Vetus M2.02 User manual

Operation manual
M2
M2.02
M2.06

ii

1
Operation manual
Please enter the serial numbers here.
These numbers should be quoted when inquiring about Customer Ser-
vice, Repairs or Spare Parts (see page 6).
We reserve the right to make any changes without previous notice.
Copyright © 2012 Vetus N.V. Schiedam Holland
Serial numbers
Engine serial number Vetus:
Engine serial number Mitsubishi:
Gearbox serial number:
M2.02
M2.06
340802.01

2
Please read and observe the information giv-
en in this operation manual. This will enable
you to avoid accidents, preserve the manu-
facturer’s warranty and maintain the engine
in peak operating condition.
Make sure that the manual will remain intact
and damage is prevented. Keep the manual
away from humidity and heat.
Do not alter the content of the manual.
The manual is an integral part of the engine.
Hand over the manual tot the new owner if
boat or engine is being sold.
For the Guarantee Conditions, see the Ve-
tus Diesel ‘Service and Warranty Manual’
(320199.06).
This engine has been built exclusively for the
application specied in the scope of sup-
ply 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 as-
sume 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 con-
ditions 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 guidelines
and other generally accepted safety and
industrial hygiene regulations must be ob-
served.
Unauthorized engine modications will in-
validate any liability claims against the man-
ufacturer for resultant damage.
Manipulations of the injection and regulating
system may also inuence the performance
of the engine, and its emissions. Adherence
to legislation on pollution cannot be guaran-
teed under such conditions.

3
Contents
1 Safety measures 4
Warning indications 4
Preventing re and explosion 5
Prevention of injury 6
When problems occur 8
2 Introduction 9
Data tag 10
Serial number 10
Cylinder numbering and direction
of rotation 11
Fuel pump seal 11
Identication of engine parts 12
Control panels 14
Control lever 15
3 First commissioning 16
4 Running-in 25
5 Use 26
General guidelines 26
Starting 28
Cruising 32
Stopping 34
6 Maintenance 36
Introduction 36
Maintenance schedule 38
Checking engine oil level 40
Checking and cleaning the raw
water strainer 41
Checking coolant level 42
Draining of water from the water
separator/fuel lter 44
Engine oil change 47
Battery, cables and connections 50
Gearbox oil level check 54
Fuel lter replacement 55
Bleeding, after fuel lter replace-
ment 57
Changing the gearbox oil (Techn-
odrive) 58
Changing the gearbox oil (ZF-
Hurth) 59
Checking valve clearance 60
Checking the V-belt 62
Flexible engine mounts, hose con-
nections and fasteners 63
Raw water pump inspection 64
Coolant replacement 66
Checking the starter motor and
alternator 70
Checking engine speed 71
Cleaning the heat exchanger 72
7 Winter storage procedure 76
8 Recommissioning after win-
ter storage 84
9 Troubleshooting 90
9 Troubleshooting 97
10 Technical data 100
Engine specications 100
Gearbox specications 103
Torque wrench settings 104
11 Operating media 105
Fuel 105
Lubricating oil 106
Coolant 109
12 Wiring diagram 110
13 Overall dimensions 112
14 Index 113

4
1 Safety measures
Danger
Indicates that great potential danger exists
that can lead to serious injury or death.
Warning
Indicates that a potential danger that can lead
to injury exists.
Caution
Indicates that the usage procedures, actions
etc. concerned can result in serious damage
to or destruction of the engine. Some CAU-
TION indications also advise that a potential
danger exists that can lead to serious injury or
death.
note
Emphasises important procedures, circum-
stances etc.
Symbols
Indicates that the relevant procedure
must be carried out.
Indicates that a particular action is for-
bidden.
Pass the safety precautions on to other peo-
ple who will use the engine.
General rules and laws concerning safety
and accident prevention must always be ob-
served.
Warning indications
The following warning indications are used in
this manual in the context of safety:
Warning indications

5
1 Safety measures
• Do not smoke if refuelling.
• Avoid spilling fuel on hot surfaces. Spilled
fuel must be cleaned up immediately.
• Do not use petrol or diesel to clean compo-
nents but make use of good quality, non-
inammable, non-poisonous solvents that
are available from dealers.
• Always be alert to possible fuel or oil leak-
age!
If you discover a leak, take counter-meas-
ures immediately. If fuel or oil is spilled on
a hot engine, re can break out. This can
cause physical injury or damage to the
equipment.
• Do not ll the fuel tank while the engine is
running!
Only refuel with the engine stopped.
• Never put ammable materials in the vicin-
ity of the engine!
• Keep the engine and engine compartment
clean!
Remove all inammable materials such as
fuel, oil and other litter before it builds up
in the vicinity of the engine.
• Connecting (emergency) extra starting bat-
tery
Proceed as follows when an extra starting
battery is used to jump start the engine:
-First connect the positive lead
-Lastly connect the earth cable (negative
pole) to the engine block
If this cable is connected in error to the
negative pole of the engine battery, a
spark can occur. The result of this could
be that explosive gas produced by the
battery explodes.
-Once the engine is started, rst remove the
earth cable.
Preventing re and explosion
Fire risk!

6
1 Safety measures Prevention of injury
• The moving parts of the engine are danger-
ous. Never touch moving parts of the en-
gine while it is running, to prevent cuts and
other injuries.
• Stop the engine before carrying out main-
tenance!
• Always stop the engine before topping up
or replacing fuel, oil or coolant.
• Before carrying out inspection or mainte-
nance, the ignition key must be removed
and the main battery switch turned o.
• Satisfy yourself that everything is in order
before the engine is started again!
Make sure that no-one is working on or
close to the engine before you start it. Re-
move all foreign objects from around the
engine, such as litter, oil, tools and other
components that are not part of the engine.
• Install all protective covers!
To prevent injury, make sure that all protec-
tive covers and cover plates are replaced
over moving parts.
• Remove any tool used to turn the engine
over. If you leave this in position, serious
injury or damage to the equipment can re-
sult.
• NEVER open the cap of the expansion tank
when the engine is at working temperature.
• Only check the coolant level after the en-
gine has been stopped and the ller cap
on the heat exchanger is cool enough to be
removed with bare hands.
• Never attempt to adjust the fan belt on a
running engine.

7
1 Safety measures Prevention of injury
• Be careful with battery acid!
If battery acid comes in contact with the
eyes or skin, rinse the aected part imme-
diately with copious amounts of water. If
battery acid comes in contact with the eyes,
rinse them out immediately with plenty of
water and consult a doctor.
• Be careful with antifreeze!
If you accidentally swallow antifreeze, make
yourself vomit and consult a doctor imme-
diately. If antifreeze comes in contact with
your eyes, wash them out immediately with
plenty of water and consult a doctor.
• Make sure that you are wearing suitable
clothing before starting work!
For your own safety you will most likely
need special equipment – safety helmet,
eye protection, safety boots, safety gog-
gles, heavy gloves, ear protectors etc. Use
them when necessary.
• Carry out maintenance procedures safely
by only using suitable tools.
• Exhaust gases
Do not start the engine if the exhaust sys-
tem is not connected.

8
When the engine stops suddenly:
If the engine stops suddenly, do not start it
again immediately. Track down the cause and
carry out the necessary repairs before you
start the engine again. If you do not do this,
serious engine problems can develop.
If the oil pressure is too low:
Stop the engine immediately and check the
lubrication system. Running an engine with
low oil pressure can cause bearing and other
parts to seize.
lf the engine overheats:
If the engine should overheat, do not switch
it o immediately. If an overheated engine is
stopped suddenly, this can cause the coolant
temperature to rise rapidly and moving parts
to seize. First let the engine run in neutral to al-
low the hot parts of the engine to cool down,
stop the engine and allow it to cool, and then
gradually top up the coolant. Remember:
adding coolant to an overheated engine can
cause damage to the cylinder head.
If the fan belt is broken:
Immediately stop the engine. If an engine is
used with a broken fan belt, this can lead to
the engine overheating, which in turn can
cause coolant to spray out of the expansion
tank.
If the engine behaves strangely:
Stop the engine or reduce the speed as far as
possible.
Do not use the engine again until the cause of
the defect has been solved.
1 Safety measures When problems occur

9
Vetus diesel engines are designed for pleas-
ure craft. Consequently, a wide range of vari-
ants are oered to meet the requirements of
specic cases.
Your engine is appropriately equipped for
your vessel, which means that not necessarily
all components described in this manual are
mounted to your engine.
We have endeavoured to highlight any dier-
ences so that you will able to locate the oper-
ating and maintenance instructions 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 additional
inquiries.
Sincerely,
Vetus n.v.
2 Introduction
Dear customer,

10
2 Introduction Data tag
Serial number
1 Engine data tag
The Vetus engine serial number and perfor-
mance data are printed on the engine data
tag.
Model and engine serial number must be giv-
en when ordering spare parts.
2 Engine data tag location
The type plate is positioned as shown.
3 Engine serial number
The Mitsubishi engine serial number is
stamped on the fuel injection pump. (arrow)
VD01036 VD01044 VD01035

Lead seal
Maximum speed
adjustment screw
11
2 Introduction Cylinder numbering and direction of rotation
Fuel pump seal
4 Cylinder numbering and direction of
rotation
Cylinder numbering
Cylinders are numbered consecutively, begin-
ning at the front end.
Direction of rotation
The direction of rotation is viewed towards
the ywheel counter clockwise.
5 Fuel pump seal
Caution
Breaking the seals on the regulator to alter
the settings of maximum rpm and maximum
injector volume may only be carried out by
authorised Vetus Service personnel.
Breaking the seals and altering the settings
can lead to:
-Accelerated wear of engine components.
-Increased fuel and oil consumption.
-Incorrectly adjusted injector volume and
poor engine performance.
-Breaking emission regulations.
VD00930 VD00922

1235 46789
1 171614 1513121110 18
12
2 Introduction Identication of engine parts
Service side
1 Oil ller cap
2 Raw water inlet ø 20 mm
3 Raw water pump
4 Oil dipstick
5 Manual operation of fuel supply pump
6 Oil lter
7 Water separator/fuel lter drain plug
8 Water separator/Fuel lter
9 Connection for gearbox push-pull cable
10 Fuse
11 Electrical system connector box
12 Fuel return pipe connection ø 8 mm
13 Air inlet silencer
14 Water separator/fuel lter air bleed
nipple
15 Manual operation of electric stop
16 Fuel supply pipe connection ø 8 mm
17 Fuel lift pump
18 Connection for throttle push-pull cable
VD01253

19
20
212223
30 31, 2628 2925, 26, 2724 32 33
13
2 Introduction Identication of engine parts
Starter side
19 Gearbox
20 Gearbox drain plug
21 Gearbox oil dipstick/ller cap
22 Starter motor
23 Alternator
24 V-belt
25 Connection for extra expansion tank
(Keel cooling model only)
26 Calorier connection
27 Cooling system air bleed nipple
28 Filler cap for cooling system
29 Expansion tank
30 Heat exchanger
31 Cooling system drain plug
32 Airvent connection
33 Exhaust injection bend ø 40 mm
VD01254

53
78
6
49
1 2
53
7
8
6
4
14
8 Indicator light pre-heating
9 Warning light gearbox low oil pressure [1]
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
2 Introduction Control panels
Basic panel, model 22
Fly-bridge panel, excl. voltmeter, model 21
Sailingboat panel, model 10
VD00576 VD00575
[1] This is an option, not tted as standard.

Single lever control
handle for two engines
Single lever control
handle for 1 engine
neutral
gearbox reverse gearbox forward
forward throttlereverse throttle
15
2 Introduction Control lever
6 Operating lever
Operating lever for 1 or 2 engines. The control lever works as shown in the dia-
gram.
Starting from neutral put the engine in ahead
or astern by moving the lever 35° forwards or
backwards.
The throttle lever operates at an angle of 60°
forwards and 60° reverse.
VD00788

OIL OIL
16
3 First commissioning
1 Commissioning the engine
Before starting the engine for the rst 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 ller
neck on top of the valve cover.
For quantity and oil specication see page
102 and 106.
• Check the oil level with the dipstick, see
page 40.
A second oil lling cap is located at the distri-
bution cover.
Engine Oil
2.4 litres 15 W40
(4.2 Imp. pt, 5.1 US pt)
API: CF4, CG4, CH4, CI4
ACEA: A3/B3, A3/B4, E7
For example:
-Vetus Marine Diesel Engine Oil 15W40
-Shell Rimula R4 L 15W40
VD01013 VD01002

27 17
OIL OIL
17
3 First commissioning
3 Filling gearbox with oil
• Fill the gearbox with oil.
• Check the oil level with the dipstick, see
page 42.
Technodrive:
type TMC40P : 0.2 litres, ATF [1]
(0.35 Imp. pt, 0.42 US pt)
type TMC60A : 0.6 litres, ATF [1]
(1.05 Imp. pt, 1.25 US pt)
ZF Hurth:
type ZF10M : 0,42 litres ATF [1]
(0.73 Imp. pt, 0.89 US pt)
Vetus engines are normally equipped
with Technodrive or ZF-Hurth gearboxes.
In case your engine is equipped with
another brand of gearbox follow the in-
structions given in the supplied owners
manual.
[1] ATF :Automatic Transmission Fluid;
Transmissie olie type A, Sux A.
[1] ATF :Automatic Transmission Fluid;
Transmissie olie type A, Sux A.
VD01033 VD01034

1 cm
(3/8”)
COOLANT
17
COOLANT
18
3 First commissioning
4 Filling the cooling system,
interCooling
,
• Remove the cap of the ller neck on the top
of the heat exchanger housing.
• Remove the bolt from the upper side of the
thermostat cover, so that air can escape
from the cooling system.
• Fill the cooling system.
Use a mixture of 40% antifreeze (ethylene-
glycol based) and 60% tap water or use a spe-
cial coolant.
For specications see page 109.
The level of the coolant must be approx. 1 cm
(3/8”) below the lower edge of the ller neck.
Bleeding will take place automatically during
lling!
• Replace the ller cap.
• Reinstall the bolt in the thermostat cover..
Coolant quantity
: 2.2 litres
(3.9 Imp. pt, 4.6 US pt)
VD01005 VD01004 VD00158
note
If a water heater is connected to the engine,
see page 20 and 21.
Caution
Never ll the cooling system with sea water or
brackish water.