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25 Oil level check (ZF-Hurth)

6 Maintenance

Gearbox oil level check

Every 100 operating hours.

Vetus engines are normally equipped with
Technodrive or ZF-Hurth gearboxes. Consult
the supplied Owners Manual for more details
about care and maintenance. In case your
engine is equipped with another brand of
gearbox follow the instructions given in the
supplied owners manual for changing oil and
other care and maintenance.

24 Oil level check (Technodrive)

• Take the dipstick out of the gearbox hous-

ing by pulling or unscrewing.

• Check the oil level by lowering the dipstick

(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 the dipstick hole.

For oil type and specification see page

108

.

17

VD01038

VD01032

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Summary of Contents for M2.02

Page 1: ...Operation manual M2 M2 02 M2 06 ...

Page 2: ...ii ...

Page 3: ... inquiring about Customer Ser vice Repairs or Spare Parts see page 6 We reserve the right to make any changes without previous notice Copyright 2012 Vetus N V Schiedam Holland Serial numbers Engine serial number Vetus Engine serial number Mitsubishi Gearbox serial number M2 02 M2 06 340802 01 ...

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: ...44 Engine oil change 47 Battery cables and connections 50 Gearbox oil level check 54 Fuel filter replacement 55 Bleeding after fuel filter replace ment 57 Changing the gearbox oil Techn odrive 58 Changing the gearbox oil ZF Hurth 59 Checking valve clearance 60 Checking the V belt 62 Flexible engine mounts hose con nections and fasteners 63 Raw water pump inspection 64 Coolant replacement 66 Checki...

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: ...rking 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 in...

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: ...ponents 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 inquiries Si...

Page 12: ...ce data are printed on the engine data tag Model and engine serial number must be giv en when ordering spare parts 2 Engine data tag location The type plate is positioned as shown 3 Engine serial number The Mitsubishi engine serial number is stamped on the fuel injection pump arrow VD01036 VD01044 VD01035 ...

Page 13: ...f rotation is viewed towards the flywheel counter clockwise 5 Fuel pump seal Caution Breaking the seals on the regulator to alter the settings of maximum rpm and maximum injector volume may only be carried out by authorised Vetus Service personnel Breaking the seals and altering the settings can lead to Accelerated wear of engine components Increased fuel and oil consumption Incorrectly adjusted i...

Page 14: ...mp 6 Oil filter 7 Water separator fuel filter drain plug 8 Water separator Fuel filter 9 Connection for gearbox push pull cable 10 Fuse 11 Electrical system connector box 12 Fuel return pipe connection ø 8 mm 13 Air inlet silencer 14 Water separator fuel filter air bleed nipple 15 Manual operation of electric stop 16 Fuel supply pipe connection ø 8 mm 17 Fuel lift pump 18 Connection for throttle p...

Page 15: ...ox oil dipstick filler cap 22 Starter motor 23 Alternator 24 V belt 25 Connection for extra expansion tank Keel cooling model only 26 Calorifier connection 27 Cooling system air bleed nipple 28 Filler cap for cooling system 29 Expansion tank 30 Heat exchanger 31 Cooling system drain plug 32 Airvent connection 33 Exhaust injection bend ø 40 mm VD01254 ...

Page 16: ... 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 Basic panel model 22 Fly bridge panel excl voltmeter model 21 Sailingboat panel model 10 VD00576 VD00575 1 This is an option not fitted as standard ...

Page 17: ...rottle reverse throttle 15 2 Introduction Control lever 6 Operating lever Operating lever for 1 or 2 engines 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 backwards The throttle lever operates at an angle of 60 forwards and 60 reverse VD00788 ...

Page 18: ... Fill the engine with oil through the filler neck on top of the valve cover For quantity and oil specification see page 102 and 106 Check the oil level with the dipstick see page 40 A second oil filling cap is located at the distri bution cover Engine Oil 2 4 litres 15 W40 4 2 Imp pt 5 1 US pt API CF4 CG4 CH4 CI4 ACEA A3 B3 A3 B4 E7 For example Vetus Marine Diesel Engine Oil 15W40 Shell Rimula R4 ...

Page 19: ...1 1 05 Imp pt 1 25 US pt ZF Hurth type ZF10M 0 42 litres ATF 1 0 73 Imp pt 0 89 US pt Vetus engines are normally equipped with Technodrive or ZF Hurth gearboxes In case your engine is equipped with another brand of gearbox follow the in structions given in the supplied owners manual 1 ATF Automatic Transmission Fluid Transmissie olie type A Suffix A 1 ATF Automatic Transmission Fluid Transmissie o...

Page 20: ...ifreeze ethylene glycol based and 60 tap water or use a spe cial coolant For specifications see page 109 The level of the coolant must be approx 1 cm 3 8 below the lower edge of the filler neck Bleeding will take place automatically during filling Replace the filler cap Reinstall the bolt in the thermostat cover Coolant quantity 2 2 litres 3 9 Imp pt 4 6 US pt VD01005 VD01004 VD00158 Note If a wat...

Page 21: ...er cap do not open Remove the pressure cap 2 of the extra expansion tank Top up the extra expansion tank to the min imum level Reinstall the pressure cap 2 Use a mixture of 40 antifreeze ethylene glycol based and 60 tap water or use a spe cial coolant For specifications see page 109 Note If a water heater is connected to the engine see page 20 and 21 VD00929 VD00925 Caution Never fill the cooling ...

Page 22: ...ll be filled and bled auto matically during filling of the cooling system Remove the do not open cap 1 and fill the cooling system via the filler neck Add coolant into the expansion tank 2 un til minimal level has been reached Use a mixture of 40 antifreeze ethylene glycol based and 60 tap water or use a spe cial coolant For specifications see page 109 VD00895 VD00925 Caution Never fill the coolin...

Page 23: ... not be filled and bled automatically during filling of the cooling system Fill the cooling system via the expansion tank 2 Open valve 3 during filling and bleeding the system Use a mixture of 40 antifreeze ethylene glycol based and 60 tap water or use a spe cial coolant For specifications see page 109 VD00896 VD00925 Note Remember to close valve 3 after filling the system Caution Never fill the c...

Page 24: ...or fuel grade see page 105 Bleed the fuel system see page 45 9 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 VD Warning Never fill the fuel tank while the engine is running Do not spill fuel Prevent unnec essary pollution VD00002 VD00789 ...

Page 25: ...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 VD01001 VD01046 Caution Stop the engine immediately if it makes any strange noises vibrates excessively or if black smoke...

Page 26: ... normal working tem perature 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 12 Sea trial Check the operation of the remote control Carry out a sea trial VD00663 VD01003 VD00791 ...

Page 27: ...3 4 of maximum RPM After the first 50 operation hours carry out the following maintenance Drain water from fuel filter see page 44 Engine oil change see page 47 Replace oil filter see page 48 Replace fuel filter see page 55 Change gearbox oil Technodrive see page 58 Change gearbox oil ZF Hurth see page 59 Check V belt see page 62 Check flexible engine mounts see page 63 Check engine for leaks see ...

Page 28: ...r long this helps prevent corrosion as well as protecting against frost damage For specifications see page 109 Never run the engine without a thermostat Use a good quality lubricating oil For speci fications see page 106 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 pressure high coolant temperature ...

Page 29: ...ge 16 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 30: ...neutral position 1 Control lever Set the control lever to half throttle without engaging the gearbox 2 Switching on 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 Warning Never start the engine with the fuel injec tion pump removed Disconnect battery VD00923 VD00107 ...

Page 31: ...e pre heating takes place the preheating indicator light will be on and the alarm buzzer off Hold the key in this position for about 6 sec onds Ambient Tem perature Pre heating time Above 5 C 41 F about 6 seconds 5 C to 5 C 41 F to 23 F about 12 seconds Below 5 C 23 F about 18 seconds Maximum pre heating time 1 minute VD00108 Caution To prevent the glow plugs from burning out never exceed the stat...

Page 32: ... 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 VD00110 VD00109 ...

Page 33: ... the engine immediately 1 Let the engine run for 5 to 10 minutes in neu tral A good warm up is essential to ensure maximum lifetime and good performance 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 1 Only engines with intercooling ...

Page 34: ...panel see page 17 5 Tachometer Indicating the number of revolutions per minute of the engine Also the number of running hours is indicat ed Idling speed 850 rpm 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 VD00577 ...

Page 35: ... and the start key in the first position the voltmeter should indi cate 12 Volts 7 Warning lights None of the five warning lights should light up while the engine is running 8 Alarm buzzer Oil pressure battery charging and tempera ture indicator lights are all connected to an alarm buzzer If this alarm buzzer sounds while running Stop the engine immediately VD00578 ...

Page 36: ...n the engine has stopped turn the key to the Off position VD00105 VD00790 VD00106 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 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 ...

Page 37: ...gine itself On the engine itself stopping is possible by pressing the black button on the fuel injec tion pump If the fuel supply is not shut off by the electri cally operated fuel solenoid stopping of the engine can be done this way VD01037 ...

Page 38: ...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 39: ... 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 conducted 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 40: ...ck flexible engine mounts 63 Check engine for leaks 63 Check tightness of all fasteners bolts and nuts 63 Every 100 hours at least once every year page Drain water from fuel filter 44 Engine oil change 47 Replace oil filter 48 Battery cables and cable connections 50 Check gearbox oil level 54 Every 500 hours at least once every year page Replace fuel filter 55 Change gearbox oil Technodrive 58 Cha...

Page 41: ...engine before carrying out any maintenance work Every 500 hours page Check glow plugs 1 Every 1000 hours at least once every 2 years page Raw water pump inspection 64 Replace coolant 66 Every 1000 hours page Check starter motor 70 Check alternator 70 When required page Bleeding fuel system 45 Check idle rpm 71 Cleaning heat exchanger 72 ...

Page 42: ...evel 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 A second oil filling cap is located at the distru bution cover see page 16 VD00155 VD01001 VD01013 1 The difference between the two oil level marks is 1 0 litres 1 8 Imp pt 2 1 US pt ...

Page 43: ... 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 water pump which again wi...

Page 44: ... cm 3 8 below the lower edge of the filler neck 8 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 specifica tion see page 109 VD00158 VD01003 VD01004 Warning Never open the cap on the header tank when the engine is at operating temperature Note For a keel cooled version see page 19 If a...

Page 45: ...43 6 Maintenance Checking coolant level Daily before starting When topping up coolant remove the bolt from the upper side of the thermo stat cover so that air can escape from the cooling system VD01005 ...

Page 46: ... litter before you start the engine 9 Empty 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 separa tor 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 47: ...tem is self bleeding but manual bleeding the system is recommended Open the two bleeding nipples One 1 bleeding nipple is located at the filter A second bleeding nipple is located at the fuel injection pump Prime the fuel system by pumping the fuel pump Close the bleeding nipples when all air has escaped N B It is necessary to operate the lever over the full stroke for proper operation 14 10 13 VD...

Page 48: ...12 Start the engine Operate the starter switch until the engine fires release the starter switch if the engine does not fire within 20 seconds Wait until the starter motor has stopped before making a new attempt to start the engine Repeat the above if the engine cuts out af ter a short time VD00109 ...

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: ...ipstick insert the suction hose of the supplied sump pump in the dipstick tube Push down the pump handle 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 15 Removing the oil filter Unscrew the oil filter with a commercially available tool Catch any dripping oil VD01026 VD01010 Danger Beware of burns from hot oil ...

Page 51: ...n the filter element housing 18 Refilling with oil Refill the engine with new oil for specifica tion see page 106 through the filler open ing in the valve cover Operate the engine at idling speed for a short period of time Check for oil leaks whilst the engine is running Stop the en gine Allow 5 minutes for the oil to return to the sump Check the oil level with the dipstick VD01011 VD00124 VD01013...

Page 52: ...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 53: ... 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 VD00117 ...

Page 54: ...er 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 and or voltage reg...

Page 55: ...electrolyte 23 Checking specific gravity Measure the electrolyte specific gravity of the individual cells with a commercial hydrom eter 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 l 50 rec...

Page 56: ...er brand of gearbox follow the instructions given in the supplied owners manual for changing oil and other care and maintenance 24 Oil level check Technodrive Take the dipstick out of the gearbox hous ing by pulling or unscrewing Check the oil level by lowering the dipstick cleaned into the hole The oil level must between the two marks on the dipstick If necessary top up by pouring oil into the fi...

Page 57: ...00 operating hours 26 Fuel filter removal The fuel filter is to be replaced as a unit Close the fuel stopcock Remove the fuel filter use a filter wrench Catch any fuel Danger Keep naked flames away when working on the fuel system Do not smoke VD01017 ...

Page 58: ... 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 gasket touches the housing apply another tight ening of a half to three quarters of a turn by hand Open fuel stopcock Check for leaks VD00133 VD00154 Fuel filter art code STM3690 ...

Page 59: ...uel system For bleeding see page 45 29 Start the engine Operate the starter switch until the engine fires release the starter switch if the engine does not fire within 20 seconds Wait until the starter motor has stopped before making a new attempt to start the engine Repeat the above if the engine cuts out af ter a short time Check for leaks once more VD00109 ...

Page 60: ...heck if all oil has been drained Collect the oil in a dripping pan 31 Filling with new oil Refill the gearbox to the correct level via the filling hole For quantity and oil specification see page 108 In case your engine is equipped with another brand of gearbox follow the instructions giv en in the supplied owners manual for chang ing oil and other care and maintenance 14 VD01033 VD01255 ...

Page 61: ... 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 33 Filling with new oil Refill the gearbox to the correct level via the dipstick opening For oil specification see page 108 In case your engine is equipped with another brand of gearbox follow the instructions giv en in...

Page 62: ...t 6 hours 35 Remove rocker cover Remove the 2 nuts of the rocker cover Complete the following steps 36 Locating TDC Locate the Top Dead Center TDC at the end of the compression stroke for cylinder 1 by barring the engine slowly until theTDC marks of the engine block and the crank pulley match Note There are two TDC s e g compression and suction At theTDC at the end of the com pression stroke the r...

Page 63: ...clearance Cylinders are numbered consecutively begin ning at the front end Check valve clearance at cylinder 1 and ad just if necessary Rotate the crankshaft 180 clockwise and check valve clearance at cylinder 2 10 VD01016 VD00922 Valve clearance Inlet 0 25 mm 0 010 Exhaust 0 25 mm 0 010 ...

Page 64: ...n 12 mm 1 2 using about 10 kg 20 lbs thumb pressure it should be tensioned 40 Tensioning V belt Loosen the bolt of the adjustment bracket and both the alternator mounting bolts Now push the alternator outwards until the belt tension is correct Now first re tighten the upper mounting bolt of the alternator Then re tighten the bolt of the adjustment bracket and the lower mounting bolt 14 12 VD00128 ...

Page 65: ...justment 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 cooling system Cracked hoses loose hose clamps 43 Check fasteners Check tightness of all fasteners bolts and nuts 42 Inspection...

Page 66: ... a spare impeller on board 45 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 46 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 installed in the same positio...

Page 67: ...ith glycerin or a non 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 49 Reinstall the pump cover Reinstall the cover with a new O ring Check the water filter and open the sea cock VD00004 VD00127 VD00927 Impeller O Ring art code STM7691 O...

Page 68: ...ry 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 during draining the hot coolant Used coolant must be collected in a container for proper disposal according to laws and regulations Warning Cooling system protective liquids must be disposed of in accordance with...

Page 69: ...oolant has been drained After draining replace the drain plugs 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 in structions for this Check using a coolant hydrometer wheth er the coolant is providing sufficient pro tection against freezing if total draining off is not poss...

Page 70: ... 60 tap water or use a spe cial coolant For specifications see page 109 Caution Never fill the cooling system with sea water or brackish water Water heater If a water heater is connected to the en gine and this heater is positioned above the upper side of the engine than bleeding of the heater will not take place automati cally Fill the heater separately to bleed the cooling system completely Cool...

Page 71: ...ke place automatically during filling After filling replace the filler cap and re install the plug After the engine has run for the first time and has reached operating temperature and has cooled down again to ambient temperature check the coolant level in the heat exchanger housing If necessary add coolant Caution Never fill the cooling system with sea water or brackish water VD00158 ...

Page 72: ... Bendix engages with the starter ring when the starter motor is activated If the Bendix does not engage properly contact your Vetus dealer 54 Checking the alternator Check for visible defects Remove the alternator belt Turn the pulley by hand to check whether the alternator can be turned easily If this is not the case contact your Vetus dealer VD01252 VD01251 ...

Page 73: ...djusting engine idling speed If the engine speed differs from that stated above it must be adjusted The engine idling speed can be reset using the adjustment screw on the fuel pump 55 Checking engine speed The engine idling speed should be 850 rpm Allow the engine to warm up normally un til the coolant temperature reaches at least 60 C 140 F before checking and or ad justing the idling speed Check...

Page 74: ...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 sea water pump impeller Growth of algae or seaweed Note Only engines with intercooling ...

Page 75: ...n plug from the heat exchanger hous ing Remove the filler cap from the top of the heat exchanger housing to allow air into the system and check that all coolant has drained off 58 Removal of bolts out of the end covers Take out both central bolts from the end covers and take the end covers with the O rings out of the housing Note Only engines with intercooling 13 5 VD01003 VD01018 VD01019 ...

Page 76: ...of the hous ing 60 Cleaning the heat 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 Ensure that both heat exchanger end chambers are free from dirt Note Only engines with intercooling 6 VD01021 VD01020 STM7217 ...

Page 77: ...Use new O rings 61 x 2 5 mm which have been greased Refit the drain plug Reconnect all hoses previously removed Refill the cooling system see page 68 Note Only engines with intercooling O ring art code STM6113 2 x 62 Replacing the end covers Fit the end covers in the housing Tighten up the bolts when both covers are in the correct position STM6202 VD00157 ...

Page 78: ...ventilation prevents damp in the en gine compartment thus preventing corrosion 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 car ried out are ...

Page 79: ...k 78 3 Make sure that the engine fuel system is filled with a fuel mixture with protective properties 79 4 Flush out the raw water circuit with fresh water and if necessary fill with antifreeze Clean the heat exchanger if necessary 80 5 Make sure that the cooling system is filled with a suitable anti freeze 81 6 Change the oil filter and the engine oil 82 7 Change the oil in the gearbox 82 8 Disco...

Page 80: ... 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 55 VD00803 VD00133 ...

Page 81: ...tes 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 VD00136 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 VD ...

Page 82: ...a cock The raw water system must be protected in areas where the temperature drops to be low zero during the winter Pour1litre 1 4gallon ofanti freeze prefer ably a non toxic biodegradable anti freeze into the water strainer and run the engine until the anti freeze has disappeared into the cooling system Tip Combine flushing the raw water circuit with fresh water with running the en gine with the ...

Page 83: ...n during winter storage the cooling system must be filled with an anti freeze water mixture or a coolant For specifications see page 109 N B Replacing the coolant is only necessary if the coolant present in the cooling system of fers insufficient protection for the winter For coolant replacement see page 66 VD01003 Tip Protect the sea cock as follows With the motor stopped Place the sea cock in a ...

Page 84: ...run the engine until warm then turn off Replace the oil filter and change the engine oil use oil with protective properties See page 47 For quantity and oil specification see page 102 and 106 7 Changing the gearbox oil Stop the engine and change the oil of the gearbox page 58 and 59 VD01026 VD01010 VD01034 ...

Page 85: ...ct the battery cables Charge batteries during winter lay up regu larly if required Follow the recommendations given on pages 50 to 53 or consult the recommen dations given by the battery supplier for in spection and maintenance of the batteries CT40063 VD00139 ...

Page 86: ...to be car ried out are Inspections and maintenance work to be carried out are page 1 Drain the water from the fuel system 85 2 Check the raw water system 86 3 Check the coolant level in the internal cooling system 87 4 Check the oil level 87 5 Check the batteries and reconnect these 88 6 Check the operation of the engine 88 7 Check all hose connections for leaks 89 8 Check the operation of the ins...

Page 87: ...85 8 Recommissioning after winter storage 1 Fuel system Drain the water from the water separator fuel filter page 44 Drain the water from the fuel tank Open the fuel valve VD00141 VD00803 VD00137 ...

Page 88: ...ing 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 64 67 Re tighten possible loose hose clamps 10 VD01125 VD00801 VD01045 Note Only engines with intercooling ...

Page 89: ...OOLANT 87 8 Recommissioning after winter storage Open the sea cock 3 Fresh water cooling system Check the coolant level page 42 4 Lubrication system Check the engine oil level page 40 VD01003 VD00138 VD01001 ...

Page 90: ...sure that the batteries are fully charged page 50 83 Connect the batteries 6 Switching on 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 VD00140 CT40063 VD00107 ...

Page 91: ...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 con trols Check the operation of the instruments the remote control and the gearbox VD00581 VD01046 ...

Page 92: ...ation 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 repair never start the en gine with th...

Page 93: ...ly rough idling or stalls 93 5 Engine does not reach maximum rpm under load 94 6 Engine overheats 95 7 Engine not firing on all cylinders 95 8 Engine has little or no oil pressure 96 9 Engine oil consumption excessive 96 10 Fuel consumption excessive 97 11 Black exhaust smoke idling 97 12 Blue exhaust smoke idling 97 13 Black exhaust smoke at load 98 14 White exhaust smoke at full load 98 15 Burnt...

Page 94: ...Check replace Faulty starter motor or pinion does not engage Check replace starter motor Seized components Repair Control lever not in neutral Put operating lever in neutral 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 clog...

Page 95: ...eck replace Insufficient intake air Check 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 pump Check replace if required ...

Page 96: ... quality or contami nated fuel Check fuel Drain 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 Exhaust restricted Check clean Incorrect valve clearance Adjust Transmission defect Ch...

Page 97: ...icles 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 Motor becomes apparently overheated as a result of faulty temperature switch sensor or meter Check replace 7 Engine not firing on all cylinders Possible fault Remedy Fuel supply line restricted Check clean Fuel filt...

Page 98: ...ck Adjust Oil pressure apparently too low 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 Insufficient intake air Check Excessive wear of cylinder pis ton Check compression overh...

Page 99: ...eplace with new fuel Fuel leaks Check and repair Incorrect injection timing Check adjust Insufficient 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 ...

Page 100: ...ax rpm is not reached Check sizes of propeller Engine overloaded dirty propel ler 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 Drain and flush fuel tank Replace with new fuel Water in fuel system C...

Page 101: ... Troubleshooting Fault finding table 15 Burnt oil trace in exhaust line Possible fault Remedy Oil level too high Lower level Excessive wear of cylinder piston piston rings Check compression refurbish engine ...

Page 102: ...0 mm 70 mm Total displacement 635 cm3 39 cu in 635 cm3 39 cu in Compression ratio 23 1 23 1 Idling speed 850 rpm 850 rpm Max no of revolutions at no load 3000 rpm 3600 rpm Direction of rotation Counter clockwise viewed towards the flywheel Valve Clearances cold Inlet 0 25 mm 0 010 Exhaust 0 25 mm 0 010 Weight with standard gearbox 98 kg 216 lbs 98 kg 216 lbs Engine installation Max installation an...

Page 103: ...tion 268 g kW h 196 g hp h 6 9 oz hp h 268 g kW h 196 g hp h 6 9 oz hp h at no of revolutions 2500 rpm 2500 rpm Fuel System Self bleeding Injection pump Bosch model NC Nippon Denso Injectors Plug injector Opening pressure 140 bar kgf cm2 2030 psi Firing order 1 2 Injection timing 17 BTDC Fuel filter element Vetus STM3690 Fuel lift pump Suction height max max 1 5 m 5 ft Fuel supply connection for h...

Page 104: ...5 3 Imp pt 6 3 US pt Thermostat opening at 71 C 160 F fully opened at 84 C 183 F Coolant pump Flow at max engine rpm 50 l min 11 Imp Gal min 13 2 US Gal min Total head keelcooler at max flow 2 m Water 6 7 Inlet connection for hose keelcooler 28 mm 1 1 8 I D Raw water pump Flow at max engine rpm 20 l min 4 4 Imp Gal min 5 3 US Gal min Total head at max flow 2 m Water 6 7 Impeller Vetus STM6161 Inle...

Page 105: ...ar 2 2 psi Electrical System Voltage 12 Volt Alternator 14 Volt 75 Amp Starter motor 14 Volt 1 2 kW Battery capacity min 55 Ah max 108 Ah Protection Tubular glass fuse 32 x 6 3 mm 10 A slow blow V belt Vetus STM7369 Gearbox Gear ratio Gear ratio Technodrive model TMC40P 2 05 2 60 1 2 05 2 60 1 model TMC60A 2 00 2 45 1 2 00 2 45 1 ZF Hurth model ZF10M 2 05 2 72 1 2 05 2 72 1 ...

Page 106: ... 5 0 8 Nozzle holder M20 21 54 5 5 5 0 5 40 3 5 Fuel leak oil pipe nut M12 17 25 5 2 5 0 5 18 3 5 Nozzle retaining nut M16 21 37 2 5 3 75 0 25 27 2 Fuel injection pipe nut M12 17 29 5 3 0 0 5 21 3 5 Delivery valve holder M16 17 36 2 3 7 0 2 26 1 5 Injection pump hollow screw M10 14 12 2 5 1 25 0 25 9 2 Injection pump air vent screw M6 10 6 1 0 6 0 1 4 5 0 8 Solenoid lock nut M30 36 44 5 4 5 0 5 32...

Page 107: ...e guaranteed with other fuels 11 Operating media Fuel Biodiesel Caution Use only the prescribed diesel fuel or diesel blends Do not use 100 biodiesel 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 b...

Page 108: ... 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 start possi...

Page 109: ...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 110: ...type TMC60A 0 6 litres ATF 1 1 05 Imp pt 1 25 US pt ZF Hurth type ZF10M 0 42 litres ATF 1 0 73 Imp pt 0 89 US pt 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 111: ...e 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 coolant preparation Use preferably tap water If an other av...

Page 112: ...or Oil press 30 85 87 86 A1 A3 A4 A2 A5 A6 B4 B1 B2 B5 B3 B6 Red Yellow Orange Violet White Black 1 2 Engine panel model 20 21 22 Voltmeter Tachometer hourcounter Starter switch Plug A Socket A Warning lights Pre heating Battery charging Gearbox oil pressure Plug B Socket B Transparent Yellow Green Green Brown Blue Gray Battery Battery switch Fuse Pre heating relay Model 20 21 22 Voltmeter 1 Tacho...

Page 113: ...5 A6 Red Yellow Orange Violet White Black Engine panel model 10 W Transparent Green Brown Blue Gray J3 J4 Plug A Warning lights Pre heating Starter switch Yellow Green Plug B L2 Battery charging L3 Exhaust temperature L4 Oil pressure L5 Coolant temperature L6 Oil pressure gearbox 111 12 Wiring diagram Options panel model 10 VD00216 ...

Page 114: ...14 3 16 332 13 1 16 500 19 11 16 168 6 5 8 430 16 15 16 505 19 7 8 min 70 2 3 4 max 90 3 9 16 67 5 2 11 16 112 13 Overall dimensions 1 Exhaust ø 40 mm 2 Fuel return ø 8 mm 3 Fuel supply ø 8 mm 4 Sea water intake ø 20 mm 1 10 M2 02 M2 06 VD00924 ...

Page 115: ...em air bleed nipple 13 Cooling system drain plug 13 Corrosion protection 78 Cruising 32 Cylinder numbering 11 17 D Direction of rotation 11 17 Draining of coolant 67 Drain plug Water separator fuel filter 12 E Electrical system 83 88 Electrical system connector box 12 electrolyte level 53 Empty fuel filter 44 Empty water separator 44 Engine data tag 10 16 Engine oil 106 Engine oil change 47 Engine...

Page 116: ...rating media 105 109 Overall dimensions 112 P Pre heating 29 Pre heating Indicator light 14 Protective fuel mixture 79 R Raw water cooling system 80 86 Raw water inlet 12 Raw water pump 12 Raw water pump inspection 64 Raw water strainer 41 Raw water temperature Warning light high 14 Recommissioning after winter storage 84 89 Check engine for leaks 89 Electrical system 88 Fresh water cooling system...

Page 117: ...ight high High coolant temperature 14 Warning lights 33 water separator fuel filter 44 Water separator Fuel filter 12 Water separator fuel filter air bleed nipple 12 Water separator fuel filter drain plug 12 Winter grade fuel 105 Winter storage procedure 76 83 Changing the gearbox oil 82 Corrosion protection 78 Electrical system 83 Fresh water cooling system 81 Fuel system 78 Lubrication system 82...

Page 118: ...116 ...

Page 119: ... Bruksanvisning M2 02 M2 06 Norsk 340810 01 Käyttöopas M2 02 M2 06 Suomeksi 320331 01 STM0032 Installatiehandleiding Installation manual Nederlands English 320199 06 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 Servi...

Page 120: ...lands 340802 01 2012 04 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 M2 02 M2 06 English vetus n v ...

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