Craftsman Marine CM4.65 Manual Download Page 5 | Manualshive

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Crafted with CRAFTSMAN MARINE

Table of contents

Safety

9

10

11

12

14

13

8

3

2

1

4

5

6

7

Disclaimer

Product identification

Product description

Standard scope of supply

Service side

CM4.80 with ZF25 Gearbox

Starter motor side

CM4.65 with TM345 Gearbox

Prior to commissioning the engine

Maintenance and inspection

Winter storage

Preparations for the new season

Problems and solutions

Technical data

Lubricants and cooling liquids

Overall Dimensions

Topping up the lubrication oil
Changing of the engine lubrication oil
Replacing the oil filter
Adding new oil
Checking of oil level in gearbox
Check-up of coolant level
Replace cooling liquid
Check-up of raw water pump impeller
Impeller removal
Checking of the cooling water strainer
Draining of the water separator/fuel filter

Inspection of the V-belt

Engine operation

Calorifier installation

Maintenance schedule

Engine lubrication oil
Gearbox
Cooling liquid
Engine panel

First check
The starting procedure
Monitoring lights oil pressure and battery
charging current
Electric engine stop

4

3

7

8

10

8

40

9

41

11

20

30

32

34

38

42

40

20
21
21
21
22
23
23
24
24
25
26

29

16

18

19

11
12
13
14

16
16
17

17

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7
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Summary of Contents for CM4.65

Page 1: ...Propulsion Crafted with craftsman marine CM4 65 CM4 80 Engine manual ...

Page 2: ......

Page 3: ...se adhere strictly to the recommendations in this chapter and instruct anybody else who may be operating or servicing the engine to do likewise These are the safety recommendations Never touch any moving parts when the engine is running When in operation the engine or certain parts thereof may becomevery hot Do not ever touch these parts and be very careful with flammable products in the neighbour...

Page 4: ...r engine and who are fully aware of any danger involved should be allowed to work at your engine Note 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 imm...

Page 5: ...oil Changing of the engine lubrication oil Replacing the oil filter Adding new oil Checking of oil level in gearbox Check up of coolant level Replace cooling liquid Check up of raw water pump impeller Impeller removal Checking of the cooling water strainer Draining of the water separator fuel filter Inspection of the V belt Engine operation Calorifier installation Maintenance schedule Engine lubri...

Page 6: ...6 Crafted with CRAFTSMAN MARINE Notes ...

Page 7: ...rvice and warranty book The Craftsman Marine identification tag is located on top of the rocker cover next to the oil filler cap The Hyundai engine serial number is engraved into the engine block to the starboard side and into the flywheel housing Identification tag Position of the identification tag Hyundai engine serial number You will need this information if and when you have to order spare pa...

Page 8: ...uct description Service side Alternator V Belt Raw water pump Ø 28 mm Engine Oil Cooler Drain plug internal cooling system Drain valve internal cooling system Exhaust injection bend Ø 60 Ø 75 mm Heat exchanger Air inlet silencer Oil filter ...

Page 9: ...RAFTSMAN MARINE 2 Product description Starter motor side Oil filter cap Connection to fuel supply Ø 8 mm Fuel supply pump Starter motor Fuel filter Filler cap inner cooling circuit Connections of electrical system fuse ...

Page 10: ... long use a good quality anti freeze product protecting your engine against corrosion and frost damage Please see page 41 for the specifications of the cooling liquid Do not ever put the engine into operation without a properly functioning thermostat so as to avoid overheating of the engine Always use the correct quality of lubricants as specified on page 11 of this manual Always use good quality ...

Page 11: ...for the first time it must be filled with 5 4 liters of lubrication oil for diesel engines 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 Engine lubrication oil When the filling of oil is completed check with the dipstick whether the level of lubricating oil is correct 4 ...

Page 12: ...ntities are specified on the right side of this page Please consult the appropriate instruction manuals in the case of other gearbox makes and models Gearbox ZF Hurth Type ZF25 2 2 litres ATF Type ZF25A 2 0 litres ATF Type ZF25M 0 8 litres ATF Technodrive Type TMC345 1 8 liter SAE 20 30 Type TMC345A 1 8 liter SAE 20 30 Automatic Transmission Fluid type A suffix A Here it is shown how the gearbox c...

Page 13: ...basis of ethylene glycol and 60 of clean tap 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 close the drain valve on the engine 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 When a calorifie...

Page 14: ...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 The voltmeter may be replaced by a temperature gauge Optional 4 5 6 7 8 9 10 1 2 3 4 ...

Page 15: ...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 Revolution counter hour counter Voltmeter Monitoring lights 1 2 3 4 5 6 The instrument panel features six monitoring lights for respectively 1 oil pressure 2 battery charging current 3 temperature inner...

Page 16: ...he monitoring lights for oil pressure charging current 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 4 Then turn the starter key one step further to the ri...

Page 17: ... gearbox lever into the neutral position and let the engine idle during a few moments Turn the starter key to the OFF position to stop the engine After a long trip it is recommended to have the engine idling for a few minutes before putting it to full stop 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 prolon...

Page 18: ...f the calorifier or one of its components it s important that it can be disconnected from the engine s cooling circuit It is advised to add ball valves and a bypass line In normal operation the bypass line is closed When the coolant lines to the calorifier are closed the bypass line must be opened otherwise part of the engine cooling circuit is inter rupted see schematic above Note that the ball v...

Page 19: ...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 After every 500 hours of operation at least once a year Have your dealer check and execute the following Verify the toleran...

Page 20: ... 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 Any lubricating oil in excess will be burnt in the cylinders causing black smoke from the exhaust and strong internal pollution of the engine Dipstick Oil level Topping up the lubrication oil The filler cap is located on top of the rocker cover at the ...

Page 21: ...er ring in the rim of the new oil filter and grease it with fresh engine lubrication oil Turn the new oil filter onto the engine thereby following the instructions given on the filter housing Changing of the engine lubrication oil Replacing the oil filter Adding new oil Fill the engine with lubrication oil with specifications as outlined on page 11 through the filling opening on top of the engine ...

Page 22: ...r cap dependent on the gearbox model Position the hose of the special sump pump into the hole 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 the oil in a bowl ...

Page 23: ... from the engine After draining reconnect the hose but leave the drain cock opened 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 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 recom...

Page 24: ...e cover and use an impeller removal tool to remove the impeller Inspect the impeller blades for cracks and replace if necessary When the impeller is damaged be sure any rubber residues are removed from the pump housing and water pipes before replacing the impeller Use a silicone spray to lubricate the impeller before fitting Fit the impeller to the pump shaft Fit cover while placing a new gasket O...

Page 25: ... the cooling water strainer gets clogged up the cooling liquid in the engine may overheat When closing the strainer 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 Open the raw water seacock before starting the engine Checking of the cooling water str...

Page 26: ...Position the filter against the filter housing and tighten it with one half to three quarters of a turn After changing the fuel filter element the fuel system must be bled see next page Remove the fuel filter Fit the fuel filter Cleaning the filter of the fuel lift pump When changing the fuel filter the filter of the fuel lift pump must also be cleaned This should only be done by a qualified mecha...

Page 27: ...el system must be freed from air bled The fuel system is self bleeding and this goes as follows Turn the key in the start switch in the ON position and after about 1 minute the fuel lift pump will begin to operate and bleed the system automatically Danger Note A water separator does not belong to the standard scope of supply but must be procured and fitted none theless Do not smoke when you drain ...

Page 28: ...mounting must be replaced 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 Check the flexible engine mountings Verify the hose connections Verify the fasteners Make sure that all and sundry bolts nuts and screws are well tightened Make sure as well that the damper element is ...

Page 29: ... 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 Inspection of the V belt Verifying the tension of the V belt Tensioning the V belt In order to tension the V belt both bolts of the alternator must be loosened Tension the belt by pushing the alter nator outward Thereafter first tighten the upper bolt of th...

Page 30: ...n the water strainer cover and start the engine while adding antifreeze until the sea water circuit is filled completely Place a bucket underneath the exhaust exit to catch any excessive antifreeze while running the engine Anti freeze is poisonous and must be disposed of correctly Remove the impeller during winter storage see page 24 When closing the cover of the raw water strainer make sure that ...

Page 31: ...relevant specifications If it appears that there is not enough anti freeze in the coolant replace the liquid as described on page 23 Disconnect the battery cables and charge the batteries from time to time during the winter period Inner circuit of the cooling system Electrical system Filters Drain the water from the fuel filter water separator in order to avoid frost damage Fit a new fuel filter s...

Page 32: ...ed well 7 Open the seacock of the raw water entry 8 Check the level of the cooling liquid as described on page 23 9 Make sure that the engine has sufficient lubrication oil as described on page 20 10 Start the engine and make sure that there are no leaks in the fuel system the cooling system and the exhaust assembly Place a bucket underneath the exhaust exit to catch any excessive antifreeze while...

Page 33: ...33 Crafted with CRAFTSMAN MARINE Notes ...

Page 34: ... fuel system Check replace if necessary Check readjust Check replace Readjust Check readjust Check air intaker and remove blockage Check fuel quality Drain fuel tank and rinse it well Fill with good quality fuel Replace by good quality lubrication oil Fuel cock closed Empty fuel tank Air in fuel system Fuel filter clogged up by water or dirt Leak in fuel supply or fuel injection line s Defective i...

Page 35: ...ect SAE specification or quality of lubrication oil Incorrect valve clearance Clogging in the exhaust Insufficient quantity of combusition air Poor fuel quality or polluted fuel Incorrect injection moment Leakage of air intake manifold Engine overload Fill the tank Check bleed the system Check clean or replace Check and replace if necessary Check and clean or replace Check remove blockage Check re...

Page 36: ...rrect SAE specification or quality of lubrication oil Oil 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 Ch...

Page 37: ...ion 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 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 th...

Page 38: ...ips angle Max exhaust back pressure Basic engine General specifications Type of engine CM4 65 CM4 80 Hyundai 91 1 x 100 mm 2607 cm 4 in line Natural 22 1 IDI indirect 3000 rpm 170 Nm at 2200 rpm 48 kW 65 pk ISO 8665 3046 260 g kW h 191 g pk h Ø 60 240 kg 15 backwards 25 continuous 30 intermittent 13kpa Hyundai 91 1 x100 mm 2607 cm 4 in line Natural 22 1 IDI indirect 4000 rpm 170 Nm at 2200 rpm 59 ...

Page 39: ...ine ZF Hurth or Technodrive Automatic 12 Volt 110 A Oil pressure Temperature of coolant inner circuit Charging current Exhaust gas temperature Pre heating Alfa 20E Standard Dual circuit with heat exchanger CM type 4 Hyundai ZF Hurth or Technodrive Automatic 12 Volt 110 A Oil pressure Temperature of coolant inner circuit Charging current Exhaust gas temperature Pre heating Alfa 20E Standard Dual ci...

Page 40: ...ER INTAKE 75 mm EXHAUST 265 178 456 99 634 465 274 360 MIN 72 MAX 87 Overall Dimensions 13 CM4 80 with ZF25 Gearbox Both engine versions 65hp and 80hp have identical dimensions Dimensional drawings on these pages only differ in gearbox type and exhaust diameter ...

Page 41: ... Dordrecht Copyright reserved acc law It is not to be copied in whole or in part or other wise disclosed without the written consent of Craftsman Marine B V Sheet of CM4 80 Engine Assembly Material Weight Dim in mm Initials Description Product group 1 5 A3L 3 3 634 984 Exhaust 75 mm CM4 80 60 mm CM4 65 178 456 95 3 233 585 161 SEA WATER INTAKE 28 mm MIN 72 MAX 87 mm 465 379 274 CM4 65 CM4 80 with ...

Page 42: ...hich the engine operates We recommend the use of a four seasons engine lubricant branded SAE 15 W 40 which is suitable for ambient temperatures of between 15 ºC and 35 ºC It is strongly recommended to use a type of engine lubrication oil made by a well known manufacturer with the following classifications Type 15W40 API CD CE or CF4 CCMC D4 or D5 Oil lubrication system Capacity with inter cooler v...

Page 43: ...er 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 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...

Page 44: ...44 Crafted with CRAFTSMAN MARINE Notes ...

Page 45: ...Notes 45 Crafted with CRAFTSMAN MARINE ...

Page 46: ...46 Crafted with CRAFTSMAN MARINE Notes ...

Page 47: ...tioned EC type approval certificate s has have been issued and will meet the exhaust emission requirements of EC Directive 2003 44 EC amending Directive 94 25 EC when installed in a recreational craft in accordance with the engine manufacturer s supplied instructions and that this these engine s must not be put into service until the recreational craft into which it is they are to be installed has...

Page 48: ...Crafted with craftsman marine ZD 010 016 2 1 04 12 info craftsmanmarine com www craftsmanmarine com ...

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