Vetus M Series, M3.28 SOLAS, M2.13, M2.18, M4.15 SOLAS Operation Manual

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M-LINE Marine Diesel Engines

Operation manual

345102.01

Operation manual

Engine serial number Vetus:

Engine serial number Mitsubishi:

M2.13 M2.18 M3.29 M3.28 SOLAS M4.35 M4.15 SOLAS M4.45 M4.17 SOLAS M4.56 M4.55 SOLAS

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 6).

345102.01

We reserve the right to make any changes without previous notice.

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).

This engine has been built exclusively for the application specied 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 modications will invalidate any liability claims against the manufacturer for resultant damage.

Manipulations of the injection and regulating system may also inuence 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 Cylinder numbering and direction of rotation 11 Fuel pump seal 11 Identication of engine parts M2, M3 12 Identication of engine parts M4 14 Control panels 16 Control lever 19

3 First commissioning 20

4 Running-in 31

5 Use 32

General guidelines 32 Starting 34 Starting using the spring starter 38 Cruising 40 Stopping 43

6 Maintenance 44

Introduction 44 Maintenance schedule 46 Checking engine oil level 48 Checking coolant level 50 Checking and cleaning the raw water strainer 52 Draining of water from the water separator/fuel lter 53 Engine oil change 56 Battery, cables and connections 60 Gearbox oil level check 64 Fuel lter replacement 65 Cleaning lter fuel lift pump 66 Bleeding, after fuel lter replacement 67 Changing the gearbox oil 68 Flexible engine mounts, hose connections and fasteners 69 Checking valve clearance 70 Checking the V-belt 74 Checking valve oil sump ventilation 76 Raw water pump inspection 77 Coolant replacement 80 Air lter replacement 84 Checking the starter motor and alternator 85

Checking engine speed 86 Cleaning the heat exchanger 88

7 Lay-up / Winter storage

procedure 92

8 Recommissioning after lay-

up or winter storage 100

9 Troubleshooting 106

10 Technical data 116

Engine specications 116 Gearbox specications 121 Torque wrench settings 122

11 Operating media 124

Fuel 124 Lubricating oil 126 Coolant 129

12 Wiring diagrams 130

13 Overall dimensions 136

14 Parts for maintenance 140

15 Index 141

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.

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, noninammable, 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 inammable 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.

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.

1 Safety measures

Prevention of injury

• Be careful with battery acid! If battery acid comes in contact with the eyes or skin, rinse the aected 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.

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.

2 Introduction

Dear customer,

Vetus diesel engines are designed both for pleasure craft and commercial craft. Consequently, a wide range of variants are oered to meet the requirements of specic 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 dierences 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.

2 Introduction

MXXX---A XXXXXXXXXXXX

Type:

123456 654321

Engine Nr.:

XX XX

Power

Weight, approx.:

BSO cert.:

Meets exhaust emission regulations acc. 94/25/EC, 2003/44/EC Light Diesel Fuel Only (B7Allowed)

kW HP

XXX

XXXXXXXX

MARINE DIESEL ENGINE

SCHIEDAM HOLLAND

XXXX

Mfg Date:

RPM

XX/XXXX

1580

Data tag

Serial number

1 Engine data tag

The Vetus engine serial number and performance data are printed on the engine data tag.

Model and engine serial number must be given when ordering spare parts.

VD00957

2 Engine data tag location

The type plate is positioned as shown.

VD00973

3 Engine serial number

The Mitsubishi engine serial number is stamped on the fuel injection pump.

VD00974

2 Introduction

Cylinder numbering and direction of rotation

Fuel pump seal

4 Cylinder numbering and direction of

rotation

Cylinder numbering

Cylinders are numbered consecutively, beginning at the front end.

Direction of rotation

The direction of rotation is viewed towards the ywheel counter clockwise.

M2 M3

Maximum speed

adjustment screw

Lead seal

VD00950

5 Fuel pump seal

Caution

Breaking the seals on the regulator to alter the settings of maximum rpm and maximum injector volume may only be carried out by authorised Vetus Service personnel.

Lead seal

Maximum speed

adjustment screw

VD00930

Breaking the seals and altering the settings can lead to:

- Accelerated wear of engine components.

- Increased fuel and oil consumption.

- Incorrectly adjusted injector volume and

poor engine performance.

- Breaking emission regulations.

VD00145

2 Introduction

1 Calorier connection, engine ‘IN’

2 Calorier connection, engine ‘OUT’

3 Cooling system air bleed nipple / Con-

nection for extra expansion tank (Keel cooling model only)

4 Oil ller cap

5 Filler cap for cooling system

6 Expansion tank

7 Heat exchanger

8 Cooling system drain plug

9 V-belt

10 Alternator

11 Starter motor

12 Exhaust injection bend ø 40 mm

Identication of engine parts M2, M3

1 2 3 4 5 6 7 8

9 10 11 12

VD02022

2 Introduction

13 14 15 16 17 18 19 20 21 22

Identication of engine parts M2, M3

13 Airvent connection

14 Water separator/Fuel lter

15 Water separator/fuel lter air bleed

nipple

16 Fuse

17 Fuel lift pump

18 Connection electrical system

19 Fuel supply pipe connection ø 8 mm

20 Air inlet silencer / Air lter

21 Oil dipstick

22 Connection for throttle push-pull cable

23 Gearbox ller cap

24 Water separator/fuel lter drain plug

25 Gearbox

26 Fuel return pipe connection ø 8 mm

27 Oil lter

28 Manual operation of electric stop

29 Raw water inlet ø 20 mm

30 Raw water pump

31 Fuel pump air bleed nipple

23 24 25 26 27 28 29 30 31

VD02023

2 Introduction

1 Calorier connection, engine ‘OUT’

2 Cooling system air bleed nipple / Con-

nection for extra expansion tank (Keel cooling model only)

3 Oil ller cap

4 Filler cap for cooling system

5 Expansion tank

6 Heat exchanger

7 Cooling system drain plug

8 Airvent connection

9 Calorier connection, engine ‘IN’

10 V-belt

11 Raw water inlet ø 20 mm

12 Raw water pump

13 Alternator

14 Starter motor

15 Connection for gearbox push-pull cable

16 Gearbox drain plug

Identication of engine parts M4

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

VD00971

2 Introduction

17 18 19 20 21 22 23 24 25 26

Identication of engine parts M4

17 Exhaust injection bend ø 50 mm

18 Water separator/Fuel lter

19 Water separator/fuel lter air bleed

nipple

20 Fuse

21 Fuel lift pump

22 Connection electrical system

23 Fuel supply pipe connection ø 8 mm

24 Air inlet silencer / Air lter

25 Oil dipstick

26 Fuel pump air bleed nipple

27 Gearbox

28 Gearbox ller cap

29 Water separator/fuel lter drain plug

30 Gearbox oil dipstick

31 Fuel return pipe connection ø 8 mm

32 Cooling system drain plug

33 Oil lter

34 Manual operation of electric stop

35 Connection for throttle push-pull cable

27 28 29 30 31 32 33 34 35

VD00972

2 Introduction

1 2

Panel, model MP22 Panel, excl. voltmeter, model MP21

1 Tachometer/Operating hours counter 2 Voltmeter 3 Starter pre-heat switch/lock 4 Warning light high raw water temperature 5 Warning light low oil pressure 6 Warning light high coolant temperature 7 Warning light battery charging

Control panels

VD00576

Panel, model MP10

8 Indicator light pre-heating 9 Warning light gearbox low oil pressure

[1]

This is an option, not tted as standard.

[1]

VD00575

2 Introduction

Control panels,

option

1 2

VD00631

Panel, model MP34 Panels, model MP10, MP22, MP34

for SOLAS engines only

1 Tachometer/Operating hours counter 2 Voltmeter 3 Starter pre-heat switch/lock 4 Warning light high raw water temperature 5 Warning light low oil pressure

8 Indicator light pre-heating 9 Warning light gearbox low oil pressure 10 Temperature gauge, coolant 11 Oil pressure gauge

12 Starter pre-heat switch 6 Warning light high coolant temperature 7 Warning light battery charging

[1]

This is an option, not tted as standard.

1212

VD02043

[1]

2 Introduction

Control panels,

option

1 2

Panel, model MP22 for keel cooled engines with second alternator only

1 2

VD00630

Panel, model MPA22

8 Indicator light pre-heating

9 Warning light gearbox low oil pressure

13 Warning light second alternator

14 Warning light general

[1]

This is an option, not tted as standard.

VD00952

[1]

2 Introduction

Control lever

neutral

gearbox reverse gearbox forward

forward throttlereverse throttle

Single lever control

handle for two engines

Single lever control handle for 1 engine

6 Operating lever

Operating lever for 1 or 2 engines. The control lever works as shown in the dia-

gram.

Starting from neutral put the engine in ahead or astern by moving the lever 35° forwards or backwards. The throttle lever operates at an angle of 60° forwards and 60° reverse.

VD00788

3 First commissioning

Engine Oil 15W40

API: CF4, CG4, CH4, CI4 ACEA: A3/B3, A3/B4, E7

For example:

- Vetus Marine Diesel Engine Oil 15W40

- Shell Rimula R4 L 15W40

litres Imp. pt US pt

M2 : 2.3 4.0 4.9

M3 : 3.4 6.0 7.2

M4 : 5.5 9.7 11.6

1 Commissioning the engine

Before starting the engine for the rst time, the following procedures must be carried out:

OIL OIL

2 Filling with engine oil

VD00976

As a rule engines are delivered empty of oil.

A second oil lling cap is located at the distribution cover.

• Fill the engine with oil through the ller neck on top of the valve cover.

For quantity and oil specication see page

118 and 126.

• Check the oil level with the dipstick, see page 48.

VD00977

3 First commissioning

Vetus engines are normally equipped with Technodrive or ZF-Hurth gearboxes.

In case your engine is equipped with another brand of gearbox follow the instructions given in the supplied owners manual.

OIL OIL

3 Filling gearbox with oil

• Fill the gearbox with oil. Technodrive:

For quantity and oil specication see page

128.

• Check the oil level with the dipstick, see page 64.

VD00975

ZF Hurth:

For quantity and oil specication see page

128.

• Check the oil level with the dipstick, see page 64.

3 First commissioning

COOLANT

4 Filling the cooling system, interCooling,

• Remove the cap (1) of the ller neck on the top of the heat exchanger housing.

• Remove the bolt (2) from the upper side of the thermostat cover, so that air can escape from the cooling system.

If a water heater is connected to the engine, see page 26 and 27. 22

note

VD00978

• Fill the cooling system.

Use a mixture of 40% antifreeze (ethyleneglycol based) and 60% tap water or use a special coolant.

For specications see page 129.

Coolant quantity:

litres Imp. pt US pt

M2 : 2.2 3.9 4.6

M3 : 3.0 5.3 6.3

M4 : 6.5 11.4 13.7

VD00979

Caution

Never ll the cooling system with sea water or brackish water.

3 First commissioning

COOLANT

1 cm

(

/8”)

VD00158

VD00980

VD00981

The level of the coolant must be approx. 1 cm (3/8”) below the lower edge of the ller neck.

Bleeding will take place automatically during lling!

• Replace the ller cap. • Reinstall the bolt in the thermostat cover..

3 First commissioning

1.0 bar

DO NOT OPEN

5 Filling the cooling system, keel Cooling

• Remove the cap ‘do not open’ (1) of the ller neck on the top of the heat exchanger housing.

• Fill the cooling system.

• Reinstall the ller cap ‘do not open’.

Coolant quantity (engine only):

1.0 bar

litres Imp. pt US pt

M2 : 3.0 5.3 6.3

M3 : 4.0 7.0 8.4

M4 : 7.2 12.7 15.2

DO NOT OPEN

Caution

Never ll the cooling system with sea water or brackish water.

VD00925

• • Remove the pressure cap (2) of the extra expansion tank.

Use a mixture of 40% antifreeze (ethyleneglycol based) and 60% tap water or use a special coolant.

For specications see page 129.

VD00932

note

If a water heater is connected to the engine, see page 26 and 27. 24

3 First commissioning

• Top up the extra expansion tank to the minimum level.

VD00929

• Reinstall the pressure cap (2).

VD00953

3 First commissioning

6 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. The water heater will be filled and bled auto- matically during lling of the cooling system.

1.0 bar

DO NOT OPEN

VD00895

• Remove the ‘do not open’ cap (1) and ll the cooling system via the ller neck.

• Add coolant into the expansion tank (2) until minimal level has been reached.

Use a mixture of 40% antifreeze (ethyleneglycol based) and 60% tap water or use a special coolant.

For specications see page 129.

Caution

Never ll the cooling system with sea water or brackish water.

VD00925

3 First commissioning

7 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.

1.0 bar

DO NOT OPEN

VD00896

• Fill the cooling system via the expansion tank (2).

• Open valve (3) during lling and bleeding the system.

note

• Remember to close valve (3) after lling the system.

Use a mixture of 40% antifreeze (ethyleneglycol based) and 60% tap water or use a special coolant.

For specications see page 129.

Caution

Never ll the cooling system with sea water or brackish water.

VD00925

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)

8 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 124.

• Bleed the fuel system, see page 54.

VD00002

9 Other preparations

• Check that the battery is charged and check the battery cable connections.

• Set the main switch to position ‘

on’.

• Open the sea cock.

VD00789

• Check that the gearbox control lever is set to ‘neutral’.

3 First commissioning

OIL

10 Test run

• Start the engine.

How to start the engine and what to check before, during and immediately after starting is described on page 34 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.

VD00982

• 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!

VD00983

3 First commissioning

11 Bleeding

The cooling system must be bled as soon as the engine has reached normal working temperature.

• Open the cap on the ller neck.

• Vary the revolutions between idling and 2000 rev/min.

• Add coolant if necessary.

VD00984

• Replace the cap on the ller neck.

• Check the coolant temperature.

VD00663

12 Sea trial

• Check the operation of the remote control.

• Carry out a sea trial

VD00791

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 53.

• Engine oil change, see page 56.

• Replace oil lter, see page 58.

• Replace fuel lter, see page 65.

• Change gearbox oil, see page 68.

• Check V-belt, see page 74.

• Check exible engine mounts, see page 69.

• Check engine for leaks, see page 69.

• Check tightness of all fasteners, bolts and nuts, see page 69.

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 specications see page 129.

• Never run the engine without a thermostat.

• Use a good quality lubricating oil. For specications see page 126.

• 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 temperature

[1]

or battery charging lights up.

• Always follow the safety advice, see page 4.

[1]

Only engines with intercooling.

5 Use

General guidelines

note

First commissioning

Follow the instructions given for ‘First commissioning’ on page 20 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.

5 Use

Before starting, always check the following points:

Starting

• Engine oil level.

• Coolant level.

• Sea cock open.

• Main switch ‘on’.

• Gearbox in ‘neutral’ position.

Warning

Never start the engine with the fuel injection pump removed. Disconnect battery.

half throttle, gearbox not engaged

1 Control lever

Set the control lever to ‘half throttle’ without engaging the gearbox.

VD00923

2 Control panel

The starter switch on the control panel is key operated or knob operated (for SOLAS engines only).

The knob has exactly the same functions as the starter key.

VD02055

5 Use

Starting

3 Switching on

• 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.

Ambient Tem-

perature

Above + 5°C

(41°F)

+5°C to -5°C

(+41°F to +23°F)

Pre-heating time

about 6 seconds

about 12 seconds

Below -5°C (23°F) about 18 seconds

Maximum pre-

heating time

VD02054

1 minute

4 Pre-heating

The ideal pre-heating time depends on ambient temperature; the lower the ambient temperature, the longer the pre-heating time required. See table.

Caution

To prevent the glow plugs from burning out, never exceed the stated maximum pre-heating time.

• Turn the key further clockwise to the ‘ position.

While pre-heating takes place the preheating indicator light will be on and the alarm buzzer o.

• Hold the key in this position for about 6 seconds.

VD02056

’

5 Use

Starting

5 Starting

Now turn the key further to the ‘ tion.

start’ posi-

VD00109

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.

VD00110

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 the indicator lights for oil pressure and alternator are o.

Cooling water should now ow out of the exhaust; if this is not the case, stop the engine immediately

[1]

Only engines with intercooling.

[1].

VD02057

Let the engine run for 5 to 10 minutes in neutral. A good warm up is essential to ensure maximum lifetime and good performance.

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.

VD00629

5 Use

half throttle, gearbox not engaged

1 2

Starting using the spring starter

(option)

3 4

6 Preparation

• Convince yourself that it is safe to start the engine.

• Set the control lever to ‘half throttle’ with- out engaging the gearbox.

• Turn the start key on the instrument panel clock-wise to the ‘ON’ position.

VD00951

7 Re-set trip mechanism

• Re-set the trip mechanism by lifting the plunger (1) allowing the trip lever (2) to move upwards.

• Place the handle (3) on the spring starter.

VD02005

8 Winding the springs

• Using the handle (3) clockwise to wind the springs.

For a warm engine wind until the white springs are visible through the inspection window (4). For a cold engine wind further until the red springs are visible through the inspection window. Overwinding will reduce the life of the starter.

VD02006

5 Use

3 2

Starting using the spring starter

(option)

Caution

Never leave the spring starter partwound.

note

It is possible to unwind the starter, should the need occur, by turning the handle anti-clockwise. Additional force will be required to overcome the initial friction.

9 Starting

• Remove the handle (3) from the starter.

note

The starter must NEVER be tripped with

the winding handle in place.

VD02008

• Now start the engine by moving the trip lever (2) through 90 degrees until it holds out. Throttle back as soon as the engine runs.

Leave the key in the ‘ON’ position while the engine is running.

VD02007

note

If the engine does not start rst time, allow it to come to a complete rest before retrying.

5 Use

Cruising

Idling speed:

The instrument panel is provided with the following instruments (Depending of the type of panel, see page 16).

10 Tachometer

Indicating the number of revolutions per minute of the engine.

Also the number of running hours is indicated.

M2.13, M2.18

M3.29 M3.28 SOLAS

M4.35 M4.45 M4.15 SOLAS M4.17 SOLAS

M4.56 M4.55 SOLAS

VD00577

Avoid idling for more than 10 minutes.

This can lead to carbon deposits in the combustion chambers and incomplete combustion of fuel.

: 850 rpm

: 900 rpm

: 840 rpm

: 900 rpm

Warning

5 Use

Cruising

11 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.

VD00578

12 Temperature gauge

Indicating the temperature of the internal cooling system. Fot the operating temperature, see technical data page 119. In case the engine is overheated: turn o the engine and establish the cause, see fault nding table, page 106 .. 115.

VD00663

13 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 106 .. 115.

VD00664

5 Use

Cruising

14 Warning lights

None of the ve warning lights should light up while the engine is running.

VD002058

15 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!

VD02059

5 Use

Stopping

Neutraal

16 Stopping

• Reduce engine speed to idle and shift the gearbox to ‘Neutral’.

• Turn the key entirely to the left, through

oFF’ position.

the ‘

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.

VD02045

• When the engine has stopped, turn the key to the ‘oFF’ position.

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.

VD00106

17 Stopping on the engine itself

On the engine itself stopping is possible by pressing the black button on the fuel injection pump. If the fuel supply is not shut o by the electrically operated fuel solenoid stopping of the engine can be done this way.

VD00986

6 Maintenance

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.

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.

6 Maintenance

Maintenance schedule

Every 10 hours or daily, before starting page

Check engine oil level 48

Check engine oil level, at free-fall lifeboats (SOLAS) 49

Check coolant level 50

Check water strainer 52

After the rst 50 hours page

Drain water from fuel lter 53

Engine oil change 56

Replace oil lter 58

Check gearbox oil level 64

Replace fuel lter 65

Check exible engine mounts 69

Check engine for leaks 69

Check tightness of all fasteners, bolts and nuts 69

Check V-belt 74

Every 100 hours, at least once every year page

Drain water from fuel lter 53

Replace oil filter 58

Battery, cables and cable connections 60

Check gearbox oil level 64

Every 250 hours, at least once every year page

Engine oil change 56

Every 500 hours, at least once every year page

Replace fuel filter 65

Cleaning fuel lift pump 66

Change gearbox oil 68

Check flexible engine mounts 69

Check engine for leaks 69

Check tightness of all fasteners, bolts and nuts 69

Check valve clearance 70

Check V-belt 74

Danger

Stop the engine before carrying out any maintenance work

Check valve oil sump ventilation (SOLAS) 76

6 Maintenance

Maintenance schedule

Every 500 hours

Check glow plugs

Check and adjust injector pressure

page

[1]

Every 1000 hours, at least once every 2 years page.

Raw water pump inspection 77

Replace coolant 80

Replace air filter 84

Every 1000 hours page.

Check starter motor 85

Check alternator 85

Check turbocharger

[1]

When required page

Bleeding fuel system 54

Check idle rpm 86

Cleaning heat exchanger

[2]

Danger

Stop the engine before carrying out any maintenance work

[1]

Consult the service manual, work to be carried out by a Vetus Mit-

subishi dealer.

[1]

Only engines with intercooling.

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.

VD00982

2 Oil level

The oil level must be at or near the upper

[1]

mark on the dipstick

• If necessary top up with the same brand and type of oil.

[1]

The dierence between the

two oil level marks is:

VD00155

3 Topping up oil

The oil lling cap is on top of the the valve cover,.

A second oil lling cap is located at the distrubution cover, see page 20.

litres Imp. pt US pt

M2 : 1.25 2.2 2.6

M3 : 1.3 2.3 2.7

M4 : 1.8 3.2 3.8

VD00976

6 Maintenance

Checking engine oil level

For free-fall life boats.

4 Position of the boat

• Determine the angle on which the boat is positioned.

M3: 15 mm (

/8”) M3: 23 mm (7/8”) M3: 30 mm (1 3/16”)

M4: 14 mm (9/16”) M4: 16 mm (5/8”) M4: 18 mm (11/16”)

α = 0° α = 25° α = 30° α = 35°

VD00968

5 Oil level

The oil level must be at or near the with ‘H’ in-

[1]

dicated level on the dipstick

• If necessary top up with the same brand and type of oil.

VD02061

6 Maintenance

Checking coolant level

Daily, before starting.

6 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. 50

COOLANT

1 cm (3/8”)

VD00984

7 Coolant level

The level of the coolant must be approx. 1 cm (3/8”) below the lower edge of the ller neck.

note

For a keel-cooled version, see page 24. If a water heater is connected, see page 26 and 27

COOLANT

VD00158

8 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 specication, see page 129.

Caution

Never ll the cooling system with sea water or brackish water.

VD00987

6 Maintenance

• When topping up coolant, remove the bolt from the upper side of the thermostat cover, so that air can escape from the cooling system.

Checking coolant level

Daily, before starting.

VD00988

6 Maintenance

Checking and cleaning the raw water strainer

Daily, before starting.

9 Checking the raw water strainer

• Check daily whether there is any dirt in the raw water strainer.

note

Only engines with intercooling!

VD00801

10 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.

VD00802

• Check the sealing between the lid and housing after cleaning and re-assembling the strainer. An improperly sealed lid will result in air sucked in by the sea water pump which again will result in overheating of the engine.

6 Maintenance

Draining of water from the water separator/fuel lter

Every 100 operating hours.

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.

11 Empty fuel lter

• Open the drain plug at the lower side of the lter.

• Drain the water and close the drain plug.

VD02038

12 Empty water separator

Empty the separately installed water separator/fuel lter:

• Open the drain plug at the lower side of the lter.

• Drain the water and close the drain plug.

Note : The water separator is not within the scope of supply but installation is required!

VD00803

6 Maintenance

13 Bleeding

Draining of water from the water separator/fuel lter

Every 100 operating hours.

VD00107

VD02011

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.

• Turn the key of the starter switch to position ‘ON’ and the fuel lift pump will feed the fuel system.

• Open the two bleeding nipples to speed up the bleeding process.

One (1) bleeding nipple is located at the lter.

6 Maintenance

Draining of water from the water separator/fuel lter

Every 100 operating hours.

M2 M3

1410

A second bleeding nipple is located at the fuel injection pump.

• Close the bleeding nipples when all air has escaped.

VD02029

2112

VD02028

14 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.

VD00109

6 Maintenance

15 Engine oil change

Engine oil change

Every 250 operating hours.

Change the engine oil every 250 hours of operation (together with engine oil lter replacement).

If the engine runs less than 250 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.

6 Maintenance

Engine oil change

Every 250 operating hours.

16 Draining the oil

• Remove the dipstick; insert the suction hose of the supplied sump pump in the dipstick tube.

• Push down the pump handle quickly and pull it up slowly.

• Pump the sump empty.

VD00997

• After draining remove the suction hose of the sump pump out of the dipstick tube.

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 250 operating hours.

17 Removing the oil lter

• Unscrew the oil lter, with a commercially available tool. Catch any dripping oil.

Danger

Beware of burns from hot oil.

VD00998

18 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 140.

VD00124

19 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)

VD00999

6 Maintenance

Engine oil change

Every 250 operating hours.

amount oF oil (oil Filter inCl.):

litres Imp. pt US pt

M2 : 2.5 4.4 5.3

M3 : 3.6 6.3 7.6

M4 : 5.7 10 12

20 Relling with oil

• Rell the engine with new oil (for specication see page 126) through the ller opening in the valve cover.

VD00976

• 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

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.

• 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.

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

Battery, cables and connections

Every 100 operating hours.

21 Battery, battery connections

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.

VD00117

Ensure that clamps make good contact after reassembling.

• Hand tighten the bolts only.

Vetus maintenance-free batteries

GREEN DOT

ALL DARK

CLEAR

6 Maintenance

Battery, cables and connections

Every 100 operating hours.

22 Checking specic 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:

VD00118

23 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.

VD00121, VD00122, VD00123

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

24 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 (

/8” to 5/8”) above 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.

Conventional batteries

VD00119

25 Checking specic gravity

Measure the electrolyte specic 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.

Specic

gravity

State of

charge

1,.8 kg/l 100%

1.20 kg/l 50% recharge

1.12 kg/l 10%

VD00120

recharge

immediately

During checking the temperature of the electrolyte should preferably be 20°C (68°F).

Measuring the specic gravity shortly after water has been added results in an incorrect measurement. First charge the battery to mix the added water thoroughly.

6 Maintenance

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

Gearbox oil level check

Every 100 operating hours.

26 Oil level check

• Techno Drive, TMC40, TMC60 en TM345:

Take the dipstick out of the gearbox housing by pulling.

• Check the oil level by cleaning the dipstick

and lowering it into the hole up to the rubber grommet and pulling out again. The oil level must between the two marks on the dipstick.

• If necessary top up by pouring oil into the

ller hole.

• ZF keerkoppeling: 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.

VD02001

For oil type and specication see page 128.

• Remember to replace the dipstick.

VD02002

6 Maintenance

27 Fuel lter removal

VD01012

28 Fuel lter installation

VD00154

Fuel lter replacement

Every 500 operating hours.

1 2

VD00133

The fuel lter is to be replaced as a unit.

• Close the fuel stopcock.

• Remove the fuel lter, use a lter wrench. Catch any fuel.

Danger

Keep naked ames away when working on the fuel system. Do not smoke!

• Clean any debris from the lter carrier rim.

• Lubricate the rubber gasket sparingly with clean engine oil.

• Fill the new lter with clean diesel fuel.

For fuel filter art. code see page 140.

• Install the lter. When the rubber gasket touches the housing, apply another tightening of a half to three quarters of a turn by hand.

• Open fuel stopcock.

• Check for leaks.

Fuel lter

6 Maintenance

Cleaning lter fuel lift pump

Every 500 operating hours.

29 Fuel lift pump

• Check, and if necessary clean, lter inside the fuel lift pump.

• Open the fuel stop cock.

• Check for leakage.

For fuel filter art. code see page 140.

VD00954

6 Maintenance

Bleeding, after fuel lter replacement

Every 500 operating hours.

30 Bleeding

• After replacing the fuel lter the air has to be bled from the fuel system.

• For bleeding see page 45.

31 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.

VD00109

• Check for leaks once more.

6 Maintenance

32 Draining the oil

VD02004

14 / 17

Changing the gearbox oil

VD02003

33 Filling with new oil

Every 500 operating hours.

OIL

VD00975

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 sucient 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.

• Rell the gearbox to the correct level via the dipstick opening.

For oil specication see page 128.

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.

6 Maintenance

Flexible engine mounts, hose connections and fasteners

Every 500 operating hours.

34 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 deection of the damper element, the deection inuences the alignment of engine and propshaft! Re-align engine in case of doubt.

VD00806

35 Inspection hose connections

• Inspect all hose connections of the coolingsystem. (Cracked hoses, loose hose clamps)

VD00983

36 Check fasteners

• Check tightness of all fasteners, bolts and nuts.

6 Maintenance

Checking valve clearance

Every 500 operating hours.

1 2

37 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.

38 Remove upper cover

• Close the sea cock.

• Disconnect the hoses (1) and (2).

• Remove the 4 bolts and remove the upper cover.

VD02030

39 Remove the V-belt protection cover

• Loosen the the screws -the screws can be loosened without tools and they have antiloss 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.

VD02036

6 Maintenance

Checking valve clearance

Every 500 operating hours.

40 Remove rocker cover

• Remove the 2 nuts of the rocker cover.

• Complete the following steps:

gearcase

TDC mark

Mark on

VD02040

41 Locating TDC

• Locate the Top Dead Center (TDC), at the end of the compression stroke, for cylinder 1 by barring the engine slowly until the TDC marks of the engine block and the crank pulley match.

Note: There are two TDC’s e.g. compression and suction. At the TDC at the end of the compression stroke the rocker arm does not move when the crank pulley is rotated a little.

Valve clearance:

Inlet 0.25 mm (0.010”) Exhaust 0.25 mm (0.010”)

VD01049

10 1.0 x 5.5

42 Adjusting valve clearance

Cylinders are numbered consecutively, beginning at the front end.

• Check valve clearance at cylinder 1 and adjust if necessary.

• Rotate the crankshaft 180° clockwise and check valve clearance at cylinder 2.

VD00989

6 Maintenance

Checking valve clearance

Every 500 operating hours.

43 Remove rocker cover

• Remove the 2 nuts of the rocker cover.

• Complete the following steps:

gearcase

TDC mark

Mark on

VD02039

44 Locating TDC

• Locate the Top Dead Center (TDC), at the end of the compression stroke, for cylinder 1 by barring the engine slowly until the TDC marks of the engine block and the crank pulley match.

Note: There are two TDC’s e.g. compression and suction. At the TDC at the end of the compression stroke the rocker arm does not move when the crank pulley is rotated a little.

Valve clearance:

Inlet 0.25 mm (0.010”) Exhaust 0.25 mm (0.010”)

VD01049

10 1.0 x 5.5

45 Adjusting valve clearance

Cylinders are numbered consecutively, beginning at the front end.

• Check valve clearance at cylinder 1 and adjust if necessary.

• Rotate the crankshaft 240° clockwise and check valve clearance at cylinder 3.

• Again rotate the crankshaft 240° and check valve clearance at cylinder 2.

VD00989

6 Maintenance

Checking valve clearance

Every 500 operating hours.

46 Remove rocker cover

• Remove the 2 nuts of the rocker cover.

• Complete the following steps:

Note 1: There are two TDC’s e.g. compression and suction. At the TDC at the end of the compression stroke the rocker arm does not move when the crank pulley is rotated a little.

TDC mark for no. 1

TDC mark for no. 2 and no. 3 pistons

Injection timing mark

VD02037

47 Locating TDC 48 Adjusting valve clearance

• Locate the Top Dead Center (TDC), at the end of the compression stroke, for cylinder 1 by barring the engine slowly until the TDC marks of the engine block and the crank pulley match.

Note 2: Cylinders are numbered consecutively, beginning at the front end.

and no. 4 pistons

Mark on gearcase

VD00130

• Check valve clearance at cylinder 1 and adjust if necessary.

• Rotate the crankshaft 180° clockwise and check valve clearance at cylinder 3.

• Again rotate the crankshaft 180° and check valve clearance at cylinder 4.

• Finally again rotate the crankshaft 180° and check valve clearance at cylinder 2.

Valve clearance: Inlet 0.25 mm (0.010”) Exhaust 0.25 mm (0.010”)

12 1.2 x 6.5

VD00990

6 Maintenance

Checking the V-belt

Every 500 operating hours.

49 Remove the V-belt protection cover

• Loosen the the screws -the screws can be loosened without tools and they have antiloss rings- and remove the V-belt protection.

VD02041

50 Inspection V-belt

• Inspect the belt for wear and tear (fraying and cracking). Belts which are in poor condition should be replaced.

For V-belt art. code see page 140.

VD00034

•

Danger

Check, tension and change belts only with the engine o. Ret belt guard, if provided.

6 Maintenance

Checking the V-belt

Every 500 operating hours.

51 Checking tension

• Check tension of the V-belt by applying moderate nger and thumb pressure. If the deection of the belt is more than 12 mm (1/2”), using about 10 kg (20 lbs) thumb pressure, it should be tensioned.

VD00128

52 Tensioning V-belt

• Loosen the bolt of the adjustment bracket and both the alternator mounting bolts. Now push the alternator outwards until the belt tension is correct.

• Now rst re-tighten the upper mounting bolt of the alternator.

• Then re-tighten the bolt of the adjustment bracket and the lower mounting bolt.

1412

VD00129

VD02047

53 Reinstall the protection cover

• Always reinstall the V-belt guard onto the engine.

6 Maintenance

Checking valve oil sump ventilation

Once every year.

54 Checking valve

• Loosen bolt (1) and lift the valve from the engine.

VD02020

• Remove the plug (2).

• Check if the ball (3) can move freely in the valve housing.

• Also inspect the ball for corrosion. A corroded ball needs to be replaced.

note

Only at engines (SOLAS) for lifeboats!

VD02021

• Re-assemble the valve in reverse order.

6 Maintenance

note

Only engines with intercooling!

55 Raw water pump inspection

56 Pump cover removal

101.6 x 6.3

VD02013

57 Impeller removal

Raw water pump inspection

Every 1000 operating hours.

VD02014

The rubber impeller of the outboard water pump is not proof against running dry.

Note The impeller used on SOLAS engines is indeed 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.

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.

The position of the hose connections on the pump may be dierent as in the drawing

• 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.

58 Impeller inspection

• Inspect the impeller for damage.

• Replace the impeller if necessary.

VD00127

For impeller art. code see page 140.

VD02045

59 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.

VD02019

6 Maintenance

Raw water pump inspection

Every 1000 operating hours.

60 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).

VD00004

61 Reinstall the pump cover

• Reinstall the cover with a new O-ring.

• Check the water lter and open the sea cock.

For O-ring art. code see page 140.

VD00961

6 Maintenance

62 Coolant replacement

The coolant has to be replaced every 1000 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 oers insucient protection for the winter.

note

Keel cooler

How the cooling system in engines with keel cooling should be drained depends on the installation of the keel cooler. Refer to the keel cooler manufacturer’s instructions for this.

Check using a coolant hydrometer whether the coolant is providing sucient protection against freezing if total draining o is not possible.

Coolant replacement

Every 1000 operating hours.

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.

63 Preparation

VD00995

• Remove the plug (1) and the ller cap (2) to vent the cooling system.

6 Maintenance

Coolant replacement

Every 1000 operating hours.

64 Draining of coolant

• Remove the drain plugs from the engine block (1) and heat exchanger housing (2).

• After draining replace the drain plugs.

VD02025

VD02024

PH2

VD02026

• For M4.56 and M4.55 SOLAS only

• Detach the hose to the oil coiler (3) and remove the drain plug from the heat exchanger housing (2).

• After draining re-install the hose and the drain plug.

6 Maintenance

65 Filling the cooling system

VD00987

Coolant replacement

Every 1000 operating hours.

Coolant quantity:

litres Imp. pt US pt

M2 : 2.2 3.9 4.6

M3 : 3.0 5.3 6.3

M4 : 6.5 11.4 13.7

Caution

Never ll the cooling system with sea wa-

ter or brackish water.

VD00988

• Remove the cap of the ller neck on the top of the heat exchanger housing.

• Remove the bolt from the upper side of the thermostat cover, so that air can escape from the cooling system.

• Fill the cooling system.

Use a mixture of 40% antifreeze (ethyleneglycol based) and 60% tap water or use a special coolant.

For specications see page 129.

note

For a keel-cooled version, see page 24. If a water heater is connected, see page 26 and 27

6 Maintenance

COOLANT

1 cm (3/8”)

Coolant replacement

Every 1000 operating hours.

Water heater

If a water heater is connected to the engine and this heater is positioned above the upper side of the engine than bleeding of the heater will not take place automatically! Fill the heater separately to bleed the cooling system completely.

VD00158

The level of the coolant must be approx. 1 cm

/8”) below the lower edge of the ller neck.

(

Bleeding will take place automatically during lling!

• After lling replace the ller cap and reinstall the plug.

• After the engine has run for the rst time and has reached operating temperature and has cooled down again to ambient temperature, check the coolant level in the heat exchanger housing.

• If necessary, add coolant.

Caution

Never ll the cooling system with sea water or brackish water.

6 Maintenance

2 1 3

Air lter replacement

Every 1000 operating hours.

note

Engines for lifeboats (SOLAS) are supplied without an air filter.

never install an air lter into the lter housing at these engines.

66 Air lter replacement

• Loosen the hose clamp (1).

• Remove the lter housing (2).

VD02009

• Remove the old lter and t a new lter (3).

• Replace the unit in reverse order and tighten the hose clamp again.

For air filter art. code see page 140.

VD02010

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.

6 Maintenance

Checking the starter motor and alternator

Every 1000 operating hours.

67 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.

VD00991

• If a spring starter is installed then check functioning by starting the engine as described on pages 38 and 39.

VD02048

68 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.

VD00992

6 Maintenance

Warning

The maximum engine speed adjustment screw has been correctly set at the factory and sealed. DO NOT attempt to remove this seal.

69 Checking engine speed

Checking engine speed

Speed (rpm)

Max. Idle M2.13 3000 850 M2.18 3600 850 M3.29

M3.28 SOLAS M4.35

M415 SOLAS M4.45

M4.17 SOLAS M4.56

M4.55 SOLAS

VD00134

3600 900

3600 840

3200 840

3000 900

At full load (with the boat cruising) the maximum engine speed should be approximately as specied in the table. If the engine does not reach this speed, it is being overloaded! If this is the case, check the ship’s propeller for defects or irregularities, and also to see that it is the correct pitch and diameter.

• Allow the engine to warm up normally (until the coolant temperature reaches at least 60°C (140°F).

• Check the engine RPM using a rev. counter, or use the rev. counter tted to the control panel.

Idle speed must be as specicated in the table.

• Now check the speed and adjust if required.

6 Maintenance

Checking engine speed

M2 M3

Minimum speed

adjustment screw

Maximum speed

adjustment screw

Lead seal

70 Adjusting engine idling speed

If the engine speed diers from that stated above, it must be adjusted. The engine idling speed can be reset using the adjustment screw on the fuel pump.

VD00994

Lead seal

Increasing RPM

Minimum

speed

adjustment

screw

Maximum

speed

adjustment

screw

VD00993

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.

note

Only engines with intercooling!

6 Maintenance

Cleaning the heat exchanger

71 Remove the drain plug

• Close the seacock and detach the water inlet hose from the sea water pump.

• Drain the coolant: To do this, remove the drain plug from the heat exchanger housing.

VD02024

• Remove the ller cap from the top of the heat exchanger housing to allow air into the system and check that all coolant has drained o.

VD00984

72 Removal of bolts out of the end covers

• Take out both central bolts from the end covers and take the end covers with the Orings out of the housing.

Turn the alternator outwards, by loosening the bolts and removing the V-belt, if more space is required for the Allen key.

note

Only engines with intercooling!

VD02027

6 Maintenance

Cleaning the heat exchanger

VD02031

73 Remove heat exchanger

VD02033

74 Cleaning the heat exchanger

VD02032

Only engines with intercooling!

note

• Slide the heat exchanger out of the housing.

• At the M4.56 and M4.55 SOLAS the heat exchanger must be slide out of the housing to the front, instead of to the rear. Therefore loosen the bolts of the alternator, remove the V-belt and turn the alternator outwards.

• Clean the heat exchanger: Use a pipe cleaner to remove fouling in the pipes.

• Then rinse the heat exchanger pipes with clean water.

• Ensure that both heat exchanger end chambers are free from dirt.

6 Maintenance

Cleaning the heat exchanger

75 Replacing heat exchanger

• Replace the heat exchanger in the original position in the heat exchanger housing.

• Use new O-rings (61 x 2.5 mm) which have been greased.

For O-ring art. code see page 140.

VD00157

76 Replacing the end covers

• Fit the end covers in the housing.

• Tighten up the bolts when both covers are in the correct position.

VD02042

• Ret the drain plug.

• Reconnect all hoses previously removed.

• Rell the cooling system, see page 82.

note

Only engines with intercooling!

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:

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. 94

3 Make sure that the engine fuel system is lled with a fuel mixture with protective properties. 95

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. 97

6 Change the oil lter and the engine oil. 98

7 Change the oil in the gearbox. 98

8 Disconnect the battery cables, charge the batteries if necessary and grease the battery terminals. 99

7 Lay-up / Winter storage procedure

1 Corrosion protection

2 Fuel system

VD00803

1 2

VD00133

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.

• 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 65).

7 Lay-up / Winter storage procedure

Caution

Never run the engine under load with this mixture of fuel and oil.

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’.

VD00136

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

[1]

of 1 part of engine oil

[2]

fuel

to 9 parts of clean

• 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 Rimula R4 L 15W40

[2]

Only use CEN EN 590 Diesel fuel. Preferably water-free fuel. Collect some fuel from the return pipe,

while engine is running.

7 Lay-up / Winter storage procedure

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 88.

Raw water pump

Check the impeller of the raw water pump at least once every two years, see page 77.

VD00125

4 Raw water cooling system

• Close the sea cock.

• Remove the lid of the water strainer.

• If necessary, clean the raw water strainer.

note

Only engines with intercooling!

VD00801

• 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 sucient 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.

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

5 Fresh water cooling system

To avoid corrosion during winter storage the cooling system must be lled with an antifreeze/water mixture (or a coolant).

For specications see page 129.

VD00984

N.B. Replacing the coolant is only necessary if the coolant present in the cooling system offers insucient protection against temperatures below 0˚C (32˚F).

For coolant replacement see page 80.

7 Lay-up / Winter storage procedure

6 Lubrication system

With the engine still at operating temperature: (If not, run the engine until warm, then turn o.)

VD00997

• Replace the oil lter and change the engine oil; use oil with protective properties. See page 56.

For quantity and oil specication see page

118 and 126.

VD00998

7 Changing the gearbox oil

• Stop the engine and change the oil of the gearbox. (page 68)

VD00975

Vetus M Series, M3.28 SOLAS, M2.13, M2.18, M4.15 SOLAS Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual