1. COXSWAIN ENGINEERING

2. Marine Engines -Basic Operation 4 Stroke & 2 Stroke

3. How Car Engines Work by Marshall BrainMarshall Brain More Great Links About the smoothness of engines InnerAuto: Automotive Learning Online - great set of figures and animations showing different engine types and the parts inside an engineInnerAuto: Automotive Learning Online Animated Engines How Things Work: Automobiles - questions and answers about carsHow Things Work: Automobiles Erbman's Engine Emporium - great article describing factors affecting engine performanceErbman's Engine Emporium Engine Science Harry's Old Engine Home Page - good list of showsHarry's Old Engine Home Page Understanding Your Car Home Store Newsletter Search Advertising Privacy Contact About Help © 1998 - 2004 HowStuffWorks, Inc. 4 Stroke Engine

4. 2-Stroke Engine *Ignition Power stroke drives piston downwards Downward piston movement compresses air/fuel mixture in crankcase. As exhaust port is uncovered, pressure from ignition drives out exhaust gases At bottom of stroke, inlet port opens allowing pressurised air/fuel mixture to rush into cylinder (also displaces remaining exhaust gases) As air/fuel mix is compressed, vacuum in crankcase is created and sucks more air/fuel mixture from carburetor Power (incl Exhaust) Power (incl Induction) Compression

5. 4 Stroke2 Stroke (Fires once every 2 revolutions of crankshaft, or once every 4 th piston stroke) (Fires once every revolution of crankshaft, or once every 2 nd piston stroke)

6. DIRECT INJECTION

7. INDIRECT INJECTION

8. Petrol, Diesel & Outboard Engines

9. OUTBOARD AND INBOARD PROPULSION UNITS Outboard

10. OUTBOARD AND INBOARD PROPULSION UNITS Shaft Drive

11. OUTBOARD AND INBOARD PROPULSION UNITS V Drive

12. OUTBOARD AND INBOARD PROPULSION UNITS Stern Drive (Inboard / Outboard

13. OUTBOARD AND INBOARD PROPULSION UNITS Z Drive

14. KORT NOZZLE

15. OUTBOARD AND INBOARD PROPULSION UNITS Sail Drive

16. OUTBOARD AND INBOARD PROPULSION UNITS Sail Drive

17. OUTBOARD AND INBOARD PROPULSION UNITS Hydraulic Drive

18. Drive Train Assembly Stern Tube Arrangements

19. Propeller Engine As seen aboard larger vessels

20. Typical Stern Tube arrangement on smaller vessel

21. Mechanical Shaft Seals (Packless, Non-Drip) “Duramax” “PSS”

22. Steering Gear Wire and Pulley Push/Pull Chain and Steering Box Hydraulic

23. Steering Wire & Pulley

24. Steering Push/Pull

25. Steering Chain and Steering Box

26. Steering Hydraulic

27. Steering Hydraulic

28. Cooling, Lubricating & Fuel Systems

29. Direct Cooling System

30. Indirect Cooling System

31. Shell and Tube Heat Exchangers

32. Keel Cooling

34. Lubrication System

35. Diesel Fuel System

36. Bleeding the fuel system

37. Typical Fuel Tank Arrangement

38. Typical Fuel Arrangement

39. Bilge & Pumping Arrangements

40. Bilge Pumping Manifold

41. Valves and Pipework

42. BACK FLOODING Q. WHAT IS BACK FLOODING? Ans. Water entering vessel through existing pipework

43. BACKFLOODING Prevention? Screw Down Non-Return Valves L-Ported Cocks Non-Return Valves Isolating Valves

44. O/BD/Wash Open – from Sea Cock to Deck Wash O/BD/Wash Open – from Sea Cock/Bilge to Overboard Discharge O/B D/Wash CLOSED L-Ported Cock

45. Non-Return Valve

46. Screw Down Non-Return Valve

47. Isolating Valves Ball Valve Globe Valve Gate Valve Butterfly Valve

50. BILGE PUMPING 2. Select Seawater suction 3. Select Over Board discharge 4. Start pump and ensure seawater is being pumped over board 5. Select Bilge suction - ensure bilge water discharge over board 6. As soon as over board discharge flow lessens, select Seawater suction and ensure water is being pumped over board 7. Shut down pump 1.Ensure Sea Water isolating valve is OPEN

51. BILGE PUMPING PROBLEMSOLUTION Not pumpingBilge compartment not selected Not pumpingBilge suction blocked Not pumpingBilge pump not operating Not pumpingBroken pipe/hole in suction line

52. Monitoring machinery

53. Pre-start Checks Fuel – Sufficient amount for journey, Fuel cock on, Water drained from sedimenter Oil – At correct level, top up if necessary Water – At correct level, top up if necessary Batteries – Electrolyte level OK, Correct Battery Bank selected Drive belts, Hoses in good condition & adjusted correctly Sea Water Cock open (strainer clean) Bilge pump valves set correctly

54. Operating Checks Engine gauges (Coolant Temperature, Oil Pressure, Oil Temperature, Exhaust Temperature, Gearbox Oil Pressure, Gearbox Oil Temperature……..) Visual checks for oil/water leaks, unusual vibration Pumps operational (o/board cooling discharge, wet exhaust discharge) Genset charging Sterntube not overheating/leaking excessively Colour of exhaust gases not abnormal –Black smoke = injector problems –Blue smoke = faulty piston rings –White smoke = poor compression

55. Checks on Shut-down Let engine idle for some time to cool down (especially if turbocharged) Shut down as per manufacturer’s instructions Turn off Fuel cock Turn off Sea Water Suction Turn off Battery Master Switch Check bilge pump is off and ensure no backflooding

56. Troubleshoothing Starting problems –Battery, Connections, Starter motor, Water in cylinder… Cooling system problems –Strainer, Seawater pump, Engine water pump, Thermostat, Coolant, Header tank cap, Sender unit Lubrication problems –Oil level, Fuel in oil, Oil pump, Blocked Filter, Fuel Problems –Low fuel level, Air in system, Blocked Filter, Fuel lift Pump, Injector Pump, Injectors Engine stops –Check Fuel, Cooling, Lubrication systems

57. Electrical Systems Direct Current (DC) & Alternating Current (AC)

58. Care and Maintenance of Lead Acid Batteries Series & Parallel connection  Batteries may be connected in series for increased voltage, or in parallel for increased capacity  Series = positive to negative connection  Parallel = positive to positive & negative to negative connection

59. + _ + _ Batteries - Series + _ 12 V 50 AH 12 V 50 AH 24 V 50 AH (Increased Voltage, same Capacity)

60. + _ + _ Batteries - Parallel 12 V 50 AH 12 V 50 AH + _ 12 V 100 AH (Same Voltage, increased Capacity)

61. Care and Maintenance of Lead Acid Batteries For best performance:  Keep Battery clean, dry and free from terminal corrosion  Electrolyte at correct level  Correctly charged

62. Battery Cleanliness  A dirty battery or spilt electrolyte may provide a path for electrical current to leak away  Corrosion on battery terminals (green-white powder) may seriously affect or prevent battery from supplying current

63. Electrolyte Level  Keep topped up with Distilled or Demineralised water only (Chemical action inside battery causes water loss)  Maintain water level at approximately 10mm above plates inside battery

64. Correct Charging  To provide the best service, a battery must be correctly charged  Both overcharging and undercharging can seriously affect a battery’s performance

65. CONSTRUCTION OF LEAD ACID BATTERIES Chemical combination of lead and lead peroxide plates, in a solution of sulphuric acid produces a voltage between the plates

66. Essential Battery Maintenance Keep clean & dry Electrolyte at correct level Correctly charged

67. GENERAL MAINTENANCE Check battery fluid level and state of charge w/- hydrometer Remove battery connections and clean Ensure battery is correctly stowed & secured Check cables for cracks / damage Check operation of charging system (voltmeter if fitted) Electrical System

68. Care and Maintenance of Lead Acid Batteries Battery condition may be determined by:  Measuring the Specific Gravity  Measuring On-Load Terminal Voltage

69. Specific Gravity  Specific Gravity of electrolyte varies proportionally with amount of charge in battery  SG is highest when fully charged, and lowest when discharged  SG measured with Hydrometer Fully charged = 1.250 Discharged = 1.150

70. How to Measure Specific Gravity 1.250 = Fully Charged 1.150 = Discharged HYDROMETER

71. Measuring ON-Line Terminal Voltage  Must be measured when battery is supplying current to a load (i.e. radio, spot light etc)  Should not drop below 11.4 Volts  (Measuring Off-load voltage does NOT indicate true condition of battery)  Use Voltmeter

72. Battery Hazards Risk of Explosion  Hydrogen gas is given off during charging  Any spark may ignite when mixed with air  Use metal tools with care when working on battery connections to avoid short circuits Chemical Burns  Electrolyte contains Sulphuric Acid  Most concentrated after charging  Ensure eye protection  Dilute spills with running water

73. Shore Power Connection

74. 3 Phase – 415V AC - -Common Ship’s Power Single Phase – 240V AC - -Domestic Power Supply SINGLE and THREE PHASE

75. Shore Power Connection When connecting shore power, ensure correct phase rotation prior to engaging switch on distribution panel (otherwise pumps will rotate in opposite direction)

76. Connecting Shore Power Check Shore Power lead is correctly connected to vessel shore supply inlet Ensure shore supply facility is “Off” Connect vessel shore power lead to shore facility Turn “ON” power at shore facility Check vessel electrical distribution board to ensure correct phase rotation (3-phase) If phase rotation is incorrect, use “Reverse Polarity” switch to ensure correct phasing Engage switch to select “Shore Power” Shut down ship supply genset

77. Disconnecting Shore Power Start Ship Genset (allow to warm up) Select “Ship Power” on electrical distribution board Ensure correct power supply Turn “OFF” shore supply facility Remove shore power lead and store on vessel

78. LPG

79. Keep cylinder upright (otherwise liquid will enter the regulator/piping and expand 250 times causing failure/explosion and a major leak) A gas smell is an indication of a leak Gas is heavier than air and will settle in the lowest part (bilge) of the vessel Check joins/connections with soapy water Store cylinder above decks, well secured and ventilated Check test date on cylinder (10 years)

80. BLEVE Boiling Liquid Expanding Vapour Explosion

81. END COXSWAIN ENGINEERING