Vetus M4.55 Service Manual

Operation manualM4.55

81 Safety measures • When the engine stops suddenly: If the engine stops suddenly, do not start it again immediately. Track down the cause

FOKKERSTRAAT 571 - 3125 BD SCHIEDAM - HOLLAND - TEL.: +31 (10) 4377700FAX: +31 (10) 4372673 - 4621286 - E-MAIL: sales@ vetus.nl - INTERN

99Vetus diesel engines are designed both for pleasure and commercial craft. Consequently, a wide range of variants are offered to mee

101 Engine data tagThe Ve t u s engine serial number and per-formance data are printed on the engine data tag.Model and engine serial number m

114 Cylinder numberingCylinders are numbered consecutively, beginning at the front end.5 Fuel pump seal Ca u t i o nBreaking the seals on the

12 1 Oil filler cap 2 8 mm fuel hose connection 3 Fuel pump 4 Oil filter 5 Engine oil cooler 6 Water separator/fuel filter drain plug 7

13 21 Push-pull gearbox cable connec-tion 22 Gearbox drain plug 23 Gearbox oil dipstick/filler cap 24 Starter motor 25 Alternator 26 Sea w

1 Tachometer/Operating hours counter 2 Voltmeter 3 Starter pre-heat switch/lock 4 Warning light high raw water temperature 5 Warning light

15 1 Tachometer/Operating hours counter 2 Voltmeter 3 Starter pre-heat switch/lock 4 Warning light battery charging second alternator 5 Warn

16 1 Tachometer/Operating hours counter 2 Voltmeter 3 Starter pre-heat switch/lock 4 Warning light high raw water temperature 5 Warning ligh

17Implementing the following recommenda-tions will result in longer life and better performance and more economical opera-tion of your engine.•

1 Commissioning the engineBefore starting the engine for the first time, the following procedures must be carried out:2 Filling with engine oilAs

193 Filling gearbox with oilFill the gearbox with oil.Check the oil level with the dipstick, see page 42. Technodrive:type TM345 : 1,6 litre

VD01130VD01129204 Filling the cooling systemRemove the cap of the filler neck on the top of the heat exchanger housing.Remove the bolt from t

215 FuelEnsure that the fuel tank is filled with die-sel fuel.Use only clean, water-free, commercial approved diesel fuel.For fuel grade see page

22After repair work:Check that all guards have been replaced and that all tools have been removed from the engine.When starting with pre-heating, do n

23 Turn the start key on the instrument panel clock-wise; the warning lights for oil pres-sure and alternator will now light up and the alarm

2412 StartingNow turn the key further to the ‘s t a r t ’ position. Release the key as soon as the engine fires (the key will retu

253 UseStarting Check that the indicator lights for oil pres-sure and alternator are off. Cooling water should now flow out of the exhaust; if t

26Cruising3 UseVD00113The instrument panel is provided with the following instruments (Depending of the type of panel, see page 14).13 Tachometer

Cruising3 Use2714 VoltmeterIndicating the battery voltage.When the engine is running, the battery voltage should be between 12 and 14 Vol

Operation manualPlease enter the serial numbers here.These numbers should be quoted when inquiring about Customer Service, Repairs or Spare Parts (see

17 Electrical shutdownReduce engine speed to idle and shift the gearbox to ‘ne u t r a l ’. Turn the key entirely to the left, through the ‘of f ’ po

29The following guidelines should be observed for daily and periodic mainte-nance. Perform each function at the indi-cated time interval.

30Maintenance schedule4 MaintenanceEvery 10 hours or daily, before startingCheck engine oil level 32Check coolant level 33Check water strainer 34After

31Maintenance schedule4 Maintenance Da n g e rStop the engine before carrying out any maintenance work.When requiredBleeding fuel system 36Cleaning he

321 Check oil levelTurn the engine off.The dipstick is located on the starboard side of the engine.2 Oil levelThe oil level must be at or near

33VD001584 Checking coolant levelCheck the coolant level in the header tank. This has to be checked when the engine is cold.Remove the cap of

6 Checking the raw water strainerCheck daily whether there is any dirt in the raw water strainer. 7 Cleaning the strainerClose the seacock before r

35 Da n g e rDo not smoke when draining off water and sediment.Keepflameandsourcesofigni-tion out of the area. Remove spilled fuel and li

10 BleedingAfter the water separator/fuel filter has been drained, the air has to be bled from the fuel systemThe fuel system is self-bleeding.T

3712 Engine oil changeChange the engine oil every 100 hours of operation (together with engine oil filter replacement).If the engine runs less t

Please read and observe the information given in this operation manual. This will enable you to avoid accidents, preserve the manufacturer’s

4 MaintenanceEngine oil changeEvery 100 operating hours.VD00124oil f i l t e r , a r t .C o d e : StM00513814 Removing the oil filterUnscrew the oil

VD010523917 Refilling with oilRefill the engine with new oil (for specifica-tion see page 84) through the filler open-ing in the valve cover.Operate

4018 Battery, battery connectionsKeepbatterycleananddry.Remove battery cables (negative first).Clean battery posts (+ and -) and clamps and greas

4121 Checking electrolyte levelFor conventional batteries it is required to check the electrolyte level regularly. Remove vent caps (tak

42 Vetus engines are normally equipped with Technodrive or ZF-Hurth gearbox-es. Consult the supplied Owners Manual for more details a

4325 Draining the oilRemove the drain plug to drain the oil. Remove the fillercap to vent the gearbox and check if all oil has been drainedCollec

4427 Draining the oilDrain the oil with the aid of a separate sump pump. Insert the suction hose of the sump pump in the dipstick hole. Push

45 Withdraw the filter element (1).Check the O-rings (2 and 3) for damage and replace if necessary.Install the new filter and mount the unit o

4630 Checking / adjusting valve clea-ranceChecking the valve clearance must be done with a cold engine, that is an engine which did not run for

4732 Adjusting valve clearance• Checkvalveclearanceatcylinder1andadjust if necessary.• Rotate the crankshaft 180° clockwise and check valve

1 Safety measures 4 2 Introduction 9 Data tag 10 Serial number 10 Cylinder numbering 11 Fuel pump seal 11 Identification of engin

35 Fuel filter removalThe fuel filter is to be replaced as a unit.• Closethefuelstopcock.• Removethefuelfilter,useafilterwrench.Catch an

4937 Fuel lift pump• Check, and if necessary clean, filterinside the fuel lift pump.• Openthefuelstopcock.• Checkforleakage.38 Bleedi

5039 Inspection V-beltInspect the belt for wear and tear (fraying and cracking). Belts which are in poor condition should be replaced.Check, t

5142 Check flexible engine mountsCheck the bolts which secure the damper element, the mounting bolts to engine bed and the nuts at the adjustment spi

5245 Raw water pump inspectionThe rubber impeller of the outboard water pump is not proof against running dry. If the water supply has bee

5348 Impeller inspection• Inspecttheimpellerfordamage.• Replacetheimpellerifnecessary. no t eOnly engines with intercooling!49 Re-install

5451 Coolant replacementThe coolant has to be replaced every 1000 operating hours or at least once every two years.N.B. Replacing the coolant may

554 MaintenanceCoolant replacementEvery 1000 operating hours.VD01147 VD01148PH21312VD0113152 Draining of coolantDetach the hose to the oil coll

56VD00158VD01129VD0113053 Filling the cooling systemRemove the cap of the filler neck on the top of the heat exchanger housing.Remove the bol

574 MaintenanceCoolant replacementEvery 1000 operating hours.VD00626 VD00627A B54 Filling coolant system if a water heater is connectedA) The h i g h

441 Safety measures Da n g e rIndicates that great potential danger exists that can lead to serious injury or death. Wa r n i n gIndicates that a pote

5855 Changing the air filter• Loosenthehoseclamp(1).• Removethefilterhousing(2).• Removetheoldfilterandfitanewfilter(3).• Replac

59 At full load (with the boat cruising) the maximum engine speed should be about 3000 RPM (see technical data page 80). If the engine does

60VD0114813 Only clean the heat exchanger if this is (badly) fouled.Under normal conditions of use cleaning the heat exchanger is not necessary!

61 • Removethefillercapfromthetopoftheheat exchanger housing to allow air into the system and check that all coolant has drained off.6

4 MaintenanceCleaning the heat exchangerSTM721762VD01146VD0114513 (2x)1762 Revolving the alternator out-wardsLoosen the bolts of the adjustment br

no t eOnly engines with intercooling!6365 Replacing heat exchangerReplace the heat exchanger in the original position in the heat exchanger housing.

641 Fuel systemDrain the water from the water separator/fuel filter and the fuel tank. Ensure that the tank is completely filled with fuel.Running wi

652 Lubrication systemWith the engine still at operating tem-perature: (If not, run the engine until warm, then turn off.)Replace the oil fi

664 Fresh water cooling systemTo avoid corrosion during winter storage the cooling system must be filled with an antifreeze/water mixture (or

67VD00027 VD001416 Recommissioning after winter storage1 Fuel systemDrain the water from the water separator/fuel filter. (page 35)Drain the wate

51 Safety measures• Donotsmokeifrefuelling.• Avoid spilling fuel on hot surfaces.Spilled fuel must be cleaned up imme-diately.• Do not

68VD00137 VD001256 Recommissioning after winter storage Open the fuel valve.2 Lubrication systemCheck the engine oil level. (page 32)3 Raw water co

69VD001386 Recommissioning after winter storageThe lid of the raw water pump and drain plugs are reinstalled. (pages 52, 53) no t eOnly engine

70CT40063VD001406 Recommissioning after winter storage4 Fresh water cooling systemCheck the coolant level. (page 38)5 Electrical systemMake sure t

71VD005816 Recommissioning after winter storage6 Check engine for leaksStart the engine.Check the fuel system, the cooling system and the exhaust for

72Engine faults are in most cases caused by improper operation or insufficient mainte-nance.In case of a fault, always check first that the

73Fault finding table7 Troubleshooting1 Engine will not crankPossible fault RemedyFaulty or discharged battery. Check / recharge battery and check en

74Fault finding table7 Troubleshooting3 Engine cranks but will not start, smoke from exhaustPossible fault RemedyAir in fuel system. Check and bleed.

75Fault finding table7 Troubleshooting5 Engine does not reach maximum rpm under loadPossible fault RemedyAir in fuel system. Check and bleed.Fuel fil

76Fault finding table7 Troubleshooting7 Engine not firing on all cylindersPossible fault RemedyAir in fuel system. Check and bleed.Fuel filter clogged

77Fault finding table7 Troubleshooting9 Engine oil consumption excessivePossible fault RemedyOil level too high. Lower level. Excessive inclination o

61 Safety measuresPrevention of injury• Themovingpartsoftheenginearedan-gerous. Never touch moving parts of the engine while it is runnin

78Fault finding table7 Troubleshooting11 Blue exhaust smoke (idling)Possible fault RemedyOil level too high. Lower level.Excessive inclination of eng

79Fault finding table7 Troubleshooting13 White exhaust smoke (at full load)Possible fault RemedyAir in fuel system. Check and bleed.Faulty injector/i

808 Technical dataEngine specificationsModel M4.55General Make : Vetus MitsubishiNumber of cylinders : 4Based on : S4L2-TType : 4-stroke d

818 Technical dataEngine specificationsOil lubrication systemOil capacity, max. withoutoilfilter : 5.5litres (1gal-1.7pt,UK) (1 ga

Screw connection Wrench Torque Diameter Pitch Size Nm (kgm) (ft.lbf)Cylinder head bolt M10 1.25 14 88 ±5 (9 ±0.5) (65 ±3.5)Connecti

83Fuel Quality GradeUse commercially available diesel fuel with less than 0.5% sulfer content. If the sulfur content is higher than 0.5%, the

849 Operating mediaLubricating oilEngine oilLubricating oils are specified by perform-ance and quality classes. It is usual for the specification

859 Operating mediaLubricating oil Ca u t i o nDo not mix oil of different brands together. Oils of different brands are mostly not com-patible with

86Gearbox Lubricating OilOnly use a recognised brand of oil for lubricating the gearbox.Technodrive:type TM345 : 1.6 litres, Motorolie SAE 20W40-CD

87Coolant fluidThe preparation and monitoring of coolant in inter-cooled engines is especially important because corrosion, cavitation and freezing ca

71 Safety measuresPrevention of injury• Becarefulwithbatteryacid! If battery acid comes in contact with the eyes or skin, rinse the affect

88-4 -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

89BlackYellow/GreenVioletWhiteRedYellowRed2nd AlternatorG3Y2nd AlternatorD+WB+BatteryBatterymain switch3085 878687aFuse 5A3085878687a1N40023085878687a

9010 Wiring diagramEngine with panel model ‘20’, ‘21’, ‘22’engine with keel cooling-4 -1 -2 -5 -3Q1R1 61 91 92 93 WL1 L2 L3 L4 L5R2R3-619/94X2M

9110 Wiring diagramEngine with panel model ‘20’, ‘21’, ‘22’engine with keel cooling-4 -1 -2 -5 -3Q1R1 61 91 92 93 WL1 L2 L3 L4 L5R2R3-619/94X2M

9210 Wiring diagramOptions, panel model ‘10’engine with intercoolingQ1R1 61 91 92 93 95L1 L2 L3 L4 L5R3R219/94155817/1931D1D2D3 D4D5D6D7D8D9D

9310 Wiring diagramOptions, panel model ‘34’engine with intercooling-4 -1 -2 -5 -3Q1R1 61 91 92 93 W Ð + (31) (15)-1 -2L1 L2 L3 L4 L5R2R3-6

9411 Overall dimensions1:101 Exhaust ø 40 mm2 Fuel return ø 8 mm3 Fuel supply ø 8 mm4 Sea water intake ø 20 mm242 58590275430490195380575200971 2 43MI

95BBattery 40, 41Bleeding 36CChanging the gearbox oil 43, 44, 45Checking engine oil level 32Checking engine speed 59Checking the V-belt 50Checki

96TTachometer 26Technical data 80–82Tensioning V-belt 50Topping up coolant 33Topping up oil 32Torque wrench settings 82Troubleshooting 72–77UUs

ManualsArt. code Description340401.01 Bedieningshandleiding M4.55 (Nederlands)340402.01 Operation manual M4.55 (English)340403.01 Bedienungsan