Vetus DT4.70 Operation Manual Download Page 86

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6 Maintenance

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.

Clean the contact surfaces of the O-

•

rings.

VD00864

ote

Only engines with intercooling!

VD00746

VD00863

Summary of Contents for DT4.70

Page 1: ...Operation manual DT4 70 DTA4 85 ...

Page 2: ...ii ...

Page 3: ...oted when inquiring about Customer Service Repairs or Spare Parts see page 6 We reserve the right to make any changes without previous notice Copyright 2010 Vetus N V Schiedam Holland Serial numbers Engine serial number Vetus Mitsubishi Gearbox serial number DT4 70 DTA4 85 360502 01 ...

Page 4: ...is considered to be contrary to the intended purpose The manufacturer will not not assume responsibility for any damage resulting there from 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 operated maintained and ser...

Page 5: ... fuel filter 49 Gearbox oil level check 52 Draining the after cooler charge air cooler 53 Battery cables and connections 54 Engine oil change 58 Changing the gearbox oil Tech nodrive 61 Changing the gearbox oil ZF Hurth 62 Fuel filter replacement 64 Cleaning filter fuel lift pump 66 Bleeding after fuel filter replace ment 67 Checking the V belt 68 Flexible engine mounts 70 Hose connections and fas...

Page 6: ...s also advise that a potential danger exists that can lead to serious injury or death Note Emphasises important procedures cir cumstances etc Symbols 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 al...

Page 7: ...ly refuel with the engine stopped Never put flammable materials in the vi cinity 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 Connecting emergency extra starting battery Proceed as follows when an extra start ing battery is used to jump start the en gine First connect...

Page 8: ...in 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 pro tective covers and cover plates are re placed over moving parts Remove any tool used to bar the engine If you leave thi...

Page 9: ...freeze make yourself vomit and consult a doc tor immediately 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: ...d 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 If the drive belt has broken Stop the engine immediately If ...

Page 11: ...ly all components described in this manual are mounted to your engine We have endeavoured to highlight any dif ferences so that you will able to locate the operating and maintenance instructions relevant to your engine quickly and easily Please read this manual before starting your engine and always observe the oper ating and maintenance instructions We are available to help with any additional in...

Page 12: ...e type plate The engine type and serial number must be quoted when ordering spare parts Position of the type plate 2 The type plate is positioned as shown 3 Serial number The serial number is stamped in the engine block in the position shown DT470A3452 123456 A 2500 52 70 200910 VD00800 VD00875 VD00880 ...

Page 13: ... of rotation Cylinder numbering direction of rotation 4 Cylinder numbering Cylinders are numbered consecutively be ginning at the flywheel end Direction of rotation The direction of rotation is viewed towards the flywheel counter clockwise VD00881 ...

Page 14: ...nnection airvent 9 Raw water pump inlet ø 28 mm 10 V belt 11 Oil filter 12 Engine oil cooler 13 Cooling system drain plug engine block 14 Alternator 15 Flexible engine mount 16 Zinc anode 17 Heat exchanger 18 Cooling system drain plug heat exchanger 19 Connection for prop shaft lubrication G 3 8 20 Connection of push pull cable gear box 21 Exhaust injection bend ø 75 mm 2 3 4 5 6 8 18 11 14 15 16 ...

Page 15: ...ooling option 27 Connection water heater OUT 28 Return fuel pipe connection 8 mm 29 Push pull throttle cable connection 30 Air inlet 31 Gearbox 32 Oil cooler gearbox Water separator fuel filter bleed nipple 33 34 Drain plug for water separator fuel filter 35 Water separator fuel filter 36 Counter plug electrical system 37 Starter motor 38 Fuel supply pipe connection 8 mm 39 Fuel lift pump 40 Fuse ...

Page 16: ...nt 9 Raw water pump inlet ø 28 mm 10 V belt 11 Oil filter 12 Engine oil cooler 13 Cooling system drain plug engine block 14 Alternator 15 Flexible engine mount 16 Zinc anode 17 Heat exchanger 18 Cooling system drain plug heat exchanger 19 Connection for prop shaft lubrication G 3 8 20 Connection of push pull cable gear box 21 Exhaust injection bend ø 75 mm 22 Turbocharger 23 Air filter 2 3 4 5 6 8...

Page 17: ...tion 29 Connection water heater OUT 30 Return fuel pipe connection 8 mm 31 Push pull throttle cable connection 32 Air inlet 33 Gearbox 34 Oil cooler gearbox Water separator fuel filter bleed nipple 35 36 Drain plug for water separator fuel filter 37 Water separator fuel filter 38 Counter plug electrical system 39 Starter motor 40 Fuel supply pipe connection 8 mm 41 Fuel lift pump 42 Drain plug aft...

Page 18: ...ock 4 Warning light high raw water temperature 5 Warning light low oil pressure 6 Warning light high coolant temperature 7 Warning light battery charging 8 Indicator light pre heating 9 Warning light gearbox low oil pressure 1 10 Temperature gauge coolant 11 Oil pressure gauge 1 This is an option not fitted as standard 5 3 7 8 6 4 9 1 2 10 11 VD00631 ...

Page 19: ...2 Voltmeter 3 Starter pre heat switch lock 4 Warning light high raw water temperature 5 Warning light low oil pressure 6 Warning light high coolant temperature 7 Warning light battery charging 2 Introduction Control panels Engines with intercooling Panel model 22 Panel without voltmeter model 21 5 3 7 8 6 4 9 1 2 VD00576 5 3 7 8 6 4 VD00575 Panel model 10 ...

Page 20: ...erating hours counter 2 Voltmeter 3 Starter pre heat switch lock 4 Warning light second alternator 5 Warning light low oil pressure 6 Warning light high coolant temperature 7 Warning light battery charging 2 Introduction Control panels Engines with keel cooling Panel model 22 Panel without voltmeter model 21 5 3 7 8 6 4 9 1 2 VD00630 ...

Page 21: ...arbox astern throttle astern throttle ahead Operating lever for 2 engines Operating lever for 1 engine The control lever works as shown in the diagram Starting from neutral put the engine in ahead or astern by moving the lever 35 forwards or backwards The throttle lever operates at an angle of 60 forwards and 60 reverse ...

Page 22: ...elivered empty of oil Fill the engine with oil through the filler neck on top of the valve cover for quantity and specification see page 124 Check the oil level with the dipstick see page 46 Engine Oil 6 litres 15 W40 or 10W40 10 6 UK pt 12 7 US pt API CH 4 CG 4 CI 4 ACEA E3 96 E4 07 E5 02 E7 04 For example Vetus Marine Diesel Engine Oil 15W40 Shell Rimula R4 L 15W40 VD00809 VD00810 OIL OIL ...

Page 23: ...ooler approx ca 0 3 litres 0 5 UK pt 0 6 US pt ZF Hurth type ZF25 2 5 litres 1 ATF 4 4 UK pt 5 3 US pt type ZF25A 1 8 litres 1 ATF 3 2 UK pt 3 8 US pt ATF Automatic Transmission Fluid Transmissie olie type A Suffix A 1 Without oil cooler content oil cooler approx ca 0 3 litres 0 5 UK pt 0 6 US pt Vetus engines are normally equipped with Technodrive or ZF Hurth gearbox es In case your engine is equ...

Page 24: ...er is connected to the en gine see page 24 and 25 Fill the cooling system Use a mixture of 40 antifreeze ethylene glycol based and 60 tap water or use a special coolant For specifications see page 127 Caution Never fill the cooling system with sea water or brackish water The level of the coolant must be at the low er edge of the filler neck After filling replace the filler cap 1 and reinstall the ...

Page 25: ... en gine see page 26 and 27 Fill the cooling system Use a mixture of 40 antifreeze ethylene glycol based and 60 tap water or use a special coolant For specifications see page 127 Caution Never fill the cooling system with sea water or brackish water Reinstall the plug 2 after the system has been bled and the coolant is flowing out of the bleeder hole Top up the expansion tank to the mini mum level...

Page 26: ...ated at a lower level than the expan sion tank for the ship s engine The water heater will be filled and bled automatically during filling of the cooling system Remove the do not open cap 1 and fill the cooling system via the filler neck Unscrew plug 2 on top of the lid of the thermostat housing a few turns to bleed the system properly Tighten plug 2 after the cooling system has been filled and bl...

Page 27: ...pansion tank 3 Open valve 4 during filling and bleed ing the system Unscrew plug 2 on top of the lid of the thermostat housing a few turns to bleed the system properly Tighten plug 2 after the cooling system has been filled and bled and continue filling Note Remember to close valve 4 after filling the system 1 2 3 4 1 5 bar DO NOT OPEN VD00877 Use a mixture of 40 antifreeze ethylene glycol based a...

Page 28: ... the cooling system via the filler neck Unscrew plug 2 on top of the lid of the thermostat housing a few turns to bleed the system properly Tighten plug 2 after the cooling system has been filled and bled and replace the filler cap 1 Add coolant into the expansion tank 3 until minimal level has been reached 1 2 3 1 5 bar DO NOT OPEN VD00878 Use a mixture of 40 antifreeze ethylene glycol based and ...

Page 29: ...oling system via the expansion tank 3 Open valve 4 during filling and bleed ing the system Unscrew plug 2 on top of the lid of the thermostat housing a few turns to bleed the system properly Tighten plug 2 after the cooling system has been filled and bled and and con tinue filling Note 1 2 3 1 5 bar DO NOT OPEN 4 VD00879 Use a mixture of 40 antifreeze ethylene glycol based and 60 tap water or use ...

Page 30: ...ee page 50 Other preparations 11 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 VD Warning Never fill the fuel tank while the engine is running Do not spill fuel Prevent un necessary pollution VD00789 Neutral No throttle gearbox not engaged FUEL ...

Page 31: ...s 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 connec tions fuel coolant and exhaust for leaks Caution Stop the engine immediately if it makes any strange noises vibrates excessively or if black smoke comes out of the ex ...

Page 32: ... normal working temperature Open the cap on the filler neck Vary the revolutions between idling and 2000 rev min Add coolant if necessary Replace the cap on the filler neck Check the coolant temperature 14 Sea trial Check the operation of the remote con trol Carry out a sea trial VD00819 VD00663 VD00791 ...

Page 33: ... operation hours carry out the following maintenance Draining of water from the water separa tor fuel filter see page 49 Engine oil change see page 58 Oil filter replacement see page 58 Changing the gearbox oil Technodrive see page 61 Changing the gearbox oil en filter re placement ZF Hurth see page 62 Fuel filter replacement see page 64 Check V belt see page 68 Check flexible engine mounts see pa...

Page 34: ...r long this helps prevent corrosion as well as protecting against frost dam age For specifications see page 127 Never run the engine without a thermo stat Use a good quality lubricating oil For specifications see page 124 Use a good quality diesel fuel that is free of water and other pollutants Always stop the engine immediately if one of the warning lamps for oil pres sure high coolant temperatur...

Page 35: ...0 and further if the engine 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 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 ...

Page 36: ... 1 Control lever Put the control lever in neutral position 2 Switching on Turn the starter key on the instrument pan el to the right the oil pressure and dynamo control lights will come on and the alarm buzzer will sound VD00789 VD00107 Neutral No throttle gearbox not engaged Warning Never start the engine with the fuel in jection pump removed Disconnect battery ...

Page 37: ... burning out never exceed the stated maximum pre heating time Turn the key further clockwise to the position While pre heating takes place the preheat ing indicator light will be on and the alarm buzzer off Hold the key in this position for about 5 seconds VD00107 Ambient Temperature Pre heating time Below 0 C 32 F 15 seconds 0 C to 10 C 32 F to 50 F 10 seconds 10 C to 30 C 50 F to 86 F 5 seconds ...

Page 38: ...engine fires the key will return to the on position and throttle back Leave the key in this position while the en gine is running 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 VD00109 VD00110 ...

Page 39: ...op 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 en sure maximum lifetime and good perform ance Never turn the main switch off while the en gine is running Caution Never turn the key to the start position while the engine is running Doing so will damage the starter motor VD00629 ...

Page 40: ...age 16 Tachometer 5 Indicating the number of revolutions per minute of the engine Also the number of running hours is indi cated Idling speed DT4 70 900 rpm DTA4 85 900 rpm Warning Avoid idling for more than 10 minutes This can lead to carbon deposits in the combustion chambers and incomplete combustion of fuel VD00577 ...

Page 41: ...ting the temperature of the internal cooling system The operating temperature is 82 C 97 C 180 F 207 F In case the engine is overheated turn off the engine and establish the cause see fault finding table page 106 115 Oil pressure gauge 8 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 engine and establis...

Page 42: ...ive warning lights should light up while the engine is running 10 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 im mediately ...

Page 43: ...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 The Stop position left of the Off position on the control panel has normally no function for this engine When 2 control panels are connected to one engine the engine can always be stopped by turning the key to the Stop position no matter what the position is of the key o...

Page 44: ...orm each function at the indicated time interval The intervals stated are for normal opera tional conditions Service the unit more fre quently under severe conditions Failure to carry out maintenance can result in faults and permanent damage to the en gine No claim can be made on the Guarantee if maintenance has been neglected ...

Page 45: ... 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 46: ... mounts 70 Check tightness of all fasteners bolts and nuts 71 Check engine for leaks 71 Every 100 hours at least once every year page Drain water from fuel filter 49 Check gearbox oil level 52 Drain charge air cooler 53 Battery cables and cable connections 54 Every 500 hours at least once every year page Engine oil change 58 Replace oil filter 58 Change gearbox oil Technodrive 61 Change gearbox oi...

Page 47: ...Check glow plugs 1 Every 800 hours at least once every 2 years page Raw water pump inspection 72 Replace coolant 74 Replace air filter 78 Every 1000 hours page Check starter motor 79 79 Check alternator 79 79 Check turbocharger 1 Every 3000 hours page Check and adjust injector pressure 1 6 Maintenance Maintenance schedule Gevaar Stop the engine before carrying out any maintenance work ...

Page 48: ...The oil level must be at or near the upper mark on the dipstick1 If necessary top up with the same brand and type of oil 1 The difference between the two oil level marks is 0 8 litres 1 4 UK pt 1 7 US pt 1 The difference between the two oil level marks is 0 8 litres 1 4 UK pt 1 7 US pt 3 Topping up oil The oil filling cap is on top of the valve cover VD00810 VD00126 VD00809 ...

Page 49: ...e level of the coolant must be at the low er edge of the filler neck Note For a keel cooled version see page 23 If a water heater is connected see page 24 and 25 For a keel cooled version with a water heater connected see page 26 and 27 Topping up coolant 6 Top up if necessary The internal cooling system can be filled with a mixture of anti freeze 40 and tap water 60 or with a special coolant For ...

Page 50: ...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 result in air sucked in by the sea water p...

Page 51: ... litter before you start the engine 9 Drain fuel filter Open the drain plug at the lower side of the filter Drain the water and close the drain plug 10 Empty water separator Empty the separately installed water sepa rator fuel filter Open the 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 installati...

Page 52: ...he 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 leave the key in this posi tion for 30 seconds The fuel lift pump will now feed the fuel system Open the bleeding nipple at the filter to speed up the bleeding process Close the bleeding nipple when all air has escaped VD00823 VD00107 13 ...

Page 53: ... 12 Start the engine Operate the starter switch until the en gine fires release the starter switch if the engine does not fire within 6 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 after a short time VD00109 ...

Page 54: ...rand of gearbox follow the instructions given in the supplied owner s manual for changing oil and other care and mainte nance 13 Oil level check Take the dipstick out of the gearbox housing by pulling or unscrewing Check the oil level by lowering the dip stick cleaned into the hole The oil level must between the two marks on the dipstick If necessary top up by pouring oil into the filler hole or t...

Page 55: ...er cooler 14 Condensate accumulating in the after cooler must be drained every 100 hours of at least once a year Remove the drain plug from the after cooler and check whether all the con densate is drained After draining replace the drain plug Note Only for engines equipped with an after cooler VD00899 ...

Page 56: ...t battery acid can es cape from the degassing open ings or vents First aid Rinse off acid splashed in the eyes immediately for several min utes with fresh water Then con sult a doctor immediately Neutralize acid splash on skin or clothes immediately with acid neutralizer soda or soap suds and rinse with plenty of water If acid is consumed consult a doctor immediately Warning note Do not place batt...

Page 57: ... Battery 15 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 af ter reassembling Hand tighten the bolts only VD00117 ...

Page 58: ...three conditions Hydrometer operation 17 Green dot visible State of charge 65 or more Dark State of charge less than 65 Recharge immediately Clear or light yellow Electrolyte level low n case of low level caused by over charg ing the battery for a long period of time with a voltage too high replace battery Check alternator and or voltage regulator VD00118 GREEN ALL DARK CLEAR VD00121 VD00122 VD001...

Page 59: ...of the individual cells with a commercial hy drometer The hydrometer reading see ta ble indicates the state of charge Hydrom eter 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 During checking the temperature of the electrolyte should preferably be 20 C 68 F The temperature of the electrolyte dur ing checking should be...

Page 60: ...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 Danger Be aware of the risk of skin burning dur ing draining the hot oil Used oil must be collected in a container for proper disposal according to laws and regulations Warning Never use additive...

Page 61: ... quickly and pull it up slowly Pump the sump empty After draining remove the suction hose of the sump pump out of the dipstick tube Warning The engine oil must be disposed in accordance with the applicable environmental regulations 22 Removing the oil filter Unscrew the oil filter with a commercially available tool when all the oil has been pumped out Catch any dripping oil Danger Beware of burns ...

Page 62: ...using Tightening torque 15 17 Nm 11 12 ft lbf Refilling with oil 25 Fill the engine with fresh oil see page 124 for the specification through the filler opening 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 en gine Allow 5 minutes for the oil to return to the sump and check the oil level with the dipstick ...

Page 63: ...nd check if all oil has been drained Collect the oil in a dripping pan Filling with new oil 27 Refill the gearbox to the correct level via the filling hole For amount of oil and specification see page 126 In case your engine is equipped with an other brand of gearbox follow the instruc tions given in the supplied owner s manual for changing oil and other care and main tenance VD00871 14 22 ...

Page 64: ...le quickly and pull it up slowly Remove the sump pump when all the old oil has been pumped out 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 Changing the oil filter 29 The filter element must be replaced at the same time as the oil Turn the screw that holds on the filter cover to the left and remove the filter ...

Page 65: ... mount the unit on the gearbox Filling with new oil 30 Refill the gearbox to the correct level via the dipstick opening For amount of oil and specification see page 126 In case your engine is equipped with an other brand of gearbox follow the instruc tions given in the supplied owner s manual for changing oil and other care and main tenance 1 2 3 VD00645 Filter element art code CT50081 VD00867 ...

Page 66: ...00 operating hours Fuel filter removal 31 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 Danger Keep naked flames away when working on the fuel system Do not smoke VD00825 ...

Page 67: ... carrier rim Lubricate the rubber gasket sparingly with clean engine oil Fill the new filter with clean diesel fuel Install the filter When the rubber gas ket touches the housing apply another tightening of a half to three quarters of a turn by hand Open fuel stopcock Check for leaks VD00154 VD00830 Fuel filter art code STM3690 ...

Page 68: ...ing filter fuel lift pump Every 500 operating hours Fuel lift pump 33 Check and if necessary clean filter in side the fuel lift pump Open the fuel stop cock Check for leakage STM7220 Fuel filter art code STM4050 Fuel filter ...

Page 69: ...ey in the ignition lock to ON and leave the key in this position for 30 seconds The fuel pump will now bleed the system Start the engine 35 Start the engine Operate the starter switch until the en gine fires release 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...

Page 70: ...olts Danger Check tension and change V belts only with the engine off Always reinstall the protection cover Remove the protection cover Inspection V belt 37 Inspect the belt for wear and tear fraying and cracking Belts which are in poor condition should be replaced VD00034 VD00826 V belt art code 08 00083 VD00834 13 ...

Page 71: ...d 39 Tensioning V belt Loosen the bolt of the adjustment brack et 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 Reinstall the protection cover 40 Always reinstall the V belt guard and re install the...

Page 72: ...ecure the damp er element the mounting bolts to engine bed and the nuts at the adjustment spin dle for tightness Inspect the rubber element of the en gine support for cracks Also check the deflection of the damper element the deflection influences the alignment of engine and prop shaft Re align engine in case of doubt VD ...

Page 73: ...ns and fasteners Every 500 operating hours Inspection 42 hose connections Inspect all hose connections of the cool ing system Cracked hoses loose hose clamps Check 43 fasteners Check tightness of all fasteners bolts and nuts VD00820 ...

Page 74: ...ler on board Pump cover removal 45 Inspection where appropriate changing is as follows Close the sea cock Remove the cover of the pump by un screwing the screws out of the housing Impeller removal 46 Use a special impeller puller or pipe wrench to slide the impeller off the shaft Mark the impeller to ensure correct re in stallation if it is to be re used The impel ler must be installed in the same...

Page 75: ...ased lu bricant 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 The direction of rotation of the impeller is anti clockwise Replacing the pump cover 49 Always use a new O ring when replacing the cover Check the water filter and open the sea cock VD00127 VD00004 VD I...

Page 76: ...as part of the winter storage procedure in case that the coolant present in the cooling system offers insufficient protection for the winter Danger Be aware of the risk of skin burning dur ing draining the hot coolant Used coolant must be collected in a container for proper disposal according to laws and regula tions Warning Cooling system protec tive liquids must be dis posed of in accordance wit...

Page 77: ...id drains out After draining re install the drain plugs and re install the hose to the oil cooler 3 5 4 VD00873 1 2 VD00882 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 sufficient pro...

Page 78: ...ecifications Caution Never fill the cooling system with sea water or brackish water The level of the coolant must be at the low er edge of the filler neck After filling replace the filler cap and re install the plug Note When keel cooled see page 23 With a water heater connected see page 24 and 25 When keel cooled and a water heater con nected see page 26 and 27 VD00812 VD00814 Coolant quantity 8 ...

Page 79: ...olant level after the engine has been run again for the first time has reached operating temperature and then has cooled back to ambient tempera ture Remove the filler cap Top up if necessary Caution Never fill the cooling system with sea water or brackish water VD00831 VD00822 ...

Page 80: ...ilter housing 2 Remove the old filter and fit a new filter 3 Replace the unit in reverse order and tighten the hose clamp again Warning Never clean the filter element with petrol or hot liquids Never apply any oil to the air filter Never start the engine without the air filter in place 1 2 VD00859 VD 3 VD00860 Air filter art code 08 00084 1 2 x 6 5 7 ...

Page 81: ...Bendix engages with the starter ring when the starter motor is activated If the Bendix does not engage properly contact your Vetus dealer Checking the 55 alternator Check for visible defects Remove the alternator belt Turn the pul ley by hand to check whether the alter nator can be turned easily If this is not the case contact your Vetus dealer VD00848 VD00849 ...

Page 82: ...ger 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 raw water pump impeller Growth of algae or seaweed Note Only engines with intercooling ...

Page 83: ... this remove the drain plug from the heat exchanger housing Remove the filler cap on the top of the expansion tank to allow air into the cool ing system and check that all the liquid drains out Reinstall the drain plug VD00839 VD00819 17 Note Only engines with intercooling ...

Page 84: ... Removing the raw water hoses 57 Close the sea cock Remove both the raw water hoses Removing the exhaust hose 58 Remove the exhaust hose from the ex haust injection bend VD00841 Note Only engines with intercooling VD00840 1 2 x 6 5 7 1 2 x 6 5 7 ...

Page 85: ...anger Removing the end covers 59 Unscrew the 2 cap nuts and pull the rod out of the end covers Remove the end covers and the O rings Take out the heat exchanger 60 Slide the heat exchanger out of the housing VD00847 Note Only engines with intercooling 17 17 ...

Page 86: ...e 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 Clean the contact surfaces of the O rings VD00864 Note Only engines with intercooling VD00746 VD00863 ...

Page 87: ...n greased and place them on the heat exchanger Fit the end covers in the housing Grease the ends of the threaded rod Refit the threaded Use new copper washers M10 and refit the nuts with the washers Tightening torque 30 Nm 22 ft lbf Refit all hoses disconnected Top up the cooling system see page 76 Open the sea cock VD00866 Note Only engines with intercooling O Rings art code 08 00061 2 x Copper w...

Page 88: ...r 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 A possible cause of fouling of the fins of the after cooler is Deposition dust and oil particles Caution The heat exchanger element in the after cooler is very vulnerable Note Only engines with a charge ai...

Page 89: ...a cock Remove both the raw water hoses Take out the heat exchanger 65 Unscrew the 2 cap nuts Remove the end covers and the O rings Slide the heat exchanger out of the hous ing Caution Avoid damage of the fins Note Only engines with a charge air cooler after cooler VD00901 VD00902 VD00903 ...

Page 90: ...anger tubes with clean water Clean the fins using petrol and com pressed air maximum pressure 2 bar 28 psi to prevent damage to the fins Ensure that both heat exchanger end chambers are free from dirt Clean the contact surfaces of the O rings Caution Handle with care to prevent damage to the tube stack and the cooling fins VD00898 VD00905 Note Only engines with a charge air cooler after cooler VD0...

Page 91: ...mm which have been greased and place them on the heat exchanger Fitting end covers 68 Fit the end covers in the housing Grease the threaded rods Use new copper washers M10 and refit the nuts with the washers Tightening torque 30 Nm 22 ft lbf Refit all hoses disconnected Open the sea cock VD00905 VD00907 Note Only engines with a charge air cooler after cooler O Rings art code 08 00061 2 x Copper wa...

Page 92: ...ventilation prevents damp in the en gine compartment thus preventing corro sion of the engine from occurring The engine should be inspected at the end of the sailing season and any necessary repairs carried out Consult a Vetus Dealer if help is required with this Inspections and maintenance work to be carried out are ...

Page 93: ... the fuel tank 94 4 Make sure that the engine fuel system is filled with a fuel mixture with protective properties 95 5 Flush out the raw water circuit with fresh water and if necessary fill with antifreeze Clean the heat exchanger if necessary 96 6 Make sure that the cooling system is filled with a suitable anti freeze 97 7 Change the oil filter and the engine oil 98 8 Change the oil in the gearb...

Page 94: ... paint should be touched up Engine parts that become hot must be touched up with heat resistant paint 2 Zinc anode There is a zinc anode in the heat exchang er to protect engine parts that come into contact with the external water from gal vanic corrosion The speed at which the zinc anodes are sacrificed depends on many external fac tors Check the zinc anodes a new zinc an ode is 13 mm 1 2 in leng...

Page 95: ...e the zinc anode from the heat ex changer housing and respectively Replace the new zinc anode and the copper ring Use a sealant for example Loctite Thread Sealant with PTFE or LOXEAL 18 10 Pipe Sealant Open the sea cock start the engine and check for leaks 19 VD00829 Zinc anode art code 08 00034 Seal washer art code STM9315 ...

Page 96: ...uel system Drain the water from the water separator fuel filter and the fuel tank Make sure that the tank is completely filled with fuel This to prevent the forming of condensation Fit a new fuel filter element page 64 VD00803 VD00830 ...

Page 97: ...g speed Stop the engine Engine oil with protective properties E g Vetus Marine Diesel Engine Oil 15 W 40 Shell Nautilus Premium Inboard 15 W 40 Only use DIN EN 590 Diesel fuel Preferably water free fuel Collect some fuel from the return pipe while engine is running VD00136 Tip Combine running the engine with the protective fuel mixture with flushing the raw water circuit with fresh water see Raw w...

Page 98: ...ne from overheating Stop the engine and close the sea cock The external water system must be pro tected in areas where the temperature drops to below zero during the winter Pour 1 litre 1 4 gallon of anti freeze into the water strainer and run the engine un til the anti freeze has disappeared into the cooling system Tip Combine flushing the raw water cir cuit with fresh water with running the engi...

Page 99: ... sucked in by the raw water pump which again will result in overheating of the en gine 6 Fresh water cooling system To avoid corrosion during winter storage the cooling system must be filled with an antifreeze water mixture or a coolant For specifications see page 127 N B Replacing the coolant is only neces sary if the coolant present in the cooling system offers insufficient protection for the wi...

Page 100: ... ture If not run the engine until warm then turn off Replace the oil filter and change the en gine oil see page 58 use oil with protec tive properties For oil specification see page 124 8 Gearbox oil change Stop the engine and change the oil of the gearbox page 61 and 62 VD00817 VD00832 VD00867 ...

Page 101: ...ct the battery cables Charge batteries during winter lay up regularly if required Follow the recommendations given on pages 54 to 57 or consult the recom mendations given by the battery sup plier for inspection and maintenance of the batteries VD00139 CT40063 ...

Page 102: ...o be carried out are Inspections and maintenance work to be carried out are page 1 Drain the water from the fuel system 101 2 Check the raw water system 102 3 Check the coolant level in the internal cooling system 103 4 Check the oil level 103 5 Check the batteries and reconnect these 104 6 Check the working of the engine 104 7 Check all hose connections for leaks 105 8 Check the working of the in...

Page 103: ...101 8 Recommissioning after winter storage 1 Fuel system Drain the water from the water separator fuel filter page 49 Drain the water from the fuel tank Open the fuel valve VD00141 VD00137 VD00803 ...

Page 104: ... winter storage 2 Raw water cooling system Check that the lid of the raw water strain er is reinstalled Check that the lid of the raw water pump is in place page 72 73 Re tighten possible loose hose clamps VD00125 VD00874 VD00874 ...

Page 105: ...103 8 Recommissioning after winter storage Open the sea cock 3 Fresh water cooling system Check the coolant level page 47 4 Lubrication system Check the engine oil level page 46 VD00138 VD00810 VD00831 ...

Page 106: ...e sure that the batteries are fully charged page 54 99 Connect the batteries Switching on 6 Turn the starter key on the instrument panel to ON the indicator lights for oil pressure and the dynamo will now come on and the alarm buzzer will sound CT40063 VD00140 VD00107 ...

Page 107: ...Check engine for leaks 7 Start the engine Check the fuel system the cooling sys tem and the exhaust for leakage Checking instruments and remote 8 controls Check the operation of the instruments the remote control and the gearbox VD00581 VD00820 ...

Page 108: ...information is given about the possible causes of faults and suggested remedies 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 Danger Before starting make sure that nobody is in the immediate vicinity of the engine When carrying out repair never start the engine with...

Page 109: ...ough idling or stalls 109 5 Engine does not reach maximum RPM under load 110 6 Engine overheats 111 7 Engine not firing on all cylinders 112 8 Engine has little or no oil pressure 112 9 Engine oil consumption excessive 113 10 Fuel consumption excessive 113 11 Black exhaust smoke idling 114 12 Blue exhaust smoke idling 114 13 Black exhaust smoke at load 114 14 White exhaust smoke at full load 115 1...

Page 110: ...er 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 Faulty injector injection pump Check replace if required Fuel electric pressure regula tor...

Page 111: ...ce Insufficient intake air Check Intake air filter clogged Clean replace Incorrect valve clearance Adjust 4 Engine starts but runs unevenly rough idling or stalls 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 ...

Page 112: ...in and flush fuel tank Replace with new fuel Incorrect injection timing Check adjust Setting of stop valve incorrect 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 ...

Page 113: ...mp Check replace Faulty thermostat Check replace Leak in coolant circuit Check Heat exchanger dirty or clogged as a result of rubber particles from a worn impeller Check clean Oil level too low Increase level Oil level too high Lower level Faulty oil filter Replace Insufficient intake air Check replace air intake filter Leak in inlet manifold Check replace Faulty turbo compressor Check replace 6 E...

Page 114: ...jection line Check replace Air in fuel system Check and bleed Faulty glow plugs Check replace Intake valve blocked Check replace Incorrect valve clearance Adjust 8 Engine has little or no oil pressure Possible fault Remedy Oil level too low Increase level Incorrect lube oil SAE class or quality for ambient tempera ture Replace Blocked oil filter Replace Faulty oil pump Repair replace Oil leaks Che...

Page 115: ...n Check compression overhaul engine Turbocharger oil leaks Replace or repair Engine overloaded Check size of propeller Clean the propeller Excessive inclination of en gine Check Adjust 10 Fuel consumption excessive Possible fault Remedy Faulty injector injector pump Check replace if necessary Incorrect fuel quality or dirty fuel Check fuel Drain and rinse fuel tank Replace with new fuel Fuel leaks...

Page 116: ...d Possible fault Remedy Faulty injector injection pump Check replace if required Incorrect injection timing Check adjust Oil level incorrect Check Insufficient intake air air filter dirty Check clean the filter Leak in inlet manifold Check replace Intercooler dirty Check clean Incorrect valve clearance Adjust Excessive wear of cylinder piston Check compression refurbish engine Faulty turbo compres...

Page 117: ... tank Replace with new fuel Water in fuel system Check water separator Incorrect injection timing Check adjust Faulty glow plugs Check replace Incorrect valve clearance Adjust Vapour in exhaust gases con denses as a result of very low ambient temperature 15 Burnt oil trace in exhaust line Possible fault Remedy Oil level too high Lower level Excessive wear of cylinder piston piston rings Check comp...

Page 118: ...tal displacement 2290 cm3 140 cu inch Compression ratio 16 1 Idling speed 900 rpm Max no of revolutions at no load 3050 rpm Direction of rotation counter clockwise viewed from the flywheel side Number of valves 2 per cylinder Valve Clearances Self adjusting hydraulic tappet Weight with standard gearbox 290 kg 639 Ibs 298 kg 657 Ibs Engine installation Max installation angle 15 degrees backwards Ma...

Page 119: ...uel consumption 264 g kW h 194 g hp h 6 8 oz hp h 244 g kW h 179 g hp h 6 3 oz hp h at no of revolutions 2800 rpm 3000 rpm Fuel System Self bleeding Injection pump Delphi DP210 Injectors Delphi Opening pressure 250 bar 3626 psi Firing order 1 3 4 2 Injection timing 1 CA ATDC Fuel filter element Vetus STM3690 Fuel lift pump Suction height max 1 5 m 5 ft Fuel supply connection for hose 8 mm 5 16 I D...

Page 120: ...4 1 UK pt 16 9 US pt Thermostat opening at 82 C 180 F fully opened at 97 C 207 F Coolant pump Flow at max engine rpm 135 litres min 29 7 UK gal min 35 7 US gal min Raw water pump Flow at max engine rpm 80 litres min 17 6 UK gal min 21 1 US gal min Total head at max flow 2 metre 6 7 H2O Impeller STM8074 Inlet connection for hose 28 mm 1 1 8 I D Heater supply connection 16 mm 5 8 I D Heater return c...

Page 121: ...g Turbo pressure at max load max 760 mbar 22 4 in Hg Exhaust system Exhaust diameter 75 mm 3 Exhaust back pressure at specified output max 100 mbar 3 in Hg Electrical System Voltage 12 Volt Alternator 14 Volt 90 A 130 A optional Starter 14 Volt 2 0 kW Capacity starter battery min 65 Ah max 143 Ah Protection Blade fuse ATO 10 Amp V belt 08 00083 ...

Page 122: ...el DT4 70 DTA4 85 Gearbox Gear ratio Gear ratio Technodrive type TM345 1 54 2 00 2 47 1 54 2 00 2 47 type TM345A 1 54 2 00 2 47 1 54 2 00 2 47 ZF type ZF25 1 969 2 800 1 969 2 800 type ZF25A 1 548 1 926 2 292 2 480 2 714 1 548 1 926 2 292 2 480 2 714 ...

Page 123: ...eye Cyl head M8 8 8 21 Nm Oil drain plug M14 39 Nm Use new copper washers Exhaust manifold Cyl Head M8 8 8 27 Nm Exhaust manifold Turbo charger M8 8 8 41 Nm Use screw thread mounting compound Turbo charger exhaust bend M8 8 8 27 Nm Use screw thread mounting compound Air intake manifold AIM M8 8 8 27 Nm Observe tightening sequence Injector holder Cylinder head M8 10 9 35 Nm Torx Injector holder Cyl...

Page 124: ...nk shaft M12 10 9 96 Nm Use new bolts Pulley Crank shaft M20 10 9 300 Nm Pulley Coolant pump M6 8 8 9 Nm Starter Flywheel housing M10 8 8 41 Nm Alternator Timing cover M8 8 8 21 Nm Alternator Tensioner bracket M8 8 8 21 Nm Tensioner bracket Timing cover M8 8 8 21 Nm Glow plug Cylinder head M10 15 Nm Connection strip Glow plugs M4 2 5 Nm Lock nut Battery cable Starter M8 9 Nm Nuts end covers heat e...

Page 125: ...e 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 Winter grade fuel Waxing may occur at low temperatures clogging the fuel system and reducing engine efficiency If the ambient temperature is less than O C 32 F winter grade fuel suitable down to 15 C 5 F should be used This fuel is ...

Page 126: ...tional resistance and more effort which forms a hindrance to reaching the starting rpm required for a dependable start and this results in a reduced life span 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 star...

Page 127: ...he 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 analy sis method based on perchloric acid 11 Operating media Lubricating oil Limits concerning motor oil Characteristic Unit Test method Limit Viscosity...

Page 128: ... pt ZF Hurth type ZF25 2 5 litres 1 4 4 UK pt 5 3 US pt ATF 2 type ZF25A 1 8 litres 1 3 2 UK pt 3 8 US pt ATF 2 1 Without oil cooler content oil cooler approx 0 3 litres 0 53 UK pt 0 63 US pt 2 ATF Automatic Transmission Fluid Transmission oil type A Suffix A For example Vetus Transmission Oil Shell Donax T6 Gulf Synth Other brands of gearboxes See supplied owner s manual for oil type and quantiti...

Page 129: ...ive liquid Anti freeze Water Protection against freezing to max 45 vol 35 C 31 F 55 40 vol 28 C 18 F 60 min 35 vol 22 C 8 F 65 The protective liquid concentration must be maintained under all circumstances Therefore if coolant must be added always use the same mixture of anti freeze and tap water Water quality for coolant preparation Use preferably tap water If available fresh water is used the va...

Page 130: ...jection advance Alternator Fuel lift pump Pre heating Glow plugs Starter motor Battery Battery main switch Pre heating relay Auxiliary start relay Key switch Plug A Socket A Stop solenoid ETR Engine panel model 34 M M A1 A3 A4 A2 A5 A6 A1 A3 A4 A2 A5 A6 87a 30 85 87 86 30 85 86 D W B 30 85 87 86 L4 L2 L1 L5 L3 L6 ...

Page 131: ... Brown Blue Gray Warning lights Battery charging Gearbox oil press Plug B Socket B Coolant temp Oil press Plug C Socket C Gearbox oil press 4 1 2 5 3 6 19 94 X2M B6 B6 61 B4 91 B1 92 B2 93 B5 W B3 B4 B1 B2 B5 B3 1 2 1 2 3 4 X3M X4M C1 C2 C1 C2 G1 G2 NC NC 31 15 95 W 3 6 Q1 R1 L2 L3 L4 L5 R2 R3 D1 D2 D3 D5 D6 D7 D8 D9 L6 BZ 15 58 17 19 31 X1 8 7 5 4 L1 D10 M1 M2 1 2 12 Wiring diagrams Engine with p...

Page 132: ... 86 30 85 86 D W B 30 85 87 86 L4 L2 L1 L5 L3 L6 Fuse Stop relay Red Yellow Orange Violet White Black Injection advance Alternator Fuel lift pump Pre heating Glow plugs Starter motor Battery Battery main switch Pre heating relay Auxiliary start relay Key switch Plug A Socket A Stop solenoid ETR Engine panel model ...

Page 133: ...D8 D9 L6 BZ 15 58 17 19 31 X1 8 7 5 4 L1 D10 Voltmeter Tachometer hour counter Pre heating Yellow Green Transparent Brown Black Blue Red Coolant temp Exhaust temp Oil press Yellow Green Green Brown Blue Gray Warning lights Battery charging Gearbox oil press Plug B Socket B Coolant temp Oil press Socket C Gearbox oil press 12 Wiring diagrams Engine with panel model 22 ...

Page 134: ...132 13 Overall dimensions 883 34 3 4 989 38 15 16 400 15 3 4 229 9 231 9 1 8 230 9 1 16 490 19 5 16 629 24 3 4 111 4 3 8 DT4 70 TM345A 8 1 2 3 DT4 70 ...

Page 135: ...133 30 1 3 16 81 3 3 16 465 18 5 16 554 21 13 16 4 13 Overall dimensions 1 Exhaust ø 75 mm 2 Fuel supply ø 8 mm 3 Fuel return ø 8 mm 4 Raw water intake ø 28 mm 1 10 ...

Page 136: ...134 13 Overall dimensions 883 34 3 4 400 15 3 4 229 9 629 24 3 4 111 4 3 8 TM345A 8 DTA4 85 989 38 15 16 231 9 1 8 230 9 1 16 490 19 5 16 1 2 3 DTA4 85 ...

Page 137: ...135 30 1 3 16 81 3 3 16 465 18 5 16 554 21 13 16 4 13 Overall dimensions 1 Exhaust ø 75 mm 2 Fuel supply ø 8 mm 3 Fuel return ø 8 mm 4 Raw water intake ø 28 mm 1 10 ...

Page 138: ...g 11 D Direction of rotation 11 Drain coolant 75 Draining of water from the water separa tor fuel filter 49 Draining the after cooler charge air cooler 53 Drain plug after cooler 15 Drain plug Cooling system engine block 12 14 Drain plug Cooling system heat ex changer 12 14 Drain plug water separator fuel filter 13 15 E Electrical system 99 104 Electrical system Counter plug 13 15 Electrolyte leve...

Page 139: ...15 Lubricating oil 124 Lubrication system 98 103 M Maintenance 42 Maintenance schedule 44 O Oil Capacity Incl Oil Filter 60 Oil cooler gearbox 13 15 Oil dipstick 13 15 Oil filler cap 12 14 Oil filter 12 14 60 Oil filter Renewal 59 Oil level 46 Operating lever 19 Operating media 123 Overall dimensions 132 P Pre heating 35 Pre heating Indicator light 16 17 18 Prop shaft lubrication Connection for 12...

Page 140: ...ning lights 40 Battery charging 16 17 18 Gearbox low oil pressure 16 17 18 High coolant temperature 16 17 18 High raw water temperature 16 17 Low oil pressure 16 17 18 Second alternator 18 Water heater Connection 12 13 14 15 Water separator 49 Water separator fuel filter 13 15 Winter grade fuel 123 Winter storage procedure 90 Corrosion protection 92 Electrical system 99 Fresh water cooling system ...

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Page 142: ...140 ...

Page 143: ...Bruksanvisning DT4 70 DTA4 85 Norsk 360510 01 Käyttöopas DT4 70 DTA4 85 Suomeksi 320331 01 STM0032 Installatiehandleiding Installation manual Nederlands English 320199 05 STM0016 Service en Garantieboek Service and Warranty Manual Nederlands English Service und Garantieheft Livret Garantie et Service Deutsch Français Manual de servicio y garantía Libretto di assistenza e garanzia Español Italiano ...

Page 144: ...nds 360502 01 2010 11 Printed in the Netherlands 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 Vetus Diesel DT4 70 DTA4 85 English vetus n v ...

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