M2 M3 M2.

C5
M2.D5
M2.06
Operation manual M3.09
 Operation manual M2.C5 M2.D5
M2.06 M3.09

Serial numbers

Engine serial number Vetus:

Mitsubishi:

Gearbox serial number:

Please enter the serial numbers here.

These numbers should be quoted when inquiring about Customer
Service, Repairs or Spare Parts (see page 6).
340102.04

We reserve the right to make any changes without previous

notice.
Copyright © 2009 Vetus N.V. Schiedam Holland
1
Please read and observe the information given in this operation pliance with the conditions laid down by the manufacturer for
manual. This will enable you to avoid accidents, preserve the operation, maintenance and servicing. The engine should only
manufacturer’s warranty and maintain the engine in peak operat- be operated, maintained and serviced by persons which are
ing condition. familiar with the former and the hazards involved.

For the Guarantee Conditions, see the Vetus Diesel Service and The relevant accident prevention guidelines and other gener-
Warrantee Manual. ally accepted safety and industrial hygiene regulations must be
observed.
This engine has been built exclusively for the application speci-
fied in the scope of supply and is to be used only for the intended Unauthorized engine modifications will invalidate any liability
purpose. Any use exceeding that scope is considered to be claims against the manufacturer for resultant damage.
contrary to the intended purpose. The manufacturer will not not
assume responsibility for any damage resulting therefrom. The Manipulations of the injection and regulating system may also
risks involved are to be borne by the user. influence the performance of the engine, and its emissions.
Adherence to legislation on pollution cannot be guaranteed
Use in accordance with the intended purpose also implies com- under such conditions.

2
Contents
Serial numbers 1 5 Maintenance 6 Winter lay-up
Checking the oil level 23 Winter storage procedure 49
1 Introduction 4 Checking the coolant level 24 Recommissioning after winter
Checking and cleaning the storage 51
2 Engine description raw water strainer 25
General 6 Draining water from the water 7 Troubleshooting 54
Identification of engine parts 8 separator/fuel filter 26
Control panels 10 (Bleeding) 26 8 Technical Data 60
Changing the oil 28
3 Use Battery, cables and cable 9 Operating media
General guidelines 11 connections 30 Lubrication Oil 65
First commissioning 12 Checking the gearbox oil level 32 Fuel 66
Running-in 15 Changing the gearbox oil 33 Coolant 67
Starting 16 Checking valve clearance 34
Pre-heating 17 Replacing the fuel filter 36 10 Wiring Diagrams 68
Cruising 19 Checking the V-belt 38
Stopping 20 Checking flexible engine mounts 39
11 Overall Dimensions 70
Checking hose connections 39
4 Routine maintenance Checking fastenings 39
Introduction 21 Checking the raw water pump 40
Maintenance schedule 22 Coolant replacement 42
Cleaning the heat exchanger 44
Checking engine rpm 47

3
Introduction

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 n.v.

4
 Introduction
Safety measures

All safety instructions in this manual are desig- • Never attempt to touch moving parts when the engine is run-
nated by the accompanying symbol. Please follow ning.
them carefully.
• Never touch hot parts of the engine, and keep flammable
materials well away from the engine.
Pass the safety instructions to other persons operating the
engine as well. • Always stop the engine before checking or adjusting compo-
nents.
General regulations and laws for safety and accident prevention
must also be observed. • 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.

5
Engine description General

VD01044 VD01036 VD01035

Engine data tag Engine data tag location Engine serial number

The Vetus engine serial number and per- The Vetus engine data tag is attached to The Mitsubishi engine serial number
formance data are printed on the engine the flywheel housing. is stamped on the fuel injection pump.
data tag. (arrow)

Model and engine serial number must be

given when ordering spare parts.

6
General Engine description

Maximum
rpm adjust-
ment screw

Lead seal

Adjustments to the fuel pump

are to be carried out by author-
ized Vetus-Mitsubishi Service
specialists only.
VD00152 VD00153 VD00150

Cylinder numbering Fuel pump seal

Cylinders are numbered consecutively, The manufacturer shall not be held liable
beginning at the front end. for damages resulting from adjustments
made to the fuel injection pump.
The maximum engine speed adjustment
screw has been sealed to prevent this.

7
Engine description Identification of engine parts
Service side

1 Oil filler cap

2 Raw water inlet ø 20 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
ø 8 mm
13 Air inlet silencer
14 Water separator/fuel filter 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 M2.06
VD01028

8
Identification of engine parts Engine description
Starter side

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 ø 40 mm

M2.06
VD01029

9
Engine description Control panels

1 2

5 4 6 8 7 3

4 5 6 7 8 9 3
VD00576 VD00575

Basic panel (model 22) Sailingboat panel (model 10)

Fly-bridge panel (excl. voltmeter, model 21)
1 Tachometer/Operating hours counter 7 Warning light battery charging
2 Voltmeter 8 Indicator light pre-heating
3 Starter pre-heat switch/lock 9 Warning light gearbox low oil pressure *
4 Warning light high raw water temperature
*) This is an option, not fitted as standard.
5 Warning light low oil pressure
6 Warning light high coolant temperature
10
General guidelines Use
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.

11
Use First commissioning

Engine Oil
OIL 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 Diesel Engine Oil 15W-40
- Shell Nautilus Premium Inboard
15W-40

VD01013 VD01002

Commissioning the engine Filling with engine oil

Before starting the engine for the first time, As a rule engines are delivered empty of A second oil filling cap is located at the
the following procedures must be carried oil. distribution cover.
out: Fill the engine with oil through the filler
neck on top of the valve cover, for quantity
and specification see page 65.

Check the oil level with the dipstick, see

page 23.

12
First commissioning Use
Vetus engines are normally equipped with
ZF-Hurth or Technodrive gearboxes. OIL OIL
In case your engine is equipped with
another brand of gearbox follow the
instructions given in the supplied owners
manual.

VD01024
17 VD01024
27
Filling gearbox with oil
Fill the gearbox with oil.
ZF Hurth: Technodrive:
Check the oil level with the dipstick, see type HBW50 : 0.3 litres (1/2 UKpt) type TMC40 : 0.20 litres (1/3 UKpt),
page 32. type HBW100 : 0.35 litres (2/3 UKpt) Engine oil SAE 20/30
type HSW150V : 1.0 litre (1 3/4 UKpt) type TMC40M : 0.20 litres ATF *)
type ZF10M : 0.42 litres (3/4 UKpt) (1/3 UKpt)
type ZF15MA : 0.56 litres (1 UKpt) type TMC40P : 0.20 litres ATF *)
type ZF15MV : 1.0 litre (1 3/4 UKpt) (1/3 UKpt)
ATF: Automatic Trans­
mission Fluid type A, *) ATF: Automatic Trans­mission Fluid
Suffix A. type A, Suffix A.

13
Use First commissioning

Coolant 2 Cil.: 2.2 litres (4 UKpt)

quantities : 3 Cil.: 3.0 litres (5 UKpt) 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
separately to bleed the cooling system
(3/8”) completely.

VD01004 VD00158 VD01005

Filling the cooling system

Remove the cap of the filler neck on the The level of the coolant must be approx. If necessary, add coolant.
top of the heat exchanger housing. 1 cm (3/8”) below the lower edge of the
Remove the bolt from the upper side of the filler neck.
thermostat cover, so that air can escape Bleeding will take place automatically dur-
from the cooling system. ing filling!
Fill the cooling system. Replace the filler cap.
Use a mixture of 40% antifreeze (ethylene- After the engine has run for the first time
glycol based) and 60% tap water or use a and has reached operating temperature Never fill the cooling system
special coolant. and has cooled down again to ambient with sea water or brackish
temperature, check the coolant level in the water.
For specifications see page 67. heat exchanger housing.

14
First commissioning Use
Running-in
Never fill the fuel tank while
FUEL the engine is running. Do not
spill fuel. Prevent unneces-
sary pollution.

VD00002

Fuel Other preparations Running-in

Ensure that the fuel tank is filled with die- • Check battery and cable connections. In order to ensure a long life for your
sel fuel. engine, please observe the following for
Use only clean, water-free, commercial • Start the engine, see page 16, and let it the first 50 operating hours:
approved diesel fuel. run for about 10 minutes without load.
For fuel grade see page 66. Check the engine and all connections • Allow the engine to reach operating
Bleed the fuel system, see page 26. (fuel, cooling water and exhaust) for temperature before applying a load.
leaks. • Avoid fast acceleration.
• Do not allow the engine to run faster
than 3/4 of maximum RPM.

15
Use Starting

Before starting, always check the follow-

ing points:

neutral
• Engine oil level.
gearbox
• Coolant level. gearbox
reverse half throttle,
• Sea cock open. forward
• Main switch ‘on’. gearbox not engaged
• Gearbox in ‘neutral’ position.
reverse forward
throttle throttle

VD00111 VD00112

After repair work: Preparation starting

Check that all guards have been replaced Before starting the engine, always check Set the control lever to ‘half throttle’ with-
and that all tools have been removed from that the control lever(s) is (are) in the neu- out engaging the gearbox.
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.
Never start the engine with
the fuel injection pump
removed.
Disconnect battery.

16
Starting Use

Ambient
Pre-heating time
Temperature

Above + 5°C (41°F) about 6 seconds

+5°C to -5°C
about 12 seconds
(+41°F to +23°F)

Below -5°C (23°F) about 18 seconds

Maximum
1 minute
pre-heating time
VD00107 VD00108

Pre-heating Pre-heating time

Turn the start key on the instrument panel Turn the key further clockwise to the ­‘ ’ The ideal pre-heating time depends on
clock-wise; the warning lights for oil pres- position; only the pre-heating indica- ambient temperature; the lower the ambi-
sure and alternator will now light up and tor light will be lit now. ent temperature, the longer the pre-heat-
the alarm buzzer will sound. ing time required. See table.
Hold the key in this position for about 6
seconds.
Warning
To prevent the glow plugs from
burning out, never exceed the
stated maximum pre-heating
time.
17
Use Starting

Warning Warning

Release the key if the engine does Never turn the key to the ‘start’ posi-
not fire within 10 seconds. Wait until tion while the engine is running.
VD00109 the starter motor has stopped running Doing so will damage the starter
completely before turning the key to motor.
the ‘start’ position again. Never allow
the starter motor to run for more than
30 seconds consecutively.

VD00110

Starting

Now turn the key further to the ‘start’ Check that the indicator lights for oil pres- The instrument panel is provided with the
position. sure and alternator are off. Cooling water following instruments (Depending of the
should now flow out of the exhaust; if this type of panel, see page 10).
Release the key as soon as the engine is not the case, stop the engine immedi-
fires (the key will return to the ‘on’ posi- ately. Before submitting the engine to full
tion) and throttle back. load it should be brought up to operating
Leave the key in this position while the temperature as quickly as possible by
engine is running. running at 3/4 of maximum revs. never
turn the main switch off while the engine
is running.

18
Cruising Use

VD00113 VD00114

Tachometer Voltmeter Warning lights

Indicating the number of revolutions per Indicating the battery voltage. None of the five warning lights should light
minute of the engine. When the engine is running, the battery up while the engine is running. Oil pres-
Avoid idling for more than 10 minutes. voltage should be between 12 and 14 sure, battery charging and temperature
Also the number of running hours is indi- Volts. indicator lights are all connected to an
cated. With the engine stopped and the start key alarm buzzer. If this alarm buzzer sounds
in the first position, the voltmeter should while running, Stop the engine immedi-
Idling speed, indicate 12 Volts. ately!
M2.C5, M2.D5, M2.05 : 850 rpm
M3.09 : 850 rpm

19
Use Stopping

VD00105 VD00106 VD01037

Electrical shutdown Mechanical shutdown

Reduce engine speed to idle and shift the When the engine has stopped, turn the On the engine itself stopping is possible
gearbox to ‘Neutral’. Turn the key entirely key to the ‘Off’ position. by pressing the black button on the fuel
to the left, through the ‘Off’ position. injection pump.
If the fuel supply is not shut off by the elec-
If the engine is not to be used for some trically operated fuel solenoid stopping of
Never stop the engine immediately after time, it is recommended that the sea cock the engine can be done this way.
it has been in operation for a long time. is closed and the battery main switch
Allow the engine to idle for a few minutes turned off.
before stopping.

20
Introduction Routine Maintenance
Introduction
The following guidelines should be observed for daily and peri-
odic maintenance. Perform each function at the indicated time
interval.
The intervals stated are for normal operational conditions. Service
the unit more frequently under severe conditions.
Failure to carry out maintenance can result in faults and perma-
nent damage to the engine.
No claim can be made on the Guarantee if maintenance has been
neglected.

21
Routine Maintenance Maintenance schedule

Every 10 hours or daily, before starting Every 500 hours, at least once every year
Check engine oil level 23 Gearbox oil change 33
Check coolant level 24 Check valve clearance 34
Check water strainer 25 Replace fuel filter 36
Check V-belt 38
After the first 50 hours Check flexible engine mounts 39
Drain water from fuel filter 26 Check engine for leaks 39
Engine oil change 28 Check tightness of all fasteners, bolts and nuts 39
Replace oil filter 28
Gearbox oil change 33 Every 1000 hours, at least once every 2 years
Replace fuel filter 36 Raw water pump inspection 40
Check idle rpm 47 Replace coolant 42

Every 100 hours, at least once every year When required

Drain water from fuel filter 26 Bleeding fuel system 26
Engine oil change 28 Cleaning heat exchanger 44
Replace oil filter 28 Check idle rpm 47
Battery, cables and cable connections 30
Check gearbox oil level 32

Stop the engine before carrying out any maintenance

work.

22
Checking engine oil level Maintenance
Daily, before starting.

VD01001 VD00155 VD01013

Check oil level Oil level 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.
A second oil filling cap is located at the
*) The difference between the two oil level distrubution cover, see page 12.
marks is:
M2.C5, M2.D5, M2.06 : 1,0 litres
(1 3/4 UKpt)
M3.09 : 1,8 litres
(3 1/4 UKpt)

23
Maintenance Checking coolant level
Daily, before starting.

VD01003

(3/8”)
VD00158 VD01005 VD01004

Checking coolant level Topping up coolant

Check the coolant level in the header tank. If necessary, top up. The internal cooling system can be filled
This has to be checked when the engine with a mixture of anti-freeze (40 %) and tap
is cold. When topping up coolant, remove the water (60 %) or with a special coolant. For
Remove the cap of the filler neck on the bolt from the upper side of the thermostat specification, see page 67
heat exchanger. cover, so that air can escape from the
cooling system.
The level of the coolant must be approx. Warning
1 cm (3/8”) below the lower edge of the Never open the cap on the Never fill the cooling system
filler neck. header tank when the engine is with sea water or brackish
at operating temperature. water.

24
Checking and cleaning the raw water strainer Maintenance
Daily, before starting.

VD00125 CT30119

Checking the raw water strainer Cleaning the strainer

Check daily whether there is any dirt in the
raw water strainer. Close the seacock before removing the lid Check the sealing between the lid and
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.

25
Maintenance Draining of water from the water separator/fuel filter
Every 100 operating hours.

VD01006 CT30119 VD01007

13
Empty fuel filter Empty water separator Bleeding

• Open the drain plug at the lower side of Empty the separately installed water sepa- After the water separator/fuel filter has
the filter. rator/fuel filter: been drained, the air has to be bled from
• Drain the water and close the drain • Open the drain plug at the lower side of the fuel system
plug. the filter. The fuel system is self-bleeding; but manu-
• Drain the water and close the drain al bleeding the system is recommended.
plug. Open the two bleeding nipples.

Note : The water separator is not within One (1) bleeding nipple is located at the
the scope of supply but installation is filter.
required!

26
Draining of water from the water separator/fuel filter Maintenance
Every 100 operating hours.

VD01008
10 14 VD01009 VD00109

Start the engine

A second bleeding nipple is located at the Prime the fuel system by pumping the fuel Operate the starter switch until the engine
fuel injection pump. pump. fires; release the starter switch if the engine
Close the bleeding nipples when all air does not fire within 20 seconds. Wait until
has escaped. the starter motor has stopped before mak-
ing a new attempt to start the engine.
N.B. It is necessary to operate the lever
over the full stroke for proper operation. Repeat the above if the engine cuts out
after a short time.

27
Maintenance Engine oil change
Every 100 operating hours.
Engine oil change

Change the engine oil every 100 hours of

operation (together with engine oil filter
replacement).

If the engine runs less than 100 hours dur-

ing the year the oil should be changed at
least once a year.

Run the engine for a few minutes before

changing the oil; warm oil can be pumped
out more easily.
VD01010 VD01026

Draining the oil Removing the oil filter

Change the oil with a switched off engine Remove the dipstick; insert the suction Unscrew the oil filter, with a commercially
at operation temperature. (Lube oil tem- hose of the supplied sump pump in the available tool, when all the oil has been
perature approx. 80°C (176°F).) dipstick tube. pumped out.
Push down the pump handle quickly and Catch any dripping oil.
Be aware of the risk of skin pull it up slowly.
burning during draining the
hot oil! Used oil must be col-
lected in a container for proper Beware of burns from hot oil.
disposal according to laws and regula-
tions.

28
Engine oil change Maintenance
Every 100 operating hours.

Oil filter, [Link]: STM0051 Amount of oil: 2 Cil.: 2.9 litres (5 UKpt)
(oil filter incl.) 3 Cil.: 4.1 litres (7 UKpt)

VD00124 VD01011 VD01013

Oiling the oil seal Oil filter installation Refilling with oil

Clean the contact surface of the gasket. Install the filter in accordance with the Refill the engine with new oil (for specifica-
Lubricate the oil seal of the new filter ele- instructions printed on the filter element tion see page 65) through the filler open-
ment with clean engine oil. housing. ing 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.

29
Maintenance Battery, cables and connections
Every 100 operating hours.

Green All Dark clear

Vetus maintenance-free batteries Dot

VD00117 VD00118 VD00121 VD00122 VD00123

Battery, battery connections Checking specific gravity 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.

30
Battery, cables and connections Maintenance
Every 100 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

Checking electrolyte level Checking specific gravity

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

31
Maintenance Gearbox oil level check
Every 500 operating hours.

VD01038
17 VD01032

Oil level check (ZF-Hurth) Oil level check (Technodrive)

Unscrew the dipstick out of the gearbox The oil level must between the two marks Vetus engines are normally equipped
housing. on the dipstick with ZF-Hurth or Technodrive gearbox-
If necessary top up. es. Consult the supplied Owners Manual
Check the oil level by cleaning the dip- The fillercap is on top of the gearbox for more details about care and mainte-
stick and lowering it into the hole, without housing. For oil type and specification see nance. In case your engine is equipped
screwing it in. The oil level should be page 65. with another brand of gearbox follow the
between the end and the notch in the instructions given in the supplied owners
dipstick. manual for changing oil and other care
If necessary top up by pouring oil in the and maintenance.
dipstick hole. For oil type and specification
see page 65.

32
Changing the gearbox oil Maintenance
Every 500 operating hours.

VD01043 VD01042 VD01034

Draining the oil Filling with new oil

Or, if sufficient space below the gearbox is
Drain the oil with the aid of a separate available, oil can be drained by removing Refill the gearbox to the correct level via
sump pump. the drain plug. the dipstick opening (ZF-Hurth, 17) or
Remove the dipstick (ZF-Hurth, 17) or via the filling hole (Techno­drive, 27).
remove the dipstick (Technodrive, 27). Drain plug: ZF-Hurth 17 For oil specification see page 65.
Technodrive 14
Insert the suction hose of the sump pump In case your engine is equipped with
in the dipstick hole. Push down the pump Collect the oil in a dripping pan. another brand of gearbox follow the
handle quickly and pull it up slowly. instructions given in the supplied owners
Remove the sump pump when all the old manual for changing oil and other care
oil has been pumped out. and maintenance.

33
Maintenance Checking valve clearance
Every 500 operating hours.

Mark on gear-
case

TDC mark
2 Cil.: 17°
3 Cil.: 19° Injection timing
mark

VD01040
10 VD00149
27
Checking / adjusting valve clear- Remove rocker cover Locating TDC
ance
Remove the 2 nuts of the rocker cover. Locate the Top Dead Center (TDC), at the
Checking the valve clearance must be Complete the following steps: end of the compression stroke, for cylin-
done with a cold engine, that is an engine der 1 by barring the engine slowly until the
which did not run for at least 6 hours. TDC marks of the engine block and the
crank pulley match.

Note: There are two TDC’s e.g. compres- does not move when the crank pulley is
sion and suction. At the TDC at the end rotated a little.
of the compression stroke the rocker arm

34
Checking valve clearance Maintenance
Every 500 operating hours.

Valve clearance: Inlet0.25 mm (0.010”)

Exhaust 0.25 mm (0.010”)

VD01016
10 VD00152 VD00153

Adjusting valve clearance

Cylinders are numbered consecutively, 2-cilinder engine 3-cilinder engine

beginning at the front end. • Check valve clearance at cylinder 1 and • Check valve clearance at cylinder 1 and
adjust if necessary. adjust if necessary.

• Rotate the crankshaft 180° clockwise • Rotate the crankshaft 240° clockwise
and check valve clearance at cylin- and check valve clearance at cylin-
der 2. der 3.
• Again rotate the crankshaft 240° and
check valve clearance at cylinder 2.

35
Maintenance Fuel filter replacement
Every 500 operating hours.

Fuel filter, [Link]: STM3690

VD01017 VD00154 VD00133

Fuel filter removal Fuel filter installation

The fuel filter is to be replaced as a unit. • Clean any debris from the filter carrier • Install the filter. When the rubber gasket
• Close the fuel stopcock. rim. touches the housing, apply another
tightening of a half to three quarters of
• Remove the fuel filter, use a filter wrench. • Lubricate the rubber gasket sparingly a turn by hand.
Catch any fuel. with clean engine oil.
• Open fuel stopcock.
• Fill the new filter with clean diesel fuel.
• Check for leaks.
Keep naked flames away when
working on the fuel system. Do
not smoke!

36
Fuel filter replacement Maintenance
Every 500 operating hours.

VD00109

Bleeding Start the engine

After replacing the fuel filter the air has to Operate the starter switch until the engine
be bled from the fuel system. fires; release the starter switch if the engine
does not fire within 20 seconds. Wait until
For bleeding see page 26. the starter motor has stopped before mak-
ing a new attempt to start the engine.

Repeat the above if the engine cuts out

after a short time.

37
Maintenance Checking the V-belt
Every 500 operating hours.

V-belt, [Link]: STM7369

VD00034 VD00128 VD00129

12 14
Inspection V-belt Checking tension Tensioning V-belt

Inspect the belt for wear and tear (fraying Check tension of the V-belt by applying Loosen the bolt of the adjustment bracket
and cracking). Belts which are in poor moderate finger and thumb pressure. If and both the alternator mounting bolts.
condition should be replaced. the deflection of the belt is more than Now push the alternator outwards until the
12 mm (1/2”), using about 10 kg (20 lbs) belt tension is correct.
Check, tension and change belts only thumb pressure, it should be tensioned. Now first re-tighten the upper mounting
with the engine off. Refit belt guard, if bolt of the alternator.
provided. Then re-tighten the bolt of the adjustment
bracket and the lower mounting bolt.

38
Flexible engine mounts, hose connections and fasteners Maintenance
Every 500 operating hours.

VD01039 VD01041

Check flexible engine mounts Inspection hose connections Check fasteners

Check the bolts which secure the damper Inspect all hose connections of the cool- Check tightness of all fasteners, bolts and
element, the mounting bolts to engine bed ingsystem. (Cracked hoses, loose hose nuts.
and the nuts at the adjustment spindle for clamps)
tightness.
Inspect the rubber element of the engine
support for cracks. Also check the deflec-
tion of the damper element, the deflection
influences the alignment of engine and
propshaft! Re-align engine in case of
doubt.

39
Maintenance Raw water pump inspection
Every 1000 operating hours.

VD01022
1,6 x 6,3 VD01030 VD01031

Raw water pump inspection Pump cover removal Impeller removal

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

40
Raw water pump inspection Maintenance
Every 1000 operating hours.

Impeller, [Link]: STM8061 Gasket, [Link]: STM8002

VD00127 VD00004 VD00156

Impeller inspection Re-install the impeller 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 lubri-
• Replace the impeller if necessary. cant such as a silicone spray before fit- • Check the water filter and open the sea
ting it into the impeller housing. cock.

• Fit the impeller to the pump shaft. (if an

existing impeller is re-used, install it in
the same position as removed).

41
Maintenance Coolant replacement
Every 1000 operating hours.
Coolant replacement

The coolant has to be replaced every 1

1000 operating hours or at least once
every two years.

N.B. Replacing the coolant may also

be necessary as part of the winter stor-
age procedure; in case that the coolant
present in the cooling system offers insuf-
ficient protection for the winter. 2

VD01025
14 VD01018
13
Draining of coolant

Be aware of the risk of skin Remove the drain plugs from the engine
burning during draining the block (1) and heat exchanger (2). Remove
hot coolant! Used coolant the filler cap to vent the cooling system
must be collected in a con- and check that all the coolant has been
tainer for proper disposal according to drained. After draining replace the drain
laws and regulations. plugs.

42
Coolant replacement Maintenance
Every 1000 operating hours.

Coolant: 2 Cil.: 2.2 litres (4 UKpt) Water heater

quantities : 3 Cil.: 3.0 litres (5 UKpt)
If a water heater is connected to the
engine and this heater is positioned
above the upper side of the engine
than bleeding of the heater will not
take place automatically! Fill the heater
separately to bleed the cooling system
completely.
(3/8”)

VD01004 VD00158 VD01005

Filling the cooling system

Remove the cap of the filler neck on the The level of the coolant must be approx. heat exchanger housing.
top of the heat exchanger housing. 1 cm (3/8”) below the lower edge of the
Remove the bolt from the upper side of the filler neck. If necessary, add coolant.
thermostat cover, so that air can escape Bleeding will take place automatically dur-
from the cooling system. ing filling!
Fill the cooling system. Replace the filler cap.
Use a mixture of 40% antifreeze (ethylene-
glycol based) and 60% tap water or use a After the engine has run for the first time Never fill the cooling system
special coolant. and has reached operating temperature with sea water or brackish
and has cooled down again to ambient water.
For specifications see page 67. temperature, check the coolant level in the

43
Maintenance Cleaning the heat exchanger

VD01018
13 VD01003 VD01019
6
Remove the drain plug Removal of bolts out of the end cov-
ers
• Close the seacock and detach the • Remove the filler cap from the top of the
water inlet hose from the sea water heat exchanger housing to allow air into Take out both central bolts from the end
pump. the system and check that all coolant covers and take the end covers with the
has drained off. O-rings out of the housing.
• Drain the coolant: To do this, remove
the drain plug from the heat exchanger • Remove the alternator.
housing.

44
Cleaning the heat exchanger Maintenance

VD01020
6 VD01021 STM7217

Remove heat exchanger Cleaning the heat exchanger

Slide the heat exchanger out of the hous- Clean the heat exchanger: Use a pipe
ing. cleaner to remove fouling in the pipes.
Then rinse the heat exchanger pipes with
clean water.
Ensure that both heat exchanger end
chambers are free from dirt.

45
Maintenance Cleaning the heat exchanger

O-ring, [Link]: STM6113 (2 x)

VD00157 STM6202

Replacing heat exchanger Replacing the end covers

Replace the heat exchanger in the original
position in the heat exchanger housing. Fit the end covers in the housing; the con- Tighten up the bolts when both covers are
Use new O-rings (61 x 2.5 mm) which nector cover is fitted with a locating pin in the correct position.
have been greased. so that it can be fitted in one way only in
relation to the heat exchanger. • Refit the drain plug.
This ensures the correct position of the
separator baffle in the connector cover in • Reconnect all hoses previously
relation to the heat exchanger. removed.

• Refill the cooling system, see page 43.

46
Checking engine speed Maintenance

Warning Minimum
speed adjust-
The maximum engine speed adjust- ment screw
ment screw has been correctly set
at the factory and sealed. DO NOT Maximum
attempt to remove this seal. speed adjust-
ment screw

Lead seal

VD00134 VD00150
10
Checking engine speed Adjusting engine idling speed

At full load (with the boat cruising) the The engine idling speed should be If the engine speed differs from that stated
maximum engine speed should be about 850 rpm. above, it must be adjusted.
3,000 resp. 3600 RPM (see technical data Allow the engine to warm up normally The engine idling speed can be reset
page 60). If the engine does not reach this (until the coolant temperature reaches at using the adjustment screw on the fuel
speed, it is being overloaded! least 60°C (140°F).) before checking and/ pump.
If this is the case, check the ship’s pro- or adjusting the idling speed.
peller for defects or irregularities, and Check the engine RPM using a rev. coun-
also to see that it is the correct pitch and ter, or use the rev. counter fitted to the
diameter. control panel.

47
Winter lay-up Winter storage procedure

VD01006 VD00136

Fuel system Running with protective fuel mix-

ture
Drain the water from the water separator/ * Engine oil with protective properties.
fuel filter and the fuel tank. Ensure that the Connect the fuel supply pipe to a can filled E.g.
tank is completely filled with fuel. with a mixture of one (1) part of engine oil* Vetus Marine Diesel Engine Oil 15W-40
to nine (9) parts of clean fuel**. Use this Shell Nautilus Premium Inboard 15W-40
mixture to run the engine at no load for ** Preferably water-free fuel.
approx. 10 minutes. Collect some fuel from the return pipe,
Stop the engine. while engine is running.

Never run the engine under

load with this mixture of fuel
and oil.

48
Winter storage procedure Winter lay-up

VD01010 VD00125

Lubrication system Raw water cooling system

With the engine still at operating tem- Close the seacock before removing the lid Check the seal between the lid and hous-
perature: (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 (1/4 [Link].) of anti-freeze into An improperly sealed lid will result in air
Replace the oil filter and change the the water strainer and run the engine until sucked in by the raw water pump which
engine oil; use oil with protective proper- the anti-freeze has disappeared into the again will result in overheating of the
ties. See page 65. cooling system. engine.
Take care that no anti-freeze is spilled into
the waterway (anti-freeze is poisonous).

49
Winter lay-up Winter storage procedure

VD01003 VD00139 CT40063

Fresh water cooling system Electrical system Charging the batteries

To avoid corrosion during winter storage Disconnect the battery cables. Charge batteries during winter lay-up reg-
the cooling system must be filled with an ularly if required!
antifreeze/water mixture (or a coolant). For
specifications see page 67.
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 42.

50
Recommissioning after winter storage Winter lay-up
1 Check that the lid of the raw water 4 Open the sea cock.
strainer is reinstalled.

VD00125 VD00138

2 Check that the lid of the raw water 5 Check the coolant level. (page 24)
pump and drain plugs are reinstalled.
(pages 40)

VD01022 VD01003

3 Re-tighten possible loose hose 6 Check the engine oil level. (page
clamps. 23)

VD01045 VD01001

51
Winter lay-up Recommissioning after winter storage

7 Drain the water from the water sepa- 10 Open the fuel valve.
rator/fuel filter. (page 26)

VD00027 VD00137

8 Drain the water from the fuel tank. 11 Make sure that the batteries are fully
charged. (page 30)

VD00141 CT40063

9 Install a new fuel filter. (page 36) 12 Connect the batteries.

VD01017 VD00140

52
Recommissioning after winter storage Winter lay-up
13 Start the engine.
Check the fuel system, the cooling
system and the exhaust for leakage.

VD01046

14 Stop the engine and change the oil

of the gearbox. (page 33)

VD01043

15 Check the operation of the instru-

ments, the remote control and the
gearbox.

VD00142

53
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.

Before starting, make sure that nobody is in the

immediate vincinity of the engine.
When carrying out repair, never start the engine with
the fuel injection pump removed removed.
Disconnect battery!

54
Fault finding table 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 Vent line of fuel supply tank g Check / clean.
e Starter relay is not engaged e Install an auxiliary starter clogged.
due to a voltage too low; cau- relay. h Exhaust restricted. h Check.
sed by a very long intermediate
cable from engine to control
panel.

55
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 Setting of stop valve incorrect. c Check / adjust. and/or contamination.
d Faulty glow plugs. d Check / replace. d Leaking fuel supply line or fuel d Check / replace.
e Incorrect valve clearance. e Adjust. injection line.
f Incorrect injection timing after f Check / adjust. e Faulty injector/injection pump. e Check, replace if
overhauling of engine. required.
g Insufficient intake air. g Check. f Vent line of fuel supply tank f Check / clean.
clogged.
h Wrong fuel quality or contami- h Check fuel. Drain and g Fuel supply line restricted. g Check / clean.
nated fuel. flush fuel tank. Replace h Incorrect valve clearance. h Adjust.
with new fuel. i Idle setting too low. i Check/ adjust.
i Incorrect lube oil SAE class or i Replace. j Exhaust restricted. j Check.
quality for ambient tempera- k Wrong fuel quality or contami- k Check fuel. Drain and
ture. nated fuel. flush fuel tank. Replace
with new fuel.

56
Fault finding table 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 Coolant pump defective. e Check / clean.
required. f Heat exchanger dirty or clogged f Check / clean.
e Setting of stop valve incorrect. e Check / adjust. as a result of rubber particles
f Oil level too high. f Lower level. from a worn impeller.
g Incorrect valve clearance. g Adjust. g Coolant level too low. g Check / top up.
h Exhaust restricted. h Check / clean. h Sea cock closed. h Open.
i Insufficient intake air. i Check. i Raw water strainer clogged. i Check / clean.
j Wrong fuel quality or contami- j Check fuel. Drain and j Leaking raw water intake j Check / replace.
nated fuel. flush fuel tank. Replace system.
with new fuel. k Faulty thermostat. k Check / replace.
k Engine overloaded. k Check size of propeller. l Faulty impeller raw water pump. l Check / replace.
m Insufficient intake air. m Check / replace air
intake filter.
n Motor becomes apparantly n Check / replace.
overheated as a result of faulty
temperature switch, sensor or
meter.

57
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. a Increase level.
b Fuel filter clogged with water b Check or replace. b Excessive inclination of engine. b Check / Adjust.
and/or contamination. c Incorrect lube oil SAE class or c Replace.
c Leaking fuel supply line or fuel c Check / replace. quality for ambient tempera-
injection line. ture.
d Faulty injector/injection pump. d Check, replace if
required.
e Fuel supply line restricted. e Check / clean.
9 Engine oil consumption excessive
f Faulty glow plugs. f Check / replace.
g Incorrect valve clearance. g Adjust.
Possible fault Remedy

a Oil level too high. a Lower level.

b Excessive inclination of engine. b Check / Adjust.
c Incorrect lube oil SAE class or c Replace.
quality for ambient tempera-
ture.
d Excessive wear of cylinder/ d Check compression;
piston. overhaul engine.
e Insufficient intake air. e Check.
f Engine overloaded. f Check size of propeller.

58
Fault finding table 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
required.
c Water in fuel system. c Check water separator.
d Faulty glow plugs. d Check / replace.
e Incorrect valve clearance. e Adjust.
f Incorrect injection timing. f Check / adjust.
g Wrong fuel quality or contami- g Check fuel. Drain and
nated fuel. flush fuel tank. Replace
with new fuel.
h Vapour in exhaust gases con- h -
10B Black exhaust smoke (at load)
denses as a result of very low
ambient temperature.
Possible fault Remedy

a Insufficient intake air. a Check.

b Faulty injector / injection pump. b Check / replace if
required.
c Engine overloaded, max. rpm c Check sizes of propeller.
is not reached.

59
Technical data Engine specifications

Model M2.C5 M2.D5 M2.06 M3.09

General
Make Vetus Mitsubishi
Number of cylinders 2 2 2 3
Based on L2C-61DM L2C-61DM L2E-61DM L3E-61DM
Type 4-stroke diesel, in-line
Injection Indirect
Aspiration Natural
Bore 70 mm 70 mm 76 mm 76 mm
Stroke 70 mm 70 mm 70 mm 70 mm
Total displacement 538 cm3 538 cm3 635 cm3 952 cm3
Compression ratio 23 : 1 23 : 1 23 : 1 23 : 1
Idling speed 850 rpm 850 rpm 850 rpm 850 rpm
Max. no. of revolutions at no load 3000 rpm 3600 rpm 3600 rpm 3600 rpm
Valve Clearances (cold) Inlet 0.25 mm (0.010”)
Exhaust 0.25 mm (0.010”)
Weight (with standard gearbox) 98 kg (216 lbs) 98 kg (216 lbs) 98 kg (216 lbs) 123 kg (271 lbs)

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

60
Engine specifications Technical data
Model M2.C5 M2.D5 M2.06 M3.09

Maximum Output
at the flywheel (ISO 3046-1) 8.2 kW (11 hp) 9.5 kW (13 hp) 11.8 kW (16 hp) 18.4 kW (25 hp)
at the prop shaft (ISO 3046-1) 7.9 kW (10.7 hp) 9.3 kW (12.6 hp) 11.6 kW (15.8 hp) 17.7 kW (24 hp)
at no. of revolutions of 3000 rpm 3600 rpm 3600 rpm 3600 rpm
Torque, 26 Nm 25 Nm 29.3 Nm 49.1 Nm
(2.7 kgm, 19.2 [Link]) (2.6 kgm, 18.4 [Link]) (3.0 kgm, 21.6 [Link]) (5.0 kgm, 36.2 [Link])

at no. of revolutions 3000 rpm 3600 rpm 3600 rpm 3600 rpm

Fuel consumption 265 g/kW.h 265 g/kW.h 268 g/kW.h 256 g/kW.h
(195 g/hp.h, (195 g/hp.h, (196 g/hp.h, (187 g/hp.h,
6.9 oz/hp.h) 6.9 oz/hp.h) 6.9 oz/hp.h) 6.6 oz/hp.h)
at no. of revolutions 2300 rpm 2300 rpm 2500 rpm 2600 rpm

Fuel System (Self-bleeding)

Injection pump Bosch model NC (Nippon Denso)
Injectors Plug injector
Opening pressure 140 bar (kgf/cm3) (2030 psi)
Firing order 1-2 1-2 1-2 1- 3 - 2
Injection timing 17° BTDC 17° BTDC 17° BTDC 19° BTDC
Fuel filter element STM3690 STM3690 STM3690 STM3690
Fuel lift pump
Suction height max. max. 1,5 m (5 ft)
Fuel supply connection for hose 8 mm (5/16”) I.D.
Fuel return connection for hose 8 mm (5/16”) I.D.
61
Technical data Engine specifications

Model M2.C5 M2.D5 M2.06 M3.09

Oil lubrication system

Oil capacity, max.
without oil filter 2,4 litres (4 UKpt) 2,4 litres (4 UKpt) 2,4 litres (4 UKpt) 3,6 litres (6 UKpt)
with oil filter 2,9 litres (5 UKpt) 2,9 litres (5 UKpt) 2,9 litres (5 UKpt) 4,1 litres (7 UKpt)
Oil Filter STM0051
Oil temperature in sump max. 130°C (266°F)

Cooling system
Capacity,
Intercooler version 2.2 litres (4 UKpt) 2.2 litres (4 UKpt) 2,2 litres (4 UKpt) 3 litres (4 UKpt)
Keel cooler version 3 litres (5 UKpt) 3 litres (5 UKpt) 3 litres (5 UKpt) 4 litres (5 UKpt)
Thermostat opening at 71°C±1.5°C (160°F±3°F),
fully opened at 84°C (183°F)
Coolant pump,
Flow at max. engine rpm 50 l/min (11 UKGal/min)
Total head keelcooler at max. flow 2 m Water (6’ 7”)
Inlet connection for hose keelcooler 28 mm (1 1/8”) I.D.
Raw water pump,
Flow at max. engine rpm 20 l/min (4.4 UKGal/min)
Total head at max. flow 2 m Water (6’ 7”)
Impeller STM8061
Inlet connection for hose 20 mm (3/4”) I.D.
Heater supply connection 10 mm (3/8”)
Heater return connection 8 mm (5/16”)

62
Engine specifications Technical data
Model M2.C5 M2.D5 M2.06 M3.09

Exhaust system
Exhaust diameter 40 mm 40 mm 40 mm 40 mm
Exhaust back pressure at specified output
max. 150 mbar (2.2 psi)

Electrical System
Voltage 12 Volt 12 Volt 12 Volt 12 Volt
Alternator 14 Volt, 40 Amp 14 Volt, 40 Amp 14 Volt, 40 Amp 14 Volt, 40 Amp
Battery capacity min. 55 Ah, max. 108 Ah
Protection Tubular glass fuse, 32 x 6.3 mm 10 A slow blow

V-belt STM7369 STM7369 STM7369 STM7369

Gearbox Gear ratio

ZF Hurth: model HBW50 2,05 / 2,72 : 1 2,05 / 2,72 : 1 2,05 / 2,72 : 1 2,05 : 1
model HBW100 – – – 2,72 : 1
model HBW150V 2,05 / 2,72 : 1 2,05 / 2,72 : 1 2,05 / 2,72 : 1 2,05 / 2,72 : 1
model ZF10M 2,05 / 2,72 : 1 2,05 / 2,72 : 1 2,05 / 2,72 : 1 2,05 / 2,72 : 1
model ZF15MA 1,88 / 2,14 / 2.63 : 1 1,88 / 2,14 / 2.63 : 1 1,88 / 2,14 / 2.63 : 1 1,88 / 2,14 / 2.63 : 1
model ZF15MIV 2,13 / 2,99 : 1 2,13 / 2,99 : 1 2,13 / 2,99 : 1 2,13 / 2,99 : 1

Technodrive: typ TMC40 2,05 / 2,60 : 1 2,05 / 2,60 : 1 2,05 / 2,60 : 1 2,05 / 2,60 : 1
model TMC40M 2,05 / 2,60 : 1 2,05 / 2,60 : 1 2,05 / 2,60 : 1 2,05 / 2,60 : 1
model TMC40P 2,05 / 2,60 : 1 2,05 / 2,60 : 1 2,05 / 2,60 : 1 2,05 / 2,60 : 1

63
Technical data Torque wrench settings

Screw connection Wrench Torque

Diameter size Nm (kgm) ([Link])
Cylinder head bolt M10 14 78 ±5 (8 ±0.5) (58 ±3.5)
Cilinder head bolt M8 12 25 ±5 (2.5 ±0.5) (18 ±3.5)
Connecting rod nut M8 14 33 ±1.5 (3.35 ±0.15) (24 ±1)
Fly wheel bolt M10 17 88 ±5 (9 ±0.5) (65 ±3.5)
Crank shaft pulley nut M16 24 108 ±10 (11 ±1.0) (80 ±7)
Main bearing cap bolt M10 17 52 ±2.5 (5.25 ±0.25) (38 ±2)
Rocker stay bolt M8 12 18 ±3.5 (1.85 ±0.35) (13 ±2.5)
Valve cover nut M6 10 6 ±1 (0.6 ±0.1) (4.5 ±0.8)
Nozzle holder M20 21 54 ±5 (5.5 ±0.5) (40 ±3.5)
Fuel leak oil pipe nut M12 17 25 ±5 (2.5 ±0.5) (18 ±3.5)
Nozzle retaining nut M16 21 37 ±2.5 (3.75 ±0.25) (27 ±2)
Fuel injection pipe nut M12 17 29 ±5 (3.0 ±0.5) (21 ±3.5)
Delivery valve holder M16 17 36 ±2 (3.7 ±0.2) (26 ±1.5)
Injection pump hollow screw M10 14 12 ±2.5 (1.25 ±0.25) (9 ±2)
Injection pump air vent screw M6 10 6 ±1 (0.6 ±0.1) (4.5 ±0.8)
Solenoid lock nut M30 36 44 ±5 (4.5 ±0.5) (32 ±3.5)
Temperature switch M16 19 22.5 ±4 (2.3 ±0.4) (16.5 ±3)
Oil filter M20 — 12 ±1 (1.2 ±0.1) (9 ±0.8)
Oil pressure switch PT1/8 26 10 ±2 (1 ±0.2) (7 ±1.5)
Pressure relief valve M18 22 44 ±5 (4.5 ±0.5) (32 ±3.5)
Oil drain plug M18 19 54 ±5 (5.5 ±0.5) (40 ±3.5)
Glow plug M10 12 17.5 ±2.5 (1.75 ±0.25) (13 ±2)

64
Lubricating oil Operating media
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 type HBW50 : 0,3 litres (1/2 UKpt) ATF*)
API (American Petroleum Institute) and CCMC (Committee of type HBW100 : 0,35 litres (2/3 UKpt) ATF*)
Common Market Automobile Constructors). type HBW150V : 1,0 litres (1 3/4 UKpt) ATF*)
Approved API Oils : CD, CE and CF4 type ZF10M : 0.42 litres (3/4 UKpt) ATF*)
Approved CCMC Oils : D4, D5 type ZF15MA : 0.56 litres (1 UKpt) ATF*)
type ZF15MV : 1.0 litre (1 3/4 UKpt) ATF*)
As the viscosity of lube oil is dependent on temperature, the oil
vicosity (SAE grade) should be selected according to the ambient Technodrive:
temperature when the the engine is started. type TMC40 : 0,20 litres (1/2 UKpt), Engine oil SAE 20/30
To avoid oil changes dictated by the seasons we advise one of type TMC40M : 0.20 litres (1/3 UKpt) ATF *)
the following multi-grade oils. type TMC40P : 0.20 litres (1/3 UKpt) ATF *)

- SAE 10W40 for temperatures of -25°C up to +30°C *) ATF : AutomaticTransmission Fluid;

(-13°F up to +86°F) Transmissie olie type A, Suffix A.
- SAE 15W40 for temperatures of -20°C up to +35°C For example : Vetus Transmission Oil
(-4°F up to +95°F) Shell Donax T6
Gulf Dextron
For example: Vetus Marine Diesel Engine Oil 15W-40
Shell Nautilus Premium Inboard 15W-40 Other brands of gearboxes:
See supplied owners manual for oil type and quantities.

65
Operating media Fuel

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. If the sulfur content is higher than 0.5%, the intervals and reducing engine efficiency.
between oil changes should be halved e.g. change oil every 250 If the ambient temperature is less than 0°C (+32°F), winter-grade
hours. Don’t use fuel with more than 1% sulfur! fuel -suitable down to -15°C (+5°F) - should be used. This fuel is
usually available from filling stations well in advance of the cold
The following fuel specifications / standards are approved: months. Diesel fuel containing additives (Super Diesel) is often
• CEN EN 590 or DIN/EN 590 (under development) on sale as well, for use down to -20°C (-4°F).
• 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.

66
Coolant Operating media
Coolant fluid Water quality for coolant preparation

The preparation and monitoring of coolant in inter-cooled engines Use preferably tap water.
is especially important because corrosion, cavitation and freezing
can lead to engine damage. Use as coolant a mixture of a cool- If an other available fresh water is used; the values given below
ing system protective liquid (anti-freeze, ethylene glycol based) must not be exceeded.
and tap water.

In tropical climates, where anti-freeze availability may be limited, Water quality min. max.
use a corrosion inhibitor to protect the engine cooling system.
pH-value at 20°C (68°F) 6.5 8.5

The concentration of the cooling system protective liquid in the Chloride ion content [mg/dm3] – 100
coolant should not fall below/exceed the following limits: Sulfate ion content [mg/dm3] – 100
Total hardness [degrees] 3 12

Cooling system protective Water Protection against

liquid (Anti-freeze)   freezing to
Never use sea-water or brackish water.
max. 45 vol% 55% -35°C (-31°F)
40 vol% 60% -28°C (-18°F)
min. 35 vol% 65% -22°C (-8°F)

The protective liquid concentration must be maintained under all

circumstances. Therefor if coolant must be added always use the Cooling system protective liquids must be disposed of
same mixture of anti-freeze and tap water. in accordance with environmental regulations.

67
Wiring diagram Engine with panel model ‘20’, ‘21’, ‘22’

Starter switch Voltmeter Tachometer/

Engine panel model hourcounter
'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 pressure
D8
A1 A3 A4 A2 A5 A6
D9
Fuse
D10
Pre-heating X2M 19/94 61 91 92 93 W
-6 -4 -1 -2 -5 -3
Pre-
heating B6 B4 B1 B2 B5 B3
relay Plug 'B'
30 86

Battery Socket 'B'

switch 87 85
B6 B4 B1 B2 B5 B3

Yellow/Green
Transparent

Brown
Green

Gray
Blue
B+ R
ϑ p ϑ
G L Battery charging
Battery 3Y
W

Starter motor Pre-heating Stop solenoid Alternator Exhaust Oil Coolant

VD00215 (ETS) temp. press. temp.

68
Options, panel model ‘10’ Wiring diagram

Starter switch Engine panel model

'10'
L2: Battery charging
L3: Exhaust temperature
L4: Oil pressure
L5: Coolant temperature
L6: Oil pressure gearbox

31 17/19 58 15

D1 D2 D3 D4
J3 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
D7
D8
D9
D10
Pre-heating
19/94 61 91 92 93 95
W

Yellow/Green
Transparent

Brown
Green

Gray
Blue
B6 B4 B1 B2 B5 B3
Plug 'B'

VD00216

69
Overall dimensions

Fuel return
ø 8 mm

Fuel supply
ø 8 mm

Exhaust ø 40 mm

Sea water intake ø 20 mm

STM6150
M2.C5 / M2.D5 1:10
70
 Overall dimensions

Fuel return
ø 8 mm

Fuel supply
ø 8 mm

Exhaust ø 40 mm

Sea water intake ø 20 mm

STM6150A
M2.06 1:10
71
Overall dimensions

Fuel return
ø 8 mm

Exhaust ø 40 mm

Fuel supply ø 8 mm
Sea water intake ø 20 mm

STM6286
M3.09 1:10
72
Manuals

Art. code Description

340101.04 (STM0131) Bedieningshandleiding M2.C5 / M2.D5 / M2.06 / M3.09 (Nederlands)

340102.04 (STM0132) Operation manual M2.C5 / M2.D5 / M2.06 / M3.09 (English)
340103.03 (STM0133) Bedienungsanleitung M2.C5 / M2.D5 / M2.06 / M3.09 (Deutsch)
340104.03 (STM0134) Manuel d’utilisation M2.C5 / M2.D5 / M2.06 / M3.09 (Français)
340105.03 (STM0135) Manual de operacion M2.C5 / M2.D5 / M2.06 / M3.09 (Español)
340106.03 (STM0136) Istruzioni per l’uso M2.C5 / M2.D5 / M2.06 / M3.09 (Italiano)
340107.02 (STM0137) Brugsanvisning M2.C5 / M2.D5 / M2.06 / M3.09 (Dansk)
340108.02 (STM0138) Användarmanual M2.C5 / M2.D5 / M2.06 / M3.09 (Svenska)
340109.01 (STM0139) Bruksanvisning M2.C5 / M2.D5 / M2.06 / M3.09 (Norsk)
340110.01 (STM6342) Käyttöopas M2.C5 / M2.D5 / M2.06 / M3.09 (Suomeksi)

320331.01 (STM0032) Installatiehandleiding / Installation manual (Nederlands / English)

320199.05 (STM0016) Service- en Garantieboek / Service and Warranty Manual / (Nederlands / English /
Service- und Garantieheft / Livret Garantie et Service / Deutsch / Français /
Manual de servicio y garantía / Libretto di assistenza e garanzia Español / Italiano /
Service- og garantibog / Service- och garantihäfte Dansk / Svenska /
Service- og garantibok / Huolto- ja takuukirja Norsk / Suomeksi)

341131.01 (STM0034) Onderdelenboek / Parts manual M2.C5 / M2.D5 / M2.06 (Nederlands / English)

342102.01 (STM0143) Service manual M2.C5 / M2.D5 / M2.06 / M3.09 (English)

 Nederlands
Vetus Diesel  M2.C5 M2.D5 M2.06 M3.09
vetus
340401.01   12-07   Nederlands
n. v.
Printed in the Netherlands
FOKKERSTRAAT 57 - 3125 BD SCHIEDAM - HOLLAND - TEL.:+31(10) 4377700
FAX:+31 (10) 4372673 - 4621286 - E-MAIL: sales@[Link] - INTERNET: [Link]

340102.04 (STM0132) 12-09 Printed in the Netherlands