system Make sure that the batteries are fully charged page 52 89 Connect the batteries 6 Switching on Turn the start key on the instrument panel clock wise ...

Page 97: ...nter storage 7 Check engine for leaks Start the engine Check the fuel system the cooling system and the exhaust for leakage 8 Checking instruments and remote controls Check the operation of the instruments the remote control and the gearbox ...

Page 98: ...lowed In the following tables information is given about the possible causes of faults and sug gested remedies Please note that these ta bles can never be complete If you are unable to identify the cause of the fault or to rectify it yourself then contact the nearest service representative Danger Before starting make sure that nobody is in the immediate vincinity of the engine When carrying out re...

Page 99: ...alls 99 5 Engine does not reach maximum rpm under load 100 6 Engine overheats 101 7 Engine not firing on all cylinders 101 8 Engine has little or no oil pressure 102 9 Engine oil consumption excessive 102 10 Fuel consumption excessive 103 11 Black exhaust smoke idling 103 12 Blue exhaust smoke idling 103 13 Black exhaust smoke at load 104 14 White exhaust smoke at full load 104 15 Burnt oil trace ...

Page 100: ... starting Check error according to error code and eliminate fault Water in the cylinder Check Repair 2 Engine cranks but will not start no smoke from exhaust Possible fault Remedy Nearly Empty fuel tank Refill Fuel stop valve closed Open Fuel pre filter clogged Clean replace Fuel filter clogged with water and or contamination Check or replace Vent line of fuel supply tank clogged Check clean Fault...

Page 101: ... Possible fault Remedy Nearly Empty fuel tank Refill Fuel supply line restricted Check clean Fuel filter clogged with water and or contamination Check or replace Vent line of fuel supply tank clogged Check clean Faulty injector injection pump Check replace if required Leaking fuel supply line or fuel injection line Check replace Air in fuel system Check and bleed Wrong fuel quality or contami nate...

Page 102: ...ality or contami nated fuel Check fuel Drain and flush fuel tank Replace with new fuel Incorrect injection timing Check adjust Oil level too high Lower level Lubricating oil incorrect SAE spec or quality for ambient temperature Replace Insufficient intake air Check Leak in inlet manifold Check replace Intercooler dirty Check clean Exhaust restricted Check clean Incorrect valve clearance Adjust Tra...

Page 103: ...el too high Lower level Faulty oil filter Replace Faulty oil heat exchanger Replace Insufficient intake air Check replace air intake filter Leak in inlet manifold Check replace Faulty turbo compressor Check replace Intercooler dirty Check clean Incorrect valve clearance Adjust 6 Engine overheats Possible fault Remedy Motor becomes apparently overheated as a result of faulty temperature switch sens...

Page 104: ...due to faulty oil pressure switch sensor or meter Check replace 9 Engine oil consumption excessive Possible fault Remedy Oil level too high Lower level Incorrect lube oil SAE class or quality for ambient temperature Replace Leak in lubricating oil system Repair replace Crank case vapour condenser clogged Replace Insufficient intake air Check Excessive wear of cylinder pis ton Check compression ove...

Page 105: ... air intake Check Excessive wear of cylinder piston Check compression refurbish engine 11 Black exhaust smoke idling Possible fault Remedy Injector fault Check replace Oil level too high Lower level Excessive inclination of engine Check Adjust 12 Blue exhaust smoke idling Possible fault Remedy Oil level too high Lower level Leaking from turbo compressor oil seal Check replace oil seal Excessive in...

Page 106: ...bish engine Faulty turbo compressor Check replace Engine overloaded max rpm is not reached Check sizes of propeller Engine overloaded dirty pro peller boat hull excessive load on board Check clean 14 White exhaust smoke at full load Possible fault Remedy Faulty injector injection pump Check replace if required Air in fuel system Check and bleed Wrong fuel quality or contami nated fuel Check fuel D...

Page 107: ...epair Replace 16 Idle speed 750 800 RPM Possible fault Remedy Coolant temperature lower than 40 C On normal functioning Run the engine at a speed of 900 RPM until the coolant temp is over 40 C Wrong indication of tachometer Adjust replace Fault on electric electronic equipment Check repair Low battery voltage On normal functioning If the battery voltage is lower than 13 5 V increase engine speed t...

Page 108: ...ed Bore 101 mm 101 mm 101 mm 101 mm Stroke 126 mm 126 mm 126 mm 126 mm Total displacement 4038 cm3 4038 cm3 6057 cm3 6057 cm3 Compression ratio 18 0 1 18 0 1 18 0 1 18 0 1 Idling speed 800 rpm 800 rpm 800 rpm 800 rpm Max no of revolutions at no load 2520 rpm 2520 rpm 2520 rpm 2520 rpm Direction of rotation Counter clockwise viewed towards the flywheel Valve Clearances Inlet Exhaust Setting with ro...

Page 109: ...hp 120 kW 163 hp 149 kW 203 hp at no of revolutions of 2400 rpm 2400 rpm 2400 omw min 2400 rpm Torque 449 Nm 45 8 kgm 331 ft lb 520 Nm 53 kgm 383 ft lb 680 Nm 69 3 kgm 502 ft lb 810 Nm 82 6 kgm 597 ft lb at no of revolutions of 1600 rpm 1600 rpm 1600 omw min 1600 rpm Fuel consumption 235 g kW h 173 g hp h 6 1 oz hp h 235 g kW h 173 g hp h 6 1 oz hp h 240 g kW h 177 g hp h 6 2 oz hp h 240 g kW h 17...

Page 110: ...flow max 4 l min 0 9 Imp Gal min 1 1 US Gal min Oil lubrication system Oil capacity max without oil filter 7 5 litres 13 2 Imp Gal min 5 8 US Gal min 7 5 litres 13 2 Imp Gal min 5 8 US Gal min 12 5 litres 22 Imp Gal min 26 4 US Gal min 12 5 litres 22 Imp Gal min 26 4 US Gal min with oil filter 8 5 litres 15 Imp Gal min 18 US Gal min 8 5 litres 15 Imp Gal min 18 US Gal min 14 litres 24 6 Imp Gal mi...

Page 111: ...n 50 7 US Gal min Total head 0 3 bar 4 3 psi 0 3 bar 4 3 psi 0 3 bar 4 3 psi 0 3 bar 4 3 psi Raw water pump Flow at max engine rpm 94 l min 20 7 Imp Gal min 24 8 US Gal min 94 l min 20 7 Imp Gal min 24 8 US Gal min 117 l min 25 7 Imp Gal min 30 9 US Gal min 117 l min 25 7 Imp Gal min 30 9 US Gal min Total head at max flow 0 5 bar 7 psi 0 5 bar 7 psi 0 5 bar 7 psi 0 5 bar 7 psi Inlet connection for...

Page 112: ... Volt min 2x 66 Ah max 2x 110 Ah at 24 Volt Fuses Oil change pump Immobiliser Blade fuse ATO 3 A see page 111 EMR Power Blade fuse ATO 25 A see page 111 Dashboard Blade fuse ATO 10 A see page 111 CAN Diagnosis EMR Control Blade fuse ATO 7 5 A see page 111 V belts Tension Alternator Pre tension 650 N 145 lbf Re tension 400 50 N 90 11 lbf Fuel pump Coolant pump Pre tension 650 N 145 lbf Re tension 4...

Page 113: ... 2 78 1 1 51 1 93 2 5 2 78 1 model 63A 1 22 1 56 2 04 2 52 1 1 22 1 56 2 04 2 52 1 model 63IV 1 29 1 56 1 99 2 47 1 1 29 1 56 1 99 2 47 1 1 29 1 56 1 99 2 47 1 1 29 1 56 1 99 2 47 1 10 Technical data Engine specifications Gearbox specifications Electrical system Relay K1 70A Starting K2 30A Elec Oil sump drain pump K3 70A EMR K4 30A Diagnosis CAN relay K1 2 3 1 K3 K2 4 K4 ...

Page 114: ... arm set screw M8x60 8 8 21 2 1 Flange injection pump M8x30 10 9 30 3 0 Injector holder Torx M8x50 10 9 16 5 1 6 0 5 Fuel lift pump clamping strap M8x20 10 9 A4C 21 2 2 1 0 2 Pulley fuel lift pump M8x20 8 8 21 2 2 1 0 2 Screw banjo connector fuel line M14x1 5 39 10 3 9 1 Injection line mounting M14x1 5 25 3 5 2 5 0 35 Exhaust insulator M8 8 8 21 10 2 1 1 Air intake manifold AIM M6x75 10 9 11 10 1 ...

Page 115: ...1 1 6 Cyl M10 22 10 2 2 1 Turbo oplader Uitlaatinjectiebocht Stud 4 Cyl M8 22 10 2 2 1 6 Cyl M10 22 10 2 2 1 Nut 4 Cyl M8 21 10 2 1 1 6 Cyl M10 21 10 2 1 1 Alternator mounting M8x80 10 9 21 10 2 1 1 Starter M10x55 10 9 70 7 0 Engine bracket front M16x75 8 8 260 10 26 0 1 Engine bracket rear M12x40 8 8 95 10 9 5 1 Flywheel housing M12x150 10 9 99 10 9 9 1 Flywheel housing M16x140 10 9 243 10 24 3 1...

Page 116: ...sing authority are always based on the reference fuel described by law These fuels match the diesel fuels which are in accordance with CEN EN 590 and ASTM D 975 Emission levels cannot be guaranteed with other fuels 11 Operating media Fuel Winter grade fuel Waxing may occur at low temperatures clogging the fuel system and reducing engine efficiency If the ambient temperature is less than 0 C 32 F w...

Page 117: ...iodiesel B100 Although the use of biodiesel is allowed in diesel blends with up to 7 FAME Fatty Acid Methyl Esters B7 fast degradation of the biodiesel should be taken in account Problems caused by using FAME of poor quality or degraded fuel are not covered by warranty 11 Operating media Fuel ...

Page 118: ...frictional resistance and more effort which forms a hindrance to reaching the starting rpm required for a dependable start and this results in a reduced lifespan Recommended lubricating oil viscosity There are two important considerations when it comes to ambient temperature in order to achieve satisfactory engine performance the possibility to turn the engine over quickly enough to make an easy s...

Page 119: ...the oil if one or more of the conditions is not met Note How often the oil has to be changed de pends 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 11 Operating media Lubricating oil Limits concerning motor oil Characteristic Unit Test method Limit Viscosity...

Page 120: ... litres ATF 1 model ZF63 3 8 litres ATF 1 model ZF63A 4 0 litres ATF 1 model ZF63IV 4 0 litres ATF 1 1 ATF AutomaticTransmission Fluid Transmission oil type A Suffix A For example Vetus Transmission Oil Shell Donax T6 Gulf Synth Other brands of gearboxes See supplied owners manual for oil type and quantities 11 Operating media Lubricating oil ...

Page 121: ...ow exceed the following limits Cooling system protective liquid Anti freeze Water Protection against 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 cir cumstances Therefor if coolant must be added always use the same mixture of anti freeze and tap water 11 Operating media Coolant Water quality for cool...

Page 122: ...2 A5 A6 A3 A4 X A X P 12 p Contrasteker DT04 12P 3 p Contrasteker DT04 3P 5 P Contrasteker M12 X M Red Yellow Yellow Yellow Yellow Orange Purple Brown Red Red Red Red Red Red Red Red Red Black Green Throttle Input Variable Voltage Main Relay Starter B Terminal Engine B Terminal Engine Battery Switch 12 V Battery 12 V Battery Optional for 24 V Oil Sump Drain Pump Oil Pump Start Alternator Oil Pump ...

Page 123: ...nector DT06 6S MPYA 30 50 17 19 15 58 X A X A6 X A4 X A1 X A2 X A5 X A3 K4 85 D B 15 TS 30 30 50 17 19 15 58 X A X A6 X A4 X A1 X A2 X A5 X A3 K4 85 D B 15 TS 30 X C X C5 X C4 X C3 X C2 X C1 X C X C5 X C4 X C3 X C2 X C1 Key Switch Yellow Orange Purple Red Brown 6p Dashboard Connector DT06 6S Exhaust Temp Alarm Switch Neutral if alarm NO Connect to Alarm Indicator Key Switch Yellow Orange Purple Re...

Page 124: ...1 1 2 5 46 1 4 572 22 1 2 699 27 1 2 153 6 290 11 7 16 151 5 15 16 106 4 3 16 122 13 Overall dimensions VD4 120 VD4 140 1 10 ...

Page 125: ...800 31 1 2 1175 46 1 4 142 5 9 16 153 6 884 34 13 16 649 25 9 16 235 9 1 4 290 11 7 16 151 5 15 16 123 13 Overall dimensions ...

Page 126: ...ZF63 572 22 1 2 726 28 9 16 197 7 3 4 245 9 5 8 127 5 106 4 3 16 VD6 170 VD6 210 1 10 124 13 Overall dimensions ...

Page 127: ...ZF63 1028 40 1 2 1418 55 13 16 142 5 9 16 140 5 1 2 197 7 3 4 859 33 13 16 619 24 3 8 240 9 7 16 245 9 5 8 127 5 125 13 Overall dimensions ...

Page 128: ...258 16 4258 16 4258 500 60 Fuel pump Coolant pump VD40069 VD40069 VD40069 VD40069 500 60 Raw water pump Impeller O ring STM8250 STM8250 STM8250 STM8250 1000 62 Impeller STM8246 STM8246 STM8246 STM8246 1000 62 O ring STM9974 STM9974 STM9974 STM9974 1000 62 Air intake filter 16 4797 16 4797 15 2768 15 2768 1000 65 Set of seals for heat exchanger DM10001 DM10001 DM10001 DM10001 73 Set of seals for ch...

Page 129: ...34 36 Cylinder numbering 11 D Direction of rotation 11 Display 16 Draining of coolant 71 Draining the charge air cooler 51 Draining the oil 48 Drain plug after cooler condens water 13 15 Drain plug after cooler raw water 13 15 E Electrolyte level 55 Engine data tag 10 Engine oil 18 116 Engine oil change 47 50 Engine serial number 1 11 Engine specifications 106 113 Fuses 110 Relay 111 Exhaust injec...

Page 130: ...ng after winter storage 90 95 Check engine for leaks 95 Checking instruments and remote controls 95 Electrical system 94 Fresh water cooling system 93 Fuel system 91 Lubrication system 93 Raw water cooling system 92 Relays and fusses 13 15 Removing the oil filter 49 Running in 27 S Safety measures 4 8 Serial numbers 1 Starter motor 13 15 66 Starter pre heat switch lock 16 Starting 30 33 32 Stoppin...

Page 131: ... 45 Winter grade fuel 114 Winter storage procedure 82 89 Changing the gearbox oil 88 Corrosion protection 84 Electrical system 89 Fresh water cooling system 87 Fuel system 84 Lubrication system 88 Protective fuel mixture 85 Raw water cooling system 86 Wiring diagrams 120 121 ...

Page 132: ...130 ...

Page 133: ...12 01 Manual de operação D LINE VD4 VD6 Português 360619 01 Instrukcja obsługi D LINE VD4 VD6 Polski 320331 01 STM0032 Installatiehandleiding Installation manual Nederlands English 320199 06 Service en Garantieboek Service and Warranty Manual Service und Garantieheft Livret Garantie et Service Manual de servicio y garantía Libretto di assistenza e ga ranzia Service og garantibog Service och garant...

Page 134: ...Vetus Diesel D LINE VD4 VD6 English ...

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