Canaline Engines Canaline 30 Service manual

Canaline
Marine Engines
Operator’s handbook
Engines Models
Canaline 25
Canaline 30
Canaline 38
Canaline 42
Canaline 52
Canaline 60
Failure to read this or carry out the required service programme may invalidate your warranty

3
Index
Introduction 4
Engine Identification 5
Safety precautions 6
Canal Boat Specification 8
Starting / Stopping 9
Fuel and Oil Specifications 1
Maintenance Schedule 15
Installation Information
Wiring diagrams 3
Anti Vibration Mounts / Alignment installation 9
Calorfier Connections / Position 31
PRM 80/1 0 Cable installation 33
Fast Moving Parts list 34
UK Dealer Network 35
RCD Certificate 36
Warranty Terms and conditions 37
Service Record 40
Warranty registration card Loose

4
Introduction
This Canaline Marine diesel engine is based on the Kioti diesel engine which is
manufactured by the Daedong Industrial Co Ltd.
Engines Plus Ltd wishes to thank you for purchasing your new Canaline Marine
Diesel engine. Your new engine is the result of many years of research and
development and high quality manufacturing, this engine is designed based on
strict quality standards established by the unit assuring quality of Kioti genuine
components. Its knowledge on the operation of the diesel engine is based on
faithful services and reliability for years. This manual makes users familiar with
the diesel engine and provides useful information on safety, operation, and
maintenance of the diesel engine.
To get the fullest use and benefit from your marine engine, it is important that
you install, operate and maintain it correctly. This manual, along with gearbox
operators’ handbook, is designed to help you do this.
Please read this manual carefully and follow its operating maintenance
recommendations, along with the installation guidelines. This will ensure many
years of trouble-free and economical engine operation.
Should you require further advice, technical assistance or an engine service,
please contact your nearest marine engine outlet, he knows your engine best and
is ready to meet your requirements.
On completion of the warranty registration card, you will receive a warranty
certificate which forms part of your warranty agreement with Engines Plus Ltd
All information, illustrations, and specifications contained in this Manual are based
on the latest product information available at the time of publication.
Engines Plus Ltd is a mariniser of industrial diesel engines, of which the Canaline
product is part of our product portfolio. Engines Plus Ltd produces this manual for
use on the Canaline marine engine based on the Kioti Diesel engine.
Engines Plus Ltd reserves the right to make changes in this manual at any time
without prior notice.
The information given is subject to the company’s current conditions of Tender
and Sale, is for the assistance of users, and is based upon results obtained from
tests carried out at the place of manufacture and in vessels used for development
purposes. We do not guarantee the same results will be obtained elsewhere
under different conditions.

5
Engine Identification
NOTE: In all communications with the Engines Plus Ltd or a local dealer the
engine serial number and engine type must be quoted.
The engine serial number is on the top of the engine, on a designated number
plate.
As part of your engine warranty please return your registration card, which is
supplied loose, as soon as possible.
Engine Information
Fill in your engine information below, so you have it to hand when contacting
your local dealer.
Engine Type:
EP Serial No:
Gearbox Type:
Gearbox Number:
Date of Installation:

6
Safety Precautions
Keep the engine, gearbox and surrounding area clean, including the area
immediately below the engine.
Drives Power Take Off Areas
Gearbox Output Flange
The purpose of the marine diesel propulsion engine is to provide motive
power to propel a vessel. Accordingly the gearbox output shaft rotates at
between 133 and 400rev/min. This flange is designed to be coupled to a
propeller shaft by the installer and steps must be taken to ensure adequate
guarding.
Forward End Drive
Engines are supplied with unguarded vee and poly vee belt drives to power
the fresh water pump and battery-charging alternator. The installer must
ensure that it is not possible for injury to occur by allowing accessibility to this
area of the engine. The pulleys run at high speed and can cause injury if
personnel or clothing come in contact with the belts or pulleys, when the
engine is running.
Exhaust
Exhaust Outlet
Diesel marine propulsion engines emit exhaust gases at very high
temperatures – around 400 - 500°C. Engines are supplied with either wet
exhaust outlet (water injection bend) or dry outlet (dry exhaust stub) – see
engine price list. At the outlet next to the heat exchange header tank, the
exhaust outlet can become very hot and if touched, can injure. This must be
lagged or avoided by ensuring adequate guarding. It is the responsibility of
the installer to lag the exhaust system if a dry system is used. Exhaust gases
are harmful if ingested, the installer must therefore ensure that exhaust lines
are lead overboard and that leakage in the vessel does not occur.
Fuel
Fuel Lines
Diesel engines are equipped with high pressure fuel injection pumps, if
leakage should occur, or if pipes fracture, fuel at high pressure can harm
personnel. Skin must be thoroughly cleaned in the event of contact with
diesel fuel.
Fuel Supply Connections
Engines are supplied with 8mm compression fittings. The installer must
ensure that when connections are made, they are clean and free of leaks.
Oil
The Canaline marine propulsion package is supplied with dipsticks, one for
the engine and one for the gearbox. Ensure dipsticks are returned and secure
after checking, if not oil leaks can cause infection when touched. Do not

7
remove dipsticks whilst engine is running, as this can cause oil to blow out. All
oil must be removed from the skin to prevent infection.
Scalding
An engine running under load will have a closed circuit fresh water
temperature of 71° to 85°C. The pressure cap on the top of the header tank
must not be removed when the engine is running. It should only be removed
when the engine is stopped and has cooled down.
Transportation/Lifting
Engines are supplied on transportable pallets. Lifting eyes on engines are
used for lifting engine and gearbox assembly only, not the pallet and
associated kit.
GENERAL DECLARATION
This machinery is not intended to be put into service until it has been
incorporated into or with other machinery. It is the responsibility of the
purchaser/installer/owner, to ensure that the machinery is properly guarded and
that all necessary health and safety requirements, in accordance with the laws of
the relevant country, are met before it is put into service.
Note: Recreational Craft
Where applicable, the purchaser/installer/owner and operator must be
responsible for making sure that the Recreational Craft Directive 94/ 5/EC is
complied with.

8
Canal Boat Engines – Technical Data
Model Canaline
25
Canaline
30
Canaline
38
Canaline
42
Canaline
52
Canaline
60
Cylinders 3 3 4 4 4 4
Bore 75.0 80.0 83.0 83.0 87.0 87.0
Stroke 76.0 9 .4 9 .4 9 .4 9 .4 10 .4
CC 1000 1390 1999 1999 179 430
Combustion
Indirect Injection
Cooling Keel Cooled
BHP 8 38 4 5 60
Max r/min 3000 3000 600 3000 3000 3000
Oil Capacity
3.8 5.8 8.0 8.0 8.0 9.7
Weight 130 05 35 37 48 56
Alternator 50 & 90 50 & 100
75 & 100
75 & 175
75 & 175
50 & 175
Gearbox PRM 80 PRM 80 PRM 1 0 PRM 150 PRM 150 PRM 150
Starter
Battery size
Minimum recommended size - 700 CCA / 100 Ah
Note: The specification details above are our standard configurations.

9
Starting and Stopping
Important checks prior to use
Your engine has been filled with new oil for both engine and gearbox when it
leaves the factory. However, please check, see section on engine maintenance.
Ensure the engine is free to turn without obstructions, and daily checks have
been carried out.
Ensure battery is fully charged and connected (the isolator is in the ‘ON’ position).
Ensure Morse speed and gearbox cables are fitted correctly and that cable travel
lengths are correct.
Ensure engine is out of gear with 1/3 throttle – see single lever control instruction
manual
Ensure fuel taps from fuel tank have been turned on
CAUTION: for safety’s sake conduct inspection before start up with
engine stopped.
Engine starting
On turning the key to position “1” on your panel, the panel will go through a
procedure, to ensure all lights and the buzzer are working, once this has been
completed you can then start the engine.
First Start of the day, from cold or initial installation
Turn the Key to the “1” position.
Turn the Key to the Pre-Heat position and hold until the yellow light goes
out
Turn the Key to the Start/Crank position and release when the engine fires.
Starting an engine already at running temperature.
Turn the Key to Pre-Heat and hold until the yellow light goes out.
Turn the Key to the Start/Crank position and release when the engine fires.
Ensure alarm buzzer is not sounding and red warning lights are off.
Note:
If the alternator warning light is still on then increase the engine speed to excite
the alternator, then return to idle. The light should then go out.

10
Continuous engagement of the starter to the flywheel ring gear without giving
them a break will result in the damaged starter pinion gear and flywheel ring
gear. Crank for no longer than 0 seconds, with a 0 second break between
attempts.
The oil pressure gauge on the deluxe engine control panel will read high on start
up and whilst the engine is cold. This is normal it will then decrease.
STOPPI G
Every propulsion engine is fitted with a stop solenoid. To stop engine simply turn
the key to the “0” position and the engine will stop.
When leaving the boat for an extended period, turn off battery isolator
Canaline Engine Control Panels
Canaline Engine control panels feature LED Module to indicate as listed below. An
Intermediate Panel is shown for illustration only.
14
5
3 6
1. Yellow ~ Timed PreHeat LED
Illuminates when Key is switched to Preheat position to indicate Preheat time.
. Red & Buzzer ~ Engine Coolant Temperature
LED Illuminates and Buzzer sounds if Engine Temperature is too high.
3. Red & Buzzer ~ Starter Alternator
LED Illuminates and Buzzer sounds if no charge from Alternator or Belt breaks.
4. Green ~ Panel Power
LED illuminates when Key is switched on.
5. Red & Buzzer ~ Engine Oil Pressure
LED Illuminates and Buzzer sounds if Oil Pressure is too low.
6. Red & Buzzer ~ Auxiliary / Domestic Alternator
LED Illuminates and Buzzer sounds if no charge from Alternator or Belt breaks.

11
Checks during operation
While operating the engine, keep checking whether all parts of the engine are
operating smoothly and properly.
COOLING SYSTEM
If steam or coolant is escaping from the overflow tube; stop the engine, allow it
to cool, and check the following and correct as needed.
1. Check for cooling system leaks.
. Check for obstructions that block cooling air.
3. Check and adjust the fan belt tension.
4. Ensure that the system is filled to the correct coolant level with the proper mix
of anti-freeze and water.
5. Check the radiator cap for proper type and condition.
IMPORTANT
To avoid personal injury :
DO NOT remove the manicooler cap while the engine is hot.
Pressurized steam or coolant will escape and cause serious injury to
you and any bystanders.
Open the cap at least 10 minutes after the engine is stopped.
OIL PRESSURE LED
The oil pressure LED comes on when the oil pressure drops below a safe level. If
the lamp comes on while the engine is operated at or above 850 rpm,
immediately stop the engine and check the engine oil level.
FUEL
The fuel tank should never be allowed to become completely empty. An empty
tank will allow air into the fuel system; and the engine will not operate without
bleeding the fuel system.
EXHAUST SMOKE
The engine exhaust should be colorless during normal operation within the rated
output of the engine. Continuous dark emissions or smoke may indicate improper
usage or an engine malfunction.
STOP THE ENGINE IMMEDIATELY:
1. If the engine speed suddenly changes.
. If there is an unusual noise.
3. If the engine exhausts suddenly darkens.
4. If the oil pressure, temperature light or alternator comes on.

12
Fuel and Oil Specifications
Fuel
Important
•It as advisable to fit a fuel/water separator in the fuel supply system. Water in
the fuel can damage the injection system. However if the engine is being fitted
into an existing boat (re-installation), it is compulsory to fit a fuel/water
separator
•If a fuel supply shutoff valve is fitted do not use taper tap, only use a ball
valve tap. The valve type are more reliable and less likely to let air into the
fuel system.
•Do not use kerosene, which is very low in cetane rating, and adversely affects
the engine.
•Be careful not to let the fuel tank become empty, or air can enter the fuel
system, necessitating bleeding before next engine start.
Fuel selection
The following criteria is required for the diesel fuel
1. Must be free from minute dust particles
. Must have adequate viscosity
3. Must have high cetane value
4. Must have high fluidity at low temperature
5. Must have low sulphur content
6. Must have little residual carbon
Diesel fuels
Applicable standard Recommendation
JIS (Japanese Industrial Standard)
DIN (Deutsche Industrie Normen)
SAE (Society of Automotive Engineers)
Based on SAE-J-313C
BS (British Standard)
Based on BS/ 869-1970
NO.
DIN 51601
NO. -D
Class A-1
If fuel other than the specified one is used, engine function will be lowered.
Fuel Requirements
NOTICE: The fuel injection pump, injector or other parts of the fuel system and
engine can be damaged if you use any fuel or fuel additive other than those
specifically recommended by Canaline / Kioti.
Such damage is not Canaline / Kioti’s responsibility and is not covered by the
warranty. To help avoid fuel system or engine damage, please read the
following:
•Some service stations mix used engine oil with diesel fuel. Some
manufacturers of large diesel engines allow this; however for your diesel
engine, do not use diesel fuel, which has been contaminated with engine oil.

13
•Do not use any fuel additive (other than as recommended under “Biocide” in
this section). At the time this manual was printed, no other fuel additive was
recommended. (See your authorisation dealer to find out if this has changed).
Fuel system air bleeding
The entry of air into the fuel system will cause difficult engine starting or engine
malfunction. When servicing such as emptying the fuel tank, draining the water
sedimentor, and the fuel filter element change is done, be sure to bleed air.
Air Bleeding Procedure:
1. Please use the fuel primer located on top of the fuel filter to prime the
engine through with fuel.
. Start the engine and check the fuel system for fuel leaks.
CAUTION: the water/diesel fuel mixture is flammable and could be hot. To help
avoid personal injury and/pr property damage to not touch the fuel coming from
the drain valve and do not expose the fuel to open flames or sparks. Be sure you
do not overfill the container. Heat (such as from the engine) can cause the fuel
to expand. If the container is too full, fuel could be forced out of the container.
This could lead to a fire and the risk of personal injury and/or vehicle or
equipment damage.
Biocides
In warm or humid weather, fungus and/or bacteria may form in diesel fuel if
there is water in the fuel.
NOTICE: fungus or bacteria can cause fuel systems damage by plugging the fuel
lines, fuel filters or injector. They can also cause fuel system corrosion.
If fungus or bacteria has caused problems, you should have your authorised
dealer correct these problems. Then, use a diesel fuel biocide to sterilise the fuel
system (follow the biocide manufacturers instructions). Biocides are available
from your dealer, service stations, parts stores and other automotive places. See
your authorised dealer for advice on using biocides in your area and for
recommendations on which biocides you should use.
Smoke suppressants
Because of extensive testing of treated fuel versus untreated fuel, the use of a
smoke suppressant additive is not recommended because of the greater
possibility of stuck rings and valve failure, resulting from extensive ash deposits.
Lubricant
The quality of engine oil may largely affect engine performance, startibility and
engine life.
Use of unsuitable oil may result in piston ring stick, piston and cylinder seizure
and accelerate the sliding surface wear causing increased oil consumption,
lowered output and finally engine failure. To avoid this, use the specified engine
oil.

14
Engine Oil Selection
Engines Plus recommends that API CC grade oil is used in all of its marine
engines. Alternatively an API CD grade can be used if an API CC grade is
unavailable.
The correct grade oil is available from your local marine dealer.
•5 litres API CC 10W/40 – EP part no - EP710008
•5 litres API CC 10W/40 – EP part no - EP710009

15
Maintenance
Schedule
Daily or every 8 hours running
•Check engine oil level
•Check gearbox oil level, see gearbox manual
•Check coolant level
•Check drive belt tension, adjust if necessary
•Check colour of exhaust fumes and unusual engine noise on start up
•Check stern gland lubrication
After first 50 hours
•Change gearbox lubricant (see separate gearbox manual)
•Change engine lubricating oil
•Change oil filter
•Change fuel filter
•Check fuel contamination and drain off water trap/agglomerator if fitted
•Check all water pipes are not chaffing and for any leaks, and adjust if
necessary
•Check all fuel pipes are not chaffing and for any leaks, and adjust if necessary
•Check exhaust system for any leaks, etc, and adjust if necessary
•Check wiring looms and cables are not chaffing, and adjust if necessary
•Check coupling alignment and ensure all bolts are tight
•Check bolts/nuts on the anti vibration mounts are tight and secure
•Check control cables installation to ensure gearbox is correctly being engaged,
and adjust if necessary
Every 00 hours or every year
•As 50 hours and the following -
•Check air cleaner element and replace if necessary
•Change oil and oil filter
Every 400 hours
•As 50 & 00 hours and the following -
•Change air cleaner element
•Change fuel filter
•Change anti-freeze
•Check electrical equipment, condition of hoses and belts, replace as necessary

16
Checking engine oil level
For quantities of oil please refer to page 7. When checking the engine oil level,
do so before starting or more than five minutes after stopping.
1. To check the oil level, draw out the dipstick, wipe clean, re-insert it and
draw it out again. Check to see that the oil level lies between the two
major marks on the dipstick. (please ignore the middle smaller mark)
. If the level is too low add new oil via the oil filler port, to the specified level
– do not overfill.
Important
When using oil of different make or viscosity from the previous one, drain old oil.
Never mix two different types of oil. Engine oil and filter should be changed after
the first 50 hours running time and then every 00 hours or every year. Oil filter
is a cartridge type mounted on the side of the engine.
Engine Dipstick
Engine Oil goes in here

17
Sump drain
Pump
-
tap
Changing Engine Oil
1. Run the engine for 10 minutes to warm up the oil.
. Your engine is provided with a sump drain pump. Turn the tap to “on”.
Use the hand pump as shown to pump out the oil into a bucket. Turn the
tap to off position and replace end cap.
3. Unscrew the oil filter and replace with a new one. See diagram below
Note: it is best to have a plastic bag wrapped around the filter to catch any oil left
in the system. (Always keep your bilges clean!) Before screwing in the new filter
spread a thin film of oil round the rubber gasket to ensure a good seal and screw
in – hand tight.
4. Fill the engine with new oil, refer to page 13 for specification, as described
above.
Note: once you have re-filled the engine will oil, run the engine for about 5
minutes, so the oil can be pumped around the engine and into the new filter. Stop
the engine, and let it settle for about 10 minutes, and re-check the oil level, fill if
required.
Sump drain
Pump
Oil Filter

18
Changing the fuel filter
1. The fuel filter is a spin type. Remove by
turning anti-clockwise when viewed
from below, see picture
. Replace the fuel filter cartridge every
400 hours.
1. Remove metal bung from old fuel filter
and fit to new fuel filter (see below)
. Apply fuel oil thinly over the gasket
and tighten into position – hand tight
3. Prime fuel system as indicated on page 13
4. Check for leaks
Note: Do not get fuel on the flexible mounts.
Checking Gearbox Oil Level – please refer to gearbox manual, but on the PRM
80 and 1 0 gearbox, please ensure the following
Never exceed the maximum oil level on the dipstick!
Always use ATF Dextron II or III for your gearbox
Fuel Filter
Metal bung in Fuel filter, must
be transferred to new fuel filter
Ensure the oil mark is below the marker
on the dipstick (shaded). Ensure thread (shaded) is fully screwed down
into case with its relevant bonded seal when
measuring the oil level.

19
Freshwater system
New engines are supplied with the freshwater drained off. The following
instructions must be followed to fill the system.
(a) Mix up in a clean bucket the correct strength of anti-freeze solution.
(b) Check that the drain tap or plug is turned off.
(c) Fill engine with freshwater/anti freeze solution through the top of the
header tank with the filler cap removed.
(d) Fill the header tank to the top of the filler neck and replace cap. Press
down firmly on filler cap and hand tighten in a clockwise direction.
Note: for keeled cooled engines a much larger quantity of freshwater/anti freeze
solution is required depending on the size of the keel cooling tank – refer to the
builder.
(e) run the engine for 5 minutes on no load (out of gear) and check coolant
level. Top up if necessary.
(f) Check systems for leaks, including calorifier circuit if fitted.
Note: for keel cooled engines it is very important to bleed all the air out of the
system before the engine is run on load (check with builders instructions).
(g) If a calorifier is fitted care must be taken to see that this is also full of
coolant and all the air is expelled. (see calorifier fitting notes under
installation section)
(h) Run the engine on one third speed for 15 minutes, preferably with the boat
tied up. As the system warms up coolant may be expelled from the
overflow pipe into the bilge. Stop the engine and allow the engine to cool
down before removing the pressure cap and top up the coolant to 5mm
below the filler neck.

20
Important
Removal of the pressure cap when the engine is hot can cause severe injury from
scalding hot water under pressure. Always allow the engine to cool and then use
a large cloth when turning the cap anti-clockwise to the stop. This allows the
pressure to be released. Press firmly down on the cap and continue to turn
anticlockwise to release the cap.
(i) Repeat (h) if coolant level is more than 5mm below the base of the filler
neck when the engine has cooled down.
(j) Run engine on /3 speed for 0 minutes, check for leaks and repeat (i)
(k) Anti-freeze solutions should be drained off every 500 hours or years
which ever is sooner, and replaced with a new solution.
Engine water filler
cap, integrated into
the header tank.

21
Changing the Air filter
The Air filter should be changed every 400 hours, once per year or sooner if
necessary, the air cleaner fitted to the Canaline marine engines, has a
replaceable element, part no EP1105 9.
1. Remove Air cleaner lid, by unscrewing anti-clockwise
. Remove and replace element
3. Re-fit lid, accordingly
Air cleaner
Element