Vetus M2.06 Service Manual

Operation manualM2M2.02M2.06

8When the engine stops suddenly:If the engine stops suddenly, do not start it again immediately. Track down the cause and carry out the necessary repa

989 TroubleshootingFault nding table13 Black exhaust smoke (at load)Possible fault RemedyFaulty injector / injection pump. Check / replace if require

999 TroubleshootingFault nding table15 Burnt oil trace in exhaust line .Possible fault RemedyOil level too high . Lower level.Excessive wear of cylin

10010 Technical dataEngine specicationsModel : M2.02 M2.06General Make : Vetus Mitsubishi Vetus MitsubishiNumber of cylinders : 2 2Based on : L2E-61

101Model : M2.02 M2.06Maximum Outputat the ywheel (ISO 8665) : 8.8 kW (12 hp) 11.8 kW (16 hp)at the prop shaft (ISO 8665) : 8.7 kW (11.8 hp) 11.6 kW

102Model : M2.02 M2.06Oil lubrication systemOil capacity, max. without oil lter : 2.4 litres (4.2 Imp. pt, 5.1 US pt) with oil lter : 2.9 litres (

10310 Technical dataEngine specicationsGearbox specicationsModel : M2.02 M2.06Exhaust systemExhaust diameter : 40 mmExhaust back pressure : at speci

10410 Technical dataTorque wrench settingsScrew connection TorqueDiameter Wrench size Nm (kgm)(ft.lbf)Cylinder head bolt M10 14 78 ±5 (8 ±0.5)(58 ±3

105Fuel Quality GradeUse only diesel fuel or diesel blends with up to 7% FAME (B7), with less than 0.5% sulphur content of which the quality is fully

106Engine oilLubricating oils are specied by performance and quality classes. It is usual for the specications to be indicated according to the API

107 CautionDo not mix oil of dierent brands together. Oils of dierent brands are mostly not com-patible with each other. If they are mixed, the mixt

9Vetus 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.Y

108Gearbox Lubricating OilOnly use a recognised brand of oil for lubricating the gearbox.Technodrive:type TMC40P : 0.2 litres, ATF [1] (0.35 Imp.

109Coolant uidThe preparation and monitoring of coolant in inter-cooled engines is especially important because corrosion, cavitation and freezing ca

-4 -1 -2 -5 -3Q1R1 61 91 92 93 WL1 L2 L3 L4 L5R2R3-619/94X2M95W155817/1931X1-8-7-5 -4-3 -6D1D2D3 D4D5D6D7D8D9D10L6BZn/hVG3Y B4 B1 B2 B5

Q1R1 61 91 92 93 95L1 L2 L3 L4 L5R3R219/94155817/1931D1D2D3 D4D5D6D7D8D9D10L6BZ B4 B1 B2 B5 B3B6A1 A3 A4 A2 A5 A6Red Yellow Orange

1 2 3 4612 (24 1/8”)160 (6 5/16”) 92 (3 5/8”)360 (14 3/16”)332 (13 1/16”)500 (19 11/16”)168 (6 5/8”)430 (16 15/16”)505 (19 7/8”)min. 70 (2 3/4”)max. 9

11314 IndexAAir bleed nipple, Water separator/fuel lter 12Air inlet silencer 12Airvent connection 13Alarm buzzer 33Alternator 13BBattery 50Batt

11414 IndexGearbox low oil pressure, Warning light gearbox 14Gearbox Lubricating Oil 108Gearbox oil dipstick/ller cap 13Gearbox oil level check 5

11514 IndexUUse 26–35VValve clearance, Checking / adjusting 60V-belt 13V-belt, Checking the 62V-belt, Tensioning 62Voltmeter 14, 33WWarning indi

116

117ManualsArt. code Description340801.01 Bedieningshandleiding M2.02, M2.06 (Nederlands)340802.01 Operation manual M2.02, M2.06 (English)34080

102 IntroductionData tagSerial number1 Engine data tagThe Vetus engine serial number and perfor-mance data are printed on the engine data tag.Model a

Vetus Diesel VF4 VF5 Nederlands340802.01 2012-04 Printed in the NetherlandsFOKKERSTRAAT 57 - 3125 BD SCHIEDAM - HOLLAND - TEL.:+ 31(10) 43

Lead sealMaximum speedadjustment screw112 IntroductionCylinder numbering and direction of rotation Fuel pump seal4 Cylinder numbering and direction o

1235 467891 171614 1513121110 18122 IntroductionIdentication of engine partsService side1 Oil ller cap2 Raw water inlet ø 20 mm3 Raw water pump4

192021222330 31, 2628 2925, 26, 27243233132 IntroductionIdentication of engine partsStarter side19 Gearbox20 Gearbox drain plug21 Gearbox oil dips

53786491 2537864148 Indicator light pre-heating9 Warning light gearbox low oil pressure [1]1 Tachometer/Operating hours counter2 Voltmeter3 Start

Single lever controlhandle for two enginesSingle lever controlhandle for 1 engineneutralgearbox reverse gearbox forward forward throttlereverse throt

OIL OIL163 First commissioning1 Commissioning the engineBefore starting the engine for the rst time, the following procedures must be carried out:2

27 17OIL OIL173 First commissioning3 Filling gearbox with oil• Fill the gearbox with oil.• Check the oil level with the dipstick, see page 42.Tec

ii

1 cm(3/8”)COOLANT 17COOLANT183 First commissioning4 Filling the cooling system, interCooling, • Remove the cap of the ller neck on the top of the

21DO NOT OPEN1.5 bar21DO NOT OPEN1.5 bar193 First commissioning5 Filling the cooling system, keel Cooling• Remove the cap ‘do not open’ (1) of th

21DO NOT OPEN1.5 bar203 First commissioning6 Filling coolant system, if a water heater is connected (1)The highest point of the water heater is situ

231DO NOT OPEN1.5 bar213 First commissioning7 Filling coolant system, if a water heater is connected (2)The highest point of the water heater is sit

Neutral(No throttle, gearboxnot engaged)FUEL223 First commissioning8 Fuel• Ensure that the fuel tank is lled with diesel fuel.Use only clean, wate

OIL233 First commissioning10 Test run• Start the engine.How to start the engine and what to check before, during and immediately after start-ing is

243 First commissioning11 BleedingThe cooling system must be bled as soon as the engine has reached normal working tem-perature. • Open the cap on

254 Running-inIn order to ensure a long life for your en-gine, please observe the following for the first 50 operating hours:• Allow the engine to r

265 UseGeneral guidelinesGeneral guidelines for useImplementing the following recommenda-tions will result in longer life and better per-formance and

275 UseGeneral guidelines noteFirst commissioningFollow the instructions given for ‘First com-missioning’ on page 16 and further if the en-gine is bei

1Operation manualPlease enter the serial numbers here.These numbers should be quoted when inquiring about Customer Ser-vice, Repairs or Spare Parts (s

half throttle,gearbox not engaged285 UseStartingBefore starting, always check the following points:• Engine oil level.• Coolant level.• Sea cock op

295 UseStarting3 Pre-heatingThe ideal pre-heating time depends on am-bient temperature; the lower the ambient temperature, the longer the pre-heating

305 UseStarting4 StartingNow turn the key further to the ‘start’ posi-tion.Release the key as soon as the engine res (the key will return to the ‘on

315 UseStartingCheck that the indicator lights for oil pressure and alternator are o. Cooling water should now ow out of the ex-haust; if this is no

325 UseCruisingThe instrument panel is provided with the fol-lowing instruments (Depending of the type of panel, see page 17).5 TachometerIndicating

335 UseCruising6 VoltmeterIndicating the battery voltage.When the engine is running, the battery volt-age should be between 12 and 14 Volts.With the

Neutral345 UseStopping9 Stopping• Reduce engine speed to idle and shift the gearbox to ‘Neutral’.• Turn the key entirely to the left, through the ‘

355 UseStopping10 Stopping on the engine itselfOn the engine itself stopping is possible by pressing the black button on the fuel injec-tion pump.If

366 MaintenanceIntroductionIntroductionThe following guidelines should be observed for daily and periodic maintenance. Perform each function at the i

376 MaintenanceIntroductionKeep record of the following information in the logbook and/or the ‘Service and War-ranty Manual’: - Total engine hours (re

2Please read and observe the information giv-en in this operation manual. This will enable you to avoid accidents, preserve the manu-facturer’s warran

386 MaintenanceMaintenance schedule DangerStop the engine before carrying out any maintenance workEvery 10 hours or daily, before starting pageCheck e

39[1] Consult the service manual, work to be carried out by a Vetus Mit-subishi dealer.6 MaintenanceMaintenance schedule DangerStop the engine before

OIL OIL406 MaintenanceChecking engine oil levelDaily, before starting.1 Check oil level• Turn the engine o.The dipstick is located on the starboard

416 MaintenanceChecking and cleaning the raw water strainerDaily, before starting.4 Checking the raw water strainer• Check daily whether there is an

1 cm(3/8”)COOLANTCOOLANT426 MaintenanceChecking coolant levelDaily, before starting.6 Checking coolant level• Check the coolant level in the header

436 MaintenanceChecking coolant levelDaily, before starting.• When topping up coolant, remove the bolt from the upper side of the thermo-stat cover,

446 MaintenanceDraining of water from the water separator/fuel lterEvery 100 operating hours. DangerDo not smoke when draining o water and sediment.

456 MaintenanceDraining of water from the water separator/fuel lterEvery 100 operating hours.11 BleedingAfter the water separator/fuel lter has bee

466 MaintenanceDraining of water from the water separator/fuel lterEvery 100 operating hours.12 Start the engine• Operate the starter switch until

476 MaintenanceEngine oil changeEvery 100 operating hours.13 Engine oil changeChange the engine oil every 100 hours of operation (together with engin

3Contents1 Safety measures 4Warning indications 4Preventing re and explosion 5Prevention of injury 6When problems occur 82 Introductio

48 WarningThe engine oil must be disposed in accordance with the applicable en-vironmental regulations.6 MaintenanceEngine oil changeEvery 100 operati

496 MaintenanceEngine oil changeEvery 100 operating hours.16 Oiling the oil seal• Clean the contact surface of the gasket.• Lubricate the oil seal

506 MaintenanceBattery, cables and connectionsEvery 100 operating hours.Warning notes and safety regulations for working with batteriesWear eye protec

516 Maintenance Battery, cables and connectionsEvery 100 operating hours.19 Battery, battery connectionsKeep battery clean and dry.• Remove battery

1Vetus maintenance-free batteriesGREEN DOTALL DARKCLEAR526 Maintenance Battery, cables and connectionsEvery 100 operating hours.20 Checking specic g

Conventional batteriesConventional batteries536 Maintenance Battery, cables and connectionsEvery 100 operating hours.22 Checking electrolyte levelFor

5425 Oil level check (ZF-Hurth)6 Maintenance Gearbox oil level checkEvery 100 operating hours.Vetus engines are normally equipped with Technodrive or

556 MaintenanceFuel lter replacementEvery 500 operating hours.26 Fuel lter removalThe fuel lter is to be replaced as a unit.• Close the fuel stop

566 MaintenanceFuel lter replacementEvery 500 operating hours.27 Fuel lter installation• Clean any debris from the lter carrier rim.• Lubricate

576 MaintenanceBleeding, after fuel lter replacementEvery 500 operating hours.28 Bleeding• After replacing the fuel lter the air has to be bled fr

41 Safety measures DangerIndicates that great potential danger exists that can lead to serious injury or death. WarningIndicates that a potential dan

OIL586 MaintenanceChanging the gearbox oil (Technodrive)Every 500 operating hours.30 Draining the oil• Remove the drain plug to drain the oil.• Rem

596 MaintenanceChanging the gearbox oil (ZF-Hurth)Every 500 operating hours.32 Draining the oilDrain the oil with the aid of a separate sump pump.•

17°Markering opmotorblokMarkering BDPMarkeringinjectietijdstip2°2°606 MaintenanceChecking valve clearanceEvery 500 operating hours.34 Checking / adju

616 MaintenanceChecking valve clearanceEvery 500 operating hours.37 Adjusting valve clearanceCylinders are numbered consecutively, begin-ning at the

626 MaintenanceChecking the V-beltEvery 500 operating hours.38 Inspection V-belt• Inspect the belt for wear and tear (fraying and cracking). Belts w

636 MaintenanceFlexible engine mounts, hose connections and fastenersEvery 500 operating hours.41 Check exible engine mounts• Check the bolts which

646 MaintenanceRaw water pump inspectionEvery 1000 operating hours.44 Raw water pump inspectionThe rubber impeller of the outboard water pump is not

656 MaintenanceRaw water pump inspectionEvery 1000 operating hours.47 Impeller inspection• Inspect the impeller for damage.• Replace the impeller i

666 MaintenanceCoolant replacementEvery 1000 operating hours.50 Coolant replacementThe coolant has to be replaced every 1000 op-erating hours or at l

676 MaintenanceCoolant replacementEvery 1000 operating hours.51 Draining of coolant• Remove the drain plugs from the engine block (1) and heat excha

51 Safety measures• Do not smoke if refuelling.• Avoid spilling fuel on hot surfaces. Spilled fuel must be cleaned up immediately.• Do not use pet

686 MaintenanceCoolant replacementEvery 1000 operating hours.52 Filling the cooling system• Remove the cap of the ller neck on the top of the heat

1 cm(3/8”)COOLANT696 MaintenanceCoolant replacementEvery 1000 operating hours.The level of the coolant must be approx. 1 cm (3/8”) below the lower edg

706 MaintenanceChecking the starter motor and alternatorEvery 1000 operating hours.53 Checking the starter motor• Check for visible defects.• Check

Lead sealMaximum speedadjustment screwMinimum speedadjustment screw716 MaintenanceChecking engine speedAt full load (with the boat cruising) the maxi-

726 MaintenanceCleaning the heat exchanger noteCleaning of the heat exchanger is not a routine maintenance job.Only clean the heat exchanger if this i

736 MaintenanceCleaning the heat exchanger57 Remove the drain plug• Close the seacock and detach the water in-let hose from the sea water pump.• Dr

746 MaintenanceCleaning the heat exchanger59 Remove heat exchanger• Slide the heat exchanger out of the hous-ing.60 Cleaning the heat exchanger• C

756 MaintenanceCleaning the heat exchanger61 Replacing heat exchanger• Replace the heat exchanger in the original position in the heat exchanger hou

767 Winter storage procedureMake sure that the engine compartment is well ventilated during the winter period.Good ventilation prevents damp in the e

777 Winter storage procedureInspections and maintenance work to be carried out: page1 Clean the engine, remove any salt. Paint any rust spots and sp

61 Safety measuresPrevention of injury• The moving parts of the engine are danger-ous. Never touch moving parts of the en-gine while it is running,

787 Winter storage procedure1 Corrosion protectionThe various parts of the engine (except the engine block) have been treated with an anti-corrosion

797 Winter storage procedure3 Protective fuel mixture• Connect the fuel supply pipe to a can lled with protective diesel fuel, for example ‘Cal-ib

807 Winter storage procedure4 Raw water cooling system • Close the sea cock. • Remove the lid of the water strainer. • If necessary, clean the ra

817 Winter storage procedureAnti-freeze can be toxic. Take care that no anti-freeze is spilled into the waterway• Check the seal between the lid and

827 Winter storage procedure6 Lubrication systemWith the engine still at operating tempera-ture: (If not, run the engine until warm, then turn o.)•

837 Winter storage procedure8 Electrical system• Disconnect the battery cables. • Charge batteries during winter lay-up regu-larly if required!•

848 Recommissioning after winter storageThe engine must be inspected and any main-tenance work carried out at the beginning of the sailing season. Co

858 Recommissioning after winter storage1 Fuel system• Drain the water from the water separator/fuel lter. (page 44)• Drain the water from the fu

868 Recommissioning after winter storage2 Raw water cooling system• Check that the lid of the raw water strainer is reinstalled.• Check whether th

OILCOOLANT878 Recommissioning after winter storage• Open the sea cock.3 Fresh water cooling system• Check the coolant level. (page 42)4 Lubricati

71 Safety measuresPrevention of injury• Be careful with battery acid!If battery acid comes in contact with the eyes or skin, rinse the aected part

888 Recommissioning after winter storage5 Electrical system• Make sure that the batteries are fully charged. (page 50, 83)• Connect the batteries.

898 Recommissioning after winter storage7 Check engine for leaks• Start the engine.• Check the fuel system, the cooling system and the exhaust for

909 TroubleshootingGeneralEngine faults are in most cases caused by im-proper operation or insucient maintenance.In case of a fault, always check r

919 TroubleshootingFault nding tableFault page1 Engine will not crank 922 Engine cranks but will not start, no smoke from exhaust 923 Engine cranks b

921 Engine will not crankPossible fault RemedyFaulty or discharged battery (too low voltage ) .Check / recharge battery and check engine alternator an

939 TroubleshootingFault nding table3 Engine cranks but will not start, smoke from exhaustPossible fault RemedyFaulty injector/injection pump. Check,

949 TroubleshootingFault nding table5 Engine does not reach maximum rpm under loadPossible fault RemedyFuel pre lter clogged . Clean/replace.Fuel l

959 TroubleshootingFault nding table6 Engine overheatsPossible fault RemedyFaulty injector/injection pump. Check, replace if required.Sea cock closed

969 TroubleshootingFault nding table8 Engine has little or no oil pressurePossible fault RemedyOil level too low. Increase level.Incorrect lube oil S

979 TroubleshootingFault nding table10 Fuel consumption excessivePossible fault RemedyFaulty injector/injector pump. Check, replace if necessary.Inco