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PleasureCraft Engine Group crusader, Owner'S Operation And Maintenance Manual, Page: 1 / 96

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PleasureCraft Engine Group crusader Owner'S Operation And Maintenance Manual Download Page 1

OWNER’S OPERATION

and

MAINTENANCE MANUAL

A Division of

Summary of Contents for crusader

Page 1: ...OWNER S OPERATION and MAINTENANCE MANUAL A Division of...

Page 2: ...for clarification or assistance Ask your Dealer for a demonstration of actual starting and operating procedures The descriptions and specifications contained in this manual were in effect at the time...

Page 3: ...now About The Warranty 11 California Emission Control Warranty Statement 12 Crusader Inc Model Years 2003 2008 General Emissions Warranty Coverage 13 Marine Transmissions 15 Captain s Choice Series En...

Page 4: ...EMENTS 38 Engine Oil Recommendations 38 Transmission and V Drive Oil Requirements 38 ENGINE MAINTENANCE 39 68 Engine Maintenance 39 Checking Fluid Levels 39 40 Lubrication 41 Electrical System Circuit...

Page 5: ...ransmission Fluid Capacities 66 Filter Requirements 67 On Board Parts Kits 67 69 ENGINE SPECIFICATIONS 70 72 OUT OF SEASON STORAGE 73 76 Engine Storage 73 Draining Instructions 74 Battery Storage 74 O...

Page 6: ...oast Guard approved could cause a re or explosion hazard and should be avoided Always request that genuine Crusader Marine Engines replacement parts be used in any repairs or maintenance being perform...

Page 7: ...factory you will be issued an Owner Warranty Registration Card The Owner Registration Card is your only valid registration identi cation and must be presented to the servicing dealer should warranty s...

Page 8: ...ses as to whether a malfunction is caused by lack of maintenance or a defect in material or workmanship An Engine Maintenance Log is provided in the MAINTENANCE SCHEDULE section of the OPERATION AND M...

Page 9: ...U S Coast Guard rules and regulations to minimize the risks of re or explosion Use of replacement electrical ignition or fuel system components which do not comply with these rules and regulations cou...

Page 10: ...anty does not apply to Product defects caused by normal wear and tear to Products and or damage to Products arising out of negligence or lack of proper care improper installation or service operation...

Page 11: ...DIRECT INCIDENTAL except as speci cally provided herein OR CONSEQUENTIAL DAMAGES Some state do not allow the exclusion or limitation of incidental or consequential damages so this limitation or exclus...

Page 12: ...ngine cylinders or oiling system through the intake manifold system exhaust system submersion or in any manner if not caused by a Crusader manufacturing defect Water in starters Improper winterizing r...

Page 13: ...nges in the engines built and or sold by it at any time without incurring any obligation to make the same or similar changes on engines previously built and or sold Proof of Date of Purchase Crusader...

Page 14: ...to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE Select emission control parts from Model Years 2003 2008 inboard engines are warranted for 2 years OWNER S WARRANTY RESPONSI...

Page 15: ...y will be warranted for the remainder of the two 2 year period 4 Any part covered under this Warranty that is scheduled only for regular inspection in the written instructions to be found within the C...

Page 16: ...rt has been abused neglected or improperly maintained and that such abuse neglect or improper maintenance was the direct cause of the need for repair or replacement of the part 11 Crusader original eq...

Page 17: ...smission model and serial number Have this tag information available whenever contacting the manufacturer Velvet Drive Transmissions 1208 Old Norris Road P O Box 238 Liberty SC 29657 Phone 864 843 923...

Page 18: ...ontact the dealership s owner Step Two If Your Complaint Has Not Been Resolved To Your Satisfaction Contact The Crusader Captain s Club Concierge When contacting the Club Concierge Call the con dentia...

Page 19: ...or to delivery make certain that the Crusader Engine is in proper operating condition Make all necessary adjustments for maximum ef ciency Familiarize you the owner with the on board equipment Explain...

Page 20: ...The forms and instructions necessary to transfer the unused portion of the Crusader One year Limited Warranty are provided in Forms section 18 of this manual The Captain s Choice Series Extended Buye...

Page 21: ...19 L510001 05 SERVICE and WARRANTY 1...

Page 22: ...on reveals possible leaks DO NOT operate your engine s until it can be serviced by a quali ed technician Proper and adequate air circulation around and throughout the boat is absolutely necessary to a...

Page 23: ...ever possible Follow the Rules of the Road when boating Always be on the alert and watch out for the other guy Plan and chart your course Be aware of and avoid hazardous areas Be sure your boat is equ...

Page 24: ...the boat that are designed for that purpose If water is rough carry fewer passengers Observe the Rules of the Road PORT Left Leaving the harbor with green buoys to your right STARBOARD Right Entering...

Page 25: ...E MODEL SERIAL FIRING ORDER THIS ENGINE CONFORMS TO ALLAPPLICABLE U S GOVERNMENT STANDARDS FOR MARINE ENGINES IN EFFECT AT DATE OF MANUFACTURE LITTLE MOUNTAIN SC 29075 2 1 1 ENGINE SPECIFICATION DECAL...

Page 26: ...LTI PORT FUEL INJECTION SERIAL NUMBER I D 1st DIGIT INDICATES DECADE ENGINE WAS MANUFACTURED 5 1990 6 2000 7 2010 2nd DIGIT INDICATES YEAR ENGINE WAS MANUFACTURED 1st Space MANUFACTURER C Crusader 2nd...

Page 27: ...RPM to prevent engine damage from over revving The sensors that the ECM monitors are Engine Coolant Temperature ECT Sensor Throttle Position TP Sensor Manifold Absolute Pressure MAP Sensor Knock Senso...

Page 28: ...Once the RPM is brought down below 1200 RPM normal engine operation is restored until the RPM exceeds 2000 RPM The feature allows maneuverability of the boat while removing the possibility of high eng...

Page 29: ...IL PRESS Light Illuminated High Transmission Fluid Temperature During operation if the transmission uid temperature exceeds 235 F 113 C the engine enters Power Reduction mode and illuminates the TRANS...

Page 30: ...e engine or transmission NOTICE Some boat builders may install their own alarm system It is recommended that the boat owner check with his or her boat dealer for an explanation of the particular alarm...

Page 31: ...00 170 100 TEMP 200 170 100 80 40 0 OIL CHECK ENGINE CHECK ENGINE 8 3 1 2 6 7 4 5 Figure 5 1 Typical Instrument Panel CAUTION Never shift transmission into or out of gear unless throttle is at the idl...

Page 32: ...on Figure 5 3 At this throttle position the ECM will command the injectors to deliver no fuel during engine cranking IMPORTANT If the engine fails to start within 20 30 seconds turn the ignition key t...

Page 33: ...ensure the engine is operating within the normal temperature range If the temperature is abnormally high stop the engine immediately and determine the cause SHIFTING TRANSMISSION CAUTION Never shift t...

Page 34: ...valve 3 Close the seacock 4 Flush the cooling system if in a salt water area OPERATING INSTRUCTIONS 5 FREEZING TEMPERATURE OPERATION If the possibility of freezing exists the cooling system must be pr...

Page 35: ...cruising running against a choppy wave condition acceleration onto plane and operating at slow planing speeds Will improve rough water ride and handling In extreme may cause the boat to bow steer veer...

Page 36: ...of the major factors and should be one of the primary considerations when selecting a propeller Other factors to take into consideration are as follows Warmer weather and higher humidity will cause an...

Page 37: ...ne in complete safety Reduce the throttle to 2800 3000 RPM and cruise at or below this speed for 1 2 hour Reduce the speed to idle Go to wide open throttle until maximum RPM is reached and operate for...

Page 38: ...vels Check the throttle and the shift cable adjustments and check for freedom of movement Cooling System Inspect all the hoses for leaks damage and deterioration Check all the hose clamps for adequate...

Page 39: ...alcohol is not recommended for use in your engine Gasoline containing alcohol will attract and hold moisture and may cause the following Hard starting and operating dif culties vapor lock low speed st...

Page 40: ...contain solid additives non detergent oils or low quality oils speci cally are not recommended WARRANTY NOTICE Crusader Marine Engines reserves the right to refuse warranty on part s and or engine s...

Page 41: ...erated which will affect the oil pressure and may result in internal engine damage from lack of lubrication 1 Stop the engine if running Allow approximately 5 minutes for the oil to drain back into th...

Page 42: ...l Replace the dipstick and tighten securely 2 Operate the engine until the engine and the transmission reach operating temperature 3 Stop the engine and quickly check the uid level to minimize the dra...

Page 43: ...Velvet Drive Transmissions Lubricate the detent ball and holes in shift lever Figure 11 4 with white grease Lubriplate or equivalent Figure 11 4 Transmission Shift Lever Velvet Drive 5000 Shift Cable...

Page 44: ...circuits ELECTRICAL SYSTEM FUSES Crusader engines utilize fuses to control the fuel pump ECM and fuel injectors The fuse block is mounted to a bracket near the exhaust elbow under a weather tight cov...

Page 45: ...e engine with an open in the battery circuit as this may cause damage to the alternator Make sure that all connections are clean and secure When removing the battery cables always remove negative cabl...

Page 46: ...gone replace with a new zinc anode Different geographic locations and water make up can result in either high or low sacri cial requirements A high rate of zinc anode consumption should also alert th...

Page 47: ...arge violently and cause severe burns DeGas Bottle The see through degas bottle is connected to the heat exchanger by a small hose The degas bottle collects coolant that expands with rising temperatur...

Page 48: ...hout water being supplied to the sea water pump The sea water pump impeller may be damaged and subsequent overheating damage may result Figure 11 9 Typical Sea Water Inlet CAUTION Do not run the engin...

Page 49: ...olant properly Check your local restrictions for proper disposal instructions of removed coolant NOTICE Refer to cooling system water ow diagrams for drain locations 1 Remove the following drain plugs...

Page 50: ...vice interval will be reduced from 5 years to 2 years The fresh water cooling side of the cooling system must be lled with a 50 50 mixture of DEX COOL or equivalent which meets GM6277M extended life a...

Page 51: ...acility 1 Remove the bolts securing the heat exchanger end plates Remove the end plates and gaskets 2 Clean the water passages in the heat exchanger by inserting a suitable size wire brush into each p...

Page 52: ...umps to provide an uninterrupted ow of fuel to your Crusader marine engine Fuel is fed into the FCC bowl by a low pressure high volume electric fuel pump This pump ows fuel at a volume much greater th...

Page 53: ...f the fuel Replace the lter element at least once a year or when a loss of power is noticed whichever occurs rst WARNING Improper use installation or servicing may cause an explosion or re resulting i...

Page 54: ...e fuel pump with one hand and pulling the lter element downward with the other hand 6 Push on new lter element part number RP080026 over the electric fuel pump 7 Using a pick made of soft material suc...

Page 55: ...nal components i e hoses wires etc 7 Push on new lter element part number RP080026 over the electric fuel pump 8 Using a pick made of soft material such as a toothpick remove the old O rings from the...

Page 56: ...the hose clamp securing the lter to the bracket 3 Using two wrenches secure the housing closest to the low pressure fuel pump and unscrew the outer retaining tting Separate the housing 4 Remove the se...

Page 57: ...r Clean the ame arrestor with solvent and dry with compressed air Reinstall the ame arrestor and tighten the clamp s securely Figure 11 17 Flame Arrestor 5 7L Typical Figure 11 18 Flame Arrestor 8 1L...

Page 58: ...L 8 1L SERPENTINE BELT R066024A 1 Note the routing of the belt before removing 2 Using a 15 mm box wrench or socket turn the belt tensioner to relieve the tension on the belt Slide the belt off of the...

Page 59: ...pulley Release the tension slowly to tension the belt Figure 11 22 Belt Tensioner 6 0L 6 0L ACCESSORY DRIVE BELT The Crusader 6 0L engine uses a single serpentine belt to drive the engine water circul...

Page 60: ...the pulleys using the same routing as noted prior to removal 4 Compress the belt tensioner and slide the belt over the tensioner pulley Release the tension slowly to tension the belt SERVICING RAW WAT...

Page 61: ...adapter DO NOT remove this adapter when changing the oil 1 With the engine at normal operating temperature remove the dipstick and install a crankcase oil pump onto the dipstick tube Figure 11 25 Inse...

Page 62: ...ting Surface Check 8 Degree Down Angle Figure 11 28 Shaft Mating Surface Check V Drives 2 Center the propeller shaft in the shaft log as follows Push down and then lift the propeller shaft as far as i...

Page 63: ...Down Angle 4 Check for any angular misalignment Hold coupling faces tightly together and check for a gap between the coupling faces with a 0 003 in 0 07 mm feeler gauge at 90 degree intervals Figure...

Page 64: ...engine mounts as follows UP or DOWN ADJUSTMENT Loosen the lag bolt 1 4 turn Use the mount adjusting tool or a 3 8 in 0 95 cm or 1 2 1 27 cm diameter rod through both sides of the adjusting sleeve to...

Page 65: ...63 L510001 05 ENGINE MAINTENANCE 11 ENGINE MAINTENANCE LOG Operating Date Maintenance Repair Hours...

Page 66: ...mpeller X X Drive Belt Inspect condition and check tension X X X Exhaust System Check condition and tightness of all hose clamps X X1 X Exhaust System Check for water leaks at the manifold riser and e...

Page 67: ...X preventative oil D Salt water areas Every 30 days X Cooling System SALT WATER AREAS ONLY Flush sea water section After use each day X Notes X Denotes service to be performed by the owner operator O...

Page 68: ...4 26 4 73 L DEXRON III Hurth Exc V Drive All Ratios 1 2 4 0 Quarts 3 79 L DEXRON III Hurth V Drive All Ratios 1 2 4 5 5 0 Quarts 4 26 4 73 L DEXRON III Walters RV 36D V Drive 1 5 Quarts 1 42 L SAE 30...

Page 69: ...VS 1 RA108009 Fuse 20 Amp 3 R153017B Relay 12V Fuel Pump Ignition Start 1 R130011A SparkPlug Set Platinum 1 RP030010 Impeller Raw Water Pump 1 RP061022 Primary Fuel Filter Element 150 Micron 1 RP07701...

Page 70: ...ent RH RK173089G 05 Box On Board 1 22433 Belt Serpentine 1 R066029A Rotor Distributor HVS 1 R103011 Cap Distributor HVS 1 RA108009 Fuse 20 Amp 3 R153017B Relay 12V Fuel Pump Ignition Start 1 R130011A...

Page 71: ...L SYSTEM 05 To Present RK173087 05 Box On Board 1 22433 Belt Serpentine 1 R066024A Fuse 20 Amp 3 R153017B Relay 12V Fuel Pump Ignition Start 1 R130011A SparkPlug Set Platinum 1 RP030009 Impeller Kit R...

Page 72: ...69 kPa 10 psi 69 kPa 10 psi 69 kPa 10 psi 69 kPa 10 psi 69 kPa at Idle at Idle at Idle at Idle at Idle at Idle Spark Plug P N R030010 R030010 R030009 R030009 R030011 R030010 Spark Plug Gap 0 060 in 0...

Page 73: ...arning 1 Gen Warning 1 Gen Warning 1 Gen Warning 1 Gen Warning 1 Check Gauges Lamp Switch Trans Temp Lamp Trans Temp Lamp Trans Temp Lamp Trans Temp Lamp Trans Temp Lamp and or Buzzer Power Reduction...

Page 74: ...Rotation 5 7 Liter RH ROTATION FRONT 1 4 c 6 7 8 2 5 3 Rotation TUNE UP SPECIFICATIONS Model MP 5 0L 275 HP MP 8 1L STD 385 HP MP 5 7L 330 HP MP 6 0L 375 HP MP 8 1L HO 425 HP Spark Plug Type R030010 R...

Page 75: ...g solution and spray a suf cient amount into each cylinder Spray 5 seconds per cylinder minimum Turn the crankshaft several revolutions by hand to spread the oil evenly throughout the cylinders NOTE I...

Page 76: ...ANCE If inspection proves the impeller to be in good condition store it in an accessible spot for re installation at the end of the storage period A damaged or badly worn impeller should be discarded...

Page 77: ...re clean and free from corrosion Coat the battery terminal connections with an anti corrosion battery terminal spray 4 Readjust alternator and water pump drive belt tension 5 Check engine alignment 6...

Page 78: ...ion high voltage spark by removing the MEFI System Relay Using rags draped over the exhaust manifolds or some other suitable material or method create a de ector or catcher for the oil that will be sp...

Page 79: ...ng Check the battery cables and connections starter circuit wiring Clean and tighten all connections Repair or replace the damaged wiring Dead Battery Recharge test and replace as necessary Engine Cra...

Page 80: ...leaks equipped with Fresh Water section of the cooling system Re ll the system See Warning Cooling FWC systems before removing the ll cap Heat exchanger passages plugged Clean and ush the exchanger w...

Page 81: ...fuel pump replaced by a Crusader Marine Engines Dealer Plugged or kinked fuel lines or Repair or replace the fuel lines fuel tank vent Remove obstruction Anti siphon valve faulty Clean or replace as n...

Page 82: ...Hook Up Location 1 Water OUT to heater or hot water tank T Fitting required at temp sender location Location 2 Water RETURN from heater or hot water tank Fitting at bottom of heat exchanger OR circ p...

Page 83: ...RAW WATER FLOW NOTE Location is the location in order to hook up a hot water accessory IMPORTANT Accessory i e heater hot water tank Hook Up FRESH WATER FLOW A A 5 Drain Locations 3 4 2 1 Pressure Ret...

Page 84: ...FRESH WATER FLOW IMPORTANT Accessory i e heater hot water tank Hook Up Location 1 Water OUT to heater or hot water tank Fitting at end of crossover Location 2 Water RETURN from heater or hot water tan...

Page 85: ...w Diagrams and Fill Riser Water ow 8 1L Fresh Water Cooled HEAT EXCHANGER BYPASS COOLANT FLOW FROM EXHAUST MANIFOLDS WARM UP OPERATION HEAT EXCHANGER BYPASS FROM EXHAUST MANIFOLDS NORMAL OPERATION HEA...

Page 86: ...NESS COLOR CHART 10 4 3 2 ENGINE HARNESS 5 6 7 9 8 1 A NOTE The light green wire pigtail located near the engine harness connector is for connection of a buzzer or light to indicate low oil pressure I...

Page 87: ...the following IMPORTANT When contacting the factory for service information be sure to include your engine model and serial number to insure the service information you receive is correct Crusader Ma...

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Page 89: ...ission Base Engine 1 year 200 hours with exclusions Note 1994 1998 1 year unlimited hours for Champion Series Platinum Series has addditional 4 years extended warranty administered by First Protection...

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Page 91: ...ICE The checks listed below are designed to insure safety and satisfaction Premier Crusader Dealer Technicians have received step by step instruction in the performance of the Pre Delivery Inspection...

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Page 93: ...ICE The checks listed below are designed to insure safety and satisfaction Premier Crusader Dealer Technicians have received step by step instruction in the performance of the Pre Delivery Inspection...

Page 94: ......

Page 95: ...93 L510001 05 NOTES 19...

Page 96: ...Pleasurecraft Engine Group 1737 Highway 76 East Little Mountain SC 29075...

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