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Vetus Dt44 Dta44 Dt66 Dta66 Operators Manual



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  DT44 DTA44
  DT66 DTA66




Operation manual
                                                                                                      DT44
VD00466



          C o p y r i g h t  2 0 0 4 Ve t u s d e n O u d e n n . v. S c h i e d a m H o l l a n d
             Operation manual                                              DEUTZ
                                                                           DT44 DTA44
                                                                           DT66 DTA66

                                 Serial numbers

                        Engine serial number Vetus:


                                            Deutz:


                            Gearbox serial number:

                                                      Please enter the serial numbers here.
Rev. 12-04




                                                      These numbers should be quoted when inquiring about
                                                      Customer Service, Repairs or Spare Parts (see page 6).
STM9707




                                                      We reserve the right to make any changes without previous
                                                      notice.
                                                                                                             1
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.
tain the engine in peak operating condi-     conditions laid down by the manufacturer
tion.                                        for operation, maintenance and servicing.    Manipulations of the injection and regu-
                                             The engine should only be operated,          lating system may also influence the per-
This engine has been built exclusively for   maintained and serviced by persons           formance of the engine, and its emis-
the application specified in the scope of    which are familiar with the former and the   sions. Adherence to legislation on pollu-
supply and is to be used only for the        hazards involved.                            tion cannot be guaranteed under such
intended purpose. Any use exceeding                                                       conditions.
that scope is considered to be contrary to   The relevant accident prevention guide-
the intended purpose. The manufacturer       lines and other generally accepted safety    *) For warranty conditions see `Service
will not not assume responsibility for any   and industrial hygiene regulations must         and Warranty Manual' STM0016.
damage resulting therefrom. The risks        be observed.
2
Contents
1   Safety measures                   4   Checking the oil level          28    5   Winter storage procedure 50
                                          Checking the coolant level      29
2   Introduction                      5   Checking and cleaning the             6   Recommissioning after
    Data tag                          6   raw water strainer              30        winter storage           53
    Engine serial number              7   Draining water from the water
    Cylinder numbering                7   separator/fuel filter           31    7   Troubleshooting          58
    Identification of engine parts    8   Battery, cables and cable
    Control panels                   12   connections                     32    8   Technical Data           64
                                          Changing the oil                34
3   Use                                   Checking the V-belts            36    9   Operating media
    General guidelines               14   Replacing the V-belt            38        Lubrication Oil          70
    First commissioning              15   Checking the gearbox oil level 40         Fuel                     71
    Running-in                       18   Replacing the fuel filter       41        Coolant                  72
    Starting                         19   Checking the raw water pump 42
    Cruising                         22   Changing the gearbox oil        44   10   Wiring Diagrams          74
    Stopping                         24   Combustion air intake           45
                                          Flexible engine mounts          45   11   Overall Dimensions       78
4   Maintenance                           Hose connections                45
    Introduction                     25   Checking valve clearance        46   12   Index                    82
    Maintenance schedule             26   Coolant replacement             46
    Maintenance chart                27

                                                                                                              3
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.             when the engine is running.
                                                                                       NEVER open cap on top of header tank
General regulations and laws for safety       Never touch hot parts of the engine,     when the engine is at operating tem-
and accident prevention must also be           and keep flammable materials well        perature.
observed.                                      away from the engine.
                                                                                       Always carry out maintenance safely
                                              Always stop the engine before check-     by only using tools well matched in
                                               ing or adjusting components.             size.

                                              Always stop the engine before check-

4
                                                                                                        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      the operating and maintenance instruc-
are offered to meet the requirements of     tions relevant to your engine quickly and     Sincerely, Vetus den Ouden n.v.
specific cases.                             easily.

Your engine is appropriately equipped for   Please read this manual before starting
your vessel, which means that not neces-    your engine and always observe the
sarily all components described in this     operating and maintenance instructions.
manual are mounted to your engine.



                                                                                                                               5
2 Introduction                                                                                                      Data tag




                                                                                                           D



              DTA44452
              778959           200001
                 A
              2500       103        140



VD00496                                     VD00846                                     VD00485

1 Engine data tag                           2 Engine data tag location

Model (A), Deutz engine serial number (B)   The DEUTZ engine data tag (C) is attached   The VETUS engine data tag is attached to
and performance data are stamped on the     to the crank case.                          the valve cover.
engine data tag.

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




6
Serial number, Cylinder numbering                                           2 Introduction




VD00465                             VD00031

3 Engine serial number              4 Cylinder numbering

The DEUTZ engine serial number is   Cylinders are numbered consecutively,
stamped at the indicated spot.      beginning at the flywheel end.




                                                                                         7
2 Introduction                                                                        Identification of engine parts

    1    Oil filler cap                                                                                 Service side DT44, DT66
    2    Lifting eye
    3    Alternator
    4    Filler cap for cooling system                       21     22        23   24 1   2    3                 4
    5    Calorifier connection, engine `IN'
    6    V-belt alternator
    7    Coolant pump
    8    V-belt alternator fuel pump /                                                                                    5
         coolant pump
    9    P.T.O. (Mounting facility for extra                                                                              6
                                                20
         belt pulley)
    10   Fuel lift pump                         19                                                                        7
    11   Fuel supply pipe connection            18
          12 mm                                                                                                          8
                                                17
    12   Fuel filter
    13   Oil filter
    14   Oil dipstick
    15   Oil cooler
    16   P.T.O. (Mounting facility for
         hydraulic pumps)
    17   Raw water inlet  32 mm
    18   Raw water pump
    19   Circuitbreaker
    20   Electrical system connector
    21   Connection for throttle push-pull
                                                         16 15 14        13               12       11   10   9
         cable
    22   Manual operated stop                  VD00461


8
Identification of engine parts                                                      2 Introduction
Starter side DT44, DT66                                                 23 Fuel return pipe connection
                                                                            10 mm
                                                                        24 Calorifier connection, engine `OUT'
                                                                        25 Exhaust insulator
                           25   26   27        28   29        30
                                                                        26 Starter motor
                                                                        27 Lifting eye
                                                                        28 Exhaust injection bend
                                                                   31
                                                                        29 Turbocharger
                                                                        30 Speed governor
                                                                        31 Air intake filter
                                                                   32
                                                                        32 Gearbox lube oil cooler
                                                                        33 Gearbox filler cap/ oil dipstick
                                                                        34 Connection for gearbox push-pull
                                                                           cable
                                                                   33   35 Gearbox
                                                                        36 Flexible engine mounts
                                                                   34   37 Oil sump drain pump
                                                                        38 Cooling system drain plug, heat
                                                                           exchanger cover
                                                                        39 Cooling system drain plug, heat
                                                                           exchanger
                                                                        40 Cooling system drain plug, engine
                                                                           block
                                                                        41 Heat exchanger

  41 40   39   38     37                  36             35

VD00462


                                                                                                            9
2 Introduction                                                                     Identification of engine parts

     1   Oil filler cap                                                                              Service side DTA44, DTA66
     2   Lifting eye
     3   Alternator
     4   Filler cap for cooling system
                                                             21* 22* 23* 24   25   1   2    3                  4
     5   Calorifier connection, engine `IN'
     6   V-belt alternator
     7   Coolant pump
     8   V-belt alternator fuel pump /                                                                                   5
         coolant pump
     9   P.T.O. (Mounting facility for extra                                                                             6
         belt pulley)                          20
 10      Fuel lift pump                        19*                                                                       7
 11      Fuel supply pipe connection
                                               18
          12 mm                                                                                                         8
 12      Fuel filter                           17
 13      Oil filter
 14      Oil dipstick
 15      Oil cooler
 16      P.T.O. (Mounting facility for
         hydraulic pumps)
 17      Raw water inlet  32 mm
 18      Raw water pump
 19      Circuitbreaker
 20      Electrical system connector
 21      Connection for throttle push-pull
         cable                                           16 15 14    13                12       11    10   9
 22      Manual operated stop
                                               VD00463


10
Identification of engine parts                                                        2 Introduction
Starter side DTA44, DTA66                                                23 Fuel return pipe connection
                                                                             10 mm
                                                                         24 Calorifier connection, engine `OUT'
                                                                         25 Aftercooler
                            26   27   28        29   30        31        26 Exhaust insulator
                                                                         27 Starter motor
                                                                         28 Lifting eye
                                                                    32   29 Exhaust injection bend
                                                                         30 Turbocharger
                                                                         31 Speed governor
                                                                    33   32 Air intake filter
                                                                         33 Gearbox lube oil cooler
                                                                         34 Gearbox filler cap/ oil dipstick
                                                                         35 Connection for gearbox push-pull cable
                                                                    34   36 Gearbox
                                                                         37 Flexible engine mounts
                                                                    35   38 Oil sump drain pump
                                                                         39 Cooling system drain plug, heat
                                                                            exchanger cover
                                                                         40 Cooling system drain plug, heat
                                                                            exchanger
                                                                         41 Cooling system drain plug, block
                                                                         42 Heat exchanger

                                                                          * See drawing on page 8 for
  42 41   40   39     38                   37             36                identification; part numbers are
                                                                            identical
VD00464


                                                                                                               11
2 Introduction                                                                   Control panels

           10             1                2                       1             2




          11     4   5   6 7   8   9   3                  4   5   6 7   8    9   3
VD00104                                        VD00103


Basic panel (model 34)                         Fly-bridge panel (model 22)




12
Control panels                                                                                   2 Introduction

              5     4     6    8     7     3                                      4   5   6      7




                                                                         8

                                                                        12                              15
                                                                        13                              14


VD00102                                               VD00101


Sailingboat panel (model 10)                          Push button panel (model 00)



   1      Tachometer/Operating hours counter           10       Temperature gauge, coolant
   2      Voltmeter                                    11       Oil pressure gauge
   3      Starter pre-heat switch/lock                 12       On push button switch
   4      Warning light high raw water temperature     13       Pre-heating push button switch
   5      Warning light low oil pressure               14       Starter push button switch
   6      Warning light high coolant temperature       15       Stop push button switch
   7      Warning light battery charging
   8      Indicator light pre-heating
   9      Warning light gearbox low oil pressure *)     *) This is an option, not fitted as standard.

                                                                                                             13
3 Use                                                                                                    General guidelines




General guidelines for use

Implementing the following recommenda-          sion as well as protecting against frost     free of water and other pollutants.
tions will result in longer life and better     damage. For specifications see page
performance and more economical oper-           72.                                         Always stop the engine immediately if
ation of your engine.                                                                        one of the warning lamps for oil pres-
                                               Never run the engine without a ther-         sure, high coolant temperature, high
 Carry out the maintenance described           mostat.                                      raw water temperature or battery
  regularly, including the `Daily proce-                                                     charging lights up.
  dures before starting'.                      Use a good quality lubricating oil. For
                                                specifications see page 70.
 Use anti-freeze in the engine coolant
  all year long, this helps prevent corro-     Use a good quality diesel fuel that is

14
First commissioning                                                                                                          3 Use

                                                      OIL




                                                 VD00012

1 Commissioning the engine                       2 Filling with engine oil
                                                                                                         Engine Oil
Before starting the engine for the first time,   As a rule engines are delivered empty of
the following procedures must be carried         oil.                                          4 cyl.:   8.5 litres 10W40 or 15W40
out:                                             Fill the engine with oil through the filler             (1.9 UK gal)
                                                 neck on top of the valve cover, for quanti-   6 cyl.:   14 litres 10W40 or 15W40
                                                 ty and specification see page 70.                       (3.1 UK gal)
                                                                                               API:      CD, CE, CF or CF4
                                                 Check the oil level with the dipstick, see    CCMC:     D4, D5
                                                 page 28.
                                                                                               For example:
                                                                                               - Vetus Marine Inboard Diesel Motor Oil
                                                                                               - Shell Super Diesel T

                                                                                                                                     15
3 Use                                                                                                  First commissioning


     OIL




VD00469

3 Filling gearbox with oil
                                                                                                  Oil gearbox

Vetus engines are normally equipped with    Fill the gearbox with oil.
                                                                                         model   ZF45    :   2.0   litres   (3.5 UK pt) ATF
ZF-Hurth gearboxes.
                                            Check the oil level with the dipstick, see   model   ZF45A   :   3.0   litres   ( 5.3 UK pt) ATF
                                            page 40.                                     model   ZF63    :   3.8   litres   (6.7 UK pt) ATF
In case your engine is equipped with
                                                                                         model   ZF63A   :   4.0   litres   (7 UK pt) ATF
another brand of gearbox follow the
instructions given in the supplied owners
                                                                                         *) ATF: Automatic Transmission Fluid;
manual.
                                                                                            type A, Suffix A.

                                                                                         For example          : Shell Donax T6
                                                                                                                Gulf Dextron

16
First commissioning                                                                                                          3 Use
 COOLANT 4 CYL.: 8.5 litres (1.9 UK gal)
 QUANTITY : 6 CYL.: 12 litres (2.6 UK gal)
                                                                           COOLANT                  Calorifier
                                                                                           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.




VD00477                                      VD00473

4 Filling the cooling system

Remove the cap of the filler neck on the     The level of the coolant must be at the       After the engine has run for the first time
top of the header tank.                      lower edge of the filler neck.                and has reached operating temperature
Fill the cooling system.                     Replace the filler cap.                       and has cooled down again to ambient
Use a mixture of 40% antifreeze (ethylene-   Bleeding will take place automatically dur-   temperature, check the coolant level in the
glycol based) and 60% tap water or use a     ing filling!                                  heat exchanger housing.
special coolant.                                                                           If necessary, add coolant.
For specifications see page 72.
                                                                                                    Caution!

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

                                                                                                                                     17
3 Use                                                                                                  First commissioning
                                                                                                                Running-in
     FUEL                                           Warning!

                                           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    Check battery and cable connections.         In order to ensure a long life for your
diesel fuel.                                                                              engine, please observe the following for
Use only clean, water-free, commercial      Start the engine, see page 19, and let it    the first 50 operating hours:
approved diesel fuel.                        run for about 10 minutes without load.
For fuel grade see page 71.                  Check the engine and all connections          Allow the engine to reach operating
The fuel system is self-bleeding.            (fuel, cooling water and exhaust) for          temperature before applying a load.
                                             leaks.                                        Avoid fast acceleration.
                                                                                           Do not allow the engine to run faster
                                            Check tension of the V-belt, see page          than 3/4 of maximum RPM.
                                             36.


18
Starting                                                                                                                      3 Use
Before starting,   ALWAYS   check the follow-
ing points:
                                                                                                                 Neutral
                                                                neutral
   Engine oil level.
                                                 gearbox                                            (No throttle, gearbox not engaged)
   Coolant level.                                                              gearbox
                                                 reverse
   Sea cock open.                                                               forward
   Main switch `ON'.
   Gearbox in `NEUTRAL' position.
                                                    reverse                          forward
                                                    throttle                          throttle




                                                VD00111                                          VD00112

After repair work:                              1 Starting, preparation                          2 Control lever

Check that all guards have been replaced        Before starting the engine, always check         Leave the control lever in position
and that all tools have been removed from       that the control lever(s) is (are) in the neu-   `neutral'.
the engine.                                     tral position.
When starting with pre-heating, do not use
any other substance (e.g. injection with
`Easy Start'). Doing so could result in an
accident.                                                 Warning!

                                                Never start the engine with the fuel
                                                injection pump removed.
                                                Disconnect battery.
                                                                                                                                         19
3 Use                                                                                                                    Starting




VD00107                                        VD00109                                   VD00110

3 Starting

Turn the start key on the instrument panel     Now turn the key further to the `START'   Release the key as soon as the engine
clock-wise; the warning lights for oil pres-   position.                                 fires (the key will return to the `ON' posi-
sure and alternator will now light up and                                                tion) and throttle back.
the alarm buzzer will sound.                                                             Leave the key in this position while the
                                                                                         engine is running.
As standard VETUS DEUTZ engines are not
equiped with a pre-heating system, there-
fore both the pre-heating indication light
and the pre-heating position of the the key
switch on the operating panel can be
ignored.
20
Starting                                                                                                                    3 Use




                                               VD00107




                                               Check that the indicator lights for oil pres-
         Caution!                              sure and alternator are off. Cooling water      NEVER turn the main switch off while the
                                               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. Wait until the starter      ately. Before submitting the engine to full
motor has stopped running completely           load it should be brought up to operating
before turning the key to the `START' posi-    temperature as quickly as possible by run-
tion again. Never allow the starter motor to   ning at 3/4 of maximum revs.
run for more than 30 seconds consecuti-
vely.



                                                                                                                                    21
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 `START' position
while the engine is running.
Doing so will damage the starter motor.

                                              VD00113                                     VD00114

                                              4 Tachometer                                5 Voltmeter

When the engine reaches operational tem-      Indicating the number of revolutions per    Indicating the battery voltage.
perature, exhaust gases should be colour-     minute of the engine.                       When the engine is running, the battery
less or light-blue. (In the winter, the low   Avoid idling for more than 10 minutes.      voltage should be between 12 and 14
temperatures will turn the exhaust emis-      Also the number of running hours is indi-   Volts resp. between 24 and 28 Volts.
sions white.)                                 cated.                                      With the engine stopped and the start key
If black smoke is emitted from the exhaust,                                               in the first position, the voltmeter should
this indicates that combustion is incom-      Idling speed,                               indicate 12 Volts resp. 24 Volts.
plete.                                            DT44, DTA44 : 800 rpm
If white smoke is emitted, this indicates         DT66, DTA66 : 800 rpm
combustion of oil forced up.


22
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. Oil
The operating temperature is 83C - 85C     When idling: at least 0.8 bar (6 psi).          pressure, battery charging and tempera-
(181F - 185F).                             In case the oil pressure is too low: turn off   ture indicator lights are all connected to an
In case the engine is overheated: turn off   the engine and establish the cause, see         alarm buzzer. If this alarm buzzer sounds
the engine and establish the cause, see      fault finding table, page 59 .. 63.             while running, STOP THE ENGINE IMMEDIATE-
fault finding table, page 59 .. 63.                                                          LY!




                                                                                                                                       23
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 `NEUTRAL'. Turn the key to the    before stopping.                              by operating the mechanical shutdown
left to the `OFF' position.                                                                lever on the fuel injection pump until the
                                             N.B. The `STOP' position, left of the `OFF'   engine comes to a stand-still.
If the engine is not to be used for some     position on the control panel, has normal-    If the fuel supply is not shut off by the elec-
time, it is recommended that the sea cock    ly no function for this engine.               trically operated fuel solenoid, stopping of
is closed and the battery main switch        When 2 control panels are connected to        the engine can be done this way.
turned off.                                  one engine, the engine can always be
                                             stopped by turning the key to the `STOP'
Never stop the engine immediately after it   position, no matter what the position is of
has been in operation for a long time.       the key on the other panel.
24
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.
tional conditions. Service the unit more
frequently under severe conditions.




                                                                                                   25
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                               page 36
                                                                     Check gearbox oil level                     page 40
     After the first 50 hours )     1


     Drain water from fuel filter                          page 31   Every 1000 hours, at least once every 2 years
     Engine oil change                                     page 34   Replace fuel filter                         page 41
     Replace oil filter                                    page 34   Raw water pump inspection                   page 42
     Check V-belts                                         page 36   Gearbox oil change                          page 44
     Check gearbox oil level                               page 40   Replace air cleaner                         page 45
     Replace fuel filter                                   page 41   Check flexible engine mounts                page 45
     Check flexible engine mounts                          page 45   Check hose connections                      page 45
     Check valve clearance                                 page 46
     Check tightness of all fasteners, bolts and nuts 2)             Every 1500 hours, at least once every 2 years
     Controle van de motor op lekkage                                Check valve clearance                       page 46


     Every 125 hours, at least once every year                       Every 2000 hours, at least once every 2 years
     Drain water from fuel filter                          page 31   Replace coolant 3)                          page 48
     Battery, cables and cable connections                 page 32




26
Maintenance chart                                                                                      4 Maintenance
The maintenance chart shown here is
supplied as self-adhesive label with each
engine. It should be affixed on the                                   in. 0.3 mm        SAE 10W40
engine where it can be seen clearly.                                      0.012 in.
                                                           1500 h                        API = CD/CE    500 h
                                                                      ex. 0.5 mm
Check that this is the case.                                              0.20 in.     CCMC = D4/D5


If necessary, ask your engine supplier for
                                                           1000 h                                        10 h
anothre label.

Routine work should be carried out
according to the schedule.                                  10 h                                        500 h




                                                           500 h                                        1000 h


                                                                               DEUTZ                                06-04
                                                                    DT44       DTA44 DT66       DTA66            STM9720


1) Commisioning of new or overhauled
   engine.
2) Re-tightening of cylinder head bolts is
                                                     Warning!
   not required!
3) Cleaning of heat exchanger and after-     Stop the engine before carrying out any
   cooler (if installed) is not required.    maintenance work.




                                                                                                                            27
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*. If necessary top up    cover.
side of the engine.                        with the same brand and type of oil.



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

                                             - DT44, DTA44 : 1.5 litres (2.6 UK pt)
                                             - DT66, DTA66 : 2 litres (3.5 UK pt)


28
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.            The internal cooling system can be filled
cold.                                                                                   with a mixture of anti-freeze (40 %) and tap
Remove the cap of the filler neck on the                                                water (60 %) or with a special coolant. For
heat exchanger.                                                                         specification, see page 72.


          Warning!
                                                                                                  Caution!
Never open the cap on the header tank
when the engine is at operating tempera-                                                Never fill the cooling system with sea
ture.                                                                                   water or brackish water.
                                                                                                                                 29
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.                            of the water strainer.                        housing after cleaning and re-assembling
                                                                                             the strainer. An improperly sealed lid will
                                               Clean the raw water strainer as often as is   result in air sucked in by the sea water
                                               necessary, depending on the pollution of      pump which again will result in overheat-
                                               the waterways, but at least once every 6      ing of the engine.
                                               months. A clogged raw water strainer will
                                               result in excessive temperatures or over-
                                               heating of the engine coolant.



30
Draining of water from the water separator/fuel filter                                                   4 Maintenance
Every 125 operating hours.




VD00027                                       VD00109

9 Empty fuel filter                           10 Bleeding

Empty the separately installed water sepa-    The system doesn't need to be bled after      Repeat the above if the engine cuts out
rator/fuel filter:                            the water separator/fuel filter has been      after a short time.
 Open the drain plug at the lower side of    drained.
   the filter.                                The fuel system is self-bleeding.
 Drain the water and close the drain         Operate the starter switch until the engine
   plug.                                      fires; release the starter switch if the
                                              engine does not fire within 20 seconds.
                                              Wait until the starter motor has stopped
          Waterseparator                      before making a new attempt to start the
The water separator is not within the scope   engine.
of supply but installation is required!

                                                                                                                                31
4 Maintenance                                                                       Battery, cables and connections
                                                                                                       Every 125 operating hours.

                                                Vetus maintenance-free batteries        GREEN DOT ALL DARK              CLEAR




VD00117                                      VD00118                                    VD00121        VD00122       VD00123

11 Battery, battery connections              12 Checking specific gravity               13 Hydrometer operation

Keep battery clean and dry.                  Every Vetus Maintenance-free battery has    Green dot visible - State of charge
Remove battery cables (negative first).      a hydrometer (1) built into the cover.       65 % or more.
Clean battery posts (+ and -) and clamps     Visual inspection of the hydrometer will    Dark - State of charge less than 65 %.
and grease with acid-free and acid-resist-   show one of three conditions:                Recharge immediately.
ant grease.                                                                              Clear or light yellow - Electrolyte level
Ensure that clamps make good contact                                                      low.
after reassembling. Hand tighten the bolts                                                In case of low level, caused by over-
only.                                                                                     charging the battery for a long period of
                                                                                          time with a voltage too high, replace
                                                                                          battery. Check alternator and/or voltage
                                                                                          regulator.
32
Battery, cables and connections                                                                            4 Maintenance
Every 125 operating hours.

          Conventional batteries                         Conventional batteries
                                                                                                Specific      State of
                                                                                                gravity       charge


                                                                                                 1.280         100%


                                                                                                 1.200          50%       recharge


                                                                                                 1.120          10%       recharge
                                                                                                                          immediately

VD00119                                        VD00120

14 Checking electrolyte level                  15 Checking specific gravity                           Warning!

For conventional batteries it is required to   Measure the electrolyte specific gravity of         The gases emitted by the battery
check the electrolyte level regularly.         the individual cells with a commercial              are explosive!
Remove vent caps (taking care no spark         hydrometer. The hydrometer reading (see             Keep sparks and naked flames
or open flame is nearby) and inspect the       table) indicates the state of charge.               away from the battery!
level. Fluid should be 10 to 15 mm (3/8" to    Hydrometer reading of all cells should be           Do not allow battery acid to come
5/8") above top of all plates. If necessary    at least 1.200 and show less than 0.050             into contact with skin or clothing!
top up with distilled water. Replace vent      between high and low. If not, recharge or           Wear protective goggles!
caps and charge the battery for 15 min-        replace battery. During checking the tem-
utes at 15 - 25 Amps to mix electrolyte.       perature of the electrolyte should prefer-    Do not rest tools on the battery!
                                               ably be 20C (68F).


                                                                                                                                     33
4 Maintenance                                                                                              Engine oil change
                                                                                                          Every 500 operating hours.

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


         Caution!

Used oil must be collected in a container
for proper disposal according to laws and
regulations.



                                              VD00017                                      VD00023

16       Engine oil change                    17 Draining the oil                          18 Removing the oil filter

Change the engine oil every 500 hours of      The pump for the oil sump is (normally)      Unscrew the oil filter, with a commercially
operation (together with engine oil filter    located at the heat exchanger side of the    available tool, when all the oil has been
replacement).                                 engine.                                      pumped out.
                                              As an option for twin engine installation,   Catch any dripping oil.
If the engine runs less than 500 hours dur-   the pump may be located on the other
ing the year the oil should be changed at     side at one of the engines.
least once a year.
                                                                                                     Warning!
Run the engine for a few minutes before
changing the oil; warm oil can be pumped                                                   Beware of burns from hot oil.
out more easily.
34
Engine oil change                                                                                            4 Maintenance
Every 500 operating hours.
 OILFILTER: 4 CYL.:   ART.CODE:   VD20262                                                     AMOUNT OF OIL: 4 CYL.: 8.5 litres (1.9 UK gal)
            6 CYL.:   ART.CODE:   VD20263                                                     (OIL FILTER INCL.)6 CYL.: 14 litres (3.1 UK gal)




VD00030                                         VD00011                                      VD00367

19 Oiling the oil seal                          20 Oil filter installation                   21 Refilling with oil

Clean the contact surface of the gasket.        Install the filter in accordance with the    Refill the engine with new oil (for specifi-
Lubricate the oil seal of the new filter ele-   instructions printed on the filter element   cation see page 70) through the filler
ment with clean engine oil.                     housing.                                     opening in the valve cover.

                                                                                             Operate the engine at idling speed for a
                                                                                             short period of time. Check for oil leaks
                                                                                             whilst the engine is running.
                                                                                             Stop the engine. Allow 5 minutes for the oil
                                                                                             to return to the sump. Check the oil level
                                                                                             with the dipstick.


                                                                                                                                          35
4 Maintenance                                                                                               Checking the V-belts
                                                                                                              Every 500 operating hours.




                                                                                                                             13      1/ "
VD00034                                          VD00010                                       VD00021                                 2
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        Loosen bolts (1) and (2).
and cracking). Belts which are in poor           moderate finger and thumb pressure. If
condition should be replaced.                    the deflection of the belt is more than 9 -    Rotate the tension device with the fuel
                                                 11 mm (approx. 3/8"), using about 10 kg         pump in the direction of the arrow using
                                                 (20 lbs) thumb pressure, it should be ten-      a key in (a), square 1/2", until the ten-
          Warning!                               sioned.                                         sion of the V-belt is correct.

Check, tension and change belts only with                                                       Re-tighten bolts (1) and (2).
the engine off. Refit belt guard, if provided.



36
Checking the V-belts                                                                                     4 Maintenance
Every 500 operating hours.



                                                      (   Max. 28 Nm)   22 Nm




                                                                                4




VD00001
                             10     19      VD00495
                                                                                    19
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.     mounting bolts (1) and (2).
  bolt (3) of the adjustment bracket and      Never apply a torque to the pinion of
  simultaneously keep the pinion (4) in       more than 28 Nm! (max. belt force is
  the same position.                          achieved at about 22 Nm).
                                                                                                   Warning!
                                             Re-tighten the bolt (3) of the adjustment
                                              bracket.                                    Check, tension and change belts only with
                                                                                          the engine off. Refit belt guard, if provided.



                                                                                                                                     37
4 Maintenance                                                                                           Replacing the V-belts

V-BELT COOLANT PUMP      AND   FUELPUMP,
ART.CODE: VD40069




                                                                           13      1/ "
VD00019                                      VD00021                                 2
26 Replacing V-belt of coolant and
   fuel pump
 Loosen bolts (1) and (2).                   Rotate the tension device with the fuel
                                               pump in the direction of the arrow using
 Rotate the tension device with the fuel      a key in (a), square 1/2", until the ten-
  pump in the direction of the arrow using     sion of the V-belt is correct.
  a key in (a), square 1/2".
                                              Re-tighten bolts (1) and (2).
 Remove and replace belt.
                                                                                                    Warning!

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

38
Replacing the V-belts                                                                                        4 Maintenance
V-BELT    ALTERNATOR ART.CODE:   VD40067

                                                    (     Max. 28 Nm)   22 Nm




                                                                                4




VD00001
                                  10       19   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).
  bolt (3) of the adjustment bracket and
  rotate the pinion (4) clockwise.               Re-tighten the bolt (3) of the adjustment
                                                  bracket.
 Remove and replace belt.
                                                 Then re-tighten both the alternator
 Tension the belt by rotating the pinion         mounting bolts (1) and (2).                          Warning!
  (4) counter-clockwise until the tension
  of the belt is correct.                                                                     Check, tension and change belts only with
                                                                                              the engine off. Refit belt guard, if provided.

                                                                                                                                         39
4 Maintenance                                                                                       Gearbox oil level check
                                                                                                          Every 500 operating hours.




VD00468                                     VD00469

28 Unscrewing the dipstick                  29 Oil level check

 Unscrew the dipstick out of the gearbox    Check the oil level by cleaning the dip-     Vetus engines are normally equipped with
  housing.                                    stick and lowering it into the hole, with-   ZF-Hurth gearboxes. Consult the supplied
                                              out screwing it in.                          Owners Manual for more details about
                                              The oil level must between the two           care and maintenance. In case your
                                              marks on the dipstick.                       engine is equipped with another brand of
                                              If necessary top up by pouring oil in the    gearbox follow the instructions given in the
                                              dipstick hole.                               supplied owners manual for changing oil
                                                                                           and other care and maintenance.
                                            For oil type and specification see page 70.



40
Fuel filter replacement                                                                                      4 Maintenance
Every 1000 operating hours.

                                                FUEL     FILTER, ART.CODE:   VD60210




VD00013                                        VD00009
                                                                                       1       VD00009
                                                                                                                                     2
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.
 Close the fuel stopcock.                       rim.
                                                                                                Open the fuel stop cock.
 Remove the fuel filter, use a filter          Lubricate the rubber gasket sparingly
  wrench. Catch any fuel.                        with clean engine oil.                         Check for leakage.

                                                Fill the new filter with clean diesel fuel.   32 Bleeding
          Warning!                                                                             After replacing the fuel filter, the system
                                                Install the filter. When the rubber gasket    doesn't need to be bled
Keep naked flames away when working              touches the housing, apply another            The fuel system is self-bleeding.
on the fuel system. Do not smoke!                tightening of a half to three quarters of     See page 31, 10 Bleeding.
                                                                                                                                       41
4 Maintenance                                                                            Raw water pump inspection
                                                                                                     Every 1000 operating hours.




                                            VD00008
                                                                          1.2 x 6.5    VD00007

33 Raw water pump inspection                34 Pump cover removal                      35 Impeller removal

        Caution!                            Inspection where appropriate changing is    Slide the impeller off of the shaft using
                                            as follows:                                  a waterpump plier.
The rubber impeller of the raw water pump
is not proof against running dry. If the     Close the sea cock.                       Mark the impeller to ensure correct re-
water supply has been blocked, it may be                                                 installation if it is to be re-used. The
necessary to replace the impeller. Always    Remove the cover of the pump by            impeller must be installed in the same
carry a spare impeller on board.              unscrewing the screws out of the hous-     position as removed.
                                              ing.




42
Raw water pump inspection                                                                              4 Maintenance
Every 1000 operating hours.

IMPELLER,   ART.CODE:   STM8246                                                         GASKET,   ART.CODE:   STM8235




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         Replace the cover with a new gasket.
                                         glycerin or a non-petroleum based
 Replace the impeller if necessary.     lubricant such as a silicone spray             Check the water filter and open the sea
                                         before fitting it into the impeller hous-       cock.
                                         ing.

                                        Fit the impeller to the pump shaft. (if an
                                         existing impeller is re-used, install it in
                                         the same position as removed).



                                                                                                                             43
4 Maintenance                                                                                    Changing the gearbox oil
                                                                                                         Every 1000 operating hours.




VD00025                                    VD00024

39 Draining the oil                        40 Filling with new oil

Drain the oil with the aid of a separate    Refill the gearbox to the correct level via   Vetus engines are normally equipped with
sump pump.                                   the dipstick opening.                         ZF-Hurth gearboxes. Consult the supplied
                                                                                           Owners Manual for more details about
 Remove the dipstick.                     For oil specification see page 66.              care and maintenance. In case your
 Insert the suction hose of the sump                                                      engine is equipped with another brand of
  pump in the dipstick hole. Push down                                                     gearbox follow the instructions given in the
  the pump handle quickly and pull it up                                                   supplied owners manual for changing oil
  slowly.                                                                                  and other care and maintenance.
 Remove the sump pump when all the
  old oil has been pumped out.


44
Combustion air intake, Flexible engine mounts, Hose connections                                            4 Maintenance
Every 1000 operating hours.
 AIR   FILTER:   4 CYL.:   ART.CODE:   CT30053
                 6 CYL.:   ART.CODE:   CT30108




VD00472                                          VD00470                                       VD00471

41 Air cleaner replacement                       42 Check flexible engine mounts              43 Inspection hose connections

 The air cleaner is to be replaced as a unit.   Check the bolts which secure the damper       Inspect all hose connections of the
 Loosen the 2 plastic cable ties securing       element, the mounting bolts to engine bed      coolingsystem. (Cracked hoses, loose
  the cleaner housing and loosen the             and the nuts at the adjustment spindle for     hose clamps)
  hose clamp at the air intake.                  tightness.
 Install a new air cleaner and tighten the
  clamp and the cable ties again.                Also check the deflection of the damper
                                                 element, the deflection influences the
           Warning!                              alignment of engine and propshaft! Re-
                                                 align engine in case of doubt.
Never clean the air cleaner with petrol
(gasoline) or hot fluids.
                                                                                                                                 45
4 Maintenance                                                                                    Checking valve clearance
                                                                                                         Every 1500 operating hours.
                                             VALVE    CLEARANCE:   INLET 0.3 mm (0.012")            EXHAUST 0.5 mm (0.020")




VD00375                                     VD00376
                                                                                                                    13      1.2 x 8.0
44 Checking / adjusting valve clear-
   ance
 Remove the two bolts out off the            least 30 minutes. The oil temperature            - Use screwdriver (7) to turn setscrew
  breather valve and swing the breather       should be below 80C (176F).                       (5) so that the correct clearance is
  valve aside. (For convienance first        Check the valve clearanve (1) between               obtained after the locknut has been
  remove the air cleaner).                    the rocker lever (2) and valve stem (3)             tightened.
 Remove the air intake from after cooler     with feeler gauge (6).                          Check and adjsut valve clearance on all
  (if installed).                             Note the clearance is correct if some            remaining cylinders.
 Remove rocker cover.                        resistance is felt when the feeler gauge        Re-install rocker cover (use a new gas-
 Position crankshaft as per schematic.       is slipped between the valve stem and            ket if needed).
 Before adjusting the valve clearance        rocker lever                                    Re-install air intake from aftercooler.
  allow the engine to cool down for at       Adjust valve clearance if necessary:            Re-install breather valve.
                                              - Release locknut (4)

46
Valve Clearance Adjustment Schematic                 4 Maintenance
                                        Crankshaft Position 1
 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




                                        Crankshaft Position 2
 2                                       Bar crankshaft one full revolution
                                         (360).

                                         Adjust clearance of valves marked in
                                         black on schematic.




VD00377


                                                                                47
4 Maintenance                                                                                             Coolant replacement
                                                                                                          Every 2000 operating hours.




                                                  1

                                                  2
                                                                                                      1           2
                                                VD00475                                     VD00474
                                                                                                                          19       18
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). Remove
years.                                          the filler cap to vent the cooling system   Be aware of the risk of skin burning during
                                                and check that all the coolant has been     draining the hot coolant!
N.B. Replacing the coolant may also be          drained. After draining replace the drain
necessary as part of the winter storage         plugs.
                                                                                                      Caution!
procedure; in case that the coolant pres-
ent in the cooling system offers insufficient                                               Used coolant must be collected in a con-
protection for the winter.                                                                  tainer for proper disposal according to
                                                                                            laws and regulations.


48
Coolant replacement                                                                                       3 Maintenance
Every 2000 operating hours.
 COOLANT 4 CYL.: 8.5 litres (1.9 UK gal)
 QUANTITY : 6 CYL.: 12 litres (2.6 UK gal)
                                                                           COOLANT                  Calorifier
                                                                                           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.




VD00477                                      VD00473

47 Filling the cooling system

Remove the cap of the filler neck on the     The level of the coolant must be at the       After the engine has run for the first time
top of the header tank.                      lower edge of the filler neck.                and has reached operating temperature
Fill the cooling system.                     Replace the filler cap.                       and has cooled down again to ambient
Replace plug A as soon as coolant flows      Bleeding will take place automatically dur-   temperature, check the coolant level in the
out.                                         ing filling!                                  heat exchanger housing.
Use a mixture of 40% antifreeze (ethylene-                                                 If necessary, add coolant.
glycol based) and 60% tap water or use a
special coolant.                                                                                    Caution!
For specifications see page 72.
                                                                                           Never fill the cooling system with sea
                                                                                           water or brackish water.

                                                                                                                                     49
5 Winter storage procedure




VD00027                                     VD00136

1 Fuel system

Drain the water from the water              Running with protective fuel mixture            * Engine oil with protective properties.
separator/fuel filter and the fuel tank.    Connect the fuel supply pipe to a can filled       E.g. Shell Super Diesel T 10W40
Ensure that the tank is completely filled   with a mixture of one (1) part of engine oil*   ** Preferably water-free fuel.
with fuel.                                  to nine (9) parts of clean fuel**. Use this        Collect some fuel from the return pipe,
                                            mixture to run the engine at no load for           while engine is running.
                                            approx. 10 minutes.
                                            Stop the engine.
                                                                                                    Caution!

                                                                                            Never run the engine under load with this
                                                                                            mixture of fuel and oil.
50
                                                                                    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. If necessary, clean       ing after cleaning and re-assembling the
then turn off.)                               the raw water strainer.                          strainer.
                                              Pour 1 litre (2 UK pt) of anti-freeze into the   An improperly sealed lid will result in air
Replace the oil filter and change the         water strainer and run the engine until the      sucked in by the raw water pump which
engine oil; use oil with protective proper-   anti-freeze has disappeared into the cool-       again will result in overheating of the
ties. See page 70.                            ing system.                                      engine.
                                              Take care that no anti-freeze is spilled into
                                              the waterway (anti-freeze is poisonous).



                                                                                                                                       51
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.                     ularly if required!
N.B. Replacing the coolant is only neces-
sary if the coolant present in the cooling
system offers insufficient protection for the
winter.
For coolant replacement see page 48.



52
                                                       6 Recommissioning after winter storage
                                                                                  FUEL     FILTER, ART.CODE:   VD60210




VD00027                                    VD00141                               VD00009

1 Fuel system

Drain the water from the           water   Drain the water from the fuel tank.   Install a new fuel filter. (page 41)
separator/fuel filter. (page 31)




                                                                                                                         53
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.




54
                                                         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,
43)




                                                                                                            55
6 Recommissioning after winter storage




VD00476                              CT40063                                  VD00140

4 Fresh water cooling system         5 Electrical system

Check the coolant level. (page 29)   Make sure that the batteries are fully   Connect the batteries.
                                     charged. (pages 32, 52)




56
                                                       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. (page 44)                          Check the operation of the instruments,
and the exhaust for leakage.                                                            the remote control and the gearbox.




                                                                                                                            57
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. Please note that these
                    tables can never be complete.

                    If you are unable to identify the cause of the fault or to rectify it
                    yourself, then contact the nearest service representative.




                             Warning!

                    Before starting, make sure that nobody is in the immediate vincin-
                    ity of the engine.
                    When carrying out repair, never start the engine with the fuel
                    injection pump removed removed.
                    Disconnect battery!




58
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

A   Faulty or discharged battery.     A   Check / recharge bat-       A    Fuel stop valve closed.            A   Open.
                                          tery and check engine       B    (Nearly) Empty fuel tank.          B   Refill.
                                          alternator and/or battery   C    Air in fuel system.                C   Check and bleed.
                                          charger.                    D    Fuel filter clogged with water     D   Check or replace.
B   Loose or corroded connections     B   Clean and tighten con-           and/or contamination.
    in starting circuit.                  nections.                   E    Leaking fuel supply line or fuel   E   Check / replace.
C   Faulty starter-switch or faulty   C   Check / replace.                 injection line.
    starter-relay.                                                    F    Faulty injector/injection pump.    F   Check, replace if
D   Faulty starter-motor or pinion    D   Check / replace starter-                                                required.
    does not engage.                      motor.                      G    Engine shut down lever in stop     G   Check / replace.
                                                                           position.
                                                                      H    Faulty V-belt fuel pump.           H   Replace V-belt.
                                                                      I    Vent line of fuel supply tank      I   Check / clean.
                                                                           clogged.
                                                                      J    Exhaust restricted.                J   Check.




                                                                                                                                      59
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

A    Air in fuel system.                A   Check and bleed.           A    (Nearly) Empty fuel tank.          A   Refill.
B    Faulty injector/injection pump.    B   Check, replace if          B    Air in fuel system.                B   Check and bleed.
                                            required.                  C    Fuel filter clogged with water     C   Check or replace.
C    Faulty glow plugs (if installed)   C   Check / replace.                and/or contamination.
     or below starting limit tempera-                                  D    Leaking fuel supply line or fuel   D   Check / replace.
     ture.                                                                  injection line.
D    Incorrect valve clearance.         D   Adjust.                    E    Faulty injector/injection pump.    E   Check, replace if
E    Incorrect injection timing after   E   Check / adjust.                                                        required.
     overhauling of engine.                                            F    Faulty V-belt fuel pump.           F   Replace V-belt.
F    Insufficient intake air.           F   Check.                     G    Vent line of fuel supply tank      G   Check / clean.
                                                                            clogged.
G    Wrong fuel quality or contami-     G   Check fuel. Drain and      H    Fuel supply line restricted.       H   Check / clean.
     nated fuel.                            flush fuel tank. Replace   I    Incorrect valve clearance.         I   Adjust.
                                            with new fuel.             J    Idle setting too low.              J   Check/ adjust.
H    Incorrect lube oil SAE class or    H   Replace.                   K    Exhaust restricted.                K   Check.
     quality for ambient tempera-                                      L    Wrong fuel quality or contami-     L   Check fuel. Drain and
     ture.                                                                  nated fuel.                            flush fuel tank. Replace
                                                                                                                   with new fuel.




60
Fault finding table                                                                                      7 Troubleshooting
    5 Engine does not reach maximum rpm under load                          6 Engine overheats

Possible fault                           Remedy                         Possible fault                              Remedy

A    Air in fuel system.                 A   Check and bleed.           A    Faulty injector/injection pump.        A   Check, replace if
B    Fuel filter clogged with water      B   Check or replace.                                                          required.
     and/or contamination.                                              B    Oil level too high.                    B   Lower level.
C    Leaking fuel supply line or fuel    C   Check / replace.           C    Oil level too low.                     C   Increase level.
     injection line.                                                    D    Faulty oil filter.                     D   Replace.
D    Faulty injector/injection pump.     D   Check, replace if          E    Faulty turbocharger                    E   Check / clean.
                                             required.                  F    Coolant pump defective.                F   Check / clean.
E    Engine shut down lever in stop      E   Check / replace.           G    Heat exchanger dirty or clogged        G   Clean
     position, faulty fuel valve.                                            as a result of rubber particles from
F    Faulty V-belt fuel pump.            F   Replace V-belt.                 a worn impeller.
G    Oil level too high.                 G   Lower level.               H    Vent pipe blocked.                     H   Check / clean
H    Incorrect valve clearance.          H   Adjust.                    I    Coolant level too low.                 I   Check / top up.
I    Exhaust restricted.                 I   Check / clean.             J    Sea cock closed.                       J   Open.
J    Charge air (after)-cooler con-      J   Check / clean.             K    Raw water strainer clogged.            K   Check / clean.
     taminated.                                                         L    Leaking raw water intake system.       L   Check / replace.
K    Insufficient intake air.            K   Check.                     M    Faulty thermostat.                     M   Check / replace.
L    Faulty `charge air pressure oper-   L   Check / replace.           N    Faulty impeller raw water pump.        N   Check / replace.
     ated max. powerr output device'.                                   O    Insufficient intake air.               O   Check / replace air
M    Leaking air intake manifold.        M   Check / replace.                                                           intake filter.
N    Wrong fuel quality or contami-      N   Check fuel. Drain and      P    Leaking air intake manifold.           P   Check / replace.
     nated fuel.                             flush fuel tank. Replace   Q    Motor becomes apparantly over-         Q   Check / replace.
                                             with new fuel.                  heated as a result of faulty temper-
O    Engine overloaded.                  O   Check size of propeller.        ature switch, sensor or meter.

                                                                                                                                            61
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
A    Air in fuel system.                A   Check and bleed.    A   Oil level too low.
B    Fuel filter clogged with water     B   Check or replace.   B   Excessive inclination of engine.   A   Increase level.
     and/or contamination.                                      C   Incorrect lube oil SAE class or    B   Check / Adjust.
C    Leaking fuel supply line or fuel   C   Check / replace.        quality for ambient tempera-       C   Replace.
     injection line.                                                ture.
D    Faulty injector/injection pump.    D   Check, replace if
                                            required.           9 Engine oil consumption excessive
E    Faulty V-belt fuel pump.           E   Replace V-belt.
F    Fuel supply line restricted.       F   Check / clean.      Possible fault                         Remedy
G    Faulty glow plugs (if installed)   G   Check / replace.
     or below starting limit tempera-                           A   Oil level too high.                A   Lower level.
     ture.                                                      B   Excessive inclination of engine.   B   Check / Adjust.
H    Incorrect valve clearance.         H   Adjust.             C   Incorrect lube oil SAE class or    C   Replace.
                                                                    quality for ambient tempera-
                                                                    ture.
                                                                D   Excessive wear of cylinder/pis-    D   Check compression;
                                                                    ton.                                   overhaul engine.
                                                                E   Insufficient intake air.           E   Check.
                                                                F   Engine overloaded.                 F   Check size of propeller.




62
Fault finding table                                                                                     7 Troubleshooting
10A       Blue exhaust smoke (idling)                                   10C       White exhaust smoke (at full load)

Possible fault                          Remedy                          Possible fault                         Remedy

A   Oil level too high.                 A   Lower level.                A   Air in fuel system.                A   Check and bleed.
B   Excessive inclination of engine.    B   Check / Adjust.             B   Faulty injector/injection pump.    B   Check, replace if
C   Leaking turbocharger oil seal.      C   Check / replace oil seal.                                              required.
                                                                        C   Water in fuel system.              C   Check water separator.
                                                                        D   Faulty glow plugs (if installed)   D   Check / replace.
                                                                            or below starting limit tempera-
10B       Black exhaust smoke (at load)                                     ture.
                                                                        E   Incorrect valve clearance.         E   Adjust.
Possible fault                          Remedy                          F   Incorrect injection timing.        F   Check / adjust.
                                                                        G   Wrong fuel quality or contami-     G   Check fuel. Drain and
A   Faulty turbocharger.                A   Check / replace.                nated fuel.                            flush fuel tank. Replace
B   Charge air (after)-cooler con-      B   Check / clean.                                                         with new fuel.
    taminated.                                                          H   Vapour in exhaust gases con-       H   -
C   Insufficient intake air.            C   Check / replace air             denses as a result of very low
                                            intake filter.                  ambient temperature.
D   Faulty `charge air pressure oper-   D   Check / replace.
    ated max. powerr output device'.
E   Leaking air intake manifold.        E   Check / replace.
F   Faulty injector / injection pump.   F   Check / replace if
                                            required.
G   Engine overloaded, max. rpm         G   Check sizes of propeller.
    is not reached.


                                                                                                                                         63
8 Technical data                                                                        Engine specifications

Model                                     DT44               DTA44                 DT66              DTA66

General

Make                                                                Vetus Deutz
Number of cylinders                        4                   4                      6                6
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              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                        18.4 : 1            18.4 : 1             18.4 : 1           18.4 : 1

                                            + 50                + 50                 + 50               + 50
Idling speed                            800  0 rpm         800  0 rpm          800  0 rpm        800  0 rpm
Max. no. of revolutions at no load       2950 rpm            2950 rpm             2950 rpm           2950 rpm

Valve Clearances (cold)                                        Inlet 0.3 +0.1 mm (0.012")
                                                              Exhaust 0.5 +0.1 mm (0.020")

Weight                               513 kg (1131 lbs)   532 kg (1173 lbs)   652 kg (1437 lbs)   657 kg (1448 lbs)
(with standard gearbox)

64
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

Special Light Duty            84 kW        103 kW          125 kW      155 kW
(ISO 3046/IOFN)              (114 hp)     (140 hp)        (170 hp)    (210 hp)
at no. of revolutions of     2500 rpm     2500 rpm     2500 omw/min   2500 rpm



Fuel consumption

At max. power and max. rpm   208 g/kW.h   202 g/kW.h    202 g/kW.h    202 g/kW.h




                                                                                   65
8 Technical data                                                                         Engine specifications

Model                                        DT44           DTA44                 DT66              DTA66

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 filter element                         VD60210        VD60210              VD60210             VD60210
Fuel lift pump     Suction height max.                            max. 1.5 m (5 ft)
                   Pressure loss                          max. 0.15 bar (kgf/cm3) (2.2 psi)
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. 9 l/min (2 UK gal/min)

Oil lubrication system

Oil capacity, max.   without oil filter      7.5 litres      7.5 litres         12.5 litres         12.5 litres
                                          (1.65 UK gal)   (1.65 UK gal)       (2.75 UK gal)       (2.75 UK gal)
                     with oil filter         8.5 litres      8.5 litres          14 litres           14 litres
                                           (1.9 UK gal)    (1.9 UK gal)        (3.1 UK gal)        (3.1 UK gal)
Oil Filter                                   VD20262        VD20262              VD20263             VD20263
Oil pressure with warm oil
(120C, 248F) and low idle                                    min. 0.8 bar (11.6 psi)
Oil temperature in sump                                         max. 120C (248F)
66
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              
                                                (1.35 UK gal)                              (1.94 UK gal)              
Thermostat                                             opening at 83C (181F), fully opened at 95C (203F) (VD20833)
Coolant pump,      Flow                            170 l/min           170 l/min               180 l/min           180 l/min
                                              (37.4 UK gal/min)    (37.4 UK gal/min)      (39.6 UK gal/min)   (39.6 UK gal/min)
                   Total head                      0.23 bar             0.23 bar               0.26 bar            0.26 bar
                                                   (3.3 psi)            (3.3 psi)              (3.8 psi)           (3.8 psi)
Raw water pump, Flow at max. engine rpm             98 l/min            98 l/min               123 l/min           123 l/min
                                              (21.6 UK gal/min)    (21.6 UK gal/min)       (27 UK gal/min)     (27 UK 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)
                    Impeller                      STM8246              STM8246                STM8246             STM8246
                    Inlet connection                                          for hose 32 mm I.D.
Calorifier connection                                                    M26 x 1.5 (Kit no. STM9738)

Combustion air system / Exhaust

Air intake filter                                 CT30053              CT30053              CT30108              CT30108
Intake vacuum pressure                                                    max. 25 mbar (0.74 in Hg)
Exhaust diameter                                   90 mm                100 mm              125 mm                125 mm
Exhaust back pressure                                          at specified output max. 120 mbar (3.5 in Hg)
                                                                  absolute maximum 120 mbar (3.5 in Hg)
                                                                                                                             67
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

Alternator                    VD40067                VD40067               VD40067                VD40067
Tension                             Pre-tension     400 N (90 lbf) / Re-tension 25050 N (5611 lbf)
Fuel pump / Coolant pump      VD40069                VD40069               VD40069                VD40069
Tension                             Pre-tension     400 N (90 lbf) / Re-tension 25050 N (5611 lbf)

Engine installation

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



Gearbox, standard

ZF-Hurth type                    ZF45                   ZF45                 ZF45                ZF63
Reduction ratio              2.2/2.5/3.0:1          2.2/2.5/3.0:1        2.2/2.5/3.0:1    1.51/1.93/2.5/2.78:1

68
Torque wrench settings                                                                             8 Technical data
Screw connection         Size       Class     Torque    Angle   Screw connection           Size        Class   Torque    Angle
                                               [Nm]                                                             [Nm]


Oil pan                   M8x16                 30              Exhaust manifold / Cyl. head
Oil drain plug           M18x1.5                50               - Stud                     M10                  15
Cylinder head,                                                   - Locknut                   M8                2510%
 - long bolts            M12x200     10.9       40/70   180    Turbocharger / Exhaust manifold
 - short bolts           M12x120     10.9       40/70   180      - Bolt    - 4 Cyl.         M8                2110%
Lifting eye / Cyl. head M10x30        8.8     4010%                        - 6 Cyl.        M10                2210%
Rocker cover              M6x75      10.9     8.510%           Turbo-oplader / Uitlaatinjectiebocht
Rocker arm set-screw      M8x60       8.8        21               - Stud    - 4 Cyl.         M8                 2210%
Flange injection pump M8x30          10.9        30                         - 6 Cyl.        M10                 2210%
Injector holder (Torx)    M8x50      10.9       16+5              - Nut     - 4 Cyl.         M8                 2110%
Fuel lift pump /                                                            - 6 Cyl.        M10                 2110%
clamping strap            M8x20    10.9 A4C    212             Alternator mounting        M8x80       10.9     2110%
Pulley fuel lift pump     M8x20       8.8      212             Starter                   M10x55       10.9       70
Screw, banjo connector                                          Engine bracket front      M16x75       8.8     18710%
fuel line                M14x1.5              3910%            Engine bracket rear       M12x40        8.8     8010%
Injection line mounting M14x1.5                253.5           Flywheel housing         M12x150       10.9    9910%
Exhaust insulator          M8        8.8      2110%            Flywheel housing         M16x140       10.9    24310%
Air intake manifold (AIM) M6x75      10.9     1110%            Gear-wheel raw water
Cover (AIM),                                                    pump shaft                  M12                  80
 - pre-tightening         M6x25               1510%
 - re-tightening          M6x25               1510%
Plugs (AIM)               M10x1               1310%
                                                                  Nm to ft.lb conversion:
Plugs (AIM)              M16x1.5              3810%
                                                                  Torque in ft.lb = 0.74 x Torque in Nm
Plugs (AIM)              M18x1.5                50

                                                                                                                            69
9 Operating media                                                                                                     Lubricating oil

Engine Lubricating Oil                                              Gearbox Lubricating Oil

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

Lube oils are differentiated according to their performance and     ZF Hurth:
quality class. 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
Approved CCMC Oils         :        D4, D5

As the viscosity of lube oil is dependent on temperature, the oil   model   ZF45    (HSW450H2)      :   2.0   liter   (3.5 UK pt)
vicosity (SAE grade) should be selected according to the ambi-      model   ZF45A   (HSW450A)       :   3.0   liter   (5.3 UK pt)
ent temperature when the the engine is started.                     model   ZF63    (HSW630H1)      :   3.8   liter   (6.7 UK pt)
To avoid oil changes dictated by the seasons we advise one of       model   ZF63A   (HSW630A)       :   4.0   liter   (7 UK pt)
the following multi-grade oils.
                                                                    Other brands of gearboxes:
- SAE 10W40 for temperatures of -25C up to +30C                   See supplied owners manual for oil type and quantities.
                               (-13F up to +86F)
- SAE 15W40 for temperatures of -20C up to +35C
                               (-4F up to +95F)

For example:      Vetus Marine Inboard Motor Oil
                  Shell Super Diesel T




70
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 0C (+32F), winter-grade
If the sulfur content is higher than 0.5%, the intervals between oil   fuel -suitable down to -15C (+5F) - should be used. This fuel is
changes should be halved e.g. change oil every 250 hours.              usually available from filling stations well in advance of the cold
                                                                       months. Diesel fuel containing additives (Super Diesel) is often
Don't use fuel with more than 1% sulfur!                               on sale as well, for use down to -20C (-4F).

The following fuel specifications / standards are approved:
 CEN EN 590 or DIN/EN 590 (under development)
 DIN 51 601 (Feb. 1986)
 BS 2869 (1988): A1 and A2
 ASTM D975-88: D1 and D2
 NATO Code F-54 and F75

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




                                                                                                                                       71
9 Operating media                                                                                                              Coolant

Coolant fluid                                                          Coolingsystem protective liquidl (Anti-freeze)

The preparation and monitoring of coolant in inter-cooled              As cooling system protetctive liquid use a ethylene-glycol based
engines is especially important because corrosion, cavitation and      anti-freeze. This will give an adequate protetcion against corro-
freezing can lead to engine damage. Use as coolant a mixture of        sion, cavitation and frost damage.
a cooling system protective liquid (anti-freeze, ethylene glycol
based) and tap water.                                                  For example:      ARAL     Antifreeze Extra
                                                                                         ESSO     ESSO Antifreeze Extra
In tropical climates, where anti-freeze availability may be limited,                     Mobil    Mobil Antifreeze Extra
use a corrosion inhibitor to protect the engine cooling system.                          Shell    GlycoShell
                                                                                         TOTAL    ELF Glacelf MDX
The concentration of the cooling system protective liquid in the                         BP       BP Antifrost Code No. X2270 A
coolant should not fall below/exceed the following limits:
                                                                       In tropical climates, where anti-freeze availability may be limited,
 Cooling system protective                    Protection against       use a corrosion inhibitor to protect the engine cooling system.
                                  Water
    liquid (Anti-freeze)                          freezing to

          35 vol.%              65 vol. %        -22C (-8F)
          40 vol.%              60 vol.%         -28C (-18F)
          45 vol.%              55 vol.%         -35C (-31F)


The protective liquid concentration must be maintained under all
circumstances. Therefor if coolant must be added always use the                 Caution!
same mixture of anti-freeze and tap water.
                                                                       Cooling system protective liquids must be disposed of in accor-
                                                                       dance with environmental regulations.

72
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 20C (68F)                 6.5          8.5
  Chloride ion content      [mg/dm ]
                                   3
                                                    100
  Sulfate ion content       [mg/dm ]
                                   3
                                                    100
  Total hardness            [degrees]      3          20




        Caution!

Never use sea-water or brackish water.


                                                                                   73
10 Wiring diagram                                                                                                                                                                                            Options, panel model `34'

                                                      Key switch                                                                                                           Voltmeter    Tachometer/                          Oil pressure         Temperature
                                                                                       Engine panel model                                                                               hour counter                            gauge               gauge


                                                                                                      '34'

                                                                                                                                                                               V             n/h                                      p            


                                                                                                             -8              -7       -5     -4                                                    -3                -6                   -1            -2
                                                                                                      X1     31             17/19 58        15                                                     W                 95                   M1            M2

                                                                                                                             D1        D2     D3                D4
                                                                                                                                                                     Warning lights

                                                                                                                                      Q1
                    Red                      Yellow    Orange Violet           White    Black
                                                                                                                       L1                   BZ         L2       R3     L3        L4      L5                   L6
                   A1                        A3        A4          A2          A5      A6
                                                                                                                             R1       R2
      Plug 'A'                                                                                                                                   D5
                                                                                                                                                 D6                                                     Gearbox
     Socket 'A'                                                                                                                                                                                         oil press.
                                                                                                                                                 D7
                   A1                         A3        A4         A2          A5      A6                                                        D8
                   Fuse or                                                                                                                       D9
                   circuit breaker
                                                                                                                                                       D10
                                                                                                                   Pre-                                                                                                   +
                                                                                                                  heating             X2M 19/94 61                   91        92      93      W           X3M (31)        (15) X4M G1            G2         NC   NC
                                                                                                                                           -6    -4                   -1        -2      -5     -3              -1           -2      -1             -2        -3   -4

                                              Auxiliary               Stop                                                                  B6        B4             B1        B2      B5      B3                                         C1       C2
                                              start relay             relay                                                   Plug 'B'
                                        30   86                    30     86                                                                                                                                               Plug 'C'

         Battery                                                                                                             Socket 'B'
                                                                                                                                                                                                                          Socket 'C'
           main                         87   85             87a          85
          switch                                                                                                                            B6        B4             B1        B2      B5      B3                                         C1       C2
                                                                                                                                                      Yellow/                                                                 Brown/                               Yellow/
                                                                                                                             Transparent              Green          Green Brown Blue              Gray                        Black               Blue/Red        Green

                                                                                                                                                                           p                                                      p                                     p
                                                                                                 B+
                                                                                                                                  Battery charging
                           M                                                                     G     D+
         Battery                                                                                3Y
                                                                                                       W


                        Starter motor                   Fuel valve ETR                                                                                          Exhaust Oil Coolant                                                 Oil Coolant                        Gearbox
                                                                                                Alternator
VD00402                                                                                                                                                          temp. press. temp.                                                press. temp.                        oil press.


74
Options, panel model `22'                                                                                                                                                                             10 Wiring diagram
                                                        Key switch                                                                                                                       Tachometer/
                                                                                          Engine panel model                                                              Voltmeter
                                                                                                                                                                                         hour counter

                                                                                          '20'          '21'           '22'
                                                                                                                                                                                                                 Model      20 21 22
                                                                                                                                                                                  V            n/h               Voltmeter     1
                                                                                                                                                                                                                 Tachometer  1 1



                                                                                                               -8              -7       -5      -4                                 -1     -2         -3                -6
                                                                                                        X1     31             17/19 58         15                                                    W                 95

                                                                                                                               D1        D2     D3                 D4
                                                                                                                                                                         Warning lights

                                                                                                                                        Q1
                        Red                    Yellow    Orange Violet            White   Black
                                                                                                                        L1                     BZ         L2       R3     L3        L4     L5                  L6
                        A1                     A3         A4        A2            A5      A6
                                                                                                                               R1       R2
           Plug 'A'                                                                                                                                 D5
                                                                                                                                                    D6                                                    Gearbox
          Socket 'A'                                                                                                                                D7                                                    oil press.

                        A1                     A3         A4         A2           A5      A6                                                        D8
                        Fuse or                                                                                                                     D9
                        circuit breaker
                                                                                                                                                          D10
                                                                                                                     Pre-
                                                                                                                    heating             X2M 19/94 61                    91        92     93      W
                                                                                                                                             -6    -4                    -1        -2     -5     -3

                                                Auxiliary                                                                                      B6        B4             B1        B2     B5      B3
                                                start relay          Stop relay
                                                                                                                                    Plug 'B'
                                          30   86                   30      86

              Battery                                                                                                          Socket 'B'                                                                      Socket 'C'
                main                      87   85             87a           85
               switch                                                                                                                          B6        B4             B1        B2     B5      B3                             C1   C2
                                                                                                                                                         Yellow/                                                    Brown/                      Yellow/
                                                                                                                               Transparent               Green          Green Brown Blue             Gray            Black           Blue/Red
                                                                                                                                                                                                                                                Green

                                                                                                                                                                              p                                             p                       p
                                                                                                   B+

                              M                                                                    G     D+                         Battery charging
              Battery                                                                             3Y
                                                                                                         W



                                                         Fuel valve ETR                                                                                            Exhaust Oil Coolant                                       Oil Coolant           Gearbox
                 Starter motor                                                                    Alternator
VD00401                                                                                                                                                             temp. press. temp.                                      press. temp.           oil press.


                                                                                                                                                                                                                                                                75
10 Wiring diagram                                                                                                                                                                   Options, panel model `10'

                                                    Key switch
                                                                                      Engine panel model
                                                                                                    '10'




                                                                                                           31              17/19 58       15



                                                                                                                      J3    D1     D2      D3                 D4
                                                                                                                                                                        Warning lights

                                                                                                                                  Q1
                    Red                    Yellow   Orange Violet           White     Black
                                                                                                                      L1                  BZ         L2       R2    L3       L4    L5         L6
                    A1                     A3            A4    A2           A5        A6
                                                                                                                            R1    R3
      Plug 'A'                                                                                                                                 D5
                                                                                                                                                                                         J4
                                                                                                                                               D6
     Socket 'A'                                                                                                                                D7
                    A1                     A3            A4    A2                A5   A6                                                       D8
                    Fuse or                                                                                                                    D9
                    circuit breaker
                                                                                                                                                     D10
                                                                                                                 Pre-
                                                                                                                heating                   19/94 61                 91       92    93               95
                                                                                                                                                                                         W
                                           Auxiliary                                                                                      B6        B4             B1       B2    B5      B3
                                           start relay         Stop relay
                                                                                                                              Plug 'B'
                                      30   86                  30     86

          Battery                                                                                                           Socket 'B'
                                                                                                                                                                                                   Socket 'C'
            main                      87   85            87a          85
           switch                                                                                                                         B6        B4             B1       B2    B5      B3                     C1   C2
                                                                                                                                                    Yellow/                                             Brown/
                                                                                                                            Transparent             Green          Green Brown Blue       Gray           Black        Blue/Red


                                                                                                                                                                        p                                  p      
                                                                                               B+
                                                                                                                              Battery charging
                          M                                                                    G     D+
          Battery                                                                             3Y
                                                                                                     W



                                                     Fuel valve                                                                                               Exhaust Oil Coolant                            Oil Coolant
                     Starter motor                                                            Alternator
VD00400                                                                                                                                                        temp. press. temp.                           press. temp.
                                                       ETR


76
77
11 Overall Dimensions                                         DT44

          1   2    3    4




                            1   Sea water intake 32 mm dia.
                            2   Exhaust 90 mm dia.
                            3   Fuel return 10 mm dia.
VD00480
                            4   Fuel supply: 12 mm dia.

78
DTA44                            11 Overall Dimensions

          1   2   3   4




                          1   Sea water intake 32 mm dia.
                          2   Exhaust 100 mm dia.
                          3   Fuel return 10 mm dia.
VD00482
                          4   Fuel supply: 12 mm dia.

                                                            79
11 Overall Dimensions                                         DT66

          1   2   3     4




                            1   Sea water intake 32 mm dia.
                            2   Exhaust 125 mm dia.
                            3   Fuel return 10 mm dia.
VD00481
                            4   Fuel supply: 12 mm dia.

80
DTA66                            11 Overall Dimensions

          1   2   3   4




                          1   Sea water intake 32 mm dia.
                          2   Exhaust 125 mm dia.
                          3   Fuel return 10 mm dia.
VD00483
                          4   Fuel supply: 12 mm dia.

                                                            81
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;                            Cooling system drain plug, engine block    Filling the cooling system 17, 49;
Anti-freeze 72;                              9;                                         First commissioning 15-18;
                                             Cooling system drain plug, heat exchang-   Flexible engine mounts 9, 11;
Battery 32-33;                               er 9, 11;                                  Fuel 18, 71;
Bleeding 31;                                 Cooling system drain plug, heat exchang-   Fuel consumption 65;
                                             er cover 9, 11;                            Fuel filter 8, 10;
Calorifier 17;                               Cruising 22-23;                            Fuel filter replacement 41;
Calorifier connection 8-11;                  Cylinder numbering 7;                      Fuel lift pump 8, 10;
Changing the gearbox oil 44;                                                            Fuel Quality Grade 71;
Check oil level 28;                          Data tag 6;                                Fuel return pipe connection 9, 11;
Checking coolant level 29;                   Draining the oil 34;                       Fuel supply pipe connection 8, 10;
Checking engine oil level 28;                                                           Fuel System 66;
Checking valve clearance 46;                 Electrical system 68;
Circuitbreaker 8, 10;                        Electrical system connector 8, 10;         Gearbox 9, 11;
Combustion air system 67;                    Engine installation 68;                    Gearbox filler cap/ oil dipstick 9, 11;
Connection for gearbox push-pull cable 9,    Engine Lubricating Oil 70;                 Gearbox lube oil cooler 9, 11;
11;                                          engine mounts 39;                          Gearbox Lubricating Oil 70;
Connection for throttle push-pull cable 8,   Engine Oil 15;                             Gearbox oil level check 40;
10;                                          Engine oil change 34-35;                   Gearbox, standard 68;
Control lever 19;                            Engine serial number 1;
Control panels 12-13;                        Engine specifications 64-68;               Heat exchanger 9, 11;
Coolant 72-73;                               Exhaust 67;                                hose connections 45;
Coolant level 29;                            Exhaust injection bend 9, 11;              Hydrometer 32;
Coolant pump 8, 10;                          Exhaust insulator 9, 11;

82
                                                                                                                    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;
Lifting eye 8-11;                               raw water strainer 30;                     V-belt alternator fuel pump / coolant pump
Lubricating oil 70;                             Recommissioning after winter storage 53-   8, 10;
                                                57;                                        V-belts 36-39, 68;
Maintenance 25-49;                              Running-in 18;                             Valve Clearance Adjustment Schematic
Maintenance chart 27;                                                                      47;
Maintenance schedule 26;                        Safety measures 4;                         Voltmeter 13, 22;
Manual operated stop 8, 10;                     Serial number 1, 7;
                                                Speed governor 9, 11;                      Warning light 13;
Oil cooler 8, 10;                               Starter motor 9, 11;                       Warning lights 23;
Oil dipstick 8, 10;                             Starter pre-heat switch/lock 13;           warranty conditions 2;
Oil filler cap 8, 10;                           Starting 19-21;                            water separator/fuel filter 31;
Oil filter 8, 10, 34-35;                        Stopping 24;                               Winter storage procedure 50-52;
Oil level 28;                                   strainer 30;                               Winter-grade fuel 71;
Oil lubrication system 66;                                                                 Wiring diagram 74-76;
Oil pressure gauge 13, 23;                      Tachometer 22;
Oil sump drain pump 9, 11;                      Tachometer/Operating hours counter 13;
Operating media 70-73;                          Technical data 64-69;
output 65;                                      Temperature gauge 13, 23;
Overall Dimensions 78-81;                       Topping up coolant 29;
                                                Topping up oil 28;
P.T.O. (Mounting facility for extra belt pul-   Torque wrench settings 69;
ley) 8, 10;                                     Troubleshooting 58-63;

                                                                                                                                  83
84
Manuals

Art. code   Description

STM9706     Bedieningshandleiding                         DT44 / DTA44 / DT66 / DTA66             (Nederlands)
STM9707     Operation manual                              DT44 / DTA44 / DT66 / DTA66                  (English)
STM9708     Betriebsanleitung                             DT44 / DTA44 / DT66 / DTA66                 (Deutsch)
STM9709     Manuel d'utilisation                          DT44 / DTA44 / DT66 / DTA66                (Franais)
STM9710     Manual de operacion                           DT44 / DTA44 / DT66 / DTA66                 (Espaol)
STM9711     Istruzioni per l'uso                          DT44 / DTA44 / DT66 / DTA66                  (Italiano)
STM9717     Bruksanvisning                                DT44 / DTA44 / DT66 / DTA66                    (Norsk)
STM9727     Brugsanvisning                                DT44 / DTA44 / DT66 / DTA66                   (Dansk)
STM9728     Anvndarmanual                                DT44 / DTA44 / DT66 / DTA66                (Svenska)
STM9729     Kyttopas                                    DT44 / DTA44 / DT66 / DTA66               (Suomeksi)

STM9679     Onderdelenboek / Parts manual                 DT44 / DTA44 / DT66 / DTA66   (Nederlands / English)

STM9718     Werkstatthandbuch / Workshop Manual /         DT44 / DTA44 / DT66 / DTA66      (Deutsch / English /
            Manuel d'Atelier / Manual de Taller                                            Franais / Espaol)

STM0016     Service- en Garantieboek / Service and Warranty Manual /                    (Nederlands / English /
            Service- und Garantieheft / Livret Garantie et Service /                       Deutsch / Franais /
            Manual de servicio y garanta / Libretto di assistenza e garanzia               Espaol / Italiano /
            Service- og garantibog / Service- och garantihfte                              Dansk / Svenska /
            Service- og garantibok / Huolto- ja takuukirja                                  Norsk / Suomeksi)
                                                                                 English
                                                                                 DT(A)66
                                                                                 DT(A)44
                                                                                 Vetus Diesel
FOKKERSTRAAT 571 - 3125 BD SCHIEDAM - HOLLAND - TEL.: +31 (10) 4377700
FAX: +31 (10) 4621286 - 4373474 - 4153249 - 4372673 - E-MAIL: DIESEL@ VETUS.NL
STM9707 09-04, Rev.12-04     English
Printed in the Netherlands


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