M4.15 M4.17 Operation manual ii M4.15 M4.17 Operation manual Serial numbers Engine serial number Vetus: Mitsubishi: Gearbox serial number: 340202.03 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 © 2011 Vetus N.V. Schiedam Holland 1 Please read and observe the information given in this operation manual. This will enable you to avoid accidents, preserve the manufacturer’s warranty and maintain the engine in peak operating condition. pliance 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. For the Guarantee Conditions, see the Vetus Diesel Service and Warrantee Manual. The relevant accident prevention guidelines and other generally accepted safety and industrial hygiene regulations must be observed. 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 com- 2 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. Contents Serial numbers1 1Introduction4 5 Maintenance Checking the oil level 23 Checking the coolant level 24 Checking and cleaning the raw water strainer 2 Engine description General Identification of engine parts Control panels Cleaning the heat exchanger 44 Checking engine rpm 47 6 Winter lay-up 25 Winter storage procedure 48 6 Draining water from the water 8 separator/fuel filter 26 (Bleeding) 26 Changing the oil 28 7 Troubleshooting54 30 8 Technical Data60 10 Recommissioning after winter storage 51 Battery, cables and cable 3Use 11 connections First commissioning 12 Checking the gearbox oil level 32 Running-in 15 Changing the gearbox oil 33 Starting 16 Checking valve clearance 34 Lubrication Oil 63 (Pre-heating) 17 Replacing the fuel filter 36 Fuel 64 Cruising 19 Cleaning fuel lift pump 37 Coolant 65 Stopping 20 Checking the V-belt 38 General guidelines Checking flexible engine mounts39 Checking hose connections 39 21 Checking fastenings 39 22 Checking the raw water pump 40 4 Routine maintenance Introduction Maintenance schedule Coolant replacement 9 Operating media 10 Wiring Diagrams66 1 1 Overall Dimensions68 42 3 Introduction 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. 4 Introduction Safety measures All safety instructions in this manual are designated by the accompanying symbol. Please follow them carefully. • 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. 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. • 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. 5 Engine description VD01077 General VD01048 VD01049 Engine data tag Engine data tag location Engine serial number The Vetus engine serial number and performance data are printed on the engine data tag. The Vetus engine data tag is attached to the valve cover. The Mitsubishi engine serial number is stamped on the fuel injection pump. Model and engine serial number must be given when ordering spare parts. 6 Engine description General Lead seal VD00147 Maximum rpm adjustment screw VD00145 Cylinder numbering Fuel pump seal Cylinders are numbered consecutively, beginning at the front end. 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-Mitsubishi Service specialists only. 7 Engine description Identification of engine parts Service side 1 Oil filler cap 2 Fuel pump air bleed nipple 3Fuel supply pipe connection ø 8 mm 4 Fuel lift pump 5 Oil dipstick 6 Oil filter 7Water separator/fuel filter drain plug 8 Water separator/Fuel filter 9 Gearbox filler cap 10 Gearbox oil dipstick 11 Electrical system connectoion box 12 Fuse 13 Fuel return pipe connection ø 8 mm 14 Water separator/fuel filter air bleed nipple 15 Air inlet silencer 16 Manual operation of electric stop 17 Connection for throttle push-pull cable 18 Cooling system air bleed nipple / Connection for extra expansion tank (Keel cooling model only) 19 Calorifier connection 20 Gearbox drain plug 21 Gearbox VD01050 8 Identification of engine parts Starter side Engine description 22 Starter motor 23 Raw water inlet ø 20 mm 24 Raw water pump 25 V-belt 26 Alternator 27 Filler cap for cooling system 28 Expansion tank 29 Heat exchanger 30 Cooling system drain plug 31 Airvent connection 32 Exhaust injection bend ø 50 mm 33 Connection for gearbox push-pull cable VD01051 9 Engine description 1 Control panels 2 5 4 5 6 7 8 9 4 6 8 3 3 VD00576 VD00575 Basic panel (model 22) Fly-bridge panel (excl. voltmeter, model 21) Sailingboat panel (model 10) 1 Tachometer/Operating hours counter 2Voltmeter 3 Starter pre-heat switch/lock 4 Warning light high raw water temperature 5 Warning light low oil pressure 10 7 6 7 8 9 Warning light high coolant temperature Warning light battery charging Indicator light pre-heating Warning light gearbox low oil pressure * *) This is an option, not fitted as standard. 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. • 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 65. • Never run the engine without a thermostat. • Use a good quality lubricating oil. For specifications see page 63. • 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. 11 Use Engine Oil First commissioning OIL OIL 5 litres (1 UKgal) 15W40 API: CD, CE or CF4 ACEA: A3/B3, A3/B4 For example: - Vetus Marine Diesel Engine Oil 15W-40 - Shell Nautilus Premium Inboard Oil 15W-40 VD01052 Commissioning the engine 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 specification see page 63. Check the oil level with the dipstick, see page 23. 12 VD01053 A second oil filling cap is located at the front of the engine on starboard side. Use First commissioning Vetus engines are normally equipped with Technodrive or ZF-Hurth gearboxes. OIL OIL In case your engine is equipped with another brand of gearbox follow the instructions given in the supplied owners manual. VD01034 Filling gearbox with oil Fill the gearbox with oil. Check the oil level with the dipstick, see page 32. 17 Technodrive: type TMC40 :0.20 litres Engine oil SAE 20/30 type TMC40 M/P:0.20 litres, ATF*) (0.35 UK pt, 0.4 US pt) type TMC60 :0,80 liter, Engine oil SAE 20/30 type TMC60 E/P :0,80 liter, ATF*) (1.4 UK pt, 1.7 US pt) type TM345 A / H:1.6 litres, Engine oil SAE 20W40-CD (2.8 UK pt, 3.4 US pt) *) ATF: Automatic Transmission Fluid type A, Suffix A. VD01054 27 ZF Hurth: type ZF10M :0.35 litres ATF*) (0.6 UK pt, 0.74 US pt) type ZF12 :1.1 litres ATF*) (1.9 UK pt, 2.3 US pt) type ZF15MA :0.56 litres ATF*) (1 UK pt, 1.2 US pt) type ZF15V :1.0 litres ATF*) (1.8 UK pt, 2.1 US pt) *) ATF: Automatic Transmission Fluid type A, Suffix A. 13 Use First commissioning Coolant quantity : 6.5 litres (1.4 UKgal) Water 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. (3/8”) VD01055 VD00144 heater VD01056 13 Filling the cooling system 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. Fill the cooling system. Use a mixture of 40% antifreeze (ethyleneglycol based) and 60% tap water or use a special coolant. For specifications see page 65. 14 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. Never fill the cooling system with sea water or brackish water. First commissioning Running-in FUEL Use Never fill the fuel tank while the engine is running. Do not spill fuel. Prevent unnecessary pollution. VD00002 Fuel Other preparations Running-in Ensure that the fuel tank is filled with diesel fuel. Use only clean, water-free, commercial approved diesel fuel. For fuel grade see page 64. Bleed the fuel system, see page 26. • Check battery and cable connections. In order to ensure a long life for your engine, please observe the following for the first 50 operating hours: • Start the engine, see page 16, and let it run for about 10 minutes without load. Check the engine and all connections (fuel, cooling water and exhaust) for leaks. • 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. 15 Use Before starting, ing points: • • • • • Starting always check the follow- Engine oil level. Coolant level. Sea cock open. Main switch ‘on’. Gearbox in ‘neutral’ position. neutral gearbox reverse gearbox forward forward throttle reverse throttle VD00111 VD00112 After repair work: Preparation starting 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. 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. 16 half throttle, gearbox not engaged Set the control lever to ‘half throttle’ without engaging the gearbox. Use Starting Ambient Pre-heating time Temperature 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 1 minute pre-heating time VD00107 VD00108 Pre-heating 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. Turn the key further clockwise to the ‘ position; only the pre-heating indicator light will be lit now. Pre-heating time ’ Hold the key in this position for about 6 seconds. The ideal pre-heating time depends on ambient temperature; the lower the ambient temperature, the longer the pre-heating time required. See table. Warning To prevent the glow plugs from burning out, never exceed the stated maximum pre-heating time. 17 Use Starting VD00109 Warning 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. Never turn the key to the ‘start’ position while the engine is running. Doing so will damage the starter motor. 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. The instrument panel is provided with the following instruments (Depending of the type of panel, see page 10). VD00110 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. 18 Use Cruising VD00577 VD00578 Tachometer Voltmeter Warning lights 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. 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. If this alarm buzzer sounds while running, Stop the engine immediately! Idling speed, M4.15: 840 rpm M4.17: 840 rpm 19 Use VD00105 Stopping VD00106 Electrical shutdown Mechanical shutdown 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. 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. 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. 20 VD01057 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. Routine 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. 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. 21 Routine Maintenance Maintenance schedule Every 10 hours or daily, before starting Every 500 hours, at least once every year Check engine oil level 23 Gearbox oil change 33 Check coolant level 24 Check valve clearance 34 Check water strainer 25 Replace fuel filter 36 Cleaning fuel lift pump 37 Check V-belt 38 After the first 50 hours Drain water from fuel filter 26 Check flexible engine mounts 39 Engine oil change 28 Check engine for leaks 39 Replace oil filter 28 Check tightness of all fasteners, bolts and nuts 39 Gearbox oil change 33 Replace fuel filter 36 Every 1000 hours, at least once every 2 years Check idle rpm 47 Raw water pump inspection 40 Replace coolant 42 Every 100 hours, at least once every year Drain water from fuel filter 26 When required Engine oil change 28 Bleeding fuel system 26 Replace oil filter 28 Cleaning heat exchanger 44 Battery, cables and cable connections 30 Check idle rpm 47 Check gearbox oil level 32 Stop the engine before carrying out any maintenance work. 22 Maintenance Checking engine oil level Daily, before starting. VD01058 VD00126 VD01052 Check oil level Oil level Topping up oil Turn the engine off. The dipstick is located on the starboard side of the engine. The oil level must be at or near the upper mark on the dipstick*. If necessary top up with the same brand and type of oil. The oil filling cap is on top of the the valve cover. A second oil filling cap is located at the front of the engine on starboard side, see page 12. *) The difference between the two oil level marks is: 1.9 litres (3 1/4 UKpt) 23 Maintenance Checking coolant level Daily, before starting. VD01059 (3/8”) VD00144 13 VD01056 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 filler neck on the heat exchanger. The level of the coolant must be approx. 1 cm (3/8”) below the lower edge of the filler neck. 24 VD01055 Topping up coolant If necessary, top up. When topping up coolant, remove the bolt from the upper side of the thermostat cover, so that air can escape from the cooling system. Warning Never open the cap on the header tank when the engine is at operating temperature. The internal cooling system can be filled with a mixture of anti-freeze (40 %) and tap water (60 %) or with a special coolant. For specification, see page 65. Never fill the cooling system with sea water or brackish water. Checking and cleaning the raw water strainer Daily, before starting. VD00125 Maintenance CT30119 Checking the raw water strainer 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. A clogged raw water strainer will result in excessive temperatures or overheating of the engine coolant. Check the sealing between the lid and housing after cleaning and re-assembling the strainer. An improperly sealed lid will result in air sucked in by the sea water pump which again will result in overheating of the engine. 25 Maintenance VD01060 Draining of water from the water separator/fuel filter Every 100 operating hours. VD00027 VD00107 Empty fuel filter Empty water separator Bleeding • Open the drain plug at the lower side of the filter. • Drain the water and close the drain plug. Empty the separately installed water separator/fuel filter: • Open the drain plug at the lower side of the filter. • Drain the water and close the drain plug. 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. Note : The water separator is not within the scope of supply but installation is required! 26 Turn the key of the starter switch to position ‘ON’ and the fuel lift pump will feed the fuel system. Maintenance Draining of water from the water separator/fuel filter Every 100 operating hours. VD01061 13 VD01062 12 21 VD00109 Start the engine Open the two bleeding nipples to speed up the bleeding process. A second bleeding nipple is located at the fuel injection pump. One (1) bleeding nipple is located at the filter. Close the bleeding nipples when all air has escaped. 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. 27 Maintenance Engine oil change Every 100 operating hours. 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. VD01063 Change the oil with a switched off engine at operation temperature. (Lube oil temperature approx. 80°C (176°F).) 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. 28 VD01064 Draining the oil Removing the oil filter 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. Unscrew the oil filter, with a commercially available tool, when all the oil has been pumped out. Catch any dripping oil. Beware of burns from hot oil. Maintenance Engine oil change Every 100 operating hours. Oil filter, art.code: Amount of oil: 5.6 litres (1.25 UKgal) (oil filter incl.) STM0051 VD00124 VD01065 VD01052 Oiling the oil seal Oil filter installation Refilling with oil Clean the contact surface of the gasket. Lubricate the oil seal of the new filter element with clean engine oil. Install the filter in accordance with the instructions printed on the filter element housing. Refill the engine with new oil (for specification see page 63) through the filler opening in the valve cover. Operate the engine at idling speed for a short period of time. Check for oil leaks whilst the engine is running. Stop the engine. Allow 5 minutes for the oil to return to the sump. Check the oil level with the dipstick. 29 Maintenance Battery, cables and connections Every 100 operating hours. Vetus maintenance-free batteries VD00117 VD00118 Green Dot VD00121 All Dark VD00122 clear VD00123 Battery, battery connections Checking specific gravity Hydrometer operation Keep battery clean and dry. Remove battery cables (negative first). Clean battery posts (+ and -) and clamps and grease with acid-free and acid-resistant grease. Ensure that clamps make good contact after reassembling. Hand tighten the bolts only. Every Vetus Maintenance-free battery has a hydrometer (1) built into the cover. Visual inspection of the hydrometer will show one of three conditions: • Green dot visible - State of charge 65 % or more. • Dark- State of charge less than 65 %. Recharge immediately. • Clear or light yellow - Electrolyte level low. In case of low level, caused by overcharging the battery for a long period of time with a voltage too high, replace battery. Check alternator and/or voltage regulator. 30 Maintenance Battery, cables and connections Every 100 operating hours. Conventional batteries Conventional batteries Specific gravity State of charge 1.280 100% 1.200 50% recharge 1.120 10% recharge immediately VD00119 VD00120 Checking electrolyte level 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. Fluid should be 10 to 15 mm (3/8” 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. Measure the electrolyte specific 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. During checking the temperature of the electrolyte should preferably be 20°C (68°F). The gases emitted by the battery are explosive! Keep sparks and naked flames away from the battery! Do not allow battery acid to come into contact with skin or clothing! Wear protective goggles! Do not rest tools on the battery! 31 Maintenance VD01038 Gearbox oil level check Every 100 operating hours. 17 VD01066 27 Oil level check (ZF-Hurth) Oil level check (Technodrive) Unscrew the dipstick out of the gearbox housing. The oil level must between the two marks on the dipstick If necessary top up. The fillercap is on top of the gearbox housing. For oil type and specification see page 63. Check the oil level by cleaning the dipstick and lowering it into the hole, without screwing it in. The oil level should be between the end and the notch in the dipstick. If necessary top up by pouring oil in the dipstick hole. For oil type and specification see page 63. 32 Vetus engines are normally equipped with ZF-Hurth or Technodrive 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. Maintenance Changing the gearbox oil Every 500 operating hours. VD01043 VD01042 Draining the oil Drain the oil with the aid of a separate sump pump. Remove the dipstick (ZF-Hurth, 17) or 27). remove the dipstick (Technodrive, 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. VD01034 Filling with new oil Or, if sufficient space below the gearbox is available, oil can be drained by removing the drain plug. 17 Drain plug: ZF-Hurth Technodrive 14 Collect the oil in a dripping pan. Refill the gearbox to the correct level via the dipstick opening (ZF-Hurth, 17) or via the filling hole (Technodrive, 27). For oil specification see page 63. 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. 33 Maintenance Checking valve clearance Every 500 operating hours. Mark on TDC mark cylinder 1 and 4 gearcase Injection timing mark TDC mark cylinder 2 and 3 VD01067 12 VD00130 27 Checking / adjusting valve clearance Remove rocker cover 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 5 bolts of the rocker cover. Complete the following steps: 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 34 does not move when the crank pulley is rotated a little. Maintenance Checking valve clearance Every 500 operating hours. Valve VD01068 clearance:Inlet 0.25 mm (0.010”) Exhaust 0.25 mm (0.010”) 12 1.2 x 6.5 VD00146 Adjusting valve clearance Cylinder numbering • 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. Cylinders are numbered consecutively, beginning at the front end. 35 Maintenance Fuel filter replacement Every 500 operating hours. Fuel filter, art.code: STM3690 VD00154 VD01017 Fuel filter removal Fuel filter installation The fuel filter is to be replaced as a unit. • Close the fuel stopcock. • Clean any debris from the filter carrier rim. • Remove the fuel filter, use a filter wrench. Catch any fuel. • Lubricate the rubber gasket sparingly with clean engine oil. Keep naked flames away when working on the fuel system. Do not smoke! 36 • Fill the new filter with clean diesel fuel. VD00133 • Install the filter. When the rubber gasket touches the housing, apply another tightening of a half to three quarters of a turn by hand. Maintenance Cleaning fuel lift pump Every 500 operating hours. Fuel filter , art.code: STM4050 Fuel filter STM7220 VD00109 Fuel lift pump Bleeding Start the engine • Check, and if necessary clean, filter inside the fuel lift pump. After replacing the fuel filter and cleaning the pilot filter inside the fuel lift pump 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. • Open the fuel stop cock. For bleeding see page 26. • Check for leakage. Repeat the above if the engine cuts out after a short time. 37 Maintenance V-belt, art.code: Checking the V-belt Every 500 operating hours. STM7966 VD00034 VD00128 VD00129 12 14 Inspection V-belt Checking tension 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. 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 first re-tighten the upper mounting bolt of the alternator. Then re-tighten the bolt of the adjustment bracket and the lower mounting bolt. Check, tension and change belts only with the engine off. Refit belt guard, if provided. 38 Flexible engine mounts, hose connections and fasteners Every 500 operating hours. VD00160 Maintenance VD01069 Check flexible engine mounts Inspection hose connections 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 the rubber element of the engine support for cracks. Also check the deflection of the damper element, the deflection influences the alignment of engine and propshaft! Re-align engine in case of doubt. Inspect all hose connections of the coolingsystem. (Cracked hoses, loose hose clamps) Check tightness of all fasteners, bolts and nuts. 39 Maintenance Raw water pump inspection Every 1000 operating hours. VD01070 1.6 x 6.3 VD01071 VD01031 Raw water pump inspection Pump cover removal 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. Inspection where appropriate changing is as follows: • Slide the impeller off of the shaft using a waterpump plier. • Close the sea cock. • 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. • Remove the cover of the pump by unscrewing the screws out of the housing. 40 Maintenance Raw water pump inspection Every 1000 operating hours. Impeller, art.code: STM8061 VD00127 Gasket, VD00004 art.code: STM8002 VD00159 Impeller inspection Re-install the impeller Replacing 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. • Replace the cover with a new gasket. • Replace the impeller if necessary. • Check the water filter and open the sea cock. • Fit the impeller to the pump shaft. (if an existing impeller is re-used, install it in the same position as removed). 41 Maintenance Coolant replacement Every 1000 operating hours. Coolant replacement The coolant has to be replaced every 1000 operating hours or at least once every two years. 1 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. VD01072 2 14 Draining of coolant 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. 42 Remove the drain plugs from the engine block (1) and heat exchanger (2). Remove the filler cap to vent the cooling system and check that all the coolant has been drained. After draining replace the drain plugs. VD01073 13 Maintenance Coolant replacement Every 1000 operating hours. Coolant quantity : Water 6.5 litres (1.4 UKgal) 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. (3/8”) VD01055 VD00144 VD01056 13 Filling the cooling system 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. Fill the cooling system. Use a mixture of 40% antifreeze (ethyleneglycol based) and 60% tap water or use a special coolant. For specifications see page 65. 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. Never fill the cooling system with sea water or brackish water. 43 Maintenance VD01073 Cleaning the heat exchanger 13 VD01059 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. 44 VD01076 6 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. Take out both central bolts from the end covers and take the end covers with the O-rings out of the housing. Maintenance Cleaning the heat exchanger VD01075 6 VD01021 STM7217 Remove heat exchanger 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. 45 Maintenance Cleaning the heat exchanger O-ring, VD00157 art.code: STM6113 (2 x) VD00143 Replacing heat exchanger Replacing the end covers 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. Fit the end covers in the housing; the connector cover is fitted with a locating pin so that it can be fitted in one way only in relation to the heat exchanger. This ensures the correct position of the separator baffle in the connector cover in relation to the heat exchanger. Tighten up the bolts when both covers are in the correct position. • Refit the drain plug. • Reconnect all hoses previously removed. • Refill the cooling system, see page 43. 46 Maintenance Checking engine speed Warning Increasing RPM The maximum engine speed adjustment screw has been correctly set at the factory and sealed. DO NOT attempt to remove this seal. Minimum speed adjustment screw Lead seal VD00134 At full load (with the boat cruising) the maximum engine speed should be about 3,200 RPM (see technical data page 60). 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. Maximum speed adjustment screw VD00145 10 Checking engine speed Adjusting engine idling speed The engine idling speed should be 840 rpm. Allow the engine to warm up normally (until the coolant temperature reaches at least 60°C (140°F).) before checking and/ or adjusting the idling speed. Check the engine RPM using a rev. counter, or use the rev. counter fitted to the control panel. If the engine speed differs from that stated above, it must be adjusted. The engine idling speed can be reset using the adjustment screw on the fuel pump. 47 Winter lay-up VD01060 Winter storage procedure VD00136 Fuel system Running with protective fuel mixture Drain the water from the water separator/ fuel filter and the fuel tank. Ensure that the tank is completely filled with fuel. Connect the fuel supply pipe to a can filled with a mixture of one (1) part of engine oil* to nine (9) parts of clean fuel**. Use this mixture to run the engine at no load for approx. 10 minutes. Stop the engine. * Engine oil with protective properties. E.g. Shell Super Diesel T 10W40 **Preferably water-free fuel. Collect some fuel from the return pipe, while engine is running. Never run the engine under load with this mixture of fuel and oil. 48 Winter lay-up Winter storage procedure VD01063 VD00125 Lubrication system Raw water cooling system With the engine still at operating temperature: (If not, run the engine until warm, then turn off.) Close the seacock before removing the lid of the water strainer. If necessary, clean the raw water strainer. Pour 1 litre (2 UK pt) of anti-freeze into the water strainer and run the engine until the anti-freeze has disappeared into the cooling system. Take care that no anti-freeze is spilled into the waterway (anti-freeze is poisonous). Replace the oil filter and change the engine oil; use oil with protective properties. See page 63. 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. 49 Winter lay-up VD01059 Winter storage procedure VD00139 VD001xx Fresh water cooling system Electrical system Charging the batteries To avoid corrosion during winter storage the cooling system must be filled with an antifreeze/water mixture (or a coolant). For specifications see page 65. N.B. Replacing the coolant is only necessary if the coolant present in the cooling system offers insufficient protection for the winter. For coolant replacement see page 42. Disconnect the battery cables. Charge batteries during winter lay-up regularly if required! 50 Winter lay-up Recommissioning after winter storage 1 Check that the lid of the raw water strainer is reinstalled. VD00125 2 VD01074 Open the sea cock. VD00138 Check that the lid of the raw water pump and drain plugs are reinstalled. (pages 40, 42) VD01070 3 4 5 Check the coolant level. (page 24) VD01059 Re-tighten clamps. possible loose hose 6 Check the engine oil level. (page 23) VD01058 51 Winter lay-up 7 Recommissioning after winter storage Drain the water from the water separator/fuel filter. (page 26) VD00027 8 VD01017 52 Open the fuel valve. VD00137 Drain the water from the fuel tank. VD00141 9 10 11 Make sure that the batteries are fully charged. (pages 30, 50) CT40063 Install a new fuel filter. (page 36) 12 VD00140 Connect the batteries. Recommissioning after winter storage 13 Winter lay-up Start the engine. Check the fuel system, the cooling system and the exhaust for leakage. VD01078 14 Stop the engine and change the oil of the gearbox. (page 33) VD01043 15 Check the operation of the instruments, the remote control and the gearbox. VD00581 53 Troubleshooting General 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. If you are unable to identify the cause of the fault or to rectify it yourself, then contact the nearest service representative. Before starting, make sure that nobody is in the immediate vincinity of the engine. When carrying out repair, never start the engine with the fuel injection pump removed removed. Disconnect battery! 54 Troubleshooting Fault finding table 1 Engine will not crank 2 Engine cranks but will not start, no smoke from exhaust Possible fault Remedy Possible fault Remedy a a a aOpen. b Faulty or discharged battery Loose or corroded connections in starting circuit. c Faulty starter-switch or faulty starter-relay. d Faulty starter-motor or pinion does not engage. e Starter-relay is not engaged due to a voltage too low; caused by a very long intermediate cable from engine to control panel. Check / recharge battery and check engine alternator and/or battery charger. b Clean and tighten connections. c Check / replace. b c d e f d Check / replace startermotor. e Install an auxiliary starter relay. g Fuel stop valve closed. (Nearly) Empty fuel tank. Air in fuel system. Fuel filter clogged with water and/or contamination. Leaking fuel supply line or fuel injection line. Faulty injector/injection pump. bRefill. c d Check and bleed. Check or replace. e Check / replace. f Check, replace if required. g Check / clean. Vent line of fuel supply tank clogged. h Exhaust restricted. hCheck. i Check / replace. i Electric fuel lift pump doesn’t operate. j Delivery and suction valves of j Check / clean. electric fuel lift pump obstructed Install a fuel pilot filter in fuel line from tank to by dirt. engine. k Clogged filter of electric fuel lift k Check / clean. pump. 55 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 a a a aRefill. b b b b Air in fuel system. Faulty injector/injection pump. c Setting of stop valve incorrect. Faulty glow plugs. e Incorrect valve clearance. f Incorrect injection timing after overhauling of engine. g Insufficient intake air. d h i Wrong fuel quality or contaminated fuel. Incorrect lube oil SAE class or quality for ambient temperature. Check and bleed. Check, replace if required. c Check / adjust. d Check / replace. eAdjust. f Check / adjust. (Nearly) Empty fuel tank. Air in fuel system. c Fuel filter clogged with water and/or contamination. d Leaking fuel supply line or fuel injection line. e Faulty injector/injection pump. gCheck. f h g Check fuel. Drain and flush fuel tank. Replace with new fuel. iReplace. h i j k l 56 Vent line of fuel supply tank clogged. Fuel supply line restricted. Incorrect valve clearance. Idle setting too low. Exhaust restricted. Wrong fuel quality or contaminated fuel. Clogged filter of electric fuel lift pump. c Check and bleed. Check or replace. d Check / replace. e f Check, replace if required. Check / clean. g Check / clean. hAdjust. i Check/ adjust. jCheck. k Check fuel. Drain and flush fuel tank. Replace with new fuel. l Check / clean. Troubleshooting Fault finding table 5 Engine does not reach maximum rpm under load 6 Engine overheats Possible fault Remedy Possible fault a a b Check and bleed. Check or replace. a b c Check / replace. Air in fuel system. Fuel filter clogged with water and/or contamination. c Leaking fuel supply line or fuel injection line. d Faulty injector/injection pump. e f g h i j k Setting of stop valve incorrect. Oil level too high. Incorrect valve clearance. Exhaust restricted. Insufficient intake air. Wrong fuel quality or contaminated fuel. Engine overloaded. b c d d Check, replace if required. e Check / adjust. f Lower level. gAdjust. h Check / clean. iCheck. j Check fuel. Drain and flush fuel tank. Replace with new fuel. k Check size of propeller. e f g h i j k l m n Remedy Check, replace if required. Oil level too high. b Lower level. c Increase level. Oil level too low. Faulty oil filter. dReplace. e Check / clean. Coolant pump defective. Heat exchanger dirty or clogged f Check / clean. as a result of rubber particles from a worn impeller. g Check / top up. Coolant level too low. hOpen. Sea cock closed. Raw water strainer clogged. i Check / clean. j Check / replace. Leaking raw water intake system. k Check / replace. Faulty thermostat. Faulty impeller raw water pump. l Check / replace. m Check / replace air Insufficient intake air. intake filter. n Check / replace. Motor becomes apparantly overheated as a result of faulty temperature switch, sensor or meter. Faulty injector/injection pump. a 57 Troubleshooting Fault finding table 7 Engine not firing on all cylinders 8 Engine has little or no oil pressure Possible fault Remedy Possible fault Remedy a a a b Check and bleed. Check or replace. a b b b c Check / replace. Air in fuel system. Fuel filter clogged with water and/or contamination. c Leaking fuel supply line or fuel injection line. d Faulty injector/injection pump. e f g h i Check, replace if required. e Check / clean. Fuel supply line restricted. Faulty glow plugs. f Check / replace. gAdjust. Incorrect valve clearance. Clogged filter of electric fuel lift h Check / clean. pump. i Check / replace. Faulty electric fuel lift pump. Oil level too low. Excessive inclination of engine. c Incorrect lube oil SAE class or quality for ambient temperature. d 9 Engine oil consumption excessive Possible fault Remedy a a b c d e f 58 Increase level. Check / Adjust. cReplace. Oil level too high. Excessive inclination of engine. Incorrect lube oil SAE class or quality for ambient temperature. Excessive wear of cylinder/ piston. Insufficient intake air. Engine overloaded. Lower level. Check / Adjust. cReplace. b d Check compression; overhaul engine. eCheck. f Check size of propeller. Troubleshooting Fault finding table 10A Blue exhaust smoke (idling) 10C White exhaust smoke (at full load) Possible fault Remedy Possible fault Remedy a a a a b Oil level too high. Excessive inclination of engine. b Lower level. Check / Adjust. b Air in fuel system. Faulty injector/injection pump. c Water in fuel system. Faulty glow plugs. e Incorrect valve clearance. f Incorrect injection timing. g Wrong fuel quality or contaminated fuel. d 10B Black exhaust smoke (at load) Possible fault Remedy a aCheck. b b Insufficient intake air. Faulty injector / injection pump. c Engine overloaded, max. rpm is not reached. h Vapour in exhaust gases condenses as a result of very low ambient temperature. Check and bleed. Check, replace if required. c Check water separator. d Check / replace. eAdjust. f Check / adjust. g Check fuel. Drain and flush fuel tank. Replace with new fuel. hb Check/replace if required. c Check sizes of propeller. 59 Technical data Model Engine specifications M4.15M4.17 Model M4.15M4.17 General Maximum output Make Vetus Mitsubishi Number of cylinders 4 4 Based on S4L-61DM S4L2-61DM Type 4-stroke diesel, in-line InjectionIndirect AspirationNatural Bore 78 mm 78 mm Stroke 78.5 mm 92 mm Total displacement 1500 cm3 1758 cm3 Compression ratio 22 : 1 22 : 1 Idle speed 840 rpm 840 rpm Max. no. of revolutions at no load 3200 rpm 3200 rpm Valve clearance (cold) Inlet 0.25 mm Exhaust 0.25 mm Weight 185 kg (408 lbs) (with standard gearbox) at the flywheel (ISO 3046-1) 24.3 kW (33 hp)30.9 kW (42 hp) at the prop shaft (ISO 3046-1) 23.6 kW (32.1 hp)30 kW (40.8 hp) at no. of revolutions of 3000 rpm 3000 rpm Torque, 77.4 Nm 98 Nm (7.9 kgm, (10 kgm, 57.1 ft.lb) 72.3 ft.lb) at no. of revolutions 3000 rpm 3000 rpm Engine installation Max. installation angle Max. athwartships angle 60 15 degrees backwards 25 degrees continuously, 30 degrees intermittent Fuel consumption at no. of revolutions of 1800 rpm 252 g/kW.h (185 g/hp.h) 252 g/kW.h (185 g/hp.h) Fuel System (Self-bleeding) Injection pump Bosch model M (Nippon Denso) Injectors Plug injector Opening pressure140 bar (kgf/cm2) (2030 psi) Firing order 1-3-4-2 Injection timing 21° BTDC 17° BTDC Fuel filter elementSTM3690 Fuel lift pump Suction height max. max. 1.5 m (5 ft) Fuel supply connection for hose 8 mm (5/16”) I.D. Fuel return connection for hose 8 mm (5/16”) I.D. Technical data Engine specifications Model M4.15M4.17 Model M4.15M4.17 Oil lubrication system Exhaust system Oil capacity, max. without oil filter 5.4 litres (1.2 UKgal) with oil filter 5.6 litres (1.25 UKgal) Oil FilterSTM0051 Oil temperature insump max. 130°C (266°F) Exhaust diameter Exhaust back pressure Cooling system Capacity, Intercooler version Keel cooler version Thermostat Coolant pump, Flow at max. engine rpm Total head keelcooler at max. flow Raw water pump, Flow at max. engine rpm Total head at max. flow Impeller Inlet connection Heater return connection 6.5 litres (1.4 UKgal) 7.2 litres (1.6 UKgal) opening at 82°C±1.5°C (180°F±3°F), fully opened at 95°C (203°F) 50 l/min (11 UKgal/min) 2 m Water (6’ 7”) 30 l/min (6.6 UKgal/min) 2 m Water (6’ 7”) STM8061 for hose 20 mm (3/4”) I.D. 8 mm (5/16”) 50 mm at specified output max. 150 mbar (2.2 psi) Electrical system Voltage Alternator Battery capacity Protection 12 Volt 14 Volt, 50 A min. 55 Ah, max. 108 Ah Tubular glass fuse, 32 x 6.3 mm 10 A slow blow V-beltSTM7966 Gearbox Reduction ratio Technodrive: model model model model TMC40 TMC40M TMC60 (E,M) TM345 (A,H) ZF Hurth: model model model model ZF10M ZF12 ZF15MA ZF15V 1.45 / 2.00 : 1 1.45 / 2.00 : 1 1.5 / 2.00 / 2.50 : 1 1.54 / 2.0 / 2.47 : 1 2.05 2.14 1.88 2.13 / / / / 2.72 2.63 2.63 2.99 : : : : 1 1 1 1 61 Technical data Screw connection Torque wrench settings WrenchTorque Size Nm(kgm) DiameterPitch Cylinder head bolt M10 1.25 14 88 ±5 (9 ±0.5) Connecting rod nut M9 1.0 14 34.8 ±2.5 (3.55 ±0.25) (ft.lbf) (65 ±3.5) (26 ±2) Fly-wheel bolt M12 1.25 19 132 ±5 (13.5 ±0.5) (98 ±3.5) Crank shaft pulley nut M18 1.5 27 172 ±25 (17.5 ±2.5) (127 ±19) Main bearing cap bolt M10 1.25 17 51.5 ±2.5 (5.25 ±0.25) (38 ±2) Rocker stay bolt M8 1.25 12 14.7 ±5 (1.5 ±0.5) (10 ±3.5) Valve cover bolt M8 1.25 12 11.3 ±1.5 (1.15 ±0.15) (8 ±1) Nozzle holder M20 1.5 21 54 ±5 (5.5 ±0.5) (40 ±3.5) Fuel leak oil pipe nut M12 1.5 18 27 ±2.5 (2.75 ±0.25) (20 ±2) Nozzle retaining nut M16 0.75 19 37 ±2.5 (3.75 ±0.25) (27 ±2) Fuel injection pipe nut M12 1.5 — 29 ±5 (3 ±0.5) (22 ±3.5) 19 44 ±5 (4.5 ±0.5) (32 ±3.5) Delivery valve holder — Solenoid lock nut M30 1.5 36 44 ±5 (4.5 ±0.5) (32 ±3.5) Temperature switch M16 1.5 17 22.6 ±4 (2.3 ±0.4) (16 ±3) Oil filter M20 1.5 — 12 ±1 (1.2 ±0.1) (9 ±0.8) 26 10 ±2 (1 ±0.2) (7 ±1.5) 22 49 ±5 (5 ±0.5) (36 ±3.5) ±0.5) Oil pressure switch Pressure relief valve PT1/8 M22 1.5 Oil drain plug M14 1.5 22 39 ±5 (4 Glow plug M10 1.25 12 17.2 ±2.5 (1.75 ±0.25) (13 ±2) Fly-wheel housing bolt M12 1.25 17 64 ±10 (6.5 ±1) (47 ±7) 62 (29 ±3.5) Operating media Lubricating oil Engine Lubricating Oil Gearbox Lubricating Oil Only use a recognised brand of oil for lubricating the engine. Only use a recognised brand of oil for lubricating the gearbox. Lube oils are differentiated according to their performance and quality class. In common use are specifications named after API (American Petroleum Institute) and CCMC (Committee of Common Market Automobile Constructors). Approved API Oils : CD, CE and CF4 Approved ACEA Oils : A3/B3, A3/B4 Technodrive: model TMC40 :0.20 litres, Engine oil SAE 20/30 model TMC40 M / P:0.20 litres, ATF*) (0.35 UK pt, 0.4 US pt) model TMC60 :0.80 litres, Engine oil SAE 20/30 model TMC60 E / P:0.80 litres, ATF*) (1.4 UK pt, 1.7 US pt) model TM345 A / H :1.6 litres, Engine oil SAE 20W-40-CD (2.8 UK pt, 3.4 US pt) As the viscosity of lube oil is dependent on temperature, the oil vicosity (SAE grade) should be selected according to the ambient temperature when the the engine is started. To avoid oil changes dictated by the seasons we advise one of the following multi-grade oils. - SAE 10W40 for temperatures of -25°C up to +30°C (-13°F up to +86°F) - SAE 15W40 for temperatures of -20°C up to +35°C (-4°F up to +95°F) For example: Vetus Marine Diesel Engine Oil 15W-40 Shell Nautilus Premium Inboard Oil 15W-40 ZF Hurth: model ZF10M model 12 model 15MA model 15V :0.35 litres, ATF*) (0.6 UK pt, 0.74 US pt) :1.1 litres, ATF*) (1.9 UK pt, 2.3 US pt) :0.56 litres, ATF*) (1 UK pt, 1.2 US pt) :1.0 litres, ATF*) (1.8 UK pt, 2.1 US pt) Other brands of gearboxes: See supplied owners manual for oil type and quantities. *) ATF :AutomaticTransmission Fluid; Transmissie olie type A, Suffix A. For example :Vetus Transmission Oil Shell Donax T6 Gulf ATF Synth 63 Operating media Fuel Fuel Quality Grade Winter-grade fuel Use commercially available diesel fuel with less than 0.5% sulfer content. If the sulfur content is higher than 0.5%, the intervals between oil changes should be halved e.g. change oil every 250 hours. Don’t use fuel with more than 1% sulfur! 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. This fuel is usually available from filling stations well in advance of the cold months. Diesel fuel containing additives (Super Diesel) is often on sale as well, for use down to -20°C (-4°F). The following fuel specifications / standards are approved: • CEN EN 590 or DIN/EN 590 (under development) • DIN 51 601 (Feb. 1986) • BS 2869 (1988): A1 and A2 • ASTM D975-88: D1 and D2 • NATO Code F-54 and F75 The exhaust emission levels determined during certification by the supervising authority are always based on the reference fuel described by law. 64 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. In tropical climates, where anti-freeze availability may be limited, use a corrosion inhibitor to protect the engine cooling system. The concentration of the cooling system protective liquid in the coolant should not fall below/exceed the following limits: Cooling system protective Water Protection against liquid (Anti-freeze) freezing to max. 45 vol% 55% -35°C (-31°F) 40 vol% 60% -28°C (-18°F) min. 35 vol% 65% -22°C (-8°F) The protective liquid concentration must be maintained under all circumstances. Therefor if coolant must be added always use the same mixture of anti-freeze and tap water. If an other available fresh water is used; the values given below must not be exceeded. Water quality min. pH-value at 20°C (68°F) 6.5 Chloride ion content [mg/dm max. 8.5 3]– 100 Sulfate ion content [mg/dm3]– 100 Total hardness [degrees] 3 12 Never use sea-water or brackish water. Cooling system protective liquids must be disposed of in accordance with environmental regulations. 65 Wiring diagram Engine with panel model ‘20’, ‘21’, ‘22’ Key switch Engine panel model '20' 03-09 <- '21' Voltmeter Tachometer/ hour counter '22' -8 X1 -5 -4 17/19 58 15 -7 31 D1 D2 -1 D3 Model 20 21 22 Voltmeter Ð Ð 1 Tachometer Ð 1 1 n/h V -2 -3 -6 W 95 D4 Warning lights Red A1 Yellow Orange Violet A3 A4 A2 White Q1 Black A5 BZ L1 A6 R1 Plug 'A' R2 L2 R3 L3 L4 L5 L6 D5 Gearbox oil press. D6 Socket 'A' D7 A1 Fuse or circuit breaker A3 A4 A2 A5 D8 A6 D9 Auxiliary start relay Preheating relay D10 Preheating 30 86 30 86 87 85 87 85 X2M 19/94 61 -6 -4 91 -1 92 -2 93 -5 W -3 B6 B4 B1 B2 B5 B3 B6 B4 Yellow/ Green B1 B2 B5 B3 Plug 'B' Socket 'B' Battery main switch Transparent Green Brown Blue ϑ R Battery M ϑ Yellow/ Green p B+ G M p Gray D+ Battery charging 3Y W Starter motor VD00407 66 Pre-heating Fuel pump ETR Stop solenoid ETS Alternator Exhaust Oil Coolant temp. press. temp. Gearbox oil press. Wiring diagram Options, panel model ‘10’ Key switch Engine panel model '10' 03-09 <- 31 17/19 58 J3 Red A1 Yellow Orange A3 A4 Violet A2 White D1 D3 D4 Warning lights Q1 Black A5 D2 15 BZ L1 A6 R1 Plug 'A' R3 L2 R2 L3 L4 L5 D5 J4 D6 Socket 'A' D7 A1 Fuse or circuit breaker A3 A4 A2 A5 D8 A6 D9 Auxiliary start relay D10 Preheating 30 86 Preheating relay 30 86 87 85 87 19/94 61 91 92 93 W B6 B4 B1 B2 B5 B3 B6 B4 Yellow/ Green B1 B2 B5 B3 95 Plug 'B' Socket 'B' Battery main switch 85 Transparent Green Brown Blue ϑ R Battery L6 M ϑ B+ G M p Gray D+ Battery charging 3Y W Starter motor VD00406 Pre-heating Fuel pump ETR Stop solenoid ETS Alternator Oil Coolant Exhaust temp. press. temp. 67 Wiring diagram Engine with panel model ‘20’, ‘21’, ‘22’ engine with intercooling Key switch Engine panel model '20' '21' Voltmeter Tachometer/ hour counter '22' 03-09 -> n/h V -8 X1 -5 -4 17/19 58 15 -7 31 D1 D2 -1 D3 Model 20 21 22 Voltmeter − − 1 Tachometer − 1 1 -2 -3 -6 W 95 D4 Warning lights Red A1 Yellow Orange Violet A3 A4 A2 White Q1 Black A5 BZ L1 A6 R1 Plug 'A' R2 L2 R3 L3 L4 L5 L6 L3 L4 L5 L2 L1 L6 D5 Gearbox oil press. D6 Socket 'A' D7 A1 Fuse or circuit breaker A3 A4 A2 A5 D8 A6 D9 Auxiliary start relay Preheating relay D10 Preheating 30 86 30 86 87 85 87 85 X2M 19/94 61 -6 -4 91 -1 92 -2 93 -5 W -3 B6 B4 B1 B2 B5 B3 B6 B4 Yellow/ Green B1 B2 B5 B3 Violet Socket 'B' Battery main switch Transparent Green Brown Blue ϑ R Battery Connection for 2nd alternator Plug 'B' M ϑ Yellow/ Green p B+ G M p Gray D+ Battery charging Starter motor 68 Pre-heating Fuel pump ETR Stop solenoid ETS Alternator Battery charging 2nd alternator 1 Yellow/ Green Black 2 3Y W VD00407 3 Oil Coolant Exhaust temp. press. temp. Gearbox oil press. Wiring diagram Options, 2nd alternator engine with intercooling 03-09 -> 2nd Alternator Fuse 5A Violet Red 30 86 85 Consumers Red 87a 87 Battery main switch White 30 86 30 86 3 87a Yellow/ 2 Green 1 Black 87 85 87a 87 85 1N4002 B+ D+ G Yellow 3Y W Battery 2nd Alternator VD00650 69 Wiring diagram Engine with panel model ‘20’, ‘21’, ‘22’ engine with keel cooling Key switch Engine panel model 03-09 -> '20' '21' Voltmeter Tachometer/ hour counter '22' -8 X1 -5 -4 17/19 58 15 -7 31 D1 D2 -1 D3 Model 20 21 22 Voltmeter − − 1 Tachometer − 1 1 n/h V -2 -3 -6 W 95 D4 Warning lights Red A1 Yellow Orange Violet A3 A4 A2 White Q1 Black A5 BZ L1 A6 R1 Plug 'A' R2 L2 R3 L3 L4 L5 L6 D5 Gearbox oil press. D6 Socket 'A' D7 A1 Fuse or circuit breaker A3 A4 A2 A5 D8 A6 D9 Auxiliary start relay Preheating relay D10 Preheating 30 86 30 86 87 85 87 85 X2M 19/94 61 -6 -4 91 -1 92 -2 93 -5 W -3 B6 B4 B1 B2 B5 B3 B6 B4 Yellow/ Green B1 B2 B5 B3 Plug 'B' Socket 'B' Battery main switch Transparent Green Brown Blue p R Battery M Yellow/ Green p B+ G M ϑ Gray D+ Battery charging 3Y W Starter motor VD00651 70 Pre-heating Fuel pump ETR Stop solenoid ETS Alternator Oil Coolant press. temp. Gearbox oil press. Engine with panel model ‘20’, ‘21’, ‘22’ engine with keel cooling Wiring diagram 03-09 -> 2nd Alternator L3 L4 L5 L2 L1 L6 Fuse 5A Violet Red 30 86 85 Consumers Red 87a 87 Battery main switch White 30 87a 87 86 85 87a 30 86 87 85 1N4002 B+ D+ G Yellow 3Y Green Black W Battery 2nd Alternator Battery charging 2nd alternator 71 Wiring diagram Options, panel model ‘10’ engine with intercooling Key switch Engine panel model '10' 03-09 -> 31 17/19 58 J3 Red A1 Yellow Orange A3 A4 Violet A2 White D1 D3 D4 Warning lights BZ L1 A6 R1 Plug 'A' R3 L2 R2 L3 L4 L5 D5 A3 A4 A2 A5 L4 & L6 D8 A6 D9 Auxiliary start relay D10 Preheating 30 86 Preheating relay 30 86 87 85 87 19/94 61 B6 B4 91 92 93 B1 B2 B5 B3 Plug 'B' 85 B6 B4 Yellow/ Green B1 M B5 p ϑ B+ G M B2 Green Brown Blue ϑ R D+ Battery charging Pre-heating Fuel pump ETR Stop solenoid ETS Alternator Connection for 2nd alternator 3 B3 Gray Battery charging 2nd alternator 1 Yellow/ Green Black 2 3Y W Starter motor 95 Violet Transparent 72 W Socket 'B' Battery main switch VD00652 L6 D7 A1 Fuse or circuit breaker L1 L2 J4 D6 Socket 'A' Battery L3 L5 Q1 Black A5 D2 15 Oil Coolant Exhaust temp. press. temp. Wiring diagram Options, panel model ‘34’ engine with intercooling Key switch Tachometer/ hour counter Voltmeter Engine panel model Oil pressure gauge Temperature gauge 03-09 -> '34' -5 -4 -3 -6 -1 -2 17/19 58 15 W 95 M1 M2 -8 X1 -7 31 ϑ p n/h V D1 D2 D3 D4 Warning lights Q1 BZ L1 R1 R2 L2 R3 L3 L4 L5 L6 L3 L4 L5 L2 L1 L6 D5 Gearbox oil press. D6 D7 D8 D9 D10 Red A1 Yellow Orange Violet A3 A4 A2 White Preheating Black A5 X2M 19/94 61 -6 -4 91 -1 92 -2 93 -5 W -3 Ð X3M (31) -1 A6 + (15) X4M G1 -1 -2 G2 NC NC -2 -3 -4 + Plug 'A' Interface STM6911 Socket 'A' A1 Fuse or circuit breaker 30 A3 A4 A2 A5 -1 A6 86 Preheating relay 30 B6 B4 B1 87 85 87 B2 B5 B3 B6 B4 B1 -3 -1 -2 -3 -4 2nd B3 panel Interface cable MPVB2 Connection for 2nd alternator B6 R B4 Yellow/ Green B1 B2 B5 Green Brown Blue p ϑ D+ 3 B3 Gray Yellow/ Green p B+ G M Violet Socket 'B' 85 ϑ M B5 Plug 'B' Transparent Battery B2 86 Socket 'B' To Battery main switch -2 Auxiliary start relay Battery charging 2nd alternator 1 Yellow/ Green Black 2 Battery charging 3Y W Starter motor Pre-heating (Glow plugs) Fuel lift pump ETR Stop solenoid ETS Alternator Exhaust Oil Coolant temp. press. temp. Gearbox oil press. VD00635 73 Overall Dimensions Sea water intake ø 20 mm Fuel return ø 8 mm Exhaust ø 50 mm Fuel supply ø 8 mm M4.15 / M4.17 74 1:10 75 76 Manual Art. code 340201.03 (STM0118) 340202.03 (STM0119) 340203.02 (STM0124) 340204.03 (STM0125) 340205.02 (STM0126) 340206.02 (STM0127) 340207.02 (STM0128) 340208.02 (STM0129) 340210.01 Description Bedieningshandleiding Operation manual Bedienungsanleitung Manuel d’utilisation Manual de operacion Istruzioni per l’uso Brugsanvisning Användarmanual Käyttöopas 320331.01 (STM0032) Installatiehandleiding / Installation manual 320199.05 (STM0016) Service- en Garantieboek / Service and Warranty Manual (Nederlands/English / Service- und Garantieheft / Livret Garantie et Service / (Deutsch/Français) Manual de servicio y garantía / Libretto di assistenza e garanzia (Español/Italiano) 341331.01 (STM0091) Onderdelenboek / Parts manual M4.15 / M4.17 (Nederlands/English) 342402.02 Service manual M4.15 / M4.17 (English) M4.15 M4.15 M4.15 M4.15 M4.15 M4.15 M4.15 M4.15 M4.15 / / / / / / / / / M4.17 M4.17 M4.17 M4.17 M4.17 M4.17 M4.17 M4.17 M4.17 (Nederlands) (English) (Deutsch) (Français) (Español) (Italiano) (Dansk) (Svenska) (Suomeksi) (Nederlands/English) 77 Nederlands English 78 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: firstname.lastname@example.org - INTERNET: http://www.vetus.com 340202.03 2011-11 Printed in the Netherlands Vetus Vetus Diesel VF4 VF5 Diesel M4.15 M4.17 vetus n. v.