Manual - CM2.16 & CM3.27
Contents
1. umo 08 52 218 0 Ji 1 lt m 2 Magen naran NU a E aa E a uu ND d nti xp lineas cr EY m oe a 3 x n 27 ENGINE MANUAL CRAFTED WITH CRAFTSMAN MARINE PROPULSION 2 CRAFTED WITH CRAFTSMAN MARINE Note This manual applies to model CM2 16 and model CM3 27 Therefore it can happen that a drawing or picture is not always an exact referral to the engine that you have purchased Please read this manual carefully before commissioning the engine Improper use of this engine may cause accidents and all warranty conditions may become invalid In this manual you will also find detailed instructions of how and how regularly the various components of your engine must be serviced This engine must be used exclusively accordance with the prescription given in the General Conditions of Sale and Supply In the case of deviating use the manufacturer does not accept any responsibility whatsoever for resulting damage This type of risk is to be borne exclusively by the User Correct and proper use also implies strictly adhering to the prescriptions of operation maintenance and repair Only such persons who are acquainted with the operation the maintenance and the repair of your engine and who are fully aware of any danger involved should be allowed to work at2. ER Exhaust injection bend 430 040 mm L3 OU eg BEES Jie T SIT viae r3 iB CT Ji C VI J Drain plug cooling system n yy 2n ME m ali og 3 Wo HS Starter motor 17 d WT T tore TUS I 1 EN m res YT IT Gal VS Y nni e i 1 lt a CRAFTED WITH CRAFTSMAN MARINE 9 2 Product description CM CODE AA 250 21120 ENGINE NUMBER 146 201 M7 RPM KWJ HP 3 600 11 8 16 GEARBOX no RED 11302 2 05 identification tag The Craftsman Marine identification tag is the place to find the engine model the serial number and a few more data concerning your engine D You will need this information if and when you have to order spare parts or if you want to correspond with our service department 10 CRAFTED WITH CRAFTSMAN MARINE Position of the identification tag The Craftsman Marine identification tag is located on top of the rocker cover next to the filler cap for the inner cooling system The identification tag of the 2 cilindre engines is located on the gearbox housing X iz iil e TR etit Mitsubushi engine serial number The Mitsubishi engine serial number is engraved into the engine block to the starboard side Prior to commissioning the engine Engine lubrication oil The Craf
3. Dipstick Oil level Topping up the lubrication oil In order to verify the level of lubricating oil the engine The markings on the dipstick indicate the upper and the The filler cap is located on top of the rocker cover at the must be stopped and cooled down lower limit of the oil level The correct oil level is front of the engine at the right side of the engine there spot on or close to the upper mark If the engine has not is another filling entry The dipstick is located at the right side seen from the enough oil fresh oil of the same specifications must be rear of the engine in between the oil filter and the raw added The difference between the upper and the lower water pump mark is about 2 liters of oil Do not spill oil over the engine better use a funnel when adding oil 17 Make sure that no oil is added above the upper mark of the dipstick Any lubricating oil in excess will be burnt in the cylinders causing black smoke from the exhaust and strong internal pollution of the engine CRAFTED WITH CRAFTSMAN MARINE 19 Maintenance and inspection Check up of coolant level Always verify the level of the cooling fluid when the engine is cold Open the filler cap on the expansion tank if fitted or else the filler cap on top of the housing of the heat exchanger and make sure that the coolant is level is about 1 cm below the bottom of the filler pipe If so required top up with fresh cooling liquid se
4. If there is sufficient space below the bottom of the gearbox you may also remove the drain plug of the gearbox for letting the oil out In both cases collect the oil in a bowl and treat it in accordance with the environ mental directives in your country Maintenance and inspection Adding oil Fill the gearbox with its lubricant through the hole of the dipstick or via the filler cap if available dependent on the model of gearbox Please consult the owner s manual provided by the manufacturer in question CRAFTED WITH CRAFTSMAN MARINE 25 6 Maintenance and inspection ii Remove the fuel filter Fit the fuel filter Cleaning the filter of the fuel lift pump Close off the fuel supply to the engine Remove the Clean the surface to touch the engine before fitting the Consult your dealer entire filter with the aid of a special tool It is possible filter Grease the rubber ring with clean engine oil Fill that the filter still contains some fuel which please the filter with clean diesel fuel Position the filter collect and treat it in accordance with the environ against the filter housing and tighten it with one half to mental directives in your country three quarters of a turn Clean the filter of the fuel lift pump and reopen the cock of the fuel supply Do not smoke when working at or around the fuel system and avoid open fire 26 CRAFTED WITH CRAFTSMAN MARINE
5. e Setting of stop valve incorrect e Defective glow plugs e Incorrect valve tolerance e After engine overhaul incorrect injection moment e Insufficient combustion air e Poor fuel quality or polluted fuel e Incorrect SAE specification or quality of lubricant 32 CRAFTED WITH CRAFTSMAN MARINE e Open e Fill e Check breathe e Check replace e Check replace e Check and replace if necessary e Check clean e Check e Check clean e Replace Moreover position a water separator fuel filter into the fuel line between tank and engine e Check clean e Check bleed the system e Check replace if necessary e Check readjust e Check replace e Read just e Check readjust e Check air intaker and remove blockage e Check fuel quality Drain fuel tank and rinse it well Fill with good quality fuel e Replace by good quality lubrication oil Problems and solutions 9 Problem Probable cause Solution 4 Engine starts running but with Empty fuel tank e Fillit irregular cycles or it stops again e Air in the fuel system e Check bleed the system e Fuel filter clogged up with water and or dirt e heck clean or replace e Leaking fuel supply or fuel injection line e Check and replace if necessary e Defective injector injection pump e Check and clean or replace e Breather line of fuel tank clogged up e Check remove blockage e Fuel line clogged e Check remove blockage e Incorrect valve clearance e Readjust
6. Check the flexible engine mountings Use a suitable tool to make sure that the bolts on the engine bed and the nuts on the spindle are securely tightened The rubber element must not show any fissures Should this be the case then the engine mounting must be replaced DS Make sure as well that the damper element is still sufficiently flexible If not so the engine must be realigned Maintenance and inspection Verify the hose connections Verify the fasteners Inspect all hoses of the cooling system and of the fuel Make sure that all and sundry bolts nuts and screws system Check for loose connections or cracks and are well tightened fissures in the rubber hoses In such case the hose must be replaced CRAFTED WITH CRAFTSMAN MARINE 27 Maintenance and inspection Spanner 1 13 Inspection of the V belt Verifying the tension of the V belt Tensioning the V belt Check the V belt for wear and tear cracks and fissures tension of the V belt is correct if it can be moved by In order to tension the V belt the bolts of the support and ravels In all of these cases the V belt must be more than 12 mm using thumb and forefinger anda and both bolts of the alternator must be loosened replaced Only check the V belt when the engine is not force of about 10 kg If the travel of the belt is greater Tension the belt by pushing the alternator outward running the tension must be adjusted
7. Thereafter first tighten the upper bolt of the alternator and thereafter the support and the lower bolt of the alternator 28 CRAFTED WITH CRAFTSMAN MARINE Winter storage Protective fuel mixture So as to protect your engine well during the standstill of the winter season it is recommended to have the engine running for some 10 minutes with a protective mixture of 10 lubrication oil and 90 of clean diesel fuel With this mixture idling revolutions only no revving up allowed Lubrication oil system Replace the oil filter and change the engine lubrication oil with a good quality of oil with protective properties see page 23 Raw water cooling system Close the raw water seacock and clean the raw water Strainer Drain so much cooling liquid from the inner cooling circuit so as to enable you to add 1 liter of extra anti freeze into the cooling circuit Have the motor idling for a few seconds so that the additional anti freeze can be spread throughout the system Anti freeze liquid is very poisonous Make sure anti freeze is not getting mixed up with raw water When closing the cover of the raw water strainer make sure that it tightens well If false air is coming into the system through a cover that is not closed tightly there is a Severe risk of overheating of the engine CRAFTED WITH CRAFTSMAN MARINE 29 7 Winter storage Inner circ
8. and ask him to solve the problem To up till corect oil level Replace Repair replace Check adjust alignment Replace by good quality engine lubricating oil Replace defective component Lower the oil level Check adjust alignment Replace by good quality lubricating oil Repair replace Check compression overhaul engine if needed Check air inlet and ventilation openings in engine room Check the dimensions of the boat propeller Problems and solutions Problem Probable cause Solution 10 Excessive fuel consumption of engine 11 Blue smoke coming out of the exhaust when idling 12 Black smoke coming out of the exhaust under load 13 Engine produces white smoke from the exhaust at full load e Poor or polluted fuel quality e Defective injector injection pump e Incorrect injection moment e Excessive wear and tear of cylinder piston e Insufficient supply of combustion air Oil level too high Excessive inclination angle of the engine Leaking oil seal of the turbo compressor Defecte turbocompressor Insuffient supply of combustion air Leakage in air intake manifold Defective injector injection pump Incorrect injection moment Incorrect valve clearance Excessive wear and tear of cylinder piston Engine overheated does not reach maximum rpm Air inclusion in the fuel system Defective injector injection pump Water in the fuel system Defective pre heating plugs Incorrect
9. e Idling revolutions too low e Readjust e Exhaust clogged up e heck remove blockage e Poor fuel quality or polluted fuel e Check fuel quality Drain fuel tank and rinse it well e Filter of electrical fuel lift pump is clogged Fill with good quality fuel e Check clean 5 Engine does not arrive at maxi Air in the fuel system e Check and bleed the system mum revolutions under full load e Fuel filter clogged up with water and or dirt e Clean or replace e Leakage in fuel supply line or fuel injection line e Check and replace if necessary e Setting of stop valve incorrect e Check reset e Oil level too high e Drain suffcient oil quantity e Incorrect SAE specification or quality of lubrication oil e Replace by engine lubrication oil of good quality e Incorrect valve clearance e Adjust e Clogging in the exhaust e Check remove clogging e Insufficient quantity of combusition air e Check air inlet and ventilation openings in engine e Poor fuel quality or polluted fuel room e Incorrect injection moment e Check fuel quality Drain fuel tank and rinse it well e Leakage of air intake manifold Fill with good quality fuel e Engine overload e Check readjust e Replace manifold e Check dimensions of boat propeller CRAFTED WITH CRAFTSMAN MARINE 33 9 Problemsandsolutions Problem Probable cause Solution 6 Engine becomes overheated 1 Not all cylinders are performing well 8 Engine has little or no oil
10. dimming Monitoring light charging current Monitoring light pre heating system 0 Low oil pressure gearbox e _ m m6 6 lt x wvAfa10E Optional The voltmeter may be replaced by a temperature gauge 4 5 678 9 10 Alfa 20 E 14 CRAFTED WITH CRAFTSMAN MARINE Revolution counter hour counter The revolution counter indicates the number of the engines revolutions per minute When underway do not let the engine run at maximum revolutions during a prolonged period of time Also do not have the engine idling for more than a few minutes and never run the engine at full throttle in order to heat it up quickly The hour counter indicates the total running time of the engine in hours Idling speed of the engines CM 2 16 and CM 3 27 850 rpm Prior to commissioning the engine Voltmeter The voltmeter shows the voltage of the battery When the engine is stopped and the starter switch turned to on or pre heat the battery voltage must be about 12 Volt When the engine is running the figure must read between 12 and 14 5 Volt e d m Monitoring lights The instrument panel features six monitoring lights for respectively 1 oil pressure 2 battery charging current 3 temperature inner cooling circuit 4 temperature raw water 5 low oil pressure gearbox 6 pre heating These monitoring lights except the pre heating monitor are connected to a buzzer If
11. eee eee ere eee ree reece errr rer ee ree reer errr errr rer reser reer rer errr errr errr errr eter re reer rece errr ree rer rer rer rer rere errr reer errr eres rer terre ee rere eee eee eee ee ere eee reer errr errr rere seer re ree ree rer rer reser ree rer errr errr terre ree reer er res rere eres terres terre reser rere rrr rer rere rr errr rere recreate rs rere ere eee ere eee ree ere re errr rer re rere reer rere errr terre 0 00 errr reese errr rer rer rer re reer verre rrr ree rer rer rer terre rrr rrr ere reer ere reer terre ree reer eee eee eee reer errr reer errr rere rer rer rer re ree reece creer ser re re rer rere errr res rer errr errr reser reece steerer rer re rec terre rrr re errr terre rrr reer er terre e eters 42 CRAFTED WITH CRAFTSMAN MARINE Notes rere eee ere reer rece errr reser rrr r rer rer re reer rere e reer er rer rer rere 0 00000000000 000000 00000000 000000000 000000000 e00ccceecececc secc 000000 000000000000 000 eee reer errr rere er re ree rer rer re rre rer errr errr ree rer reer errr reer errr rrr reece reer rere errr reser e rr errr reer errr reer rrr er rer re reer er rer terre seer r irri rs eee e eee ere eee ere cere rere errr terre reer rere errr reece reer rer rer rere errr ree rer reece reer rere errr reece rere rer rer errr errr reer errr erect er reer esr e rere errr terre eee e eee eee reer errr rere rere ree reece reer rere errr rer rr ere rer reer errr reer errr seer rere reer rere errr res rer
12. engine has sufficient lubrication and of all drain plugs see page 20 oil as described on page 11 CRAFTED WITH CRAFTSMAN MARINE 31 9 Problemsandsolutions Problem Probable cause Solution 1 Starter motor does neither rotate nor engage e Defective or discharged battery e Burnt fuse e loose or corroded connections in the starter circuit e Defective starter switch or relay e Defective starter motor or pinion does not engage e Starter relay not activated owing to insufficient voltage on account of a too long cable from engine to instrument panel e Jammed components e Check battery charge or replace and check alternator for proper functioning e Replace e Clean and tighten the connections e Replace defective component e Replace starter motor Fit an auxiliary starter relay e Repair 2 Starter motor turns round but engine does not respond 3 Starter motor turns round but engine does not respond smoke comes from exhaust e Fuel valve closed e Empty fuel tank e Airin fuel system e Fuel filter clogged up by water or dirt e Leak in fuel supply or fuel injection line s e Defective injector injection pump e Breather line of fuel tank clogged up e Clogging in exhaust line e Electrical fuel lift pump defective e Dirt in press or suction valves of the electric fuel lift pump e Filter of electrical fuel lift pump is clogged up e Airin the fuel system e Defective injector injection pump
13. pressure 9 Engine oil cumsump tion excessively Level of cooling liquid too low Raw water seacock closed Raw water strainer clogged Leakage in raw water entry system Defective thermostat Cooling liquid pump defective Defective impeller of raw water pump Defective injector injector pump Oil level too high Oil level too low Defective oil filter Air in the fuel system Fuel filter clogged up by water and or dirt Leakage in fuel supply line or fuel injection line Defective injector injection pump Fuel line clogged Defective glow plugs Incorrect valve tolerance Filter of electrical fuel lift pump clogged Defective electrical fuel lift pump Oil level too low Clogged oil filter Defective oil pump Excessive inclination angle of engine Incorrect SAE specification or quality of lubrication oil il pressure apparently too low on account of defective oil pressure switch sensor or gauge Oil level too high Excessive inclination angle of engine Incorrect SAE specification or quality of lubrication oil Leakage in lubrication oil system Excessive wear and tear to cylinder or piston Insufficient supply of combustion air Overload of engine CRAFTED WITH CRAFTSMAN MARINE Check top up Check and open Check clean Check replace Check replace Check replace Check replace Check and clean or replace if necessary Lower oil level Top up Replace In all these cases please consult your authorized dealer
14. reser ree re rier rer rr rer rer reer errr rect err ese errr errs eee reer ere eee ere eee ree ree rer re errr ee rrr reer rere eres reece seer re reer errr errr reece reer reer er reer ere errr res rer rer rere rrr errr reer ee rer errr errr rere errr rere eee eee ree re eee ree reer errr creer ere reer rere reer rer rere errr rere rer rere c errr eer e reece errr rere errr res terres rere eres terre reer er rer rere errr rer rer reser reer errs rere eee ere eee ree ere rer terre reer rarer rrr seer er reece reer re reer errr ere reer cere er re sre ree reese errr res rer rer re reer rere errr res rer reer eer e rere ere errr eee eee eee re eee ree rere rere creer eres rer rere reer er rere errr ree rer ee cre rer rec rer rere rer reser reece steerer rere eres reer errr rer terre reer rere eter rere sires rs eee ere eee ere eee ree ree rer reece reer terre reece errr reece reer rere errr ere cee rer rere r reer rer reer ere errr rer rer rer re reer re creer rere rer reer errr rte ree ree reer eee eee eee reer errr rere rere creer eres eer re ree re errr reer errr reer errr rece e eres rer rere ster rere errr rec ree reser reer errr reer rere errr rere errr reser rece steer errs rere ere reer re eee rer ree rer reece reer rere rrr errr rer rer reer errr reer rere errr reer errr rte reer errr errr err re ere r rer rer rere errr rer rere terre reer terre reer ers er reer errr rere errr reer er rer err re rer rrr rer terre rer rere rer rec
15. the buzzer becomes audible when the engine is running a problem has occurred to one of the functions described here above In that case stop the engine IMMEDIATELY cS CRAFTED WITH CRAFTSMAN MARINE 15 3 4 Engine operation Check first The starting procedure Note Always check on following points before starting the 1 Prior to starting the engine position the throttle lever at The time required for pre heating the engine is determined engine half of its travel without engaging the gearbox by the ambient temperature The lower the temperature the 2 Turn the key from the off position one stepfurtherto longer the pre heating procedure will take At freezing the right to the on position The monitoring lights for temperature it may take as long as 20 seconds and up to oil pressure charging currents and pre heating will light 10 seconds at temperatures of up to 7 degrees Do not e 011 level up and the buzzer is audible pre heat the engine any longer than 1 minute maximum e Coolant level 3 From the on position turn the key one step further to ls the raw water seacock opened the right to the pre heating position Now only the e 5 the main electrical switch on pre heating monitoring light is burning Keep the key e 15 the gearbox lever in the neutral position about 6 seconds in this position at an ambient temperature of 15 C or more 4 The turn the starter key one step further
16. valve clearance Incorrect injection moment Poor fuel quality or polluted fuel Condensation of vapour in the exhaust system on account of very low ambient temperature Check fuel quality Drain fuel tank and rinse it well Fill with good quality fuel Check and replace if necessary Check adjust Check compression overhaul engine if necessary Check the air intake and the ventilation openings in the engine room Lower oil level Check adjust alignment of engine Check replace Check air intake as well as the ventilation openings in the engine room Check replace Check replace Check and replace when necessary Check readjust Readjust Check compression overhaul the engine if needed Check the dimensions diameter and pitch of the propeller and replace the propeller if necessary Check bleed the system Check replace if necessary Check replace water separator fuel filter Check replace Check adjust Check adjust Check fuel quality Drain fuel tank and rinse it well Fill with good quality fuel No problem no danger CRAFTED WITH CRAFTSMAN MARINE 35 10 Technical data General specifications Basic engine Bore x stroke Capacity Number of cylinders Compression ratio Order of fuel injection Maximum number of revolutions Maximum torque Maximum output at flywheel Fuel consumption at 1800 rpm Exhaust diameter Weight 36 CRAFTED WITH CRAFTSMAN MARINE Type of
17. ce p tl Notes s000000000000000 000000000 000000000 soceeccosecesecceececc 00 00 000 000 000000e00 0 000000 00000000000000000 000000000000 000000e00c00e00c00c0 00000000 000000000e e00000000000000000000 000000000000 0ese0ecccecic cecco 000 0 00000000 0 000 00 00000000 000000 0000000000000 0seseececceccoccecccc sce0c 00000000 00000000 0000000000 s0000000000 000000000000 0000000000000 000sosereseseecec0sec0 secc 0000 0000 000000 00000000000000000000000 000000000000 e00secec0cccc0 00000000000 00000000000e e00000000000000000000 0000000000000 0e0ce0ceceecseccccce 0000 0000000000000 00000000 0000000000 0000 00000000000 cecceccocceeccc cc 000000000 00000000 00000000008 e0000000000 0000000000000 0000000000000 sosesesoseccececc sec 0000000000 000000 0000000000000 0000000000so0ec00e0cec0eccccccc 000000000000 00000000000 0000000 eee eee eee ee eee ree reer errr reer er reser rere ree ree rec re rrr see ree rer reer 00000 0000000000000000000000 000000 00000000 00000000000 00000000 0e00c0 00000000 000000000 rere eee eee errr errr ree ere reer ee rer rer re rrer rere eres reece sree reer errr ere seer r reer rere ere reer rece errr reece reer rer rer rere errr ere rer rr ere ere rere reer ere eee eee ree eee eee reer errr errr rere errr verre ree rec rer reser ree rer rere errr res rer rece errr reser reece sree re creer rec reer errr ree rer reer errr reer er reer 0000000000 rere
18. ct in question 05 Note a water separator does not belong to the standard scope of supply but must be procured and fitted none theless Danger Do not smoke when you drain liquids from engine or filters Keep open fire away from the location Remove any spilled oil or liquids before starting the engine 22 CRAFTED WITH CRAFTSMAN MARINE Changing of the engine lubrication oil Remove the dipstick first Then insert the hose of the special sump pump into the pipe of the dipstick Extract the oil from the engine by quickly pushing down the grip of the sump pump and then pull it slowly upwards Fitting the oil filter When all lubricating oil has been drained replace the oil filter A little more oil may then come out of the engine Collect this oil in a beaker or bowl and bring it with the rest of the used oil to the service station all in accordance with the environmental directives Replacing the oil must take place when the engine has its operating tempe rature but is stopped of course so that the fluid can be pumped out easily The oil temperature is then about 80 degrees Celsius so watch out for burning the skin Replace the engine lubricant and the oil filter after every 100 hours of service or at least once a year Maintenance and inspection Preparation of the new oil filter Clean the surface of the rubber ring in the rim of the oil filter and grease it with fresh e
19. d models ATF Automatic Transmission Fluid type A suffix A 12 CRAFTED WITH CRAFTSMAN MARINE Cooling liquid Prior to commissioning the engine for the first time the inner cooling circuit must be filled with cooling liquid In order to do so the filler cap on top of the heat exchanger housing must be removed Alternatively if and when an expansion tank is fitted remove the cap on top Prior to commissioning the engine The cooling system must be filled with 6 5 liters of cooling liquid You can fill the system with a ready to use product or prepare a mixture of 40 anti freeze on the basis of ethylene glycol and 60 of clean tap water Never fill the cooling system with sea water Never fill the cooling system with sea water Fill the system to about 1 cm below the bottom of the filler pipe The system will breathe automatically Do not forget to put the filler cap in place again and tighten the breather bolt Once the engine being commissioned and having run for the first time verify again the level of the cooling liquid and top up if necessary CRAFTED WITH CRAFTSMAN MARINE 13 3 3 Prior to commissioning the engine Standard panel type Alfa10E Alfa20E Revolution counter hour counter Voltmeter Starter switch Monitoring light temperature raw water Monitoring light oil pressure engine Monitoring light cooling liquid temperature Sensor for automatic backlight
20. do such work Pay attention to the symbols and read the instructions in the text Attention especially with a view to a safety risk for man or material cS Table of contents Disclaimer Safety 1 Standard scope of supply 2 Product description Service side Starter motor side 3 Priorto commissioning the engine Engine lubrication oil Gearbox Cooling liquid Standard panel type ALFATOE ALFA20E 4 Engineoperation Check first The starting procedure Monitoring lights oil pressure and battery charging current Maintenance Maintenance and inspection Topping up the lubrication oil Check up of coolant level Replace cooling liquid Checking of the cooling water strainer Draining of the water separator Check the flexible engine mountings Inspection of the V belt Winter storage Preparations for the new season Problems and solutions Technical data Lubricants and cooling liquids Overall Dimensions Table of contents 18 19 19 20 20 21 22 2 28 29 31 32 36 38 40 CRAFTED WITH CRAFTSMAN MARINE 5 1 Standard scope of supply General maintenance directives e Engine instrument panel type Alfa or type Alfa 20E By carefully adhering to the following recommendations you will be sure of the best e Engine cable loom with fuse and multi plugs possible conditions to operate your engine resulting in a long life span excellent e Connection parts for the push pull cabl
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22. e page 39 20 CRAFTED WITH CRAFTSMAN MARINE Replace cooling liquid Remove the two drain plugs of the cooling system from the engine block 1 and the housing of the heat exchanger 2 Remove the filler cap from the expansion tank and or the heat exchanger housing in order to quickly drain the liquid from the internal cooling circuit and to make sure that all of the liquid has been discharged from the engine Replace the drain plugs and tighten them well The inner cooling circuit is filled through the filler cap on top of the heat exchanger housing or as the case may be of the expansion tank Before filling in the fresh coolant remove as well the bolt on top of the cover of the thermostat housing This enables the cooling system to be vented air bled Fill the system with a mixture of 40 of anti freeze and 60 of clean tap water You may also use ready made cooling liquid see page 43 for the relevant specifications of the recommended coolant Top up to a level of about 1 cm below the bottom of the filler pipe After the engine being commissioned for the first time i e has warmed up and cooled down completely thereafter check again the coolant level and top up if necessary A Never add sea or salt water into the inner cooling circuit Open the filler cap on top of the heat exchanger housing only when the engine is cold Maintenance and inspection C
23. ec rer res rer rere cree rere errr reste eres rere eres terre rrr rer rer rere errr rer rer rere e reer eee reer errr cere errr errr reeves rer verre rrr rer rer rrr rer rer verre rrr ree rer rrr re reer reer errr ree ree rrr rer rer rer rer rrr rere reer reer errr reer reer errr rere rr eee eee eee Ce eee ree re reer rere errr rer eer re ree rer rer rere errr rer rer rere e rer re reer rere cre r verre rrr res rer rer re ree rer terre rrr rer rer rere errr reer err eres rrr errs CRAFTED WITH CRAFTSMAN MARINE 2 Product description Service side Air inlet silencer Filler cap inner cooling circuit Breather nipple cooling system Connections of i Connection for electrical system amp throttle push pull fuse A BALI rS cable A Ag ESITO m N Si bi LL id Exhaust 7 25 T lai DES TE X CA I d OFT Oil filler cap Connection to fuel return line 8 mm L Bm es i 4 AL GS IA i Y Fuel supply pump ay i l r 7 m x Connection to fuel He E al supply 8 mm SA Fuel filter aa m e X POTER gt F Raw water pump 0 20 mm Oil dipstick Manual operation of electrical Oil filter Stop Carter plug 8 CRAFTED WITH CRAFTSMAN MARINE Starter motor side Product description 2 Filler cap inner cooling circuit Heat exchanger Alternator r3 A ie d E A HA QU my
24. engine CM2 16 CM3 27 Mitsubishi Mitsubishi 76x70 mm 16 x 70mm 635 cm 952 cm 2 in line in line 23 1 22 1 IDI indirect IDI indirect 3600 rpm 3600 rpm 29 3 Nm at 3600 rpm 53 1 Nm at 3600 rpm 11 8 kW 16 pk 150 8665 3046 268 g kW h 196 g pk h 40 90 kg 20 kW 7 2 pk ISO 8665 3046 210 g kW h 199 g pk h 0 40 118 kg General specifications Gearbox Electric circuit protection Alternator Warning functions in instrument panel Instrument panel Connections for calorifier boiler Cooling system Flexible engine mountings Technical data 10 Type of engine CM2 16 CM3 27 no no automatic automatic 12 Volt 75 A 12 Volt 75 A il pressure Temperature of coolant inner circuit Charging current Exhaust temperature Pre heating Alfa 10E optional Dual circuit with heat exchanger CM type 2 il pressure Temperature of coolant inner circuit Charging current Exhaust temperature Pre heating Alfa 20E optional Dual circuit with heat exchanger CM type 3 CRAFTED WITH CRAFTSMAN MARINE 37 11 Lubricants and cooling liquids Viscosity Lubrication oil in gearbox Viscosity means that a liquid is syrupy and in this case it applies to lubricating oil Also in this case a lubricant of a well known and trusted brand is highly recom The viscosity is largely dependent on the ambient temperature and is expressed in mended terms of an SAE standard ZF Hurth T
25. es performance and fuel economy e Four flexible engine mountings e Sump pump e Have the maintenance procedures regularly executed as mentioned in this manual Accessory equipment required for a perfect engine installation optional e Prior to starting the engine always verify the correct level of the various fluids e All yearlong use a good quality anti freeze product protecting your engine against corrosion and frost damage Please see page 43 for the specifications of e Fuel filter water separator in the fuel supply line the cooling liquid e not ever put the engine into operation without a properly functioning thermostat so as to avoid overheating of the engine e Always use the correct quality of lubricants as specified on page 13 of this manual e Always use good quality diesel fuel free trom water and or other impurities e Switch off the engine immediately if the monitoring light s of oil pressure fresh e water temperature raw water temperature and or battery charging control light up For a complete list of supply take a look at our website www craftsmanmarine com b CRAFTED WITH CRAFTSMAN MARINE Notes rere eee rere rere cee re errs rer reece rrr rrr reer rere errr rer re ec 0c0 00000 000000000 000000000000 00000000000 s0s0s0sosce0ccccececcccse0 cc 00c0 00000000000000 0008 eee e eee reer errr rere rere reer errr reer rarer errr errr reer er rer rere eres rrr res terre rect e reer re rrr rer terre rrr r
26. free for many years to come This instruction manual informs you about the control the maintenance and the inspection of the Craftsman Marine diesel engines models CM2 16 and CM3 27 Please store this manual in an accessible place Should you have any further questions after having read this manual we shall be delighted to be of service Craftsman Marine B V 4 CRAFTED WITH CRAFTSMAN MARINE Safety This page will provide you with a survey of all warning pictograms used throughout this manual Notes referring to safety issues show this symbol Please adhere strictly to the recommendations in this chapter and instruct anybody else who may be operating or servicing the engine to do likewise hese are the safety recommendations DANGER ATTENTION e Never touch any moving parts when the engine is running e When in operation the engine or certain parts thereof may become very hot Do not ever touch these parts and be very careful with flammable products in the neighbourhood of the engine e When checking upon or adjusting any parts or when checking or filling lubricants or cooling liquids make sure that the engine is stopped e not open the filler cap on the expansion tank or on the heat exchanger unless the engine is completely cooled down e Maintenance and service to the engine must only be provided by experienced people using suitable tools If possible entrust only an authorized Craftsman Marine dealer to
27. hecking of the cooling water strainer Cleaning of the cooling water strainer Check once again Each day prior to starting the engine make sure that Clean the filter element at least twice a year or Make absolutely sure that the cover fits the strainer the cooling water strainer is not clogged by dirt Close whenever necessary If the cooling water strainer gets housing well and without any air leaks the raw water seacock and remove the cover from the clogged up the cooling liquid in the engine may filter housing for proper inspection overheat When closing the strainer gain make sure that the cover is perfectly shutting the unit off If and when air is sucked into the system on account of a badly closing filter cover there is a severe risk of overheating of the engine CRAFTED WITH CRAFTSMAN MARINE 21 6 Maintenance and inspection The fuel filter Draining of the water separator Bleeding of the fuel system After every 50 hours of service To drain the water separator After having drained the water separator fuel filter the Replace the fuel filter as described on page 26 e pen the drain plug at the bottom of the filter fuel system must be freed from air bled e Drain the water and collect it in a bowl close the drain plug Prime the fuel system by pumping the fuel pump manually with handle When all air has escaped close the bleeding nipples Uv Consult the manual supplied with the produ
28. ifications may be used CEN EN 590 or DIN EN 590 DIN 51 601 Febr 1986 Table of anti freeze concentration used for engine coolant BS 2869 1988 AT and A2 ASTM 0975 88 D1 and D2 NATO Code F 54 and F 75 Anti freeze Protection against freezing ethylene glycol up to 6 40 5 Fuel winter period During the winter season clogging up of the fuel system may occur and cause engine failure on account of separation of the paraffin content in the fuel Please use a winter type fuel suitable up to 15 C when the ambient temperature is less than zero degrees Celsius or a diesel fuel with additives suitable up to 20 C CRAFTED WITH CRAFTSMAN MARINE 39 12 Overall Dimensions Exhaust 40 mm Fuel supply 8 mm A A LO N OON SET ANI AOA SERO fears iS wa a ce 40 CRAFTED WITH CRAFTSMAN MARINE Overall Dimensions 12 Exhaust 40 mm Fuel supply 8 mm v TP ADT j i 3 reo 2 57 da 70 N X NN 9 Ns f CO ESSI i a ye yo lt A GLG ILL Sea Water Intake 20 mm 92 443 5 6 6 Tr E tl
29. ilter e Change the oil in the gearbox e Clean the filter which is located just before the fuel lift pump e Verify the flexible engine mountings to have the correct compression and adjust if necessary e heck all hoses and hose connections for leaks e Verify the tension of the V belt After the first 50 hours of operation Ask your dealer to execute this maintenance job e Drain water from the fuel filter water separator page 22 e Change engine lubrication oil page 23 e Replace oil filter page 23 e Change lubricating fluid in gearbox page 25 e Replace fuel filter page 26 e Verify idling revolutions and adjust if necessary page 15 After every 1000 hours of operation or at least once every two years Have your dealer check and execute the following After every 100 hours of operation or at least once a year e Verify the proper functioning of the raw water pump e Replace the cooling liquid in the inner cooling circuit Ask your dealer to execute this service job e Drain water from the fuel filter water separator e Change engine lubrication oil If necessary e Replace oil filter e Verify level of lubricating fluid in gearbox e Replace fuel filter e Check batteries cables and connections Bleed the fuel system page 22 Verify the number of revolutions when idling page 15 Only service the engine when it is not running 18 CRAFTED WITH CRAFTSMAN MARINE Maintenance and inspection 6
30. ngine lubrication oil CRAFTED WITH CRAFTSMAN MARINE 23 6 Maintenance and inspection Positioning of the oil filter Adding new oil filter Turn the new oil filter onto the engine thereby Fill the engine with lubrication oil with specifications as following the instructions given on the filter housing outlined on page 11 through one of both filling entries Use a funnel in order to avoid spilling of oil over the engine Have the engine idling during a few moments and check after leaks Stop the engine and check the oil level by means of the dipstick after about 5 minutes time 24 CRAFTED WITH CRAFTSMAN MARINE Checking of oil level in gearbox Remove the dipstick from the housing of the gearbox Clean the dipstick and position it again into the opening so as to verify the level of the lubricant If the level is too low fresh lubricant must be added through the opening for the dipstick See page 12 for the specifications of the lubrication oil for your gearbox As regards the maintenance of the gearbox please consult the owner s manual provided by the manufac turer in question Draining the oil from the gearbox First remove either the dipstick or the filler cap dependent on the gearbox model Position the hose of the special sump pump into the pipe of the dipstick Extract the oil from the gearbox by quickly pushing down the grip of the sump pump and then pull it slowly upwards
31. r errr terre rrr re reer rere errr reer errr restr errr rs reer ere eee ere cee ree reece reer re reer verre rrr reece ere rere errr rere errr ere reer rere reer re reer errr eres terres rer rer rer errr errr errr ester terres rere ree ree errr eee eee reer errr rer rer re reer er reser rre rer reer errr ree rer rer rer rere r rer re scree eres rer reser rrr res reer errr reer errr rr errr rer rer rere errr reer errr reer reir eee reer r eee rere eee ree ree rer re ere reer rarer rrr reece reer reser rrr reer er ree rer reer er rrr reer errr ere ree reer rere reer rer rere ere e errr re rer errr er rere eee ree reer ey eee eee eee reer errr rere errr creer eres rere errr rere er reer errr ree rer errr cree res rer reser rer rere errr rec rer rarer reer er reer errr ree rer errr errr rere reese r rrr errs eee eee ere eee rece errr ere rer reece reer rere e rrr reece reer reser reer rere rere rere r eres errr eer e ree rrr seer e erect er reer errr rrr seer r eres rer errr rere terre ree reer ree ee eee reer e ree rer reer ese e rer rer re rrr rer rer rer rere eres reer errr seer er res rer rere reer rece errr rer rer rece e reer errr reer rere errr terre rer reer er reser stress errr eee ere eee eee eee ree eee rer re ere reer rere e rer reece reer rer re ree reer errr errr rer rere e reer errr reese errr reer er reece reer re reer rere r er errr er rere ree ree reer ey eee eee eee reer e reece reer verre rer rer rer rere errr rer re ree sere e errr ee r
32. rter key keep the black button on top of the position and let the engine idle during a few moments Turn fuel lift pump depressed during a few seconds The engine the starter switch to the far left position of stop After a will stop immediately by lack of fuel supply long trip it is recommended to have the engine idling for a few minutes before putting it to full stop When the engine has stopped turn the key one step to the right to the off position Close the seacock of the raw water inlet and turn the main electrical switch to the off position if the engine will not be used during a prolonged period of time CRAFTED WITH CRAFTSMAN MARINE 17 4 5 Maintenance In order to ensure a long life span of your engine it is imperative to adhere to the following directives pertaining to the periodical maintenance of the engine and its compo nents In the case of inadequate maintenance serious damage can be caused to the engine and no warranty claim can be accepted by the manufacturer These are the jobs to be performed Recording of data for verification Every 10 hours or daily before starting After every 500 hours of operation at least once a year e heck level of engine lubricating oil page 19 e Check level of cooling liquid page 20 Have your dealer check and execute the following e Check cooling water strainer for blockage of the water flow page 21 e Verify the tolerance of the valves e Replace the fuel f
33. to the right to the start position and release the key as soon as the Stop the starting procedure if the engine does engine springs to life the key will return automatically not come to life within 10 seconds Release to the on position where it will remain parked as long the key and wait till the starter motor has as the engine is running Have the engine running at come to a complete stand still before giving it idling revolutions during a short period of time so that another try Do not have the starter motor the engine will warm up to some extent running during more than 30 seconds in order to avoid damage by overheating 16 CRAFTED WITH CRAFTSMAN MARINE et Engine operation Monitoring lights oil pressure and battery charging current Make sure that the monitoring lights for oil pressure and charging current are extinguished and that cooling water is coming out of the exhaust line If not so stop the engine IMMEDIATELY Never turn the electric main switch to the off position when the engine is running Also do not turn the starter switch to the start position when the engine is running This may cause serious damage to the starter motor Electric engine stop Manual stop Before stopping the engine shift the throttle lever back to Should the engine not respond to the stop command by its neutral position place the gearbox lever into the neutral means of the sta
34. tsman Marine diesel engines are supplied without lubrication oil The engine can be filled with oil through the filler cap on the rocker cover or through the filler pipe at the front of the engine Before commissioning the engine for the first time it must be filled with 5 liters of lubrication oil for diesel engines with following specifications Type 15W40 API CD CE or CF4 CCMC D4 or DI When the filling of oil is completed check with the dipstick whether the level of lubricating oil is correct cS 3 A second filler cap is located at the starboard side next to the engine identification tag CRAFTED WITH CRAFTSMAN MARINE Il 3 Prior to commissioning the engine Gearhox The gearbox is located at the rear of the engine and it Here it is shown how the gearbox can be filled up with ZF Hurth must also be filled with the correct type and quantity of its lubricant When the filling is completed verify with lubricant the dipstick whether the correct level of fluid is Type ZF 10 0 35 liter ATF obtained Type ZF 12 1 1 liter ATF Craftsman Marine diesel engines are supplied with gearboxes of several brands and types Technodrive For the ZF Hurth and Technodrive brands the types and quantities are specified here below Please consult the Type TMC40 0 20 liter SAE 20 30 appropriate instruction manuals in the case of other Type 60 0 80 liter SAE 20 30 gearbox makes an
35. uit of the cooling system Electrical system Filters Make sure that the inner cooling system contains suffi Disconnect the battery cables and charge the batteries Drain the water from the fuel filter water separator in cient anti freeze in order to avoid corrosion Check with from time to time during the winter period order to avoid frost damage the aid of a volume gauge See page 39 for the relevant specifications If it appears that there is not enough Fit a new fuel filter see page 26 anti freeze in the coolant replace the liquid as described on page 20 30 CRAFTED WITH CRAFTSMAN MARINE Preparations for the new season 8 1 Open the fuel supply cock 6 If you have disconnected any hoses before winter 10 Start the engine and make sure that there are no storage these must all be connected again and leaks in the fuel system the cooling system and the 2 Charge the battery ies if necessary tightened well exhaust assembly 3 Connect the battery cables 7 Open the seacock of the raw water entry 11 Verify the proper functioning of all electronic parts and all engine instruments Also verify the proper 4 Verify that the cover of the raw water cooling 8 Check the level of the cooling liquid as described functioning of the mechanical remote control and the strainer is tightened well on page 20 gearbox 9 Verify the tightness of the raw water pump cover 9 Make sure that the
36. your engine Disclaimer For that reason always have your engine serviced maintained and repaired by an authorized CRAFTSMAN MARINE dealer In the case of modifications of the engine which have not been previously approved by Craftsman Marine in writing the responsibility of the manufacturer for any resulting damage is immediately rendered null and void Modifications of the injection and distribution system also form part of the aforemen tioned exclusion of the manufacturer s warranty Moreover they may affect the performance of the engine and the exhaust gas emission in a negative fashion It may be possible that the fulfillment of the legal prescriptions regarding the emission of exhaust gases aiming at the protection of the environment is no longer guaranteed in that case The specifications and the descriptions in this instruction manual were correct at the time of going to press However Craftsman Marine is continuously striving after the improvement of its products and therefore reserves the right to modify at all times and without prior notification product specifications and instruction manuals CRAFTED WITH CRAFTSMAN MARINE 3 Preface Dear owner of this engine We should like to thank you very much indeed for your decision to procure a marine diesel engine made by Craftsman Marine Provided you will make proper use of it and take care of adequate maintenance this engine will serve you faithfully and trouble
37. ype ZF10 0 35 liter ATF Type ZF12 1 1 liter ATF Engine oil Always use a type of oil that suits the environment in which the engine operates We Type TMC40 0 20 liter recommend the use of a four seasons engine lubricant branded SAE 15 W 40 Engine lubricating oil SAE 20 30 which is suitable for ambient temperatures of between 15 and 35 C Type TMC40M 0 20 liter ATF Type TMC60 0 80 liter It is strongly recommended to use a type of engine lubrication oil made by a well Egine lubricating oil SAE 20 30 known manufacturer with the following classifications ATF Automatic Transmission Fluid Type 15W40 API CD CE of CF4 CCMC D4 of D5 Oil lubrication system 011 capacity maximum 2 4 litres without oil filter maximum 2 9 litres with oil filter CM2 16 011 capacity maximum 3 6 litres without oil filter maximum 4 1 litres with oil filter CM3 27 Cooling system Capacity with inter cooler version 2 2 litres with keel cooler version 3 litres CM2 16 Capacity with inter cooler version 3 litres with keel cooler version 4 litres CM3 2 38 CRAFTED WITH CRAFTSMAN MARINE Lubricants and cooling liquids 11 Fuel summer period Cooling liquid Always use a good diesel fuel with sulphur contents of less than 0 5 The maximum Always use a mixture of anti freeze on the basis of ethylene glycol and clean tap admissible sulphur percentage is 1 Water Following fuel spec
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