[
I
I 1213
100.CDK 11.05.96
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CllE:EiE:L
Operation manual
mrnrlm~ DEUTZ
DT43
DT64
DT67
~
I
DTA43
DTA64
DTA67
Uitgeyoerd ~et DMC CALAMUS® SL
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1213
100.CDK 11.05.96
DT43
UitgeYoerd ~et DMC CALAMUS@ SL
LJ
1213
100.CDK 11 .05.96
mrnrJmm DEUTZ
Operation manual
DT43 DTA43
DT64 DTA64
DT67 DTA67
Serial numbers
Engine serial number Vetus:
Deutz:
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.
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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 .
This engine has been built exclusively for the application specified in the scope of supply and is to be used only for the intended purpose. Any use exceeding that scope is considered
to be contrary to the intended purpose. The manufacturer will
not not assume responsibility for any damage resulting therefrom. The risks involved are to be borne by the user.
Use in accordance with the intended purpose also implies
compliance with the conditions laid down by the manufacturer
for operation, maintenance and servicing. The engine should
2
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only be operated , maintained and serviced by persons which
are familiar with the former and the hazards involved.
The relevent 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 Introduction
4
2 Engine description
Model
6
Identification of engine parts
8
Control panels
16
3 Use
General guidelines
18
Preparation
19
Running-in
22
Starting
23
Cruising
26
Stopping
28
4 Routine maintenance
Introduction
29
Maintenance schedule
30
Maintenance chart
31
5 Maintenance
6 Winter lay-up
Checking the oil level
32
Winter storage procedure
58
Checking the coolant level
34
Recommissioning after winter
storage
61
Checking and cleaning the raw
water strainer
36
Draining water from the water
separator/fuel filter
37
Battery, cables and cable
connections
38
Changing the oil
40
Checking the V-belts
42
7 Troubleshooting
64
8 Technical Data
70
9 Operating media
Checking flexible engine mounts 45
Lubrication Oil
76
Checking the gearbox oil level
46
Fuel
77
Replacing the fuel filter
47
Coolant
78
Checking the raw water pump
48
Changing the gearbox oil
50
Combustion air intake
51
Checking/adjusting valve
clearance
52
Coolant replacement
54
10 Electrical Circuit Diagram
80
11 Overall Dimensions
84
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Introduction
1
Dear customer,
Vetus Deutz 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 endeavored 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.
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Introduction
Safety measures
1
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.
Pass the safety instructions to other persons operating the
engine as well.
• Always stop the engine before checking or adjusting components.
General regulations and laws for safety and accident prevention rnust also be observed.
• Never touch hot parts of the engine, and keep flammable
materials well away from the engine.
Ensure that the engine can not be started by accident.
• 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
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Model
Engine description
2
0
..,...
-
-
-
-
-
o
D
C
Engine data tag
Engine data tag location
Engine serial number
Model (A), Deutz engine serial number
(B) and performance data are stamped
on the engine data tag.
Model and engine serial number must
be given when ordering spare parts.
The Deutz engine data tag (C) is attached to the crankcase.
The Vetus engine data tag (D) is attached to the flywheel housing.
The Deutz engine serial number is also
stamped on the crankcase itself
(arrow).
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102.CDK 11 .05.96
Model
Engine description
2
I
I
I
I
r---,--,,-,
~--------'
Cylinder numbering
Cylinders are numbered consecutively,
beginning at the flywheel end.
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Identification of engine parts
Engine description
Service side DT43, DT64
1
2
3
4
2
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Oil filler cap
Lifting eye
Alternator
Pressure filler cap for cooling
system
Expansion tank
Filler cap for cooling system
Water heater connection 'IN'
V-belt alternator
Coolant pump
V-belt fuel pump / coolant pump
P.T.O. (Mounting facility for extra
belt pulley)
Fuel lift pump
Fuel supply pipe connection
12 mm diam.
Fuel filter
Lube Oil filter
Oil dipstick
Lube oil cooler
P.T.O. (Mounting facility for
hydraulic pumps)
Raw water inlet 32 mm diam.
Raw water pump
Circuitbreaker
Electrical system connector
Connection for throttle push-pull
cable
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23
24
16
15
25
26
1
2
4
3
22
21
20
19
18
17
14
13
12
11
5
n
Identification of engine parts
Engine description
Starter side DT43, DT64
27
28
29
30
31
32
33
L.1
3L.
L.O
35
39
38
37
24 Manual operated stop
25 Fuel return pipe connection 10 mm
diam.
26 Water heater connection 'OUT'
27 Starter motor
28 Lifting eye
29 Exhaust injection bend
30 Turbocharger
31 Speed governor
32 Air intake filter
33 Gearbox lube oil cooler
34 Gearbox oil dipstick/filler cap
35 Connection for gearbox push-pull
cable
36 Gearbox
37 Oil sump drain pump
38 Cooling system drain plug, heat
exchanger cover
39 Cooling system drain plug, heat
exchanger
40 Cooling system drain plug, block
41 Heat exchanger
2
---
36
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102.CDK 11 .05.96
Identification of engine parts
Engine description
Service side DTA43, DTA64
2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Oil filler cap
Lifting eye
Alternator
Pressure filler cap for cooling
system
Expansion tank
Filler cap for cooling system
Water heater connection 'IN '
V-belt alternator
Coolant pump
V-belt fuel pump / coolant pump
P.T.O. (Mounting facility for extra
belt pulley)
Fuel lift pump
Fuel supply pipe connection
12 mm diam.
Fuel filter
Lube Oil filter
Oil dipstick
Lube oil cooler
P.T.O. (Mounting facility for
hydraulic pumps)
Raw water inlet 32 mm diam.
Raw water pump
Circuitbreaker
Electrical system connector
Connection for throttle push - pull
cable
6
7
8
22
9
20
10
19
18
17 16
15
14
13
12
11
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Identification of engine parts
Engine description
Starter side DTA43, DTA64
28
29
30
31
32
33
34
42
41
35
36
40
39
38
37
24 Aftercooler
25 Manual operated stop
26 Fuel return pipe connection 10 mm
diam.
27 Water heater connection 'OUT'
28 Starter motor
29 Lifting eye
30 Exhaust injection bend
31 Turbocharger
32 Speed governor
33 Air intake filter
34 Gearbox lube oil cooler
35 Gearbox oil dipstick/filler cap
36 Connection for gearbox push ~pull
cable
37 Gearbox
38 Oil sump drain pump
39 Cooling system drain plug, heat
exchanger cover
40 Cooling system drain plug, heat
exchanger
41 Cooling system drain plug, block
42 Heat exchanger
*
2
---
See drawing on page 8 for identification ; part numbers are identical.
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Identification of engine parts
Engine description
Service side DT67
2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Oil filler cap
Lifting eye
Alternator
Pressure filler cap for cooling
system
Expansion tank
Water heater connection 'IN '
V-belt alternator
Coolant pump
V-belt fuel pump / coolant pump
P.T.O. (Mounting facility for extra
belt pulley)
Fuel lift pump
Fuel supply pipe connection
12 mm diam.
Fuel filter
Lube Oil filter
Oil dipstick
Lube oil cooler
P.T.O. (Mounting facility for
hydraulic pumps)
Raw water inlet 32 mm diam.
Raw water pump
Circuitbreaker
Electrical system connector
Connection for throttle push-pull
cable
Manual operated stop
6
7
21
8
20
19
18
17
16
15
14
13
12
11
10
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Identification of engine parts
Engine description
Starter side DT67
24 Fuel return pipe connection 10 mm
26
27
28
29
30
31
32
40
33
34
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
38
37
36
diam.
Water heater connection 'OUT'
Starter motor
Lifting eye
Exhaust injection bend
Turbocharger
Speed governor
Air intake filter
Gearbox lube oil cooler
Gearbox oil dipstick/filler cap
Connection for gearbox push-pull
cable
Gearbox
Oil sump drain pump
Cooling system drain plug, heat
exchanger cover
Cooling system drain plug, heat
exchanger
Cooling system drain plug, block
Heat exchanger
2
35
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Identification of engine parts
Engine description
Service side DTA67
2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Oil filler cap
Lifting eye
Alternator
Pressure filler cap for cooling
system
Expansion tank
Water heater connection 'IN '
V-belt alternator
Coolant pump
V- belt fuel pump / coolant pump
P.T.O. (Mounting facility for extra
belt pulley)
Fuel lift pump
Fuel supply pipe connection
12 mm diam .
Fuel filter
Lube Oil filter
Oil dipstick
Lube oil cooler
P.T.O. (Mounting facility for
hydraulic pumps)
Raw water inlet 32 mm diam.
Raw water pump
Circuitbreaker
Electrical system connector
Connection for throttle push-pull
cable
Manual operated stop
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6
7
21
8
9
19
18
13
12
11
10
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102.CDK 13.05.96
Identification of engine parts
Engine description
Starter side DTA67
26
27
28
29 * 30
31
33
34
43
35
42
36
40
39
38
37
24 Fuel return pipe connection 10 mm
diam.
25 Water heater connection 'OUT'
26 After-cooler
27 Vent plug after-cooler
28 Lifting eye
29 Starter motor
30 Exhaust injection bend
31 Turbocharger
32 Speed governor
33 Air intake filter
34 Gearbox lube oil cooler
35 Gearbox oil dipstick/filler cap
36 Connection for gearbox push-pull
cable
37 Gearbox
38 Drain plugs raw water after-cooler
39 Oil sump drain pump
40 Cooling system drain plug, heat
exchanger cover
41 Cooling system drain plug, heat
exchanger
42 Cooling system drain plug, block
43 Heat exchanger
44 Lifting hook
*
2
See drawing on page 13, part
number 27, for identification.
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Engine description
Control panels
----------
10
2
2
2
@
@
@
@
@
@
11
4 5 6 7 8 9
Basic panel (model 34)
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4
5
6
7
8
9
Fly-bridge panel (model 22)
3
1213_102.CDK 11.05.96
Control panels
5
4
6
Engine description
8
7
3
4
5
6
7
2
@
@
o"
I
8 - -++-- -~
12 ----,.+--+
13 - -1-----"-c----===-----i
Sailingboat panel (model 10)
1
2
3
4
5
6
7
8
9
Tachometer/Operating hours counter
Voltmeter
Starter pre-heat switch/lock
Warning light high raw water temperature
Warning light low oil pressure
Warning light high coolant temperature
Warning light battery charging
Indicator light pre-heating
Warning light gearbox low oil pressure *
+--+,>-- 15
i.::..:...c:::::;:::.._.,L-J.-- 14
Push button panel (model 00)
10
11
12
13
14
15
Temperature gauge, coolant
Oil pressure gauge
On push button switch
Pre-heating push button switch
Starter push button switch
Stop push button switch
* This is an option , not fitted as standard.
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General guidelines
Use
General guidelines for use
Implementing the following recommendations will result in
longer life and better performance and more economical
operation of your engine.
3
•
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 78.
•
Never run the engine without a thermostat.
•
Use a good quality lubricating oil. For specifications see
page 76.
•
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.
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n
Preparation
Use
Preparation the engine for use
Before starting the engine for the first
time, the following procedures must be
carried out:
\
3
Filling with engine oil
Filling gearbox with oil
As a rule engine 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 76.
Fill the gearbox with oil, for quantity
and specification, see page 76.
Check the oil level with the dipstick,
see page 46.
Check the oil level with the dipstick*,
see page 32.
* The dipstick must be calibrated see
installation manual.
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Use
Preparation
Water heater
COOLANT
±_~v),
3
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.
Filling the cooling system DT43, DTA43, DT64, DTA64
Remove both the cap of the filler neck
on the top of the header tank and the
cap on top of the expansion tank.
Fill the cooling system up to the lower
edge of filler neck.
Use a mixture of 40% antifreeze (ethylene-glycol based) and 60% tap water
or use a special coolant.
For specifications see page 78.
Replace filler cap on header tank.
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Continue filling into expansion tank; fill
up to the 'MAXI ' mark.
Replace the filler cap on expansion tank.
Bleeding will take place automatically
during filling!
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 expansion tank. If necessary, add coolant.
&
Never fill the cooling system
with sea water or brackish
water.
1213_103.CDK 11 .05.96
Use
Preparation
Water heater
COOLANT
COOLANT
*~ ~\O
/~
-t-
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
cf',
Filling the cooling system DT67, DTA67
Remove the cap of the filler neck on the
top of the header tank.
Fill the cooling system.
Use a mixture of 40% antifreeze (ethylene-glycol based) and 60% tap water
or use a special coolant.
For specifications see page 78.
The level of the coolant must be approx. 1 cm (3/8 " ) below the lower edge
of the filler neck on the header tank.
Replace the filler cap on header tank.
Bleeding will take place automatically
during filling!
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 header tank. If necessary,
add coolant.
&
Never fill the cooling system
with sea water or brackish
water.
21
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Use
3
Preparation
Running-in
ll ]
--'-.
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 77.
The fuel system is self-bleeding.
• 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:
&
22
Never fill the fuel tank while
the engine is running. Do not
spill fuel. Prevent unnecessary
pollution.
Uitgevoerd Met DMC CALAMUS@SL
• Start the engine, see page 23, 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.
n
n
Use
Starting
Before starting, ALWAYS check the following points:
•
•
•
•
•
Engine oil level
Coolant level
Sea cock open
Main switch 'ON'
Gearbox in 'NEUTRAL' position.
neutral
gearbox
reverse
reverse
throttle
L -
gearbox
- - - forward
half throttle,
gearbox not
engaged
3
forward
throttle
___J
Electric starting
After repair work:
Check that all guards have been replaced and that all tools have been removed from the engine.
When starting with glow plugs, do not
use any other substance (e.g. injection
with start pilot). 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'
without engaging the gearbox.
Never start the engine with
the speed governor removed. Disconnect battery.
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Use
Starting
3
IT Oe~ :
OFF
I
Starting, without 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.
As standard Vetus Deutz engines are
not equiped with a pre-heating system,
therefore both the pre- heating indicator light and the pre-heating position of
the key switch on the operating panel
can be ignored.
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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.
n
n
Starting
Use
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 20 seconds consecutively.
3
OFF
STOP'
I
OFF
~
0~:
STOP'
I
)II
0,~
Starting, with pre-heating
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.
In case your Vetus Deutz engine is
equiped with the optional automatic
pre-heating system:
Turn the start key on the instrument panel clock-wise; the warning lights for
oil pressure and alternator will now light
up and the pre-heating indicator light
will be lit now.
Leave to pre-heat until the pre-heating
indicator light goes out.
Now turn the key further to the 'START'
position.
Due to the automatic timer of the preheating system the pre-heating position of the key switch on the operating
panel can be ignored.
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.
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Cruising
Use
The instrument panel is provided with
the following instruments (Depending of
the type of panel, see page 16 and 17).
\\ \\\111 11
"\ 20
25 / /
.::: 15 eleclron,c
30 / -:::.,
'
3
RPM,. 100
h
I~
~
WARNING
NEVER turn the key to the 'START' position while the engine is running.
Doing so will damage the starter motor.
26
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Tachometer
Voltmeter
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 resp. between 24 and 28 Volts.
With the engine stopped and the start
key in the first position, the voltmeter
should indicate 12 Volts resp. 24 Volts.
Idling speed ,
DT 43, DTA43: 720 - 770 rpm
DT64, DTA64: 650 - 700 rpm
DT67, DTA67: 600 - 650 rpm
1213_103.CDK 11.05.96
Cruising
Use
3
Temperature gauge
Oil pressure gauge
Warning lights
Indicating the temperature of the internal cooling system.
The operating temperature is 83 85 °C.
In case the engine is overheated; turn
off the engine and establish the cause,
see fault finding table, page 65 .. 69.
With the engine at operating temperature the oil pressure is:
When idling: at least 0.8 bar (6 psi).
In case the oil pressure is too low; turn
off the engine and establish the cause,
see fault finding table, page 65 .. 69.
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
sound while running , STOP THE ENGINE IMMEDIATELY!
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Stopping
Use
3
OFF
~
I
/
ON
(~t:
Electrical shutdown
Reduce engine speed to idle and shift
the gearbox to 'NEUTRAL'. Turn the
key to the left to the 'OFF' position.
If the engine is not to be used for some
time , it is recommended that the sea
cock is closed and the main switched
off.
Never stop the engine immediately after
it has been in operation for a long time.
Allow the engine to idle for a few minu-
28
Uitgeyoerd Met DMC CALAMUS® SL
Mechanical shutdown
tes before stopping.
N.B. The 'STOP' position, left of the
'OFF' position on the control panel, has
normally no function for this engine.
When 2 control panels are connected
to one engine, the engine can always
be stopped by turning the key to the
'STOP ' position, no matter what the
position is of the key on the other panel.
On the engine itself stopping is possible
by operating the mechanical shutdown
lever on the fuel injection pump until
the engine comes to a stand-still.
If the fuel supply is not shut off by the
electrically operated fuel solenoid stopping of the engine can be done this
way.
n
Introduction
Routine Maintenance
Introduction
The following guidelines should be observed for daily and
periodic maintenance. Perform each function at the indicated time interval. The intervals stated are for normal operational conditions. Service the unit more frequently under severe conditions. Neglecting maintenance can result in faults
--and permanent damage to the engine.
4
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Routine Maintenance
Maintenance schedule
Page
Every 10 hours or daily, before starting
4
Page
Every 500 hours, at least once every year
Check engine oil level
32
Engine oil change
40
Check coolant level
34
Replace oil filter
40
Check water strainer
36
Check V-belts
42
Check flexible engine mounts
45
Check gearbox oil level
46
After the first 50 hours 1)
Drain water from fuel filter
37
Engine oil change
40
Every 1000 hours, at least once every 2 years
Replace oil filter
40
Replace fuel filter
47
Check V-belts
42
Raw water pump inspection
48
Check flexible engine mounts
45
Gearbox oil change
50
Check gearbox oil level
46
Replace air cleaner
51
Replace fuel filter
47
Check glowplugs (if installed), replace if required
Check valve clearance
52
Check tightness of all fasteners, bolts and nuts 2)
Check engine for leaks
Check glow plugs (if installed)
Battery, cables and cable connections
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Check valve clearance
52
1213
104.CDK 11.05.96
Maintenance chart
Routine Maintenance
The maintenance chart shown here is
supplied as self-adhesive label with
each engine. It should be affixed on the
engine where it can be seen clearly.
Check that this is the case.
4
If necessary, ask your engine supplier for
another label.
Routine work should be carried out according to the schedule.
..
1) Commisioning new or overhauled
engine
2) Re-tightening of cylinder head bolts
is not required!
3) Cleaning of heat exchanger and
aftercooler (if installed) is not
required.
f11/Jlr1lllmDEUn
DT67 DTA67
Stop de engine before carrying out any maintenance work.
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1213_ 105.CDK 11 .05.96
Maintenance
Checking engine oil level
Daily, before starting.
5
Check oil level
Oil level
Turn the engine off.
The dipstick is located on the starboard
side of the engine.
The oil level must be between the two
marks on the dipstick*. If necessary top
up with the same brand and type of oil.
* The difference between the two oil level marks is :
-
DT 43, DTA43 : 1.5 litre
DT64, DTA64 : 2 litres
DT67, DTA67 : 3 litres
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Checking engine oil level
Daily, before starting.
Maintenance
5
Topping up oil
The oil filling cap is on top of the valve
cover.
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Maintenance
Checking coolant level DT43, DTA43, DT64, DTA64
Daily, before starting.
5
- \/
Checking coolant level
Coolant level
Topping up coolant
Check the coolant level in the
expansion tank.
This has to be checked when the engine is cold.
The level of the coolant must be
between the two marks 'MAXI ' and
'MINI'.
If necessary, top up.
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 78
&
Warning
Never open the cap on the
header tank when the engine
is at operating temperature.
&
Never fill the cooling system
with sea water or brackish
water.
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Checking coolant level DT67, DTA67
Maintenance
Daily, before starting.
5
Checking coolant level
Coolant level
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
header tank.
The level of the coolant must be
approx. 1 cm (3/8 " ) below the lower
edge of the filler neck.
If necessary, top up.
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 78.
&
Warning
Never open the cap on the
header tank when the engine
is at operating temperature.
&
Never fill the cooling system
with sea water or brackish
water.
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Maintenance
Checking and cleaning the raw water strainer
Daily, before starting.
5
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
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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.
1213_105.CDK 11.05.96
Draining of water from the water separator/fuel filter
Every 125 operating hours.
Maintenance
,rn,~ :
5
OFF
I
Empty water separator
Bleeding
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.
The system doesn't need to be bled after the water separator/fuel filter has
been drained.
The fuel system is self-bleeding.
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.
Note : The water separator is not within
the scope of supply but installation is
required!
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Maintenance
Battery, cables and connections
Every 125 operating hours.
Vetus maintenance-free batteries
5
GREEN DOT
ALL DARK
CLEAR
(Q)
(Q)
I
I
Battery, battery connections
Checking specific gravity
Hydrometer operation
Keep battery clean and dry.
Every Vetus Maintenance-free battery
has a hydrometer CD built into the cover.
• 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
Remove battery cables (negative fi rst).
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.
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Visual inspection of the hydrometer will
show one of three conditions:
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Battery, cables and connections
Maintenance
Every 125 operating hours.
Conventional batteries
Conventional batteries
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 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 kg/I and show less
than 0.050 kg/I between high and low. If
not, recharge or replace battery.
During checking the temperature of the
electrolyte should preferably be 20°c
(68°F).
Specific
gravity
State of
charge
1.28 kg/I
100 %
1.20 kg/I
50 %
recharge
1.12 kg/I
10 %
recharge
immediately
5
&
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!
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Engine oil change
Maintenance
Every 500 operating hours.
Engine oil change
Change the engine oil every 500 hours
of operation (together with engine oil filter replacement).
If the engine runs less than 500 hours
during the year the oil should be chan- - - ged at least once a year.
5
Run the engine for a few minutes before changing the oil ; warm oil can be
pumped out more easily.
Change the oil with a switched off engine at operation temperature. (Lube oil
temperature approx. 80°C.)
&
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.
Draining the oil
Removing the oil filter
The pump for the oil sump is (normally)
located at the heat exchanger side of
the engine.
As an option , for twin engine installation , the pump may be located on the
other side at one of the engines.
Unscrew the oil filter, with commercial
available tool, when all the oil has been
pumped out.
Catch any dripping oil.
&
Beware of burns from hot oil.
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Engine oil change
Maintenance
Every 500 operating hours.
5
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 76) through the filler
opening in the valve cover.
For required amount of oil (oil filter included) see page 72.
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.
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Checking the V-belts
Maintenance
Every 500 operating hours.
5
Inspection V-belt
Checking tension
Tensioning alternator 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 9 11 mm(± \ "), using about 10 kg (20 lbs)
thumb pressure, it should be tensioned .
• First loosen both the alternator mounting bolts CD and ® ; then loosen the
bolt ® of the adjustment bracket and
simultaneously keep the pinion ® in
the same position.
&
Check, tension and change
belts only with the engine off.
Refit belt guard, if provided.
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• Rotate the pinion ® counter-clockwise until the tension of the belt is correct.
Never apply a torque to the pinion of
more than 28 Nm (max. belt force is
achieved at about 22 Nm).
1213
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Checking the V-belts
Maintenance
Every 500 operating hours.
5
Replacing alternator V-belt
• Re-tighten the bolt @ of the adjustment bracket.
• Then re-tighten both the alternator
mounting bolts CD and @ .
• First loosen both the alternator mounting bolts CD and U; then loosen the
bolt @ of the adjustment bracket and
rotate the pinion ® clockwise.
• Remove and replace belt.
&
Check, tension and change
belts only with the engine off.
Refit belt guard, if provided.
achieved at about 22 Nm).
• Re-tighten the bolt @ of the adjustment bracket.
• Then re-tighten both the alternator
mounting bolts CD and @.
• Tension the belt by rotating the pinion
® counter-clockwise until the tension
of the belt is correct.
Never apply a torque to the pinion of
more than 28 Nm (max. belt force is
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Maintenance
Checking the V-belts
Every 500 operating hours.
5
Tensioning V-belt of coolant and
fuel pump
• Loosen bolts G) and ® .
Changing V-belt of coolant and
fuel pump
• Loosen bolts G) and ® .
• Rotate the tension device with the fuel
pump in the direction of the arrow
using a key in @, square '!, " , until the
tension of the belt is correct.
• Turn the tension device with the fuel
pump in the direction of the arrow
using a key in @, square 1/,".
• Re- tighten bolts G) and ® .
• Remove and replace belt.
• Re-tighten bolts G) and ® ·
• Rotate the tension device with the fuel
pump in the opposite direction of the
arrow using a key in @, square '!,",
until the tension of the belt is correct.
&
Check, tension and change
belts only with the engine off.
Refit belt guard, if provided .
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Flexible engine mounts
Every 500 operating hours.
Maintenance
5
Check flexible engine mounts
Check the bolts which secure the damper element, de mouting 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! Realign engine in case of doubt.
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Maintenance
Gearbox oil level check
Every 500 operating hours.
5
Unscrewing the dipstick
Checking the oil level
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
76.
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As standard Vetus engines are equipped with Hurth gearboxes.
Consult the Hurth 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 checking the oil level and
other care and maintenance.
1213_105.CDK 11 .05.96
Fuel filter replacement
Maintenance
Every 1000 operating hours.
.\
~~
5
>f~
-
-
'
>
'
I
\ _
Fuel filter removal
Fuel filter installation
The fuel filter is to be replaced as a unit.
• Clean any debris from the filter carrier
rim.
• Close the fuel stopcock.
• Remove the fuel filter, use a filter
wrench.
2
• Open fuel stopcock.
• Check for leaks.
• Lubricate the rubber gasket sparingly
with clean engine oil.
• Fill the new filter with clean diesel fuel.
• Catch any fuel.
&
Keep naked flames away
when working on the fuel
system . Do not smoke!
• Install the filter. When the rubber gasket touches the housing, apply
another tightening of a half to three
quarters of a turn by hand.
Bleeding
After replacing the fuel filter, the system
doestn't need to be bled.
The fuel system is self-bleeding.
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1213_105.CDK 11.05.96
Raw water pump inspection
Maintenance
Every 1000 operating hours.
5
Raw water pump inspection
Pump cover removal
Impeller removal
&
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.
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.
• Remove the cover of the pump by unscrewing the screws out of the housing.
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1213_105.CDK 11 .05.96
Raw water pump inspection
Maintenance
Every 1000 operating hours.
5
Impeller inspection
Re-install the impeller
Replacing the pump cover
• Inspect the impeller for damage.
• Fit the impeller to the pump shaft. (if
an existing impeller is re-used, install
it in the same position as removed).
• Replace the cover with a new gasket.
• Replace the impeller if necessary.
• Check the water filter and open the
sea cock.
• 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.
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Maintenance
Changing the gearbox oil
Every 1000 operating hours.
5
Draining the oil
Filling with new oil
• Remove the dipstick.
• Refill the gearbox to the correct level
via the dipstick opening. For oil specification see page 76.
• Drain te oil with the aid of a separate
sump pump. 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.
As standard Vetus engines are equipped with Hurth gearboxes.
Consult the Hurth 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.
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Combustion air intake
Maintenance
Every 1000 operating hours.
5
Air cleaner replacement
Inspection hose connections
• The air cleaner is to be replaced as a
unit.
• Inspect all hose connections of the air
intake system.
(Cracked hoses, loose hose clamps)
• Loosen the clamp, securing the air
cleaner housing, and loosen the hoseclamp at the air intake.
• Install a new air cleaner and tighten
the clamp again.
&
Never clean the air cleaner
with petrol (gasoline) or hot
fluids.
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Checking/adjusting valve clearance
Maintenance
Every 1500 operating hours.
5
Checking/adjusting valve clearance
• Remove the two bolts out off the breather valve and swing the breather valve aside. (For convienance first
remove the air cleaner.)
• Remove the air intake from after
cooler (if installed).
• Remove rocker cover.
• Position crankshaft as per schematic.
• Before adjusting the valve clearance,
allow the engine to cool down for at
least 30 minutes. The oil temperature
should be below 80°C (176°F).
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• Check valve clearance G) between
rocker lever ® and valve stem ® with
feeler gauge @ .
Note: The clearance is correct if some
resistance is felt when the feeler gauge is slipped in between the valve
stem and rocker lever.
Valve clearance:
Inlet 0.3 •0 ·1 mm
Exhaust 0.5 • 0 1 mm
• Adjust valve clearance if necessary:
- Release locknut ® .
- Use screwdriver (!) to turn setscrew @ so that the correct clearance is obtained after locknut ®
has been tightened.
• Check and adjust valve clearance on
all remaining cylinders.
• Re-install rocker cover (use new cover
if needed).
• Re-install air intake from aftercooler.
• Re-install breather valve.
1213
105.CDK 11.05.96
Valve Clearance Adjustment Schematic
Maintenance
• Crankshaft Position 1
Turn crankshaft until both valves in cylinder 1 overlap (exhaust valve about
to close, inlet valve about to open).
Adjust clearance of valves marked in
black on schematic. Mark respective
rocker arm with chalk to show that adjustment has been done.
5
• Crankshaft Position 2
Turn crankshaft one full revolution
(360°).
Adjust clearance of valves marked in
black on schematic.
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Maintenance
Coolant replacement DT43, DTA43, DT64, DTA64
Every 2000 operating hours.
Coolant replacement
The coolant has to be replaced every
2000 operating hours or at least once
every two years.
--5
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.
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.
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Remove the drain plugs from the engine
block G) and heat exchanger ® . Remove
the filler cap to vent the cooling system
and check that all the coolant has been
drained. After draining replace the drain
plugs.
n
Coolant replacement DT43, DTA43, DT64, DTA64
Maintenance
Every 2000 operating hours.
5
Filling the cooling system
Remove both the cap of the filler neck on
the top of the header tank and the cap on
top of the expansion tank.
Fill the cooling system up to the lower
edge of filler neck.
Use a mixture of 40% antifreeze (ethylene- glycol based) and 60% tap water or
use a special coolant.
For specifications see page 78.
Replace filler cap on header tank.
Continue filling into expansion tank; fill
up to the 'MAXI' mark.
Replace the filler cap on expansion tank.
Bleeding will take place automatically
during filling!
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 expansion tank. If necessary, add
coolant.
Water heater
If a water heater is connected to the
engine and this heater is positioned
above the upper side of the engine than
bleeding of the heater will not take place
automatically! Fill the heater separately
to bleed the cooling system completely.
&
Never fill the cooling system
with sea-water or brackish
water.
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Coolant replacement DT67, DTA67
Maintenance
Every 2000 operating hours.
Coolant replacement
The coolant has to be replaced every
2000 operating hours or at least once
every two years.
___5_
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.
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.
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Remove the drain plugs from the engine
block G) and heat exchanger @. Remove
the filler cap to vent the cooling system
and check that all the coolant has been
drained. After draining replace the drain
plugs.
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Coolant replacement DT67, DTA67
Maintenance
Every 2000 operating hours.
5
Filling the cooling system
Remove the cap of the filler neck on the
top of the header tank.
Fill the cooling system.
Use a mixture of 40% antifreeze (ethylene-glycol based) and 60% tap water or
use a special coolant.
For specifications see page 78.
The level of the coolant must be approx.
1 cm (3/8 ") below the lower edge of the
filler neck .on the header tank.
Replace filler cap on header tank.
Bleeding will take place automatically
during filling!
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 header tank. If necessary, add
coolant.
Water heater
If a water heater is connected to the
engine and this heater is positioned
above the upper side of the engine than
bleeding of the heater will not take place
automatically! Fill the heater separately
to bleed the cooling system completely.
&
Never fill the cooling system
with sea-water or brackish
water.
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Winter storage procedure
Winter lay-up
6
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.
&
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Never run the engine under
load with this mixture of fuel
and oil.
1213
106.CDK 11.05.96
Winter storage procedure
Winter lay-up
6
Lubrication system
Raw water cooling system
With the engine still at operating tempeture:
(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 (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).
Replace the oil filter and change the engine oil; use oil with protective properties. See page 76.
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.
Check the seal between the lid and housing after cleaning and re-assembling
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Winter lay-up
Winter storage procedure
Fresh water cooling system
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 78.
Disconnect the battery cables.
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 54.
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Charge batteries during winter lay-up
regularly if required!
n
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Recommissioning after winter storage
2
Winter lay-up
Check that the lid of the raw water
strainer is reinstalled.
4
Open the sea cock.
Check that the lid of the raw water
pump and drain plugs are reinstalled. (pages 48, 49)
5
Check the coolant level. (page 34)
Re-tighten
clamps.
possible
loose
hose
6
Check the engine oil level. (page 32)
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Recommissioning after winter storage
Winter lay-up
Drain the water from the water separator/fuel filter. (page 37)
10
Open the fuel valve.
Drain the water from the fuel tank.
11
Make sure that the batteries are fully charged. (page 38)
1- - - - - - - - - - · · -
Install a new fuel filter. (page 47)
62
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12
Connect the batteries.
1213
106.CDK 11.05.96
Recommissioning after winter storage
13
Winter lay-up
Start the engine.
Check the fuel system, the cooling
system and the exhaust for leakage.
6
Stop the engine and change the oil
of the gearbox. (page 50)
Check the operation of the instruments, the remote control and the
gearbox.
63
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1213
I_]
107.CDK 11.05.96
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 is information given about the possible causes of faults and suggested remedies. Please note
that this 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.
7
Before starting, make sure that nobody is in the
immediate vincinity of the engine.
When carrying out repair, never start the engine
with speed governor removed.
Disconnect battery!
64
Uitgeyoerd ~et DMC CALAMUS® SL
1213
107.CDK 11.05.96
Fault finding table
Troubleshooting
1 Engine will not crank
liliM'®Wii,MGffiN,ii1,,MAIM,,.
Possible fault
Remedy
· Check / recharge battery
and check engine alternator and/or battery
charger.
· Loose or corroded connections · Clean and tighten connections.
in starting circuit.
· Check / replace.
· Faulty starter-switch or faulty
starter-relay.
· Check / replace starter· Faulty starter-motor or pinion
motor.
does not engage.
· Faulty or discharged battery.
Possible fault
Remedy
· 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.
·
·
·
·
· Engine shutdown lever in stop
position, faulty fuel solenoid.
· Faulty V-belt fuel pump.
· Vent line of fuel supply tank
clogged.
· Exhaust restricted.
Open.
Refill.
Check and bleed.
Check or replace.
· Check / replace.
7
· Check, replace if required .
· Check / replace.
· Replace V-belt.
· Check / clean.
· Check.
65
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1213
I_]
107.CDK 11.05.96
Fault finding table
Troubleshooting
111r111@1i i&i'i,iMM,iA+frilMiffll·i •
1
7
Possible fault
Remedy
Possible fault
Remedy
· Air in fuel system.
· Faulty injector/injection pump.
· Check and bleed.
· Check, replace if required.
· Check / replace.
· (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.
· Refill.
· Check and bleed.
· Check or replace.
· Faulty glow plugs (if installed)
or below starting limit temperature.
· Adjust.
· Incorrect valve clearance.
· Check / adjust.
· Incorrect injection timing.
· Check / replace air inta· Insufficient intake air.
ke filter.
· Check fuel. Drain and
· Wrong fuel quality or contaflush fuel tank. Replace
minated fuel.
with new fuel.
· Incorrect lube oil SAE class or · Replace.
quality for ambient temperature.
66
Uitgevoerd Met DMC CALAMUS® SL
· Faulty V- belt fuel pump.
· 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.
· Check / replace.
· Check, replace if required.
· Replace V- belt.
· Check / clean.
· Check / clean.
· Adjust.
· Check/ adjust.
· Check.
· Check fuel. Drain and
flush fuel tank. Replace
with new fuel.
n
Fault finding table
Troubleshooting
5 Engine not developing full power
6 Engine overheats
Possible fault
Remedy
Possible fault
· Air in fuel system.
· Fuel filter clogged with water
and/or contamination.
· Leaking fuel supply line or fuel
injection line.
· Faulty injector/injection pump.
· Check and bleed.
· Check or replace.
· Faulty injector/injection pump.
· Engine shutdown lever in stop
position, faulty fuel solenoid.
· Faulty V-belt fuel pump.
· Oil level too high.
· Incorrect valve clearance.
· Exhaust restricted.
· Charge air (after)-cooler contaminated.
· Insufficient intake air.
· Check / replace .
· Check, replace if required .
· Check / replace.
· Replace V-belt.
· Lower level.
· Adjust.
· Check/ clean.
· Check/ clean.
· Check/replace air intake
filter.
· Faulty 'charge air pressure ope- · Check / replace.
rated max. power output
device'.
· Leaking air intake manifold.
· Check / replace.
· Wrong fuel quality or conta· Check fuel. Drain and
flush fuel tank. Replace
minated fuel.
with new fuel.
· Oil level too high.
· Oil level too low.
· Faulty oil filter.
· Faulty turbocharger.
· Coolant pump defective.
· Coolant heat exchanger dirty.
· Vent pipe blocked.
· Coolant level too low.
· Sea cock closed.
· Raw water strainer clogged .
· Leaking raw water intake
system.
· Faulty thermostat.
· Faulty impeller raw water
pump.
· Insufficient intake air.
· Leaking air intake manifold.
Remedy
· Check, replace if required.
· Lower level.
· Increase level.
· Replace.
· Check / replace.
· Check/ clean .
· Clean.
· Check/ clean .
· Check / top up.
· Open.
· Check / clean .
· Check / replace.
7
· Check / replace .
· Check / replace.
· Check / replace air intake filter.
· Check / replace.
67
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n
0
Fault finding table
Troubleshooting
7 Engine not firi.r:ig on all cylinders
7
8 Engine has little or no oil pressure
Possible fault
Remedy
Possible fault
· Air in fuel system.
· Fuel filter clogged with water
and/or contamination.
· Leaking fuel supply line or fuel
injection line.
· Faulty injector/injection pump.
· Check and bleed.
· Check or replace.
· Oil level too low.
· Increase level.
· Excessive inclination of engine. · Check/ Adjust.
· Incorrect lube oil SAE class or · Replace.
quality for ambient temperature.
· Check / replace.
· Check, replace if required.
· Replace V- belt.
· Check / clean .
· Check / replace.
· Faulty V-belt fuel pump.
· Fuel supply line restricted.
· Faulty glow plugs (if installed)
or below starting limit temperature.
· Adjust.
· Incorrect valve clearance.
68
Uitgeyoerd ~et DMC CALAMUS® SL
Remedy
9 Engine oil consumption excessive
Possible fault
Remedy
· Oil level too high.
· Excessive inclination of engine.
· Incorrect lube oil SAE class or
quality for ambient temperature.
· Lower level.
· Check/ Adjust.
· Replace.
1213_107.CDK 11.05.96
Fault finding table
Troubleshooting
10A Blue exhaust smoke (idling)
10C White exhaust smoke (at full load)
Possible fault
Remedy
Possible fault
Remedy
· Oil level too high.
· Excessive inclination of engine.
· Leaking turbocharger oil seal.
· Lower level.
· Check / Adjust.
· Check/ replace oil seal.
· Air in fuel system.
· Faulty injector/injection pump.
· Check and bleed.
· Check, replace if required.
· Check water separator.
· Check / replace.
1OB Black exhaust smoke (at load)
Possible fault
Remedy
· Faulty turbocharger.
· Check /
· Charge air (after)-cooler conta- · Check /
minated.
· Check /
· Insufficient intake air.
ke filter.
· Faulty 'charge air pressure ope- · Check /
rated max. power output
device'.
· Check /
· Leaking air intake manifold.
replace.
clean.
· Water in fuel system .
· Faulty glow plugs (if installed)
or below starting limit temperature.
· Incorrect valve clearance.
· Adjust.
· Incorrect injection timing.
· Check / adjust.
· Wrong fuel quality or conta· Check fuel. Drain and
minated fuel.
flush fuel tank. Replace
with new fuel.
7
replace air intareplace.
replace.
69
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1213_108.CDK 11.05.96
Engine specifications
Technical data
Model
DT43
DTA43
DT64
DTA64
DT67
DTA67
General
Make
Number of cylinders
Based on
Type
Injection
Aspiration
8
Bore
- - - Stroke
Total displacement
Compression ratio
Idling speed
Max. no. of revolutions
at no load
Vetus Deutz
BF4M ~012 E I BF4M 1012 EC I BF6M ~012 E I BF6M ~012 EC I BF6M ~013 E I BF6M ~013 EC
4-stroke diesel, in-line
Direct
Turbo-charged Turbo-charged/ Turbo-charged Turbo-charged/ Turbo-charged Turbo-charged/
After cooled
After cooled
After cooled
94 mm
94 mm
94 mm
94 mm
108 mm
108 mm
115 mm
115 mm
115 mm
115 mm
130 mm
130 mm
3192 cm 3
3192 cm 3
4788 cm 3
4788 cm 3
7146 cm 3
7146 cm 3
17.5 : 1
720 ~go rpm
17.5: 1
720 ~go rpm
17.5 : 1
650 ~go rpm
17.5 : 1
650 ~go rpm
17.6: 1
600 ~go rpm
17.6 : 1
600 ~go rpm
2950 rpm
2950 rpm
2950 rpm
2950 rpm
2900 rpm
2900 rpm
695 kg
755 kg
01
Valve Clearances (cold)
Weight
(with standard gearbox)
70
Uitgevoerd ~et DMC CALAMUS® SL
480 kg
505 kg
Inlet 0.3 • mm
Exhaust 0.5 •0 ·1 mm
605 kg
630 kg
I
D
D
Engine specifications
Model
Technical data
DT43
DTA43
DT64
DTA64
DT67
DTA67
at no. of revolutions
58 kW
(78 hp)
2500 rpm
72 kW
(97 hp)
2500 rpm
85 kW
(114 hp)
2500 rpm
106 kW
(142 hp)
2500 rpm
123 kW
(165 hp)
2300 rpm
148 kW
(198 hp)
2300 rpm
Light Duty Commercial
(ISO 3046/IOFN)
at no. of revolutions
65 kW
(87 hp)
2500 rpm
78 kW
(105 hp)
2500 rpm
98 kW
(131 hp)
2500 rpm
118 kW
(158 hp)
2500 rpm
141 kW
(189 hp)
2444 rpm
174 kW
(233 hp)
2444 rpm
Special Light Duty
(ISO 3046/IOFN)
at no. of revolutions
78 kW
(105 hp)
2650 rpm
94 kW
(126 hp)
2650 rpm
117 kW
(157 hp)
2650 rpm
141 kW
(189 hp)
2650 rpm
170 kW
(228 hp)
2600 rpm
210 kW
(282 hp)
2600 rpm
Maximum Output
Heavy Duty (ISO 3046/ICFN)
8
Fuel consumption
At max. power and
max. rpm for Heavy Duty
I
230 g/kWh
I
225 g/kWh
I
230 g/kWh I 225 g/kWh
I
220 g/kWh
I
215 g/kWh
I
71
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n _______
0
Engine specifications
Technical data
Model
DT43
DTA43
DT64
DTA64
DT67
DTA67
1-5-3-6-2-4
9° BTDC
VD60210
1-5-3-6-2-4
9° BTDC
VD60210
16 litres
17.5 litres
VD20263
16 litres
17.5 litres
VD20263
Fuel System (Self-bleeding)
8
Injection pump
Injectors
Injector opening pressure
Firing order
Injection timing
Fuel filter element
Fuel lift pump
Suction height
Pressure loss
Fuel supply connection
Length fuel line
Fuel return connection
Return flow
1-3-4-2
11 ° BTDC
VD60092
1-3-4-2
11 ° BTDC
VD60092
Bosch
Bosch
250 bar (kgf/cm 3)
1-5-3-6-2-4
1-5-3-6-2-4
11 ° BTDC
9° BTDC
VD60092
VD60092
max. 1 .5 bar (kgf/cm 2)
max. 0.5 bar (kgf/cm 2)
for hose 12 mm I.D.
max. 6 m
for hose 10 mm
max. 9 I/min
Oil Lubrication System
Oil capacity, max.
without oil filter
with oil filter
Oil Filter
Oil pressure with warm
oil (120°C) and low idle
Oil temperature in oil pan
72
Uitgevoerd Met DMC CALAMUS® SL
8.5 litres
9.5 litres
VD20262
8.5 litres
9.5 litres
VD20262
14 litres
15.5 litres
VD20263
14 litres
15.5 litres
VD20263
min. 0.8 bar
max. 125°C
n
n
Engine specifications
Model
Technical data
DT64
DT43
DTA43
DTA64
DT67
DTA67
8 litres
5.6 litres
8 litres
195 I/min
1.2 bar
206 I/min
1.3 bar
213 I/min
1.2 bar
216 I/min
1.2 bar
241 I/min
1.2 bar
275 I/min
2.0 bar
85 I/min
0.5 bar
STM8246
85 I/min
0.6 bar
STM8246
105 I/min
105 I/min
0.5 bar
0.6 bar
STM8246
STM8246
for hose 32 mm I.D.
M26 x 1.5
125 I/min
0.5 bar
STM8246
125 I/min
0.6 bar
STM8246
125 mm
150 mm
Cooling system
Capacity,
with heat exchanger
engine only (keelcooler version)
Thermostat
Coolant pump,
Flow
Total head
Raw water pump,
Flow at max. engine rpm
Total head at max. flow
Impeller
Inlet connection
Heater connection
10.5 litres
10.5 litres
13.5 litres
7.3 litres
9.8 litres
opening at 83°C, fully openened at 95°C
13.5 litres
8
Combustion air system / Exhaust system
Intake vacuum pressure
Turbo pressure at full load
Exhaust diameter
Exhaust back pressure
90mm
90mm
max. 65 mbar
max. 1.6 bar
100 mm
I
I 125 mm I
at specified output max. 75 mbar
absolute maximum 150 mbar
73
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n
0
Engine specifications
Technical data
Model
DT43
DTA43
DT64
DTA64
DT67
DTA67
Electrical System
Voltage
Alternator
Battery capacity
Protection
12 Volts / 24 Volts , see alternator data plate
14 Volts, 95A /28 Volts, 55 A, see alternator data plate.
min. 88 Ah, max. 176 Ah (at 12 Volts) / min. 2 x 66 Ah , max. 2 x 110 Ah (at 24 Volts)
Circuit breaker, 10 A
V-belts
__8_
Alternator
Tension
Fuel pump - Coolant pump
Tension
VD40067
VD40069
I VD40067 I VD40067 I
VD40067
Pre-tension 400 N / Re-tension 250 •50
VD40069
VD40069
VD40069
Pre-tension 400 N / Re-tension 250 •50
I
I
I
VD40067
N
VD40068
N
VD40067
VD40068
Engine installation
Max. installation angle
Max. athwartships angle
15 degrees backwards
25 degrees continuously, 30 degrees intermittend
Gearbox, standard
Hurth type
Gear ratio
74
Uitgeyoerd ~et DHC CALAHUS® SL
HSW450
HSW450
HSW630
HSW630
HSW450
1.25/1.5/2.0 :1 1.25/1 .5/2.0 :1 1.25/1.5/2.0 :1 1.2/1 .6/2.0/2.5 :1 1.2/1 .6/2.0 : 1
HSW800
1.57/1.96 : 1
1213_108.CDK 11.05.96
Torque wrench settings
Screw connection
Size
Oil pan
M8x16
Oil drain plug
M18x1 .5
Cylinder head,
- long bolts
M12x200
- short bolts
M12x120
Lifting eye / Cyl.head
M8x20
Rocker cover
M6x75
Rocker arm set-screw
M8x60
Flange injection pump
M8x30
Injector holder (Torx)
M8x50
Fuel lift pump / Clamping
strap
M8x20
Pulley fuel lift pump
M8x20
Screw, banjo connector
fuel line
M14x1.5
Injection line mounting
M14x1.5
Thermostat housing
M8x35
Air Intake Manifold {AIM) M6x75
Cover {AIM),
- pre-tightening
M6x25
- re-tightening
M6x25
Plugs {AIM)
M10x1
Plugs (AIM)
M16x1.5
Plugs (AIM)
M18x1.5
Technical data
Class
Torque Angle
[Nm]
21
50
10.9
10.9
8.8
10.9
8.8
10.9
10.9
30/80 90°
30/80 90°
40.5 ±10%
8.5 ±10%
21
30
16+5
10.9 A4C 21 ±2
8.8
21 ±2
10.9
10.9
Screw connection
Size
Class
Torque Angle
[Nm]
Exhaust manifold / Cyl. head
- Stud
M10
15
- Lock nut
MB
25
Turbocharger I Exhaust manifold
MB nuts
21
- 4 cyl.
- 6 cyl.
M8x35 heat resistant 21
Turbocharger / Exhaust
injection bend
MB heat resistant
22
Alternator mounting
M8x80
10.9
21
Starter
M10x55
10.9
60
Engine bracket front
M16x75
8.8
187
Engine bracket rear
M12x40
8.8
80
Flywheel housing
M12x150 10.9
99
Flywheel housing
M16x140 10.9
243
±10%
±10%
±10%
±10%
±10%
8
±10%
±10%
±10%
±10%
39 ±10%
30
21 ±10%
8.5 ±10%
15
15
13
38
50
±10%
±10%
±10%
±10%
75
Uitgevoerd Met DMC CALAMUS@ SL
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I~
1213_109.CDK 11.05.96
Lubricating oil
Operating media
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
Approved CCMC Oils
: CD, CF, CE and CF4
: 04, 05
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.
g
- SAE 10W40 for temperatures of -25°C up to +30°C
- SAE 15W40 for temperatures of -20°C up to +35°C
For example
Hurth:
Transmission Oil Type A, Suffix A ATF (Automatic Transmission Fluid).
For example: Vetus Marine Gearbox Oil
Shell Donax T6
Gulf Dextron
Hurth type HSW450
Hurth type HSW630
Hurth type HSW800
: 2.0 litres
: 2.5 litres
: 4.0 litres
Other brands of gearboxes:
See supplied owners manual for oil type and quantities.
: Vetus Marine Inboard Motor Oil
Shell Super Diesel T
76
Uitgevoerd Met DMC CALAMUS@ SL
1]
n
[l
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!
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).
9
The exhaust emission levels determined during certification
by the supervising authority are always based on the reference fuel described by law.
77
Uitgevoerd ~et DMC CALAMUS® SL
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0
Coolant
Operating media
Cooling system protection
Coolant fluid
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.
The concentration of the cooling system protective liquid in
the coolant should not fall below/exceed the following limits:
9
Cooling system protective liquid
(Anti-freeze)
Water
max. 45 vol %
55 %
min. 35 vol %
65 %
78
Uitgevoerd Met DHC CALAMUS® SL
Cooling system protective
liquid (Anti-freeze)
Protection against
freezing to
35 vol %
-22 °C
40 vol %
-28 °C
45 vol %
-35 °C
1213_109.CDK 11.05.96
Coolant
Operating media
Cooling system protective liquid
Water quality for coolant preparation
As cooling system protective liquid use a ethylene- glycol
based anti - freeze. This will give an adequate protection
against corrosion , cavitation and frost damage.
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 level of the cooling system must be monitored continuously, see page 34.
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.
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)
max.
6.5
3
8.5
Chloride ion content
[mg/dm
]
-
100
Sulfate ion content
[mg/dm 3]
-
100
Total hardness
[degrees]
3
12
9
'
Never use sea-water or brackish water.
79
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1213_110.CDK 13.05.96
Engine with panel 'model 34'
Electrical Circuit Diagram
Starter switch
Tachometer/
hour counter
Oil pressure
gauge
Temperature
gauge
Warning lights
,·- ·- ·- ·- ·-·- ·- ·- ·- ·- ·- ·-·- ·- ·- ·-·- ·-·- ·- ·- ·- ·.
Voltmeter
,
I
(])
15
1:1?
o3 :5
a,
1
Ol ~
~ -S ~
(]) Ol
.... (1l
~
58 ·
....
(1l
ID
1k
~
.c
(1l
....::::,
·5
a;
0
a.
E
CJ)
CJ)
1:1?
a. .0
0 E
tii
(])
8
9
10
a;
::::,
C:
(1l
(1l
X
1:1?
....
0
(])!
SI
CJ)'
ool
~1
(]) '
u a: .2l 6 a. 0 .2l CJ Oi
J3 Ol
C:
19/
94
~
(])
31
"7
1:1?
a..
Plug
0
10
Socket
(Engine)
14
(])
(])
~
(])
(])
~
j
~
r
attery
switch
p
+
~attery
Starter motor
Fuel solenoid
80
Uitgeyoerd ~et DHC CALAMUS® SL
Alternator
Oil
Tempepressure rature
sender
sender
Temperature
switch
I
--C: -- (]) --1-'
C:
-::::,
.0
Oil
Tempepressure rature
switch
switch
1213
110.CDK 11.05.96
Options, panel 'model 22'
Electrical Circuit Diagram
Starter switch
Tachometer/
hour counter
Voltmeter
Warning lights
,·-·-·-·- ·-· -·- · - · - ·-·-·-·-·-·-·- ·-·-·-·-·-·-·'
,
I
I
15 !
58 ·
17/19i
1k
J3
19/
94
CJ)
C
~
Q)
.c
d,
Alarm
buzzer
ct
!-·- •-·- •-·- H+ _H-__ __
C
"'O
[I:'
,-------1
.!!!
C
~
Qi
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FOKKERSTRAAT 571 - 3125 BD SCHIEDAM - HOLLAND - TEL.: +31 (10) - 4377700
FAX: +31 (10)-4621286 - 4373474 - 4153249 - 4372673 - E-MAIL: DIESEL@VETUS.NL
STM0087 09-95 Rev. 06-96, 03-98
Printed in the Netherlands
English
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