Craftsman Marine CM 2.16 Generator Set

⚠ Do not smoke when working at or around the fuel system and avoid open fire.

1. Prime the fuel system by pumping the fuel pump manually (with handle).
2. When all air has escaped, close the bleeding nipples.

⚠ Replacing the oil must take place when the engine has its operating temperature (but is stopped), 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!

Tools: Sump pump, Funnel

1. Replace the engine lubricant and the oil filter after every 100 hours of service or at least once a year.
2. Run the engine to operating temperature (about 80 degrees Celsius) and then stop it.
3. Remove the dipstick first, then insert the hose of the sump pump into the pipe of the dipstick.
4. Extract the oil by quickly pushing down the grip of the sump pump and then pulling it slowly upwards.
5. When all lubricating oil has been drained, replace the oil filter.
6. Collect the used oil and bring it to the service station in accordance with the environmental directives.

1. Use a suitable tool to make sure that the bolts on the engine bed and the nuts on the spindle are securely tightened.
2. Check that the rubber element shows no fissures; if it does, replace the engine mounting.
3. Inspect all hoses of the cooling and fuel systems for loose connections, cracks and fissures; replace the hose if found.
4. Make sure that all bolts, nuts and screws are well tightened.
5. Make sure the damper element is still sufficiently flexible; if not, the engine must be realigned.

⚠ Open the filler cap on top of the heat exchanger housing only when the engine is cold.

1. Verify the level of the cooling fluid when the engine is cold.
2. Open the filler cap on the expansion tank (if fitted) or on top of the heat exchanger housing.
3. Make sure the coolant level is about 1 cm below the bottom of the filler pipe.
4. Top up with fresh cooling liquid if required.

⚠ If air is sucked into the system through a badly closing filter cover there is a severe risk of overheating of the engine.

1. Close the raw water seacock.
2. Remove the cover from the filter housing for inspection.
3. Clean the filter element at least twice a year, or whenever necessary.
4. When closing the strainer again, make sure the cover perfectly shuts the unit off without air leaks.

⚠ Do not smoke when you drain liquids from engine or filters. Keep open fire away from the location.

⚠ Remove any spilled oil or liquids before starting the engine.

1. Open the drain plug at the bottom of the filter.
2. Drain the water and collect it in a bowl.
3. Close the drain plug.

Tools: Funnel

1. Clean the surface of the rubber ring in the rim of the oil filter and grease it with fresh engine lubrication oil.
2. Turn the new oil filter onto the engine, following the instructions given on the filter housing.
3. Fill the engine with lubrication oil through one of both filling entries, using a funnel.
4. Have the engine idling during a few moments and check for leaks.
5. Stop the engine and check the oil level by means of the dipstick after about 5 minutes.

Tools: Sump pump

1. Remove the dipstick from the housing of the gearbox.
2. Clean the dipstick and position it again into the opening to verify the level of the lubricant.
3. If the level is too low, add fresh lubricant through the opening for the dipstick.
4. To drain: first remove either the dipstick or the filler cap, depending on the gearbox model.
5. Position the hose of the special sump pump into the pipe of the dipstick and extract the oil.
6. If there is sufficient space below the gearbox, the drain plug may also be removed to let the oil out.
7. Collect the oil in a bowl and treat it in accordance with the environmental directives.
8. Fill the gearbox with its lubricant through the hole of the dipstick, or via the filler cap if available.

⚠ Only check the V-belt when the engine is not running.

Tools: Spanner 17, Spanner 13

1. Only check the V-belt when the engine is not running.
2. Check the V-belt for wear and tear, cracks, fissures and ravels; replace it if any are found.
3. Check the tension: the belt must move no more than 12 mm using thumb and forefinger and a force of about 10 kg.
4. If the travel is greater, adjust the tension: loosen the bolts of the support and both bolts of the alternator.
5. Tension the belt by pushing the alternator outward.
6. First tighten the upper bolt of the alternator, thereafter the support and the lower bolt of the alternator.

1. Open the fuel supply cock.
2. Charge the battery(ies), if necessary.
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.
6. Reconnect and tighten well any hoses disconnected before winter storage.
7. Open the seacock of the raw water entry.
8. Check the level of the cooling liquid.
9. Make sure that the engine has sufficient lubrication oil.
10. Start the engine and make sure there are no leaks in the fuel system, cooling system and exhaust assembly.
11. Verify the proper functioning of all electronic parts, engine instruments, mechanical remote control and gearbox.

⚠ Never add sea (or salt) water into the inner cooling circuit!

⚠ Open the filler cap on top of the heat exchanger housing only when the engine is cold.

1. Remove the two drain plugs of the cooling system from the engine block and the heat exchanger housing.
2. Remove the filler cap from the expansion tank and/or heat exchanger housing to drain the liquid completely.
3. Replace the drain plugs and tighten them well.
4. Remove the bolt on top of the thermostat housing cover to vent (air-bleed) the system.
5. Fill the system with a mixture of 40% anti-freeze and 60% clean tap water.
6. Top up to about 1 cm below the bottom of the filler pipe.
7. After the engine has warmed up and cooled down completely, check the coolant level again and top up if necessary.

⚠ Do not smoke when working at or around the fuel system and avoid open fire.

Tools: Special filter tool

1. Close off the fuel supply to the engine.
2. Remove the entire filter with the aid of a special tool; collect any remaining fuel.
3. Clean the surface to touch the engine before fitting the filter.
4. Grease the rubber ring with clean engine oil and fill the filter with clean diesel fuel.
5. Position the filter against the filter housing and tighten it with one half to three quarters of a turn.
6. Clean the filter of the fuel lift pump and reopen the cock of the fuel supply.