Vetus D-LINE VD4.120 Operation Manual
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Vetus D-LINE VD4.120 Operation Manual

Marine diesel engines
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D-LINE
Marine Diesel Engines
Operation manual
VD6.210
VD4.120
VD6.170
VD4.140
VD6.210
360602.01

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Summary of Contents for Vetus D-LINE VD4.120

  • Page 1 VD6.210 D-LINE Marine Diesel Engines VD4.120 VD6.170 VD4.140 VD6.210 Operation manual 360602.01...
  • Page 3 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. Copyright © 2017 Vetus B.V. Schiedam Holland...
  • Page 4 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-...

  • Page 5: Table Of Contents

    Contents Safety measures Troubleshooting Checking coolant level Checking and cleaning the raw Warning indications 10 Technical data water strainer Preventing fire and explosion Engine specifications Draining of water from the water Prevention of injury Gearbox specifications separator/fuel filter When problems occur Torque wrench settings Engine oil change Introduction...

  • Page 6: Safety Measures

    1 Safety measures Warning indications Warning indications The following warning indications are used in this manual in the context of safety: Symbols anger aution 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.

  • Page 7: Preventing Fire And Explosion

    1 Safety measures Preventing fire and explosion ire 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.

  • Page 8: Prevention Of Injury

    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.
  • Page 9 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.

  • Page 10: When Problems Occur

    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.

  • Page 11: Introduction

    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.

  • Page 12: 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 the top cover. and performance data are stamped on the the crank case.

  • Page 13: Serial Number, Cylinder Numbering And Direction Of Rotation

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

  • Page 14: Identification Of Engine Parts D4

    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 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...
  • Page 15 2 Introduction Identification of engine parts D4 22 Air intake filter VD4.120, VD4.140 23 Turbocharger 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...

  • Page 16: Identification Of Engine Parts D6

    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 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...
  • Page 17 2 Introduction Identification of engine parts D6 22 Air intake filter VD6.170 VD6.210 23 Turbocharger 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...
  • Page 18 2 Introduction Control panels 1 Temperature gauge, coolant 2 Tachometer/Operating hours counter 3 Voltmeter 4 Oil pressure gauge 5 Display 6 Starter pre-heat switch/lock Panel, model MPA34...

  • Page 19: Control Lever

    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.

  • Page 20: First Commissioning

    3 First commissioning Engine Oil 10W40 of 15W40 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. 6 cyl.
  • Page 21 3 First commissioning 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.
  • Page 22 3 First commissioning COOLANT Coolant quantity: litres Imp. pt US pt 4 cyl. 14.1 16.9 6 cyl. 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).
  • Page 23 3 First commissioning COOLANT COOLANT • 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- •...
  • Page 24 3 First commissioning OPEN CAP PRESSURE CAP (1.5bar) 5 Filling coolant system, if a water heater is connected -1- point of the water heater is situ- • Follow the filling instructions as shown on Use a mixture of 40% antifreeze (ethylene-gly- highest ated at a level than the expansion tank...
  • Page 25 3 First commissioning OPEN CAP PRESSURE CAP (1.5bar) 6 Filling coolant system, if a water heater is connected -2- point of the water heater is situ- • Open valve (3) during filling and bleeding Use a mixture of 40% antifreeze (ethylene-gly- highest ated at a level than the expansion tank...
  • Page 26 3 First commissioning FUEL Neutral (No throttle, gearbox not engaged) arning 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 •...
  • Page 27 3 First commissioning 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- •...
  • Page 28 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.

  • Page 29: Running-In

    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. •...

  • Page 30: 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.
  • Page 31 5 Use General guidelines After repair work: 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 and further if the en- When starting with pre-heating, do not use gine is being commissioned for the first time.

  • Page 32: Starting

    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 ‘ ’ . • Gearbox in ‘ ’ position. neutral 1 Control lever 2 Control panel Before starting the engine, always check that...
  • Page 33 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.
  • Page 34 5 Use Starting 4 Starting Now turn the key further to the ‘ ’ posi- Release the key as soon as the engine fires start aution tion. (the key will return to the ‘ ’ position) and Release the key if the engine does not fire throttle back.
  • Page 35 5 Use Starting Check that there are no oil pressure and alter- Before fully loading the engine, it should be aution nator warnings indicated in the display. brought up to temperature with about 3/4 Never turn the key to the ‘ ’...

  • Page 36: Cruising

    5 Use Cruising 5 Tachometer The instrument panel is provided with the fol- Indicating the number of revolutions per min- arning lowing instruments ute of the engine. Avoid idling for more than 10 minutes. Also the number of running hours is indicat- This can lead to carbon deposits in the com- bustion chambers and incomplete combus- tion of fuel.
  • Page 37 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.
  • Page 38 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!

  • Page 39: Stopping

    5 Use Stopping Neutral 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. arning The engine can not be restarted, if the system data is not been saved!

  • Page 40: Maintenance

    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.
  • Page 41 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).

  • Page 42: Maintenance Schedule

    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 Drain water from fuel filter Check coolant level Engine oil change Check water strainer Replace oil filter Draining the charge-air cooler After the first 50 hours page...
  • Page 43 6 Maintenance Maintenance schedule Every 1000 hours, at least once every 2 years page When required page Raw water pump inspection Cleaning heat exchanger Replace air filter Cleaning the after cooler Every 1000 hours page. Check starter motor Check alternator Every 1500 hours page Checking valve clearance...

  • Page 44: Checking Engine Oil Level

    6 Maintenance Checking engine oil level Daily, before starting. 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 cover.

  • Page 45: Checking Coolant Level

    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.

  • Page 46: Checking And Cleaning The Raw Water Strainer

    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 •...

  • Page 47: Draining Of Water From The Water Separator/Fuel Filter

    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. anger tor: Do not smoke when draining off water and The water separator is not engined mounted, sediment.
  • Page 48 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;...

  • Page 49: Engine Oil Change

    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 arning operation (together with engine oil filter re- operation temperature. (Lube oil temperature Never use additives.
  • Page 50 6 Maintenance Engine oil change Every 100 operating hours. OPEN CLOSE 13 Draining the oil The battery master switch must be on and the Connect a Ø 10 mm hose to the crankcase oil- arning engine must be stopped; the starter key on change pump as shown.
  • Page 51 6 Maintenance Engine oil change Every 100 operating hours. O IL F I LTER 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. •...
  • Page 52 6 Maintenance Engine oil change Every 100 operating hours. mount oF oil oil Filter inCl litres Imp. pt US pt 4 cil. 6 cil. 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.
  • Page 53 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.

  • Page 54: Battery, Cables And Connections

    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.
  • Page 55 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.
  • Page 56 Vetus maintenance-free batteries 20 Checking specific gravity 21 Hydrometer operation Green dot visible: Every Vetus Maintenance-free battery has a In case of low level, caused by overcharging hydrometer (1) built into the cover. State of charge 65 % or more.
  • Page 57 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 recharge recharge 1.12 kg/l 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.

  • Page 58: Gearbox Oil Level Check

    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.

  • Page 59: Changing The Gearbox Oil

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

  • Page 60: Fuel Filter Replacement

    6 Maintenance Fuel filter replacement Every 500 operating hours. F UEL 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. •...

  • Page 61: Flexible Engine Mounts, Hose Connections And Fasteners

    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- •...

  • Page 62: Checking The V-Belts

    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).
  • Page 63 6 Maintenance Checking the V-belts Every 500 operating hours. 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 •...

  • Page 64: Raw Water Pump Inspection

    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.
  • Page 65 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).
  • Page 66 6 Maintenance Raw water pump inspection Every 1000 operating hours. 43 Re-install the impeller 44 Reinstall the pump cover • Replace the cover with a new O-ring. • The impeller should be lubricated with glycerin or a non-petroleum based lubri- cant such as a silicone spray before fitting it •...

  • Page 67: Air Filter Replacement

    6 Maintenance Air filter replacement Every 1000 operating hours. 45 Vervangen luchtfilter • Cut the Ty-rap (1). • Replace the filter. arning • Loosen the hose clamp (2). • Install the unit in reverse order, tighten the Never clean the element with petrol or hot hose clamp and fit a new Ty-rap.

  • Page 68: Checking The Starter Motor And Alternator

    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.

  • Page 69: Checking Valve Clearance

    6 Maintenance Checking valve clearance Every 1500 operating hours. 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.
  • Page 70 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. •...
  • Page 71 6 Maintenance Checking valve clearance Every 1500 operating hours. Determine which cylinders should be adjus- ted from the setup chart: Valve overlap Setting the cylinder Valve overlap Setting the cylinder • Place the angle gauge with the key socket • Rotate the angle gauge anticlockwise until on the adjusting screw.

  • Page 72: Coolant Replacement

    6 Maintenance Coolant replacement Every 2000 operating hours. 52 Coolant replacement The coolant has to be replaced every 2000 op- anger arning erating hours or at least once every two years. Be aware of the risk of skin burning during Cooling system protective liquids must be draining the hot coolant! Used coolant must disposed of in accordance with environmen-...
  • Page 73 6 Maintenance Coolant replacement Every 2000 operating hours. 53 Draining of coolant • Remove the drain plug from the heat ex- • Remove 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.
  • Page 74 6 Maintenance Coolant replacement Every 2000 operating hours. 54 Filling the cooling system Coolant quantity: • Fill the cooling system as indicated on pa- • Check the coolant level in the expansion to 23. tank after the engine has first been in ope- ration, such that the operating tempera- litres Imp.

  • Page 75: Cleaning The Heat Exchanger

    6 Maintenance Cleaning the heat exchanger Under normal conditions of use cleaning the Possible causes of fouling are: 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.
  • Page 76 6 Maintenance Cleaning the heat exchanger 1,2 x 6,5 55 Draining the coolant 56 Disconnecting raw water hoses • Remove the drain plug in the heat exchan- • Remove the filler cap to bleed the cooling • Close the tap of the raw water supply. ger housing to drain the coolant.
  • Page 77 6 Maintenance Cleaning the heat exchanger 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.
  • Page 78 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.
  • Page 79 6 Maintenance Cleaning the heat exchanger 1,2 x 6,5 60 Replacing heat exchanger 61 Replacing the end covers • Place the heat exchanger with a new gasket • Refit the connector cover with a new gasket • Refit all the disconnected hoses. (1) in the heat exchanger housing.

  • Page 80: Cleaning The After Cooler

    6 Maintenance Cleaning the after cooler 1,2 x 6,5 62 Removing the raw water hoses 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 •...
  • Page 81 6 Maintenance Cleaning the after cooler 63 Remove the nuts from the end covers 64 Removing the 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.
  • Page 82 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.
  • Page 83 6 Maintenance Cleaning the after cooler 1,2 x 6,5 66 Replacing the heat exchanger 67 Fitting end covers • Place 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.

  • Page 84: Lay-Up / Winter Storage Procedure

    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. Inspections and maintenance work to be car-...
  • Page 85 7 Lay-up / Winter storage procedure Inspections and maintenance work to be carried out: page Clean the engine, remove any salt. Paint any rust spots and spray the whole engine with a protective medium, for example CRC protective 6-66. Drain off the water from the fuel system and fill the fuel tank. Make sure that the engine fuel system is filled with a fuel mixture with protective properties.
  • Page 86 7 Lay-up / Winter storage procedure 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.
  • Page 87 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.
  • Page 88 7 Lay-up / Winter storage procedure Heat exchanger Only clean the heat exchanger if this is absolutely necessary, see page Charge-air cooler Combine flushing the raw water circuit Only clean the heat exchanger if neces- with fresh water with running the en- sary, see page gine with the protective fuel mixture, see ‘Winter storage procedure - Protec-...
  • Page 89 7 Lay-up / Winter storage procedure 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.
  • Page 90 7 Lay-up / Winter storage procedure 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;...
  • Page 91 7 Lay-up / Winter storage procedure 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- •...

  • Page 92: Recommissioning After Lay-Up Or Winter Storage

    Drain the water from the fuel system. sailing season. Check the raw water system. Consult a Vetus Dealer if help is required with Check the coolant level in the internal cooling system. this. Check the oil level.
  • Page 93 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)
  • Page 94 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.
  • Page 95 8 Recommissioning after lay-up or winter storage 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)
  • Page 96 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;...
  • Page 97 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.

  • Page 98: Troubleshooting

    9 Troubleshooting General Engine faults are in most cases caused by im- If you are unable to identify the cause of the anger proper operation or insufficient maintenance. fault or to rectify it yourself, then contact the Before starting, make sure that nobody is in nearest service representative.
  • Page 99 9 Troubleshooting Fault finding table Fault page Engine will not crank Engine cranks but will not start, no smoke from exhaust Engine cranks but will not start, smoke from exhaust Engine starts but runs unevenly (rough idling) or stalls Engine does not reach maximum rpm under load Engine overheats Engine not firing on all cylinders Engine has little or no oil pressure...

  • Page 100: Engine Will Not Crank

    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.

  • Page 101: Engine Cranks But Will Not Start, Smoke From Exhaust

    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.

  • Page 102: Engine Does Not Reach Maximum Rpm Under Load

    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 propeller.

  • Page 103: Engine Overheats

    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. overheated as a result of faulty Sea cock closed. Open. temperature switch, sensor or Raw water strainer clogged.

  • Page 104: Engine Has Little Or No Oil Pressure

    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.

  • Page 105: Fuel Consumption Excessive

    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.

  • Page 106: Black Exhaust Smoke (At Load)

    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.

  • Page 107: Burnt Oil Trace In Exhaust Line

    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 40 °C. engine at a speed of 900 RPM until Excessive wear of cylinder / Check compression;...

  • Page 108: Technical Data

    Engine specifications Model VD4.120 VD4.140 VD6.170 VD6.210 General Make Vetus Deutz Number of cylinders 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...
  • Page 109 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)
  • Page 110 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.
  • Page 111 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)
  • Page 112 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.

  • Page 113: Gearbox Specifications

    10 Technical data Engine specifications Electrical system Relay K1 70A Starting Elec. Oil sump K2 30A drain pump K3 70A K4 30A Diagnosis/ CAN relay 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 —...

  • Page 114: Torque Wrench Settings

    10 Technical data Torque wrench settings VD4.120 VD4.140 VD6.170 VD6.210 Angle Screw connection Size Class Torque (kgm) Oil pan M8x16 (3,0) Oil drain plug M18x1.5 (5,0) Cylinder head, 180˚ - long bolts M12x200 10.9 40/70 (40/70) 180˚ - short bolts M12x120 10.9 40/70...
  • Page 115 10 Technical data Torque wrench settings VD4.120 VD4.140 VD6.170 VD6.210 Angle Screw connection Size Class Torque (kgm) Exhaust manifold / Cyl. head - Stud - Locknut ±10% 2,5 ±1% Turbocharger / Exhaust manifold -Bolt - 4 Cyl. ±10% 2,1 ±1% - 6 Cyl.

  • Page 116: Operating Media

    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.
  • Page 117 11 Operating media Fuel Biodiesel aution 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.

  • Page 118: Lubricating Oil

    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.
  • Page 119 11 Operating media Lubricating oil Limits concerning motor oil aution If an analysis of the used lubricating oil is con- Do not mix oil of different brands together. - How often the oil has to be changed de- ducted to determine its condition, consult the Oils of different brands are mostly not com- pends on the characteristics of the fuel.
  • Page 120 : 4,0 litres ATF model ZF63IV : 4,0 litres 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.

  • Page 121: Coolant

    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) Chloride ion content [mg/dm – In tropical climates, where anti-freeze availability may be limited, use a corrosion inhibitor to protect the engine cooling system.

  • Page 122: Wiring Diagrams

    12 Wiring diagrams Engine B+ Battery / 30 Key Switch Exhaust Temp. TS Green Yellow Start Command / 50 Key Switch D+ Alternator Orange 15 Key Switch Purple Brown 58 Key Switch 6 p. Connector DT04-6P Dashboard Connector A (Power) 7.5 A ISO K-Line CANH...
  • Page 123 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 Exhaust Temp. Multi unction 6p. Dashboard Alarm Switch Instrument X-C5 Blue CANL Connector Neutral if alarm (NO) Dashboard CAN 0 - 4000 RPM DT06-6S...

  • Page 124: Overall Dimensions

    13 Overall dimensions VD4.120 & VD4.140 ”) 153 (6”) 572 (22 ”) 1 : 10 5 (46 ”) 699 (27 ”)
  • Page 125 13 Overall dimensions 142 (5 ”) 800 (31 ”) 153 (6”) 1175 (46 ”)
  • Page 126 13 Overall dimensions VD6.170 & VD6.210 ZF63 197 (7 ”) 572 (22 ”) 1 : 10 726 (28 ”)
  • Page 127 13 Overall dimensions ZF63 140 (5 ”) 142 (5 ”) 1028 (40 ”) 197 (7 ”) 1418 (55 ”)

  • Page 128: Parts For Maintenance

    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 Fuel filter element 17-8511 17-8511 17-8509 17-8509 V-belts Alternator 16-4258 16-4258 16-4258 16-4258 Fuel pump / VD40069 VD40069 VD40069...

  • Page 129: Index

    15 Index Control panels Exhaust injection bend 13, Coolant Exhaust insulator 13, Aftercooler 13, Coolant level Air filter replacement Coolant pump 12, Air intake filter 13, Coolant quantity 20, Fasteners Alarm buzzer Coolant replacement 70–72 Fault finding table 97–105 Alternator 12, 14, Cooling system drain plug 12, 13, 14, Filler cap 12, Cruising...
  • Page 130 15 Index Starter pre-heat switch/lock Starting 30–33, Heat exchanger 12, Panel Stopping Hose connections Parts for maintenance Switching on P.T.O. 12, Symbols Identification of engine parts 12–15 Impeller inspection Raw water inlet 13, Tachometer Introduction 9–17 Raw water 'out' for prop Tachometer/Operating hours counter shaft lubrication 13, Technical data...
  • Page 131 15 Index Warning indications Warnings Waterafscheider aftappen Winter-grade fuel Winter storage procedure 82–89 Changing the gearbox oil Corrosion protection Electrical system Fresh water cooling system Fuel system Lubrication system Protective fuel mixture Raw water cooling system Wiring diagrams 120–121...
  • Page 133 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...

This manual is also suitable for:

D-line vd4.140D-line vd6.170D-line vd6.210

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