Caterpillar 3116 Marine Engine Survey

 

Marine Engine Survey

Conducted by : Jeff Lendall & Sons. 805 Marine Diesel Mechanic

 

 

                                       M/V THE OFFICE:

      HIN/IMO: CDRE3011J596 OFFICIAL#: 1056174 LOA: 49.4FT YEAR: 1995

ENGINE 1:

• Engine Make: Caterpillar
  Engine Model: 3116
  Engine Type: Inboard
  Power HP: 350
  Fuel Type: Diesel
  Hours: 974
  Serial Number: 4KG04328
  Engine Location: Port

• TRANSMISSION PORT:  ZF Marine Transmission IRM3O1A.Z

 

ENGINE 2:

• Engine Make: Caterpillar
• Engine Model: 3116
• Engine Type: Inboard
• Power HP: 350
• Fuel Type: Diesel
• Hours: 974
• Serial Number: 4KGO4327
• Engine Location: Starboard
• TRANSMISSION STRB:  ZF Marine Transmission IRM3O1A.Z

 

GENERATOR 1:

• Generator Make: Kohler/Yanmar
• Generator Model: 9MDKDA
• Generator KW: 9

FUEL FILTRATION SYSTEM: Racor Turbine series Fuel Filter/Water Seperator 10 Micron Port side filter assembly (leaks) needs to be rebuilt or replaced

THROTTLE CONTROLS: Hynautic Hydraulic lines. Service condition

ENGINE MOUNTS AND BED:  Main engine beds are heavy longitudinal stringers inboard and outboard. Engine mounts need to be replaced.

LUBRICATION: Level indication is normal both port and starboard.

VENTILATION: controlled supply and discharge fans. Operated satisfactory.

COOLING SYSTEM TYPE: Freshwater reservoir type cooling with Seawater cooled wet exhaust, Operated satisfactory.

SEAWATER STRAINERS: 2 2.5inch Groco bronze alloy with sight glass. Appeared serviceable.

COOLANT LEVEL: Normal levels observed. Pressurized expansion tanks on both engines to 23psi no noticeable drop in pressure. used heat sensing gun on all cooling system surfaces. operated normal.

HOSES AND CLAMPS: Double clamped where sighted. All hoses Cooling System, Saltwater system, exhaust system and drains show excessive wear and should be replaced 

BELTS AND PULLEYS: Belts & Pulleys condition appeared serviceable.

SEACOCKS AND STRAINERS: Seawater seacocks were ball valve type. Operated satisfactory.

EXHAUST SYSTEM: Seawater cooled with risers and flexible coupling sections double clamped where sighted. Hoses and hose clamps need to be replaced Operated satisfactory.

ENGINE ALARMS: Test of port and starboard low oil pressure alarm and coolant overheat warning audible at helm station. Operated satisfactory.

ENGINE SHUT DOWN: Port and starboard shut down push buttons at helm station clearly marked. Operated satisfactory.

STUFFING BOXES: Dripless Shaft Seals, leaked excessively Port & Starboard, need adjusted or Replaced

          EMERGENCY SHUT-DOWNS. not available. Master Marine Diesel Troubleshooting Guide – 805 Marine Diesel Mechanic

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SEATRIAL REPORT:

1. The engines started without excessive cranking.

2. The engine exhaust appeared normal.

3. The cooling water exhaust appeared adequate and normal.

4. The engine instruments operate within normal operating limits at idle, cruising speed and at wide open throttle.

5. The steering system operated normally.

6. The throttles operated normally.

7. The transmissions Starboard side slipped in and out of gear, need serviced or rebuilt.

8. The backdown test was satisfactory.

19. There was vibrations noted. Motor mounts need replaced.

10. There were no oil or coolant leaks observed. (On main engines or in exhaust water)

WOT TEST: (wide open throttle) sea trial test for 3 minutes PORT. worked 
satisfactory STRB. briefly slipped in and out of gear

OIL ANALYSIS: Performed sample on both Caterpillar marine engines 3116, both ZF transmissions, and Kohler/Yanmar Generator. results will be added to report when final.

Oil Analysis Results:

Port Marine Transmission ZF IRM301A.Z: TRACE LEVELS OF WATER DETECTED (0.1%) MAY BE CONDENSATION. IRON IS ELEVATED AND MAY INDICATE GEAR /
BEARING WEAR. ALL OTHER ANALYSIS READINGS APPEAR NORMAL. MORE SAMPLE HISTORY NEEDED TO ESTABLISH A
NORMAL WEAR TREND. CUT OPEN FILTER(S) AND INSPECT FOR DEBRIS.
 6180149_PORT_MA_GE#PORT_MA_GE_MA_GE_PORT_H430-54352-



Starboard Marine Transmission ZF IRM301A.Z: TRACE LEVELS OF WATER DETECTED (0.1%) MAY BE CONDENSATION. ALL OTHER ANALYSIS READINGS APPEAR
NORMAL. MORE SAMPLE HISTORY NEEDED TO ESTABLISH A NORMAL WEAR TREND. RESAMPLE IN 10 HOURS TO
MONITOR.
0316_MC6180149_STBD_MA_GE#STBD_MA_GE_MA_GE_STAR_H430-54352-0315_MC




Marine Genset: TRACE LEVELS OF WATER DETECTED (0.1%) MAY BE CONDENSATION. ALL OTHER ANALYSIS READINGS APPEAR
NORMAL. MORE SAMPLE HISTORY NEEDED TO ESTABLISH A NORMAL WEAR TREND. RESAMPLE IN 10 HOURS TO
MONITOR.
6180149_805_MDM_GENSET#GENSET_ENG_GENSET_H430-54352-0738_MC




Port Main Engine Caterpillar 3116: TRACE LEVELS OF WATER DETECTED (0.1%) MAY BE CONDENSATION. ALL OTHER ANALYSIS READINGS APPEAR
NORMAL. MORE SAMPLE HISTORY NEEDED TO ESTABLISH A NORMAL WEAR TREND. RESAMPLE IN 10 HOURS TO
MONITOR.
6180149_PORT_MA_GE#PORT_MA_GE_MA_GE_PORT_H430-54352-0316_MC



Starboard Main Engine Caterpillar 3116: TRACE LEVELS OF WATER DETECTED (0.1%) MAY BE CONDENSATION. ALL OTHER ANALYSIS READINGS APPEAR
NORMAL. MORE SAMPLE HISTORY NEEDED TO ESTABLISH A NORMAL WEAR TREND. RESAMPLE IN 10 HOURS TO
MONITOR.
6180149_STBD_MA_GE#STBD_MA_GE_MA_GE_STAR_H430-54352-0315_MC

FINDINGS:

Caterpillar 3116 marine engines, port & starboard. ran very smooth & sounded strong, low hours, did not observe any black smoke or smoke of any kind that would lead me to believe that they had much wear. need to do a full maintenance schedule on both engines. Dripless shaft seals, hoses, hose clamps, heat exchangers, motor mounts, Racor filters, saltwater system flush, and new oil & filters on everything.

 

MARINE ENGINE SURVEY SUMMARY:

The results of the laboratory oil analysis will be sent under separate report.

As a result of my investigation, MARINE ENGINE SURVEY, and by virtue of my experience, my opinion is OVERALL ENGINE RATING:  VERY GOOD:

 

Estimate to Repair/Replace Maintenance Issues:

1. Racor fuel filter port side: $450.00 parts $150 labor

2. Motor Mount replacement and Propeller shaft alignment: port and starboard main engines. 8 motor mounts. $1600 parts $1400 labor

3. All hoses & hose clamps: Cooling System, Saltwater system, exhaust system, fuel system, oil system and drains show excessive wear and should be replaced. extensive number of hoses and hose clamps. maybe 30 to 40 guestimate. unable to give a complete estimate until removing and replacing. but best guess estimate. $3000 parts $3000 labor

4. Dripless shaft seals and cutlass bearings: may need to be replaced: dripless shaft seals x2 $1200 cutlass bearings x2 $1100 labor $3000

5. ZF Marine gear port side: shows levels of iron in oil analysis if this needs to be removed and rebuilt cost could be around $6,000 – $10,000 new marine gear $14,000

6. Heat Exchanger and Saltwater system maintenance: both main engines and generator.  $500 parts $750 labor

Best guesstimate to perform all maintenance tasks and bring engine room to be a well-maintained space $26,000 also i haven’t had a chance to look at some other things like rudder packing gland, bilge pumps, pluming for heads and galley and some other items that were listed by the marine surveyor?

 

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Research has analyzed the failure of heat exchangers, specifically oil coolers, in marine diesel engines operating in saltwater environments. This research identified crevice and pitting corrosion as root causes of leakages, leading to seawater mixing with engine oil. Such contamination can decrease oil viscosity and cause significant damage to critical engine components like crankshaft bearings.

This study directly supports the article’s discussion on the signs and consequences of worn oil cooler seals and degraded O-rings, emphasizing the importance of early identification to prevent costly repairs and maintain consistent engine temperatures.

1. Visual and Structural Assessment to spot corrosion, leaks, and alignment issues.
2. Compression Testing on all cylinders to measure ring and seal integrity.
3. Oil and Coolant Analysis to detect contaminants and wear metals.
4. Fuel System Inspection including injector spray pattern and pump calibration.
5. ECU Scan to retrieve fault codes, true engine hours, and diagnostic data.

• Engine Size and Configuration – Inboard vs. pod or sterndrive setups require different access methods.
• Scope of Diagnostics – Additional fluid analysis or advanced electronic testing increases hours on site.
• Location and Accessibility – On-the-water service in remote marinas or private docks may include travel fees.
• Engine Hours and History – High-hour units often need more extensive wear diagnostics.

• Ventura Harbor and Channel Islands
• Santa Barbara Marina and Harbor
• Marina del Rey, Long Beach, and surrounding Los Angeles ports