Craftsman CM4.33 Manual Download Page 38

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Title part xxx

Subtitle part xxx

craftsman marine diesel engines CM4.33 / cm4.42

Problem

Probable cause

Solution

Engine becomes
overheated

• 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

• Check/top up

• Check and open

• Check / clean

• Check/ replace

• Check / replace

• Check and clean or replace if necessary

• Lower oil level

• Top up / Replace

7.
Not all cylinders are perfor-
ming well

• 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

• In all these cases, please consult your 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 / adjust alignment

• Replace by good quality engine lubricating oil

• Replace defective component

Engine oil cumsumption
excessively

• 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

• 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

14 Problems and solutions

Summary of Contents for CM4.33

Page 1: ...propulsion Boating technology by craftsman marine CM4 33 CM4 42 engine manual ...

Page 2: ...Title part xxx Subtitle part xxx 2 craftsman marine diesel engines CM4 33 cm4 42 ...

Page 3: ...sman 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 Title part xxx Subtitle part xxx 3 craftsman marine diesel engines CM4 33 cm4 42 Operation Manual Craftsman Marine CM4 33 4 42 ...

Page 4: ...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 oper...

Page 5: ...tick 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 filter 24 Danger 25 Fuel filter 25 Draining the water separator 25 Air breathing 25 Change engine lubri cation oil 26 Prepare oil filter 26 A...

Page 6: ...ngine instrument panel type Alfa 20 E Engine cable loom with 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 ...

Page 7: ...rrect level of the various fluids All year long use a good quality 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...

Page 8: ...Title part xxx Subtitle part xxx 8 craftsman marine diesel engines CM4 33 cm4 42 Notes ...

Page 9: ...ation 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 When checking upon or adjusting any parts or when checking or filling lubricants 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 ...

Page 10: ...onents Service side Oil filler cap Connection 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 Breather nipple cooling system Oil filler cap Exhaust Carter plug Connection for throttle push pull cable ...

Page 11: ...aftsman marine diesel engines CM4 33 cm4 42 Designation of engine components Product description 8 Starter 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 ...

Page 12: ...is information if and when you have to order spare parts or if you want to correspond with our ser vice department 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 Mitsubushi engine serial number The Mitsubishi engine serial number is engraved into the engine block to the starboard s...

Page 13: ...e 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 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 le vel of lubricating oil is correct A second filler...

Page 14: ...es For the ZF Hurth and Technodrive brands the types and quantities are 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...

Page 15: ...coo ling 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 pl...

Page 16: ...rature 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 1 2 3...

Page 17: ...tmeter 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...

Page 18: ...r 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 rig...

Page 19: ...rottle 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 s...

Page 20: ...our dealer check and execute the following Verify the tolerance of the 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 oper...

Page 21: ...e correct oil level is spot on or close to the upper mark If the engine 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 cylin ders causing black smoke from the exhaust and strong int...

Page 22: ...arged 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 o...

Page 23: ...trainer Clean the filter element at least twice a year or whene ver necessary 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 suc ked into the system on account of a badly closing filter cover there is a severe risk of overheating of the engine A...

Page 24: ...1 Title part xxx Subtitle part xxx 24 craftsman marine diesel engines CM4 33 cm4 42 2 Water seperator fuel filter 11 Maintenance and inspection ...

Page 25: ...e filter Drain the water and collect it in a bowl close the drain plug Note A water separator does not be long 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 The fuel system is self bleeding and this goes as fol lows Turn the key in the start ...

Page 26: ...is oil in a beaker or bowl and bring it with the rest of the used oil to the service station all in accor dance with the environmental directives Replacing the oil must take place when the engine has its operating temperature 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 ...

Page 27: ...housing Adding new oil filter Fill the engine with lubrication oil with specifications as outlined on page 13 through one of both filling entries Use a funnel in order to avoid spilling of oil over the en gine 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 Oil filter Maintenance and inspe...

Page 28: ...rst remove either the dipstick or the filler cap depen dent on the gearbox model Position the hose of the spe cial 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 gear box you may also remove the drain plug of the gearbox for letting the oi...

Page 29: ...n your country Do not smoke when working at or around the fuel system 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...

Page 30: ...ber element must not show any fissures Should this be the case then the engine mounting must be replaced Make sure as well that the damper ele ment 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 fis sures in the rubber hoses In such case the ho...

Page 31: ...V belt is correct if it can be 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 Ten sion the belt by pushing the alternator outward Thereaf ter first tighten the upper bolt ...

Page 32: ...uality of oil with protective properties See page 26 Raw water cooling system Close the raw water seacock and clean the raw water strainer Drain so much cooling liquid from the inner coo ling 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 fre...

Page 33: ... aid of a volume gauge See page 43 for the relevant specifications If 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 batteries 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 f...

Page 34: ...sary 3 Connect the battery cables 4 Verify that the cover of the raw 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 tigh tened well 13 Preparations for the new season 5 ...

Page 35: ...sure that the engine has sufficient lubrication oil as described on page 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 ...

Page 36: ...ective injector injection pump Breather line of fuel tank clogged up 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 ...

Page 37: ... tank and rinse it well Fill with good quality fuel Check clean 5 Engine 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 e...

Page 38: ...fective electrical fuel lift pump In all these cases please consult your 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 o...

Page 39: ...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 the engine if needed ...

Page 40: ... mm Capacity 1500 cm 1758 cm Number of cylinders 4 in line 4 in line Compression ratio 22 1 22 1 Order of fuel injection IDI indirect IDI indirect Maximum number of revolu tions 3000 rpm 3000 rpm Maximum torque 77 4 Nm at 3000 rpm 98 Nm at 3000 rpm Maximum output at flywheel 24 3 kW 33 pk ISO 8665 3046 30 9 kW 42 pk ISO 8665 3046 Fuel consumption at 1800 rpm 252 g kW h 185 g pk h 252 g kW h 185 g ...

Page 41: ...10A 12 Volt 110A Warning functions in instru ment panel 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 Instrumentpanel Alfa 20E Alfa 20E Connections for calorifier boiler optional optional Cooling system Dual circuit with heat exchanger Dual circuit...

Page 42: ...d 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 of CF4 CCMC D4 of D5 Oil lubrication system Oil capacity maximum 5 4 litres without oil filter maximum 5 6 litres with oil fiter Cooling system Capacity with inter cooler version 6 5 litres with keel cooler version 7 2 liter Lubricatio...

Page 43: ...son 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 water...

Page 44: ...Exhaust 0 50 mm Fuel return Ø 8 mm Fuel supply Ø 8 mm Sea water intake Ø 20 mm 385 579 195 Title part xxx Subtitle part xxx 44 craftsman marine diesel engines CM4 33 cm4 42 17 Overall Dimensions CM4 33 ...

Page 45: ...Title part xxx Subtitle part xxx 45 craftsman marine diesel engines CM4 33 cm4 42 CM4 42 Overall Dimensions 17 579 Exhaust 0 50mm Fuel supply Ø 8 mm Sea water intake Ø 20 mm ...

Page 46: ...Notes ...

Page 47: ...Notes ...

Page 48: ...Boating technology by craftsman marine ZD 010 002 2 2 0709 info craftsmanmarine com www craftsmanmarine com Printed in the Netherlands ...

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