Vetus VF4.145 Installation manual

Operation manual
VF4 VF4.145
VF4.180
VF4.200
400302.01

ii

1
Operation manual
Please enter the serial numbers here.
These numbers should be quoted when inquiring about Customer
Service, Repairs or Spare Parts (see page 11).
We reserve the right to make any changes without previous notice.
Images shown in this manual may be different.
Copyright © 2018 Vetus B.V. Schiedam Holland
Serial numbers
Engine serial number:
Gearbox serial number:
VF4.145
VF4.180
VF4.200
400302.01

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 regulat-
ing system may also inuence the perfor-
mance of the engine, and its emissions. Ad-
herence to legislation on pollution cannot be
guaranteed under such conditions.

3
1 Safety measures 4
Warning indications 4
Preventing fire and explosion 5
Prevention of injury 6
When problems occur 8
2 Introduction 9
Data tag 10
Cylinder numbering 11
Identification of engine parts 12
Control lever 15
The ECU box 16
3 First commissioning 17
4 Running-in 22
5 Use 23
General guidelines 23
Starting 25
Cruising 29
Stopping 32
6 Maintenance 34
Introduction 34
Maintenance schedule 36
Checking engine oil level 38
Checking coolant level 39
Checking and cleaning the raw
water strainer 40
Draining of water from the water
separator/fuel filter 41
Engine oil change 43
Battery, cables and connections 46
Gearbox oil level check 49
Cleaning the air filter 50
Changing the gearbox oil
(Technodrive) 51
Changing the gearbox oil (ZF-Hurth) 52
Fuel filter replacement 54
Flexible engine mounts, hose
connections and fasteners 57
Raw water pump inspection 58
Coolant replacement 60
Replace drive belt 64
Checking the alternator 67
Cleaning the heat exchange 68
Cleaning the after cooler 72
7 Lay-up / Winter storage
procedure 74
8 Recommissioning after lay-
up or winter storage 86
9 Troubleshooting 92
10 Technical data 102
Engine specifications 102
Gearbox specifications 106
11 Operating media 107
Fuel 107
Lubricating oil 108
Coolant 111
12 Wiring diagrams 112
13 Overall dimensions 116
14 Parts for maintenance 120
15 Index 121
Contents

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 in-
jury or damage to the equipment can result.
• 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 re-
moved 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 both for
pleasure craft and commercial craft. Conse-
quently, a wide range of variants 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 b.v.
Dear customer,
2 Introduction

10
2 Introduction
Type:
Engine Nr.:
Weight, approx.:
Power
BSO cert.:
Mfg Date:
Meets exhaust emission regulations
acc. 2013/53/EU
Light Diesel Fuel Only (B7Allowed)
1262
123456 654321
kW HP
kg
RPM
MARINE DIESEL ENGINE
VETUS B.V. - FOKKERSTRAAT 571
SCHIEDAM 3125 BD - HOLLAND
XXXX
XX XX
XX/XXXX
VF4XXX XXXXXXXXXXXX
XXX
XXXXXXXX
Data tag
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. There is a second type plate on the ECU box.

11
1234
Serial number
Cylinder numbering
2 Introduction
3 Position of serial number
The serial number is stamped in the engine
block in the position shown.
4 Cylinder numbering
Cylinders are numbered consecutively, begin-
ning at the front end.

12
1 52 3
8
4
7 9 10 11 12 14 1615136
1. Oil cooler, gearbox
2. Fuel return pipe connection ø 8 mm
3. Oil ller cap
4. Oil dipstick
5. Oil drainage connection
6. Raw water intake, ø 32 mm
7. Gearbox lter
8. Water separator/fuel lter
9. Water separator/fuel lter drain plug
10. Fuel lift pump
11. Fuel supply pipe connection ø 8 mm
12. Starter motor
13. Potentiometer
14. Alternator
15. Oil lter
16. Connection of push-pull cable
2 Introduction Identication of engine parts

13
17. Expansion tank
18. Filler cap (pressure cap) for cooling
system
19. Air lter
20. Turbocharger
21. Airvent connection
22. Raw water pump
23. Exhaust injection bend
24. After cooler
25. Drive belt
26. Heat exchanger
27. Fuel cooler
28. Oil dipstick/Gearbox ller cap
29. Gearbox
30. Operating gearbox
Identication of engine parts
2 Introduction
17 18 19 21
24 25 26 27 28 29
20 2322
30

14
2 Introduction Control panel
2 31
6
5
4
1 Temperature gauge, coolant
2 Tachometer/Operating hours counter
3 Voltmeter
4 Oil pressure gauge
5 Display
6 Starter pre-heat switch/lock
Panel, model MPA34 CAN BS2

15
Single lever control
handle for two engines
Single lever control
handle for 1 engine
neutral
gearbox reverse gearbox forward
forward throttlereverse throttle
2 Introduction Control lever
5 Operating lever
Operating lever for 1 or 2 engines. The engine or engines are typically controlled
with a single-lever.
Depending on the brand and type (mechani-
cal or electronic), there may be minor differen-
ces in the mode of operation. Please refer to
the engine manual for details.
However, the principle is always as indicated
above.
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.

16
2 Introduction The ECU box
6 The ECU box
Fuses
The ECU box contains the electronic control
unit for the engine, the stop knob, the fuses,
the engine wiring connections and the con-
trol panel wiring connections.
The stop knob switches the ECU o if faults
may possibly have been caused by incorrect
connections made during the installation.
Press the red key in an emergency to stop
the engine.
Emergency stop

17
3 First commissioning
OIL
1 Commissioning the engine 2 Checking oil level
Before starting the engine for the rst time,
the following procedures must be carried out:
The engine is already lled with oil.
Check the oil level, see page 38.

18
3 First commissioning
22
OILOIL
Vetus engines are normally equipped
with Technodrive or ZF-Hurth gear-
boxes.
In case your engine is equipped with
another brand of gearbox follow the in-
structions given in the supplied owners
manual.
3 Filling gearbox with oil
Fill the gearbox with oil.
Check the oil level with the dipstick, see page
49.
Technodrive:
type TM345 : 1,6 litres Engine oil
SAE 20W40-CD
type TM345A : 1,6 litres, Engine oil
SAE 20W40-CD
type TM485A : 2,6 litres, Engine oil
SAE 20W40-CD
ZF Hurth:
type ZF25 : 2,5 litres, without oil cooler
type ZF25A : 1,8 litres, without oil cooler
type ZF45 : 3,0 litres, without oil cooler
type ZF45A : 2,0 litres, without oil cooler
type ZF63IV : 3,8 litres, without oil cooler
ATF: Automatic Transmission Fluid;
Transmissie olie type A, Sux A.