Vetus VF4.145 Operation Manuals Download

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Fault finding table

9 Troubleshooting

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 .

Check and repair.

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 level too high.

Lower level.

Leaking from turbo compressor
oil seal.

Check / replace oil seal.

Summary of Contents for VF4.145

Page 1: ...Operation manual VF4 VF4 145 VF4 180 VF4 200 400302 01 ...

Page 2: ...ii ...

Page 3: ... about Customer Service Repairs or Spare Parts see page 11 We reserve the right to make any changes without previous notice Images shown in this manual may be different Copyright 2018 Vetus B V Schiedam Holland Serial numbers Engine serial number Gearbox serial number VF4 145 VF4 180 VF4 200 400302 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 se...

Page 5: ... oil change 43 Battery cables and connections 46 Gearbox oil level check 49 Cleaning the air filter 50 Changing the gearbox oil Technodrive 51 Changing the gearbox oil ZF Hurth 52 Fuel filter replacement 54 Flexible engine mounts hose connections and fasteners 57 Raw water pump inspection 58 Coolant replacement 60 Replace drive belt 64 Checking the alternator 67 Cleaning the heat exchange 68 Clean...

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

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

Page 8: ...king on or close to the engine before you start it Re move all foreign objects from around the engine such as litter oil tools and other components that are not part of the engine Install all protective covers To prevent injury make sure that all protec tive covers and cover plates are replaced over moving parts Remove any tool used to turn the engine over If you leave this in position serious 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: ...rily all components described in this manual are mounted to your engine We have endeavoured to highlight any differ ences so that you will able to locate the oper ating and maintenance instructions relevant to your engine quickly and easily Please read this manual before starting your engine and always observe the operating and maintenance instructions We are available to help with any additional ...

Page 12: ...GINE VETUS B V FOKKERSTRAAT 571 SCHIEDAM 3125 BD HOLLAND XXXX XX XX XX XXXX VF4XXX XXXXXXXXXXXX XXX XXXXXXXX Data tag 1 Engine data tag The Vetus engine serial number and perfor mance 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 There is a second type plate on the ECU...

Page 13: ...ber Cylinder numbering 2 Introduction 3 Position of serial number The serial number is stamped in the engine block in the position shown 4 Cylinder numbering Cylinders are numbered consecutively begin ning at the front end ...

Page 14: ...Oil drainage connection 6 Raw water intake ø 32 mm 7 Gearbox filter 8 Water separator fuel filter 9 Water separator fuel filter drain plug 10 Fuel lift pump 11 Fuel supply pipe connection ø 8 mm 12 Starter motor 13 Potentiometer 14 Alternator 15 Oil filter 16 Connection of push pull cable 2 Introduction Identification of engine parts ...

Page 15: ...charger 21 Airvent connection 22 Raw water pump 23 Exhaust injection bend 24 After cooler 25 Drive belt 26 Heat exchanger 27 Fuel cooler 28 Oil dipstick Gearbox filler cap 29 Gearbox 30 Operating gearbox Identification of engine parts 2 Introduction 17 18 19 21 24 25 26 27 28 29 20 23 22 30 ...

Page 16: ...2 Introduction Control panel 2 3 1 6 5 4 1 Temperature gauge coolant 2 Tachometer Operating hours counter 3 Voltmeter 4 Oil pressure gauge 5 Display 6 Starter pre heat switch lock Panel model MPA34 CAN BS2 ...

Page 17: ...typically controlled with a single lever Depending on the brand and type mechani cal or electronic there may be minor differen ces in the mode of operation Please refer to the engine manual for details However the principle is always as indicated above The control lever works as shown in the dia gram Starting from neutral put the engine in ahead or astern by moving the lever 35 forwards or backwar...

Page 18: ... the engine the stop knob the fuses the engine wiring connections and the con trol panel wiring connections The stop knob switches the ECU off if faults may possibly have been caused by incorrect connections made during the installation Press the red key in an emergency to stop the engine Emergency stop ...

Page 19: ...ioning OIL 1 Commissioning the engine 2 Checking oil level Before starting the engine for the first time the following procedures must be carried out The engine is already filled with oil Check the oil level see page 38 ...

Page 20: ... oil Check the oil level with the dipstick see page 49 Technodrive type TM345 1 6 litres Engine oil SAE 20W40 CD type TM345A 1 6 litres Engine oil SAE 20W40 CD type TM485A 2 6 litres Engine oil SAE 20W40 CD ZF Hurth type ZF25 2 5 litres without oil cooler type ZF25A 1 8 litres without oil cooler type ZF45 3 0 litres without oil cooler type ZF45A 2 0 litres without oil cooler type ZF63IV 3 8 litres...

Page 21: ...39 Top up if necessary Caution Never fill the cooling system with sea water or brackish water Note Water Heater If the engine is connected to a water heater the cooling system must be topped up see page 63 Note If the water heater is positioned higher than the top of the engine then it will not be bled automatically Follow the instructions for filling on page 63 ...

Page 22: ...only clean water free commercial ap proved diesel fuel For fuel grade see page 107 Bleed the fuel system see page 42 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 Check that switch A on the ECU box is on Turn the knob in the direction of the arrow Check that the f...

Page 23: ...the engine to test run for about 10 minutes at idling speed Check that the engine and all connections fuel coolant and exhaust for leaks The cooling system must be bled as soon as the engine has reached normal working tem perature Open the cap on the expansion tank Vary the revolutions between idling and 2000 rev min Add coolant if necessary Close the cap on the expansion tank Check the coolant te...

Page 24: ...allow the engine to run faster than 3 4 of maximum RPM After the first 50 operation hours carry out the following maintenance Drain water from fuel filter see page 41 Engine oil change see page 43 Replace oil filter see page 44 Change gearbox oil see page 51 52 Replace fuel filter see page 54 Check flexible engine mounts see page 57 Check engine for leaks see page 57 Check tightness of all fastene...

Page 25: ...l as protecting against frost damage For specifications see page 111 Never run the engine without a thermostat Use a good quality lubricating oil For speci fications see page 108 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 high raw water tem perature or battery cha...

Page 26: ...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 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 5 Use General guidelines ...

Page 27: ...is are in the neutral posi tion 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 Before starting always check the follow ing points Engine oil level Coolant level Sea cock open Main switch on Gearbox in neutral position ...

Page 28: ...ition ON 3 Pre heating Automatic pre heating will take place de pending on the engine temperature The pre heat time depends on the engine temperature During pre heating the pre heating symbol will be shown in the display If the symbol for pre heating disappears the engine can be started ...

Page 29: ...ient tempera ture is low Release the key as soon as the 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 be fore turning the key to the start position again ...

Page 30: ...od warm up is essential to ensure maximum lifetime and good performance Caution Never turn the main switch off while the engine is running Caution Never turn the key to the start position while the engine is running Doing so will damage the starter motor 5 Use Starting Note Idling speed will be about 100 rev min higher than normal when the engine is cold the coolant temperature is lower than 40 C ...

Page 31: ...5 Tachometer Indicating the number of revolutions per minute of the engine Also the number of running hours is indicat ed Idling speed 800 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 ...

Page 32: ... gauge Indicating the temperature of the internal cooling system The operating temperature is 75 C 90 C 167 F 194 F In case the engine is overheated turn off the engine and establish the cause see fault find ing table page 93 101 8 Oil pressure gauge With the engine at operating temperature the oil pressure is When idling at least 1 bar 7 psi In case the oil pressure is too low turn off the engine...

Page 33: ...unning no warnings should be displayed 10 Alarm buzzer The alarm buzzer sounds if the oil pressure is too low or the alternator does not charge or the engine temperature is too high If this alarm buzzer sounds while running Stop the engine immediately ...

Page 34: ...or a few minutes before stopping N B The Stop position left of the Off posi tion 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 on the other panel Note If the engine is not to be used for some time it is recommended that...

Page 35: ...If there is a fault the engine can be stopped by pressing the red button on the ECU box Turn the knob in the direction of the arrow when the engine has stopped Trace the source of the fault and repair this The engine can then be started again ...

Page 36: ...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 37: ...ur counter Amounts of oil and coolant needed for top ping 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 38: ...r ZF Hurth 52 Replace fuel filter 54 Check flexible engine mounts 57 Check engine for leaks 57 Check tightness of all fasteners bolts and nuts 57 Every 100 hours at least once every year page Draining of water from the water separator fuel filter 41 Engine oil change 43 Replace oil filter 44 Battery cables and cable connections 46 Check gearbox oil level 49 Check oil level power steering Sterndriv...

Page 39: ...elt 64 Check alternator 67 Check turbocharger Replace distributor belt When required page Bleeding fuel system 42 Cleaning heat exchanger 68 Cleaning the after cooler 72 Every 400 hours at least once every year page Change gearbox oil Technodrive 51 Change gearbox oil and replace filter ZF Hurth 52 Replace fuel filter 54 Check flexible engine mounts 57 Check engine for leaks 57 Check tightness of ...

Page 40: ...l Turn the engine off The dipstick is located on the starboard side of the engine The oil level must be at or near the upper mark on the dipstick If necessary top up with the same brand and type of oil The difference between the two oil level marks is 0 8 litres The oil filling cap is on top of the the valve cover ...

Page 41: ...vel must be between the mark ings MIN and MAX Warning Never open the cap of the expansion tank when the engine is at operating temperature Top up if necessary Remove the cap from the expansion tank The internal cooling system can be filled with a mixture of anti freeze 40 and tap water 60 or with a special coolant For specification see page 111 Caution Never fill the cooling system with sea water ...

Page 42: ...rainer Clean the raw water strainer as often as is necessary depending on the pollution of the waterways but at least once every 6 months A clogged raw water strainer will result in excessive temperatures or over heating of the engine coolant Check the sealing between the lid and housing after cleaning and re assembling the strainer An improperly sealed lid will re sult in air sucked in by the sea...

Page 43: ...ve spilled fuel and litter before you start the engine The drain plug is on the bottom of the filter First disconnect the connection on the drain plug The locking spring must be pushed in to re lease the connection Unscrew the drain plug Allow the water to drain out and then close the drain plug Put the connection back on the drainplug The locking spring must be pushed in to al low the connection ...

Page 44: ...ly but installation is required After the water separator fuel filter has been drained the air has to be bled from the fuel system The fuel system is self bleeding Turn the key in the ignition lock to ON and leave the key in this position for 30 seconds The fuel pump will now bleed the system Operate the starter switch until the engine fires release the starter switch if the engine does not fire w...

Page 45: ...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 46: ...er and pump the sump empty Put the plug back in the oil drain pipe again after draining off the oil Warning The engine oil must be disposed in accordance with the applicable envi ronmental regulations 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 from hot oil 6 Maintenance Engine oil change Every 100 ope...

Page 47: ...ter element housing Tightening torque 25 Nm 8 10 ft lbf Refill the engine with new oil for specifica tion see page 108 through the filler open ing in the valve cover Operate the engine at idling speed for a short period of time Check for oil leaks whilst the engine is running Stop the engine Allow 5 minutes for the oil to return to the sump Check the oil level with the dipstick Engine oil change E...

Page 48: ...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 49: ...at clamps make good contact after reassembling Hand tighten the bolts only Every Vetus Maintenance free battery has a hydrometer 1 built into the cover Visual inspection of the hydrometer will show one of three conditions 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 In case of low level caused by ove...

Page 50: ...ove top of all plates If necessary top up with distilled water Replace vent caps and charge the battery for 15 minutes at 15 25 Amps to mix electrolyte 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...

Page 51: ...oil and other care and maintenance 23 Oil level check Technodrive 24 Oil level check ZF Hurth The oil level must between the two marks on the dipstick If necessary top up The filler cap is on top of the gearbox housing Unscrew the dipstick out of the gearbox housing Check the oil level by cleaning the dip stick and lowering it into the hole without screwing it in The oil level must between the end...

Page 52: ...wder Let the filter dry or blow dry using com pressed air maximum pressure 5 bar 70 psi to prevent damage to the filter Replace the filter and tighten the hose clamp A filter which is in bad condition needs to be replaced For air filter art code see page 120 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 ai...

Page 53: ...the fillercap to vent the gearbox and check if all oil has been drained Collect the oil in a dripping pan 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 the supplied owners manual for chang ing oil and other care and maintenance ...

Page 54: ...uickly 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 Remove the fillercap to vent the gearbox and check if all oil has been drained Collect the oil in a dripping pan The filter element must be replaced at the same time as the oil Turn the screw that holds on the...

Page 55: ...ce if necessary Install the new filter and mount the unit on the gearbox For filter element art code see page 120 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 the supplied owners manual for chang ing oil and other care and maintenance ...

Page 56: ...ain plug at the lower side of the filter housing Press the retainer spring to loosen the con nector 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 Clean any debris from the filter carrier rim Lubricate the rubber gasket sparingly with clean engine oil Fill the new filter with clean diesel fuel For fuel filter art...

Page 57: ...g hours 6 Maintenance 1 2 Install the filter When the rubber gasket touches the hous ing apply another tightening of a half to three quarters of a turn by hand Open fuel stopcock Check for leaks Put the connection back on the bottom of the filter ...

Page 58: ...f bleeding Turn the key 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 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...

Page 59: ...nt the mounting bolts to engine bed and the nuts at the adjustment spindle for tightness Inspect the rubber element of the engine support for cracks Also check the deflec tion of the damper element the deflection influences the alignment of engine and propshaft Re align engine in case of doubt Inspect all hose connections of the cooling system Cracked hoses loose hose clamps Check tightness of all...

Page 60: ...s been blocked it may be necessary to replace the impeller Always carry a spare impeller on board 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 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 ...

Page 61: ...For impeller art code see page 120 The impeller should be lubricated with 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 Replace the cover with a new gasket Check the water filter and open the sea cock For gasket art cod...

Page 62: ...so be neces sary as part of the winter storage procedure in case that the coolant present in the cooling system offers insufficient protection for the winter 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 Cooling system protective liquids must be disposed of in accordance with ...

Page 63: ...ting hours 1 6 x 6 3 7 1 6 x 6 3 7 45 Drain coolant Remove the hose to the oil cooler 1 and the hose of the heat exchanger 2 Remove the filler cap on the top of the ex pansion tank to allow air into the cooling system and check that all the liquid drains out ...

Page 64: ...asis and 60 clean tap water or use a coolant See page 111 for specifications Put the filler cap back Check the coolant level after the engine has been run again for the first time has reached operating temperature and then has cooled back to ambient temperature Top up if necessary Caution Never fill the cooling system with sea water or brackish water Coolant quantity litres Imp pt US pt 7 6 5 4 2 ...

Page 65: ...will be filled and bled au tomatically during filling of the cooling sys tem Note B The highest point of the water heater is situated at a higher level than the expansion tank for the ship s engine The water heater will not be filled and bled automatically during filling of the cooling system Fill the cooling system via the extra expan sion tank Open the valve during the filling and bleed ing of t...

Page 66: ...er Only check tension or replace the drive belt when the engine is stopped Stop the engine close the sea cock and drain the system Loosen the hose clamps and take the hos es 4 off the hose connections Loosen the bolt 5 so that the expansion tank 1 is released from the charge air cooler The expansion tank does not need to be removed Remove the hose clamps from the charge air cooler and remove the h...

Page 67: ... Maintenance Replace drive belt Every 800 operating hours 2 3 Remove the 4 bolts and remove the charge air cooler 2 together with the drive belt cover 3 The charge air cooler and drive belt cover is 1 unit ...

Page 68: ...erating hours 6 24 32 Remove the spacer Slacken the belt tensioner 6 in order to be able to remove the worn out belt Fit a new belt Make sure that the teeth on the belt fit well in the grooves of the belt pulleys For drive belt art code see page 120 ...

Page 69: ...ator Every 800 operating hours 50 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 ...

Page 70: ...an the heat exchanger if this is badly fouled Under normal conditions of use cleaning the heat exchanger is not necessary The engine temperature will be higher than normal if the heat exchanger is fouled Possible causes of fouling are Small rubber particles from a damaged sea water pump impeller Growth of algae or seaweed ...

Page 71: ...er Close the valve to the raw water supply and remove the water input hose to the oil cooler Remove the hose to the oil cooler 1 and the hose of the heat exchanger 2 Remove the filler cap on the top of the ex pansion tank to allow air into the cooling system and check that all the liquid drains out ...

Page 72: ...or the raw water 2 Remove the nuts 3 The heat exchanger is now free from the engine Unscrew the 2 cap nuts and pull the rod out of the end covers Remove the heat exchanger from the hous ing 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 ...

Page 73: ...ace the heat exchanger in the original position in the heat exchanger housing Use new O rings which have been greased For O ring art code see page 120 Fit the end covers in the housing Put the threaded rod back and refit the nuts Reconnect all hoses previously removed Refill the cooling system see page 62 ...

Page 74: ... exchanger must then be cleaned 56 After cooler removal Stop the engine close the sea cock and drain the system Loosen the hose clamps and take the hoses 4 off the hose connection points Loosen the bolt 5 so that the expansion tank 1 is released from the charge air cool er The expansion tank does not need to be removed Remove the hose clamps from the charge air cooler and remove the hoses 6 off th...

Page 75: ... pipes Then rinse the heat exchanger pipes with clean water Clean the fins using petrol and compressed air maximum pressure 2 bar 28 psi to pre vent damage to the fins Make sure there is no dirt on either of the covers to the after cooler housing Put the heat exchanger back in exactly the same position in the after cooler housing Clean the seatings for the silicone gaskets and the O rings Put the ...

Page 76: ...r pe riod Make sure that the engine compartment is well ventilated during the winter period Good ventilation prevents damp in the en gine compartment thus preventing corrosion of the engine from occurring The engine should be inspected at the start of the storage period and any necessary repairs should be carried out Consult a Vetus Dealer if help is required with this Inspections and maintenance ...

Page 77: ...s filled with a fuel mixture with protective properties 79 5 Flush out the raw water circuit with fresh water and if necessary fill with antifreeze Clean the heat exchanger if necessary 80 6 Make sure that the cooling system is filled with a suitable anti freeze 81 7 Change the oil filter and the engine oil 82 8 Change the oil in the gearbox 82 9 Grease moving parts of the engine including the tur...

Page 78: ...ater cir cuit to protect engine parts that come into contact with the external water from galvanic corrosion The speed at which the zinc anodes are sacri ficed depends on many external factors The arrows indicate where the zinc anodes are located The zinc anodes are marked with black ink ...

Page 79: ...ck and replace the zinc anodes as follows Stop the engine Close the sea cock Remove the zinc anodes from the heat exchanger housing and the after cooler re spectively Replace the new zinc anodes and the cop per rings 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 ...

Page 80: ...medium In order to prevent corrosion the engine should be rinsed off to remove any salt residues If there is any corrosion the paint should be touched up Engine parts that become hot must be touched up with heat resistant paint 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 54 ...

Page 81: ...Connect the fuel supply pipe to a can filled with protective diesel fuel for example Cal ibration Fluid ISO 4113 or with a mixture of 1 part of engine oil 1 to 9 parts of clean fuel 2 Use this mixture to run the engine at no load for approx 5 minutes Stop the engine 1 Engine oil with protective properties E g Vetus Marine Diesel Engine Oil 15W40 Shell Nautilus Premium Inboard 15W 40 2 Only use DIN...

Page 82: ...ean the raw water strainer Connect the raw water intake to a fresh wa ter tap water supply or a tank containing fresh water Open the tap and allow the en gine to idle for at least 5 minutes to remove any salt and contamination from the raw water cooling system Make sure that there is a sufficient supply of water to prevent the engine from over heating Stop the engine and close the sea cock The raw...

Page 83: ...pilled into the waterway Check the seal between the lid and hous ing after cleaning and re assembling the strainer An improperly sealed lid will result in air sucked in by the raw water pump which again will result in overheating of the engine To avoid corrosion during winter storage the cooling system must be filled with an anti freeze water mixture or a coolant For specifications see page 111 N ...

Page 84: ... engine still at operating tempera ture If not run the engine until warm then turn off Replace the oil filter and change the engine oil use oil with protective properties See page 43 For quantity and oil specification see page 108 Stop the engine and change the oil of the gearbox page 51 and 52 ...

Page 85: ... is to work on the best pos sible way Apply long life water resistant lithium based grease for example ZEP RED LITHI UM GREASE to the operating mechanism Then spray the cast iron housing and the aluminium parts of the turbo with liquid lubricant containing Teflon for example ZEP 2000 Disconnect the hose connecting the turbo to the after cooler from the turbo Remove any oil residue from the surface...

Page 86: ...84 7 Lay up Winter storage procedure 10 Belt tensioner Spray the spring and the rotation point of the belt tensioner with a liquid lithium based lubricant Be careful not to get any lubricant on the belt ...

Page 87: ...tem Disconnect the battery cables Charge batteries during winter lay up regu larly if required Follow the recommendations given on pages 46 to 48 or consult the recommen dations given by the battery supplier for in spection and maintenance of the batteries ...

Page 88: ...e oil level 89 5 Check the batteries and reconnect these 90 6 Check the working of the ECU box 90 7 Check all hose connections for leaks 91 8 Check the operation of the instruments and the engine controls 91 The engine must be inspected and any main tenance work carried out when re commis sioning for example at the beginning of the sailing season Consult a Vetus Dealer if help is required with thi...

Page 89: ...87 8 Recommissioning after lay up or winter storage 1 Fuel system Drain the water from the water separator fuel filter page 41 Drain the water from the fuel tank Open the fuel valve ...

Page 90: ... or winter storage 2 Raw water cooling system Check that the lid of the raw water strainer is reinstalled Check whether the lid of the raw water pump and drain plugs are reinstalled pag es 58 59 Re tighten possible loose hose clamps 8 ...

Page 91: ...89 8 Recommissioning after lay up or winter storage 3 Fresh water cooling system 4 Lubrication system Open the sea cock Check the coolant level page 39 Check the engine oil level page 38 ...

Page 92: ...he batteries are fully charged page 46 85 Connect the batteries 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 All indicator LEDs for the fuses must light up when the starter key is in position ON ...

Page 93: ...nter storage 7 Check engine for leaks 8 Checking instruments and remote controls Start the engine Check the fuel system the cooling system and the exhaust for leakage Check the operation of the instruments the remote control and the gearbox ...

Page 94: ...les information is given about the possible causes of faults and sug gested remedies Please note that these ta bles can never be complete If you are unable to identify the cause of the fault or to rectify it yourself then contact the nearest service representative 9 Troubleshooting General Danger Before starting make sure that nobody is in the immediate vincinity of the engine When carrying out re...

Page 95: ...ximum rpm under load 96 6 Engine overheats 97 7 Engine not firing on all cylinders 97 8 Engine has little or no oil pressure 98 9 Engine oil consumption excessive 98 10 Fuel consumption excessive 99 11 Black exhaust smoke idling 99 12 Blue exhaust smoke idling 99 13 Black exhaust smoke at load 100 14 White exhaust smoke at full load 100 15 Burnt oil trace in exhaust line 101 16 Idle speed 750 800 ...

Page 96: ...ol lever not in neutral Put operating lever in neutral The emergency stop knob is pushed in ECU Box Pull the emergency stop knob out 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 filter clogged with water and or contamination Check or replace Fuel pre filter clogged Cl...

Page 97: ...venly 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 Fuel electric pressure regulator fault Replace Clogged filter of electric fuel lift pump Check clean Le...

Page 98: ...r contami nated fuel Check fuel Drain and flush fuel tank Replace with new fuel 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 Exhaust restricted Check clean Transmission defect Check Turbocharger damaged Replace VGT turbocharger actuator blocked Check unblock or replace...

Page 99: ...e level Oil level too high Lower level Faulty oil filter Replace Faulty oil heat exchanger Replace Insufficient intake air Check replace air intake filter Faulty turbo compressor Check replace Motor becomes apparently overheat ed 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 ...

Page 100: ...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 qual ity for ambient temperature Replace Leak in lubricating oil system Repair replace Crank case vapour condenser clogged Replace Insufficient intake air Check Excessive wear of cylinder piston Check compression ove...

Page 101: ... new fuel Fuel leaks Check and repair 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 level too high Lower level Leaking from turbo compr...

Page 102: ... replace VGT Turbocharger actuator blocked Unblock replace Engine overloaded max 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 Che...

Page 103: ...pair Replace 16 Idle speed 750 800 RPM Possible fault Remedy Coolant temperature lower than 40 C On normal functioning Run the engine at a speed of 900 RPM un til the coolant temp is over 40 C Wrong indication of tachometer Adjust replace Fault on electric electronic equip ment Check repair Low battery voltage On normal functioning If the battery voltage is lower than 13 5 V increase engine speed ...

Page 104: ... charged with variable geometrie Bore 83 mm Stroke 90 4 mm Total displacement 1956 cm3 119 cu inch Compression ratio 16 5 1 Idling speed 800 rpm Max no of revolutions at no load 4700 rpm Direction of rotation Counter clockwise viewed towards the flywheel side Number of valves 16 Valve Clearances mini lash hydraulic adjusters with roller fingers Weight with standard gearbox 320 kg 705 lbs Engine sp...

Page 105: ...1 kW 170 1 hp 135 8 kW 184 3 hp at no of revolutions of 4100 rpm 4100 rpm 4100 rpm Torque 280 Nm 28 6 kgm 206 ft lb 340 Nm 34 7 kgm 251 ft lb 355 Nm 36 2 kgm 262 ft lb at no of revolutions 2300 rpm 2300 rpm 2300 rpm Fuel consumption 235 g kW h 173 g hp h 6 1 oz hp h 222 g kW h 163 g hp h 5 8 oz hp h 237 g kW h 174 g hp h 6 1 oz hp h at no of revolutions 4100 rpm 4100 rpm 4100 rpm Fuel System Self ...

Page 106: ...stem Oil capacity max without oil filter 4 L 7 UK pt 8 5 US pt with oil filter 4 5 L 7 9 UK pt 9 5 US pt Oil temperature in sump max 130 C 266 F Cooling system Capacity Thermostat opening at 65 C 1 5 C 149 F 3 F fully opened at 76 C 169 F Coolant pump Flow at max engine rpm 90 l min 19 8 UK gal min 23 8 US gal min Raw water pump Flow at max engine rpm 100 l min 22 UK gal min 26 4 US gal min Total ...

Page 107: ...ustion air Exhaust system Turbo pressure at max load max 2450 mbar 35 5 psi max 2700 mbar 39 1 psi max 2850 mbar 41 3 psi Exhaust diameter for gear box 90 mm 3 5 8 for stern drive 76 mm 3 Exhaust back pressure at specified output max 300 mbar 43 5 psi Electrical System Voltage 12 Volt Alternator 14 Volt 105 A Starter motor 14 Volt 2 3 kW Battery capacity min 70 Ah max 200 Ah Protection Fuse ATO 10...

Page 108: ...M485A 2 09 2 40 2 51 1 ZF Hurth model ZF25 1 97 1 model ZF25A 2 03 1 model ZF45 2 20 2 51 1 model ZF45A 1 26 1 51 2 03 2 43 1 model ZF63 IV 2 00 2 48 1 Stern drive Reduction ratio MerCruiser model Bravo 1 1 36 1 50 1 65 1 model Bravo 2 2 00 2 20 1 model Bravo 3 1 65 2 00 2 20 1 Volvo model 290 A B C model SX A M Gearbox specifications ...

Page 109: ...el 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 Biodiesel Caution Use only the prescribed diesel fuel Do not use 100 biodiesel B100 Winter grade fuel Waxing may occur at low temperatures clogging the fuel system and reducing engine efficiency If the ambient temperature is less than 0...

Page 110: ... turn lead to higher frictional resistance and more effort which forms a hindrance to reaching the starting rpm required for a dependable start and this results in a reduced lifespan Recommended lubricating oil viscosity There are two important considerations when it comes to ambient temperature in order to achieve satisfactory engine performance the possibility to turn the engine over quickly eno...

Page 111: ...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 112: ...thout oil cooler model ZF45A 2 0 litres ATF without oil cooler model ZF63IV 3 8 litres ATF without oil cooler ATF Automatic Transmission Fluid Transmissie olie type A Suffix A For example Vetus Transmission Oil Shell Donax T6 Gulf Dextron Other brands of gearboxes See supplied owners manual for oil type and quantities Sterndrive Power steering and trim Hydraulic oil ATF 1 0 litres Tail piece Bravo...

Page 113: ...ow exceed the following limits Cooling system protective liquid Anti freeze Water Protection against freezing to max 45 vol 55 35 C 31 F 40 vol 60 28 C 18 F min 35 vol 65 22 C 8 F The protective liquid concentration must be maintained under all cir cumstances Therefor if coolant must be added always use the same mixture of anti freeze and tap water Water quality for coolant preparation Use prefera...

Page 114: ... 2 3 1 2 1 2 3 4 5 6 1 2 B A 1 2 3 1 2 3 5 V 5 V High Side PWM Low Side 64 PIN 12 V 4 B7 STARTER MOTOR COOLANT TEMPERATURE SENDER 1 RPM SENDER INJECTOR 1 INJECTOR 2 INJECTOR 3 Signal GROUND FUEL FILTER TEMPERATURE SENDER FUEL PRE HEATING FUEL PUMP TURBO PRESSURE SENDER RAIL PRESSURE SENDER FUEL PRESSURE REGULATOR Signal Signal Signal Signal Signal ...

Page 115: ...e CID KESS 12 V K line 12 V 12 V 1 2 3 4 5 1 2 3 4 5 12 V D 12 V C14 6 B4 INJECTOR 3 INJECTOR 4 OIL PRESSURE SENDER POTENTIO METER ALTERNATOR FUEL PRESSURE REGULATOR OBD DIAGNOSE TIMING SENDER GLOW PLUGS Fuse 80 A Glowplugs WATER IN FUEL SENDING UNIT Signal Sender 1 Sender 2 signal Sender 1 signal Sender 1 Sender 2 Sender 2 Signal Switch Diagnose Warning light EXHAUST TEMPERATURE SWITCH Pre heatin...

Page 116: ... X A1 X A2 X A5 X A3 CANH CANL 0 V CANH CANL 0 V CANH CANL 0 V K4 85 D B 15 TS 50 X C5 X C4 X C3 X C2 X C1 Key Switch Oil Press 0 8 bar Temp 0 120 ºC 0 16 V Yellow Orange Purple Red Brown Red Black Gray Blue Green Temp Alarm Switch Neutral if alarm NO Multifiunction Instrument 0 4000 RPM Deutsch Conn DT06 08S Dashboard CAN Connector M12 6p Socket DT06 6S ...

Page 117: ... C2 X C1 X C X C5 X C4 X C3 X C2 X C1 Key Switch Yellow Orange Purple Red Brown 6p Socket DT06 6S Exhaust Temp Alarm Switch Neutral if alarm NO Connect to Alarm Indicator Key Switch Yellow Orange Purple Red Brown 6p Socket DT06 6S Exhaust Temp Alarm Switch Neutral if alarm NO Connect to Alarm Indicator Engine cable A Engine cable C Dashboard CAN Connector M12 Dashboard CAN Connector M12 2 panels ...

Page 118: ...116 13 Overall dimensions VF4 180 VF4 200 300 11 13 16 670 26 3 8 300 11 13 16 ...

Page 119: ...117 13 Overall dimensions 190 7 1 2 505 19 7 8 695 27 3 8 824 32 7 16 287 11 5 16 537 21 1 8 1834 72 3 16 776 30 35 64 BRAVO ONE ...

Page 120: ...118 13 Overall dimensions TM345 600 23 5 8 691 27 3 16 186 7 5 16 505 19 7 8 208 8 3 16 430 16 15 16 67 2 5 8 705 27 3 4 960 37 13 16 255 10 1 16 VF4 145 ...

Page 121: ...119 13 Overall dimensions ZF45 600 23 5 8 691 27 3 16 186 7 5 16 505 19 7 8 208 8 3 16 430 16 15 16 67 2 5 8 705 27 3 4 972 38 1 4 267 10 1 2 VF4 180 VF4 200 ...

Page 122: ...d VF4 200 Check replace every hour See page Oil Filter VFP51800 100 45 Air filter VFP51801 200 50 Filter element gearbox CT50081 400 53 Fuel filter STM9451 400 54 Impeller VFP51802 800 59 Gasket VFP51803 800 59 Drive belt VFP51804 800 66 O ring STM9457 71 ...

Page 123: ...uising 29 31 Cylinder numbering 11 D Display 14 Drain coolant 61 Drain fuel filter 41 Draining the oil 44 Drive belt 13 E ECU box 16 Electrolyte level 48 Empty water separator 42 Engine data tag 10 Engine oil 108 Engine oil change 43 45 Engine serial number 1 Engine specifications 102 105 Exhaust injection bend 13 Expansion tank 13 F Fasteners 57 Fault finding table 93 101 Fill cooling system 62 F...

Page 124: ...59 Recommissioning after lay up or winter storage 86 91 Check engine for leaks 91 Checking instruments and remote controls 91 Electrical system 90 Fresh water cooling system 89 Fuel system 87 Lubrication system 89 Raw water cooling system 88 Removing the oil filter 44 Replace drive belt 64 66 Running in 22 S Safety measures 4 8 Serial number 11 Serial numbers 1 Starter motor 12 Starter pre heat sw...

Page 125: ...7 Winter storage procedure 74 85 Belt tensioner 84 Changing the gearbox oil 82 Corrosion protection 78 Electrical system 85 Fresh water cooling system 81 Fuel system 78 Greasing moving parts 83 Lubrication system 82 Protective fuel mixture 79 Raw water cooling system 80 Zinc anode 76 Wiring diagrams 112 114 ...

Page 126: ......

Page 127: ...1 Instrukcja obsługi VF4 Polski 400402 01 Installation manual VF4 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 Service og garantibog Service och garantihäfte Dansk Svenska Service og garantibok Huol...

Page 128: ... 07 Nederlands Printed in the Netherlands 400302 01 2018 08 Printed in the Netherlands Vetus Diesel VF4 English FOKKERSTRAAT 571 3125 BD SCHIEDAM HOLLAND TEL 31 0 0 88 4884700 sales vetus nl www vetus com vetus b v ...

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