Craftsman CM2.12, Operation Manual

Page 1: ...operation manual CM2 12 CM2 16 CM3 27 BOATING TECHNOLOGY BY CRAFTSMAN MARINE propulsion ...

Page 2: ...man 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 Craftsman Marine CM2 12 CM 2 16 CM 3 27 1 Disclaimer Disclaimer 2 craftsman marine diesel engines CM2 12 cm2 16 cm3 27 ...

Page 3: ...hi engine serial number is die cut into the engine block to the right side seen from the rear Name Address Postal area code Town Country Name Address Postal area code Town Country You will need this information when ordering spare parts or in the case of correspondence with our service department Model of Craftsman Marine diesel engine Serial number of engine Serial number of gearbox First owner S...

Page 4: ...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 t...

Page 5: ...22 Cooling water strainer 23 Checking of the cooling water strainer 23 Cleaning of the cooling water strainer 23 Check once again 23 Water seperator fuel filter 24 Danger 25 The fuel filter 25 Draining of the water separator 25 Bleeding of the fuel system 25 Engine lubrication oil 26 Changing of the engine lubrication oil 26 Fitting the oil filter 26 Preparation of the new oil filter 26 Positionin...

Page 6: ...ith fuse and multi plugs Connection parts for the push pull cables Four flexible engine mountings Sump pump Accessory equipment required for a perfect engine installation optional Fuel filter water separator in the fuel supply line For a complete list of supply take a look at our website www craftsmanmarine com 6 craftsman marine diesel engines CM2 12 cm2 16 cm3 27 ...

Page 7: ...ty anti freeze product protecting your engine against corrosion and frost damage Please see page 43 for the specifications 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 specified on page 13 of this manual Always use good quality diesel fuel free from...

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Page 9: ...and be very careful with flammable products in the neighbourhood of the engine When checking upon or adjusting any parts or when checking or filling lubri cants or cooling liquids make sure that the engine is stopped Do not open the filler 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 ex...

Page 10: ...to fuel supply Ø 8 mm Fuel supply pump Oil dipstick Oil filter Fuel filter Connections of electrical system fuse Connection to fuel return line Ø 8 mm Air inlet silencer Manual operation of electrical stop Connection for throttle push pull cable Breather nipple cooling system Filler cap inner cooling circuit Exhaust Carter plug Raw water pump Ø 20 mm ...

Page 11: ...of engine components Product description 8 11 craftsman marine diesel engines CM2 12 cm2 16 cm3 27 Filler cap inner cooling circuit Alternator Starter motor Drain plug cooling system Heat exchanger Exhaust injection bend Ø 30 Ø 40 mm ...

Page 12: ...ent 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 Mitsubushi engine serial number The Mitsubishi engine serial number is engraved into the engine block to the starboard side Identification tag engin...

Page 13: ...es with following specifications Type 15W40 API CD CE or CF4 CCMC D4 or D5 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 When the filling of oil is completed check with the dipstick whether the level of lubricating oil is correct A second filler cap is located at the starboard side next to the engine identificatio...

Page 14: ...re specified 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 filled up with its lubricant When the filling is completed verify with the dipstick whether the correct level of fluid 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...

Page 15: ... 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 commissi...

Page 16: ...ooling 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 16 craftsman marine diesel engines CM2 12 cm2 16 cm3 27 4 5 6 7 8 9 10 1 2 3 Alfa 20 E Alfa 10 E...

Page 17: ...ter 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 Monitoring lights The instrument panel features six monitoring lights for respectively 1 oil pressure 2 battery charging current 3 temperature inner cooling ci...

Page 18: ...eating the engine is determined 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...

Page 19: ...to the neutral position and let the engine idle during a few moments 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 ...

Page 20: ...e valves Replace the fuel filter Change the oil in the gearbox Clean the filter which is located just before the fuel lift pump Verify the flexible 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 exe...

Page 21: ...ine has not enough oil fresh oil of the same specifications must be added The difference between the upper and the lower mark is about 2 liters of oil 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 Topping up the lubrication oil The fill...

Page 22: ...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 an...

Page 23: ...ary If the cooling water strainer gets clogged up the cooling liquid in the engine may 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 overhea ting of the engine Check once again Make absolutely sure that the cover fits the strainer hous...

Page 24: ...1 3 Water seperator fuel filter 11 Maintenance and inspection 24 craftsman marine diesel engines CM2 12 cm2 16 cm3 27 2 ...

Page 25: ...pen the drain plug at the bottom of the filter Drain the water and collect it in a bowl close the drain plug Note A water separator does not belong to the standard scope of supply but must be procured and fitted none theless 3 Bleeding of the fuel system After having drained the water separator fuel filter the fuel system must be freed from air bled Prime the fuel system by pumping the fuel pump m...

Page 26: ...er 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 temperatu re 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 th...

Page 27: ...fications as outlined on page 13 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 Positioning of the oil filter Maintenance and inspection 11 27 craftsman marine diesel engines CM2 12 cm2 16 c...

Page 28: ...tick or the filler cap depen dent 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 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 ...

Page 29: ... and avoid open fire Fit the fuel filter Clean the surface to touch the engine before fitting the filter Grease the rubber ring with clean engine oil Fill the filter with clean diesel fuel Position the filter against the filter housing and tighten it with one half to three quarters of a turn Clean the filter of the fuel lift pump and reopen the cock of the fuel supply Cleaning the filter of the fu...

Page 30: ...the engine mounting must be replaced Make sure as well that the damper element is still sufficiently flexible If not so the engine must be realigned Verify the hose connections Inspect all hoses of the cooling system and of the fuel system Check for loose connections or cracks and fissures in the rubber hoses In such case the hose must be replaced Verify the fasteners Make sure that all and sundry...

Page 31: ...moved by no more than 12 mm using thumb and forefinger and a force of about 10 kg If the travel of the belt is greater the tension must be adjusted Tensioning the V belt In order to tension the V belt the bolts of the support and both bolts of the alternator must be loosened Tension the belt by pushing the alternator outward Thereafter first tighten the upper bolt of the alterna tor and thereafter...

Page 32: ...ng 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 mix...

Page 33: ...it appears that there is not enough anti freeze in the coolant replace the liquid as described on page 22 Electrical system Disconnect the battery cables and charge the batte ries from time to time during the winter period Filters Drain the water from the fuel filter water separator in order to avoid frost damage Fit a new fuel filter see page 29 Winter storage 12 33 craftsman marine diesel engine...

Page 34: ...water cooling strainer is tightened well 5 Verify the tightness of the raw water pump cover and of all drain plugs see page 22 6 If you have disconnected any hoses before winter storage these must all be connected again and tightened well 13 Preparations for the new season 34 craftsman marine diesel engines CM2 12 cm2 16 cm3 27 5 ...

Page 35: ...age 13 10 Start the engine and make sure that there are no leaks in the fuel system the cooling system and the exhaust assembly 11 Verify the proper functioning of all electronic parts and all engine instruments Also verify the proper functioning of the mechanical remote control and the gearbox Preparations for the new season 13 35 craftsman marine diesel engines CM2 12 cm2 16 cm3 27 ...

Page 36: ...Clogging in exhaust line Electrical fuel lift pump defective Dirt in press or suction valves of the electric fuel lift pump Filter of electrical fuel lift pump is clogged up Open Fill Check breathe Check replace Check replace Check and replace if necessary Check clean Check Check clean Replace Moreover position a water separator fuel filter into the fuel line between tank and engine Check clean 3 ...

Page 37: ...ine does not arrive at maximum revolutions under full load Air in the fuel system Fuel filter clogged up with water and or dirt Leakage in fuel supply line or fuel injection line Setting of stop valve incorrect Oil level too high Incorrect SAE specification or quality of lubrication oil Incorrect valve clearance Clogging in the exhaust Insufficient quantity of combusition air Poor fuel quality or ...

Page 38: ...our authori zed dealer and ask him to solve the problem 8 Engine has little or no oil pressure Oil level too low Clogged oil filter Defective oil pump Excessive inclination angle of engine Incorrect SAE specification or quality of lubrication oil Oil pressure apparently too low on account of defective oil pressure switch sensor or gauge To up till corect oil level Replace Repair replace Check adju...

Page 39: ...ion moment Incorrect valve clearance Excessive wear and tear of cylinder piston Engine overheated does not reach maximum rpm 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 t...

Page 40: ...1 Order of fuel injection IDI indirect IDI indirect IDI indirect Maximum number of revolutions 2500 rpm 3600 rpm 3600 rpm Maximum torque 25 Nm at 2500 rpm 29 3 Nm at 3600 rpm 53 1 Nmat 3600 rpm Maximum output at flywheel 8 8 kW 12 pk ISO 8665 3046 11 8 kW 16 pk ISO 8665 3046 20 kW 27 2 pk ISO 8665 3046 Fuel consumption at 1800 rpm 268 g kW h 196 g pk h 268 g kW h 196 g pk h 270 g kW h 199 g pk h E...

Page 41: ...perature Pre heating Oil pressure Temperature of coolant inner circuit Charging current Exhaust temperature Pre heating Oil pressure Temperature of coolant inner circuit Charging current Exhaust temperature Pre heating Instrument panel Alfa 10E Alfa 10E Alfa 20E Connections for calorifier boiler optional optional optional Cooling system Dual circuit with heat exchanger Dual circuit with heat excha...

Page 42: ...F4 CCMC D4 of D5 Oil lubrication system Oil capacity maximum 2 4 litres without oil filter maximum 2 9 litres with oil filter CM2 12 CM2 16 Oil 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 12 CM2 16 Capacity with inter cooler version 3 litres with keel cool...

Page 43: ... on account of separation of the paraffin content in the fuel Please use a winter type fuel suitable up to 15 ºC when the ambient temperature is less than zero degrees Celsius or a diesel fuel with additives suitable up to 20 ºC Cooling liquid Always use a mixture of anti freeze on the basis of ethylene glycol and clean tap water Table of anti freeze concentration used for engine coolant Anti free...

Page 44: ...Fuel return Ø 8 mm Fuel supply Ø 8 mm Exhaust Ø 40 mm Sea Water Intake Ø 20 mm 17 Overall Dimensions CM2 12 CM2 16 44 craftsman marine diesel engines CM2 12 cm2 16 cm3 27 ...

Page 45: ...CM3 27 Overall Dimensions 17 45 craftsman marine diesel engines CM2 12 cm2 16 cm3 27 Exhaust Ø 40 mm Fuel supply Ø 8mm Sea Water Intake Ø 20 mm ...

Page 46: ...Notes ...

Page 47: ...Notes ...

Page 48: ... Netherlands ZD 010 004 2 1 10 09 Craftsman Marine BV Keerweer 33 3316 KA DORDRECHT THE NETHERLANDS T 31 0 88 00 262 00 F 31 0 88 00 262 01 info craftsmanmarine com www craftsmanmarine com BOATING TECHNOLOGY BY CRAFTSMAN MARINE propulsion ...