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Shutdown SIS

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Starting the Engine

SMCS - 1000; 1450

Engine exhaust contains products of combustion which may be harmful

to your health. Always start and operate the engine in a well ventilated
area and, if in an enclosed area, vent the exhaust to the outside.

NOTICE

For initial start-up of a new or rebuilt engine, and for start-up of an

engine that has been serviced, make provision to shut the engine off
should an overspeed occur. This may be accomplished by shutting off
the air and/or fuel supply to the engine.

Do not start the engine or move any of the controls if there is a "DO NOT OPERATE" warning
tag or similar warning tag attached to the start switch or to the controls.

Ensure that no one will be endangered before the engine is started and when the engine is started.

Perform the procedures that are described in this Operation and Maintenance Manual, "Before
Starting Engine" topic (Operation Section).

1. Ensure that the driven equipment is disengaged.

Note: Two typical control panels are illustrated. If the engine is equipped with a different
control panel, follow the instructions that are provided by the OEM of the control panel.

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Illustration 1 g00539489

Marine Engine Control Panel

(1) "OFF/RESET, LOCAL, and REMOTE" switch

(2) "PRELUBE/START" switch

(3) "FUEL ON/OFF" switch

(4) "PRELUBE" indicator

Illustration 2 g00539488

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Start/Stop control panel

(1) "OFF/RESET, LOCAL, and REMOTE" switch

(2) "PRELUBE/START" switch

(3) "FUEL ON/OFF" switch

(4) "PRELUBE" indicator

2. Turn "OFF/RESET, LOCAL, and REMOTE" switch (1) to the "LOCAL" position.

NOTICE

The engine must be prelubed before the crankshaft is rotated. Damage

can result if the crankshaft is rotated on dry bearing surfaces.

3. Turn "PRELUBE/START" switch (2) to the "PRELUBE" position. Allow the prelube pump
to operate.

4. Turn "FUEL ON/OFF" switch (3) to the "ON" position.

Illustration 3 g00275016

Fuel priming pump

5. Turn the handle of the fuel priming pump clockwise in order to prime the fuel system. Turn
the handle until a resistance to the fuel flow is felt. If the engine is equipped with an electric

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fuel priming pump, activate the electric fuel priming pump. Operate the electric fuel
priming pump until fuel pressure is indicated on the fuel pressure gauge.

6. When "PRELUBE" indicator lamp (4) illuminates, start the engine at low idle rpm with no
load. Turn "PRELUBE/START" switch (2) to the "START" position. When 180 to 200 rpm
is achieved, release the "PRELUBE/START" switch. The starting motors will disengage
when the engine reaches 170 rpm.

Note: If the engine does not start after ten seconds, turn the "FUEL ON/OFF" switch to the
"OFF"position. Purge the cylinders. See this Operation and Maintenance Manual, "Before
Starting Engine" topic (Operation Section).

7. Immediately after engine start-up, ensure that oil pressure and fuel pressure are indicated on
the gauges. Allow the engine to idle for three to five minutes. The engine speed should
stabilize at low idle rpm. Check all of the pressure gauges. Inspect the engine for leaks and
listen for unusual noises. When all systems are normal, the rpm may be increased.

Ensure that the oil pressure and the fuel pressure are in the normal ranges. After the engine has
started and the warm-up is complete, the engine can be operated at low rpm and low load. The
engine will reach normal operating temperature faster if the engine is operated at low rpm and
with a low power demand. This procedure is more effective than idling the engine with no load.
The engine should reach normal operating temperature in a few minutes.

Starting the Engine After an Overhaul or Major Repair

Use the following guidelines for operation and maintenance after an overhaul or a major repair.
This will ensure that the engine is functioning correctly. The procedure for start-up requires
approximately one hour and 45 minutes.

1. Perform the procedures that are described in this Operation and Maintenance Manual,
"Before Starting Engine" topic (Operation Section).

2. Operate the jacket water heaters and the prelube pump. Allow the lubricating oil to circulate
for 1/2 hour.

3. During prelube pump operation, use the barring device to rotate the crankshaft for a
minimum of four revolutions.

4. Start the engine. Operate the engine at low idle rpm for 15 minutes. Allow the engine
temperature to rise. Check for the correct temperatures and pressures. Inspect the
installation for leaks.

5. Do not apply the load. Increase the engine rpm to high idle rpm for 5 minutes. Check for the
correct temperatures and pressures. Inspect the installation for leaks.

6. Shut off the engine. Remove the side covers. Measure the temperature of the bearings with a
123-6700 Laser Infrared Thermometer. Ensure that the large end of the connecting rod
bearings move freely. Visually inspect the piston skirts, cylinder liners, and bearings for any
abnormal signs such as flaking and/or scuffing. If the appearance of the components is
satisfactory, install the side covers.

7. Start the engine. Operate the engine at low idle rpm for five minutes. Check for the correct
temperatures and pressures. Inspect the installation for leaks.

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8. The temperatures will not stabilize for some time because the engine will be operating
without a load. To warm the engine up to "normal" operating temperature, increase the
engine rpm to high idle rpm for 5 minutes. Check for the correct temperatures and
pressures. Inspect the installation for leaks.

Note: Monitor the cooling system temperatures in order to ensure that the water to the
engine is being properly cooled. Observe the water temperature of the aftercooler and oil
cooler system. The temperature should not exceed 50 °C (122 °F).

9. Apply 25 percent of the rated load. Operate the engine with this load for 15 minutes. Check
for the correct temperatures and pressures. Inspect the installation for leaks.

10. Increase the load to 50 percent of the rated load. Operate the engine with this load for 15
minutes. Check for the correct temperatures and pressures. Inspect the installation for leaks.

11. Increase the load to the full rated load. Operate the engine with this load for 15 minutes.
Check for the correct temperatures and pressures. Inspect the installation for leaks.

If all of the temperatures and the pressures are acceptable, the engine can be returned
service.

Maintenance Procedures After an Overhaul or Major Repair

After the initial start-up, perform the maintenance that is listed in Table 1. See the maintenance
procedures that are in this Operation and Maintenance Manual (Maintenance Section).

Table 1
Maintenance Procedures After an Overhaul or Major Repair
Interval Maintenance Procedure
After the start-up Obtain an oil sample and analysis.
procedure
Remove at least one oil filter element from each oil filter housing. Cut the
element open. Inspect the filter material for debris.
100 operating Obtain an oil sample and analysis.
hours
500 operating Replace all of the oil filter elements. Cut the used elements open. Inspect
hours the filter material for debris.
Perform the procedures that are described in this Operation and
Maintenance Manual, "Engine Valve Lash - Check/Adjust" topic
(Maintenance Section).

Starting the Engine After a System Generated Shutdown

Do not perform any procedure in this Special Instruction until you read this information and you
understand this information.

This Special Instruction provides a procedure for inspecting the engine after a system generated
shutdown.

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The cause of a system generated shutdown must be corrected prior to an engine restart. Severe
engine damage may occur if the problem is not corrected. In some cases, the cause of the
shutdown may be obvious and easily corrected. In some cases, a visual inspection may not reveal
the root cause of the shutdown. The engine must be started in order to determine the root cause.

The time that is required for the start-up procedure is approximately 1 hour and 45 minutes. It is
important to determine the root cause of a system generated shutdown in order to avoid engine
damage. This procedure is a method for an engine restart when the root cause of the system
generated shutdown cannot be determined by visual inspection alone.

Note: If the engine is shutdown by the oil mist detector, refer to the engine's Operation and
Maintenance Manual.

The following conditions can cause a system generated shutdown.

• High aftercooler and oil cooler water temperature (inlet)

• High jacket water coolant temperature (outlet)

• High fuel temperature (inlet)

• High inlet manifold air temperature

• High crankcase pressure

• High engine oil temperature

• Low engine oil pressure

• High engine oil filter differential pressure

• Presence of metal particles in the oil lines

• Overspeed

If the engine must be restarted, perform the following start-up procedure.

Starting Procedure

1. Inspect the condition and the level of all fluids. Correct any problem with the fluids.

2. Ensure that the engine is off-line or that the gearbox is in neutral.

3. Open all manual valves. Use the barring device in order to turn the engine. The open valves
will indicate if there is any fluid buildup in the combustion chambers.

4. Start the prelube system and put the fuel switch in the OFF position. Rotate the crankshaft
with the barring device for a minimum of four revolutions.

5. Disengage the barring device.

6. Close all manual valves.

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7. Start the engine and allow the engine to idle at approximately 350 RPM. Do not take the
engine to high idle at this time. Monitor the temperatures and pressures. Prepare to
perform a manual engine shutdown if abnormal conditions exist.

8. Allow the engine to idle for ten minutes. While the engine is at idle, walk around the engine
and visually inspect the engine. Check for leaks and listen for any abnormal sounds. If any
abnormal conditions exist, immediately perform an engine shutdown and correct the
problem. If no problems are found go to the next step.

9. Increase the engine to 500 rpm for ten minutes. Monitor the temperatures and pressures.
Prepare to perform a manual engine shutdown if abnormal conditions exist. Walk around
the engine and visually inspect the engine. Check for leaks and listen for any abnormal
sounds. If any abnormal conditions exist, immediately perform an engine shutdown and
correct the problem. If no problems are found go to the next step.

10. Increase the engine to high idle for ten minutes. Monitor the temperatures and pressures.
Prepare to perform a manual engine shutdown if abnormal conditions exist. Walk around
the engine and visually inspect the engine. Check for leaks and listen for any abnormal
sounds. If any abnormal conditions exist, immediately perform an engine shutdown and
correct the problem. If no problems are found go to the next step.

Note: Due to the small amount of load on the engine, the temperatures will not stabilize for
some time. Apply an engine load in order to warm up the engine to normal temperatures.
Use the following procedure:

11. Apply 25 percent load to the engine and operate in this condition for ten minutes. Monitor
the temperatures and pressures. Prepare to perform a manual engine shutdown if abnormal
conditions exist. Walk around the engine and visually inspect the engine. Check for leaks
and listen for any abnormal sounds. If any abnormal conditions exist, immediately perform
an engine shutdown and correct the problem. If no problems are found go to the next step.

12. Apply 50 percent load to the engine and operate in this condition for ten minutes. Monitor
the temperatures and pressures. Prepare to perform a manual engine shutdown if abnormal
conditions exist. Walk around the engine and visually inspect the engine. Check for leaks
and listen for any abnormal sounds. If any abnormal conditions exist, immediately perform
an engine shutdown and correct the problem. If no problems are found go to the next step.

13. Apply rated load to the engine and operate in this condition for ten minutes. Monitor the
temperatures and pressures. Prepare to perform a manual engine shutdown if abnormal
conditions exist. Walk around the engine and visually inspect the engine. Check for leaks
and listen for any abnormal sounds. If any abnormal conditions exist, immediately perform
an engine shutdown and correct the problem. If no problems are found go to the next step.

14. Remove the load and allow the engine to run at high idle for five minutes as a cool down
period.

15. Return the engine to low idle for five minutes. If all temperatures and pressures are
acceptable, return the engine to service.

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