Vetus M2.C5 User manual

M2.C5
M2.D5
M2.06
M3.09
Operation manual
340102.04 M2C5D506/M309 EN 14-04-2005 10:33 Pagina a

VD01027
M2.06
340102.04 M2C5D506/M309 EN 14-04-2005 10:33 Pagina b

Operation manual
Please enter the serial numbers here.
These numbers should be quoted when inquiring about
Customer Service, Repairs or Spare Parts (see page 6).
1
We reserve the right to make any changes without previous
notice.
Serial numbers
Engine serial number Vetus:
Mitsubishi:
Gearbox serial number:
M2.C5 M2.D5
M2.06 M3.09
340102.04
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Please read and observe the information given in this operation
manual. This will enable you to avoid accidents, preserve the
manufacturer’s warranty and maintain the engine in peak oper-
ating condition.
For the Guarantee Conditions, see the Vetus Diesel Service and
Warrantee Manual.
This engine has been built exclusively for the application speci-
fied in the scope of supply and is to be used only for the intend-
ed 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 purpose also implies com-
pliance 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 guidelines 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 regulating system may also
influence the performance of the engine, and its emissions.
Adherence to legislation on pollution cannot be guaranteed
under such conditions.
2
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Serial numbers 1
1 Introduction 4
2 Engine description
General 6
Identification of engine parts 8
Control panels 10
3 Use
General guidelines 11
First commissioning 12
Running-in 15
Starting 16
Pre-heating 17
Cruising 19
Stopping 20
4 Routine maintenance
Introduction 21
Maintenance schedule 22
5 Maintenance
Checking the oil level 23
Checking the coolant level 24
Checking and cleaning the
raw water strainer 25
Draining water from the water
separator/fuel filter 26
(Bleeding) 26
Changing the oil 28
Battery, cables and cable
connections 30
Checking the gearbox oil level 32
Changing the gearbox oil 33
Checking valve clearance 34
Replacing the fuel filter 36
Checking the V-belt 38
Checking flexible engine mounts 39
Checking hose connections 39
Checking fastenings 39
Checking the raw water pump 40
Coolant replacement 42
Cleaning the heat exchanger 44
Checking engine rpm 47
6 Winter lay-up
Winter storage procedure 49
Recommissioning after winter
storage 51
7 Troubleshooting 54
8 Technical Data 60
9 Operating media
Lubrication Oil 65
Fuel 66
Coolant 67
10 Wiring Diagrams 68
11 Overall Dimensions 70
3
Contents
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4
1
Dear customer,
Vetus diesel engines are designed both for pleasure and com-
mercial 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 necessarily 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 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 den Ouden n.v.
Introduction
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5
1
Safety measures
Introduction
All safety instructions in this manual are desig-
nated by the accompanying symbol. Please fol-
low them carefully.
Pass the safety instructions to other persons 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 run-
ning.
•Never touch hot parts of the engine, and keep flammable
materials well away from the engine.
•Always stop the engine before checking or adjusting compo-
nents.
•Always stop the engine before checking or topping up the
coolant or oil.
•NEVER open cap on top of header tank when the engine is at
operating temperature.
•Always carry out maintenance safely by only using tools well
matched in size.
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6
2
Engine data tag
The VETUS engine serial number and per-
formance data are printed on the engine
data tag.
Model and engine serial number must be
given when ordering spare parts.
Engine data tag location
The VETUS engine data tag is attached to
the flywheel housing.
Engine serial number
The MITSUBISHI engine serial number is
stamped on the fuel injection pump.
(arrow)
Engine description General
VD01044 VD01036 VD01035
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VD00153
7
2
Cylinder numbering
Cylinders are numbered consecutively,
beginning at the front end.
Fuel pump seal
The manufacturer shall not be held liable
for damages resulting from adjustments
made to the fuel injection pump.
The maximum engine speed adjustment
screw has been sealed to prevent this.
General Engine description
VD00152 VD00150
Lead seal
Maximum
rpm adjust-
ment screw
Adjustments to the fuel pump
are to be carried out by author-
ized Vetus-Mitsubishi Service
specialists only.
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8
21 Oil filler cap
2 Raw water inlet ø20 mm
3 Raw water pump
4 Oil dipstick
5 Manual operation of fuel supply
pump
6 Oil filter
7 Water separator/fuel filter drain
plug
8 Water separator/Fuel filter
9 Connection for gearbox push-pull
cable
10 Fuse
11 Electrical system connector box
12 Fuel return pipe connection
ø8mm
13 Air inlet silencer
14 Water separator/fuel filter air bleed
nipple
15 Manual operation of electric stop
16 Fuel supply pipe connection
ø8mm
17 Fuel lift pump
18 Connection for throttle push-pull
cable
Engine description Identification of engine parts
Service side
VD01028 M2.06
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9
2
19 Gearbox
20 Gearbox drain plug
21 Gearbox oil dipstick/filler cap
22 Starter motor
23 Alternator
24 V-belt
25 Connection for extra expansion
tank (Keel cooling model only)
26 Calorifier 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 ø40 mm
Identification of engine parts
Starter side
Engine description
VD01029 M2.06
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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 *
*) This is an option, not fitted as standard.
10
2
Basic panel (model 22)
Fly-bridge panel (excl. voltmeter, model 21)
Sailingboat panel (model 10)
Engine description Control panels
VD00102
546873
12
456789 3
VD00103
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11
3
General guidelines for use
Implementing the following recommendations will result in longer
life and better performance and more economical operation of
your engine.
•Carry out the maintenance described regularly, including the
‘Daily procedures before starting’.
•Use anti-freeze in the engine coolant all year long, this helps
prevent corrosion as well as protecting against frost damage.
For specifications see page 67.
•Never run the engine without a thermostat.
•Use a good quality lubricating oil. For specifications see page
65.
•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 pressure, high coolant temperature, high raw
water temperature or battery charging lights up.
Use
General guidelines
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Commissioning the engine
Before starting the engine for the first time,
the following procedures must be carried
out:
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 65.
Check the oil level with the dipstick, see
page 23.
A second oil filling cap is located at the
distribution cover.
First commissioning
Use
12
3
Engine Oil
2 Cylinder: 2.4 litres (4 UKpt) 15W40
3 Cylinder: 3.6 litres (6 UKpt) 15W40
API: CD, CE or CF4
CCMC: D4, D5
For example:
- Vetus Marine Inboard Diesel Motor
Oil
- Shell Super Diesel T
OIL
VD01013
OIL
VD01002
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13
3
Filling gearbox with oil
Fill the gearbox with oil.
Check the oil level with the dipstick, see
page 32.
ZF Hurth:
type HBW50 : 0,3 litres (1/2 UKpt)
type HBW100 : 0,35 litres (2/3 UKpt)
type HSW150V : 1,0 litre (1 3/4 UKpt)
ATF: Automatic Trans-
mission Fluid type A,
Suffix A.
Technodrive:
type TMC40 : 0,20 litres (1/3 UKpt),
Engine oil SAE 20/30
First commissioning Use
OIL OIL
VD01024 17 27
VD01024
Vetus engines are normally equipped with
ZF-Hurth or Technodrive gearboxes.
In case your engine is equipped with
another brand of gearbox follow the
instructions given in the supplied owners
manual.
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14
3
Filling the cooling system
Remove the cap of the filler 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
special coolant.
For specifications see page 67.
The level of the coolant must be approx. 1
cm (3/8”) below the lower edge of the filler
neck.
Bleeding will take place automatically dur-
ing filling!
Replace the filler cap.
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.
Use First commissioning
WATER HEATER
If a water heater is connected to the
engine and this heater is positioned
above the upper side of the engine
then bleeding of the heater will not take
place automatically! Fill the heater sep-
arately to bleed the cooling system
completely.
Never fill the cooling sys-
tem with sea water or
brackish water.
VD01005
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y
y
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yy
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;;;yyy
;y
;
;
;
;
y
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;;;;;
;;;;;
;;;;;
yyyyy
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VD00158VD01004
COOLANT 2 CIL.: 2.2 litres (4 UKpt)
QUANTITIES :3CIL.: 3.0 litres (5 UKpt)
(3/8”)
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15
3
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 66.
Bleed the fuel system, see page 26.
Other preparations
•Check battery and cable connections.
•Start the engine, see page 16, and let it
run for about 10 minutes without load.
Check the engine and all connections
(fuel, cooling water and exhaust) for
leaks.
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.
First commissioning
Running-in
Use
FUEL
VD00002
Never fill the fuel tank while
the engine is running. Do
not spill fuel. Prevent
unnecessary pollution.
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16
3
After repair work:
Check that all guards have been replaced
and that all tools have been removed from
the engine.
When starting with pre-heating, do not use
any other substance (e.g. injection with
‘Easy Start’). Doing so could result in an
accident.
Preparation starting
Before starting the engine, always check
that the control lever(s) is (are) in the neu-
tral position.
Never start the engine
with the fuel injection
pump removed.
Disconnect battery.
Set the control lever to ‘half throttle’with-
out engaging the gearbox.
Use Starting
Before starting, ALWAYS check the follow-
ing points:
•Engine oil level.
•Coolant level.
•Sea cock open.
•Main switch ‘ON’.
•Gearbox in ‘NEUTRAL’position.
neutral
gearbox
forward half throttle,
gearbox not engaged
gearbox
reverse
reverse
throttle
forward
throttle
VD00111 VD00112
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17
3
Turn the start key on the instrument panel
clock-wise; the warning lights for oil pres-
sure and alternator will now light up and
the alarm buzzer will sound.
Pre-heating
Turn the key further clockwise to the ‘’
position; only the pre-heating indicator
light will be lit now.
Hold the key in this position for about 6
seconds.
Pre-heating time
The ideal pre-heating time depends on
ambient temperature; the lower the ambi-
ent temperature, the longer the pre-heat-
ing time required. See table.
WARNING
To prevent the glow plugs
from burning out, never
exceed the stated maximum
pre-heating time.
Starting Use
Ambient Pre-heating time
Temperature
Above + 5°C (41°F) about 6 seconds
+5°C to -5°Cabout 12 seconds
(+41°F to +23°F)
Below -5°C (23°F) about 18 seconds
Maximum 1 minute
pre-heating time
VD00107 VD00108
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18
3
WARNING
Never turn the key to the ‘START’posi-
tion while the engine is running.
Doing so will damage the starter motor.
Starting
Now turn the key further to the ‘START’
position.
Release the key as soon as the engine
fires (the key will return to the ‘ON’posi-
tion) and throttle back.
Leave the key in this position while the
engine is running.
Check that the indicator lights for oil pres-
sure and alternator are off. Cooling water
should now flow out of the exhaust; if this
is not the case, stop the engine immedi-
ately. Before submitting the engine to full
load it should be brought up to operating
temperature as quickly as possible by run-
ning at 3/4 of maximum revs. NEVER turn
the main switch off while the engine is run-
ning.
The instrument panel is provided with the
following instruments (Depending of the
type of panel, see page 10).
Use Starting
WARNING
Release the key if the engine does not
fire within 10 seconds. Wait until the
starter motor has stopped running
completely before turning the key to
the ‘START’position again. Never allow
the starter motor to run for more than
30 seconds consecutively.
VD00109
VD00110
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