VD6.210
D-LINE Marine Diesel Engines
Operation manual
VD4.120
VD4.140
VD6.170
VD6.210
360602.01
ii
Operation manual
Engine serial number Vetus:
Engine serial number Deutz:
VD4.120 VD6.170
VD4.140 VD6.210
Serial numbers
Gearbox serial number:
Please enter the serial numbers here.
These numbers should be quoted when inquiring about Customer Service, Repairs or Spare Parts (see page 10).
We reserve the right to make any changes without previous notice.
Images shown in this manual may be different.
360602.01
Copyright © 2017 Vetus B.V. Schiedam Holland
1
Please read and observe the information given in this operation manual. This will enable
you to avoid accidents, preserve the manufacturer’s warranty and maintain the engine
in peak operating condition.
Make sure that the manual will remain intact
and damage is prevented. Keep the manual
away from humidity and heat.
Do not alter the content of the manual.
The manual is an integral part of the engine.
Hand over the manual tot the new owner if
boat or engine is being sold.
For the Guarantee Conditions, see the Vetus Diesel ‘Service and Warranty Manual’
(320199.06).
2
This engine has been built exclusively for the
application specied in the scope of supply and is to be used only for the intended
purpose. Any use exceeding that scope is
considered to be contrary to the intended
purpose. The manufacturer will not not assume responsibility for any damage resulting
therefrom. The risks involved are to be borne
by the user.
Use in accordance with the intended purpose also implies compliance with the conditions laid down by the manufacturer for
operation, maintenance and servicing. The
engine should only be operated, maintained
and serviced by persons which are familiar
with the former and the hazards involved.
The relevant accident prevention guidelines
and other generally accepted safety and
industrial hygiene regulations must be observed.
Unauthorized engine modications will invalidate any liability claims against the manufacturer for resultant damage.
Manipulations of the injection and regulating
system may also inuence the performance
of the engine, and its emissions. Adherence
to legislation on pollution cannot be guaranteed under such conditions.
Contents
1 Safety measures 4
Warning indications 4
Preventing re and explosion 5
Prevention of injury 6
When problems occur 8
2 Introduction 9
Data tag 10
Serial number, cylinder numbering
and direction of rotation 11
Identication of engine parts D4 12
Identication of engine parts D6 14
Control lever 17
3 First commissioning 18
4 Running-in 27
5 Use 28
General guidelines 28
Starting 30
Cruising 34
Stopping 37
6 Maintenance 38
Introduction 38
Maintenance schedule 40
Checking engine oil level 42
Checking coolant level 43
Checking and cleaning the raw
water strainer 44
Draining of water from the water
separator/fuel lter 45
Engine oil change 47
Battery, cables and connections 52
Gearbox oil level check 56
Changing the gearbox oil 57
Fuel lter replacement 58
Flexible engine mounts, hose
connections and fasteners 59
Checking the V-belts 60
Raw water pump inspection 62
Air lter replacement 65
Checking the starter motor and
alternator 66
Checking valve clearance 67
Coolant replacement 70
Cleaning the heat exchanger 73
Cleaning the after cooler 78
7 Lay-up / Winter storage
procedure 82
8 Recommissioning after
lay-up or winter storage 90
9 Troubleshooting 96
10 Technical data 106
Engine specications 106
Gearbox specications 111
Torque wrench settings 112
11 Operating media 114
Fuel 114
Lubricating oil 116
Coolant 119
12 Wiring diagrams 120
13 Overall dimensions 122
14 Parts for maintenance 126
15 Index 127
3
1 Safety measures
Warning indications
The following warning indications are used in
this manual in the context of safety:
Warning indications
Danger
Indicates that great potential danger exists
that can lead to serious injury or death.
Warning
Indicates that a potential danger that can lead
to injury exists.
4
Caution
Indicates that the usage procedures, actions
etc. concerned can result in serious damage
to or destruction of the engine. Some CAUTION indications also advise that a potential
danger exists that can lead to serious injury or
death.
note
Emphasises important procedures, circumstances 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 people who will use the engine.
General rules and laws concerning safety
and accident prevention must always be observed.
1 Safety measures
Fire risk!
Preventing re and explosion
• Do not smoke if refuelling.
• Avoid spilling fuel on hot surfaces. Spilled
fuel must be cleaned up immediately.
• Do not use petrol or diesel to clean components but make use of good quality, non-inammable, non-poisonous solvents that
are available from dealers.
• Always be alert to possible fuel or oil leakage!
If you discover a leak, take counter-measures immediately. If fuel or oil is spilled on
a hot engine, re can break out. This can
cause physical injury or damage to the
equipment.
• Do not ll the fuel tank while the engine is
running!
Only refuel with the engine stopped.
• Never put ammable materials in the vicinity of the engine!
• Keep the engine and engine compartment
clean!
Remove all inammable materials such as
fuel, oil and other litter before it builds up
in the vicinity of the engine.
• Connecting (emergency) extra starting battery
Proceed as follows when an extra starting
battery is used to jump start the engine:
- First connect the positive lead
- Lastly connect the earth cable (negative
pole) to the engine block
If this cable is connected in error to the
negative pole of the engine battery, a
spark can occur. The result of this could
be that explosive gas produced by the
battery explodes.
- Once the engine is started, rst remove the
earth cable.
5
1 Safety measures
Prevention of injury
• The moving parts of the engine are dangerous. Never touch moving parts of the
engine while it is running, to prevent cuts
and other injuries.
• Stop the engine before carrying out maintenance!
• Always stop the engine before topping up
or replacing fuel, oil or coolant.
• Before carrying out inspection or maintenance, the ignition key must be removed
and the main battery switch turned o.
• Satisfy yourself that everything is in order
before the engine is started again!
Make sure that no-one is working on or
close to the engine before you start it. Remove all foreign objects from around the
engine, such as litter, oil, tools and other
components that are not part of the engine.
• Install all protective covers!
To prevent injury, make sure that all protective covers and cover plates are replaced
over moving parts.
• Remove any tool used to turn the engine
over. If you leave this in position, serious
injury or damage to the equipment can result.
• NEVER open the cap of the expansion tank
when the engine is at working temperature.
• Only check the coolant level after the engine has been stopped and the ller cap
on the heat exchanger is cool enough to be
removed with bare hands.
• Never attempt to adjust the fan belt on a
running engine.
6
1 Safety measures
Prevention of injury
• Be careful with battery acid!
If battery acid comes in contact with the
eyes or skin, rinse the aected part immediately with copious amounts of water. If
battery acid comes in contact with the eyes,
rinse them out immediately with plenty of
water and consult a doctor.
• Be careful with antifreeze!
If you accidentally swallow antifreeze, make
yourself vomit and consult a doctor immediately. If antifreeze comes in contact with
your eyes, wash them out immediately with
plenty of water and consult a doctor.
• Make sure that you are wearing suitable
clothing before starting work!
For your own safety you will most likely
need special equipment – safety helmet,
eye protection, safety boots, safety goggles, heavy gloves, ear protectors etc. Use
them when necessary.
• Carry out maintenance procedures safely
by only using suitable tools.
• Exhaust gases
Do not start the engine if the exhaust system is not connected.
7
1 Safety measures
When problems occur
When the engine stops suddenly:
If the engine stops suddenly, do not start it
again immediately. Track down the cause and
carry out the necessary repairs before you
start the engine again. If you do not do this,
serious engine problems can develop.
If the oil pressure is too low:
Stop the engine immediately and check the
lubrication system. Running an engine with
low oil pressure can cause bearing and other
parts to seize.
lf the engine overheats:
If the engine should overheat, do not switch
it o immediately. If an overheated engine is
stopped suddenly, this can cause the coolant
temperature to rise rapidly and moving parts
to seize. First let the engine run in neutral to allow the hot parts of the engine to cool down,
stop the engine and allow it to cool, and then
gradually top up the coolant. Remember:
adding coolant to an overheated engine can
cause damage to the cylinder head.
If the fan belt is broken:
Immediately stop the engine. If an engine is
used with a broken fan belt, this can lead to
the engine overheating, which in turn can
cause coolant to spray out of the expansion
tank.
If the engine behaves strangely:
Stop the engine or reduce the speed as far as
possible.
Do not use the engine again until the cause of
the defect has been solved.
8
2 Introduction
Dear customer,
Vetus diesel engines are designed both for
pleasure craft and commercial craft. Consequently, a wide range of variants are oered
to meet the requirements of specic cases.
Your engine is appropriately equipped for
your vessel, which means that not necessarily
all components described in this manual are
mounted to your engine.
We have endeavoured to highlight any dierences so that you will able to locate the operating and maintenance instructions relevant
to your engine quickly and easily.
Please read this manual before starting your
engine and always observe the operating and
maintenance instructions.
We are available to help with any additional
inquiries.
Sincerely,
Vetus b.v.
9
2 Introduction
Data tag
Serial number
A B
MARINE DIESEL ENGINE
kW HP
XXX
SCHIEDAM HOLLAND
XXXX
kg
Mfg Date:
XX/XXXX
RPM
D XXXXXXXXXXXX
Type:
123456 654321
Engine Nr.:
XX XX
Power
Weight, approx.:
BSO cert.:
XXXXXXXX
Meets exhaust emission regulations
acc. 94/25/EC, 2003/44/EC
Light Diesel Fuel Only (B7Allowed)
1 Engine data tag
Model (A), Deutz engine serial number (B)
and performance data are stamped on the
engine data tag.
Model and engine serial number must be
given when ordering spare parts.
C
2 Engine data tag location
The Deutz engine data tag (C) is attached to
the crank case.
D
The Vetus engine nameplate (D) is attached to
the top cover.
10
2 Introduction
Serial number, cylinder numbering and direction of rotation
3 Engine serial number
The Deutz engine serial number is stamped at
the indicated spot.
left
right
4 Cylinder numbering and direction of rotation
Cilinder numbering
Cylinders are numbered consecutively, beginning at the flywheel end.
left
right
Direction of rotation
The direction of rotation is viewed towards
the ywheel counter clockwise.
Motor sides
Seen from the flywheel side.
11
2 Introduction
Identication of engine parts D4
1 Fuel return pipe connection ø 10 mm
2 Calorier connection, engine ‘OUT’
3 Oil dipstick
4 Oil ller cap
5 Lifting eye
6 Cooling system drain plug, heat exchanger
cover, raw water
7 Heat exchanger
8 Filler cap (pressure cap) for cooling system
9 Cooling system drain plug, heat exchanger
10 P.T.O. (Mounting facility for hydraulic
pumps)
11 Oil cooler
12 Fuel lter
13 Oil lter
14 Alternator
15 Fuel supply pipe connection ø 12 mm
16 V-belt alternator
17 Fuel lift pump
18 V-belt alternator fuel pump / coolant pump
19 P.T.O. (Mounting facility for extra belt pulley)
20 Coolant pump
21 Calorier connection, engine ‘IN’
VD4.120, VD4.140
1 2 3 4 5 6 7 8 9
12
10 12 13 14 15 16 17 18 19 2011 21
2 Introduction
Identication of engine parts D4
VD4.120, VD4.140
22 23 24 26 27 29 30 31 32
25 28
22 Air intake lter
23 Turbocharger
24 Exhaust injection bend
25 Raw water 'out' for prop shaft lubrication
26 Connection airvent
27 Exhaust insulator
28 Lifting eye
29 Relays and fusses
30 Gearbox lube oil cooler
31 Raw water pump
32 Raw water inlet ø 32 mm
33 Cooling system drain plug, block
34 Flexible engine mounts
35 Aftercooler
36 Oil sump drain pump
37 Drain plug after cooler condens water
38 Drain plug after cooler raw water
39 Starter motor
40 Gearbox ller cap/ oil dipstick
41 Gearbox
35 3633 34 37 38 39 40 41
13
2 Introduction
Identication of engine parts D6
1 Fuel return pipe connection ø 10 mm
2 Calorier connection, engine ‘OUT’
3 Oil dipstick
4 Oil ller cap
5 Lifting eye
6 Cooling system drain plug, heat exchanger
cover, raw water
7 Heat exchanger
8 Filler cap (pressure cap) for cooling system
9 Cooling system drain plug, heat exchanger
10 P.T.O. (Mounting facility for hydraulic
pumps)
11 Fuel lter
12 Oil cooler
13 Alternator
14 V-belt alternator
15 Oil lter
16 Fuel supply pipe connection ø 12 mm
17 Fuel lift pump
18 V-belt alternator fuel pump / coolant pump
19 P.T.O. (Mounting facility for extra belt pulley)
20 Coolant pump
21 Calorier connection, engine ‘IN’
1 2
VD6.170 VD6.210
3 4 5 6 7 8 9
14
10 12 13 14 15 16 17 18 19 20 21
11
2 Introduction
Identication of engine parts D6
VD6.170 VD6.210
22 23 24 26 27 29 30 31 32
25 28
22 Air intake lter
23 Turbocharger
24 Exhaust injection bend
25 Raw water 'out' for prop shaft lubrication
26 Connection airvent
27 Exhaust insulator
28 Lifting eye
29 Relays and fusses
30 Gearbox lube oil cooler
31 Raw water pump
32 Raw water inlet ø 32 mm
33 Cooling system drain plug, block
34 Flexible engine mounts
35 Aftercooler
36 Oil sump drain pump
37 Drain plug after cooler condens water
38 Drain plug after cooler raw water
39 Starter motor
40 Gearbox ller cap/ oil dipstick
41 Gearbox
35 3633 34 37 38 39 40 41
15
2 Introduction
4
Panel, model MPA34
Control panels
2 31
1 Temperature gauge, coolant
2 Tachometer/Operating hours counter
5
6
3 Voltmeter
4 Oil pressure gauge
5 Display
6 Starter pre-heat switch/lock
16
2 Introduction
Control lever
neutral
gearbox reverse gearbox forward
forward throttlereverse throttle
Single lever control
handle for two engines
5 Operating lever
Operating lever for 1 or 2 engines. The engine or engines are typically controlled
Single lever control
handle for 1 engine
with a single-lever.
Depending on the brand and type (mechanical or electronic), there may be minor differences 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 diagram.
Starting from neutral put the engine in ahead
or astern by moving the lever 35° forwards or
backwards.
The throttle lever operates at an angle of 60°
forwards and 60° reverse.
17
3 First commissioning
Engine Oil 10W40 of 15W40
API: CD, CE, CF of CF4
ACEA: D4, D5
For example:
- Vetus Marine Diesel Engine Oil 15W40
- Shell Rimula R4 L 15W40
litres Imp. pt US pt
4 cyl. : 8,5 15 18
6 cyl. : 14 24.6 29.6
1 Commissioning the engine
Before starting the engine for the rst time,
the following procedures must be carried out:
OIL
2 Filling with engine oil
As a rule engines are delivered empty of oil.
• Fill the engine with oil through the ller
neck on top of the valve cover.
For quantity and oil specication see page
108 and 116.
• Check the oil level with the dipstick, see
page 42.
18
3 First commissioning
Vetus engines are normally equipped
with ZF-Hurth gearboxes.
In case your engine is equipped with
another brand of gearbox follow the
instructions given in the supplied owners manual for changing oil and other
care and maintenance.
3 Filling gearbox with oil
OIL OIL
17
• Fill the gearbox with oil.
For quantity and oil specication see page
118.
• Check the oil level with the dipstick, see
page 56.
19
3 First commissioning
COOLANT
2
1
4 Filling the cooling system
• Remove the pressure/filler cap on the filler
neck of the heat exchanger (1).
• Remove the expansion tank filler cap (2).
• Fill the cooling system via the filler neck on
the engine’s heat exchanger.
Use a mixture of 40% antifreeze (ethylene-glycol based) and 60% tap water or use a special
coolant.
For specications see page 119.
Coolant quantity:
litres Imp. pt US pt
4 cyl. : 8 14.1 16.9
6 cyl. : 11 19.4 23.2
Fill until the coolant is level with the bottom
of the filler neck.
Bleeding will take place automatically during
lling!
note
If a water heater is connected to the engine,
see page 22 and 23.
20
Caution
Never ll the cooling system with sea water or
brackish water.
3 First commissioning
COOLANT
COOLANT
2
1
• Replace the pressure/filler cap (1). • Fill the expansion tank until the coolant is at
the minimum level.
• Replace the filler cap (2) on the expansion
tank.
• After the first 3 times that the engine has
been in operation, such that the operating
temperature has been reached and the engine has cooled back to the ambient temperature, the coolant level in the expansion
tank must be checked.
If necessary, add coolant.
Caution
Never ll the cooling system with sea water or
brackish water.
21
3 First commissioning
5 Filling coolant system, if a water heater
is connected -1-
highest point of the water heater is situ-
The
ated at a loWer level than the expansion tank
for the ship’s engine.
PRESSURE CAP
1
(1.5bar)
• Follow the filling instructions as shown on
pages 20 and 21.
OPEN CAP
2
Use a mixture of 40% antifreeze (ethylene-glycol based) and 60% tap water or use a special
coolant.
The water heater will be filled and bled auto-
matically during lling of the cooling system.
22
For specications see page 119.
Caution
Never ll the cooling system with sea water or
brackish water.
3 First commissioning
OPEN CAP
2
3
6 Filling coolant system, if a water heater
is connected -2-
highest point of the water heater is situ-
The
ated at a higher level than the expansion tank
for the ship’s engine.
The water heater will not be filled and bled
automatically during lling of the cooling
system.
PRESSURE CAP
1
(1.5bar)
• Open valve (3) during lling and bleeding
the system.
• Follow the filling instructions as shown on
pages 20 and 21.
note
• Remember to close valve (3) after lling the
system.
Use a mixture of 40% antifreeze (ethylene-glycol based) and 60% tap water or use a special
coolant.
For specications see page 119.
Caution
Never ll the cooling system with sea water or
brackish water.
23
3 First commissioning
FUEL
Warning
Never ll the fuel tank while the engine is
running. Do not spill fuel. Prevent unnecessary pollution.
Neutral
(No throttle, gearbox
not engaged)
7 Fuel
• Ensure that the fuel tank is lled with diesel
fuel.
Use only clean, water-free, commercial approved diesel fuel.
For fuel grade see page 114.
The fuel system is self-bleeding.
24
8 Other preparations
• Check that the battery is charged and check
the battery cable connections.
• Set the main switch to position ‘
• Open the sea cock.
on’.
• Check that the gearbox control lever is set
to ‘neutral’.
3 First commissioning
9 Test run
OIL
• Start the engine.
How to start the engine and what to check
before, during and immediately after starting is described on page 30 and further.
• Allow the engine to test run for about 2
minutes at idling speed .
• Stop the engine
• Check the oil level. If necessary top up to
the indicated level.
• Start the engine.
• Allow the engine to test run for about 10
minutes at idling speed.
• Stop the engine.
• Check that the engine and all connections
(fuel, coolant and exhaust) for leaks.
Caution
Stop the engine immediately if it makes
any strange noises, vibrates excessively or
if black smoke comes out of the exhaust!
25
3 First commissioning
10 Checking the coolant level
Once the engine has reached operating temperature, check the coolant level in the expansion tank.
• Vary the revolutions between idling and
2000 rev/min.
• Add coolant if necessary.
With a warm engine, the level will be slightly
higher as indicated.
26
• Check the coolant temperature.
11 Sea trial
• Check the operation of the remote control.
- Carry out a sea trial
At full load (when the vessel is in motion), the
maximum RPM must correspond to the value
specified in the technical data. The engine
can become overloaded if it doesn’t reach this
RPM! In this case, check the propeller for irregularities and the correct choice of speed and
diameter.
4 Running-in
In order to ensure a long life for your engine,
please observe the following for the first 50
operating hours:
• Allow the engine to reach operating temperature before applying a load.
• Avoid fast acceleration.
• Do not allow the engine to run faster than
3/4 of maximum RPM.
After the rst 50 operation hours carry out the
following maintenance:
• Drain water from fuel lter, see page 45.
• Engine oil change, see page 47.
• Replace oil lter, see page 49.
• Change gearbox oil, see page 56.
• Replace fuel lter, see page 58.
• Check exible engine mounts, see page 59.
• Check engine for leaks, see page 59.
• Check tightness of all fasteners, bolts and
nuts, see page 59.
• Checking V-belts, see page 60.
27
5 Use
General guidelines for use
General guidelines
Implementing the following recommendations will result in longer life and better performance and more economical operation of
your engine.
• Carry out the maintenance described regularly, including the ‘Daily procedures before
starting’.
• Use anti-freeze in the engine coolant all
year long, this helps prevent corrosion as
well as protecting against frost damage. For
specications see page 119.
28
• Never run the engine without a thermostat.
• Use a good quality lubricating oil. For specications see page 116.
• Use a good quality diesel fuel that is free of
water and other pollutants.
• Always follow the safety advice, see page 4.
5 Use
General guidelines
note
First commissioning
Follow the instructions given for ‘First commissioning’ on page 18 and further if the engine is being commissioned for the rst 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.
29
5 Use
Starting
Before starting, always check the following
points:
• Engine oil level.
• Coolant level.
• Sea cock open.
• Main switch ‘on’.
• Gearbox in ‘neutral’ position.
Neutral
(No throttle, gearbox
not engaged)
1 Control lever
Before starting the engine, always check that
the control lever(s) is (are) in the neutral
position.
Leave the control lever in position ‘neutral’.
2 Control panel
The control panel is equipped with a starter
key.
30
5 Use
3 Switching on
Starting
• Turn the start key on the instrument panel
clock-wise; the warning lights for oil pressure and alternator will now light up and
the alarm buzzer will sound.
By default, Vetus Deutz engines are not equipped with a pre-heat supply; the pre-heat
switch/lock position on the operator panel
can therefore be ignored.
31
5 Use
4 Starting
Starting
Now turn the key further to the ‘
tion.
32
start’ posi-
Release the key as soon as the engine res
(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 re
within 10 seconds.
Let the starter motor cool for 30 seconds before turning the key to the ‘start’ position
again.
5 Use
Starting
Check that there are no oil pressure and alternator warnings indicated in the display.
The cooling water should now flow out of the
outlet; if this doesn’t happen, stop the engine
immediately.
Before fully loading the engine, it should be
brought up to temperature with about 3/4
of the maximum load as quickly as possible.
A good warming up is essential to ensure
maximum life and performance.
Caution
Never turn the main switch o 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.
33
5 Use
Cruising
5 Tachometer
The instrument panel is provided with the following instruments
34
Indicating the number of revolutions per minute of the engine.
Also the number of running hours is indicated.
Warning
Avoid idling for more than 10 minutes.
This can lead to carbon deposits in the combustion chambers and incomplete combustion of fuel.
5 Use
Cruising
6 Voltmeter
Indicating the battery voltage.
When the engine is running, the battery voltage should be between 12 and 14 Volts.
With the engine stopped and the start key in
the rst position, the voltmeter should indicate 12 Volts.
7 Temperature gauge
Indicating the temperature of the internal
cooling system.
Fot the operating temperature, see technical
data page 109.
In case the engine is overheated: turn o the
engine and establish the cause, see fault nding table, page 96..105.
8 Oil pressure gauge
With the engine at operating temperature,
the oil pressure is:
When idling: at least 1 bar (7 psi).
In case the oil pressure is too low: turn o the
engine and establish the cause, see fault nding table, page 96..105.
35
5 Use
Cruising
9 Warnings
When the engine is running, no warnings
should be displayed.
36
10 Alarm buzzer
Oil pressure, battery charging and temperature indicator lights are all connected to
an alarm buzzer. If this alarm buzzer sounds
while running, Stop the engine immediately!
5 Use
Neutral
11 Stoppen
Stopping
note
Never switch off the battery main switch directly after the engine has stopped.
Wait at least 2 minutes.
The ECU remains active for about another
40 seconds to save the system data (lag) and
then switches off automatically.
Warning
The engine can not be restarted, if the system
data is not been saved!
• Reduce engine speed to idle and shift the
gearbox to ‘Neutral’.
• Turn the key anticlockwise to the "Off" position.
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.
N.B. The ‘
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.
stop’ position, left of the ‘oFF’ posi-
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 o.
37
6 Maintenance
Introduction
Introduction
The following guidelines should be observed
for daily and periodic maintenance. Perform
each function at the indicated time interval.
The intervals stated are for normal operational conditions. Service the unit more frequently under severe conditions.
38
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.
6 Maintenance
Introduction
Keep record of the following information
in the logbook and/or the ‘Service and Warranty Manual’:
- Total engine hours (reading engine hour
counter).
- Amounts of oil, fuel and coolant needed for
topping up.
- The dates and intervals at which the oil and
coolant are changed.
- Oil pressure and coolant temperature.
- Parts on which maintenance is 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.
39
6 Maintenance
Maintenance schedule
Every 10 hours or daily, before starting page
Check engine oil level 42
Check coolant level 43
Check water strainer 44
After the rst 50 hours page
Drain water from fuel lter 45
Engine oil change 47
Replace oil lter 49
Check gearbox oil level 56
Replace fuel lter 58
Check exible engine mounts 59
Check engine for leaks 59
Check tightness of all fasteners, bolts and nuts 59
Check V-belt 60
Every 100 hours, at least once every year page
Drain water from fuel lter 45
Engine oil change 47
Replace oil filter 49
Draining the charge-air cooler 51
Battery, cables and cable connections 52
Check gearbox oil level 56
Every 500 hours, at least once every year page
Change gearbox oil 57
Replace fuel filter 58
Check flexible engine mounts 59
Check engine for leaks 59
Check tightness of all fasteners, bolts and nuts 59
Check V-belt 60
Danger
Stop the engine before carrying out any maintenance work
40
6 Maintenance
Maintenance schedule
Every 1000 hours, at least once every 2 years page
Raw water pump inspection 62
Replace air filter 65
Every 1000 hours page.
Check starter motor 66
Check alternator 66
Every 1500 hours page
Checking valve clearance 67
Every 2000 hours page
Replace coolant 70
When required page
Cleaning heat exchanger 73
Cleaning the after cooler 78
Danger
Stop the engine before carrying out any maintenance work
41
6 Maintenance
OIL OIL
Checking engine oil level
Daily, before starting.
1 Check oil level
• Turn the engine o.
The dipstick is located on the starboard side
of the engine.
42
2 Oil level
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.
[1]
The dierence be-
tween the two oil
level marks is:
[1]
.
litres Imp. pt US pt
4 cyl. : 1.5 2.6 3.2
6 cyl. : 2 3.5 4.2
3 Topping up oil
The oil lling cap is on top of the the valve
cover.
6 Maintenance
Checking coolant level
Daily, before starting.
COOLANT
4 Checking coolant level
• Check the coolant level in the header tank.
This has to be checked when the engine is
cold.
• Remove the cap of the ller neck on the
heat exchanger.
Warning
Never open the cap on the header tank when
the engine is at operating temperature.
5 Coolant level
The coolant must be at the minimum level.
note
If a water heater is connected, see page 22
and 23.
6 Topping up coolant
• If necessary, top up.
The internal cooling system can be lled with
a mixture of anti-freeze (40 %) and tap water
(60 %) or with a special coolant.
For specication, see page 119.
Caution
Never ll the cooling system with sea water or
brackish water.
43
6 Maintenance
Checking and cleaning the raw water strainer
Daily, before starting.
7 Checking the raw water strainer
• Check daily whether there is any dirt in the
raw water strainer.
44
8 Cleaning the strainer
• Close the seacock before removing the lid
of the water strainer.
• Clean the raw water strainer as often as is
necessary, depending on the pollution of
the waterways, but at least once every 6
months. A clogged raw water strainer will
result in excessive temperatures or overheating 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 will result in overheating of the
engine.
6 Maintenance
9 Waterafscheider aftappen
Draining of water from the water separator/fuel lter
Every 100 operating hours.
Empty the separately installed water separator:
• Disconnect the sensor connector (plug connection)
• Unscrew the drain plug/sensor on the underside of the filter.
• Allow the water to drain out and close the
drain plug/sensor.
• Reconnect the sensor connector.
The water separator is not engined mounted,
but installed is required and the sensor must
be connected.
Danger
Do not smoke when draining o water and
sediment. Keep ame and sources of ignition
out of the area. Remove spilled fuel and litter
before you start the engine.
45
6 Maintenance
Draining of water from the water separator/fuel lter
Every 100 operating hours.
10 Bleeding
After the water separator/fuel lter has been
drained, the air has to be bled from the fuel
system
The fuel system is self-bleeding.
46
11 Start the engine
• Operate the starter switch until the engine
res; release the starter switch if the engine
does not re 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 after a short time.
6 Maintenance
12 Engine oil change
Engine oil change
Every 100 operating hours.
Change the engine oil every 100 hours of
operation (together with engine oil lter replacement).
If the engine runs less than 100 hours during
the year the oil should be changed at least
once a year.
Run the engine for a few minutes before
changing the oil; warm oil can be pumped
out more easily.
Change the oil with a switched o 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 collected in a container for proper disposal according to laws and regulations.
Warning
Never use additives.
This could cause damage to the engine which
is not covered by the guarantee.
47
6 Maintenance
Engine oil change
Every 100 operating hours.
OPEN
SA
CLOSE
13 Draining the oil
The battery master switch must be on and the
engine must be stopped; the starter key on
the control panel must be in the OFF position.
48
Connect a Ø 10 mm hose to the crankcase oilchange pump as shown.
Open the shut-off valve ‘A’.
Turn on the oil-change pump with the switch 'S'.
Turn off the pump when all the oil is pumped
out of the crankcase.
Danger
Beware of burns from hot oil.
Warning
The engine oil must be disposed in accordance with the applicable environmental regulations.
6 Maintenance
Engine oil change
Every 100 operating hours.
O
L
I
F
I
R
L
E
T
14 Removing the oil lter
• Unscrew the oil lter, with a commercially
available tool.
Catch any dripping oil.
Danger
Beware of burns from hot oil.
15 Oiling the oil seal
• Clean the contact surface of the gasket.
• Lubricate the oil seal of the new lter element with clean engine oil.
For oil filter art. code see page 124.
16 Oil lter installation
• Install the lter in accordance with the instructions printed on the lter element
housing.
Tightening torque 11 - 13 Nm (8-10 ft.lbf)
49
6 Maintenance
17 Relling with oil
Engine oil change
Every 100 operating hours.
amount oF oil (oil Filter inCl.):
litres Imp. pt US pt
4 cil. : 8,5 15 18
6 cil. : 14 24.6 29.6
• Rell the engine with new oil (for specication see page 116) through the ller opening in the valve cover.
50
• 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.
6 Maintenance
18 Draining the charge-air cooler
Draining the charge-air cooler
Every 100 operating hours.
The condensate water collected in the charge-air cooler must be drained every 100 hours
or at least 1 x per year.
• Remove the drain plug from the charge-air
cooler housing and check that all condensate water is running out.
• After drainage, replace the drain plug.
51
6 Maintenance
Warning notes and safety regulations for
working with batteries
Wear eye protection.
Corrosive hazard:
Battery acid is highly corrosive, therefore:
Battery, cables and connections
Every 100 operating hours.
Warning note:
• Do not place batteries in direct daylight without protection.
Keep children away from acid and batteries.
Explosion hazard:
A highly-explosive oxyhydrogen gas
mixture occurs when charging batteries, therefore:
Fires, sparks, naked ames and smoking are prohibited:
• Avoid causing sparks when dealing
with cables and electrical equipment, and beware of electrostatic
discharges.
• Avoid short-circuits.
52
• Wear protective gloves and eye protection.
• Do not tilt battery, acid can escape
from the degassing openings or
vents.
First aid:
• Rinse o 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 neutralizer (soda) or soap suds and
rinse with plenty of water.
• If acid is consumed, consult a doctor immediately.
• Discharged batteries can freeze up,
therefore store in an area free from
frost.
Disposal:
Hand in old batteries at a collection
point.
Pb
Keep the batteries upright and do not
tip during transport and storage to
prevent acid leaking out.
Never dispose of old batteries as domestic waste.
Careful! Metal parts of the battery will
are always live so never lay objects or
tools on the battery.
6 Maintenance
19 Battery, battery connections
Battery, cables and connections
Every 100 operating hours.
Keep battery clean and dry.
• Remove battery cables (negative rst).
• 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.
53
1
Vetus maintenance-free batteries
GREEN DOT
ALL DARK
CLEAR
6 Maintenance
Battery, cables and connections
Every 100 operating hours.
20 Checking specic gravity
Every Vetus Maintenance-free battery has a
hydrometer (1) built into the cover.
Visual inspection of the hydrometer will show
one of three conditions:
54
21 Hydrometer operation
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 overcharging
the battery for a long period of time with a
voltage too high, replace battery. Check alternator and/or voltage regulator.
6 Maintenance
Battery, cables and connections
Every 100 operating hours.
Conventional batteries
22 Checking electrolyte level
For conventional batteries it is required to
check the electrolyte level regularly. Remove
vent caps (taking care no spark or open ame
is nearby) and inspect the level. Fluid should
be 10 to 15 mm (
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.
3
/8” to 5/8”) above top of all
Conventional batteries
23 Checking specic gravity
Measure the electrolyte specic gravity of the
individual cells with a commercial hydrometer. The hydrometer reading (see table) indicates 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.
Specic
gravity
1,.8 kg/l 100%
1.20 kg/l 50% recharge
1.12 kg/l 10%
During checking the temperature of the electrolyte should preferably be 20°C (68°F).
Measuring the specic gravity shortly after
water has been added results in an incorrect
measurement. First charge the battery to mix
the added water thoroughly.
State of
charge
recharge
immediately
55
6 Maintenance
Vetus engines are normally equipped
with ZF-Hurth gearboxes.
In case your engine is equipped with
another brand of gearbox follow the
instructions given in the supplied owners manual for changing oil and other
care and maintenance.
Gearbox oil level check
Every 100 operating hours.
24 Oil level check
56
• Unscrew the dipstick out of the gearbox
housing.
• Check the oil level by cleaning the dipstick and lowering it into the hole, without
screwing it in.
The oil level must between the end and the
mark on the dipstick.
• If necessary top up by pouring oil in the
dipstick hole.
For oil type and specication see page 118.
• Remember to replace the dipstick.
6 Maintenance
25 Draining the oil
14 / 17
Changing the gearbox oil
Every 500 operating hours.
OIL
26 Filling with new oil
Drain the oil with the aid of a separate sump
pump.
• Remove the dipstick.
• Insert the suction hose of the sump pump
in the dipstick hole. Push down the pump
handle quickly and pull it up slowly.
• Remove the sump pump when all the old
oil has been pumped out.
Or, if sucient space below the gearbox is
available, oil can be drained by removing the
drain plug.
• Remove the llercap to vent the gearbox
and check if all oil has been drained
• Collect the oil in a dripping pan.
• Rell the gearbox to the correct level via the
dipstick opening.
For oil specication see page 118.
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.
57
F
U
E
L
6 Maintenance
Fuel lter replacement
Every 500 operating hours.
1 2
27 Removing the fuel filter(s)
The filter elements are to be replaced as a unit.
• Close the fuel shut-off valve.
• Remove the fuel filters with a filter wrench.
Catch any liquid.
Danger
Keep naked ames away when working on
the fuel system. Do not smoke!
58
• Clean any debris from the filter carrier rim.
• Lubricate the rubber gasket sparingly with
clean motor oil.
• Fill the new filter with clean diesel oil.
For fuel filter art. code see page 124.
N.B. 4 cylinder engine has 1 filter element
instead of 2
28 Installing the fuel filter(s)
• Install the filters. Turn the filter an additional one-half to three-quarters of a turn
by hand after the rubber seal touches the
housing.
• Open the fuel shut-off valve.
• Check for leakage.
After the replacement of the fuel filters, it is
not necessary to bleed the system.
The fuel system is self-bleeding.
6 Maintenance
Flexible engine mounts, hose connections and fasteners
Every 500 operating hours.
29 Check exible engine mounts
• Check the bolts which secure the damper
element, the mounting bolts to engine bed
and the nuts at the adjustment spindle for
tightness.
• Inspect the rubber element of the engine
support for cracks. Also check the deection of the damper element, the deection
inuences the alignment of engine and
propshaft! Re-align engine in case of doubt.
30 Inspection hose connections
• Inspect all hose connections of the coolingsystem. (Cracked hoses, loose hose
clamps)
31 Check fasteners
• Check tightness of all fasteners, bolts and
nuts.
59
6 Maintenance
Checking the V-belts
Every 500 operating hours.
32 Remove the V-belt protection cover
• Loosen the the screws -the screws can be
loosened without tools- and remove the
V-belt protection.
Danger
Check, tension and change belts only with the
engine o. Ret belt guard, if provided.
60
33 Inspection V-belts 34 Checking tension
• Inspect the belts for wear and tear (fraying
and cracking). Belts which are in poor condition should be replaced.
For V-belt art. code see page 124.
• Check tension of the V-belt by applying
moderate nger and thumb pressure. If the
deection of the belt is more than 9 (3/8”)12 mm (1/2”), using about 10 kg (20 lbs)
thumb pressure, it should be tensioned.
6 Maintenance
Checking the V-belts
Every 500 operating hours.
1
2
35 Tensioning the V-belt of the coolant
and fuel pumps
• Unscrew the bolts (1) and (2).
• Turn the fuel pump tensioner in the direction of the arrow, using a square 1/2“ key
(a), until the tension of the belt is correct.
• Tighten the bolts (1) and (2).
3
1
2
36 Tensioning V-belt
• Unscrew the mounting bracket bolts and
both of the alternator mounting bolts. Now
push the alternator outwards until the belt
has the desired tension.
• Tighten the bolts in the order shown.
37 Reinstall the protection cover
• Always reinstall the V-belt cover and tighten the screws.
61
6 Maintenance
38 Raw water pump inspection
39 Pump cover removal
Raw water pump inspection
Every 1000 operating hours.
1,6 x 6,3
40 Impeller removal
The rubber impeller of the outboard water
pump is not proof against running dry.
If the water supply has been blocked, it may
be necessary to replace the impeller. Always
carry a spare impeller on board.
62
Inspection where appropriate changing is as
follows:
• Close the sea cock.
• Remove the cover of the pump by unscrewing the screws out of the housing.
• Slide the impeller o of the shaft using a
waterpump plier.
• Mark the impeller to ensure correct re-installation if it is to be re-used. The impeller
must be installed in the same position as
removed.
6 Maintenance
Raw water pump inspection
Every 1000 operating hours.
1
41 Impeller inspection
• Inspect the impeller for damage.
• Replace the impeller if necessary.
42 Pump housing inspection
• Check the inside of the pump housing for
damage. Pay special attention to wear of
the cam (1).
• Replace the cam and/or the pump housing
in case of excessive wear.
63
6 Maintenance
Raw water pump inspection
Every 1000 operating hours.
43 Re-install the impeller
• The impeller should be lubricated with
glycerin or a non-petroleum based lubricant such as a silicone spray before tting 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).
64
44 Reinstall the pump cover
• Replace the cover with a new O-ring.
• Check the water filter and open the sea
cock.
For O-ring art.code see page 124.
6 Maintenance
3
1
45 Vervangen luchtlter
Air lter replacement
Every 1000 operating hours.
2
• Cut the Ty-rap (1).
• Loosen the hose clamp (2).
• Remove the filter housing (3).
• Replace the filter.
• Install the unit in reverse order, tighten the
hose clamp and fit a new Ty-rap.
For air filter art. code see page 124.
Warning
Never clean the element with petrol or hot
liquids.
Never apply any oil to the air lter.
Never start the engine without the air lter in
place.
65
6 Maintenance
Checking the starter motor and alternator
Every 1000 operating hours.
46 Checking the starter motor
• Check for visible defects.
• Check whether the Bendix engages with
the starter ring when the starter motor is
activated. If the Bendix does not engage
properly, contact your Vetus dealer.
66
47 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.
6 Maintenance
Checking valve clearance
Every 1500 operating hours.
48 Checking / adjusting valve clearance
Checking the valve clearance must be done
with a cold engine, that is an engine which
did not run for at least 6 hours.
13
2
6
1
49 Remove upper cover
• Close the sea cock.
• Disconnect the hoses (1) and (2).
• Remove the 4 bolts and remove the upper
cover.
50 Remove the V-belt protection cover
• Loosen the the screws -the screws can be
loosened without tools and they have anti-loss rings- and remove the V-belt protection.
note
After checking / adjusting the valve clearance
re-install the V-belt protection and the upper
cover and re-connect the hoses.
67
6 Maintenance
51 Adjusting the valve clearance
Checking valve clearance
Every 1500 operating hours.
1 Lock nut
2 Adjusting screw
3 Angle gauge
4 Key socket for socket wrench
5 Magnet
Check valve clearance and adjust if necessary
• Allow the engine to cool down for at least
30 minutes before you adjust the valve
clearance: lube oil temperature less than
80°C.
• Loosen the screws.
• Remove the valve cover.
68
• Remove the gasket.
• The turning tool is placed on the mounting
screws of the pulleys.
• Rotate the crankshaft until the valves overlap.
Exhaust valve is not yet closed, inlet valve
starts opening.
6 Maintenance
Determine which cylinders should be adjusted from the setup chart:
Checking valve clearance
Every 1500 operating hours.
VD4
Valve overlap Setting the cylinder
1 4
3 2
4 1
2 3
• Place the angle gauge with the key socket
on the adjusting screw.
• Fix the magnet of the angle gauge.
• Turn the angle gauge in a clockwise direction until it is seated (rocker arm has no play)
and turn the scale to zero.
VD6
Valve overlap Setting the cylinder
1 6
5 2
3 4
6 1
2 5
4 3
• Rotate the angle gauge anticlockwise until
you reach the specified rotational angle:
Valve clearance IN Inlet valve 75° +10°
EX Exhaust valve 120° +10°
69
6 Maintenance
52 Coolant replacement
Coolant replacement
Every 2000 operating hours.
The coolant has to be replaced every 2000 operating hours or at least once every two years.
N.B. Replacing the coolant may also be necessary as part of the winter storage procedure;
in case that the coolant present in the cooling
system oers insucient protection for the
winter.
70
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 environmental regulations.
6 Maintenance
1
1
Coolant replacement
Every 2000 operating hours.
2
18
53 Draining of coolant
• Remove the drain plug from the heat exchanger housing (1).
• Remove the filler cap to bleed the cooling
system and check that all the fluid is running out.
• Refit the drain plug after all the liquid has
run out.
19
N.B. A small part of the coolant will remain
in the engine block.
• If necessary, remove the drain plug (2) from
the engine block to fully drain the engine.
71
6 Maintenance
54 Filling the cooling system
Coolant replacement
Every 2000 operating hours.
• Fill the cooling system as indicated on pages 20 to 23.
Use a mixture of 40% antifreeze (ethylene-glycol based) and 60% tap water or use a special
coolant.
For specications see page 119.
72
Coolant quantity:
litres Imp. pt US pt
4 cyl. : 8 14.1 16.9
6 cyl. : 11 19.4 23.2
• Check the coolant level in the expansion
tank after the engine has first been in operation, such that the operating temperature has been reached and the engine has
cooled back to the ambient temperature.
Top up, if necessary.
Caution
Never ll the cooling system with sea water or
brackish water.
6 Maintenance
Cleaning the heat exchanger
note
Cleaning of the heat exchanger is not a
routine maintenance job.
Only clean 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.
73
6 Maintenance
1
Cleaning the heat exchanger
18
55 Draining the coolant
• Remove the drain plug in the heat exchanger housing to drain the coolant.
74
• Remove the filler cap to bleed the cooling
system and check that all the fluid is running out.
• Refit the drain plug after all the liquid has
run out.
1,2 x 6,5 7
56 Disconnecting raw water hoses
• Close the tap of the raw water supply.
• Disconnect both raw water hoses.
6 Maintenance
Cleaning the heat exchanger
1
5
57 Remove the nuts from the end covers
• Remove the 3 nuts from both end covers.
• Take off the end cover (1) with the O-ring
from the housing.
2
• Take off the connector cover (2) with the
gasket from the housing.
58 Remove heat exchanger
• Slide the heat exchanger out of the housing.
• Remove the gasket from the heat exchanger
75
6 Maintenance
59 Cleaning the heat exchanger
Cleaning the heat exchanger
• Clean the heat exchanger: Use a pipe cleaner to remove fouling in the pipes.
• Then rinse the heat exchanger pipes with
clean water.
76
• Ensure that both contact surfaces of the
heat exchanger are free from dirt.
• Clean the contact surfaces of the O-ring
and gaskets.
6 Maintenance
Cleaning the heat exchanger
1
60 Replacing heat exchanger
• Place the heat exchanger with a new gasket
(1) in the heat exchanger housing.
3 1 2
61 Replacing the end covers
• Refit the connector cover with a new gasket
(2) to the housing.
• Refit the end cover with a new O-ring. (3)
For gasket set art.code see pg 124.
1,2 x 6,5 7
• Refit all the disconnected hoses.
• Refill the cooling system, see pg. 72.
• Open the tap of the raw water supply.
77
6 Maintenance
note
Cleaning of the after cooler is not a routine
maintenance job.
If the performance of the engine decreases
this can be caused by a dirty heat exchanger
in the after cooler.
The heat exchanger must then be cleaned.
Possible causes of fouling of the tubes of the
after cooler are:
- Small rubber particles from a damaged raw
water pump impeller.
- Growth of algae or seaweed.
Cleaning the after cooler
1,2 x 6,5 7
62 Removing the raw water hoses
• Close the sea cock.
• Remove both the raw water hoses.
78
6 Maintenance
Cleaning the after cooler
1
5
63 Remove the nuts from the end covers
• Remove the 3 nuts from both end covers.
• Take off the end cover (1) with the O-ring
from the housing.
2
• Take off the connector cover (2) with the
gasket from the housing.
64 Removing the heat exchanger
• Slide the heat exchanger out of the housing.
• Remove the gasket from the heat exchanger
79
6 Maintenance
65 Cleaning the heat exchanger
Cleaning the after cooler
• Clean the tube of the heat exchanger; use a
pipe brush and fresh water to remove any
growth in the pipes.
• Then rinse the heat exchanger tubes with
clean water.
80
• Make sure that both surfaces of the after
cooler housing are free from dirt residues.
• Clean the contact surfaces of the O-ring
and gaskets.
6 Maintenance
1
66 Replacing the heat exchanger 67 Fitting end covers
Cleaning the after cooler
312
1,2 x 6,5 7
• Place the heat exchanger with a new gasket
(1) in the charge-air cooler housing.
• Refit the connector cover with a new gasket
(2) to the housing.
• Refit the end cover with a new O-ring. (3)
For gasket set art.code see pg. 124.
• Refit all the disconnected hoses.
• Open the tap of the raw water supply.
81
7 Lay-up / Winter storage procedure
In case of lay-up for a long period the storage procedures as described in this chapter
should be carried out.
A long period means a period longer than 3
months, for example, during the winter period.
Make sure that the engine compartment is
well ventilated during the winter period.
Good ventilation prevents damp in the engine 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 work to be carried out are:
82
7 Lay-up / Winter storage procedure
Inspections and maintenance work to be carried out: page
1 Clean the engine, remove any salt. Paint any rust spots and spray the whole engine with a protective
medium, for example CRC protective 6-66.
2 Drain o the water from the fuel system and ll the fuel tank. 84
3 Make sure that the engine fuel system is lled with a fuel mixture with protective properties. 85
4 Flush out the raw water circuit with fresh water and if necessary ll with antifreeze. Clean the heat
exchanger if necessary.
5 Make sure that the cooling system is lled with a suitable anti-freeze. 87
6 Change the oil lter and the engine oil. 88
7 Change the oil in the gearbox. 88
8 Disconnect the battery cables, charge the batteries if necessary and grease the battery terminals. 89
84
86
83
7 Lay-up / Winter storage procedure
1 2
1 Corrosion protection
The various parts of the engine (except the
engine block) have been treated with an
anti-corrosion protective medium. In order
to prevent corrosion, the engine should be
rinsed o 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.
84
2 Fuel system
• Drain the water from the water separator/
fuel lter and the fuel tank.
Ensure that the tank is completely lled with
fuel.
• Install a new fuel lter. (page 58)
7 Lay-up / Winter storage procedure
3 Protective fuel mixture
• Connect the fuel supply pipe to a can lled
with protective diesel fuel, for example
‘Calibration Fluid’ (ISO 4113) or with a mixture of 1 part of engine oil
clean fuel
[2]
.
• Use this mixture to run the engine at no
load for approx. 5 minutes.
• Stop the engine.
[1]
to 9 parts of
[1]
E.g.:
Caution
Never run the engine under load with
this mixture of fuel and oil.
Engine oil with protective properties.
- Vetus Marine Diesel Engine Oil 15W40
- Shell Rimula R4 L 15W40
tip!
Combine running the engine with the
protective fuel mixture with ushing
the raw water circuit with fresh water,
see ‘Winter storage procedure - Raw
water cooling system’.
[2]
Only use CEN EN 590 Diesel fuel.
Preferably water-free fuel.
Collect some fuel from the return pipe,
while engine is running.
85
7 Lay-up / Winter storage procedure
4 Raw water cooling system
tip!
Combine ushing the raw water circuit
with fresh water with running the engine with the protective fuel mixture,
see ‘Winter storage procedure - Protective fuel mixture’
Heat exchanger
Only clean the heat exchanger if this is
absolutely necessary, see page 73.
Charge-air cooler
Only clean the heat exchanger if necessary, see page 78.
Raw water pump
Check the impeller of the raw water
pump at least once every two years, see
page 62.
• Close the sea cock.
• Remove the lid of the water strainer.
• If necessary, clean the raw water strainer.
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• Connect the raw water intake to a fresh water (tap water) supply or a tank containing
fresh water. Open the tap and allow the engine 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 sucient supply
of water to prevent the engine from overheating.
• Stop the engine and close the sea cock.
• The raw water system must be protected in
areas where the temperature drops to below zero during the winter.
Pour 1 litre (1/4 gallon) of anti-freeze
(preferably a non-toxic biodegradable anti-freeze) into the water strainer and run
the engine until the anti-freeze has disappeared into the cooling system.
7 Lay-up / Winter storage procedure
tip!
Protect the sea cock as follows:
With the motor stopped.
• Place the sea cock in a position that it
is just opening.
• Pour a small amount of non-toxic biodegradable anti-freeze into the raw
water strainer.
• Close the sea cock as soon as it is
lled with anti-freeze.
5 Fresh water cooling system
Anti-freeze can be toxic. Take care that no
anti-freeze is spilled into the waterway
• Check the seal between the lid and housing 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 lled with an antifreeze/water mixture (or a coolant).
For specications see page 119.
N.B. Replacing the coolant is only necessary
if the coolant present in the cooling system
oers insucient protection against temperatures below 0˚C (32˚F).
For coolant replacement see page 70.
87
7 Lay-up / Winter storage procedure
SA
6 Lubrication system
• Drain the oil, see page 48. • Replace the oil lter and change the engine
oil; use oil with protective properties. See
page 47-49.
For quantity and oil specication see page
108 and 116.
88
7 Changing the gearbox oil
• Stop the engine and change the oil of the
gearbox. (page 57)
7 Lay-up / Winter storage procedure
8 Electrical system
note
Never switch off the battery main switch directly after the engine has stopped.
Wait at least 2 minutes.
See page 37.
• Disconnect the battery cables. • Charge batteries during winter lay-up regularly if required!
• Follow the recommendations given on
pages 52 to 55 or consult the recommendations given by the battery supplier for inspection and maintenance of the batteries.
89
8 Recommissioning after lay-up or winter storage
The engine must be inspected and any maintenance work carried out when re-commissioning for example at the beginning of the
sailing season.
Consult a Vetus Dealer if help is required with
this.
Inspections and maintenance work to be carried out are:
Inspections and maintenance work to be carried out are: page
1 Drain the water from the fuel system. 91
2 Check the raw water system. 92
3 Check the coolant level in the internal cooling system. 93
4 Check the oil level. 93
5 Check the batteries and reconnect these. 94
6 Check the operation of the engine. 94
7 Check all hose connections for leaks. 95
8 Check the operation of the instruments and the engine controls. 95
90
8 Recommissioning after lay-up or winter storage
1 Fuel system
• Drain the water from the water separator/
fuel lter. (page 45)
• Drain the water from the fuel tank. • Open the fuel valve.
91
8 Recommissioning after lay-up or winter storage
2 Raw water cooling system
1,6 x 6,3
• Check that the lid of the raw water strainer
is reinstalled.
92
• Check whether the lid of the raw water
pump and drain plugs are reinstalled. (pages 62, 64)
• Re-tighten possible loose hose clamps.
8 Recommissioning after lay-up or winter storage
OIL
• Open the sea cock.
3 Fresh water cooling system
• Check the coolant level. (page43)
4 Lubrication system
• Check the engine oil level. (page 42)
93
8 Recommissioning after lay-up or winter storage
5 Electrical system
• Make sure that the batteries are fully
charged. (page 52, 89)
94
• Connect the batteries.
6 Switching on
• Turn the start key on the instrument panel
clock-wise;
8 Recommissioning after lay-up or winter storage
7 Check engine for leaks
• Start the engine.
• Check the fuel system, the cooling system
and the exhaust for leakage.
8 Checking instruments and remote
controls
• Check the operation of the instruments, the
remote control and the gearbox.
95
9 Troubleshooting
General
Engine faults are in most cases caused by improper operation or insucient maintenance.
Note Not all possible faults mentioned will be
applicable to your engine.
In case of a fault, always check rst that the
operation and maintenance instructions have
been followed.
In the following tables information is given
about the possible causes of faults and suggested remedies. Please note that these tables can never be complete.
96
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 engine with the fuel injection pump removed
removed.
Disconnect battery!
9 Troubleshooting
Fault page
1 Engine will not crank 98
2 Engine cranks but will not start, no smoke from exhaust 98
3 Engine cranks but will not start, smoke from exhaust 99
4 Engine starts but runs unevenly (rough idling) or stalls 99
5 Engine does not reach maximum rpm under load 100
6 Engine overheats 101
7 Engine not ring on all cylinders 101
8 Engine has little or no oil pressure 102
9 Engine oil consumption excessive 102
10 Fuel consumption excessive 103
11 Black exhaust smoke (idling) 103
12 Blue exhaust smoke (idling) 103
13 Black exhaust smoke (at load) 104
Fault nding table
14 White exhaust smoke (at full load) 104
15 Burnt oil trace in exhaust line 105
16 Idle speed >750-800 RPM 105
97
9 Troubleshooting
Fault nding table
1 Engine will not crank
Possible fault Remedy
Faulty or discharged battery (too
low voltage ) .
Fuse blown. Replace.
Loose or corroded connections
in starting circuit.
Wrong engine electric mass
connection.
Faulty starter-switch or faulty
starter-relay.
Faulty starter-motor or pinion
does not engage.
Seized components. Repair.
Control lever not in neutral. Put operating lever in neutral
ECU prevents starting. Check error according to error
Water in the cylinder . Check / Repair .
Check / recharge battery and
check engine alternator and/or
battery charger.
Clean and tighten connections.
Repair.
Check / replace.
Check / replace starter-motor.
code and eliminate fault.
2 Engine cranks but will not start, no smoke from exhaust
Possible fault Remedy
(Nearly) Empty fuel tank. Rell.
Fuel stop valve closed. Open.
Fuel pre-lter clogged . Clean /replace
Fuel lter clogged with water
and/or contamination.
Vent line of fuel supply tank
clogged.
Faulty injector/injection pump.. Check, replace if required.
Leaking fuel supply line or fuel
injection line.
Air in fuel system. Check and bleed.
Fuse burnt out in ECU box. Check/replace.
ECU faulty. Diagnosis -replace .
Exhaust restricted. Check.
Faulty V-belt fuel pump. Replace V-belt.
Compression too low. Check.
Check or replace.
Check / clean.
Check / replace.
98
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