Craftsman Marine CM4.42 Generator Set

Tools: Spanner 17, Spanner 13

1. Check the V-belt for wear and tear, cracks and fissures and ravels; replace if affected (engine not running).
2. Check tension: correct if it can be moved by no more than 12 mm using thumb and forefinger and a force of about 10 kg.
3. Loosen the bolts of the support and both bolts of the alternator.
4. Tension the belt by pushing the alternator outward.
5. First tighten the upper bolt of the alternator and thereafter the support and the lower bolt of the alternator.

1. Fill the engine with 5 liters of lubrication oil for diesel engines (Type 15W40; API CD, CE or CF4; CCMC D4 or D5).
2. Fill through the filler cap on the rocker cover or through the filler pipe at the front of the engine; a second filler cap is at the starboard side next to the identification tag.
3. Check with the dipstick whether the level of lubricating oil is correct.

⚠ Never fill the cooling system with sea water!

1. Remove the filler cap on top of the heat exchanger housing, or the cap on top of the expansion tank if fitted.
2. Fill the cooling system with 6.5 liters of cooling liquid.
3. Use a ready-to-use product or a mixture of 40% anti-freeze (ethylene-glycol) and 60% clean tap water.
4. Fill the system to about 1 cm below the bottom of the filler pipe.
5. Replace the filler cap and tighten the breather bolt.
6. After the first run, verify the level of the cooling liquid and top up if necessary.

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 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 the engine has sufficient lubrication oil.
10. Start the engine and check for leaks in fuel system, cooling system and exhaust assembly.
11. Verify the proper functioning of all electronic parts, engine instruments, mechanical remote control and gearbox.
12. Check exhaust for coolant water.

Tools: Funnel

1. Fill the engine with lubrication oil through one of both filling entries using a funnel.
2. Have the engine idling a few moments and check for leaks.
3. Stop the engine and check the oil level by means of the dipstick after about 5 minutes.

1. Turn the key in the start switch to the 'ON' position.
2. After about 1 minute the fuel lift pump will begin to operate and bleed the system automatically.
3. If so required the bleeding can also take place via the fuel filter (only for a 4-cylinder engine).

⚠ Oil temperature is about 80 degrees Celsius; watch out for burning the skin.

Tools: Special sump pump

1. Run engine to operating temperature, then stop.
2. Remove the dipstick and insert the hose of the special sump pump into the dipstick pipe.
3. Extract the oil by quickly pushing down the grip of the sump pump and pulling it slowly upwards.
4. Replace the oil filter after all oil has been drained.
5. Collect used oil and bring it to a service station per environmental directives.

Tools: Suitable tool

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, the engine mounting must be replaced.
3. Inspect all hoses of the cooling and fuel systems for loose connections, cracks and fissures; replace the hose if necessary.
4. Make sure that all and sundry 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 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. If required, top up with fresh cooling liquid.

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

1. Close the raw water seacock and remove the cover from the filter housing.
2. Inspect for clogging by dirt.
3. Clean the filter element at least twice a year or whenever necessary.
4. Refit the cover making sure it shuts the unit off perfectly.

1. Remove the dipstick from the gearbox housing and clean it.
2. Position it again into the opening but do not screw in, remove and verify the level of the lubricant.
3. If the level is too low, add fresh lubricant through the opening for the dipstick.

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

1. Each day, prior to starting, make sure that the cooling water strainer is not clogged by dirt.
2. Close the raw water seacock and 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 that the cover shuts the unit off perfectly.