Craftsman Cm4.33 User manual

propulsion

Boating technology by craftsman marine

CM4.33

& CM4.42

engine manual

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Subtitle part xxx

2craftsman marine diesel engines CM4.33 / cm4.42

Disclaimer

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.

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craftsman marine diesel engines CM4.33 / cm4.42

Operation Manual

Craftsman Marine CM4.33 / 4.42

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4craftsman marine diesel engines CM4.33 / cm4.42

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 faith-

fully and trouble-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 CM4.33 and CM4.42.

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.

Note:

This manual applies to model CM4.33 and model CM4.42. 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 nd detailed instructions of how and how regularly the various com-

ponents of your engine must be serviced. This engine must be used exclusively in 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, mainte-

nance 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 at your

engine.

For that reason, always have your engine serviced, maintained and repaired by an authorized

CRAFTSMAN MARINE dealer.

In the case of modications 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.

Modications of the injection and distribution system also form part of the aforementioned exclu-

sion 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 fulllment of the legal prescriptions regarding the emission of exhaust

gases, aiming at the protection of the environment, is no longer guaranteed in that case.

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craftsman marine diesel engines CM4.33 / cm4.42

Table of contents

TABLE OF CONTENTS

1 DISCLAIMER 2

2 SERIAL NUMBERS AND

DATA OF OWNER 3

3 PREFACE 4

4 TABLE OF CONTENTS 5

5 STANDARD SCOPE OF SUPPLY 6

6 GENERAL MAINTENANCE

DIRECTIVES 7

7 SAFETY 9

8 PRODUCT DESCRIPTION 10

Designation of

engine components 10

Service side 10

Starter motor side 11

Identication tag 12

Position of identication tag 12

Mitsubishi engine serial number 12

9 PRIOR TO COMMISSIONING

THE ENGINE 13

Engine lubrication oil 13

Gearbox 14

Cooling liquid 15

Instrument/control panels 16

Standard instrument panel 16

Revolution counter/hour counter 17

Voltmeter 17

Monitoring lights 17

10 OPERATING THE ENGINE 18

Starting 18

Stopping 19

Monitoring lights oil pressure/

battery charging 19

Electrical stop 19

Mechanical stop 19

11 MAINTENANCE AND

INSPECTION 20

Maintenance schedule 20

Maintenance 20

Data recording 20

Every 10 hours or daily

before starting 20

After the rst 50 hours of service 20

After every 100 hours of service 20

After every 500 hours of service 20

After every 1000 hours of service 20

Check engine lubrication oil 21

Dipstick 21

Oil level 21

Add engine lubrication oil 21

Cooling liquid 22

Check level of cooling liquid 22

Change cooling liquid 22

Cooling water strainer 23

Check cooling water strainer 23

Cleaning of cooling water strainer 23

Check again 23

Water separator / fuel lter 24

Danger! 25

Fuel lter 25

Draining the water separator 25

Air breathing 25

Change engine lubri-

cation oil 26

Prepare oil lter 26

Add oil 26

Place oil lter 27

Add oil 27

Change oil in gearbox 28

Drain oil from gearbox 28

Add oil 28

Replace fuellter 29

Remove fuel lter 29

Place fuel lter 29

Clean lter of fuel lift pump 29

Engine mountings,hose con-

nections, fasteners 30

Flexible engine mountings 30

Hose connections 30

Fasteners 30

Check condition of V-belt 31

Check tension of V-belt 31

Tensioning of the V-belt 31

12 PREPARE FOR WINTER STORAGE 32

Winter storage 32

Protective fuel mixture 32

Lubrication oil system 32

Raw water cooling system 32

Fresh water cooling system 33

Electrical system 33

Filters 33

13 PREPARE FORTHE NEW SEASON 34

Preparations 34

14 PROBLEMS AND SOLUTIONS 36

15 TECHNICAL DATA 40

Engine specications 40

16 LUBRICANTS AND

COOLING LIQUIDS 42

Viscosity 42

Engine lubrication oil 42

Gearbox lubrication oil 42

Fuel (summer period) 43

Fuel (winter period) 43

Cooling liquid 43

17 OVERALL DIMENSIONS 44

CM4.33 44

CM4.42 45

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6craftsman marine diesel engines CM4.33 / cm4.42

5 Standard scope of supply

of the CM4.33 and CM4.42 engines

Standard scope of supply:

• Engine instrument panel, type Alfa 20 E

• Engine cable loom with fuse and Multi-plugs

• Connection parts for the push-pull cables

• Four exible engine mountings

• Sump pump

Accessory equipment, required for a perfect engine installation (optional):

• Fuel lter/water separator in the fuel supply line

For a complete list of supply take a look at our website www.craftsmanmarine.com

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craftsman marine diesel engines CM4.33 / cm4.42

General maintenance directives 6

CM 4.33 / CM 4.42

By carefully adhering to the following recommendations, you will be sure of the best

possible conditions to operate your engine, resulting in a long life span, excellent per-

formance and fuel economy.

• Have the maintenance procedures regularly executed, as mentioned in this manual.

• Prior to starting the engine, always verify the correct level of the various uids.

• All year long, use a good quality anti-freeze product, protecting your engine

against corrosion and frost damage. Please see page 43 for the specications of

the cooling liquid.

• Do not ever put the engine into operation without a properly functioning thermo

stat, so as to avoid overheating of the engine.

• Always use the correct quality of lubricants, as specied on page 13 of this manual.

• Always use good quality diesel fuel, free from water and /or other impurities.

• Switch-off the engine immediately if the monitoring light(s) of oil pressure, fresh

water temperature, raw water temperature and/or battery charging control light up.

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8craftsman marine diesel engines CM4.33 / cm4.42

Notes

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craftsman marine diesel engines CM4.33 / cm4.42

Safety 7

Explanation of symbols

This page will provide you with a survey of all warning pictograms, used throughout

this manual.

Notes referring to safety issues show this symbol:

• DANGER

• ATTENTION

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:

• Never touch any moving parts when the engine is running.

• When in operation the engine (or certain parts thereof) may become very hot. Do

not ever touch these parts and be very careful with ammable products in the

neighbourhood of the engine.

• When checking upon or adjusting any parts, or when checking or lling lubricants

or cooling liquids, make sure that the engine is stopped.

• Do not open the ller cap on the expansion tank or on the heat exchanger unless

the engine is completely cooled down.

• 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 do such work

Symbols

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)

Connection to calorier

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10 craftsman marine diesel engines CM4.33 / cm4.42

8 Product description

Designation of engine components

Service side

Oil ller cap

Connection to

fuel supply

( Ø 8 mm )

Fuel supply pump

Oil dipstick

Oil lter

Fuel lter

Connections of

electrical system

& fuse

Connection to fuel

return line ( Ø 8 mm)

Air inlet silencer

Manual operation of

electrical stop

Breather nipple cooling system

Oil ller cap

Exhaust

Carter plug

Connection

for throttle

push-pull

cable

Alternator

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craftsman marine diesel engines CM4.33 / cm4.42

Designation of engine components

Product description 8Starter motor side

Filler cap inner cooling circuit

V-belt

Raw water pump

( Ø 20 mm)

Starter motor

Drain plug cooling system

Exhaust injection

bend ( Ø 50 mm)

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12 craftsman marine diesel engines CM4.33 / cm4.42

Identication tag

The Craftsman Marine identication tag is the place to

nd the engine model, the serial number and a few more

data concerning your engine.

You will need this information if and

when you have to order spare parts, or

if you want to correspond with our ser-

vice department.

Position of the identication tag

The Craftsman Marine identication tag is located on

top of the rocker cover, next to the ller cap for the inner

cooling system.

Mitsubushi engine serial number

The Mitsubishi engine serial number is engraved into

the engine block to the starboard side.

Identication tag, engine number

8 Product description

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craftsman marine diesel engines CM4.33 / cm4.42

Motor oil

Prior to commissioning the engine 9

Engine lubrication oil

The Craftsman Marine diesel engines are supplied wit-

hout lubrication oil.

Before commissioning the engine for the rst time, it

must be lled with 5 liters of lubrication oil for diesel

engines, with following specications:

Type: 15W40

API: CD, CE or CF4

CCMC: D4 or D5

The engine can be lled with oil through the ller cap

on the rocker cover or through the ller pipe at the front

of the engine.

When the lling of oil is completed,

check with the dipstick whether the le-

vel of lubricating oil is correct.

A second ller cap is located at the starboard side, next

to the engine identication tag.

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14 craftsman marine diesel engines CM4.33 / cm4.42

9 Prior to commissioning the engine

Gearbox

The gearbox is located at the rear of the engine and it

must also be lled with the correct type and quantity of

lubricant.

Craftsman Marine diesel engines are supplied with ge-

arboxes of several brands and types.

For the ZF-Hurth and Technodrive brands the types and

quantities are specied here below:

Please consult the appropriate instruction manuals in

the case of other gearbox makes and models.

Here it is shown how the gearbox can be lled up with

its lubricant. When the lling is completed, verify with

the dipstick whether the correct level of uid is obtained.

ZF Hurth

Type ZF 10: 0,35 liter ATF

Type ZF 12: 1,1 liter ATF

Technodrive

Type TMC40: 0,20 liter SAE 20/30

Type TMC60: 0,80 liter SAE 20/30

(ATF: Automatic Transmission Fluid, type A, sufx A)

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craftsman marine diesel engines CM4.33 / cm4.42

Cooling liquid

Prior to commissioning the engine for the rst time, the

inner cooling circuit must be lled with cooling liquid.

In order to do so, the ller cap on top of the heat exchan-

ger housing must be removed.

Alternatively: if and when an expansion tank is tted,

remove the cap on top.

The cooling system must be lled with 6,5 liters of coo-

ling liquid. You can ll 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 ll the cooling system with sea

water! Never ll the cooling system with

sea water!

Fill the system to about 1 cm below the bottom of the

ller pipe. The system will breathe automatically. Do not

forget to put the ller cap in place again and tighten the

breather bolt.

Once the engine being commissioned and having run for

the rst time, verify again the level of the cooling liquid

and top up, if necessary.

Cooling liquid

Prior to commissioning the engine 9

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16 craftsman marine diesel engines CM4.33 / cm4.42

Standard panel type ALFA 20 E

1. Revolution counter / hour counter

2. Voltmeter

3. Starter switch

4. Monitoring light temperature raw water

5. Monitoring light oil pressure engine

6. Monitoring light cooling liquid temperature

7. Sensor for automatic backlight dimming

8. Monitoring light charging current

9. Monitoring light pre-heating system

10. Low oil pressure gearbox

Optional

The voltmeter may be replaced by a temperature gauge

9 Prior to commissioning the engine

Engine instrument and control panels

4. 5. 6. 7. 8. 9. 10.

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craftsman marine diesel engines CM4.33 / cm4.42

Revolution counter / hour counter

The revolution counter indicates the number of the en-

gine’s 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.

The CM 4.33 and CM 4.42 marine diesel engines both

have an idling number of revs. of about 840 rpm.

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 gure must read

between 12 and 14.5 Volt.

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 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 IMME-

DIATELY!

Engine instrument and control panels

Prior to commissioning the engine 9

1. 2. 3.

4. 5. 6.

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18 craftsman marine diesel engines CM4.33 / cm4.42

Check rst

Always check on following points, before starting the

engine:

• Oil level

• Coolant level

• Is the raw water seacock opened?

• Is the main electrical switch ‘on’?

• Is the gearbox lever in the neutral position?

The starting procedure

1. Prior to starting the engine, position the throttle lever

at half of its travel, without engaging the gearbox.

2. Turn the key from the ‘off’ position one step further

to the right, to the ‘on’ position. The monitoring lights

for oil pressure, charging currents and pre-heating

will light up and the buzzer is audible.

3. From the ‘on’ position turn the key one step further

to the right, to the ‘pre-heating’ position. Now only

the pre-heating monitoring light is burning. Keep the

key about 6 seconds in this position (at an ambient

temperature of 15° C or more).

Note:

The time required for pre-heating the engine is de-

termined by the ambient temperature. The lower the

temperature, the longer the pre-heating procedure will

take. At freezing temperature, it may take as long as 20

seconds; and up to 10 seconds at temperatures of up to

7 degrees. Do not pre-heat the engine any longer than 1

minute maximum.

4. The turn the starter key one step further to the right,

to the ‘start’ position and release the key as soon as

the engine springs to life; the key will return auto-

matically to the ‘on’ position, where it will remain

parked as long as the engine is running. Have the

engine running at idling revolutions during a short

period of time, so that the engine will warm-up to

some extent.

Stop the starting procedure if the engine

does not come to life within 10 seconds.

Release the key and wait till the starter

motor has come to a complete stand-still

before giving it another try.

Do not have the starter motor running during more than

30 seconds, in order to avoid damage by overheating.

10 Engine operation

Starting

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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 wa-

ter 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 run-

ning.

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

Before stopping the engine, shift the throttle lever back

to its neutral position, place the gearbox lever into the

neutral position and let the engine idle during a few mo-

ments. Turn the starter switch to the far left position of

‘stop’. After a 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.

Manual stop

Should the engine not respond to the stop command by

means of the starter key, keep the black button on top

of the fuel lift pump depressed during a few seconds.

The engine will stop immediately, by lack of fuel supply.

To start / stop

Engine operation 10

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20 craftsman marine diesel engines CM4.33 / cm4.42

Every 10 hours or delay before starting

• Check level of engine lubricating oil (page 21)

• Check level of cooling liquid (page 22)

• Check cooling water strainer for blockage of the water ow (page 23)

After the rst 50 hours of operation

Ask your dealer to execute this maintenance job:

• Drain water from the fuel lter/water separator (page 25)

• Change engine lubrication oil (page 26)

• Replace oil lter (page 26)

• Change lubricating uid in gearbox (page 28)

• Replace fuel lter (page 29)

• Verify idling revolutions and adjust if necessary (page 17)

After every 100 hours of operation (or at least once a year)

Ask your dealer to execute this service job:

• Drain water from the fuel lter/water separator

• Change engine lubrication oil

• Replace oil lter

• Verify level of lubricating uid in gearbox

• Replace fuel lter

• Check batteries, cables and connections

After every 500 hours of operation (at least once a year)

Have your dealer check and execute the following:

• Verify the tolerance of the valves

• Replace the fuel lter

• Change the oil in the gearbox

• Clean the lter, which is located just before the fuel lift pump

• Verify the exible engine mountings to have the correct compression and adjust if

necessary

• Check all hoses and hose connections for leaks

• Verify the tension of the V-belt

After every 1000 hours of operation

(or at least once every two years

Have your dealer check and execute the following:

• Verify the proper functioning of the raw water pump

• Replace the cooling liquid in the inner cooling circuit

If necessary:

- Bleed the fuel system ( page 25 )

- Verify the number of revolutions when idling ( page 17 )

Only service the engine when it is not running!

11 Maintenance and inspection

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 components.