Craftsman Marine CM4.65, CM4.80 User Manual

PropulsionCrafted with craftsman marine

CM4.65
& CM4.80

Engine manual

3Crafted with CRAFTSMAN MARINE

Preface

Dear owner of this engine,

We would like to thank you very much 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 faithfully and trouble-free, for many years to come.

This instruction manual informs you about the control, the maintenance and the
inspection of the Craf tsman Marine diesel engines, models CM4.65 and CM4.80.

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.

This page will provide you with a survey of all warning pictograms, used throughout
this manual. Notes referring to safety issues show this symbol:

Please 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 par ts and be very careful with flammable products in the
neighbourhood of the engine.

• When checking upon or adjusting any par ts, 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 is completely cooled down.

• Maintenance and ser vice to the engine must only be provided by experienced
people, using suitable tools. If possible entrust only an authorized Craf tsman
Marine dealer to do such work.

(especially with a view to a safety risk for man or material)

Safety

DANGER
ATTENTION

Pay attention to the symbols and read the instructions in the
text.

Attention

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This manual applies to model CM4.65 and model CM4.80. 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 find detailed instructions of how and how regularly the
various components 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, maintenance 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.

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 immediately rendered null and void.

Modifications of the injection and distribution system also form part of the aforemen­tioned exclusion 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 fulfillment of the legal prescriptions regarding the
emission of exhaust gases, aiming at the protection of the environment, is no longer
guaranteed in that case.

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 reser ves the right to modify – at all times and without prior notification - product specifications and instruction manuals.

5Crafted 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

Star ter 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

Inspec tion 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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Notes

7Crafted with CRAFTSMAN MARINE

Product identification 1

The Craftsman Marine identification tag is the place to
find the engine model, the serial number and a few
more data concerning your engine.

Please make sure this information is correctly noted in
the service 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 parts, or
if you want to correspond with our
service department.

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2 Product 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

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2Product 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

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Standard scope of supply

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
performance and fuel economy.

• Engine instrument panel

• Engine cable loom with fuse and Multi-plugs

• Connection par ts for the push-pull cables

• Four flexible engine mountings

• Sump pump

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

• Prior to starting the engine, always verify the correct 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 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 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.

• Fuel filter/water separator in the fuel supply line (recommended)

(optional):

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

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11Crafted with CRAFTSMAN MARINE

Prior to commissioning the engine

The Craftsman Marine diesel engines are supplied
without lubrication oil.

Before commissioning the engine 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

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Prior to commissioning the engine

The gearbox is located at the rear of the engine and it
must also be filled with the correct type and quantity of
lubricant.

Craftsman Marine diesel engines are supplied with
gearboxes of several brands and types.

For the ZF-Hurth and Technodrive brands the types and
quantities 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 can be filled up with
its lubricant. When the filling is completed, verify with
the dipstick whether the correct level of fluid is
obtained.

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Prior to commissioning the engine

Prior to commissioning the engine for the first time, the
inner cooling circuit must be filled with cooling liquid.

In order to do so, the filler cap on top of the heat
exchanger housing must be removed and the drain
valve A on the engine must be opened. By opening the
valve, the cooling liquid can flow directly from the heat
exchanger housing into the cooling channels of the
engine.

The cooling system must be filled with 9 liters of
cooling liquid. You can fill the system with a ready-to­use product, or prepare a mixture of 40% anti-freeze (on
the 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 calorifier is installed and connected to the
engine (page 18), an additional expansion tank must be
installed When the calorifier is installed higher than the
engine, it will not bleed automatically when filling the
cooling system. Fill it separately to bleed the cooling
system completely.

Cooling liquid

Open

Drain valve positions

Close

When running

engine

When filling

coolant

Never fill the cooling system with sea
water!

4

A

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Prior to commissioning the engine

Instrument panel

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

The voltmeter may be replaced by a temperature gauge

Optional

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

1.

2.

3.

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Prior to commissioning the engine

The revolution counter indicates the number of the
engine’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 4.65 and CM 4.80 marine diesel engines both
have an idling speed of 850 rpm.

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.

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 cooling circuit

4. temperature raw water in the exhaust

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 (and a monitoring light illuminates)
when the engine is running, a problem has occurred to
one of the functions described here above.

In that case, stop the engine
IMMEDIATELY!

4