Vetus DEUTZ DT44 User manual

Operation manual
DT44 DTA44
DT66 DTA66

VD00466
DT44
Copyright © 2004 Vetus den Ouden n.v. Schiedam Holland

Operation manual
1
Serial numbers
Engine serial number Vetus:
Deutz:
Gearbox serial number:
DEUTZ
DT44 DTA44
DT66 DTA66
STM9707 Rev. 12-04
Please enter the serial numbers here.
These numbers should be quoted when inquiring about
Customer Service, Repairs or Spare Parts (see page 6).
We reserve the right to make any changes without previous
notice.

Please read and observe the information
given in this operation manual. This will
enable you to avoid accidents, preserve
the manufacturer’s warranty*) and main-
tain the engine in peak operating condi-
tion.
This engine has been built exclusively for
the application specified in the scope of
supply and is to be used only for the
intended purpose. Any use exceeding
that scope is considered to be contrary to
the intended purpose. The manufacturer
will not not assume responsibility for any
damage resulting therefrom. The risks
involved are to be borne by the user.
Use in accordance with the intended pur-
pose also implies compliance with the
conditions laid down by the manufacturer
for operation, maintenance and servicing.
The engine should only be operated,
maintained and serviced by persons
which are familiar with the former and the
hazards involved.
The relevant accident prevention guide-
lines and other generally accepted safety
and industrial hygiene regulations must
be observed.
Unauthorized engine modifications will
invalidate any liability claims against the
manufacturer for resultant damage.
Manipulations of the injection and regu-
lating system may also influence the per-
formance of the engine, and its emis-
sions. Adherence to legislation on pollu-
tion cannot be guaranteed under such
conditions.
*) For warranty conditions see ‘Service
and Warranty Manual’ STM0016.
2

1 Safety measures 4
2 Introduction 5
Data tag 6
Engine serial number 7
Cylinder numbering 7
Identification of engine parts 8
Control panels 12
3 Use
General guidelines 14
First commissioning 15
Running-in 18
Starting 19
Cruising 22
Stopping 24
4 Maintenance
Introduction 25
Maintenance schedule 26
Maintenance chart 27
Checking the oil level 28
Checking the coolant level 29
Checking and cleaning the
raw water strainer 30
Draining water from the water
separator/fuel filter 31
Battery, cables and cable
connections 32
Changing the oil 34
Checking the V-belts 36
Replacing the V-belt 38
Checking the gearbox oil level 40
Replacing the fuel filter 41
Checking the raw water pump 42
Changing the gearbox oil 44
Combustion air intake 45
Flexible engine mounts 45
Hose connections 45
Checking valve clearance 46
Coolant replacement 46
5 Winter storage procedure 50
6 Recommissioning after
winter storage 53
7 Troubleshooting 58
8 Technical Data 64
9 Operating media
Lubrication Oil 70
Fuel 71
Coolant 72
10 Wiring Diagrams 74
11 Overall Dimensions 78
12 Index 82
3
Contents

4
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-
sons operating the engine as well.
General regulations and laws for safety
and accident prevention must also be
observed.
• Never attempt to touch moving parts
when the engine is running.
• Never touch hot parts of the engine,
and keep flammable materials well
away from the engine.
• Always stop the engine before check-
ing or adjusting components.
• Always stop the engine before check-
ing or topping up the coolant or oil.
•NEVER open cap on top of header tank
when the engine is at operating tem-
perature.
• Always carry out maintenance safely
by only using tools well matched in
size.

5
Dear customer,
2 Introduction
Vetus Deutz engines are designed both
for pleasure and commercial craft.
Consequently, a wide range of variants
are offered to meet the requirements of
specific cases.
Your engine is appropriately equipped for
your vessel, which means that not neces-
sarily all components described in this
manual are mounted to your engine.
We have endeavoured to highlight any
differences so that you will able to locate
the operating and maintenance instruc-
tions relevant to your engine quickly and
easily.
Please read this manual before starting
your engine and always observe the
operating and maintenance instructions.
We are available to help with any addi-
tional inquiries.
Sincerely, Vetus den Ouden n.v.

D
6
1 Engine data tag
Model (A), Deutz engine serial number (B)
and performance data are stamped on the
engine data tag.
Model and engine serial number must be
given when ordering spare parts.
2 Engine data tag location
The DEUTZ engine data tag (C) is attached
to the crank case.
The VETUS engine data tag is attached to
the valve cover.
2 Introduction Data tag
DTA44452
778959
A
2500 103 140
200001
VD00496 VD00846 VD00485

7
3 Engine serial number
The DEUTZ engine serial number is
stamped at the indicated spot.
4 Cylinder numbering
Cylinders are numbered consecutively,
beginning at the flywheel end.
Serial number, Cylinder numbering 2 Introduction
VD00031
VD00465

8
1 Oil filler cap
2 Lifting eye
3 Alternator
4 Filler cap for cooling system
5 Calorifier connection, engine ‘IN’
6 V-belt alternator
7 Coolant pump
8 V-belt alternator fuel pump /
coolant pump
9 P.T.O. (Mounting facility for extra
belt pulley)
10 Fuel lift pump
11 Fuel supply pipe connection
ø12 mm
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 ø32 mm
18 Raw water pump
19 Circuitbreaker
20 Electrical system connector
21 Connection for throttle push-pull
cable
22 Manual operated stop
2 Introduction Identification of engine parts
1 2 3 4
13 12 11 10 9141516
20
18
17
19
21 22 23 24
8
6
7
5
Service side DT44, DT66
VD00461

9
23 Fuel return pipe connection
ø10 mm
24 Calorifier connection, engine ‘OUT’
25 Exhaust insulator
26 Starter motor
27 Lifting eye
28 Exhaust injection bend
29 Turbocharger
30 Speed governor
31 Air intake filter
32 Gearbox lube oil cooler
33 Gearbox filler cap/ oil dipstick
34 Connection for gearbox push-pull
cable
35 Gearbox
36 Flexible engine mounts
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
Identification of engine parts 2 Introduction
28 29
37 35
3839
3026 27
34
32
33
31
40
41 36
25
Starter side DT44, DT66
VD00462

10
1 Oil filler cap
2 Lifting eye
3 Alternator
4 Filler cap for cooling system
5 Calorifier connection, engine ‘IN’
6 V-belt alternator
7 Coolant pump
8 V-belt alternator fuel pump /
coolant pump
9 P.T.O. (Mounting facility for extra
belt pulley)
10 Fuel lift pump
11 Fuel supply pipe connection
ø12 mm
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 ø32 mm
18 Raw water pump
19 Circuitbreaker
20 Electrical system connector
21 Connection for throttle push-pull
cable
22 Manual operated stop
2 Introduction Identification of engine parts
1 2 3 4
13 12 11 10 9141516
20
18
17
19*
21* 22* 23* 24
8
6
7
5
25
Service side DTA44, DTA66
VD00463

11
23 Fuel return pipe connection
ø10 mm
24 Calorifier connection, engine ‘OUT’
25 Aftercooler
26 Exhaust insulator
27 Starter motor
28 Lifting eye
29 Exhaust injection bend
30 Turbocharger
31 Speed governor
32 Air intake filter
33 Gearbox lube oil cooler
34 Gearbox filler cap/ oil dipstick
35 Connection for gearbox push-pull cable
36 Gearbox
37 Flexible engine mounts
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
identification; part numbers are
identical
Identification of engine parts 2 Introduction
29 30
38 36
3940
3127 28
35
33
34
32
41
42 37
26
Starter side DTA44, DTA66
VD00464

12
Basic panel (model 34) Fly-bridge panel (model 22)
2 Introduction Control panels
12
456789 3
VD00103
12
456789 3
10
11
VD00104

13
Control panels 2 Introduction
VD00102
546873
VD00101
4567
8
12
13 15
14
1 Tachometer/Operating hours counter
2 Voltmeter
3 Starter pre-heat switch/lock
4 Warning light high raw water temperature
5 Warning light low oil pressure
6 Warning light high coolant temperature
7 Warning light battery charging
8 Indicator light pre-heating
9 Warning light gearbox low oil pressure *)
10 Temperature gauge, coolant
11 Oil pressure gauge
12 On push button switch
13 Pre-heating push button switch
14 Starter push button switch
15 Stop push button switch
*) This is an option, not fitted as standard.
Sailingboat panel (model 10) Push button panel (model 00)

14
General guidelines for use
Implementing the following recommenda-
tions will result in longer life and better
performance and more economical oper-
ation of your engine.
•Carry out the maintenance described
regularly, including the ‘Daily proce-
dures before starting’.
•Use anti-freeze in the engine coolant
all year long, this helps prevent corro-
sion as well as protecting against frost
damage. For specifications see page
72.
•Never run the engine without a ther-
mostat.
•Use a good quality lubricating oil. For
specifications see page 70.
•Use a good quality diesel fuel that is
free of water and other pollutants.
•Always stop the engine immediately if
one of the warning lamps for oil pres-
sure, high coolant temperature, high
raw water temperature or battery
charging lights up.
General guidelines
3 Use

15
1 Commissioning the engine
Before starting the engine for the first time,
the following procedures must be carried
out:
2 Filling with engine oil
As a rule engines are delivered empty of
oil.
Fill the engine with oil through the filler
neck on top of the valve cover, for quanti-
ty and specification see page 70.
Check the oil level with the dipstick, see
page 28.
Engine Oil
4 cyl.: 8.5 litres 10W40 or 15W40
(1.9 UK gal)
6 cyl.: 14 litres 10W40 or 15W40
(3.1 UK gal)
API: CD, CE, CF or CF4
CCMC: D4, D5
For example:
- Vetus Marine Inboard Diesel Motor Oil
- Shell Super Diesel T
☞
First commissioning 3 Use
OIL
VD00012

16
3 Filling gearbox with oil
Vetus engines are normally equipped with
ZF-Hurth gearboxes.
In case your engine is equipped with
another brand of gearbox follow the
instructions given in the supplied owners
manual.
Fill the gearbox with oil.
Check the oil level with the dipstick, see
page 40.
Oil gearbox
model ZF45 : 2.0 litres (3.5 UK pt) ATF
model ZF45A : 3.0 litres ( 5.3 UK pt) ATF
model ZF63 : 3.8 litres (6.7 UK pt) ATF
model ZF63A : 4.0 litres (7 UK pt) ATF
*) ATF: Automatic Transmission Fluid;
type A, Suffix A.
For example : Shell Donax T6
Gulf Dextron
☞
3 Use First commissioning
VD00469
OIL

Remove the cap of the filler neck on the
top of the header tank.
Fill the cooling system.
Use a mixture of 40% antifreeze (ethylene-
glycol based) and 60% tap water or use a
special coolant.
For specifications see page 72.
The level of the coolant must be at the
lower edge of the filler neck.
Replace the filler cap.
Bleeding will take place automatically dur-
ing filling!
After the engine has run for the first time
and has reached operating temperature
and has cooled down again to ambient
temperature, check the coolant level in the
heat exchanger housing.
If necessary, add coolant.
Caution!
Never fill the cooling system with sea
water or brackish water.
3 Use
17
VD00473
VD00477
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.
☞
COOLANT
4 Filling the cooling system
First commissioning
COOLANT 4 CYL.: 8.5 litres (1.9 UK gal)
QUANTITY :6CYL.: 12 litres (2.6 UK gal)

18
5 Fuel
Ensure that the fuel tank is filled with
diesel fuel.
Use only clean, water-free, commercial
approved diesel fuel.
For fuel grade see page 71.
The fuel system is self-bleeding.
6 Other preparations
•Check battery and cable connections.
•Start the engine, see page 19, and let it
run for about 10 minutes without load.
Check the engine and all connections
(fuel, cooling water and exhaust) for
leaks.
•Check tension of the V-belt, see page
36.
Running-in
In order to ensure a long life for your
engine, please observe the following for
the first 50 operating hours:
•Allow the engine to reach operating
temperature before applying a load.
•Avoid fast acceleration.
•Do not allow the engine to run faster
than 3/4 of maximum RPM.
3 Use First commissioning
Running-in
FUEL
VD00002
Warning!
Never fill the fuel tank while the engine is
running. Do not spill fuel. Prevent unne-
cessary pollution.