VD6.

210

D-LINE Marine Diesel Engines VD4.120 VD6.170

VD4.140 VD6.210
Operation manual
360602.01
ii
 Operation manual VD4.120
VD4.140
VD6.170
VD6.210

Serial numbers

Engine serial number Vetus:

Engine serial number Deutz:

Gearbox serial number:

Please enter the serial numbers here.

These numbers should be quoted when inquiring about Customer Ser-
vice, Repairs or Spare Parts (see page 10).

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

Images shown in this manual may be different.
360602.01

Copyright © 2017 Vetus B.V. Schiedam Holland

1
Please read and observe the information giv- This engine has been built exclusively for the The relevant accident prevention guidelines
en in this operation manual. This will enable application specified in the scope of sup- and other generally accepted safety and
you to avoid accidents, preserve the manu- ply and is to be used only for the intended industrial hygiene regulations must be ob-
facturer’s warranty and maintain the engine purpose. Any use exceeding that scope is served.
in peak operating condition. considered to be contrary to the intended
purpose. The manufacturer will not not as- Unauthorized engine modifications will in-
Make sure that the manual will remain intact sume responsibility for any damage resulting validate any liability claims against the man-
and damage is prevented. Keep the manual therefrom. The risks involved are to be borne ufacturer for resultant damage.
away from humidity and heat. by the user.
Do not alter the content of the manual. Manipulations of the injection and regulating
Use in accordance with the intended pur- system may also influence the performance
The manual is an integral part of the engine. pose also implies compliance with the con- of the engine, and its emissions. Adherence
Hand over the manual tot the new owner if ditions laid down by the manufacturer for to legislation on pollution cannot be guaran-
boat or engine is being sold. operation, maintenance and servicing. The teed under such conditions.
engine should only be operated, maintained
For the Guarantee Conditions, see the Ve- and serviced by persons which are familiar
tus Diesel ‘Service and Warranty Manual’ with the former and the hazards involved.
(320199.06).

2
Contents

1 Safety measures  4 Checking coolant level  43 9 Troubleshooting  96

Warning indications  4 Checking and cleaning the raw
Preventing fire and explosion  5 water strainer  44 10 Technical data  106
Prevention of injury  6 Draining of water from the water Engine specifications  106
When problems occur  8 separator/fuel filter  45 Gearbox specifications  111
Engine oil change  47 Torque wrench settings  112
2 Introduction  9 Battery, cables and connections  52
Data tag  10 Gearbox oil level check  56 11 Operating media  114
Serial number, cylinder numbering Changing the gearbox oil  57 Fuel  114
and direction of rotation  11 Fuel filter replacement  58 Lubricating oil  116
Identification of engine parts D4  12 Flexible engine mounts, hose Coolant  119
Identification of engine parts D6   14 connections and fasteners  59
Control lever  17
12 Wiring diagrams  120
Checking the V-belts  60
Raw water pump inspection  62 13 Overall dimensions  122
3 First commissioning  18 Air filter replacement  65

4 Running-in  27
Checking the starter motor and 14 Parts for maintenance  126
alternator  66
5 Use  28 Checking valve clearance  67 15 Index  127
General guidelines  28 Coolant replacement  70
Starting  30 Cleaning the heat exchanger  73
Cruising  34 Cleaning the after cooler  78
Stopping  37
7 Lay-up / Winter storage
6 Maintenance  38 procedure  82
Introduction  38
Maintenance schedule  40 8 Recommissioning after
Checking engine oil level  42 lay-up or winter storage  90

3
1 Safety measures Warning indications

Warning indications
The following warning indications are used in
this manual in the context of safety:

Symbols
  Danger   Caution
Indicates that great potential danger exists Indicates that the usage procedures, actions Indicates that the relevant procedure
that can lead to serious injury or death. etc. concerned can result in serious damage must be carried out.
to or destruction of the engine. Some CAU-
TION indications also advise that a potential Indicates that a particular action is for-
danger exists that can lead to serious injury or bidden.
death.

Pass the safety precautions on to other peo-

ple who will use the engine.

  Warning   Note General rules and laws concerning safety

Indicates that a potential danger that can lead Emphasises important procedures, circum-
and accident prevention must always be ob-
to injury exists. stances etc.
served.

4
1 Safety measures Preventing fire and explosion

  Fire risk!
• Do not smoke if refuelling. • Do not fill the fuel tank while the engine is • Connecting (emergency) extra starting bat-
running! tery
• Avoid spilling fuel on hot surfaces. Spilled Only refuel with the engine stopped. Proceed as follows when an extra starting
fuel must be cleaned up immediately. battery is used to jump start the engine:
• Never put flammable materials in the vicin-
• Do not use petrol or diesel to clean compo- ity of the engine! -- First connect the positive lead
nents but make use of good quality, non-in-
flammable, non-poisonous solvents that • Keep the engine and engine compartment -- Lastly connect the earth cable (negative
are available from dealers. clean! pole) to the engine block
Remove all inflammable materials such as
• Always be alert to possible fuel or oil leak- fuel, oil and other litter before it builds up If this cable is connected in error to the
age! in the vicinity of the engine. negative pole of the engine battery, a
If you discover a leak, take counter-meas- spark can occur. The result of this could
ures immediately. If fuel or oil is spilled on be that explosive gas produced by the
a hot engine, fire can break out. This can battery explodes.
cause physical injury or damage to the
equipment. -- Once the engine is started, first remove the
earth cable.

5
1 Safety measures Prevention of injury

• The moving parts of the engine are dan- • Satisfy yourself that everything is in order • Remove any tool used to turn the engine
gerous. Never touch moving parts of the before the engine is started again! over. If you leave this in position, serious
engine while it is running, to prevent cuts Make sure that no-one is working on or injury or damage to the equipment can re-
and other injuries. close to the engine before you start it. Re- sult.
move all foreign objects from around the
• Stop the engine before carrying out main- engine, such as litter, oil, tools and other • NEVER open the cap of the expansion tank
tenance! components that are not part of the engine. when the engine is at working temperature.

• Always stop the engine before topping up • Install all protective covers! • Only check the coolant level after the en-
or replacing fuel, oil or coolant. To prevent injury, make sure that all protec- gine has been stopped and the filler cap
tive covers and cover plates are replaced on the heat exchanger is cool enough to be
• Before carrying out inspection or mainte- over moving parts. removed with bare hands.
nance, the ignition key must be removed
and the main battery switch turned off. • Never attempt to adjust the fan belt on a
running engine.

6
1 Safety measures Prevention of injury

• Be careful with battery acid! • Make sure that you are wearing suitable
If battery acid comes in contact with the clothing before starting work!
eyes or skin, rinse the affected part imme- For your own safety you will most likely
diately with copious amounts of water. If need special equipment – safety helmet,
battery acid comes in contact with the eyes, eye protection, safety boots, safety gog-
rinse them out immediately with plenty of gles, heavy gloves, ear protectors etc. Use
water and consult a doctor. them when necessary.

• Be careful with antifreeze! • Carry out maintenance procedures safely

If you accidentally swallow antifreeze, make by only using suitable tools.
yourself vomit and consult a doctor imme-
diately. If antifreeze comes in contact with • Exhaust gases
your eyes, wash them out immediately with Do not start the engine if the exhaust sys-
plenty of water and consult a doctor. tem is not connected.

7
1 Safety measures When problems occur

When the engine stops suddenly: lf the engine overheats: If the fan belt is broken:
If the engine stops suddenly, do not start it If the engine should overheat, do not switch Immediately stop the engine. If an engine is
again immediately. Track down the cause and it off immediately. If an overheated engine is used with a broken fan belt, this can lead to
carry out the necessary repairs before you stopped suddenly, this can cause the coolant the engine overheating, which in turn can
start the engine again. If you do not do this, temperature to rise rapidly and moving parts cause coolant to spray out of the expansion
serious engine problems can develop. to seize. First let the engine run in neutral to al- tank.
low the hot parts of the engine to cool down,
If the oil pressure is too low: stop the engine and allow it to cool, and then If the engine behaves strangely:
Stop the engine immediately and check the gradually top up the coolant. Remember: Stop the engine or reduce the speed as far as
lubrication system. Running an engine with adding coolant to an overheated engine can possible.
low oil pressure can cause bearing and other cause damage to the cylinder head. Do not use the engine again until the cause of
parts to seize. the defect has been solved.

8
2 Introduction

Dear customer,

Vetus diesel engines are designed both for We have endeavoured to highlight any differ- We are available to help with any additional
pleasure craft and commercial craft. Conse- ences so that you will able to locate the oper- inquiries.
quently, a wide range of variants are offered ating and maintenance instructions relevant
to meet the requirements of specific cases. to your engine quickly and easily. Sincerely,
Vetus b.v.
Your engine is appropriately equipped for Please read this manual before starting your
your vessel, which means that not necessarily engine and always observe the operating and
all components described in this manual are maintenance instructions.
mounted to your engine.

9
2 Introduction Data tag
Serial number

A B
D

MARINE DIESEL ENGINE

SCHIEDAM HOLLAND
Type: D XXXXXXXXXXXX

C
Engine Nr.: 123456 654321
Power XX kW XX HP XXXX RPM

Weight, approx.: XXX kg Mfg Date: XX/XXXX

BSO cert.: XXXXXXXX
Meets exhaust emission regulations
acc. 94/25/EC, 2003/44/EC
Light Diesel Fuel Only (B7Allowed)

1  Engine data tag 2  Engine data tag location

Model (A), Deutz engine serial number (B) The Deutz engine data tag (C) is attached to The Vetus engine nameplate (D) is attached to
and performance data are stamped on the the crank case. the top cover.
engine data tag.

Model and engine serial number must be

given when ordering spare parts.

10
2 Introduction Serial number, cylinder numbering and direction of rotation

left left

right right

3  Engine serial number 4  Cylinder numbering and direction of rotation

The Deutz engine serial number is stamped at Cilinder numbering Direction of rotation
the indicated spot. Cylinders are numbered consecutively, begin- The direction of rotation is viewed towards
ning at the flywheel end. the flywheel counter clockwise.

Motor sides
Seen from the flywheel side.

11
2 Introduction Identification of engine parts D4

1 Fuel return pipe connection ø 10 mm

VD4.120, VD4.140
2 Calorifier connection, engine ‘OUT’
3 Oil dipstick 1 2 3 4 5 6 7 8 9
4 Oil filler cap
5 Lifting eye
6 Cooling system drain plug, heat exchanger
cover, raw water
7 Heat exchanger
8 Filler cap (pressure cap) for cooling system
9 Cooling system drain plug, heat exchanger
10 P.T.O. (Mounting facility for hydraulic
pumps)
11 Oil cooler
12 Fuel filter
13 Oil filter
14 Alternator
15 Fuel supply pipe connection ø 12 mm
16 V-belt alternator
17 Fuel lift pump
18 V-belt alternator fuel pump / coolant pump
19 P.T.O. (Mounting facility for extra belt pulley)
20 Coolant pump
21 Calorifier connection, engine ‘IN’

10 11 12 13 14 15 16 17 18 19 20 21

12
2 Introduction Identification of engine parts D4

22 Air intake filter

VD4.120, VD4.140
23 Turbocharger
22 23 24 25 26 27 28 29 30 31 32 24 Exhaust injection bend
25 Raw water 'out' for prop shaft lubrication
26 Connection airvent
27 Exhaust insulator
28 Lifting eye
29 Relays and fusses
30 Gearbox lube oil cooler
31 Raw water pump
32 Raw water inlet ø 32 mm
33 Cooling system drain plug, block
34 Flexible engine mounts
35 Aftercooler
36 Oil sump drain pump
37 Drain plug after cooler condens water
38 Drain plug after cooler raw water
39 Starter motor
40 Gearbox filler cap/ oil dipstick
41 Gearbox

33 34 35 36 37 38 39 40 41

13
2 Introduction Identification of engine parts D6

1 Fuel return pipe connection ø 10 mm

VD6.170 VD6.210
2 Calorifier connection, engine ‘OUT’
3 Oil dipstick 1 2 3 4 5 6 7 8 9
4 Oil filler cap
5 Lifting eye
6 Cooling system drain plug, heat exchanger
cover, raw water
7 Heat exchanger
8 Filler cap (pressure cap) for cooling system
9 Cooling system drain plug, heat exchanger
10 P.T.O. (Mounting facility for hydraulic
pumps)
11 Fuel filter
12 Oil cooler
13 Alternator
14 V-belt alternator
15 Oil filter
16 Fuel supply pipe connection ø 12 mm
17 Fuel lift pump
18 V-belt alternator fuel pump / coolant pump
19 P.T.O. (Mounting facility for extra belt pulley)
20 Coolant pump
21 Calorifier connection, engine ‘IN’

10 11 12 13 14 15 16 17 18 19 20 21

14
2 Introduction Identification of engine parts D6

22 Air intake filter

VD6.170 VD6.210
23 Turbocharger
22 23 24 25 26 27 28 29 30 31 32 24 Exhaust injection bend
25 Raw water 'out' for prop shaft lubrication
26 Connection airvent
27 Exhaust insulator
28 Lifting eye
29 Relays and fusses
30 Gearbox lube oil cooler
31 Raw water pump
32 Raw water inlet ø 32 mm
33 Cooling system drain plug, block
34 Flexible engine mounts
35 Aftercooler
36 Oil sump drain pump
37 Drain plug after cooler condens water
38 Drain plug after cooler raw water
39 Starter motor
40 Gearbox filler cap/ oil dipstick
41 Gearbox

33 34 35 36 37 38 39 40 41

15
2 Introduction Control panels

1 2 3

1 Temperature gauge, coolant

2 Tachometer/Operating hours counter
3 Voltmeter
4 5 6
4 Oil pressure gauge
5 Display
6 Starter pre-heat switch/lock
Panel, model MPA34

16
2 Introduction Control lever

neutral
gearbox reverse gearbox forward

reverse throttle forward throttle

Single lever control Single lever control

handle for two engines handle for 1 engine

5  Operating lever

Operating lever for 1 or 2 engines. The engine or engines are typically controlled The control lever works as shown in the dia-
with a single-lever. gram.
Depending on the brand and type (mechani-
cal or electronic), there may be minor diffe- Starting from neutral put the engine in ahead
rences in the mode of operation. Please refer or astern by moving the lever 35° forwards or
to the engine manual for details. backwards.
However, the principle is always as indicated The throttle lever operates at an angle of 60°
above. forwards and 60° reverse.

17
3 First commissioning

Engine Oil 10W40 of 15W40 OIL

API:  CD, CE, CF of CF4
ACEA: D4, D5

For example:
-- Vetus Marine Diesel Engine Oil 15W40
-- Shell Rimula R4 L 15W40

litres Imp. pt US pt
4 cyl. : 8,5 15 18
6 cyl. : 14 24.6 29.6

1  Commissioning the engine 2  Filling with engine oil

Before starting the engine for the first time, As a rule engines are delivered empty of oil.
the following procedures must be carried out:
• Fill the engine with oil through the filler
neck on top of the valve cover.

For quantity and oil specification see page

108 and 116.

• Check the oil level with the dipstick, see

page 42.

18
3 First commissioning

OIL OIL

Vetus engines are normally equipped

with ZF-Hurth gearboxes.

In case your engine is equipped with

another brand of gearbox follow the
instructions given in the supplied own-
ers manual for changing oil and other
care and maintenance.

17
3  Filling gearbox with oil

• Fill the gearbox with oil. • Check the oil level with the dipstick, see
page 56.
For quantity and oil specification see page
118.

19
3 First commissioning

COOLANT Coolant quantity:

2 litres Imp. pt US pt
4 cyl. : 8 14.1 16.9
6 cyl. : 11 19.4 23.2

4  Filling the cooling system

• Remove the pressure/filler cap on the filler • Fill the cooling system via the filler neck on Fill until the coolant is level with the bottom
neck of the heat exchanger (1). the engine’s heat exchanger. of the filler neck.

• Remove the expansion tank filler cap (2). Use a mixture of 40% antifreeze (ethylene-gly- Bleeding will take place automatically during
col based) and 60% tap water or use a special filling!
coolant.

For specifications see page 119.

  Note   Caution
If a water heater is connected to the engine, Never fill the cooling system with sea water or
see page 22 and 23. brackish water.
20
3 First commissioning

COOLANT COOLANT

2
1

• Replace the pressure/filler cap (1). • Fill the expansion tank until the coolant is at • After the first 3 times that the engine has
the minimum level. been in operation, such that the operating
temperature has been reached and the en-
• R
eplace the filler cap (2) on the expansion gine has cooled back to the ambient tem-
tank. perature, the coolant level in the expansion
tank must be checked.
If necessary, add coolant.

  Caution
Never fill the cooling system with sea water or
brackish water.
21
3 First commissioning

2 OPEN CAP
PRESSURE CAP 1
(1.5bar)

5  Filling coolant system, if a water heater

is connected -1-
The highest point of the water heater is situ- • F ollow the filling instructions as shown on Use a mixture of 40% antifreeze (ethylene-gly-
ated at a lower level than the expansion tank pages 20 and 21. col based) and 60% tap water or use a special
for the ship’s engine. coolant.

The water heater will be filled and bled auto- For specifications see page 119.
matically during filling of the cooling system.

  Caution
Never fill the cooling system with sea water or
brackish water.
22
3 First commissioning

2 OPEN CAP

PRESSURE CAP 1
(1.5bar)

6  Filling coolant system, if a water heater

is connected -2-
The highest point of the water heater is situ- • Open valve (3) during filling and bleeding Use a mixture of 40% antifreeze (ethylene-gly-
ated at a higher level than the expansion tank the system. col based) and 60% tap water or use a special
for the ship’s engine. coolant.
• F ollow the filling instructions as shown on
The water heater will not be filled and bled pages 20 and 21. For specifications see page 119.
automatically during filling of the cooling
system.

  Note   Caution
• Remember to close valve (3) after filling the Never fill the cooling system with sea water or
system. brackish water.
23
3 First commissioning

FUEL
Neutral

(No throttle, gearbox

not engaged)
  Warning
Never fill the fuel tank while the engine is
running. Do not spill fuel. Prevent unnec-
essary pollution.

7  Fuel 8  Other preparations

• Ensure that the fuel tank is filled with diesel • Check that the battery is charged and check • Check that the gearbox control lever is set
fuel. the battery cable connections. to ‘neutral’.

Use only clean, water-free, commercial ap- • Set the main switch to position ‘on’.
proved diesel fuel.
• Open the sea cock.
For fuel grade see page 114.

The fuel system is self-bleeding.

24
3 First commissioning

OIL

9  Test run

• Start the engine. • Check the oil level. If necessary top up to • Check that the engine and all connections
the indicated level. (fuel, coolant and exhaust) for leaks.
How to start the engine and what to check
before, during and immediately after start- • Start the engine.
ing is described on page 30 and further.
• Allow the engine to test run for about 10
• Allow the engine to test run for about 2 minutes at idling speed.
minutes at idling speed .
• Stop the engine.   Caution
• Stop the engine Stop the engine immediately if it makes
any strange noises, vibrates excessively or
if black smoke comes out of the exhaust!
25
3 First commissioning

10  Checking the coolant level 11  Sea trial

Once the engine has reached operating tem- • Check the coolant temperature. • Check the operation of the remote control.
perature, check the coolant level in the expan- - Carry out a sea trial
sion tank.
At full load (when the vessel is in motion), the
• Vary the revolutions between idling and maximum RPM must correspond to the value
2000 rev/min. specified in the technical data. The engine
can become overloaded if it doesn’t reach this
• Add coolant if necessary. RPM! In this case, check the propeller for irre-
gularities and the correct choice of speed and
With a warm engine, the level will be slightly diameter.
higher as indicated.

26
4 Running-in

In order to ensure a long life for your engine, After the first 50 operation hours carry out the
please observe the following for the first 50 following maintenance:
operating hours:
• Drain water from fuel filter, see page 45.
• Allow the engine to reach operating tem-
perature before applying a load. • Engine oil change, see page 47.

• Avoid fast acceleration. • Replace oil filter, see page 49.

• Do not allow the engine to run faster than • Change gearbox oil, see page 56.
3/4 of maximum RPM.
• Replace fuel filter, see page 58.

• Check flexible engine mounts, see page 59.

• Check engine for leaks, see page 59.

• Check tightness of all fasteners, bolts and

nuts, see page 59.

• Checking V-belts, see page 60.

27
5 Use General guidelines

General guidelines for use

Implementing the following recommenda- • Never run the engine without a thermostat.
tions will result in longer life and better per-
formance and more economical operation of • Use a good quality lubricating oil. For spec-
your engine. ifications see page 116.

• Carry out the maintenance described regu- • Use a good quality diesel fuel that is free of
larly, including the ‘Daily procedures before water and other pollutants.
starting’.
• Always follow the safety advice, see page 4.
• 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 119.

28
5 Use General guidelines

After repair work:

  Note
Check that all guards have been replaced and
First commissioning that all tools have been removed from the en-
Follow the instructions given for ‘First com- gine.
missioning’ on page 18 and further if the en- When starting with pre-heating, do not use
gine is being commissioned for the first time. any other substance (e.g. injection with ‘Easy
Start’). Doing so could result in an accident.

29
5 Use Starting

Before starting, always check the following

Neutral
points:
(No throttle, gearbox
• Engine oil level.
not engaged)
• Coolant level.

• Sea cock open.

• Main switch ‘on’.

• Gearbox in ‘neutral’ position.

1  Control lever 2  Control panel

Before starting the engine, always check that The control panel is equipped with a starter
the control lever(s) is (are) in the neutral key.
position.

Leave the control lever in position ­‘neutral’.

30
5 Use Starting

3  Switching on

• Turn the start key on the instrument panel By default, Vetus Deutz engines are not equip-
clock-wise; the warning lights for oil pres- ped with a pre-heat supply; the pre-heat
sure and alternator will now light up and switch/lock position on the operator panel
the alarm buzzer will sound. can therefore be ignored.

31
5 Use Starting

4  Starting

Now turn the key further to the ‘start’ posi- Release the key as soon as the engine fires
tion. (the key will return to the ‘on’ position) and   Caution
throttle back. Release the key if the engine does not fire
Leave the key in this position while the engine within 10 seconds.
is running.
Let the starter motor cool for 30 seconds be-
fore turning the key to the ‘start’ position
again.

32
5 Use Starting

Check that there are no oil pressure and alter- Before fully loading the engine, it should be
nator warnings indicated in the display. brought up to temperature with about 3/4   Caution
of the maximum load as quickly as possible. Never turn the key to the ‘start’ position
The cooling water should now flow out of the A good warming up is essential to ensure while the engine is running.
outlet; if this doesn’t happen, stop the engine maximum life and performance. Doing so will damage the starter motor.
immediately.

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

33
5 Use Cruising

5  Tachometer

The instrument panel is provided with the fol- Indicating the number of revolutions per min-
lowing instruments ute of the engine.   Warning
Avoid idling for more than 10 minutes.
Also the number of running hours is indicat-
ed. This can lead to carbon deposits in the com-
bustion chambers and incomplete combus-
tion of fuel.

34
5 Use Cruising

6  Voltmeter 7  Temperature gauge 8  Oil pressure gauge

Indicating the battery voltage. Indicating the temperature of the internal With the engine at operating temperature,
When the engine is running, the battery volt- cooling system. the oil pressure is:
age should be between 12 and 14 Volts. Fot the operating temperature, see technical When idling: at least 1 bar (7 psi).
With the engine stopped and the start key in data page 109. In case the oil pressure is too low: turn off the
the first position, the voltmeter should indi- In case the engine is overheated: turn off the engine and establish the cause, see fault find-
cate 12 Volts. engine and establish the cause, see fault find- ing table, page 96..105.
ing table, page 96..105.

35
5 Use Cruising

9  Warnings 10  Alarm buzzer

When the engine is running, no warnings Oil pressure, battery charging and temper-
should be displayed. ature indicator lights are all connected to
an alarm buzzer. If this alarm buzzer sounds
while running, Stop the engine immediately!

36
5 Use Stopping

Neutral   Note
Never switch off the battery main switch di-
rectly after the engine has stopped.
Wait at least 2 minutes.

The ECU remains active for about another

40 seconds to save the system data (lag) and
then switches off automatically.

  Warning
The engine can not be restarted, if the system
data is not been saved!

11  Stoppen

• Reduce engine speed to idle and shift the N.B. The ‘Stop’ position, left of the ‘Off’ posi-
gearbox to ‘Neutral’. tion on the control panel, has normally no   Note
function for this engine. If the engine is not to be used for some time,
• Turn the key anticlockwise to the "Off" po- When 2 control panels are connected to one it is recommended that the sea cock is closed
sition. engine, the engine can always be stopped and the battery main switch turned off.
by turning the key to the ‘Stop’ position, no
matter what the position is of the key on the
  Note
other panel.
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.

37
6 Maintenance Introduction

Introduction

The following guidelines should be observed Failure to carry out maintenance can result in
for daily and periodic maintenance. Perform faults and permanent damage to the engine.
each function at the indicated time interval.
No claim can be made on the Guarantee if
The intervals stated are for normal operation- maintenance has been neglected.
al conditions. Service the unit more frequent-
ly under severe conditions.

38
6 Maintenance Introduction

Keep record of the following information -- Oil pressure and coolant temperature.
in the logbook and/or the ‘Service and War-
ranty Manual’: -- Parts on which maintenance is conduct-
ed and type of maintenance (adjustment,
-- Total engine hours (reading engine hour repair or replacement), and the results of
counter). each procedure.

-- Amounts of oil, fuel and coolant needed for -- Changes in operating conditions, such as
topping up. ‘Exhaust gas became black’, etc.

-- The dates and intervals at which the oil and

coolant are changed.
39
6 Maintenance Maintenance schedule

Every 10 hours or daily, before starting page Every 100 hours, at least once every year page
Check engine oil level 42 Drain water from fuel filter 45
Check coolant level 43 Engine oil change 47
Check water strainer 44 Replace oil filter 49
Draining the charge-air cooler 51
After the first 50 hours page Battery, cables and cable connections 52
Drain water from fuel filter 45 Check gearbox oil level 56
Engine oil change 47
Replace oil filter 49 Every 500 hours, at least once every year page
Check gearbox oil level 56 Change gearbox oil 57
Replace fuel filter 58 Replace fuel filter 58
Check flexible engine mounts 59 Check flexible engine mounts 59
Check engine for leaks 59 Check engine for leaks 59
Check tightness of all fasteners, bolts and nuts 59 Check tightness of all fasteners, bolts and nuts 59
Check V-belt 60 Check V-belt 60

  Danger
Stop the engine before carrying out any maintenance work
40
6 Maintenance Maintenance schedule

Every 1000 hours, at least once every 2 years page When required page
Raw water pump inspection 62 Cleaning heat exchanger 73
Replace air filter 65 Cleaning the after cooler 78

Every 1000 hours page.

Check starter motor 66
Check alternator 66

Every 1500 hours page

Checking valve clearance 67

Every 2000 hours page

Replace coolant 70

  Danger
Stop the engine before carrying out any maintenance work
41
6 Maintenance Checking engine oil level
Daily, before starting.

OIL OIL

1  Check oil level 2  Oil level 3  Topping up oil

• Turn the engine off. The oil level must be at or near the upper The oil filling cap is on top of the the valve
mark on the dipstick [1]. cover.
The dipstick is located on the starboard side
of the engine. • If necessary top up with the same brand
and type of oil.

[1] The difference be- litres Imp. pt US pt

tween the two oil
4 cyl. : 1.5 2.6 3.2
level marks is:
6 cyl. : 2 3.5 4.2

42
6 Maintenance Checking coolant level
Daily, before starting.

COOLANT

4  Checking coolant level 5  Coolant level 6  Topping up coolant

• Check the coolant level in the header tank. The coolant must be at the minimum level. • If necessary, top up.
This has to be checked when the engine is The internal cooling system can be filled with
cold. a mixture of anti-freeze (40 %) and tap water
(60 %) or with a special coolant.
• Remove the cap of the filler neck on the For specification, see page 119.
heat exchanger.

  Warning   Note   Caution

Never open the cap on the header tank when If a water heater is connected, see page 22 Never fill the cooling system with sea water or
the engine is at operating temperature. and 23. brackish water.
43
6 Maintenance Checking and cleaning the raw water strainer
Daily, before starting.

7  Checking the raw water strainer 8  Cleaning the strainer

• Check daily whether there is any dirt in the • Close the seacock before removing the lid • Check the sealing between the lid and
raw water strainer. of the water strainer. housing after cleaning and re-assembling
the strainer. An improperly sealed lid will re-
• Clean the raw water strainer as often as is sult in air sucked in by the sea water pump
necessary, depending on the pollution of which again will result in overheating of the
the waterways, but at least once every 6 engine.
months. A clogged raw water strainer will
result in excessive temperatures or over-
heating of the engine coolant.

44
6 Maintenance Draining of water from the water separator/fuel filter
Every 100 operating hours.

9  Waterafscheider aftappen

Empty the separately installed water separa- • Reconnect the sensor connector.
tor:   Danger
The water separator is not engined mounted, Do not smoke when draining off water and
• Disconnect the sensor connector (plug con- but installed is required and the sensor must sediment. Keep flame and sources of ignition
nection) be connected. out of the area. Remove spilled fuel and litter
before you start the engine.
• Unscrew the drain plug/sensor on the under-
side of the filter.

• Allow the water to drain out and close the

drain plug/sensor.

45
6 Maintenance Draining of water from the water separator/fuel filter
Every 100 operating hours.

10  Bleeding 11  Start the engine

After the water separator/fuel filter has been • Operate the starter switch until the engine
drained, the air has to be bled from the fuel fires; release the starter switch if the engine
system does not fire within 20 seconds.
The fuel system is self-bleeding.
• Wait until the starter motor has stopped
before making a new attempt to start the
engine.

• Repeat the above if the engine cuts out af-

ter a short time.

46
6 Maintenance Engine oil change
Every 100 operating hours.

12  Engine oil change

Change the engine oil every 100 hours of Change the oil with a switched off engine at
operation (together with engine oil filter re- operation temperature. (Lube oil temperature   Warning
placement). approx. 80°C (176°F).) Never use additives.

If the engine runs less than 100 hours during This could cause damage to the engine which
the year the oil should be changed at least   Danger is not covered by the guarantee.
once a year. Be aware of the risk of skin burning during
draining the hot oil! Used oil must be collect-
Run the engine for a few minutes before ed in a container for proper disposal accord-
changing the oil; warm oil can be pumped ing to laws and regulations.
out more easily.

47
6 Maintenance Engine oil change
Every 100 operating hours.

OPEN

A S
CLOSE
13  Draining the oil

The battery master switch must be on and the Connect a Ø 10 mm hose to the crankcase oil-
engine must be stopped; the starter key on change pump as shown.   Warning
the control panel must be in the OFF position. The engine oil must be disposed in accord-
Open the shut-off valve ‘A’. ance with the applicable environmental reg-
ulations.
Turn on the oil-change pump with the switch 'S'.
Turn off the pump when all the oil is pumped
out of the crankcase.

  Danger
Beware of burns from hot oil.
48
6 Maintenance Engine oil change
Every 100 operating hours.

OIL
FILTER

14  Removing the oil filter 15  Oiling the oil seal 16  Oil filter installation

• Unscrew the oil filter, with a commercially • Clean the contact surface of the gasket. • Install the filter in accordance with the in-
available tool. structions printed on the filter element
Catch any dripping oil. • Lubricate the oil seal of the new filter ele- housing.
ment with clean engine oil.
Tightening torque 11 - 13 Nm (8-10 ft.lbf )
For oil filter art. code see page 124.

  Danger
Beware of burns from hot oil.
49
6 Maintenance Engine oil change
Every 100 operating hours.

Amount of oil (oil filter incl.):

litres Imp. pt US pt
4 cil. : 8,5 15 18
6 cil. : 14 24.6 29.6

17  Refilling with oil

• Refill the engine with new oil (for specifica- • Operate the engine at idling speed for a
tion see page 116) through the filler open- short period of time. Check for oil leaks
ing in the valve cover. whilst the engine is running. Stop the en-
gine. Allow 5 minutes for the oil to return
to the sump. Check the oil level with the
dipstick.

50
6 Maintenance Draining the charge-air cooler
Every 100 operating hours.

18  Draining the charge-air cooler

The condensate water collected in the char- • Remove the drain plug from the charge-air
ge-air cooler must be drained every 100 hours cooler housing and check that all conden-
or at least 1 x per year. sate water is running out.

• After drainage, replace the drain plug.

 

51
6 Maintenance Battery, cables and connections
Every 100 operating hours.
Warning notes and safety regulations for Corrosive hazard: Warning note:
working with batteries
Battery acid is highly corrosive, there- • Do not place batteries in direct day-
fore: light without protection.
Wear eye protection.

• Wear protective gloves and eye pro- • Discharged batteries can freeze up,
tection. therefore store in an area free from
Keep children away from acid and bat-
frost.
teries.
• Do not tilt battery, acid can escape
from the degassing openings or Disposal:
Explosion hazard:
vents. Hand in old batteries at a collection
A highly-explosive oxyhydrogen gas
point.
mixture occurs when charging batter- Pb
First aid: Keep the batteries upright and do not
ies, therefore:
tip during transport and storage to
• Rinse off acid splashed in the eyes prevent acid leaking out.
Fires, sparks, naked flames and smok-
immediately for several minutes Never dispose of old batteries as do-
ing are prohibited:
with fresh water. Then consult a mestic waste.
doctor immediately.
• Avoid causing sparks when dealing
Careful! Metal parts of the battery will
with cables and electrical equip-
• Neutralize acid splash on skin or are always live so never lay objects or
ment, and beware of electrostatic
clothes immediately with acid neu- tools on the battery.
discharges.
tralizer (soda) or soap suds and
rinse with plenty of water.
• Avoid short-circuits.

• If acid is consumed, consult a doc-

tor immediately.

52
6 Maintenance Battery, cables and connections
Every 100 operating hours.

19  Battery, battery connections

Keep battery clean and dry. Ensure that clamps make good contact after
reassembling.
• Remove battery cables (negative first).
• Hand tighten the bolts only.
• Clean battery posts (+ and −) and clamps
and grease with acid-free and acid-resistant
grease.

53
6 Maintenance Battery, cables and connections
Every 100 operating hours.

Vetus maintenance-free batteries GREEN DOT ALL DARK CLEAR

20  Checking specific gravity 21  Hydrometer operation

Every Vetus Maintenance-free battery has a Green dot visible: In case of low level, caused by overcharging
hydrometer (1) built into the cover. State of charge 65 % or more. the battery for a long period of time with a
voltage too high, replace battery. Check alter-
Visual inspection of the hydrometer will show Dark: nator and/or voltage regulator.
one of three conditions: State of charge less than 65 %. Recharge im-
mediately.

Clear or light yellow:

Electrolyte level low.

54
6 Maintenance Battery, cables and connections
Every 100 operating hours.

Conventional batteries Conventional batteries

Specific State of
gravity charge

1,.8 kg/l 100%

1.20 kg/l 50% recharge

recharge
1.12 kg/l 10%
­immediately

22  Checking electrolyte level 23  Checking specific gravity

For conventional batteries it is required to Measure the electrolyte specific gravity of the During checking the temperature of the elec-
check the electrolyte level regularly. Remove individual cells with a commercial hydrome- trolyte should preferably be 20°C (68°F).
vent caps (taking care no spark or open flame ter. The hydrometer reading (see table) indi-
is nearby) and inspect the level. Fluid should cates the state of charge. Hydrometer reading Measuring the specific gravity shortly after
be 10 to 15 mm (3/8” to 5/8”) above top of all of all cells should be at least 1.200 and show water has been added results in an incorrect
plates. If necessary top up with distilled water. less than 0.050 between high and low. If not, measurement. First charge the battery to mix
Replace vent caps and charge the battery for recharge or replace battery. the added water thoroughly.
15 minutes at 15 - 25 Amps to mix electrolyte.

55
6 Maintenance Gearbox oil level check
Every 100 operating hours.

Vetus engines are normally equipped

with ZF-Hurth gearboxes.

In case your engine is equipped with

another brand of gearbox follow the
instructions given in the supplied own-
ers manual for changing oil and other
care and maintenance.

24  Oil level check

• Unscrew the dipstick out of the gearbox For oil type and specification see page 118.
housing.
• Remember to replace the dipstick.
• Check the oil level by cleaning the dip-
stick and lowering it into the hole, without
screwing it in.
The oil level must between the end and the
mark on the dipstick.

• If necessary top up by pouring oil in the

dipstick hole.

56
6 Maintenance Changing the gearbox oil
Every 500 operating hours.

OIL

14 / 17
25  Draining the oil 26  Filling with new oil

Drain the oil with the aid of a separate sump Or, if sufficient space below the gearbox is • Refill the gearbox to the correct level via the
pump. available, oil can be drained by removing the dipstick opening.
drain plug.
• Remove the dipstick. For oil specification see page 118.
• Remove the fillercap to vent the gearbox
• Insert the suction hose of the sump pump and check if all oil has been drained
in the dipstick hole. Push down the pump In case your engine is equipped with another
handle quickly and pull it up slowly. • Collect the oil in a dripping pan. brand of gearbox follow the instructions giv-
en in the supplied owners manual for chang-
• Remove the sump pump when all the old ing oil and other care and maintenance.
oil has been pumped out.

57
6 Maintenance Fuel filter replacement
Every 500 operating hours.

1 2
FUEL

27  Removing the fuel filter(s) 28  Installing the fuel filter(s)

The filter elements are to be replaced as a unit. • Clean any debris from the filter carrier rim. • I nstall the filters. Turn the filter an additi-
onal one-half to three-quarters of a turn
• Close the fuel shut-off valve.
• L ubricate the rubber gasket sparingly with by hand after the rubber seal touches the
• Remove the fuel filters with a filter wrench. clean motor oil. housing.
Catch any liquid.
• Fill the new filter with clean diesel oil. • Open the fuel shut-off valve.

For fuel filter art. code see page 124. • Check for leakage.
  Danger
Keep naked flames away when working on N.B. 4 cylinder engine has 1 filter element After the replacement of the fuel filters, it is
the fuel system. Do not smoke! instead of 2 not necessary to bleed the system.
The fuel system is self-bleeding.
58
6 Maintenance Flexible engine mounts, hose connections and fasteners
Every 500 operating hours.

29  Check flexible engine mounts 30  Inspection hose connections 31  Check fasteners

• Check the bolts which secure the damper • Inspect all hose connections of the cool- • Check tightness of all fasteners, bolts and
element, the mounting bolts to engine bed ingsystem. (Cracked hoses, loose hose nuts.
and the nuts at the adjustment spindle for clamps)
tightness.

• Inspect the rubber element of the engine

support for cracks. Also check the deflec-
tion of the damper element, the deflection
influences the alignment of engine and
propshaft! Re-align engine in case of doubt.

59
6 Maintenance Checking the V-belts
Every 500 operating hours.

32  Remove the V-belt protection cover 33  Inspection V-belts 34  Checking tension

• Loosen the the screws -the screws can be • Inspect the belts for wear and tear (fraying • Check tension of the V-belt by applying
loosened without tools- and remove the and cracking). Belts which are in poor con- moderate finger and thumb pressure. If the
V-belt protection. dition should be replaced. deflection of the belt is more than 9 (3/8”)-
12 mm (1/2”), using about 10 kg (20 lbs)
For V-belt art. code see page 124. thumb pressure, it should be tensioned.

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

60
6 Maintenance Checking the V-belts
Every 500 operating hours.

1 3

1
2

35  Tensioning the V-belt of the coolant 36  Tensioning V-belt 37  Reinstall the protection cover
and fuel pumps
• Unscrew the bolts (1) and (2). • Unscrew the mounting bracket bolts and • Always reinstall the V-belt cover and tigh-
both of the alternator mounting bolts. Now ten the screws.
• T urn the fuel pump tensioner in the direc- push the alternator outwards until the belt
tion of the arrow, using a square 1/2“ key has the desired tension.
(a), until the tension of the belt is correct.
• Tighten the bolts in the order shown.
• Tighten the bolts (1) and (2).

61
6 Maintenance Raw water pump inspection
Every 1000 operating hours.

1,6 x 6,3
38  Raw water pump inspection 39  Pump cover removal 40  Impeller removal

The rubber impeller of the outboard water Inspection where appropriate changing is as • Slide the impeller off of the shaft using a
pump is not proof against running dry. follows: waterpump plier.

If the water supply has been blocked, it may • Close the sea cock. • Mark the impeller to ensure correct re-in-
be necessary to replace the impeller. Always stallation if it is to be re-used. The impeller
carry a spare impeller on board. • Remove the cover of the pump by unscrew- must be installed in the same position as
ing the screws out of the housing. removed.

62
6 Maintenance Raw water pump inspection
Every 1000 operating hours.

41  Impeller inspection 42  Pump housing inspection

• Inspect the impeller for damage. • Check the inside of the pump housing for
damage. Pay special attention to wear of
• Replace the impeller if necessary. the cam (1).

• Replace the cam and/or the pump housing

in case of excessive wear.

63
6 Maintenance Raw water pump inspection
Every 1000 operating hours.

43  Re-install the impeller 44  Reinstall the pump cover

• The impeller should be lubricated with • Replace the cover with a new O-ring.
glycerin or a non-petroleum based lubri-
cant such as a silicone spray before fitting it • Check the water filter and open the sea
into the impeller housing. cock.

• Fit the impeller to the pump shaft. (if an For O-ring art.code see page 124.
existing impeller is re-used, install it in the
same position as removed).

64
6 Maintenance Air filter replacement
Every 1000 operating hours.

3
2

45  Vervangen luchtfilter

• Cut the Ty-rap (1). • Replace the filter.

  Warning
• Loosen the hose clamp (2). • I nstall the unit in reverse order, tighten the
Never clean the element with petrol or hot
hose clamp and fit a new Ty-rap.
• Remove the filter housing (3). liquids.

For air filter art. code see page 124.

Never apply any oil to the air filter.

Never start the engine without the air filter in

place.

65
6 Maintenance Checking the starter motor and alternator
Every 1000 operating hours.

46  Checking the starter motor 47  Checking the alternator

• Check for visible defects. • Check for visible defects.

• Check whether the Bendix engages with • Remove the alternator belt. Turn the pulley
the starter ring when the starter motor is by hand to check whether the alternator
activated. If the Bendix does not engage can be turned easily. If this is not the case,
properly, contact your Vetus dealer. contact your Vetus dealer.

66
6 Maintenance Checking valve clearance
Every 1500 operating hours.

1 2

13 6
48  Checking / adjusting valve clearance 49  Remove upper cover 50  Remove the V-belt protection cover

Checking the valve clearance must be done • Close the sea cock. • Loosen the the screws -the screws can be
with a cold engine, that is an engine which loosened without tools and they have an-
did not run for at least 6 hours. • Disconnect the hoses (1) and (2). ti-loss rings- and remove the V-belt protec-
tion.
• Remove the 4 bolts and remove the upper
cover.
  Note
After checking / adjusting the valve clearance
re-install the V-belt protection and the upper
cover and re-connect the hoses.

67
6 Maintenance Checking valve clearance
Every 1500 operating hours.

1 Lock nut
2 Adjusting screw
3 Angle gauge
4 Key socket for socket wrench
5 Magnet

51  Adjusting the valve clearance

Check valve clearance and adjust if necessary • Remove the gasket.

• Allow the engine to cool down for at least • The turning tool is placed on the mounting
30 minutes before you adjust the valve screws of the pulleys.
clearance: lube oil temperature less than
80°C. • Rotate the crankshaft until the valves over-
lap.
• Loosen the screws.
Exhaust valve is not yet closed, inlet valve
• Remove the valve cover. starts opening.

68
6 Maintenance Checking valve clearance
Every 1500 operating hours.

Determine which cylinders should be adjus-

ted from the setup chart:

VD4 VD6

Valve overlap Setting the cylinder Valve overlap Setting the cylinder
1 4 1 6
3 2 5 2
4 1 3 4
2 3 6 1
2 5
4 3

• Place the angle gauge with the key socket • R

otate the angle gauge anticlockwise until
on the adjusting screw. you reach the specified rotational angle:

• Fix the magnet of the angle gauge.

Valve clearance IN Inlet valve 75° +10°
• Turn the angle gauge in a clockwise directi-
EX Exhaust valve 120° +10°
on until it is seated (rocker arm has no play)
and turn the scale to zero.

69
6 Maintenance Coolant replacement
Every 2000 operating hours.

52  Coolant replacement

The coolant has to be replaced every 2000 op-

erating hours or at least once every two years.   Danger   Warning
Be aware of the risk of skin burning during Cooling system protective liquids must be
N.B. Replacing the coolant may also be neces- draining the hot coolant! Used coolant must disposed of in accordance with environmen-
sary as part of the winter storage procedure; be collected in a container for proper disposal tal regulations.
in case that the coolant present in the cooling according to laws and regulations.
system offers insufficient protection for the
winter.

70
6 Maintenance Coolant replacement
Every 2000 operating hours.

1 1
2

18 19
53  Draining of coolant

• R
emove the drain plug from the heat ex- • R
emove the filler cap to bleed the cooling N.B. A small part of the coolant will remain
changer housing (1). system and check that all the fluid is run- in the engine block.
ning out.
• If necessary, remove the drain plug (2) from
• Refit the drain plug after all the liquid has the engine block to fully drain the engine.
run out.

71
6 Maintenance Coolant replacement
Every 2000 operating hours.

54  Filling the cooling system

• Fill the cooling system as indicated on pa- Coolant quantity: • Check the coolant level in the expansion
ges 20 to 23. tank after the engine has first been in ope-
litres Imp. pt US pt ration, such that the operating tempera-
Use a mixture of 40% antifreeze (ethylene-gly- ture has been reached and the engine has
4 cyl. : 8 14.1 16.9
col based) and 60% tap water or use a special cooled back to the ambient temperature.
coolant. 6 cyl. : 11 19.4 23.2 Top up, if necessary.

For specifications see page 119.

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

72
6 Maintenance Cleaning the heat exchanger

Under normal conditions of use cleaning the Possible causes of fouling are:
  Note heat exchanger is not necessary! -- Small rubber particles from a damaged sea
Cleaning of the heat exchanger is not a water pump impeller.
routine maintenance job. The engine temperature will be higher than -- Growth of algae or seaweed.
normal if the heat exchanger is fouled.
Only clean the heat exchanger if this is
(badly) fouled.

73
6 Maintenance Cleaning the heat exchanger

18 1,2 x 6,5 7
55  Draining the coolant 56  Disconnecting raw water hoses

• Remove the drain plug in the heat exchan- • R

emove the filler cap to bleed the cooling • Close the tap of the raw water supply.
ger housing to drain the coolant. system and check that all the fluid is run-
ning out. • Disconnect both raw water hoses.

• Refit the drain plug after all the liquid has

run out.

74
6 Maintenance Cleaning the heat exchanger

1 2

5
57  Remove the nuts from the end covers 58  Remove heat exchanger

• Remove the 3 nuts from both end covers. • Take off the connector cover (2) with the • Slide the heat exchanger out of the housing.
gasket from the housing.
• T ake off the end cover (1) with the O-ring • Remove the gasket from the heat exchan-
from the housing. ger

75
6 Maintenance Cleaning the heat exchanger

59  Cleaning the heat exchanger

• Clean the heat exchanger: Use a pipe clean- • Ensure that both contact surfaces of the • Clean the contact surfaces of the O-ring
er to remove fouling in the pipes. heat exchanger are free from dirt. and gaskets.

• Then rinse the heat exchanger pipes with

clean water.

76
6 Maintenance Cleaning the heat exchanger

1 3 1 2

1,2 x 6,5 7
60  Replacing heat exchanger 61  Replacing the end covers

• Place the heat exchanger with a new gasket • R

efit the connector cover with a new gasket • Refit all the disconnected hoses.
(1) in the heat exchanger housing. (2) to the housing.
• Refill the cooling system, see pg. 72.
• Refit the end cover with a new O-ring. (3)
• Open the tap of the raw water supply.
For gasket set art.code see pg 124.

77
6 Maintenance Cleaning the after cooler

1,2 x 6,5 7
62  Removing the raw water hoses
  Note
Cleaning of the after cooler is not a routine Possible causes of fouling of the tubes of the • Close the sea cock.
maintenance job. after cooler are:
-- Small rubber particles from a damaged raw • Remove both the raw water hoses.
If the performance of the engine decreases water pump impeller.
this can be caused by a dirty heat exchanger -- Growth of algae or seaweed.
in the after cooler.
The heat exchanger must then be cleaned.

78
6 Maintenance Cleaning the after cooler

1 2

5
63  Remove the nuts from the end covers 64  Removing the heat exchanger

• Remove the 3 nuts from both end covers. • T ake off the connector cover (2) with the • Slide the heat exchanger out of the housing.
gasket from the housing.
• T ake off the end cover (1) with the O-ring • Remove the gasket from the heat exchan-
from the housing. ger

79
6 Maintenance Cleaning the after cooler

65  Cleaning the heat exchanger

• Clean the tube of the heat exchanger; use a • Make sure that both surfaces of the after • Clean the contact surfaces of the O-ring
pipe brush and fresh water to remove any cooler housing are free from dirt residues. and gaskets.
growth in the pipes.

• Then rinse the heat exchanger tubes with

clean water.

80
6 Maintenance Cleaning the after cooler

2 1 3

1,2 x 6,5 7
66  Replacing the heat exchanger 67  Fitting end covers

• P
lace the heat exchanger with a new gasket • Refit the connector cover with a new gasket • Refit all the disconnected hoses.
(1) in the charge-air cooler housing. (2) to the housing.
• Open the tap of the raw water supply.
• Refit the end cover with a new O-ring. (3)

For gasket set art.code see pg. 124.

81
7 Lay-up / Winter storage procedure

In case of lay-up for a long period the stor- The engine should be inspected at the start of
age procedures as described in this chapter the storage period and any necessary repairs
should be carried out. should be carried out.

A long period means a period longer than 3 Consult a Vetus Dealer if help is required with
months, for example, during the winter peri- this.
od.
Inspections and maintenance work to be car-
Make sure that the engine compartment is ried out are:
well ventilated during the winter period.

Good ventilation prevents damp in the en-

gine compartment, thus preventing corrosion
of the engine from occurring.

82
7 Lay-up / Winter storage procedure

Inspections and maintenance work to be carried out: page

1 Clean the engine, remove any salt. Paint any rust spots and spray the whole engine with a protective 84
medium, for example CRC protective 6-66.

2 Drain off the water from the fuel system and fill the fuel tank. 84

3 Make sure that the engine fuel system is filled with a fuel mixture with protective properties. 85

4 Flush out the raw water circuit with fresh water and if necessary fill with antifreeze. Clean the heat 86
exchanger if necessary.

5 Make sure that the cooling system is filled with a suitable anti-freeze. 87

6 Change the oil filter and the engine oil. 88

7 Change the oil in the gearbox. 88

8 Disconnect the battery cables, charge the batteries if necessary and grease the battery terminals. 89

83
7 Lay-up / Winter storage procedure

1 2

1  Corrosion protection 2  Fuel system

The various parts of the engine (except the • Drain the water from the water separator/ • Install a new fuel filter. (page 58)
engine block) have been treated with an fuel filter and the fuel tank.
anti-corrosion protective medium. In order
to prevent corrosion, the engine should be Ensure that the tank is completely filled with
rinsed off to remove any salt residues. If there fuel.
is any corrosion, the paint should be touched
up. Engine parts that become hot must be
touched up with heat-resistant paint.

84
7 Lay-up / Winter storage procedure

  Tip!
Combine running the engine with the
  Caution protective fuel mixture with flushing
Never run the engine under load with the raw water circuit with fresh water,
this mixture of fuel and oil. see ‘Winter storage procedure - Raw
water cooling system’.

3  Protective fuel mixture

• Connect the fuel supply pipe to a can filled

with protective diesel fuel, for example
‘Calibration Fluid’ (ISO 4113) or with a mix-
ture of 1 part of engine oil [1] to 9 parts of
clean fuel [2].
[1] Engine oil with protective properties. [2] Only use CEN EN 590 Diesel fuel.
E.g.: Preferably water-free fuel.
• Use this mixture to run the engine at no
-- Vetus Marine Diesel Engine Oil 15W40 Collect some fuel from the return pipe,
load for approx. 5 minutes.
-- Shell Rimula R4 L 15W40 while engine is running.
• Stop the engine.

85
7 Lay-up / Winter storage procedure

Heat exchanger
Only clean the heat exchanger if this is
absolutely necessary, see page 73.
  Tip!
Combine flushing the raw water circuit Charge-air cooler
with fresh water with running the en- Only clean the heat exchanger if neces-
gine with the protective fuel mixture, sary, see page 78.
see ‘Winter storage procedure - Protec-
tive fuel mixture’ Raw water pump
Check the impeller of the raw water
pump at least once every two years, see
page 62.

4  Raw water cooling system

• Close the sea cock. • Connect the raw water intake to a fresh wa- • Stop the engine and close the sea cock.
ter (tap water) supply or a tank containing
• Remove the lid of the water strainer. fresh water. Open the tap and allow the en- • The raw water system must be protected in
gine to idle for at least 5 minutes to remove areas where the temperature drops to be-
• If necessary, clean the raw water strainer. any salt and contamination from the raw low zero during the winter.
water cooling system. Pour 1 litre (1/4 gallon) of anti-freeze
Make sure that there is a sufficient supply (preferably a non-toxic biodegradable an-
of water to prevent the engine from over- ti-freeze) into the water strainer and run
heating. the engine until the anti-freeze has disap-
peared into the cooling system.

86
7 Lay-up / Winter storage procedure

  Tip!
Protect the sea cock as follows:
With the motor stopped.
• Place the sea cock in a position that it
is just opening.
• Pour a small amount of non-toxic bi-
odegradable anti-freeze into the raw
water strainer.
• Close the sea cock as soon as it is
filled with anti-freeze.

5  Fresh water cooling system

Anti-freeze can be toxic. Take care that no To avoid corrosion during winter storage the N.B. Replacing the coolant is only necessary
anti-freeze is spilled into the waterway cooling system must be filled with an anti- if the coolant present in the cooling system
freeze/water mixture (or a coolant). offers insufficient protection against temper-
• Check the seal between the lid and hous- atures below 0˚C (32˚F).
ing after cleaning and re-assembling the For specifications see page 119.
strainer. For coolant replacement see page 70.

An improperly sealed lid will result in air

sucked in by the raw water pump which again
will result in overheating of the engine

87
7 Lay-up / Winter storage procedure

A S

6  Lubrication system 7  Changing the gearbox oil

• Drain the oil, see page 48. • Replace the oil filter and change the engine • Stop the engine and change the oil of the
oil; use oil with protective properties. See gearbox. (page 57)
page 47-49.

For quantity and oil specification see page

108 and 116.

88
7 Lay-up / Winter storage procedure

  Note
Never switch off the battery main switch di-
rectly after the engine has stopped.
Wait at least 2 minutes.
See page 37.

8  Electrical system

• Disconnect the battery cables. • Charge batteries during winter lay-up regu- • Follow the recommendations given on
larly if required! pages 52 to 55 or consult the recommen-
dations given by the battery supplier for in-
spection and maintenance of the batteries.

89
8 Recommissioning after lay-up or winter storage

The engine must be inspected and any main-

Inspections and maintenance work to be carried out are: page
tenance work carried out when re-commis-
sioning for example at the beginning of the 1 Drain the water from the fuel system. 91
sailing season.
2 Check the raw water system. 92
Consult a Vetus Dealer if help is required with 3 Check the coolant level in the internal cooling system. 93
this.
4 Check the oil level. 93
Inspections and maintenance work to be car- 5 Check the batteries and reconnect these. 94
ried out are:
6 Check the operation of the engine. 94

7 Check all hose connections for leaks. 95

8 Check the operation of the instruments and the engine controls. 95

90
8 Recommissioning after lay-up or winter storage

1  Fuel system

• Drain the water from the water separator/ • Drain the water from the fuel tank. • Open the fuel valve.
fuel filter. (page 45)

91
8 Recommissioning after lay-up or winter storage

1,6 x 6,3
2  Raw water cooling system

• Check that the lid of the raw water strainer • Check whether the lid of the raw water • Re-tighten possible loose hose clamps.
is reinstalled. pump and drain plugs are reinstalled. (pag-
es 62, 64)

92
8 Recommissioning after lay-up or winter storage

OIL

3  Fresh water cooling system 4  Lubrication system

• Open the sea cock. • Check the coolant level. (page 43) • Check the engine oil level. (page 42)

93
8 Recommissioning after lay-up or winter storage

5  Electrical system 6  Switching on

• Make sure that the batteries are fully • Connect the batteries. • Turn the start key on the instrument panel
charged. (page 52, 89) clock-wise;

94
8 Recommissioning after lay-up or winter storage

7  Check engine for leaks 8  Checking instruments and remote

controls
• Start the engine. • Check the operation of the instruments, the
remote control and the gearbox.
• Check the fuel system, the cooling system
and the exhaust for leakage.

95
9 Troubleshooting General

Engine faults are in most cases caused by im- If you are unable to identify the cause of the
proper operation or insufficient maintenance. fault or to rectify it yourself, then contact the   Danger
nearest service representative. Before starting, make sure that nobody is in
Note Not all possible faults mentioned will be the immediate vincinity of the engine.
applicable to your engine. When carrying out repair, never start the en-
gine with the fuel injection pump removed
In case of a fault, always check first that the removed.
operation and maintenance instructions have Disconnect battery!
been followed.

In the following tables information is given

about the possible causes of faults and sug-
gested remedies. Please note that these ta-
bles can never be complete.
96
9 Troubleshooting Fault finding table

Fault page

1 Engine will not crank 98

2 Engine cranks but will not start, no smoke from exhaust 98

3 Engine cranks but will not start, smoke from exhaust 99

4 Engine starts but runs unevenly (rough idling) or stalls 99

5 Engine does not reach maximum rpm under load 100

6 Engine overheats 101

7 Engine not firing on all cylinders 101

8 Engine has little or no oil pressure 102

9 Engine oil consumption excessive 102

10 Fuel consumption excessive 103

11 Black exhaust smoke (idling) 103

12 Blue exhaust smoke (idling) 103

13 Black exhaust smoke (at load) 104

14 White exhaust smoke (at full load) 104

15 Burnt oil trace in exhaust line 105

16 Idle speed >750-800 RPM 105

97
9 Troubleshooting Fault finding table

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

Possible fault Remedy Possible fault Remedy

Faulty or discharged battery (too Check / recharge battery and (Nearly) Empty fuel tank. Refill.
low voltage ) . check engine alternator and/or Fuel stop valve closed. Open.
battery charger. Fuel pre-filter clogged . Clean /replace
Fuse blown. Replace. Fuel filter clogged with water Check or replace.
Loose or corroded connections Clean and tighten connections. and/or contamination.
in starting circuit. Vent line of fuel supply tank Check / clean.
Wrong engine electric mass Repair. clogged.
connection. Faulty injector/injection pump.. Check, replace if required.
Faulty starter-switch or faulty Check / replace. Leaking fuel supply line or fuel Check / replace.
starter-relay. injection line.
Faulty starter-motor or pinion Check / replace starter-motor. Air in fuel system. Check and bleed.
does not engage.
Fuse burnt out in ECU box. Check/replace.
Seized components. Repair.
ECU faulty. Diagnosis -replace .
Control lever not in neutral. Put operating lever in neutral
Exhaust restricted. Check.
ECU prevents starting. Check error according to error
Faulty V-belt fuel pump. Replace V-belt.
code and eliminate fault.
Compression too low. Check.
Water in the cylinder . Check / Repair .

98
9 Troubleshooting Fault finding table

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

Possible fault Remedy Possible fault Remedy

Faulty injector/injection pump. Check, replace if required. (Nearly) Empty fuel tank. Refill.
Air in fuel system. Check and bleed. Fuel supply line restricted. Check / clean.
Wrong fuel quality or contami- Check fuel. Drain and flush fuel Fuel filter clogged with water Check or replace.
nated fuel. tank. Replace with new fuel. and/or contamination.
Incorrect lube oil SAE class or Replace. Vent line of fuel supply tank Check / clean.
quality for ambient temperature. clogged.
Insufficient intake air. Check. Faulty injector/injection pump. Check, replace if required.
Intake air filter clogged . Clean/replace Leaking fuel supply line or fuel Check / replace.
Incorrect valve clearance. Adjust. injection line.
Air in fuel system. Check and bleed.
Wrong fuel quality or contami- Check fuel. Drain and flush fuel
nated fuel. tank. Replace with new fuel.
Low battery voltage Recharge /replace
Exhaust restricted. Check.
Incorrect valve clearance. Adjust.
Idle setting too low. Check/ adjust.
Compression too low. Check.
ECU has detected s system error Check error according to error
and activates an equivalent code and eliminate fault.
speed.

99
9 Troubleshooting Fault finding table

5 Engine does not reach maximum rpm under load 5 Engine does not reach maximum rpm under load

Possible fault Remedy Possible fault Remedy

Fuel pre filter clogged. Clean/replace. Engine overloaded. Check size of propeller. Clean the
Fuel filter clogged with water Check or replace. propeller.
and/or contamination. Boat load inadequate. -
Clogged injectors Check, replace if required. Hull/propeller dirty. Clean
Faulty injector/injection pump. Check, replace if required.
Leaking fuel supply line or fuel Check / replace.
injection line.
Air in fuel system. Check and bleed.
Wrong fuel quality or contami- Check fuel. Drain and flush fuel
nated fuel. tank. Replace with new fuel.
Incorrect injection timing. Check / adjust.
Oil level too high. Lower level.
Lubricating oil incorrect SAE Replace.
spec or quality for ambient
temperature.
Insufficient intake air. Check.
Leak in inlet manifold. Check / replace.
Intercooler dirty. Check/clean.
Exhaust restricted. Check / clean.
Incorrect valve clearance. Adjust.
Transmission defect. Check
Turbocharger damaged. Replace

100
9 Troubleshooting Fault finding table

6 Engine overheats 6 Engine overheats

Possible fault Remedy Possible fault Remedy

Faulty injector/injection pump. Check, replace if required. Motor becomes apparently Check / replace. 
Sea cock closed. Open. overheated as a result of faulty
Raw water strainer clogged. Check / clean. temperature switch, sensor or
meter.
Faulty raw water pump impeller. Check / replace.
Leak in raw water feed system. Check / replace.
Coolant level too low. Check / top up.
Faulty coolant pump. Check / replace.
Faulty thermostat. Check / replace. 7 Engine not firing on all cylinders
Leak in coolant circuit . Check.
Possible fault Remedy
Heat exchanger dirty or clogged Check / clean.
as a result of rubber particles Fuel supply line restricted. Check / clean.
from a worn impeller. Fuel filter clogged with water Check or replace.
Oil level too low. Increase level. and/or contamination.
Oil level too high. Lower level. Leaking fuel supply line or fuel Check / replace.
injection line.
Faulty oil filter. Replace.
Air in fuel system. Check and bleed.
Faulty oil heat exchanger. Replace.
Intake valve blocked. Check /replace
Insufficient intake air. Check / replace air intake filter.
Incorrect valve clearance. Adjust.
Leak in inlet manifold. Check / replace.
Faulty turbo compressor. Check / replace.
Intercooler dirty. Check/clean.
Incorrect valve clearance. Adjust.

101
9 Troubleshooting Fault finding table

8 Engine has little or no oil pressure 9 Engine oil consumption excessive

Possible fault Remedy Possible fault Remedy

Oil level too low. Increase level. Oil level too high. Lower level.
Incorrect lube oil SAE class or Replace. Incorrect lube oil SAE class or Replace.
quality for ambient temperature. quality for ambient temperature.
Blocked oil filter. Replace. Leak in lubricating oil system. Repair / replace.
Faulty oil pump. Repair / replace. Crank case vapour condenser Replace
Oil leaks. Check. clogged.
Excessive inclination of engine. Check / Adjust. Insufficient intake air. Check.
Oil pressure apparently too low Check / replace.  Excessive wear of cylinder/pis- Check compression; overhaul
due to faulty oil pressure switch, ton. engine.
sensor or meter. Turbocharger oil leaks. Replace or repair.
Engine overloaded. Check size of propeller. Clean the
propeller.
Excessive inclination of engine. Check / Adjust.

102
9 Troubleshooting Fault finding table

10 Fuel consumption excessive 11 Black exhaust smoke (idling)

Possible fault Remedy Possible fault Remedy

Incorrect fuel quality or dirty Check fuel. Drain and rinse fuel Injector fault Check /replace.
fuel. tank. Replace with new fuel. Oil level too high. Lower level.
Fuel leaks. Check and repair. Excessive inclination of engine. Check / Adjust.
Insufficient air intake. Check. 
Excessive wear of cylinder / Check compression; refurbish
piston. engine.

12 Blue exhaust smoke (idling)

Possible fault Remedy

Oil level too high. Lower level.
Leaking from turbo compressor Check / replace oil seal.
oil seal.
Excessive inclination of engine. Check / Adjust.

103
9 Troubleshooting Fault finding table

13 Black exhaust smoke (at load) 14 White exhaust smoke (at full load)

Possible fault Remedy Possible fault Remedy

Faulty injector / injection pump. Check / replace if required. Faulty injector/injection pump. Check, replace if required.
Incorrect injection timing. Check / adjust. Air in fuel system. Check and bleed.
Oil level incorrect. Check. Wrong fuel quality or contami- Check fuel. Drain and flush fuel
Insufficient intake air, air filter Check/clean the filter. nated fuel. tank. Replace with new fuel.
dirty. Water in fuel system. Check water separator.
Leak in inlet manifold. Check / replace. Incorrect injection timing. Check / adjust.
Intercooler dirty. Check/clean. Incorrect valve clearance. Adjust.
Incorrect valve clearance. Adjust. Vapour in exhaust gases con- -
Excessive wear of cylinder / Check compression; refurbish denses as a result of very low
piston. engine. ambient temperature.
Faulty turbo compressor. Check / replace.
Engine overloaded, max. rpm is Check sizes of propeller. 
not reached.
Engine overloaded, dirty pro- Check /clean.
peller -boat hull, excessive load
on-board.

104
9 Troubleshooting Fault finding table

15 Burnt oil trace in exhaust line 16 Idle speed >750-800 RPM

Possible fault Remedy Possible fault Remedy

Oil level too high. Lower level. Coolant temperature lower than On normal functioning: Run the
Excessive wear of cylinder / Check compression; refurbish 40 °C. engine at a speed of 900 RPM until
piston, piston rings. engine. the coolant temp is over 40 °C .
Faulty turbocharger. Check, Repair / Replace . Wrong indication of tachometer. Adjust /replace .
Fault on electric -electronic Check/repair.
equipment.
Low battery voltage. On normal functioning: If the
battery voltage is lower than 13.5
V increase engine speed to 1050
RPM until the voltage is 13.5 Volt .

105
10 Technical data Engine specifications

Model : VD4.120 VD4.140 VD6.170 VD6.210

General
Make : Vetus Deutz
Number of cylinders : 4 4 6 6
Based on : TCD 2012 L04 2V Low TCD 2012 L04 2V High TCD 2012 L06 2V Low TCD 2012 L06 2V High
Type : 4-stroke diesel, in-line
Injection : Direct, Common Rail
Aspiration : Turbo-charged / After cooled
Bore : 101 mm 101 mm 101 mm 101 mm
Stroke : 126 mm 126 mm 126 mm 126 mm
Total displacement : 4038 cm3 4038 cm3 6057 cm3 6057 cm3
Compression ratio : 18,0 : 1 18,0 : 1 18,0 : 1 18,0 : 1
Idling speed : 800 rpm 800 rpm 800 rpm 800 rpm
Max. no. of revolutions at no load : 2520 rpm 2520 rpm 2520 rpm 2520 rpm
Direction of rotation : Counter clockwise, viewed towards the flywheel
Valve Clearances: Inlet/Exhaust : —
Setting with rotary angle disc : 75°+10° / 120°+10°
Weight (with standard gearbox) : 515 kg (1135 lbs) 515 kg (1135 lbs) 685 kg (1510 lbs) 685 kg (1510 lbs)

106
10 Technical data Engine specifications

Model : VD4.120 VD4.140 VD6.170 VD6.210

Engine installation
Max. installation angle : 15 degrees backwards
Max. athwartships angle : 25 degrees continuously, 30 degrees intermittent

Maximum output
90 kW 103 kW 125 kW 155 kW
at the flywheel (ISO 8665) :
(122 hp) (140 hp) (170 hp) (210 hp)
86 kW 99 kW 120 kW 149 kW
at the prop shaft (ISO 8665) :
(117 hp) (134 hp) (163 hp) (203 hp)
at no. of revolutions of : 2400 rpm 2400 rpm 2400 omw/min 2400 rpm
449 Nm 520 Nm 680 Nm 810 Nm
Torque, : (45,8 kgm) (53 kgm) (69,3 kgm) (82,6 kgm)
(331 ft.lb) (383 ft.lb) (502 ft.lb) (597 ft.lb)
at no. of revolutions of : 1600 rpm 1600 rpm 1600 omw/min 1600 rpm

235 g/kW.h 235 g/kW.h 240 g/kW.h 240 g/kW.h

Fuel consumption : (173 g/hp.h) (173 g/hp.h) (177 g/hp.h) (177 g/hp.h)
( 6.1 oz/hp.h) ( 6.1 oz/hp.h) (6.2 oz/hp.h) (6.2 oz/hp.h)
at no. of revolutions of : 2400 rpm 2400 rpm 2400 omw/min 2400 rpm

107
10 Technical data Engine specifications

Model : VD4.120 VD4.140 VD6.170 VD6.210

Fuel System (Self-bleeding)

Injection pump : Bosch
Injectors : Bosch
Opening pressure : 250 bar (kgf/cm3) (3625 psi)
Firing order : 1-3-4-2 1-3-4-2 1-5-3-6-2-4 1-5-3-6-2-4
Injection timing : 4° BTDC 4° BTDC 4° BTDC 4° BTDC
Fuel lift pump : Suction height max. 1.5 m (5 ft)
Fuel supply connection : for hose 12 mm I.D.
Length fuel line : max. 6 m (20 ft)
Fuel return connection : for hose 10 mm I.D.
Return flow : max. 4 l/min (0.9 Imp. Gal/min) (1.1 US Gal/min)

Oil lubrication system

Oil capacity, max.
7.5 litres (13.2 Imp. Gal/ 7.5 litres (13.2 Imp. Gal/ 12.5 litres (22 Imp. Gal/ 12.5 litres (22 Imp. Gal/
without oil filter :
min) (5.8 US Gal/min) min) (5.8 US Gal/min) min) (26.4 US Gal/min) min) (26.4 US Gal/min)
8.5 litres (15 Imp. Gal/ 8.5 litres (15 Imp. Gal/ 14 litres (24.6 Imp. Gal/ 14 litres (24.6 Imp. Gal/
with oil filter :
min) (18 US Gal/min) min) (18 US Gal/min) min) (29.6 US Gal/min) min) (29.6 US Gal/min)
Oil pressure with warm oil (120˚C,
: min. 0.8 bar (11.6 psi)
248°F) and low idle
Oil temperature in sump : max. 125°C (257°F)

108
10 Technical data Engine specifications

Model : VD4.120 VD4.140 VD6.170 VD6.210

Cooling system
8 liter (14.1Imp. Gal/ 8 liter (14.1Imp. Gal/ 11 liter (19.4 Imp. Gal/ 11 liter (19.4 Imp. Gal/
Capacity :
min) (16.9 US Gal/min) min) (16.9 US Gal/min) min) (23.2 US Gal/min) min) (23.2 US Gal/min)
Thermostat : opening at 83°C (181°F), fully opened at 95°C (203°F) (VD20833)
Coolant pump,
192 l/min (42.2 Imp. Gal/ 192 l/min (42.2 Imp. Gal/ 192 l/min (42.2 Imp. Gal/ 192 l/min (42.2 Imp. Gal/
Flow :
min) (50.7 US Gal/min) min) (50.7 US Gal/min) min) (50.7 US Gal/min) min) (50.7 US Gal/min)
Total head : 0.3 bar (4.3 psi) 0.3 bar (4.3 psi) 0.3 bar (4.3 psi) 0.3 bar (4.3 psi)
Raw water pump,
94 l/min (20.7 Imp. Gal/ 94 l/min (20.7 Imp. Gal/ 117 l/min (25.7 Imp. Gal/ 117 l/min (25.7 Imp. Gal/
Flow at max. engine rpm :
min) (24.8 US Gal/min) min) (24.8 US Gal/min) min) (30.9 US Gal/min) min) (30.9 US Gal/min)
Total head at max. flow : 0.5 bar (7 psi) 0.5 bar (7 psi) 0.5 bar (7 psi) 0.5 bar (7 psi)
Inlet connection : for hose 32 mm I.D.
Heater supply connection : G 1/2"
Heater return connection : M26 x 1,5

Combustion air system / Exhaust

Intake vacuum pressure : max. 25 mbar (0.74 in Hg)
Exhaust diameter : 100 mm (4") 100 mm (4") 125 mm (5") 125 mm (5")
at specified output max. 100 mbar (2.9 in Hg)
Exhaust back pressure :
absolute maximum 120 mbar (3.5 in Hg)

109
10 Technical data Engine specifications

Model : VD4.120 VD4.140 VD6.170 VD6.210

Electrical system
Voltage : 12 Volt / 24 Volt, see alternator data tag
Alternator : 14 Volt, 160 A / 28 Volt, 60 A, see alternator data tag
Starter motor : 14 Volt, 3.1 kW / 28 Volt, 4 kW
Battery capacity : min. 88 Ah, max. 176 Ah (at 12 Volt) / min. 2x 66 Ah, max. 2x 110 Ah (at 24 Volt)
Fuses
Oil-change pump/Immobiliser : Blade fuse ‘ATO’ 3 A, see page 111 
EMR Power : Blade fuse ‘ATO’ 25 A, see page 111 
Dashboard : Blade fuse ‘ATO’ 10 A, see page 111 
CAN Diagnosis/EMR Control : Blade fuse ‘ATO’ 7.5 A, see page 111 
V-belts, Tension
Alternator : Pre-tension 650 N (145 lbf ) / Re-tension 400±50 N (90±11 lbf )
Fuel pump / Coolant pump : Pre-tension 650 N (145 lbf ) / Re-tension 400±50 N (90±11 lbf )

110
10 Technical data Engine specifications

K1 K3 K2 K4 4
Electrical system
Relay
K1 70A : Starting
Elec. Oil sump
K2 30A :
drain pump
K3 70A : EMR
K4 30A : Diagnosis/ CAN relay

2 3 1

Gearbox specifications

Model : VD4.120 VD4.140 VD6.170 VD6.210

Gearbox Reduction ratio
ZF-Hurth: model 45 : 2,2 / 2,5 / 3,0 : 1 2,2 / 2,5 / 3,0 : 1 — —
model 45A : 2,2 / 2,5 / 3,0 : 1 2,2 / 2,5 / 3,0 : 1 — —
model 63 : — — 1,51 / 1,93 / 2,5 / 2,78 : 1 1,51 / 1,93 / 2,5 / 2,78 : 1
model 63A : — — 1,22 / 1,56 / 2,04 / 2,52 : 1 1,22 / 1,56 / 2,04 / 2,52 : 1
model 63IV : 1,29 / 1,56 / 1,99 / 2,47 : 1 1,29 / 1,56 / 1,99 / 2,47 : 1 1,29 / 1,56 / 1,99 / 2,47 : 1 1,29 / 1,56 / 1,99 / 2,47 : 1

111
10 Technical data Torque wrench settings
VD4.120 VD4.140 VD6.170 VD6.210
Screw connection Size Class Torque Angle
Nm (kgm)
Oil pan M8x16 30 (3,0)
Oil drain plug M18x1.5 50 (5,0)
Cylinder head,
- long bolts M12x200 10.9 40/70 (40/70) 180˚
- short bolts M12x120 10.9 40/70 (40/70) 180˚
Lifting eye / Cyl. head M10x30 8.8 40 ±10% (4,0 ±1%)
Rocker cover M6x75 10.9 8,5 ±10% (0,85 ±1%)
Rocker arm set-screw M8x60 8.8 21 (2,1)
Flange injection pump M8x30 10.9 30 (3,0)
Injector holder (Torx) M8x50 10.9 16 +5 (1,6 +0,5)
Fuel lift pump / clamping strap M8x20 10.9 A4C 21 ±2 (2,1 ±0,2)
Pulley fuel lift pump M8x20 8.8 21 ±2 (2,1 ±0,2)
Screw, banjo connector fuel line M14x1.5 39 ±10% (3,9 ±1%)
Injection line mounting M14x1.5 25 ±3,5 (2,5 ±0,35)
Exhaust insulator M8 8.8 21 ±10% (2,1 ±1%)
Air intake manifold (AIM) M6x75 10.9 11 ±10% (1,1 ±1%)
Cover (AIM),
- pre-tightening M6x25 15 ±10% (1,5 ±1%)
- re-tightening M6x25 15 ±10% (1,5 ±1%)
Plugs (AIM) M10x1 13 ±10% (1,3 ±1%)
Plugs (AIM) M16x1.5 38 ±10% (3,8 ±1%)
Plugs (AIM) M18x1.5 50 (5,0)

112
10 Technical data Torque wrench settings
VD4.120 VD4.140 VD6.170 VD6.210
Screw connection Size Class Torque Angle
Nm (kgm)
Exhaust manifold / Cyl. head
- Stud M10 15 1,5
- Locknut M8 25 ±10% 2,5 ±1%
Turbocharger / Exhaust manifold
-Bolt - 4 Cyl. M8 21 ±10% 2,1 ±1%
- 6 Cyl. M10 22 ±10% 2,2 ±1%
Turbo-oplader / Uitlaatinjectiebocht
- Stud - 4 Cyl. M8 22 ±10% 2,2 ±1%
- 6 Cyl. M10 22 ±10% 2,2 ±1%
- Nut - 4 Cyl. M8 21 ±10% 2,1 ±1%
- 6 Cyl. M10 21 ±10% 2,1 ±1%
Alternator mounting M8x80 10.9 21 ±10% 2,1 ±1%
Starter M10x55 10.9 70 7,0
Engine bracket front M16x75 8.8 260 ±10% 26,0 ±1%
Engine bracket rear M12x40 8.8 95 ±10% 9,5 ±1%
Flywheel housing M12x150 10.9 99 ±10% 9,9 ±1%
Flywheel housing M16x140 10.9 243 ±10% 24,3 ±1%
Gear-wheel raw water pump shaft M12 80 8,0

113
11 Operating media Fuel

Fuel Quality Grade Winter-grade fuel

Use only diesel fuel or diesel blends with up to 7% FAME (B7), with less Waxing may occur at low temperatures, clogging the fuel system and
than 0.5% sulphur content of which the quality is fully controlled and reducing engine efficiency.
conform the standards below. 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
The following fuel specifications / standards are approved: available from filling stations well in advance of the cold months. Die-
-- CEN EN 590 sel fuel containing additives (Super Diesel) is often on sale as well, for
-- ASTM D 975 1-D use down to -20°C (-4°F).
-- ASTM D 975 2-D

Don’t use fuel with more than 1% sulfur!

The cetane number must be at least 49.

The exhaust emission levels determined during certification by the su-

pervising authority are always based on the reference fuel described
by law. These fuels match the diesel fuels which are in accordance with
CEN EN 590 and ASTM D 975. Emission levels cannot be guaranteed
with other fuels.

114
11 Operating media Fuel

Biodiesel

  Caution
Use only the prescribed diesel fuel or diesel blends. Do not use 100%
biodiesel (B100)!

Although the use of biodiesel is allowed in diesel blends with up to 7%

FAME (Fatty Acid Methyl Esters) (B7) fast degradation of the biodiesel
should be taken in account.
Problems caused by using FAME of poor quality or degraded fuel are
not covered by warranty.

115
11 Operating media Lubricating oil

Engine oil Recommended lubricating oil viscosity

Lubricating oils are specified by performance and quality classes. It is There are two important considerations when it comes to ambient
usual for the specifications to be indicated according to the API (Amer- temperature in order to achieve satisfactory engine performance.
ican Petroleum Institute) and ACEA (European Automobile Manufac- -- the possibility to turn the engine over quickly enough to make an
turers Association). easy start possible and
-- adequate lubrication of internal wear surfaces during starting and
Acceptable API oils: CH-4, CG-4, CI-4, CJ-4, DHD-1 warming up.
Acceptable ACEA oils: E3-96, E4-07, E5-02, E7-04 By making the right choice of lubricating oil these requirements can
be met.
Only use oil of a recognised brand to lubricate the engine. The choice
of a correct oil guarantees that the engine starts easily, because an oil Because the viscosity (runniness) of lubricating oil varies with temper-
film remains on the cylinder walls and bearing surfaces. The friction is ature, the ambient temperature in which the engine is started deter-
low and so the starting rpm necessary for a dependable start can be mines the choice of viscosity class (SAE class).
achieved with a lower starting torque. An incorrect choice of oil can To avoid having to change the oil for different seasons we recommend
lead to a thickened oil layer on the cylinder walls and bearing surfac- SAE 15W-40 all-season motor oil.
es. This can in turn lead to higher frictional resistance and more effort,
which forms a hindrance to reaching the starting rpm required for a For example:
dependable start, and this results in a reduced lifespan. Vetus Marine Diesel Engine Oil 15 W40
Shell Rimula R4 15W40

For oil capacity see p. 108.

116
11 Operating media Lubricating oil

Limits concerning motor oil

  Caution If an analysis of the used lubricating oil is con-   Note
Do not mix oil of different brands together. ducted to determine its condition, consult the -- How often the oil has to be changed de-
Oils of different brands are mostly not com- overview below. Change the oil if one or more pends on the characteristics of the fuel.
patible with each other. If they are mixed, the of the conditions is not met. Only use the recommended fuels.
mixtures can cause components such as pis- -- The limit for the total base number is half
ton rings, cylinders etc. to seize up and cause of that of new oil in the case of an analysis
wear to moving parts. The best thing is to method based on perchloric acid.
keep to one brand and one type of lubricating
oil for each subsequent service.

Limits concerning motor oil

Characteristic Unit Test method Limit
+30% / -15% max.
Viscosity cSt @ 100°C JIS: K 2283
for new oil
Total base numberl (HCl) mgKOH/g 2.0 min.
JIS: K 2501
Total acid number mgKOH/g +3.0 max. for new oil
Water content % volume JIS: K 2275 0.2 max.
Flash point °C JIS: K 2265 180 min.
Pentane insolubles % weigth 0.5 max.
ASTM: D 893
Coagulated pentane insolubles % weight 3.0 max.

117
11 Operating media Lubricating oil

Gearbox Lubricating Oil

Only use a recognised brand of oil for lubricating the gearbox.

ZF Hurth:
model ZF45 : 2,0 litres ATF [1]
model ZF45A : 3,0 litres ATF [1]
model ZF63 : 3,8 litres ATF [1]
model ZF63A : 4,0 litres ATF [1]
model ZF63IV : 4,0 litres ATF [1]

[1] ATF : AutomaticTransmission Fluid;

Transmission oil type A, Suffix A.

For example: Vetus Transmission Oil

Shell Donax T6
Gulf Synth

Other brands of gearboxes:

See supplied owners manual for oil type and quantities.

118
11 Operating media Coolant

Coolant fluid Water quality for coolant preparation

The preparation and monitoring of coolant in inter-cooled engines is Use preferably tap water.
especially important because corrosion, cavitation and freezing can
lead to engine damage. Use as coolant a mixture of a cooling system If an other available fresh water is used; the values given below must
protective liquid (anti-freeze, ethylene glycol based) and tap water. not be exceeded.

Or use a, ethylene glycol based premix coolant i.e., ‘ready-to-use’ cool- Water quality min. max.
ant. For example Vetus VOC Organic coolant.
pH-value at 20°C (68°F) 6.5 8.5
In tropical climates, where anti-freeze availability may be limited, use a Chloride ion content [mg/dm3] – 100
corrosion inhibitor to protect the engine cooling system. Sulfate ion content [mg/dm3] – 100
Total hardness [degrees] 3 12
The concentration of the cooling system protective liquid in the cool-
ant should not fall below/exceed the following limits:

Cooling system protective Water Protection against

liquid (Anti-freeze) freezing to
  Caution
Never use sea-water or brackish water.
max. 45 vol% 55% -35°C (-31°F)
40 vol% 60% -28°C (-18°F)
min. 35 vol% 65% -22°C (-8°F)
  Warning
The protective liquid concentration must be maintained under all cir- Cooling system protective liquids must be disposed of
cumstances. Therefor if coolant must be added always use the same in accordance with environmental regulations.
mixture of anti-freeze and tap water.

119
12 Wiring diagrams Engine

Red B+ Battery / 30 Key Switch A1 X-A

A5 Exhaust Temp. TS Green

Yellow Start Command / 50 Key Switch A3
D+ Alternator Orange
A4
Purple 15 Key Switch A2

X-A 58 Key Switch Brown

6 p. Connector A6
DT04-6P Dashboard Connector A (Power)
F4 Red Red 15
Red 7.5 A

Red
ISO K-Line

85 30
A J 31
Main 85 CANH B
87a K4 Diagnose H
Relay K3 K4 K
86 87 87a 86 Button C M
30 CANL D L G
F
E
X-M9 X-M10 X-M11 X-M12
Throttle Input Diagnosis
Connector

Red
(Variable Voltage)
X-P X22

D2.2(K)25

D2.2(K)62
D2.2(K)61
D2.2(K)72

D2.2(K)1

D2.2(K)5

D2.2(K)3

D2.2(K)51 D2.2(K)28
0.5 - 4.5 V XP-1 0V
- Black
D2.2(K)30

CANH
CANL
XP-2 0.5 - 4.5 V Yellow
D2.2(K)9

15

31
D2.2(K)71

D2.2(K)29

D2.2(K)70
D2.2(K)68

D2.2(K)55
XP-3 5V Red

D2.2(K)6
D2.2(K)4
D2.2(K)2
D2.2(K)22
+ EMR 3 (EDC 16) X-C X-C
X-M1 X-M3
X-P 3 p. Contrasteker Dashboard Connector 5 P Contrasteker M12
DT04-3P + - + - + C (CAN Line)

Coolant Temp.
Yellow
Oil Pressure

Diagnose
Fuel/Air
94 73
Red 6 5

F1 F2 F3 3 D2.2
30 85 85 2 1
Option 28 7
10A 25A 3A K2 K2 K1
86 (Oil Pump) 86 94 p. EMR Contrasteker
87 87a (Start)
Red
Red
X-M
B+ Terminal Engine
Oil Pump
Battery Switch 30 Switch
K1 X-M6 X-M4 X-M5
87 87a X-M7 X-M8
30 B+ 12 p. Contrasteker
12 V Battery Oil Green
50 White/Red DT04-12P
M M Sump G
12 V Battery Yellow Drain D+ Exhaust Temp.
Optional for 24 V 31 Pump B− Alternator (Non EMR)
Starter
B− Terminal Engine
All not indicated wire colours: Black

120
12 Wiring diagrams Panels

2 Panels
Deutsch
Conn.
Temp Alarm
DT06-08S Engine cable ‘C’
Switch
Dashboard CAN
Neutral
Connector M12
if alarm (NO)
Green X-C Exhaust Temp.
Multifiunction 6p. Dashboard
Instrument X-C5 Alarm Switch
CANL Blue Neutral if alarm (NO) Connector
0 - 4000 RPM Dashboard CAN
Connect to Alarm Indicator DT06-6S
CANH Gray X-C4 Connector M12
X-A
0V Black X-C3 X-C
X-A5
12 V Red X-C2 X-C5 TS
Key Switch Red X-A1
X-C1 B+
X-C4 Brown X-A6
30 K4-85
X-C3 X-A4
D+
X-C2 X-A2
15
X-A3
CANL X-C1 50 17/19 15 58 30

CANH
Oil Press. 12V
p 0V Orange
0-8 bar

Purple
CANL

MPYA
Yellow Engine cable ‘A’
CANH
Temp. 12V
θ 0V
0-120 ºC Exhaust Temp.
Alarm Switch 6p. Dashboard
Dashboard CAN Neutral if alarm (NO) Connector
CANL DT06-6S
Connector M12 Connect to Alarm Indicator
6p. Dashboard X-A
CANH
12V Connector X-C
0-16 V V 0V DT06-6S X-A5
X-C5 TS
Key Switch Red
X-A X-A1
B+
X-C4 Brown
30 X-A6
K4-85
X-A5 X-C3
TS X-A4
Key Switch Red D+
X-A1
B+ X-C2 X-A2
Brown 15
30 X-A6
K4-85 X-A3
X-C1 50 17/19 15 58 30
X-A4
D+
X-A2
15
X-A3
50 17/19 15 58 30
Orange

Purple
Orange Yellow
Purple

Yellow

121
 13 Overall dimensions

VD4.120 & VD4.140

151 (5 15/16”)

106 (4 3/16”)
290 (11 7/16”)

1 1/2”) 153 (6”) 572 (22 1/2”)

5 (46 1/4”) 1 : 10 699 (27 1/2”)

122
13 Overall dimensions

649 (25 9/16”)

884 (34 13/16”)

151 (5 15/16”)
235 (9 1/4”)

290 (11 7/16”)

142 (5 9/16”) 800 (31 1/2”) 153 (6”)

1175 (46 1/4”)

123
13 Overall dimensions

VD6.170 & VD6.210

106 (4 3/16”)
127 (5”)

245 (9 5/8”)

ZF63
197 (7 3/4”) 572 (22 1/2”)
1 : 10 726 (28 9/16”)

124
13 Overall dimensions

619 (24 3/8”)

859 (33 13/16”)

127 (5”)
240 (9 7/16”)

245 (9 5/8”)
140 (5 1/2”) ZF63
142 (5 9/16”) 1028 (40 1/2”) 197 (7 3/4”)

1418 (55 13/16”)

125
14 Parts for maintenance

Engine model : VD4.120 VD4.140 VD6.170 VD6.210

Check / replace See page:
every ... hour:
Oil Filter : 17-8512 17-8512 17-8508 17-8508 100 49
Fuel filter element : 17-8511 17-8511 17-8509 17-8509 500 58
V-belts :
Alternator 16-4258 16-4258 16-4258 16-4258 500 60
Fuel pump /
: VD40069 VD40069 VD40069 VD40069 500 60
Coolant pump
Raw water pump
Impeller + O-ring : STM8250 STM8250 STM8250 STM8250 1000 62
Impeller : STM8246 STM8246 STM8246 STM8246 1000 62
O-ring STM9974 STM9974 STM9974 STM9974 1000 62
Air intake filter : 16-4797 16-4797 15-2768 15-2768 1000 65
Set of seals for
: DM10001 DM10001 DM10001 DM10001 - 73
heat exchanger
Set of seals for
: DM10001 DM10001 DM10001 DM10001 - 78
charge-air cooler

126
15 Index

A Control panels  16 Exhaust injection bend  13, 15

Coolant  119 Exhaust insulator  13, 15
Aftercooler  13, 15
Coolant level  43
Air filter replacement  65
Coolant pump  12, 14
F
Air intake filter  13, 15
Coolant quantity  20, 72 Fasteners  59
Alarm buzzer  36
Coolant replacement  70–72 Fault finding table  97–105
Alternator  12, 14, 66
Cooling system drain plug  12, 13, 14, 15 Filler cap  12, 14
B Cruising  34–36 Filling gearbox with oil  19
Cylinder numbering  11 Filling the cooling system  20, 72
Battery, cables and connections  52–55
Filling with engine oil  18
Battery connections  53 D
First commissioning  18–26
Biodiesel  115
Direction of rotation  11 Flexible engine mounts  13, 15, 59
Bleeding  46
Display  16 Fuel  24
C Draining of coolant  71 Fuel filter  12, 14
Draining the charge-air cooler  51 Fuel filter replacement  58
Calorifier connection  12, 14 Draining the oil  48 Fuel lift pump  12, 14
Changing the gearbox oil  57 Drain plug after cooler condens water  13, Fuel Quality Grade  114
Checking / adjusting valve clearance  67–69 15 Fuel return pipe connection  12, 14
Checking coolant level  43 Drain plug after cooler raw water  13, 15 Fuel supply pipe connection  12, 14
Checking engine oil level  42
Checking the coolant level  26 E G
Checking the raw water strainer  44
Electrolyte level  55 Gearbox  13, 15
Checking the V-belts  60–61
Engine data tag  10 Gearbox filler cap/ oil dipstick  13, 15
Check oil level  42
Engine oil  18, 116 Gearbox lube oil cooler  13, 15
Cleaning the after cooler  78–81
Engine oil change  47–50 Gearbox oil level check  56
Cleaning the heat exchanger  73–77
Engine serial number  1, 11 Gearbox serial number  1
Cleaning the strainer  44
Engine specifications  106–113 Gearbox specifications  111
Connection airvent  13, 15
Fuses  110
Control lever  17, 30
Relay  111
127
15 Index

H P Starter pre-heat switch/lock  16

Starting  30–33, 32
Heat exchanger  12, 14 Panel  16
Stopping  37
Hose connections  59 Parts for maintenance  126
Switching on  31
P.T.O.  12, 14
I Symbols  4
R
Identification of engine parts  12–15 T
Impeller inspection  63 Raw water inlet  13, 15
Tachometer  34
Introduction  9–17 Raw water 'out' for prop
Tachometer/Operating hours counter  16
shaft lubrication  13, 15
L Technical data  106–113
Raw water pump  13, 15
Temperature gauge  35
Lay-up  82–89 Raw water pump inspection  62–64
Temperature gauge, coolant  16
Lifting eye  12, 13, 14, 15 Recommissioning after lay-up  90–95
Tensioning V-belt  61
Recommissioning after winter storage  90–95
M Test run  25
Check engine for leaks  95
Topping up coolant  43
Maintenance  38–81 Checking instruments and remote controls  95
Topping up oil  42
Maintenance schedule  40 Electrical system  94
Torque wrench settings  112–113
Fresh water cooling system  93
O Troubleshooting  96–105
Fuel system  91
Turbocharger  13, 15
Oil cooler  12, 14 Lubrication system  93
Oil dipstick  12, 14 Raw water cooling system  92 U
Oil filler cap  12, 14 Relays and fusses  13, 15
Use  28–37
Oil filter  12, 14 Removing the oil filter  49
Oil level  42 Running-in  27 V
Oil pressure gauge  16, 35 S V-belt alternator  12, 14
Oil sump drain pump  13, 15 V-belt alternator fuel pump  14
Operating media  114–119 Safety measures  4–8
V-belt alternator fuel pump / coolant pump  12
Overall dimensions  122–125 Serial numbers  1
Voltmeter  16, 35
Starter motor  13, 15, 66

128
15 Index

W
Warning indications  4
Warnings  36
Waterafscheider aftappen  45
Winter-grade fuel  114
Winter storage procedure  82–89
Changing the gearbox oil  88
Corrosion protection  84
Electrical system  89
Fresh water cooling system  87
Fuel system  84
Lubrication system  88
Protective fuel mixture  85
Raw water cooling system  86
Wiring diagrams  120–121

129
130
 Manuals

Art. code Description

360601.01 Bedieningshandleiding D-LINE VD4, VD6 (Nederlands)

360602.01 Operation manual D-LINE VD4, VD6 (English)
360603.01 Bedienungsanleitung D-LINE VD4, VD6 (Deutsch)
360604.01 Manuel d’utilisation D-LINE VD4, VD6 (Français)
360605.01 Manual de operacion D-LINE VD4, VD6 (Español)
360606.01 Istruzioni per l’uso D-LINE VD4, VD6 (Italiano)
360607.01 Brugsanvisning D-LINE VD4, VD6 (Dansk)
360608.01 Användarmanual D-LINE VD4, VD6 (Svenska)
360609.01 Bruksanvisning D-LINE VD4, VD6 (Norsk)
360610.01 Käyttöopas D-LINE VD4, VD6 (Suomeksi)
360612.01 Manual de operação D-LINE VD4, VD6 (Português)
360619.01 Instrukcja obsługi D-LINE VD4, VD6 (Polski)

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

320199.06 Service- en Garantieboek / Service and Warranty Manual / Service- und Garantieheft / (Nederlands / English / Deutsch /
Livret Garantie et Service / Manual de servicio y garantía / Libretto di assistenza e ga- Français / Español / Italiano / Dansk /
ranzia / Service- og garantibog / Service- och garantihäfte / Service- og garantibok / Svenska / Norsk / Suomeksi / Portu-
Huolto- ja takuukirja / Manual de Assistência e Garantia / Książeczka gwarancyjna i guês / Polski)
serwisowa

361631.01 Onderdelenboek / Parts manual VD4, VD6 (Nederlands / English)

362533.01 Service manual VD4, VD6 (English, Deutsch, Français, Español)

131
Vetus Diesel   D-LINE   VD4   VD6    English