Vetus DIESEL VH4.65, VH4.80 Operation Manual

VH4.65
VH4.80

Operation manual

VD01079

VH4.80

1

Operation manual

Please enter the serial numbers here.
These numbers should be quoted when inquiring about Customer
Service, Repairs or Spare Parts (see page 6).

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

Serial numbers

Engine serial number Vetus:

Hyundai:

Gearbox serial number:

VH4.65
VH4.80

350102.01 (STM4994)

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.

For the Guarantee Conditions, see the Vetus Diesel Service and
Warrantee Manual.

This engine has been built exclusively for the application speci­fied 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 modifications will invalidate any liability
claims against the manufacturer for resultant damage.

Manipulations of the injection and regulating system may also
influence the performance of the engine, and its emissions.
Adherence to legislation on pollution cannot be guaranteed
under such conditions.

2

Serial numbers 1

1 Introduction 4

2 Engine description

General 6

Identification of engine parts 8

Control panels 10

3 Use

General guidelines 12

First commissioning 13

Running-in 16

Starting 17

(Pre-heating) 18

Cruising 20

Stopping 22

4 Routine maintenance

Introduction 23

Maintenance schedule 24

5 Maintenance

Checking the oil level 25

Checking the coolant level 26

Checking and cleaning the

raw water strainer 27

Draining water from the water

separator/fuel filter 28

(Bleeding) 29

Battery, cables and cable

connections 30

Changing the oil 32

Checking the gearbox oil level 34

Changing the gearbox oil 35

Replacing the fuel filter 36

Cleaning fuel lift pump 37

Checking the V-belts 38

Checking flexible engine mounts 40

Checking hose connections 40

Checking fastenings 40

Checking valve clearance 41

Checking the raw water pump 44

Coolant replacement 46

Cleaning the heat exchanger 48

Checking engine rpm 51

6 Winter lay-up

Winter storage procedure 52

Recommissioning after winter

storage 55

7 Troubleshooting 58

8 Technical Data 64

9 Operating media

Lubrication Oil 66

Fuel 67

Coolant 68

10 Wiring Diagrams 69

11 Overall Dimensions 72

3

Contents

4

Dear Customer,

Vetus diesel engines are designed both for pleasure and com­mercial craft. Consequently, a wide range of variants are offered
to meet the requirements of specific 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 differences 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 N.V.

Introduction

5

Safety measures

Introduction

All safety instructions in this manual are des­ignated by the accompanying symbol. Please
follow them carefully.

Pass the safety instructions to other persons operating the
engine as well.

General regulations and laws for safety and accident prevention
must also be observed.

• Never attempt to touch moving parts when the engine is run­ning.

• Never touch hot parts of the engine, and keep flammable
materials well away from the engine.

• Always stop the engine before checking or adjusting compo­nents.

• Always stop the engine before checking or topping up the
coolant or oil.

• Never open cap on top of header tank when the engine is at
operating temperature.

• Always carry out maintenance safely by only using tools well
matched in size.

6

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.

Engine data tag location

The vetus engine data tag is attached to
the valve cover.

Engine serial number

The HyuNdai engine serial number is
stamped at the indicated spot.

Engine description

General

VH480---A

D4BB1207830

A

4000 59 80

200001

ø88 MM

VD00232 VD01080 VD01081

7

Cylinder numbering

Cylinders are numbered consecutively,
beginning at the front end.

Fuel pump seal

The manufacturer shall not be held liable
for damages resulting from adjustments
made to the fuel injection pump.
The maximum engine speed adjustment
screw has been sealed to prevent this.

Adjustments to the fuel
pump are to be carried out
by authorized Vetus-Service
specialists only.

General

Engine description

VD00230

Lead seal

Maximum rpm
adjustment screw

VD00229

Port-side

Starboard

8

1 Airvent connection
2 Exhaust injection bend
VH4.65: ø 60 mm
VH4.80: ø 75 mm
3 Lifting eye
4, 5 Cooling system drain plug
6 Heat exchanger
7 Expansion tank
8 Filler cap for cooling system
9 Alternator
10 V-belt alternator/ coolant pump
11 V-belt raw water pump
12 Raw water inlet ø 25 mm
13 Raw water pump
14 Oil filter
15 Oil cooler
16 Raw water drain plug
17 Calorifier connection, engine ‘IN’
(ø 22 mm)
18 Connection for throttle push-pull

cable
19 Cooling system air bleed nipple
20 Temp. switch coolant

Engine description

Identification of engine parts

Starboard

1 2 3 4 5 6 7 8 9 10

11121314151617

VD01105

VH4.80

9

21 Oil dipstick
22 Oil filler cap
23 Fuel return pipe connection

ø 8 mm
24 Calorifier connection, engine ‘OUT’
(ø 17 mm)
25 Electrical system connection box
26 Water separator/fuel filter air bleed

nipple
27 Fuse
28 Gearbox lube oil cooler
29 Connection for gearbox push-pull

cable
30 Gearbox
31 Gearbox filler cap/ oil dipstick
32 Water separator/ fuel filter drain

plug
33 Water separator/ fuel filter
34 Starter motor
35 Fuel supply pipe connection

ø 8 mm
36 Fuel lift pump
37 Distribution cover

Identification of engine parts

Port-side

Engine description

19 20 21 22 23 24 26 27 28

293031323334353637

18 25

VD01106

VH4.80

10

Basic panel (model 22)
Fly-bridge panel (excl. voltmeter, model 21)

Extended panel (model 34)

Engine description

Control panels

5

3

7

8

6

4

9

1 2

VD00103

5

3

7

8

6

4

9

1 210

11

VD00104

11

Sailingboat panel (model 10) Push button panel (model 00)

Control panels

Engine description

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

10 Temperature gauge, coolant
11 Oil pressure gauge
12 On push button switch
13 Pre-heating push button switch
14 Starter push button switch
15 Stop push button switch

*) This is an option, not fitted as standard.

5

3

7

8

6

4

VD00102 VD00101

4 5 6 7

8

12
13

15
14

12

General guidelines for use

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 specifications see page 68.

• Never run the engine without a thermostat.

• Use a good quality lubricating oil. For specifications see page

66.

• 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 or battery charging lights up.

Use

General guidelines

13

Commissioning the engine

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

Filling with engine oil

As a rule engines are delivered empty of
oil.
Fill the engine with oil through the filler
neck on top of the valve cover, for quantity
and specification see page 66.

Check the oil level with the dipstick, see
page 25.

First commissioning

Use

Engine Oil

4.9 litres (1.1 UKgal) 15W40

API: CD, CE or CF4
CCMC: D4, D5

For example:

- Vetus Marine Inboard Diesel Motor
Oil

- Shell Super Diesel T

OIL

VD01082

Filling gearbox with oil

Fill the gearbox with oil.

Check the oil level with the dipstick, see
page 34.

ZF Hurth:
model HBW250 : 0,75 litres ATF*)
(ZF25M) (1.3 UKpt)
model HBW250A : 0,8 litres ATF*)
(ZF25MA) (1.4 UKpt)
model HSW250A : 1,8 litres ATF*)
(ZF25A) (3.2 UKpt)
model HSW250H : 2,5 litres ATF*)
(ZF25) (4.4 UKpt)

*) ATF: Automatic Transmission Fluid
type A, Suffix A.

Technodrive:
model TMC260 : 1,2 litres ATF*)
(2.1 UKpt)
model TM345H : 1,6 litres Engine oil
(2.8 UKpt) SAE 20W40-CD
model TM345A : 1,6 litres Engine oil
(2.8 UKpt) SAE 20W40-CD

*) ATF: Automatic Transmission Fluid
type A, Suffix A.

First commissioning

Use

14

OIL

VD01100

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

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

15

Filling the cooling system

Remove the cap of the filler neck on the
top of the heat exchanger housing.
Remove plug A, so that air can escape
from the cooling system.
Fill the cooling system. Replace plug A as
soon as coolant flows out.
Use a mixture of 40% antifreeze (ethylene­glycol based) and 60% tap water or use a
special coolant.
For specifications see page 68.

The level of the coolant must be approx.
1 cm (3/8”) below the lower edge of the
filler neck.
Bleeding will take place automatically dur­ing filling!
Replace the filler cap.
After the engine has run for the first time
and has reached operating temperature
and has cooled down again to ambient
temperature, check the coolant level in the
heat exchanger housing.

If necessary, add coolant.

Use

First commissioning

Water Heater

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

Never fill the cooling system
with sea water or brackish
water.

A

13

VD01083 VD00144

(3/8”)

VD01084

Coolant

quantity :

7.1 litres (1.6 UKgal)

Fuel

Ensure that the fuel tank is filled with
diesel fuel.
Use only clean, water-free, commercial
approved diesel fuel.
For fuel grade see page 67.
Bleed the fuel system, see page 29.

Other preparations

• Check battery and cable connections.

• Start the engine, see page 17, and let it
run for about 10 minutes without load.

Check the engine and all connections

(fuel, cooling water and exhaust) for
leaks.

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.

First commissioning

Running-in

Use

16

FUEL

VD00002

Never fill the fuel tank while
the engine is running.
Do not spill fuel. Prevent
unnecessary pollution.

17

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.

Preparation starting

Before starting the engine, always check
that the control lever(s) is (are) in the neu­tral position.

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

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

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

gearbox

forward

half throttle,
gearbox not engaged

gearbox
reverse

reverse

throttle

forward

throttle

VD00111 VD00112

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.

Pre-heating

Turn the key further clockwise to the ‘ ’
position; only the pre-heating indica­tor light will be lit now.

Hold the key in this position for about 2
seconds.

Starting

Use

18

VD00107 VD00108

WarNiNg

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

Maximum pre-heating time is 3
seconds.

19

Starting

Now turn the key further to the ‘start’
position.

Release the key as soon as the engine
fires (the key will return to the ‘oN’ posi­tion) and throttle back.
Leave the key in this position while the
engine is running.

Check that the indicator lights for oil pres­sure and alternator are off. Cooling water
should now flow out of the exhaust; if this
is not the case, stop the engine immedi­ately. Before submitting the engine to full
load it should be brought up to operating
temperature as quickly as possible by
running at 3/4 of maximum revs. Never
turn the main switch off while the engine
is running.

Use

Starting

WarNiNg

Release the key if the engine does
not fire within 10 seconds. Wait until
the starter motor has stopped running
completely before turning the key to
the ‘start’ position again. Never allow
the starter motor to run for more than
30 seconds consecutively.

VD00109

VD00110

The instrument panel is provided with the
following instruments (Depending of the
type of panel, see page 10 and 11).

WarNiNg

Never turn the key to the ‘start’ position
while the engine is running.
Doing so will damage the starter motor.

20

When the engine reaches operational tem­perature, exhaust gases should be colour­less or light-blue. (In the winter, the low
temperatures will turn the exhaust emis­sions white.)
If black smoke is emitted from the exhaust,
this indicates that combustion is incom­plete.
If white smoke is emitted, this indicates
combustion of oil forced up.

Tachometer

Indicating the number of revolutions per
minute of the engine.
Avoid idling for more than 10 minutes.
Also the number of running hours is indi­cated.

Idling speed,
VH4.65 : 850 rpm
VH4.80 : 850 rpm

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 first position, the voltmeter should
indicate 12 Volts.

Cruising

Use

VD00577 VD00578

21

Temperature gauge

Indicating the temperature of the internal
cooling system.
The operating temperature is 76˚C - 85˚C.
In case the engine is overheated: turn off
the engine and establish the cause, see
fault finding table, page 59 .. 63.

Oil pressure gauge

With the engine at operating temperature,
the oil pressure is:
When idling: at least 0.8 bar (6 psi).
In case the oil pressure is too low: turn off
the engine and establish the cause, see
fault finding table, page 59 .. 63.

Warning lights

None of the five warning lights should light
up while the engine is running. 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 immedi-

ately!

Cruising

VD00663 VD00664

Stopping

Reduce engine speed to idle and shift the
gearbox to ‘Neutral’. Turn the key to the
left to the ‘off’ position.

If the engine is not to be used for some
time, it is recommended that the sea cock
is closed and the battery main switch
turned off.

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 ‘stop’ position, left of the ‘off’
position on the control panel, has normally
no function for this engine.
When 2 control panels are connected to
one engine, the engine can always be
stopped by turning the key to the ‘stop’
position, no matter what the position is of
the key on the other panel.

Stopping

Use

22

VD00106 VD00105