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DEUTZ Operation manual DT44 DTA44 DT66 DTA66 Serial numbers Engine serial number Vetus: Deutz: Gearbox serial number: Please enter the serial numbers here. These numbers should be quoted when inquiring about Customer Service, Repairs or Spare Parts (see page 6).
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Please read and observe the information involved are to be borne by the user. given in this operation manual. This will Unauthorized engine modifications will enable you to avoid accidents, preserve Use in accordance with the intended pur- invalidate any liability claims against the the manufacturer’s warranty*) and main- pose also implies compliance with the manufacturer for resultant damage.
Contents Safety measures Checking the oil level Winter storage procedure Checking the coolant level Introduction Checking and cleaning the Recommissioning after raw water strainer winter storage Data tag Draining water from the water Engine serial number separator/fuel filter Troubleshooting Cylinder numbering Battery, cables and cable Identification of engine parts connections...
1 Safety measures Warning! All safety instructions in this manual are designated by the accompanying sym- bol. Please follow them carefully. Pass the safety instructions to other per- • Never attempt to touch moving parts ing or topping up the coolant or oil. sons operating the engine as well.
2 Introduction Dear customer, Vetus Deutz engines are designed both We have endeavoured to highlight any We are available to help with any addi- for pleasure and commercial craft. differences so that you will able to locate tional inquiries. Consequently, a wide range of variants...
2 Introduction Data tag DTA44452 778959 200001 2500 VD00496 VD00846 VD00485 1 Engine data tag 2 Engine data tag location Model (A), Deutz engine serial number (B) The D engine data tag (C) is attached The V engine data tag is attached to EUTZ ETUS and performance data are stamped on the...
Serial number, Cylinder numbering 2 Introduction VD00465 VD00031 3 Engine serial number 4 Cylinder numbering The D engine serial number is Cylinders are numbered consecutively, EUTZ beginning at the flywheel end. stamped at the indicated spot.
3 Use General guidelines General guidelines for use sion as well as protecting against frost free of water and other pollutants. Implementing the following recommenda- damage. For specifications see page tions will result in longer life and better • Always stop the engine immediately if performance and more economical oper- one of the warning lamps for oil pres- ation of your engine.
(3.1 UK gal) ty and specification see page 70. API: CD, CE, CF or CF4 CCMC: D4, D5 Check the oil level with the dipstick, see page 28. For example: - Vetus Marine Inboard Diesel Motor Oil - Shell Super Diesel T...
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VD00469 3 Filling gearbox with oil Oil gearbox Fill the gearbox with oil. Vetus engines are normally equipped with model ZF45 : 2.0 litres (3.5 UK pt) ATF ZF-Hurth gearboxes. model ZF45A : 3.0 litres ( 5.3 UK pt) ATF...
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First commissioning 3 Use .: 8.5 litres (1.9 UK gal) OOLANT Calorifier COOLANT : 6 C .: 12 litres (2.6 UK gal) QUANTITY If a calorifier is connected to the engine and this heater is positioned above the upper side of the engine then bleeding of the calorifier will not take place automati- cally! Fill the calorifier separately to bleed the cooling system completely.
3 Use First commissioning Running-in Warning! FUEL Never fill the fuel tank while the engine is running. Do not spill fuel. Prevent unne- cessary pollution. VD00002 5 Fuel 6 Other preparations Running-in Ensure that the fuel tank is filled with •...
Starting 3 Use Before starting, check the follow- ALWAYS ing points: Neutral neutral • Engine oil level. gearbox (No throttle, gearbox not engaged) gearbox • Coolant level. reverse forward • Sea cock open. • Main switch ‘ ’. • Gearbox in ‘ ’...
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3 Use Starting VD00107 VD00109 VD00110 3 Starting Turn the start key on the instrument panel Now turn the key further to the ‘ ’ Release the key as soon as the engine START clock-wise; the warning lights for oil pres- position.
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Starting 3 Use VD00107 Check that the indicator lights for oil pres- sure and alternator are off. Cooling water turn the main switch off while the NEVER Caution! should now flow out of the exhaust; if this engine is running. Release the key if the engine does not fire is not the case, stop the engine immedi- within 10 seconds.
3 Use Cruising The instrument panel is provided with the following instruments (Depending of the type of panel, see page 12 and 13). Caution! Never turn the key to the ‘ ’ position START while the engine is running. Doing so will damage the starter motor. VD00113 VD00114 4 Tachometer...
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Cruising 3 Use VD00115 VD00116 6 Temperature gauge 7 Oil pressure gauge 8 Warning lights Indicating the temperature of the internal With the engine at operating temperature, None of the four warning lights should cooling system. the oil pressure is: light up while the engine is running.
3 Use Stopping VD00393 VD00106 VD00105 VD00022 9 Electrical shutdown 10 Mechanical shutdown Reduce engine speed to idle and shift the Allow the engine to idle for a few minutes On the engine itself stopping is possible gearbox to ‘N ’.
Introduction 4 Maintenance Introduction The following guidelines should be Failure to carry out maintenance can observed for daily and periodic mainte- result in faults and permanent damage to nance. Perform each function at the indi- the engine. cated time interval. No claim can be made on the Guarantee The intervals stated are for normal opera- if maintenance has been neglected.
4 Maintenance Maintenance schedule Every 10 hours or daily, before starting Every 500 hours, at least once every year Check engine oil level page 28 Engine oil change page 34 Check coolant level page 29 Replace oil filter page 34 Check water strainer page 30 Check V-belts...
Maintenance chart 4 Maintenance The maintenance chart shown here is supplied as self-adhesive label with each engine. It should be affixed on the 0.3 mm SAE 10W40 0.012 in. engine where it can be seen clearly. API = CD/CE 1500 h 500 h 0.5 mm CCMC = D4/D5...
4 Maintenance Checking engine oil level Daily, before starting. VD00015 VD00126 VD00367 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 The dipstick is located on the starboard mark on the dipstick*.
Checking coolant level 4 Maintenance Daily, before starting. VD00476 VD00473 VD00477 4 Checking coolant level 5 Coolant level 6 Topping up coolant Check the coolant level in the header tank. The level of the coolant must be at the If necessary, top up. This has to be checked when the engine is lower edge of the filler neck.
4 Maintenance Checking and cleaning the raw water strainer Daily, before starting. VD00125 CT30119 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.
Draining of water from the water separator/fuel filter 4 Maintenance Every 125 operating hours. VD00027 VD00109 9 Empty fuel filter 10 Bleeding The system doesn’t need to be bled after Repeat the above if the engine cuts out Empty the separately installed water sepa- the water separator/fuel filter has been after a short time.
12 Checking specific gravity 13 Hydrometer operation Keep battery clean and dry. • Green dot visible - State of charge Every Vetus Maintenance-free battery has Remove battery cables (negative first). 65 % or more. a hydrometer (1) built into the cover.
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Battery, cables and connections 4 Maintenance Every 125 operating hours. Conventional batteries Conventional batteries Specific State of gravity charge 1.280 100% 1.200 recharge 1.120 recharge immediately VD00119 VD00120 14 Checking electrolyte level 15 Checking specific gravity Warning! The gases emitted by the battery For conventional batteries it is required to Measure the electrolyte specific gravity of are explosive!
4 Maintenance Engine oil change Every 500 operating hours. Change the oil with a switched off engine at operation temperature. (Lube oil tem- perature approx. 80°C (176°F).) Caution! Used oil must be collected in a container for proper disposal according to laws and regulations.
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Engine oil change 4 Maintenance Every 500 operating hours. : 4 C : VD20262 : 4 C .: 8.5 litres (1.9 UK gal) ILFILTER CODE MOUNT OF OIL : VD20263 .)6 C .: 14 litres (3.1 UK gal) CODE OIL FILTER INCL VD00030 VD00011 VD00367...
4 Maintenance Checking the V-belts Every 500 operating hours. ” VD00034 VD00010 VD00021 22 Inspection V-belts 23 Checking tension V-belt 24 Tensioning V-belt of coolant and fuel pump Inspect the belts for wear and tear (fraying Check tension of the V-belt by applying •...
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Checking the V-belts 4 Maintenance Every 500 operating hours. 22 Nm Max. 28 Nm) VD00001 VD00495 25 Tensioning alternator V-belt • First loosen both the alternator mount- • Rotate the pinion (4) counter-clockwise • Then re-tighten both the alternator ing bolts, (1) and (2), then loosen the until the tension of the belt is correct.
4 Maintenance Replacing the V-belts BELT COOLANT PUMP FUELPUMP : VD40069 CODE ” VD00019 VD00021 26 Replacing V-belt of coolant and fuel pump • Rotate the tension device with the fuel • Loosen bolts (1) and (2). pump in the direction of the arrow using a key in (a), square 1/2”, until the ten- •...
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Replacing the V-belts 4 Maintenance : VD40067 BELT ALTERNATOR ART CODE 22 Nm Max. 28 Nm) VD00001 VD00495 27 Replacing alternator V-belt Never apply a torque to the pinion of • First loosen both the alternator mount- more than 28 Nm! (max. belt force is ing bolts, (1) and (2), then loosen the achieved at about 22 Nm).
28 Unscrewing the dipstick 29 Oil level check • Check the oil level by cleaning the dip- Vetus engines are normally equipped with • Unscrew the dipstick out of the gearbox stick and lowering it into the hole, with- ZF-Hurth gearboxes. Consult the supplied housing.
Fuel filter replacement 4 Maintenance Every 1000 operating hours. : VD60210 UEL FILTER CODE VD00013 VD00009 VD00009 30 Fuel filter removal 31 Fuel filter installation The fuel filter is to be replaced as a unit. • Clean any debris from the filter carrier a turn by hand.
4 Maintenance Raw water pump inspection Every 1000 operating hours. 1.2 x 6.5 VD00008 VD00007 33 Raw water pump inspection 34 Pump cover removal 35 Impeller removal Inspection where appropriate changing is • Slide the impeller off of the shaft using Caution! as follows: a waterpump plier.
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Raw water pump inspection 4 Maintenance Every 1000 operating hours. : STM8246 : STM8235 MPELLER CODE ASKET CODE VD00127 VD00004 VD00006 36 Impeller inspection 37 Re-install the impeller 38 Replacing the pump cover • Inspect the impeller for damage. • The impeller should be lubricated with •...
VD00025 VD00024 39 Draining the oil 40 Filling with new oil Vetus engines are normally equipped with • Refill the gearbox to the correct level via Drain the oil with the aid of a separate ZF-Hurth gearboxes. Consult the supplied the dipstick opening.
4 Maintenance Checking valve clearance Every 1500 operating hours. 0.3 mm (0.012”) 0.5 mm (0.020”) ALVE CLEARANCE NLET XHAUST 1.2 x 8.0 VD00375 VD00376 44 Checking / adjusting valve clear- ance least 30 minutes. The oil temperature - Use screwdriver (7) to turn setscrew •...
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Valve Clearance Adjustment Schematic 4 Maintenance • Crankshaft Position 1 Bar crankshaft until both valves in cylin- der 1 overlap (exhaust valve about to close, inlet valve about to open). Adjust clearance of valves marked in black on schematic. Mark respective rocker arm with chalk to show that adjustment has been done •...
4 Maintenance Coolant replacement Every 2000 operating hours. VD00475 VD00474 45 Coolant replacement 46 Draining of coolant The coolant has to be replaced every 2000 Remove the drain plugs from the engine Warning! operating hours or at least once every two block (1) and heat exchanger (2).
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Coolant replacement 3 Maintenance Every 2000 operating hours. .: 8.5 litres (1.9 UK gal) OOLANT Calorifier COOLANT : 6 C .: 12 litres (2.6 UK gal) QUANTITY If a calorifier is connected to the engine and this heater is positioned above the upper side of the engine then bleeding of the calorifier will not take place automati- cally! Fill the calorifier separately to bleed...
5 Winter storage procedure VD00027 VD00136 1 Fuel system Drain water from water * Engine oil with protective properties. Running with protective fuel mixture separator/fuel filter and the fuel tank. E.g. Shell Super Diesel T 10W40 Connect the fuel supply pipe to a can filled Ensure that the tank is completely filled ** Preferably water-free fuel.
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5 Winter storage procedure VD00017 VD00125 2 Lubrication system 3 Raw water cooling system With the engine still at operating tempera- Close the seacock before removing the lid Check the seal between the lid and hous- ture: (If not, run the engine until warm, of the water strainer.
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5 Winter storage procedure VD00478 VD00139 4 Fresh water cooling system 5 Electrical system To avoid corrosion during winter storage Disconnect the battery cables. the cooling system must be filled with an antifreeze/water mixture (or a coolant). For Charge batteries during winter lay-up reg- specifications see page 72.
6 Recommissioning after winter storage : VD60210 UEL FILTER CODE VD00027 VD00141 VD00009 1 Fuel system Drain water from water Drain the water from the fuel tank. Install a new fuel filter. (page 41) separator/fuel filter. (page 31)
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6 Recommissioning after winter storage VD00137 VD00015 VD00125 Fuel system 2 Lubrication system 3 Raw water cooling system Open the fuel valve. Check the engine oil level. (page 28) Check that the lid of the raw water strainer is reinstalled.
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6 Recommissioning after winter storage VD00382 VD00383 VD00138 Check that the lid of the raw water pump Re-tighten possible loose hose clamps. Open the sea cock. and drain plugs are reinstalled. (pages 42,...
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6 Recommissioning after winter storage VD00476 CT40063 VD00140 4 Fresh water cooling system 5 Electrical system Connect the batteries. Check the coolant level. (page 29) Make sure that the batteries are fully charged. (pages 32, 52)
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6 Recommissioning after winter storage VD00479 VD00024 VD00142 6 Check for leakages 7 Changing the gearbox oil 8 Checking instruments and remote controls Start the engine. Stop the engine and change the oil of the Check the fuel system, the cooling system gearbox.
7 Troubleshooting General Engine faults are in most cases caused by improper operation or insufficient maintenance. In case of a fault, always check first that the operation and main- tenance instructions have been followed. In the following tables information is given about the possible causes of faults and suggested remedies.
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Fault finding table 7 Troubleshooting 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. Check / recharge bat- Fuel stop valve closed. Open. tery and check engine (Nearly) Empty fuel tank.
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7 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 Air in fuel system. Check and bleed. (Nearly) Empty fuel tank. Refill.
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Fault finding table 7 Troubleshooting 5 Engine does not reach maximum rpm under load 6 Engine overheats Possible fault Remedy Possible fault Remedy Air in fuel system. Check and bleed. Faulty injector/injection pump. Check, replace if Fuel filter clogged with water Check or replace.
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7 Troubleshooting Fault finding table 7 Engine not firing on all cylinders 8 Engine has little or no oil pressure Possible fault Remedy Possible fault Remedy Air in fuel system. Check and bleed. Oil level too low. Fuel filter clogged with water Check or replace.
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Fault finding table 7 Troubleshooting Blue exhaust smoke (idling) White exhaust smoke (at full load) Possible fault Remedy Possible fault Remedy Oil level too high. Lower level. Air in fuel system. Check and bleed. Excessive inclination of engine. Check / Adjust. Faulty injector/injection pump.
8 Technical data Engine specifications Model DT44 DTA44 DT66 DTA66 General Make Vetus Deutz Number of cylinders Based on BF4M2012 BF4M2012C BF6M2012 BF6M2012C Type 4-stroke diesel, in-line Injection Direct Aspiration Turbo-charged Turbo-charged/ Turbo-charged Turbo-charged/ After cooled After cooled Bore 101 mm...
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Engine specifications 8 Technical data Model DT44 DTA44 DT66 DTA66 Maximum output Light Duty Commercial 76 kW 93 kW 112 kW 139 kW (ISO 3046/IOFN) (103 hp) (126 hp) (153 hp) (189 hp) at no. of revolutions of 2500 rpm 2500 rpm 2500 omw/min 2500 rpm...
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8 Technical data Engine specifications Model DT44 DTA44 DT66 DTA66 Fuel System (Self-bleeding) Injection pump Bosch Injectors Bosch Opening pressure 250 bar (kgf/cm ) (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°...
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Engine specifications 8 Technical data Model DT44 DTA44 DT66 DTA66 Cooling system Capacity, Intercooler version 8.5 litres 8.5 litres 12 litres 12 litres (1.9 UK gal) (1.9 UK gal) (2.6 UK gal) (2.6 UK gal) Keelcooler version 6.1 litres – 8.8 litres –...
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8 Technical data Engine specifications Model DT44 DTA44 DT66 DTA66 Electrical system Voltage 12 Volt / 24 Volt, see alternator data tag Alternator 14 Volt, 95 A / 28 Volt, 55 A, see alternator data tag Battery capacity min. 88 Ah, max. 176 Ah (at 12 Volt) / min. 2x 66 Ah, max. 2x 110 Ah (at 24 Volt) Protection Circuitbreaker, 10 A V-belts...
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Torque wrench settings 8 Technical data Screw connection Size Class Torque Angle Screw connection Size Class Torque Angle [Nm] [Nm] Exhaust manifold / Cyl. head Oil pan M8x16 - Stud Oil drain plug M18x1.5 - Locknut 25±10% Cylinder head, Turbocharger / Exhaust manifold - long bolts M12x200 10.9...
In common use are specifications named after API AutomaticTransmission Fluid; type A, Suffix A. (American Petroleum Institute) and CCMC (Committee of Common Market Automobile Constructors). For example : Vetus Marine Gearbox Oil Shell Donax T6 Approved API Oils CD, CE, CF and CF4 Gulf Dextron...
Fuel 9 Operating media Fuel Quality Grade Winter-grade fuel Use commercially available diesel fuel with less than 0.5% sulfer Waxing may occur at low temperatures, clogging the fuel system content. and reducing engine efficiency. If the ambient temperature is less than 0°C (+32°F), winter-grade If the sulfur content is higher than 0.5%, the intervals between oil fuel -suitable down to -15°C (+5°F) - should be used.
9 Operating media Coolant Coolant fluid Coolingsystem protective liquidl (Anti-freeze) As cooling system protetctive liquid use a ethylene-glycol based The preparation and monitoring of coolant in inter-cooled anti-freeze. This will give an adequate protetcion against corro- engines is especially important because corrosion, cavitation and sion, cavitation and frost damage.
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Coolant 9 Operating media Water quality for coolant preparation Use preferably tap water. If an other available fresh water is used; the values given below must not be exceeded. Water quality min. max. pH-value at 20°C (68°F) Chloride ion content [mg/dm –...
12 Index Aftercooler 11; Coolant replacement 48-49; Fault finding table 59-63; Air cleaner 45; Cooling system 67; Filler cap for cooling system 8, 10; Air intake filter 9, 11; Cooling system drain plug, block 11; Filling gearbox with oil 16; Alternator 8, 10;...
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12 Index Identification of engine parts 8-11; P .T.O. (Mounting facility for hydraulic Turbocharger 9, 11; Idling speed 22; pumps) 8, 10; Impeller 43; Use 14-24; Introduction 5-13, 25; Raw water inlet 8, 10; Raw water pump 8, 10, 42-43; V-belt alternator 8, 10;...
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