VETUS User M3.28 Operation Manuals

M3.28

Operation manual

ii

Operation manual M3.28

Serial numbers

Engine serial number Vetus:

Mitsubishi:

Gearbox serial number:

Please enter the serial numbers here.

These numbers should be quoted when inquiring about Customer

Service, Repairs or Spare Parts (see page 6).

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

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.

For the Guarantee Conditions, see the

Vetus Diesel 'Service and Warrantee

Manual' (320199.04 / STM0016).

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

2 the intended purpose. The manufacturer will not not assume responsibility for any damage resulting therefrom. The risks involved are to be borne by the user.

Use in accordance with the intended purpose also implies compliance with the conditions laid down by the manufacturer for operation, maintenance and servicing. The engine should only be operated, maintained and serviced by persons which are familiar with the former and the hazards involved.

The relevant accident prevention guidelines and other generally accepted safety and industrial hygiene regulations must be observed.

Unauthorized engine modifications will invalidate any liability claims against the manufacturer for resultant damage.

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

Contents

1 Safety measures

2 Introduction

Data tag

Serial number

Cylinder numbering

Fuel pump seal

Identification of engine parts

Control panels

8

10

7

7

5

6

6

4

3 Use

General guidelines

First commissioning

Running-in

Starting

Pre-heating

Cruising

Stopping

4 Maintenance

Introduction

Maintenance schedule

21

22

17

19

20

11

12

15

16

Checking the oil level

Checking the coolant level

Checking and cleaning the

23

24

raw water strainer

Draining water from the water

separator/fuel filter

(Bleeding)

25

Changing the oil

Battery, cables and cable

connections 30

Checking the gearbox oil level 32

26

26

28

Changing the gearbox oil

Checking valve clearance

Replacing the fuel filter

Checking the V-belt

Checking flexible engine mounts 39

Checking hose connections 39

Checking fastenings 39

Checking the raw water pump 40

33

34

36

38

Coolant replacement 42

Cleaning the heat exchanger 44

Checking engine rpm 47

5 Winter storage procedure

49

6 Recommissioning after winter

storage

51

7 Troubleshooting

8 Technical Data

9 Operating media

Lubrication Oil

Fuel

Coolant

56

62

65

66

67

10 Wiring Diagrams

11 Overall Dimensions

12 Index

68

70

71

3

1 Safety measures

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

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

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

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

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

• Always stop the engine before checking or adjusting components.

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

• N ever

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.

4 4

2 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 den Ouden n.v.

5 5

2 Introduction

Data tag, Serial number

VD01044

1 Engine data tag

VD01036

2 Engine data tag location

VD01035

3 Engine serial number

The v etus

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

The v etus

engine data tag is attached to the flywheel housing.

The M itsubishi

engine serial number is stamped on the fuel injection pump.

(arrow)

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

6

2 Introduction

Cylinder numbering, Fuel pump seal

Maximum rpm adjustment screw

Lead seal

VD00153

4 Cylinder numbering

VD00150

5 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

2 Introduction

1 Oil filler cap

2 Raw water inlet ø 20 mm

3 Raw water pump

4 Oil dipstick

5 Manual operation of fuel supply pump

6 Oil filter

7 Water separator/fuel filter drain plug

8 Water separator/Fuel filter

9 Gearbox oil dipstick/filler cap

10 Fuse

11 Electrical system connector box

12 Fuel return pipe connection

ø 8 mm

13 Air inlet silencer

14 Water separator/fuel filter air bleed nipple

15 Manual operation of electric stop

16 Fuel supply pipe connection

ø 8 mm

17 Fuel lift pump

18 Connection for throttle push-pull cable

19 Gearbox

8

VD01118

Identification of engine parts

Service side

2 Introduction

VD01119

Identification of engine parts

Starter side

20 Gearbox drain plug

21 Connection for gearbox push-pull cable

22 Starter motor

23 Alternator

24 V-belt

25 Connection for extra expansion tank (Keel cooling model only)

26 Calorifier connection

27 Cooling system air bleed nipple

28 Filler cap for cooling system

29 Expansion tank

30 Heat exchanger

31 Cooling system drain plug

32 Airvent connection

33 Exhaust injection bend ø 40 mm

9

2 Introduction

1 2

5 4 6 8 7 3

Control panels

4 5 6 7 8 9 3

VD00576

Basic panel (model 22)

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

1 Tachometer/Operating hours counter

2 Voltmeter

3 Starter pre-heat switch/lock

4 Warning light high raw water temperature

5 Warning light low oil pressure

6 Warning light high coolant temperature

10

VD00575

Sailingboat panel (model 10)

7 Warning light battery charging

8 Indicator light pre-heating

9 Warning light gearbox low oil pressure *

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

3 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.

as well as protecting against frost damage. For specifications see page 67.

• Never run the engine without a thermostat.

• Carry out the maintenance described regularly, including the ‘Daily procedures before starting’.

• Use a good quality lubricating oil. For specifications see page 65.

• Always stop the engine immediately if one of the warning lamps for oil pressure, high coolant temperature, high raw water temperature or battery charging lights up.

• Use anti-freeze in the engine coolant all year long, this helps prevent corrosion

• Use a good quality diesel fuel that is free of water and other pollutants.

11

3 Use

First commissioning

Engine Oil

3.6 litres (6 UK pt, 7.6 US pt) 15W-40

API: CF, CF-4 or CI-4

ACEA: A3/B3, A3/B4

OIL OIL

For example:

- Vetus Marine Diesel Engine Oil

15W-40

- Shell Nautilus Premium Inboard Oil

15W-40

1 Commissioning the engine

VD01120

2 Filling with engine oil

VD01002

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 65.

A second oil filling cap is located at the distribution cover.

Check the oil level with the dipstick, see page 23.

12

3 Use

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

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

OIL OIL


3 Filling gearbox with oil

Fill the gearbox with oil.

Check the oil level with the dipstick, see page 32.

17

VD01024

ZF Hurth: type ZF10M type ZF12

: 0.35 litres ATF*)

(0.6 UK pt, 0.74 US pt)

: 1.1 litres ATF*)

(1.9 UK pt, 2.3 US pt) type ZF15MA : 0.56 litres ATF*) type ZF15V

(1 UK pt, 1.2 US pt)

: 1.0 litres ATF*)

(1.8 UK pt, 2.1 US pt)

27

VD01024

Technodrive: type TMC40 : 0.20 litres Engine oil

SAE 20/30 type TMC40M : 0.20 litres, ATF*) type TMC40P : 0.20 litres, ATF*)

(0.35 UK pt, 0.4 US pt) type TM345 A / H : 1.6 litres, Engine oil

SAE 20W40-CD

(2.8 UK pt, 3.4 US pt)

*) ATF: Automatic Trans mission Fluid type

A, Suffix A.

*) ATF: Automatic Trans mission Fluid type

A, Suffix A.

13

3 Use

C oolant quantity

: 3.0 litres

(5.3 UK pt, 6.3 US pt)

(3/8”)


W

ater heater

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

VD01121 VD00158

4 Filling the cooling system

VD01005

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 67.

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.

3 Use

FUEL


Running-in

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

VD00002

5 Fuel 6 Other preparations 7 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 66.

Bleed the fuel system, see page 26.

• Check battery and cable connections.

• 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.

In order to ensure a long life for your engine, please observe the following for the first 50 operating hours:

• Allow the engine to reach operating temperature before applying a load.

• Avoid fast acceleration.

• Do not allow the engine to run faster than 3/4 of maximum RPM.

15

3 Use

Before starting, alWays

check the following points:

• Engine oil level.

• Coolant level.

• Sea cock open.

• Main switch ‘ oN

’.

• Gearbox in ‘

Neutral

’ position.

gearbox reverse reverse throttle neutral gearbox forward forward throttle

Starting

half throttle, gearbox not engaged

After repair work:

VD00111

8 Preparation starting

VD00112

9 Control lever

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.

Set the control lever to ‘half throttle’ with-

out engaging the gearbox.

Never start the engine with the fuel injection pump removed.

Disconnect battery.

16

3 Use

Starting

Ambient

Temperature

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

VD00107 VD00108

10 Pre-heating

Maximum

pre-heating time

1 minute

11 Pre-heating time

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.

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.

W

arNiNg

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

17

3 Use

Starting

VD00109

W

arNiNg

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.

W

arNiNg

Never turn the key to the ‘ start

’ position while the engine is running.

Doing so will damage the starter motor.

VD00110

12 Starting

Now turn the key further to the ‘ start

’ position.

Release the key as soon as the engine fires (the key will return to the ‘ oN

’ position) and throttle back.

Leave the key in this position while the engine is running.

Check that the indicator lights for oil pressure and alternator are off. Cooling water should now flow out of the exhaust; if this is not the case, stop the engine immediately. Before submitting the engine to full load it should be brought up to operating temperature as quickly as possible by running at 3/4 of maximum revs.

Never turn the main switch off while the engine is running.

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

18

3 Use

Cruising

VD00113

13 Tachometer

VD00114

14 Voltmeter 15 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.

Idling speed : 900 rpm

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, s top the eNgiNe iMMedi

ately

!

19

3 Use

Stopping

VD00105

16 Electrical shutdown

VD00106 VD01037

17 Mechanical shutdown

Reduce engine speed to idle and shift the gearbox to ‘N eutral

’. Turn the key entirely to the left, through the ‘o ff

’ position.

When the engine has stopped, turn the key to the ‘o ff

’ position.

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.

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

4 Maintenance

Introduction

Introduction

The following guidelines should be observed for daily and periodic maintenance. Perform each function at the indicated time interval.

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.

The intervals stated are for normal operational conditions. Service the unit more frequently under severe conditions.

21

4 Maintenance

Every 10 hours or daily, before starting

Check engine oil level

Check coolant level

Check water strainer

After the first 50 hours

Drain water from fuel filter

Engine oil change

Replace oil filter

Gearbox oil change

Replace fuel filter

Check idle rpm

Every 100 hours, at least once every year

Drain water from fuel filter

Engine oil change

Replace oil filter

Battery, cables and cable connections

Check gearbox oil level

26

28

28

30

32

26

28

28

33

36

47

23

24

25

Maintenance schedule

Every 500 hours, at least once every year

Gearbox oil change

Check valve clearance

Replace fuel filter

Check V-belt

Check flexible engine mounts

Check engine for leaks

Check tightness of all fasteners, bolts and nuts

Every 1000 hours, at least once every 2 years

Raw water pump inspection

Replace coolant

40

42

When required

Bleeding fuel system

Cleaning heat exchanger

Check idle rpm

26

44

47

33

34

36

38

39

39

39

Stop the engine before carrying out any maintenance work.

22

4 Maintenance

Checking engine oil level

Daily, before starting.

VD01001

1 Check oil level

VD00155

2 Oil level

VD01120

3 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,.

*) The difference between the two oil level marks is:

1.8 litres (3.2 UK pt, 3.8 US pt)

A second oil filling cap is located at the distrubution cover, see page 12.

23

4 Maintenance

Checking coolant level


VD01122

(3/8”)

VD00158

4 Checking coolant level

VD01005 VD01121

5 Topping up coolant

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.



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.

W

arNiNg

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

24

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 67


4 Maintenance

Checking and cleaning the raw water strainer


VD00125

6 Checking the raw water strainer

CT30119

7 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

4 Maintenance

Draining of water from the water separator/fuel filter

Every 100 operating hours.

13

VD01006

8 Empty fuel filter

CT30119

9 Empty water separator

VD01007

10 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; but manual bleeding the system is recommended.

Open the two bleeding nipples.

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

One (1) bleeding nipple is located at the filter.

26

4 Maintenance

Draining of water from the water separator/fuel filter


10 14

VD01008 VD01009 VD00109

11 Start the engine

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

Prime the fuel system by pumping the fuel pump.

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.

N.B. It is necessary to operate the lever over the full stroke for proper operation.

Repeat the above if the engine cuts out after a short time.

27

4 Maintenance

12 Engine oil change

Change the engine oil every 100 hours of operation (together with engine oil filter replacement).

Engine oil change


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.

VD01010

13 Draining the oil

VD01026

14 Removing the oil filter

Change the oil with a switched off engine at operation temperature. (Lube oil temperature approx. 80°C (176°F).)

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.

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

Beware of burns from hot oil.

4 Maintenance o il filter

, art

.

Code

: StM0051

Engine oil change


a

Mount of oil

: 4.1 litres

( oil filter inCl

.) (7.2 UK pt, 8.7 US pt)

VD00124

15 Oiling the oil seal

VD01011

16 Oil filter installation

VD01120

17 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 65) 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

4 Maintenance

Vetus maintenance-free batteries

Battery, cables and connections


GREEN

DOT

All DARk ClEAR

VD00117

18 Battery, battery connections

VD00118

19 Checking specific gravity

VD00121 VD00122 VD00123

20 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

4 Maintenance

Conventional batteries Conventional batteries

Battery, cables and connections


Specific gravity

State of charge

1.280

1.200

100%

50% recharge

1.120 10% recharge immediately

VD00119

21 Checking electrolyte level

VD00120

22 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

4 Maintenance

Gearbox oil level check


17

VD01038

23 Oil level check (ZF-Hurth)

VD01032

24 Oil level check (Technodrive)

Unscrew the dipstick out of the gearbox housing.

Check the oil level by cleaning the dipstick and lowering it into the hole, without screwing it in. The oil level 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 65.

32

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 65.

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.

4 Maintenance

Changing the gearbox oil


VD01043

25 Draining the oil

VD01042

Drain the oil with the aid of a separate sump pump.

Remove the dipstick (ZF-Hurth, 17) or remove the dipstick (Technodrive, 27).

Insert the suction hose of the sump pump in the dipstick hole. Push down the pump handle quickly and pull it up slowly.

Remove the sump pump when all the old oil has been pumped out.

Or, if sufficient space below the gearbox is available, oil can be drained by removing the drain plug.

Drain plug: ZF-Hurth 17

Technodrive 14

Collect the oil in a dripping pan.

VD01034

26 Filling with new oil

Refill the gearbox to the correct level via the dipstick opening (ZF-Hurth, 17) or via the filling hole (Techno drive, 27).

For oil specification see page 65.

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

4 Maintenance

Checking valve clearance


Mark on gearcase

27 Checking / adjusting valve clearance

Checking the valve clearance must be done with a cold engine, that is an engine which did not run for at least 6 hours.

VD01123

28 Remove rocker cover

Remove the 2 nuts of the rocker cover.

Complete the following steps:

14

17°

TDC mark

Injection timing mark

27

VD00149

29 locating TDC

Locate the Top Dead Center (TDC), at the end of the compression stroke, for cylinder 1 by barring the engine slowly until the

TDC marks of the engine block and the crank pulley match.

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

34

4 Maintenance

V alVe ClearanCe

: i nlet

0.25 mm (0.010”) e xhauSt

0.25 mm (0.010”)

10

VD01016

30 Adjusting valve clearance

VD00153

Cylinders are numbered consecutively, beginning at the front end.

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

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

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

Checking valve clearance


35

4 Maintenance f uel filter

, art

.

Code

: StM3690

Fuel filter replacement


VD01017

31 Fuel filter removal

VD00154

32 Fuel filter installation

VD00133

The fuel filter is to be replaced as a unit.

• Close the fuel stopcock.

• Remove the fuel filter, use a filter wrench.

Catch any fuel.

• Clean any debris from the filter carrier rim.

• 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.

• Open fuel stopcock.

• Fill the new filter with clean diesel fuel.

• Check for leaks.

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

36

4 Maintenance

33 Bleeding

VD00109

34 Start the engine

After replacing the fuel filter the air has to be bled from the fuel system.

For bleeding see page 26.

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.

Fuel filter replacement


37

4 Maintenance

Vbelt

, art

.

Code

: StM7439

Checking the V-belt


12 14

VD00034

35 Inspection V-belt

VD00128

36 Checking tension

VD00129

37 Tensioning V-belt

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

Check, tension and change belts only with the engine off. Refit belt guard, if provided.

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.

38

4 Maintenance

Flexible engine mounts, hose connections and fasteners


VD01124

38 Check flexible engine mounts

VD01041

39 Inspection hose connections 40 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

4 Maintenance

Raw water pump inspection


41 Raw water pump inspection

7

VD01125

42 Pump cover removal

10

VD01126 VD01031

43 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:

• Close the sea cock.

• Remove the cover of the pump by unscrewing the screws out of the housing.

• Slide the impeller off of the shaft using a waterpump plier.

• Mark the impeller to ensure correct re-installation if it is to be re-used. The impeller must be installed in the same position as removed.

40

4 Maintenance i

Mpeller

, art

.

Code

: StM8061

Raw water pump inspection


o-r ing

, art

.

Code

:

STM7686

VD00127

44 Impeller inspection

• Inspect the impeller for damage.

• Replace the impeller if necessary.

VD00004

45 Re-install the impeller

STM7696

VD00582

46 Replacing the pump cover

• 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 O-ring.

• 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

4 Maintenance

47 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.

1

14

VD01025

48 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.

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.

VD01018

Coolant replacement


2

13

42

4 Maintenance

C oolant

: quantitieS

3.0 litres)

(5.3 UK pt, 6.3 UK pt)

(3/8”)

Coolant replacement


W

ater 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.

VD01121 VD00158

49 Filling the cooling system

VD01005

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 67.



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.


43

4 Maintenance

Cleaning the heat exchanger

VD01018

50 Remove the drain plug

13

VD01122 VD01019

6

51 Removal of bolts out of the end covers

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

• 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.

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

• Remove the alternator.

Take out both central bolts from the end covers and take the end covers with the

O-rings out of the housing.

44

4 Maintenance


VD01020

6

VD01021

52 Remove heat exchanger

STM7217

53 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

4 Maintenance oring

, art

.

Code

: StM6113 (2 x

)


VD00157

54 Replacing heat exchanger

STM6202

55 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

4 Maintenance

W

arNiNg

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

Checking engine speed

Minimum speed adjustment screw

Maximum speed adjustment screw

Lead seal

VD00134

56 Checking engine speed

10

VD00150

57 Adjusting engine idling speed

At full load (with the boat cruising) the maximum engine speed should be about

3600 RPM (see technical data page 62). 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.

The engine idling speed should be

900 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


VD01006

1 Fuel system

VD00136

Drain the water from the water separator/ fuel filter and the fuel tank. Ensure that the tank is completely filled with fuel.

Running with protective fuel mixture

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


VD01010

2 lubrication system

VD00125

3 Raw water cooling system

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

Replace the oil filter and change the engine oil; use oil with protective properties. See page 65.

Close the seacock before removing the lid of the water strainer. If necessary, clean the raw water strainer.

Pour 1 litre (1/4 Imp.gal.) 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).

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


VD01122

4 Fresh water cooling system

VD00139

5 Electrical system

To avoid corrosion during winter storage the cooling system must be filled with an antifreeze/water mixture (or a coolant). For specifications see page 67.

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.

50

CT40063

Charge batteries during winter lay-up regularly if required!

6 Recommissioning after winter storage

VD00027

1 Fuel system

VD00141

Drain the water from the water separator/ fuel filter. (page 26)

Drain the water from the fuel tank.

VD01017

Install a new fuel filter. (page 36).

51


VD00137

Open the fuel valve.

VD01001

2 lubrication system

Check the engine oil level. (page

VD00125

3 Raw water cooling system

Check that the lid of the raw water strainer is reinstalled.

52


VD01125 VD01045 VD00138

The lid of the raw water pump and drain plugs are reinstalled. (pages 40, 42)

Re-tighten possible loose hose clamps.

Open the sea cock.

53


VD01122

4 Fresh water cooling system

Check the coolant level. (page 24)

CT40063

5 Electrical system

VD00140

Make sure that the batteries are fully charged. (page 30, 50)

Connect the batteries.

54


VD01127

6 Check engine for leaks

Start the engine.

Check the fuel system, the cooling system and the exhaust for leakage.

VD01043

7 Changing the gearbox oil

Stop the engine and change the oil of the gearbox. (page 33)

VD00581

8 Checking instruments and remote controls

Check the operation of the instruments, the remote control and the gearbox.

55


General

Engine faults are in most cases caused by improper operation or insufficient maintenance.

Please note that these tables can never be complete.

In case of a fault, always check first that the operation and maintenance instructions have been followed.

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!

In the following tables information is given about the possible causes of faults and suggested remedies.

56


Fault finding table

1 Engine will not crank

Possible fault Remedy

2 Engine cranks but will not start, no smoke from exhaust

Possible fault Remedy a

Faulty or discharged battery. b

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.

a

Check / recharge battery and check engine alternator and/or battery charger.

b

Clean and tighten connections.

C

Check / replace.

d

Check / replace startermotor.

e

Install an auxiliary starter relay.

a

Fuel stop valve closed.

b

(Nearly) Empty fuel tank.

C

Air in fuel system.

d

Fuel filter clogged with water and/or contamination.

e

Leaking fuel supply line or fuel injection line.

f

Faulty injector/injection pump.

g

Vent line of fuel supply tank clogged.

h

Exhaust restricted.

a

Open.

b

Refill.

C

Check and bleed.

d

Check or replace.

e

Check / replace.

f

Check, replace if required.

g

Check / clean.

h

Check.

57



3 Engine cranks but will not start, smoke from exhaust 4 Engine starts but runs unevenly (rough idling) or stalls

Possible fault a

Air in fuel system.

b


C

Setting of stop valve incorrect.

d

Faulty glow plugs.

e

Incorrect valve clearance.

f

Incorrect injection timing after overhauling of engine.

g

Insufficient intake air.

Remedy a

Check and bleed.

b


C d e f

Check / adjust.

Check / replace.

Adjust.

Check / adjust.

g

Check.

h

Wrong fuel quality or contaminated fuel.

i

Incorrect lube oil SAE class or quality for ambient temperature.

h

Check fuel. Drain and flush fuel tank. Replace with new fuel.

i

Replace.


(Nearly) Empty fuel tank.

b

Air in fuel system.

C


d


e


a

Refill.

b

Check and bleed.

C

Check or replace.

d

Check / replace.

e


f

Check / clean.

f

Vent line of fuel supply tank clogged.

g

Fuel supply line restricted.

h


i

Idle setting too low.

j

Exhaust restricted.

k


g h

Check / clean.

Adjust.

i

Check/ adjust.

j

Check.

k


58


5 Engine does not reach maximum rpm under load

Possible fault Remedy i a

Air in fuel system.

b


C


d


a

Check and bleed.

b

Check or replace.

C

Check / replace.

e h j k

Setting of stop valve incorrect.

f

Oil level too high.

g


Exhaust restricted.



Engine overloaded.

d


e

Check / adjust.

f

Lower level.

g

Adjust.

h

Check / clean.

i

Check.

j


k

Check size of propeller.


6 Engine overheats



b

Oil level too high.

C

Oil level too low.

d

Faulty oil filter.

e

Coolant pump defective.

f

Heat exchanger dirty or clogged as a result of rubber particles from a worn impeller.

g

Coolant level too low.

h

Sea cock closed.

i

Raw water strainer clogged.

j

Leaking raw water intake system.

k

Faulty thermostat.

l

Faulty impeller raw water pump.

M


a


b

Lower level.

C

Increase level.

d

Replace.

e

Check / clean.

f

Check / clean.

g

Check / top up.

h

Open.

i

Check / clean.

j

Check / replace.

k

Check / replace.

l

Check / replace.

M

Check / replace air intake filter.

n

Check / replace.

n

Motor becomes apparantly overheated as a result of faulty temperature switch, sensor or meter.

59


7 Engine not firing on all cylinders


Air in fuel system.

b


C


d


a

Check and bleed.

b

Check or replace.

C

Check / replace.

e

Fuel supply line restricted.

f

Faulty glow plugs.

g


d


e

Check / clean.

f

Check / replace.

g

Adjust.


8 Engine has little or no oil pressure


Oil level too low.

b

Excessive inclination of engine.

C


a

Increase level.

b

Check / Adjust.

C

Replace.

9 Engine oil consumption excessive


Oil level too high.

b


C


d

Excessive wear of cylinder/ piston.

e


f

Engine overloaded.

a

Lower level.

b

Check / Adjust.

C

Replace.

d

Check compression; overhaul engine.

e

Check.

f

Check size of propeller.

60


10A Blue exhaust smoke (idling)


Oil level too high.

b


a

Lower level.

b

Check / Adjust.

10B Black exhaust smoke (at load)



b

Faulty injector / injection pump.

C

Engine overloaded, max. rpm is not reached.

a

Check.

b

Check / replace if required.

C

Check sizes of propeller.


10C White exhaust smoke (at full load)

Possible fault a

Air in fuel system.

b


C

Water in fuel system.

d

Faulty glow plugs.

e


f

Incorrect injection timing.

g


h

Vapour in exhaust gases condenses as a result of very low ambient temperature.

Remedy a

Check and bleed.

b


C

Check water separator.

d

Check / replace.

e

Adjust.

f

Check / adjust.

g

Check fuel. Drain and h

flush fuel tank. Replace with new fuel.

61

8 Technical data

Model M3.28

General

Make

Number of cylinders

Based on

: Vetus Mitsubishi

: 3

: L3E-6ADM

Type

Injection

Aspiration

Bore

Stroke

: 4-stroke diesel, in-line

: Indirect

: Natural

: 76 mm

: 70 mm

Total displacement

Compression ratio

Idling speed

: 952 cm

: 22 : 1

3

: 900 rpm

Max. no. of revolutions at no load : 3600 rpm

Valve Clearances (cold)

Weight (with standard gearbox)

: Inlet 0.25 mm (0.010”)

Exhaust 0.25 mm

(0.010”)

: 123 kg (271 lbs)

Engine installation

Max. installation angle

Max. athwartships angle

: 15 degrees backwards

: 25 degrees continuously,

30 degrees intermittent

Engine specifications

Maximum Output

at the flywheel (ISO 3046-1) : 20 kW (27.2 hp) at the prop shaft (ISO 3046-1) : 19.3 kW (26.2 hp) at no. of revolutions of : 3600 rpm

Torque, : 51.3 Nm

: (5.2 kgm, 37.8 ft.lb) at no. of revolutions : 3600 rpm

Fuel consumption

at no. of revolutions

: 270 g/kW.h

: (199 g/hp.h,

: 7.0 oz/hp.h)

: 2600 rpm

Fuel System (Self-bleeding)

Injection pump : Bosch model NC (Nippon

Injectors

Opening pressure

Firing order

Injection timing

Fuel filter element

Fuel lift pump

Suction height max.

Fuel supply connection

Fuel return connection

Denso)

: Plug injector

: 140 bar (kgf/cm 3

: 1- 3 - 2

) (2030 psi)

: 17° BTDC

: STM3690

: max. 1,5 m (5 ft)

: for hose 8 mm (5/16”) I.D.

: for hose 8 mm (5/16”) I.D.

62


Oil lubrication system

Oil capacity, max.

without oil filter

with oil filter

: 3,6 litres (6 UK pt, 7.6 US pt)

: 4,1 litres (7.2 UK pt, 8.7 US pt)

Oil Filter : STM0051

Oil temperature in sump : max. 130°C (266°F)

Cooling system

Capacity,

Intercooler version

Keel cooler version

Thermostat

Coolant pump,

: 3 litres (5.3 UK pt, 6.3 US pt)

: 4 litres (7 UK pt, 8.5 US pt)

: opening at 71°C±1.5°C

: (160°F±3°F),

: fully opened at 84°C (183°F)

Flow at max. engine rpm : 50 l/min (11 UK Gal/min,

13.2 US Gal/min)

Total head keelcooler at max. flow : 2 m Water (6’ 7”)

Inlet connection for hose keelcooler : 28 mm (1 1/8”) I.D.

Raw water pump,

Flow at max. engine rpm : 20 l/min (4.4 UKGal/min,

5.3 US Gal/min)

Total head at max. flow : 2 m Water (6’ 7”)

Impeller : STM8061

Inlet connection for hose : 20 mm (3/4”) I.D.

Heater supply connection : 10 mm (3/8”)

Heater return connection : 8 mm (5/16”)

Engine specifications

Exhaust system

Exhaust diameter

Exhaust back pressure

Electrical System

Voltage

Alternator

Battery capacity

Protection

: 40 mm

: at specified output

: max. 150 mbar (2.2 psi)

: 12 Volt

: 14 Volt, 50 Amp / 75 Amp

see alternator data tag

Fuse 'ATO'10 Amp

: min. 55 Ah, max. 108 Ah

: Fuse 'ATO'10 Amp

V-belt

: STM7439

Gearbox

ZF Hurth: type ZF10M type ZF12

Gear ratio

: 1.97 / 2 / 2.72 : 1

: 1.14 / 2.63 / : 1 type ZF15MA : 1.88 / 2.63 : 1 type ZF15V : 2.13 / 2.99 : 1

Technodrive: type TMC40 type TMC40M

: 2.00 / 2.60 : 1

: 2.00 / 2.60 : 1 type TMC40P type TM345A type TM345H

: 2.00 / 2.60 : 1

: 2.00 / 2.47 : 1

: 2.00 / 2.47 : 1

63


Screw connection

Cylinder head bolt

Cilinder head bolt

Connecting rod nut

Fly wheel bolt

Crank shaft pulley nut

Main bearing cap bolt

Rocker stay bolt

Valve cover nut

Nozzle holder

Fuel leak oil pipe nut

Nozzle retaining nut

Fuel injection pipe nut

Delivery valve holder

Injection pump hollow screw

Injection pump air vent screw

Solenoid lock nut

Temperature switch

Oil filter

Oil pressure switch

Pressure relief valve

Oil drain plug

Glow plug

64

Wrench

Diameter size

M16

M20

PT1/8

M18

M18

M10

M16

M12

M16

M10

M6

M30

M10

M8

M8

M10

M16

M10

M8

M6

M20

M12

19

—

26

22

19

12

21

17

17

14

10

36

14

12

14

17

24

17

12

10

21

17

Nm

78 ±5

25 ±5

33 ±1.5

88 ±5

108 ±10

52 ±2.5

18 ±3.5

6 ±1

54 ±5

25 ±5

37 ±2.5

29 ±5

36 ±2

12 ±2.5

6 ±1

44 ±5

22.5 ±4

12 ±1

10 ±2

44 ±5

54 ±5

17.5 ±2.5

Torque wrench settings

Torque

(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 ±0.25) (38 ±2)

(1.85 ±0.35) (13 ±2.5)

(0.6 ±0.1) (4.5 ±0.8)

(5.5 ±0.5) (40 ±3.5)

(2.5 ±0.5) (18 ±3.5)

(3.75 ±0.25) (27 ±2)

(3.0 ±0.5) (21 ±3.5)

(3.7 ±0.2) (26 ±1.5)

(1.25 ±0.25) (9 ±2)

(0.6 ±0.1) (4.5 ±0.8)

(4.5 ±0.5) (32 ±3.5)

(2.3 ±0.4) (16.5 ±3)

(1.2 ±0.1) (9 ±0.8)

(1 ±0.2) (7 ±1.5)

(4.5 ±0.5) (32 ±3.5)

(5.5 ±0.5) (40 ±3.5)

(1.75 ±0.25) (13 ±2)


Engine lubricating Oil 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 ACEA (European Automobile

Manufacturers Association).

ZF Hurth: type ZF10M : 0,35 liter ( 0.6 UK pt, 0.74 US pt) ATF*) type ZF12 : 1,1 liter (1.9 UK pt, 2.3 US pt)ATF*) type ZF15MA : 0,56 liter (1 UK pt, 1.2 US pt)ATF*) type ZF15V : 1,0 liter (1.8 UK pt, 2.1 US pt)ATF*

Approved API Oils

Approved ACEA Oils

:

:

CF, CF-4 or CI-4

A3/B3, A3/B4

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.

Technodrive: type TMC40 : 0.20 litres (0.35 UK pt, 0.42 US pt),

Engine oil SAE 20/30 type TMC40M : 0.20 litres (0.35 UK pt, 0.42 US pt), ATF*) type TMC40P : 0.20 litres (0.35 UK pt, 0.42 US pt), ATF*) type TM345A : 1.6 litres, Engine oil SAE 20W40-CD type TM345H : 1.6 litres, Engine oil SAE 20W40-CD

(2.8 UK pt, 3.4 US pt)

- 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

*) ATF

For example

: AutomaticTransmission Fluid;

Transmissie olie type A, Suffix A.

: Vetus Transmission Oil

Shell Donax T6

Gulf Dextron

Other brands of gearboxes:

See supplied owners manual for oil type and quantities.

65


Fuel Quality Grade

Fuel

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!

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

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 exhaust emission levels determined during certification by the supervising authority are always based on the reference fuel described by law.

66


Coolant fluid

Coolant

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.

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:

Water quality pH-value at 20°C (68°F)

Chloride ion content [mg/dm 3 ]

Sulfate ion content [mg/dm 3 ]

Total hardness [degrees] min.

6.5

–

–

3 max.

8.5

100

100

12

Cooling system protective Water liquid (Anti-freeze) max. 45 vol%

40 vol% min. 35 vol%

55%

60%

65%

Protection against

freezing to

-35°C (-31°F)

-28°C (-18°F)

-22°C (-8°F)

Never use sea-water or brackish water.

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.

Cooling system protective liquids must be disposed of in accordance with environmental regulations.

67

10 Wiring diagram

Plug 'A'

Socket 'A'

Red

A1

A1

Fuse

Battery switch

Engine with panel model ‘20’, ‘21’, ‘22’

Starter switch

Engine panel model

'20' '21' '22'

V n/h

Model

Voltmeter

20 21 22

- - 1

Tachometer - 1 1

Yellow

A3

A3

Preheating relay

30 86

87

Orange Violet White

A4 A2

Black

A5 A6

A4

85

A2 A5 A6

X1

-8

31

-7

17/19

-5

58

D1 D2

-4

15

D3 D4

-1

Warning lights

-2 -3

W

-6

95

L1

Pre-heating

R1

Q1

BZ

L2

R2

D5

D6

D7

D8

D9

X2M

19/94

-6

D10

61

-4

R3

B6 B4

Plug 'B'

L3 L4 L5

91

-1

92

-2

93

-5

W

-3

B1 B2 B5 B3

L6

Gearbox oil pressure

Socket 'B'

Transparent

B6 B4 B1 B2 B5 B3

VD00215

68

Battery

Starter motor Pre-heating

B+ R

G

3Y

L

W

Stop solenoid

(ETS)

Alternator

Battery charging

ϑ p ϑ

Exhaust temp.

Oil press.

Coolant temp.

10 Wiring diagram

Options, panel model ‘10’

Plug 'A'

Red

A1

Yellow

A3

Starter switch

Engine panel model

'10'

Orange Violet White

A4 A2

Black

A5 A6

31

J3

L1

Pre-heating

L2: Battery charging

L3: Exhaust temperature

L4: Oil pressure

L5: Coolant temperature

L6: Oil pressure gearbox

17/19 58 15

D1 D2 D3 D4 Warning lights

R1

Q1

BZ

L2

R3

D5

D6

D7

D8

D9

D10

19/94 61

R2 L3

91

L4

92

L5

J4

93

W

L6

95

Plug 'B'

B6 B4 B1 B2 B5 B3

VD00216

69

11 Overall dimensions

1 2 3 4

VD00574

70

ZF10M

180

M3.28

715

443

92

M3.28

430

518

1 Exhaust ø 40 mm

2 Fuel return ø 8 mm

3 Sea water intake ø 20 mm

4 Fuel supply ø 8 mm

1:10

12 Index

A

Adjusting valve clearance 35

Air inlet silencer 8

Airvent connection 9

Alternator 9

B

Battery 30, 31

Bleeding 26

C

Calorifier connection 9

Changing the gearbox oil 33

Checking engine oil level 23

Checking engine speed 47

Checking the V-belt 38

Checking valve clearance 34, 35

Cleaning the heat exchanger 44–46

Connection for extra expansion tank 9

Connection for gearbox push-pull cable 9

Connection for throttle push-pull cable 8

Control panels 10

Coolant 67

Coolant fluid 67 coolant level 24

Coolant replacement 42, 43

Cooling system air bleed nipple 9

Cooling system drain plug 9

Cruising 19

Cylinder numbering 7

D

Draining the oil 28

E

Electrical system connector box 8

Engine data tag 6

Engine Lubricating Oil 65

Engine Oil 12

Engine oil change 28, 29

Engine serial number 1, 6

Engine specifications 62, 63

Exhaust injection bend 9

Expansion tank 9

F

fasteners 39

Filler cap for cooling system 9

Filling gearbox 13

Filling the cooling system 14

First commissioning 12, 13, 15 flexible engine mounts 39

Fuel 15, 66 fuel filter 26

Fuel filter replacement 36, 37

Fuel lift pump 8

Fuel Quality Grade 66

Fuel return pipe connection 8

Fuel supply pipe connection 8

Fuse 8

G

Gearbox 8

Gearbox drain plug 9

Gearbox Lubricating Oil 65

Gearbox oil dipstick/filler cap 8

Gearbox oil level check 32

H

Heat exchanger 9 hose connections 39

I

Impeller 41

Introduction 5–10

M

Maintenance 21–47

Maintenance schedule 22

Manual operation of electric stop 8

Manual operation of fuel supply pump 8

O

Oil dipstick 8

Oil filler cap 8

Oil filter 8

71

12 Index

Oil level 23

Operating media 65–67

Overall dimensions 70

P

Pre-heating 17

R

Raw water inlet 8

Raw water pump 8, 40, 41 raw water strainer 25

Recommissioning after winter storage

51–55

Changing the gearbox oil 55

Check engine for leaks 55

Checking instruments and remote controls 55

Electrical system 54

Fresh water cooling system 54

Fuel system 51

Lubrication system 52

Raw water cooling system 52

Removing the oil filter 28

Running-in 15

S

Safety measures 4

Serial numbers 1

Starter motor 9

72

Starting 16–18

Stopping 20

T

Tachometer 19

Technical data 62–64

Tensioning V-belt 38

Topping up coolant 24

Topping up oil 23

Torque wrench settings 64

Troubleshooting 56–61

U

Use 11–20

V

V-belt 9

Voltmeter 19

W

Warning lights 19

Water separator/Fuel filter 8 water separator/fuel filter 26, 27

Water separator/fuel filter air bleed nipple

8

Water separator/fuel filter drain plug 8

Winter-grade fuel 66

Winter storage procedure 48–50

Electrical system 50

Fresh water cooling system 50

Fuel system 48

Lubrication system 49

Raw water cooling system 49

Wiring diagram 68, 69

Manuals

Art. code Description

340301.01 Bedieningshandleiding

340302.01 Operation manual

340303.01 Bedienungsanleitung

340304.01 Manuel d’utilisation

340305.01 Manual de operacion

340306.01 Istruzioni per l’uso

340307.01 Brugsanvisning

340308.01 Användarmanual

340309.01 Bruksanvisning

340310.01 Käyttöopas

M3.28

M3.28

M3.28

M3.28

M3.28

M3.28

M3.28

M3.28

M3.28

M3.28

(Nederlands)

(English)

(Deutsch)

(Français)

(Español)

(Italiano)

(Dansk)

(Svenska)

(Norsk)

(Suomeksi)

320331.01 (STM0032) Installatiehandleiding / Installation manual (Nederlands / English)

320199.04 (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

Service- og garantibog / Service- och garantihäfte

Service- og garantibok / Huolto- ja takuukirja

Español / Italiano /

Dansk / Svenska /

Norsk / Suomeksi)

341231.01 Onderdelenboek / Parts manual M3.09 / M3.28

342102.01 Service manual M2.C5 / M2.D5 / M2.06 / M3.09 / M3.28

(Nederlands / English)

(English)

74

vetus

n.v.

Printed in the Netherlands

FOKKERSTRAAT 57 - 3125 BD SCHIEDAM - HOLLAND - TEL.:+31(10) 4377700

FAX:+31 (10) 4372673 - 4621286 - E-MAIL: [email protected] - INTERNET: http://www.vetus.com

340302.01 2010-06 Printed in the Netherlands

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