M2 Operation manual M2.02 M2.
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Operation manual M2.02 M2.06 Serial numbers Engine serial number Vetus: Engine serial number Mitsubishi: Gearbox serial number: 340802.01 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. Copyright © 2012 Vetus N.V.
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.
Contents 1 2 Safety measures Warning indications Preventing fire and explosion Prevention of injury When problems occur 4 4 5 6 8 Introduction Data tag Serial number Cylinder numbering and direction of rotation Fuel pump seal Identification of engine parts Control panels Control lever 9 10 10 3 First commissioning 16 4 Running-in 25 5 Use General guidelines Starting Cruising Stopping 26 26 28 32 34 11 11 12 14 15 6 Maintenance Introduction Mainte
1 Safety measures Warning indications Warning indications The following warning indications are used in this manual in the context of safety: Danger Indicates that great potential danger exists that can lead to serious injury or death. 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.
1 Safety measures Preventing fire and explosion Fire risk! • 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, noninflammable, 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, fire can break out.
1 Safety measures • 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 off.
1 Safety measures Prevention of injury • Be careful with battery acid! If battery acid comes in contact with the eyes or skin, rinse the affected 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.
1 Safety measures 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.
2 Introduction Dear customer, Vetus diesel engines are designed for pleasure craft. Consequently, a wide range of variants are offered to meet the requirements of specific cases. 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. Your engine is appropriately equipped for your vessel, which means that not necessarily all components described in this manual are mounted to your engine.
2 Introduction VD01035 VD01036 VD01044 Data tag Serial number 1 Engine data tag 2 Engine data tag location 3 Engine serial number The Vetus engine serial number and performance data are printed on the engine data tag. The type plate is positioned as shown. The Mitsubishi engine serial number is stamped on the fuel injection pump. (arrow) Model and engine serial number must be given when ordering spare parts.
2 Introduction Cylinder numbering and direction of rotation Fuel pump seal Maximum speed adjustment screw 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 flywheel counter clockwise.
2 Introduction 15 16 17 18 Service side Oil filler cap Raw water inlet ø 20 mm Raw water pump Oil dipstick Manual operation of fuel supply pump Oil filter Water separator/fuel filter drain plug Water separator/Fuel filter Connection for gearbox push-pull cable Fuse Electrical system connector box Fuel return pipe connection ø 8 mm Air inlet silencer Water separator/fuel filter air bleed nipple Manual operation of electric stop Fuel supply pipe connection ø 8 mm Fuel lift pump Connection for throttle push
2 Introduction Identification of engine parts Starter side 24 25, 26, 27 28 29 30 31, 26 32 19 20 21 22 23 24 25 33 23 22 21 20 19 VD01254 26 27 28 29 30 31 32 33 Gearbox Gearbox drain plug Gearbox oil dipstick/filler cap Starter motor Alternator V-belt Connection for extra expansion tank (Keel cooling model only) Calorifier connection Cooling system air bleed nipple Filler cap for cooling system Expansion tank Heat exchanger Cooling system drain plug Airvent connection Exhaust injection bend
2 Introduction Control panels 1 2 5 6 7 8 9 3 6 8 7 Basic panel, model 22 Fly-bridge panel, excl.
2 Introduction Control lever neutral reverse throttle Single lever control handle for two engines Single lever control handle for 1 engine gearbox forward forward throttle VD00788 gearbox reverse 6 Operating lever Operating lever for 1 or 2 engines. 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.
3 First commissioning Engine Oil OIL OIL 2.4 litres 15 W40 (4.2 Imp. pt, 5.1 US pt) API: ACEA: CF4, CG4, CH4, CI4 A3/B3, A3/B4, E7 1 Commissioning the engine 2 Filling with engine oil Before starting the engine for the first time, the following procedures must be carried out: 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 oil specification see page 102 and 106.
3 First commissioning OIL OIL Vetus engines are normally equipped with Technodrive or ZF-Hurth gearboxes. 27 VD01034 17 VD01033 In case your engine is equipped with another brand of gearbox follow the instructions given in the supplied owners manual. 3 Filling gearbox with oil • Fill the gearbox with oil. • Check the oil level with the dipstick, see page 42. Technodrive: type TMC40P : 0.2 litres, ATF [1] (0.35 Imp. pt, 0.42 US pt) type TMC60A : 0.6 litres, ATF [1] (1.05 Imp. pt, 1.
3 First commissioning Coolant quantity : 2.2 litres (3.9 Imp. pt, 4.6 US pt) COOLANT COOLANT VD00158 17 VD01005 VD01004 1 cm (3/8”) 4 Filling the cooling system, intercooling, • Remove the cap of the filler 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. Note If a water heater is connected to the engine, see page 20 and 21. 18 • Fill the cooling system.
3 First commissioning 1.5 bar 2 2 1.5 bar DO NOT OPEN 1 DO NOT OPEN VD00929 VD00932 VD00925 1 5 Filling the cooling system, keel cooling • Remove the cap ‘do not open’ (1) of the filler neck on the top of the heat exchanger housing. • Top up the extra expansion tank to the minimum level. • Reinstall the pressure cap (2). Note If a water heater is connected to the engine, see page 20 and 21. • Fill the cooling system. • Reinstall the filler cap ‘do not open’.
3 First commissioning 1.5 bar 2 VD00925 VD00895 DO NOT OPEN 1 6 Filling coolant system, if a water heater is connected (1) The highest point of the water heater is situated at a lower level than the expansion tank for the ship’s engine. The water heater will be filled and bled automatically during filling of the cooling system. • Remove the ‘do not open’ cap (1) and fill the cooling system via the filler neck. • Add coolant into the expansion tank (2) until minimal level has been reached.
3 First commissioning 1.5 bar 2 3 VD00925 VD00896 DO NOT OPEN 1 7 Filling coolant system, if a water heater is connected (2) The highest point of the water heater is situated at a higher level than the expansion tank for the ship’s engine. The water heater will not be filled and bled automatically during filling of the cooling system. • Fill the cooling system via the expansion tank (2). • Open valve (3) during filling and bleeding the system.
3 First commissioning FUEL Neutral Warning (No throttle, gearbox not engaged) VD00789 VD VD00002 Never fill the fuel tank while the engine is running. Do not spill fuel. Prevent unnecessary pollution. 8 Fuel 9 Other preparations • Ensure that the fuel tank is filled with diesel fuel. • Check that the battery is charged and check the battery cable connections. Use only clean, water-free, commercial approved diesel fuel. • Set the main switch to position ‘on’. • Open the sea cock.
3 First commissioning VD01046 VD01001 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 28 and further. • Allow the engine to test run for about 2 minutes at idling speed . • 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.
11 Bleeding The cooling system must be bled as soon as the engine has reached normal working temperature. • Open the cap on the filler neck. • Vary the revolutions between idling and 2000 rev/min. • Add coolant if necessary. 24 VD00791 VD00663 VD01003 3 First commissioning 12 Sea trial • Replace the cap on the filler neck. • Check the operation of the remote control. • Check the coolant temperature.
4 Running-in In order to ensure a long life for your engine, please observe the following for the first 50 operating hours: After the first 50 operation hours carry out the following maintenance: • Drain water from fuel filter, see page 44. • Allow the engine to reach operating temperature before applying a load. • Engine oil change, see page 47. • Avoid fast acceleration. • Replace oil filter, see page 48. • Do not allow the engine to run faster than 3/4 of maximum RPM.
5 Use General guidelines General guidelines for use Implementing the following recommendations will result in longer life and better performance and more economical operation of your engine. • Never run the engine without a thermostat. • Carry out the maintenance described regularly, including the ‘Daily procedures before starting’. • Use a good quality diesel fuel that is free of water and other pollutants.
5 Use General guidelines Note First commissioning Follow the instructions given for ‘First commissioning’ on page 16 and further if the engine is being commissioned for the first time. After repair work: Check that all guards have been replaced and that all tools have been removed from the engine. When starting with pre-heating, do not use any other substance (e.g. injection with ‘Easy Start’). Doing so could result in an accident.
5 Use Starting Before starting, always check the following points: half throttle, gearbox not engaged • Engine oil level. • Coolant level. • Sea cock open. • Main switch ‘on’. Warning Never start the engine with the fuel injection pump removed. Disconnect battery. 28 VD00107 VD00923 • Gearbox in ‘neutral’ position. 1 Control lever 2 Switching on Set the control lever to ‘half throttle’ without engaging the gearbox.
5 Use Starting Pre-heating time Above + 5°C (41°F) about 6 seconds +5°C to -5°C (+41°F to +23°F) about 12 seconds Below -5°C (23°F) about 18 seconds Maximum preheating time 1 minute VD00108 Ambient Temperature 3 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 • Turn the key further clockwise to the ‘ position.
5 Use VD00110 VD00109 Starting 4 Starting Now turn the key further to the ‘start’ position. 30 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. Caution Release the key if the engine does not fire within 10 seconds. Let the starter motor cool for 30 seconds before turning the key to the ‘start’ position again.
5 Use VD00629 Starting 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 [1]. [1] 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 off while the engine is running. Caution Never turn the key to the ‘start’ position while the engine is running.
5 Use VD00577 Cruising 5 Tachometer The instrument panel is provided with the following instruments (Depending of the type of panel, see page 17). Indicating the number of revolutions per minute of the engine. Also the number of running hours is indicated. Idling speed : 850 rpm 32 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 VD00578 Cruising 6 Voltmeter 7 Warning lights 8 Alarm buzzer 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. 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.
5 Use Stopping VD00106 VD00105 VD00790 Neutral 9 Stopping • Reduce engine speed to idle and shift the gearbox to ‘Neutral’. • Turn the key entirely to the left, through the ‘Off’ position. • When the engine has stopped, turn the key 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.
5 Use VD01037 Stopping 10 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 off by the electrically operated fuel solenoid stopping of the engine can be done this way.
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. 36 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 Keep record of the following information in the logbook and/or the ‘Service and Warranty Manual’: Introduction -- Oil pressure and coolant temperature. -- Total engine hours (reading engine hour counter). -- Parts on which maintenance is conducted and type of maintenance (adjustment, repair or replacement), and the results of each procedure. -- Amounts of oil, fuel and coolant needed for topping up. -- Changes in operating conditions, such as ‘Exhaust gas became black’, etc.
6 Maintenance Maintenance schedule Every 10 hours or daily, before starting page page Check engine oil level 40 Drain water from fuel filter 44 Check water strainer 41 Engine oil change 47 Check coolant level 42 Replace oil filter 48 Battery, cables and cable connections 50 Check gearbox oil level 54 After the first 50 hours page.
6 Maintenance Maintenance schedule Every 500 hours page Check glow plugs [1] Every 1000 hours, at least once every 2 years page. Raw water pump inspection 64 Replace coolant 66 Every 1000 hours page. Check starter motor 70 Check alternator 70 When required page Bleeding fuel system 45 Check idle rpm 71 Cleaning heat exchanger 72 Danger Stop the engine before carrying out any maintenance work [1] Consult the service manual, work to be carried out by a Vetus Mitsubishi dealer.
6 Maintenance Checking engine oil level Daily, before starting. VD01013 VD00155 OIL VD01001 OIL 1 Check oil level 2 Oil level 3 Topping up oil • Turn the engine off. The oil level must be at or near the upper mark on the dipstick [1]. The oil filling cap is on top of the the valve cover,. • If necessary top up with the same brand and type of oil. A second oil filling cap is located at the distrubution cover, see page 16. The dipstick is located on the starboard side of the engine.
6 Maintenance Checking and cleaning the raw water strainer VD00802 VD00801 Daily, before starting. 4 Checking the raw water strainer 5 Cleaning the strainer • Check daily whether there is any dirt in the raw water 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.
6 Maintenance Checking coolant level Daily, before starting. COOLANT COOLANT VD01004 VD00158 VD01003 1 cm (3/8”) 6 Checking coolant level 7 Coolant level 8 Topping up coolant • Check the coolant level in the header tank. This has to be checked when the engine is cold. The level of the coolant must be approx. 1 cm (3/8”) below the lower edge of the filler neck. • If necessary, top up.
6 Maintenance Checking coolant level VD01005 Daily, before starting. • When topping up coolant, remove the bolt from the upper side of the thermostat cover, so that air can escape from the cooling system.
6 Maintenance Draining of water from the water separator/fuel filter Danger Do not smoke when draining off water and sediment. Keep flame and sources of ignition out of the area. Remove spilled fuel and litter before you start the engine. VD00803 VD01006 Every 100 operating hours. 9 Empty fuel filter 10 Empty water separator • Open the drain plug at the lower side of the filter. Empty the separately installed water separator/fuel filter: • Drain the water and close the drain plug.
6 Maintenance Draining of water from the water separator/fuel filter 14 VD01009 10 VD001008 13 VD01007 Every 100 operating hours. 11 Bleeding After the water separator/fuel filter has been drained, the air has to be bled from the fuel system The fuel system is self-bleeding; but manual bleeding the system is recommended. • Open the two bleeding nipples. -- A second bleeding nipple is located at the fuel injection pump. • Prime the fuel system by pumping the fuel pump.
6 Maintenance Draining of water from the water separator/fuel filter VD00109 Every 100 operating hours. 12 Start the engine • Operate the starter switch until the engine fires; release the starter switch if the engine does not fire within 20 seconds. • Wait until the starter motor has stopped before making a new attempt to start the engine. • Repeat the above if the engine cuts out after a short time.
6 Maintenance Engine oil change Every 100 operating hours. 13 Engine oil change Change the engine oil every 100 hours of operation (together with engine oil filter 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 off engine at operation temperature. (Lube oil temperature approx. 80°C (176°F).
6 Maintenance Engine oil change VD01026 VD01010 Every 100 operating hours. 14 Draining the oil • Remove the dipstick; insert the suction hose of the supplied sump pump in the dipstick tube. 15 Removing the oil filter • After draining remove the suction hose of the sump pump out of the dipstick tube. • Unscrew the oil filter, with a commercially available tool. Catch any dripping oil. • Push down the pump handle quickly and pull it up slowly. • Pump the sump empty.
6 Maintenance Engine oil change Every 100 operating hours. VD01011 VD00124 VD01013 Amount of oil (oil filter incl.): 2.9 litres (5.1 Imp. pt, 6.1 US pt) Oil filter, art.code: STM0051 16 Oiling the oil seal 17 Oil filter installation 18 Refilling with oil • Clean the contact surface of the gasket. • Install the filter in accordance with the instructions printed on the filter element housing.
6 Maintenance Warning notes and safety regulations for working with batteries Wear eye protection. Keep children away from acid and batteries. Explosion hazard: A highly-explosive oxyhydrogen gas mixture occurs when charging batteries, therefore: Fires, sparks, naked flames and smoking are prohibited: • Avoid causing sparks when dealing with cables and electrical equipment, and beware of electrostatic discharges. • Avoid short-circuits.
6 Maintenance Battery, cables and connections VD00117 Every 100 operating hours. 19 Battery, battery connections Keep battery clean and dry. Ensure that clamps make good contact after reassembling. • Remove battery cables (negative first). • Hand tighten the bolts only. • Clean battery posts (+ and −) and clamps and grease with acid-free and acid-resistant grease.
6 Maintenance Battery, cables and connections Every 100 operating hours. GREEN DOT Vetus maintenance-free batteries ALL DARK CLEAR VD00118 VD00121, VD00122, VD00123 1 20 Checking specific gravity 21 Hydrometer operation Every Vetus Maintenance-free battery has a hydrometer (1) built into the cover. Green dot visible: State of charge 65 % or more. Visual inspection of the hydrometer will show one of three conditions: Dark: State of charge less than 65 %. Recharge immediately.
6 Maintenance Battery, cables and connections Every 100 operating hours. Conventional batteries Specific gravity State of charge 1,.8 kg/l 100% 1.20 kg/l 50% recharge 1.12 kg/l 10% recharge immediately VD00120 VD00119 Conventional batteries 22 Checking electrolyte level 23 Checking specific gravity For conventional batteries it is required to check the electrolyte level regularly. Remove vent caps (taking care no spark or open flame is nearby) and inspect the level.
6 Maintenance Gearbox oil level check 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. 54 17 VD01038 VD01032 Every 100 operating hours.
6 Maintenance Fuel filter replacement VD01017 Every 500 operating hours. 26 Fuel filter removal The fuel filter is to be replaced as a unit. • Close the fuel stopcock. Danger Keep naked flames away when working on the fuel system. Do not smoke! • Remove the fuel filter, use a filter wrench. Catch any fuel.
6 Maintenance Fuel filter replacement Every 500 operating hours. VD00133 VD00154 Fuel filter, art.code: STM3690 27 Fuel filter installation • Clean any debris from the filter carrier rim. • Fill the new filter with clean diesel fuel. • Open fuel stopcock. • Lubricate the rubber gasket sparingly with clean engine oil. • Install the filter. When the rubber gasket touches the housing, apply another tightening of a half to three quarters of a turn by hand. • Check for leaks.
6 Maintenance Bleeding, after fuel filter replacement VD00109 Every 500 operating hours. 28 Bleeding 29 Start the engine • After replacing the fuel filter the air has to be bled from the fuel system. • Operate the starter switch until the engine fires; release the starter switch if the engine does not fire within 20 seconds. Wait until the starter motor has stopped before making a new attempt to start the engine. • For bleeding see page 45. • Check for leaks once more.
6 Maintenance Changing the gearbox oil (Technodrive) Every 500 operating hours. VD01033 14 VD01255 OIL 30 Draining the oil 31 Filling with new oil • Remove the drain plug to drain the oil. • Refill the gearbox to the correct level via the filling hole. • Remove the fillercap to vent the gearbox and check if all oil has been drained • Collect the oil in a dripping pan. 58 • For quantity and oil specification see page 108.
6 Maintenance Changing the gearbox oil (ZF-Hurth) 32 Draining the oil Drain the oil with the aid of a separate sump pump. VD01034 17 VD01042 VD01043 Every 500 operating hours. 33 Filling with new oil Or, if sufficient space below the gearbox is available, oil can be drained by removing the drain plug. • Remove the dipstick. • Refill the gearbox to the correct level via the dipstick opening. For oil specification see page 108. • Collect the oil in a dripping pan.
6 Maintenance Checking valve clearance Every 500 operating hours. Markering op motorblok 2° 2° Markering BDP Markering injectietijdstip 27 VD01049 10 VD01040 17° 34 Checking / adjusting valve clearance 35 Remove rocker cover 36 Locating TDC Checking the valve clearance must be done with a cold engine, that is an engine which did not run for at least 6 hours. • Remove the 2 nuts of the rocker cover.
6 Maintenance Checking valve clearance Every 500 operating hours. 10 VD01016 VD00922 Valve clearance: Inlet 0.25 mm (0.010”) Exhaust 0.25 mm (0.010”) 37 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.
6 Maintenance Checking the V-belt Every 500 operating hours. 12 14 VD00129 VD00128 VD00034 V-belt, art.code: STM7369 38 Inspection V-belt 39 Checking tension 40 Tensioning V-belt • Inspect the belt for wear and tear (fraying and cracking). Belts which are in poor condition should be replaced. • Check tension of the V-belt by applying moderate finger and thumb pressure. If the deflection of the belt is more than 12 mm (1/2”), using about 10 kg (20 lbs) thumb pressure, it should be tensioned.
6 Maintenance Flexible engine mounts, hose connections and fasteners VD01046 VD00928 Every 500 operating hours. 41 Check flexible engine mounts 42 Inspection hose connections 43 Check fasteners • Check the bolts which secure the damper element, the mounting bolts to engine bed and the nuts at the adjustment spindle for tightness. • Inspect all hose connections of the coolingsystem. (Cracked hoses, loose hose clamps) • Check tightness of all fasteners, bolts and nuts.
6 Maintenance Raw water pump inspection Every 1000 operating hours. Note VD01125 10 VD01126 / VD01031 Only engines with intercooling! 44 Raw water pump inspection 45 Pump cover removal 46 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.
6 Maintenance Raw water pump inspection Every 1000 operating hours. VD00927 VD00004 O-ring, art.code: STM7696 VD00127 Impeller + O-Ring, art.code: STM7691 47 Impeller inspection 48 Re-install the impeller 49 Reinstall the pump cover • Inspect the impeller for damage. • The impeller should be lubricated with glycerin or a non-petroleum based lubricant such as a silicone spray before fitting it into the impeller housing. • Reinstall the cover with a new O-ring.
6 Maintenance Coolant replacement Every 1000 operating hours. 50 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 offers insufficient protection for the winter.
6 Maintenance Coolant replacement Every 1000 operating hours. Note 1 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 sufficient protection against freezing if total draining off is not possible.
6 Maintenance Coolant quantitiy: Coolant replacement Every 1000 operating hours. 2.2 litres (3.8 Imp. pt, 4.6 US pt) Water heater 17 VD01005 VD01004 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. 52 Filling the cooling system • Remove the cap of the filler neck on the top of the heat exchanger housing.
6 Maintenance Coolant replacement Every 1000 operating hours. COOLANT VD00158 1 cm (3/8”) 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! • After filling replace the filler cap and reinstall the plug. • After the engine has run for the first time and has reached operating temperature and has cooled down again to ambient temperature, check the coolant level in the heat exchanger housing.
6 Maintenance Checking the starter motor and alternator VD01252 VD01251 Every 1000 operating hours. 53 Checking the starter motor 54 Checking the alternator • Check for visible defects. • 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. • Remove the alternator belt. Turn the pulley by hand to check whether the alternator can be turned easily.
6 Maintenance Checking engine speed Minimum speed adjustment screw Warning The maximum engine speed adjustment screw has been correctly set at the factory and sealed. DO NOT attempt to remove this seal. Maximum speed adjustment screw At full load (with the boat cruising) the maximum engine speed should be about 3,000 resp. 3600 RPM (see technical data page 101).
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.
6 Maintenance 57 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. VD01019 VD01003 13 VD01018 Cleaning the heat exchanger 5 58 Removal of bolts out of the end covers • Remove the filler cap from the top of the heat exchanger housing to allow air into the system and check that all coolant has drained off.
6 Maintenance STM7217 VD01021 6 VD01020 Cleaning the heat exchanger 59 Remove heat exchanger 60 Cleaning the heat exchanger • Slide the heat exchanger out of the housing. • 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 VD00157 STM6202 O-ring, art.code: STM6113 (2 x) 61 Replacing heat exchanger 62 Replacing the end covers • Replace the heat exchanger in the original position in the heat exchanger housing. • Fit the end covers in the housing. • Refit the drain plug. • Tighten up the bolts when both covers are in the correct position. • Reconnect all hoses previously removed. • Use new O-rings (61 x 2.5 mm) which have been greased.
7 Winter storage procedure 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 end of the sailing season and any necessary repairs carried out. Consult a Vetus Dealer if help is required with this.
7 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. 78 2 Drain off the water from the fuel system and fill the fuel tank. 78 3 Make sure that the engine fuel system is filled with a fuel mixture with protective properties. 79 4 Flush out the raw water circuit with fresh water and if necessary fill with antifreeze.
1 Corrosion protection 2 Fuel system 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 off to remove any salt residues. If there is any corrosion, the paint should be touched up. Engine parts that become hot must be touched up with heat-resistant paint. • Drain the water from the water separator/ fuel filter and the fuel tank.
7 Winter storage procedure Tip! Combine running the engine with the protective fuel mixture with flushing the raw water circuit with fresh water, see ‘Winter storage procedure - Raw water cooling system’. Caution VD00136 VD Never run the engine under load with this mixture of fuel and oil.
7 Winter storage procedure Tip! Raw water pump Check the impeller of the raw water pump at least once every two years, see page 64. VD00801 Combine flushing 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 72. VD00125 4 Raw water cooling system • Close the sea cock. • Remove the lid of the water strainer.
7 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. VD01003 • Close the sea cock as soon as it is filled with anti-freeze. 5 Fresh water cooling system Anti-freeze can be toxic.
6 Lubrication system With the engine still at operating temperature: (If not, run the engine until warm, then turn off.) 7 Changing the gearbox oil • Replace the oil filter and change the engine oil; use oil with protective properties. See page 47. For quantity and oil specification see page 102 and 106. 82 VD01034 VD01026 VD01010 7 Winter storage procedure • Stop the engine and change the oil of the gearbox.
CT40063 VD00139 7 Winter storage procedure 8 Electrical system • Disconnect the battery cables. • Charge batteries during winter lay-up regularly if required! • Follow the recommendations given on pages 50 to 53 or consult the recommendations given by the battery supplier for inspection and maintenance of the batteries.
8 Recommissioning after winter storage The engine must be inspected and any maintenance work carried out 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: 84 Inspections and maintenance work to be carried out are: page 1 Drain the water from the fuel system. 85 2 Check the raw water system. 86 3 Check the coolant level in the internal cooling system. 87 4 Check the oil level.
VD00137 VD00141 VD00803 8 Recommissioning after winter storage 1 Fuel system • Drain the water from the water separator/ fuel filter. (page 44) • Drain the water from the fuel tank. • Open the fuel valve.
VD01045 10 VD01125 VD00801 8 Recommissioning after winter storage 2 Raw water cooling system • Check that the lid of the raw water strainer is reinstalled. Note Only engines with intercooling! 86 • Check whether the lid of the raw water pump and drain plugs are reinstalled. (pages 64, 67) • Re-tighten possible loose hose clamps.
8 Recommissioning after winter storage • Open the sea cock. VD01001 OIL VD01003 VD00138 COOLANT 3 Fresh water cooling system 4 Lubrication system • Check the coolant level. (page 42) • Check the engine oil level.
5 Electrical system • Make sure that the batteries are fully charged. (page 50, 83) 88 VD00107 CT40063 VD00140 8 Recommissioning after winter storage 6 Switching on • Connect the batteries. • 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.
VD00581 VD01046 8 Recommissioning after winter storage 7 Check engine for leaks 8 Checking instruments and remote controls • Start the engine. • Check the operation of the instruments, the remote control and the gearbox. • Check the fuel system, the cooling system and the exhaust for leakage.
9 Troubleshooting Engine faults are in most cases caused by improper operation or insufficient maintenance. In case of a fault, always check first 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.
9 Troubleshooting Fault Fault finding table page 1 Engine will not crank 92 2 Engine cranks but will not start, no smoke from exhaust 92 3 Engine cranks but will not start, smoke from exhaust 93 4 Engine starts but runs unevenly (rough idling) or stalls 93 5 Engine does not reach maximum rpm under load 94 6 Engine overheats 95 7 Engine not firing on all cylinders 95 8 Engine has little or no oil pressure 96 9 Engine oil consumption excessive 96 10 Fuel consumption excessive
9 Troubleshooting Fault finding table 1 Engine will not crank Possible fault 2 Engine cranks but will not start, no smoke from exhaust Possible fault Remedy Faulty or discharged battery (too Check / recharge battery and low voltage ) . check engine alternator and/or battery charger. (Nearly) Empty fuel tank. Refill. Fuel stop valve closed. Open. Fuse blown. Replace. Fuel pre-filter clogged . Clean /replace Loose or corroded connections in starting circuit. Clean and tighten connections.
9 Troubleshooting Fault finding table 3 Engine cranks but will not start, smoke from exhaust 4 Engine starts but runs unevenly (rough idling) or stalls Possible fault Remedy Possible fault Remedy Faulty injector/injection pump. Check, replace if required. (Nearly) Empty fuel tank. Refill. Air in fuel system. Check and bleed. Fuel supply line restricted. Check / clean. Wrong fuel quality or contaminated fuel. Check fuel. Drain and flush fuel tank. Replace with new fuel.
9 Troubleshooting Fault finding table 5 Engine does not reach maximum rpm under load 5 Engine does not reach maximum rpm under load Possible fault Remedy Possible fault Remedy Fuel pre filter clogged . Clean/replace. Hull/propeller dirty . Clean Fuel filter clogged with water and/or contamination. Check or replace. Faulty injector/injection pump. Check, replace if required. Leaking fuel supply line or fuel injection line. Check / replace. Air in fuel system. Check and bleed.
9 Troubleshooting Fault finding table 6 Engine overheats 7 Engine not firing on all cylinders Possible fault Remedy Possible fault Remedy Faulty injector/injection pump. Check, replace if required. Fuel supply line restricted. Check / clean. Sea cock closed. Open. Check or replace. Raw water strainer clogged. Check / clean. Fuel filter clogged with water and/or contamination. Faulty raw water pump impeller. Check / replace. Faulty injector/injection pump. Check, replace if required.
9 Troubleshooting Fault finding table 8 Engine has little or no oil pressure 9 Engine oil consumption excessive Possible fault Remedy Possible fault Remedy Oil level too low. Increase level. Oil level too high. Lower level. Incorrect lube oil SAE class or Replace. quality for ambient temperature. Incorrect lube oil SAE class or Replace. quality for ambient temperature. Blocked oil filter. Replace. Leak in lubricating oil system. Repair / replace. Faulty oil pump. Repair / replace.
9 Troubleshooting Fault finding table 10 Fuel consumption excessive 11 Black exhaust smoke (idling) Possible fault Remedy Possible fault Remedy Faulty injector/injector pump. Check, replace if necessary. Injector fault Check /replace. Incorrect fuel quality or dirty fuel. Check fuel. Drain and rinse fuel tank. Replace with new fuel. Oil level too high. Lower level. Excessive inclination of engine. Check / Adjust. Fuel leaks . Check and repair. Incorrect injection timing. Check / adjust.
9 Troubleshooting Fault finding table 13 Black exhaust smoke (at load) 14 White exhaust smoke (at full load) Possible fault Remedy Possible fault Remedy Faulty injector / injection pump. Check / replace if required. Faulty injector/injection pump. Check, replace if required. Incorrect injection timing. Check / adjust. Air in fuel system. Check and bleed. Oil level incorrect. Check . Insufficient intake air, air filter dirty. Check/clean the filter .
9 Troubleshooting Fault finding table 15 Burnt oil trace in exhaust line . Possible fault Remedy Oil level too high . Lower level. Excessive wear of cylinder / piston, piston rings. Check compression; refurbish engine.
10 Technical data Model Engine specifications : M2.02 M2.06 Make : Vetus Mitsubishi Vetus Mitsubishi Number of cylinders : 2 2 Based on : L2E-61DM L2E-61DM Type : 4-stroke diesel, in-line 4-stroke diesel, in-line Injection : Indirect Indirect Aspiration : Natural Natural General Bore : 76 mm 76 mm Stroke : 70 mm 70 mm Total displacement : 635 cm3 (39 cu.in.) 635 cm3 (39 cu.in.) Compression ratio : 23:1 23:1 Idling speed : 850 rpm 850 rpm Max. no.
10 Technical data Model Engine specifications : M2.02 M2.06 at the flywheel (ISO 8665) : 8.8 kW (12 hp) 11.8 kW (16 hp) at the prop shaft (ISO 8665) : 8.7 kW (11.8 hp) 11.6 kW (15.8 hp) Maximum Output at no. of revolutions of : 3000 rpm 3600 rpm Torque, : 32.7 Nm (3.3 kgm, 24.1 ft.lb) 35.1 Nm (3.6 kgm, 25.9 ft.lb) at no. of revolutions : 1600 rpm 2000 rpm Fuel consumption : 268 g/kW.h (196 g/hp.h, 6.9 oz/hp.h) 268 g/kW.h (196 g/hp.h, 6.9 oz/hp.h) at no.
10 Technical data Model Engine specifications : M2.02 M2.06 Oil lubrication system Oil capacity, max. without oil filter : 2.4 litres (4.2 Imp. pt, 5.1 US pt) with oil filter : 2.9 litres (5.1 Imp. pt, 6.1 US pt) Oil Filter : Vetus STM0051 Oil temperature in sump : max. 130°C (266°F) Cooling system Capacity, Intercooler version : 2.2 litres (3.9 Imp. pt, 4.6 US pt) : 3 litres (5.3 Imp. pt, 6.3 US pt) : opening at 71°C (160°F), fully opened at 84°C (183°F) Flow at max.
10 Technical data Model Engine specifications Gearbox specifications : M2.02 M2.06 Exhaust system Exhaust diameter : 40 mm Exhaust back pressure : at specified output max. 150 mbar (2.2 psi) Voltage : 12 Volt Alternator : 14 Volt, 75 Amp Starter motor : 14 Volt, 1,2 kW Battery capacity : min. 55 Ah, max. 108 Ah Protection : Tubular glass fuse, 32 x 6.
10 Technical data Torque wrench settings Screw connection Torque Diameter Wrench size Nm Cylinder head bolt M10 14 78 ±5 Cilinder head bolt M8 12 25 ±5 Connecting rod nut M8 14 33 ±1.5 Fly wheel bolt M10 17 88 ±5 Crank shaft pulley nut M16 24 108 ±10 Main bearing cap bolt M10 17 52 ±2.5 Rocker stay bolt M8 12 18 ±3.5 (kgm) (ft.lbf ) (8 ±0.5) (58 ±3.5) (2.5 ±0.5) (18 ±3.5) (3.35 ±0.15) (24 ±1) (9 ±0.5) (65 ±3.5) (11 ±1.0) (80 ±7) (5.25 ±0.
11 Operating media Fuel Fuel Quality Grade Winter-grade fuel Use only diesel fuel or diesel blends with up to 7% FAME (B7), with less than 0.5% sulphur content of which the quality is fully controlled and conform the standards below. Waxing may occur at low temperatures, clogging the fuel system and reducing engine efficiency. If the ambient temperature is less than 0°C (+32°F), winter-grade fuel -suitable down to -15°C (+5°F) - should be used.
11 Operating media Lubricating oil Engine oil Recommended lubricating oil viscosity Lubricating oils are specified by performance and quality classes. It is usual for the specifications to be indicated according to the API (American Petroleum Institute) and ACEA (European Automobile Manufacturers Association). There are two important considerations when it comes to ambient temperature in order to achieve satisfactory engine performance.
11 Operating media Caution Do not mix oil of different brands together. Oils of different brands are mostly not compatible with each other. If they are mixed, the mixtures can cause components such as piston rings, cylinders etc. to seize up and cause wear to moving parts. The best thing is to keep to one brand and one type of lubricating oil for each subsequent service.
11 Operating media Gearbox Lubricating Oil Only use a recognised brand of oil for lubricating the gearbox. Technodrive: type TMC40P : type TMC60A : ZF Hurth: type ZF10M : 0.2 litres, ATF [1] (0.35 Imp. pt, 0.42 US pt) 0.6 litres, ATF [1] (1.05 Imp. pt, 1.25 US pt) 0.42 litres ATF [1] (0.73 Imp. pt, 0.89 US pt) [1] ATF : AutomaticTransmission Fluid; Transmission oil type A, Suffix A.
11 Operating media Coolant Coolant fluid Water quality for coolant preparation The preparation and monitoring of coolant in inter-cooled engines is especially important because corrosion, cavitation and freezing can lead to engine damage. Use as coolant a mixture of a cooling system protective liquid (anti-freeze, ethylene glycol based) and tap water. Use preferably tap water. If an other available fresh water is used; the values given below must not be exceeded.
12 Wiring diagram Engine with panel model ‘20’, ‘21’, ‘22’ Starter switch '20' '21' Tachometer/ hourcounter Voltmeter Engine panel model '22' -8 X1 -5 -4 17/19 58 15 -7 31 D1 Red A1 Yellow A3 Orange Violet White A4 A2 -1 D3 -2 BZ L1 A6 R1 Plug 'A' R2 D4 L2 R3 L3 L4 A4 A2 A5 A6 D5 Gearbox oil pressure D9 D10 Pre-heating Preheating relay 30 86 87 85 X2M 19/94 61 -6 -4 91 -1 92 -2 93 -5 W -3 B6 B4 B1 B2 B5 B3 B6 B4 B1 B2 B5 B3 Plug 'B' B+ R G Bat
12 Wiring diagram Options, panel model ‘10’ Starter switch Engine panel model '10' L2: L3: L4: L5: L6: 31 17/19 58 J3 Q1 Black BZ R1 Plug 'A' R3 L2 R2 L3 L4 L5 D5 L6 J4 D6 D7 D8 D9 D10 Pre-heating 19/94 61 Plug 'B' B6 91 B4 92 B1 B2 93 W 95 B5 B3 VD00216 A6 L1 Gray A5 Warning lights Blue A2 D4 Brown A4 Violet White D3 Green A3 Orange D2 Yellow/Green A1 Yellow 15 Transparent Red D1 Battery charging Exhaust temperature Oil pressure Coolant temperatu
13 Overall dimensions 360 (14 3/16”) 430 (16 15/16”) 92 (3 5/8”) 505 (19 7/8”) 612 (24 1/8”) M2.02 / M2.06 112 1 2 3 4 Exhaust ø 40 mm Fuel return ø 8 mm Fuel supply ø 8 mm Sea water intake ø 20 mm 1 : 10 VD00924 168 (6 5/8”) 67.5 (2 11/16”) 160 (6 5/16”) max. 90 (3 9/16”) 4 min.
14 Index A Air bleed nipple, Water separator/fuel filter 12 Air inlet silencer 12 Airvent connection 13 Alarm buzzer 33 Alternator 13 B Battery 50 Battery cables 51 Battery charging, Warning light 14 battery connections 51 Biodiesel 105 Bleeding 24, 45 C Calorifier connection 13 Changing the gearbox oil 58, 82 Check engine for leaks 89 Checking coolant level 42 Checking engine oil level 40 Checking engine speed 71 Checking the alternator 70 Checking the starter motor 70 Check oil level 40 Cleaning the hea
14 Index Gearbox low oil pressure, Warning light gearbox 14 Gearbox Lubricating Oil 108 Gearbox oil dipstick/filler cap 13 Gearbox oil level check 54 Gearbox push-pull cable 12 Gearbox serial number: 1 Gearbox specifications 103 H Heat exchanger 13 Hose connections 63 I Identification of engine parts 12–13 Impeller inspection 65 Indicator light pre-heating 14 Instruments and remote controls 89 Introduction 9–15 L Lubricating oil 106–108 Lubrication system 82, 87 M Maintenance 36–75 Maintenance schedule
14 Index U Use 26–35 V Valve clearance, Checking / adjusting 60 V-belt 13 V-belt, Checking the 62 V-belt, Tensioning 62 Voltmeter 14, 33 Electrical system 83 Fresh water cooling system 81 Fuel system 78 Lubrication system 82 Protective fuel mixture 79 Raw water cooling system 80 Wiring diagram 110–111 W Warning indications 4–8 Warning light Battery charging 14 Gearbox low oil pressure 14 Low oil pressure 14 Raw water temperature 14 Warning light high High coolant temperature 14 Warning lights 33 water se
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Manuals Art. code Description 340801.01 340802.01 340803.01 340804.01 340805.01 340806.01 340807.01 340808.01 340809.01 340810.01 Bedieningshandleiding M2.02, M2.06 Operation manual M2.02, M2.06 Bedienungsanleitung M2.02, M2.06 Manuel d’utilisation M2.02, M2.06 Manual de operacion M2.02, M2.06 Istruzioni per l’uso M2.02, M2.06 Brugsanvisning M2.02, M2.06 Användarmanual M2.02, M2.06 Bruksanvisning M2.02, M2.06 Käyttöopas M2.02, M2.06 320331.
Nederlands English F O K K E R S T R A AT 5 7 - 3 1 2 5 B D S C H I E D A M - H O L L A N D - T E L . : + 3 1 ( 1 0 ) 4 3 7 7 7 0 0 FAX:+31 (10) 4372673 - 4621286 - E-MAIL: sales@vetus.nl - INTERNET: http://www.vetus.com 340802.01 2012-04 Printed in the Netherlands Vetus Diesel Diesel VF4 VF5 M2.02 M2.06 vetus n. v.
