2-3.1 PRE-OPERATIONAL CHECKS. The following steps shall be used to check and prepare the engine for operation
a. Test the emergency fuel shutdown according to the following steps.
1. Actuate the emergency fuel shutdown lever and ensure the emergency fuel shutdown device operates cor- rectly.
2. Reset the emergency fuel shutdown lever and open the emergency fuel shutdown valve. b. Test the electrical shutdown valve.
c. Ensure the fuel tanks are full of fuel and stripped in accordance with the appropriate BIB or local procedures. If fuel is required, refer to table 2-2 and refuel in accordance with the NSTM, Chapter 541, and the appro- priate BIB.
d. Check and drain the fuel strainer. e. Drain the fuel/water separator.
f. Open the fuel supply shutoff valves, as required, to supply fuel from the on-service fuel tank to engine. g. Open the fuel return shutoff valves, as required, to ensure that fuel spill from the engines returns to on-service
fuel tank only.
h. Check the fuel piping, hoses, fittings, and valves for leaks. If leaks are found, refer tochapter 5 and trouble- shooting.
i. Check the starting motor and batteries; ensure the battery charge is sufficient to start the engine. j. Check the air silencer for dirt and clogging. Remove any foreign material. Clean as required. k. Operate compartment ventilation, as required, for engine operation.
l. Remove the cap from the expansion tank assembly and check the coolant level. At normal operating tempera- ture, the coolant level should be about two inches below the top of the filler neck; add engine coolant, as required. Replace the cap.
m. Check the fresh water pipes, hoses, and fittings for leaks. If leaks are found, refer to chapter 5 and trouble- shoot.
n. Close the sea water drain and vent connections. o. Clean and inspect the sea water stainer.
p. Open the sea water manual valves, as required, for engine operation S9233-C9-MMA-010
Table 2-2. Fuel and Lubricating Oil
Type Usage
Primary
Fuel, Naval Distillate (MIL-F-168834) Use when ambient temperature is consistently above 30°F.
Secondary
Turbine Fuel, Aviation, Grade JP-5 (MIL-T-5624) Use when ambient temperature is consistently below 30°F.
Primary
Lubricating Oil, Internal Combustion Engine, Diesel (MIL-9000G, Sym 9250)
Use with ambient temperature above 20°F. Secondary
Lubricating Oil, Internal Combustion Engine, Diesel (MIL-L-2104)
Ambient temperature consistently below 20°F.
CAUTION
To prevent damage to equipment, prime the sea water pumps prior to opera- tion.
q. If necessary, prime the sea water pump.
CAUTION
To prevent damage to equipment, ensure that oil in the engine is at the proper level.
r. Ensure oil in the engine is at the high level mark on the dipstick.
1. Remove the dipstick from the oil pan and check the level. The oil level should be at the full mark. 2. If the level is low, refer totable 2-2. Remove the oil fill cap from the valve cover and add lubricating oil,
as required, to bring the level to the full mark. 3. Reinstall the oil fill cap.
4. If the level is high, excess oil can be removed from the oil sump with the sump pump. Dispose of oil in accordance with the NSTM, Chapter 593.
5. Reinstall the dipstick in the dipstick tube.
s. Ensure the marine transmission is prepared for operation, if equipped. Also, ensure the clutch is disengaged. t. Ensure the auxiliary driven equipment and associated systems are prepared for operation.
u. Ensure the engine rotating components are unobstructed. v. Place the start switch in the OFF position.
w. Ensure the oil pressure and alternator warning lights are on. x. Set the engine control lever in the idle position.
2-3.2 NORMAL OPERATION. The following steps shall be used for normal operation. This procedure covers electrical starting for cold and warm weather.
CAUTION
To prevent damage to equipment, this entire procedure and the emergency operating procedures must be understood before starting the engine. Rapid automatic sequence of some events without proper operator actions may damage the equipment.
a. Review this entire procedure and the emergency engineering operating procedures (EEOP) before performing any steps. This will ensure undemanding of required actions during rapid automatic sequence of events. Where conflicts exist, the EEOP takes precedence.
b. Ensure the pre-operational checks have been performed. Refer toparagraph 2-3.1. c. Place throttle in the idle position.
d. When the ambient temperature is 40°F or less and the engine is cold, start the engine using the cold start pro- cedures contained in the BIB.
e. When the ambient temperature is greater than 40°F or the engine is warm, start the engine with the electrical starting system.
WARNING
To prevent injury or death, exercise extreme caution when working on or around rotating parts of machinery or operating equipment.
1. Ensure the area around the engine is clear of personnel and loose equipment
NOTE
The start switch has three positions: OFF, RUN, and START. OFF and RUN are continuous contact positions and START is a momentary contact position.
2. Place the switch in the RUN position and observe that the engine’s gauges and instruments are energized. The temperature gauges should read normal temperatures and the alternator and low oil pressure warning lights should be lit.
3. Place and hold the switch in the START position to activate the starter motor and crank the engine. Pro- ceed to step f.
4. If the engine does not start after 30 seconds, return the switch to the OFF position. Wait two minutes between unsuccessful attempts.
5. Repeat steps 1 through 4. If the engine does not start after four attempts, refer to chapter 5 and trouble- shoot.
WARNING
To prevent injury or death, shut down the engine when unusual noise or vibration occurs. Unusual noise or vibrations may be an indication of equip- ment failure.
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f. Within 10 to 15 seconds after the engine starts, the alternator warning light and the low oil pressure warning light should go out, and the oil pressure gauge should indicate at least 10 psi. If this does not occur, place the switch in the OFF position and shut down the engine. Refer tochapter 5 and troubleshoot.
g. If abnormal noises or vibrations are present in the engine or any driven equipment, shut down the engine according to the EEOP.
WARNING
To prevent injury or death, control all oil and fuel leakage immediately. Oil or fuel spraying on hot components is an extreme fire hazard.
h. Periodically check the engine, attached piping, and hoses for oil, fuel, coolant, and sea water leakage. 1. If oil or fuel is spraying, shut down the engine according to the EEOP.
2. If the oil or coolant levels cannot be maintained, shut down the engine according to the EEOP. 3. If fuel is leaking, shut down the engine according to the EEOP.
4. If sea water is leaking and the coolant temperature is above 190°F and rising, shut down the engine. If the temperature reaches 210°F, shut down the engine according to the EEOP.
i. Periodically monitor all engine indicators and record readings. Ensure the monitored parameters are within operating limits. Refer totable 2-1.
j. Run the engine at idle speed for one minute.
CAUTION
To prevent damage to equipment, do not engage the clutch at speeds greater than 850 rpm.
k. With the boat moored to the dock, engage the clutch and run the engine at partial load for five minutes.
CAUTION
To prevent damage to equipment, run the engine at 800 rpm or greater dur- ing extended idle periods. Running the engine at idle speed for prolonged periods will dilute oil with fuel and cause sludge build-up.
l. Operate the engine, as required, for boat operations; maintain 800 rpm or greater when operating. Ensure the clutches are not engaged at speeds greater than 850 rpm.
2-3.3 SHUTDOWN. Shut down the engine according to the following steps.
CAUTION
To prevent damage to equipment, cool the engine before pressing the stop switch. Stopping the engine before it cools down may cause damage to equipment.
a. To cool down the engine, run the engine for five minutes at idle speed with the clutch disengaged. b. Move the start switch to the OFF position; ensure the engine stops.
c. If the engine does not stop, actuate the emergency manual shutdown lever. If the emergency fuel shutdown lever does riot stop the engine, determine and correct the cause. Refer to chapter 5and troubleshoot.
d. If the engine does not stop, actuate the emergency fuel shutdown lever for the on-service fuel tank. Ensure the engine stops in about 10 seconds. Determine and correct the cause of the stop switch not stopping the engine.
e. If actuated, reset the emergency fuel shutdown lever and open the emergency fuel shutdown valve. f. Close the fuel supply shutoff valve supplying fuel from the on-service fuel tank to the engine. g. Close the fuel return shutoff valve which allows fuel spill to return to the on-service fuel tank. h. Close the sea water manual valves that were opened for engine operations
i. Open the sea water vent and drain connections.
j. After the engine has been stopped for 20 minutes, ensure oil in the engine is at the proper level. 1. Remove the dipstick from the oil pan and check the level. The oil level should be at the full mark. 2. If the level is low, remove the oil fill cap from the valve cover and add lubricating oil, as required to bring
level to full mark. (Refer totable 2-2.) Reinstall the oil fill cap on the cover.
CAUTION
If excessive oil must be repeatedly drained from the engine, troubleshoot the cause to prevent further damage to the engine.
3. If the level is high, pump oil from the oil pan into an appropriate disposal container. Dispose of oil in accordance with the NSTM, Chapter 593.
4. Reinstall the dipstick in the dipstick tube.
k. Refer to table 2-2and fill the fuel tanks with fuel in accordance with the NSTM, Chapter 541, and the BIB. l. Perform required engine maintenance.
2-3.4 EMERGENCY OPERATION. Emergency operation is necessary when the equipment malfunctions. If the equipment malfunctions, refer to chapter 5 and troubleshoot. Ensure equipment repair/replacement is per- formed as soon as possible.
2-3.4.1 Low Oil Pressure.
a. If the warning light indicating low oil pressure comes on, check the oil pressure gauge.
b. If the oil pressure gauge indicates greater than 10 psi, determine and correct the cause of the malfunctioning warning light. Refer to chapter 5 and troubleshoot.
c. If the oil pressure gauge indicates 10 psi or less, stop the engine.
d. If operation of the engine is not absolutely required, shut down the engine (refer to paragraph 2-3.3.). S9233-C9-MMA-010
e. If the engine operation is required and low oil pressure is due to oil leakage, operate the engine while per- forming the following steps.
1. Remove the dipstick from the oil pan and check the level.
2. Remove the oil fill cap from the valve cover. Add lubricating oil (table 2-2), as required, to bring the level to the full mark. Reinstall the oil fill cap on the cover.
3. Reinstall the dipstick in the oil pan.
4. Continuously repeat steps 1 through 3 while the engine is running.
5. If the oil level cannot be maintained between the low and full marks on the dipstick or the oil pressure cannot be maintained greater than 10 psi, shut down the engine according toparagraph 2-3.3.
f. Determine and correct the cause of low oil pressure. Refer tochapter 5 and troubleshoot.
2-3.4.2 High Engine Coolant Temperature.
a. If the warning light indicating high engine coolant temperature comes on, check the water temperature gauge. 1. If the water temperature gauge indicates 210°F or greater, shut down the engine to determine and correct
the malfunction. Refer tochapter 5 and troubleshoot.
2. If the water temperature gauge indicates 200°F or greater, decrease engine speed to attempt cooling of the engine. Refer to chapter 5and troubleshoot.
b. If engine operation is required and high engine coolant temperature is due to coolant leakage, operate the engine as follows:
1. Allow the engine to cool as long as possible.
WARNING
To prevent injury or death, use extreme caution when removing the cap from the expansion tank. Steam formed by the sudden release of pressure from a heated cooling system may force hot coolant through the system’s openings.
2. Using extreme caution, remove the cap from the expansion tank. 3. Add coolant, as required, to bring the tank to the proper level.
4. Operate the engine; refer to paragraph 2-3.2. Continuously monitor the tank and add coolant, as required, to maintain the proper level.
5. If the coolant level cannot be maintained, shut down the engine according to the EEOP. 6. When engine operations are complete, reinstall the cap on the tank.
c. Determine and correct the cause of a high engine coolant temperature. Refer tochapter 5 and troubleshoot.
2-3.4.3 Runaway Engine. If oil is introduced into the cylinders, the engine will become uncontrollable and may overspeed. Excessive oil level in the oil pan will cause a runaway engine. If a runaway engine is suspected, pro- ceed as follows:
a. Shut down the engine according to the EEOP.
b. If the engine speed is quickly approaching 2600 rpm, actuate the emergency manual shutdown lever. c. Determine and correct the cause of a runaway engine. Refer tochapter 5 and troubleshoot.
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CHAPTER 3