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Marine Engine Maintenance Schedules

For Marine Propulsion Engines Used in Commercial Applications

MARINE ENGINE MAINTENANCE SCHEDULES

Table of Contents
3116 & 3126 Marine Engine Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 3208 Marine Engines (all rated rpms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3304B Marine Engines (all rated rpms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3306B Marine Engines (all rated rpms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3406 Marine Engines (all rated rpms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 3408 Marine Engines (all rated rpms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 3412 Marine Engines (all rated rpms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 -13 3508 Marine Engines (rated up to 1300 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15 3508/3508B Marine Engines (rated 1301 to 1600 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17 3508/3508B Marine Engines (rated 1601 to 1800 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19 3512 Marine Engines (rated up to 1300 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21 3512/3512B Marine Engines (rated 1301 to 1600 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-23 3512/3512B Marine Engines (rated 1601 to 1800 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25 3516 Marine Engines (rated up to 1300 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-27 3516/3516B Marine Engines (rated 1301 to 1600 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-29 3516/3516B Marine Engines (rated 1601 to 1800 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31 3606 Marine Engines (all rated rpms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-33 3608 Marine Engines (all rated rpms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-35 3612 Marine Engines (all rated rpms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-37 3616 Marine Engines (all rated rpms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-39

MARINE ENGINE MAINTENANCE SCHEDULES

3116 & 3126 Marine Engine Maintenance Schedule


Use fuel consumption, service hours, or time interval, whichever occurs first.

Every 30 000 L (8000 gal) of Fuel or 1000 Hours*


Engine Protective Devices Inspect/Check Raw Water Pump Inspect/Clean Cooling System Clean/Flush/Change coolant and replace thermostat (Conventional Coolant/Antifreeze only)

Daily
Engine Crankcase Oil Check oil level Cooling System Check level Water Separator (if equipped) Drain water and sediment Walk-Around Inspection Check engine for leaks and loose connections Air Cleaner Indicator (if equipped) Check service indicator, inspect air cleaner element Marine Gear (Transmission) Check oil level

Every 60 000 L (16 000 gal) of Fuel or 2000 Hours*


Valve Lash and Injector Fuel Timing Check/Adjust Governor Clean/Replace oil screen Check/Adjust low idle Aftercooler Core and Turbocharger Compressor Housing Clean (3116 only)

Every 1500 L (400 gal) of Fuel or 50 Hours*


Zinc Rods Inspect/Replace

Every Four Years* Initial 250 Hours*


Initial Valve Lash and Injector Fuel Timing Check/Adjust Engine Coolant (for engines using LLCA only) Clean/Flush/Replace coolant

Every 7500 L (2000 gal) of Fuel or 250 Hours or Yearly*


Scheduled Oil Sampling Analysis (SOS)** Obtain Engine Crankcase** Replace oil and filter Fuel System Replace final filter and clean fuel inlet screen/Replace water separator element (if equipped) Batteries Clean/Check electrolyte level Belts, Hoses, and Clamps Inspect/Check/ Adjust Cooling System Test for coolant additive (Conventional Coolant/Antifreeze only)

Overhaul Every 114 000 L (30 000 gal) of Fuel


* First perform previous service hour items. ** The oil change interval is based on fuel consumption. The sump capacity of 25 liters (26.4 U.S. quarts) will allow the maximum consumption of 7500 liters (2000 U.S. gallons) of fuel by the engine. This would be an average fuel consumption of 30 L/hr (8.0 gal/hr). Therefore, use fuel consumption as the best indicator of oil change interval. Confirm the interval with Scheduled Oil Analysis or consult your Caterpillar dealer.

Every 15 000 L (4000 gal) of Fuel or 500 Hours*


Aftercooler Core and Turbocharger Compressor Housing Clean Crankcase Breather Clean

MARINE ENGINE MAINTENANCE SCHEDULES

3208 Marine Engines (all rated rpms)


Use fuel consumption, service hours, or time interval, whichever occurs first.

Every 36 000 L (9000 gal) of Fuel or 1000 Hours or Two Years*


Cooling System Clean/Flush/Change coolant, Check coolant level/Replace thermostats Fuel Pump/Governor Housing Drain PVC Valve (if equipped) Check diaphragm and hoses Aftercooler Core (if equipped) Inspect/Clean Valve lash Check/Adjust

Daily
Walk-Around Inspection Inspect for leaks and loose connections Engine Crankcase Check oil level Cooling System Check coolant level Marine Gear Oil Check level Air Cleaner Indicator (if equipped) Check/Inspect/ Clean/Replace Water Separator Drain water and sediment

Every 72 000 L (19 000 gal) of Fuel or 2000 Hours*


Engine Valve Lash Adjust Sea Water Pump Inspect/Replace seals & bearings Coolant Hoses Replace Fuel Injection Nozzles Test Air/Fuel Ratio Control (if equipped) Check/Adjust Turbocharger (if equipped) Inspect/Check Starting Motor Inspect Crankshaft Torsional Vibration Damper and Engine Mounts Inspect/Check Heat Exchanger Inspect/Clean Marine Engine Performance Analysis Obtain report

Every 1900 L (500 gal) of Fuel or 50 Hours*


Zinc Rods Inspect Aftercooler Drain Plug (if equipped) Inspect Air Cleaner Clean foam filter element (if equipped)

Every 9000 L (2400 gal) of Fuel or 250 Hours or Yearly*


Scheduled Oil Sampling Analysis (SOS) Obtain Engine Oil and Filters Change Fuel System Replace final fuel filter Batteries Check Crankcase Breather (if equipped) Clean Water Separator Inspect/Replace element Engine Protective Devices Inspect/Check Sea Water Strainer Inspect/Clean Sea Water Pump Replace impeller and cam Cooling System Test for supplemental coolant additive concentration/Obtain coolant sample for analysis Belts, Hoses, and Clamps Inspect/Adjust/Replace Oil Fumes Separator Canister (if equipped) Clean/Replace elements Exhaust Restricter (if equipped) Inspect/Adjust linkage Air Cleaner Paper element air cleaner (if equipped), foam element air cleaner (if equipped), AIRSEP closed crankcase system (if equipped) Clean/Inspect Valve Lash (at first oil change) only Check/Adjust

Every Four Years*


Engine Coolant (for engines using LLCA only) Clean/Flush/Replace coolant

OVERHAUL Every 114 000 L (30 000 gal) of Fuel*


Cylinder Head, Connecting Rods, Pistons, Turbocharger, Oil Pump, Fuel Ratio Control, Cam Followers, Fuel Transfer Pump, and Timing Advance Inspect/Rebuild or Exchange if necessary Piston Rings, Main Bearings, Rod Bearings, Crankshaft Seals, Engine Mounts, and Hoses Install new Fuel Nozzles, Fuel Injection Pump, Governor, Injectors Test Crankshaft, Camshaft, Cam Bearings, and Damper Inspect Marine Gear Oil Cooler Core, Aftercooler Core, Heat Exchanger Core Clean/Test Cooling System Clean/Flush/Obtain coolant analysis * First perform previous maintenance interval items.

MARINE ENGINE MAINTENANCE SCHEDULES

3304B Marine Engines (all rated rpms)


Use fuel consumption, service hours, or time interval, whichever occurs first.

First 22 500 L (6000 gal) of Fuel or 1000 Hours or Six Months


Fuel Ratio Control, Set Point and Low Idle Check/Adjust

Daily
Walk-Around Inspections Check for leaks and loose connections Engine Crankcase Check oil level Cooling System Check Coolant level Air Cleaner Check service indicator/ Service air cleaner when needed Air Starter (if equipped) Check Lubricator oil level Air Tank (if equipped) Drain water and sediment Fuel Tank Drain water and sediment Water Separator (if equipped) Drain water Clutch (if equipped) Lubricate/Check/Adjust

Every 22 500 L (6000 gal) of Fuel or 1000 Hours or Six Months


Water Separator Replace element Engine Protection Devices Check operation Fuel Control Linkage Check/Lubricate

Every 45 000 L (12 000 gal) of Fuel or 2000 Hours or Yearly


Valve Lash and Valve Rotators Check/Adjust Fuel Ratio Control, Set Point, and Low Idle Check/Adjust Fuel Nozzles Test Turbocharger (if equipped) Clean/Inspect/Check Engine Mounts Inspect/Check Crankshaft Vibration Damper Inspect/Check

Every 1100 L (300 gal) of Fuel or 50 Hours or Weekly


Zinc Rods Inspect/Replace

First 5600 L (1500 gal) of Fuel or 250 Hours or Monthly


Valve Lash Check/Adjust (within the first and fourth oil change intervals)

Every 68 220 L (18 000 gal) of Fuel or 3000 Hours or Two Years
Water Temperature Regulator (Thermostat) Replace Cooling System (Long Life Coolant/Antifreeze only) Drain/Clean/Replace coolant

Every 5600 L (1500 gal) of Fuel or 250 Hours or Monthly


Scheduled Oil Sampling Analysis (SOS) Obtain Engine Crankcase Replace oil and filter Crankcase Breather Clean Cooling System (Conventional Coolant/Antifreeze only) Test for SCA concentration/add SCA if necessary Fuel System Clean Primary fuel filter (if equipped)/Replace final fuel filter Air Cleaner Clean/Replace air filter elements Batteries Clean/Check electrolyte level Belts Check/Adjust Hoses Inspect/Replace

Every 90 000 L (24 000 gal) of Fuel or 4000 Hours or Three Years
Jacket Water Pump, Sea/Raw Water Pump, Alternator, Starting Motor, Turbocharger, and Air Compressor (if equipped) Inspect/Rebuild or exchange (if necessary)

Every 135 000 L (36 000 gal) of Fuel or 6000 Hours or Four Years
Cooling System (Long Life Coolant/Antifreeze only) Drain/Flush/Replace LLCA.

OVERHAUL Every 227 400 L (60 000 gal)

MARINE ENGINE MAINTENANCE SCHEDULES

3306B Marine Engines (all rated rpms)


Use fuel consumption, service hours, or time interval, whichever occurs first.

First 34 000 L (9000 gal) of Fuel or 1000 Hours or Six Months


Fuel Ratio Control, Set Point, and Low Idle Check/Adjust

Daily
Walk-Around Inspection Check for leaks and loose connections Engine Crankcase Check oil level Cooling System Check coolant level Air Cleaner Check service indicator/Service air cleaner when needed Air Starter (if equipped) Check lubricator oil level Air Tank (if equipped) Drain water and sediment Fuel Tank Drain water and sediment Water Separator (if equipped) Drain water Clutch (if equipped) Lubricate/Check/Adjust

Every 34 000 L (9000 gal) of Fuel or 1000 Hours or Six Months


Water Separator Replace element Engine Protection Devices Check operation Fuel Control Linkage Check/Lubricate

Every 67 000 L (18 000 gal) of Fuel or 2000 Hours or Yearly


Valve Lash and Valve Rotators Check/Adjust Fuel Ratio Control, Set Point, and Low Idle Check/Adjust Fuel Nozzles Test Turbocharger (if equipped) Clean/Inspect/Check Engine Mounts Inspect/Check Crankshaft Vibration Damper Inspect/Check

Every 1900 L (500 gal) of Fuel or 50 Hours or Weekly


Zinc Rods Inspect/Replace

First 8500 L (2200 gal) of Fuel or 250 Hours or Monthly


Valve Lash Check/Adjust (within the first and fourth oil change intervals)

Every 91 000 L (24 000 gal) of Fuel or 3000 Hours or Two Years
Water Temperature Regulator (Thermostat) Replace Cooling System (Long Life Coolant/Antifreeze only) Add extender Cooling System (Conventional Coolant/Antifreeze only) Drain/Clean/Replace coolant

Every 8500 L (2200 gal) of Fuel or 250 Hours or Monthly


Scheduled Oil Sampling Analysis (SOS)* Obtain Engine Crankcase* Replace oil and filter Crankcase Breather* Clean Cooling System (Conventional Coolant/Antifreeze only) Test for SCA concentration/Add SCA if necessary Fuel System Clean primary fuel filter (if equipped)/ Replace final fuel filter Air Cleaner Clean/Replace air filter elements Batteries Clean/Check electrolyte level Belts Check/Adjust Hoses Inspect/Replace * For larger sump capacity, these maintenance items may be performed at 500 hours.

Every 136 000 L (36 000 gal) of Fuel or 4000 Hours or Three Years
Jacket Water Pump, Sea/Raw Water Pump, Alternator, Starting Motor, Turbocharger, and Air Compressor (if equipped) Inspect/Rebuild or Exchange if necessary

Every 204 000 L (54 000 gal) of Fuel or 6000 Hours or Four Years
Cooling System (Long Life Coolant/Antifreeze only) Drain/Flush/Replace LLCA

OVERHAUL 341 000 L (90 000 gal)


7

MARINE ENGINE MAINTENANCE SCHEDULES

3406 Marine Engines (all rated rpms)


Use fuel consumption, service hours, or time interval, whichever occurs first.

Every 114 000 L (30 000 gal) of Fuel or 3000 Hours*


Fuel Ratio Control, Set Point, and Low Idle Check/Adjust Engine Mounts Inspect Crankcase Vibration Damper Inspect/Check Cooling System (Long Life Coolant/Antifreeze only) Add extender Water Temperature Regulator (Thermostat) Replace Cooling System (Conventional Coolant/Antifreeze only) Clean/Flush/Change coolant PAR Analysis Obtain Valve Lash Check/Adjust/Inspect valve rotators

Daily
Walk-Around Inspection Inspect engine for leaks and loose connections Engine Crankcase Check oil level Cooling System Check coolant level Marine Gear Check oil level Air Starter (if equipped) Check lubricator bowl oil level Air Cleaner Check service indicator/Service air cleaner when necessary Clutch Shift Collar Lubricate

Every 1900 L (500 gal) of Fuel or 50 Hours*


Zinc Rods Inspect/Replace

Every 190 000 L (50 000 gal) of Fuel or 5000 Hours*


Fuel Nozzles Test Alternator Inspect/Rebuild or Exchange Air Compressor Inspect/Rebuild or Exchange Jacket Water Pump Inspect/Rebuild or Exchange Sea Water Pump Inspect/Rebuild or Exchange Starting Motor Inspect/Rebuild or Exchange Turbocharger Inspect/Rebuild or Exchange

Every 4750 L (1250 gal) of Fuel or 125 Hours*


PTO Main Shaft, Shift Lever and Pilot Bearing (if equipped) Lubricate Clutch (if equipped) Check/Adjust

Every 9500 L (2500 gal) of Fuel or 250 Hours*


Scheduled Oil Sampling Analysis (SOS) Obtain Engine Crankcase Replace oil and filters Fuel System Replace final filter/Clean primary filter Cooling System (Conventional Coolant/Antifreeze only) Test for coolant additive concentration/Add liquid coolant additive or replace coolant additive maintenance element (if equipped) Crankcase Breather Clean Batteries Clean/Inspect/Check electrolyte level Belts Check/Adjust/Replace Hoses and Clamps Inspect/Check Fuel Tank Drain water and sediment Valve Lash (at first oil change) only Check/Adjust

OVERHAUL Every 760 000 L (200 000 gal) of Fuel for 1200-1350 rated rpm, 646 000 L (170 000 gal) of Fuel for 1800 rated rpm, 380 000 L (100 000 gal) of Fuel for 2100 rated rpm
(Fuel amounts are based on an average fuel consumption of 38 liters/hour (10 gallons/hour) for each maintenance interval. The liter quantity will not directly convert to the gallon quantity for the number of hours.) Cylinder Head, Connecting Rods, Pistons, Cylinder Liners, Turbocharger, Oil Pump, Spacer Plate, Fuel Ratio Control, Cam Followers, Fuel Transfer Pump, and Timing Advance Inspect/Rebuild or Exchange Piston Rings, Main Bearings, Rod Bearings, Valve Rotators, and Crankshaft Seals Install new Fuel Nozzles Test Fuel Injection Pump Test Crankshaft, Camshaft, Cam Bearings, Damper, Governor Inspect

Every 38 000 L (10 000 gal) of Fuel or 1000 Hours*


Engine Protective Devices Inspect/Check

MARINE ENGINE MAINTENANCE SCHEDULES

3406 Marine Engines (all rated rpms) continued


Oil Cooler Clean/Test Aftercooler Core Clean/Test Coolant Analysis Obtain * First perform previous service hour items.

MARINE ENGINE MAINTENANCE SCHEDULES

3408 Marine Engines (all rated rpms)


Use fuel consumption, service hours, or time interval, whichever occurs first.

Every 51 000 L (13 500 gal) of Fuel or 1000 Hours*


Engine Protective Devices Inspect/Check Magnetic Pickup Inspect/Adjust

Daily
Walk-Around Inspection Inspect engine for leaks and loose connections Engine Crankcase Check oil level Cooling System Check coolant level Marine Gear Check oil level Air Starter (if equipped) Check lubricator bowl oil level Air Cleaner Check service indicator/Service air cleaner when necessary Clutch Shift Collar (if equipped) Lubricate

Every 153 000 L (40 500 gal) of Fuel or 3000 Hours*


Fuel Ratio Control, Set Point, and Low Idle Check/Adjust Engine Mounts Inspect Crankcase Vibration Damper Inspect Cooling System (Long Life Coolant/Antifreeze only) Add extender Water Temperature Regulator (Thermostats) Replace Cooling System (Conventional Coolant/Antifreeze only) Clean/Flush/Change coolant PAR Analysis Obtain Valve Lash Check/Adjust/Inspect valve rotators

Every 2550 L (675 gal) of Fuel or 50 Hours*


Zinc Rods Inspect/Replace

Every 6375 L (1688 gal) of Fuel or 125 Hours*


PTO Main Shaft, Shift Lever, and Pilot Bearing (if equipped) Lubricate Clutch (if equipped) Check/Adjust

Every 256 000 L (67 500 gal) of Fuel or 5000 Hours*


Fuel Nozzles Test/Exchange Alternator Inspect/Rebuild or Exchange Air Compressor Inspect/Rebuild or Exchange Starting Motors Inspect/Rebuild or Exchange Turbocharger Inspect/Rebuild or Exchange Jacket Water Pump Inspect/Rebuild or Exchange Raw Water Pump Inspect/Rebuild or Exchange

Every 13 000 L (3400 gal) of Fuel or 250 Hours or Yearly*


Scheduled Oil Sampling Analysis (SOS)** Obtain Engine Crankcase Replace oil and filters Fuel System Drain water and sediment from tank/ Replace final filter/Clean primary filter Cooling System (Conventional Coolant/Antifreeze only) Test for coolant additive concentration/Add liquid coolant additive or replace coolant additive maintenance element (if equipped) Crankcase Breathers Clean Batteries Clean/Inspect/Check electrolyte level Belts Check/Adjust/Replace Hoses and Clamps Inspect/Check Air Cleaner Clean/Replace air filter elements Valve Lash** (at first oil change only) Check/Adjust

Every 306 000 L (81 000 gal) of Fuel or 6000 Hours or Four Years*
Cooling System ( Long Life Coolant/Antifreeze only) Drain/Flush/Replace LLCA * First perform previous service hour items.

** The oil change interval is based on fuel consumption. Use fuel consumption as the best indicator of oil change interval. The sump capacity also determines oil change interval. Standardsump capacity requires oil and filter change at 250 hours. The deep sump capacity requires oil and filter change at 500 hours. Confirm the interval with Scheduled Oil Sampling or contact your Caterpillar dealer.

10

MARINE ENGINE MAINTENANCE SCHEDULES

3408 Marine Engines (all rated rpms) continued


OVERHAUL Every 1 140 000 L (300 000 gal) of Fuel for 1250-1350 rated rpm, 874 000 L (230 000 gal) of Fuel for 1800 rated rpm, 570 000 L (150 000 gal) of Fuel for 2100 rated rpm
Cylinder Head, Connecting Rods, Pistons, Cylinder Liners, Turbocharger, Oil Pump, Spacer Plate, Fuel Ratio Control, Cam Followers, Fuel Transfer Pump, and Timing Advance Inspect/Rebuild or Exchange Piston Rings, Main Bearings, Rod Bearings, Valve Rotators and Crankshaft Seals Replace Fuel Nozzles Test Fuel Injection Pump Test Crankshaft, Camshaft, Cam Bearings, Damper, Governor Inspect Oil Cooler Clean/Test Aftercooler Core Clean/Test Coolant Analysis Obtain Fuel amounts are based on an average fuel consumption of 51 liters/hour (13.5 gallons/hour) for each maintenance interval. The liter quantity will not directly convert to the gallon quantity for the number of hours.

11

MARINE ENGINE MAINTENANCE SCHEDULES

3412 Marine Engines (all rated rpms)


Use fuel consumption, service hours, or time interval, whichever occurs first.

Every 227 500 L (60 000 gal) of Fuel or 3000 Hours*


Valve Lash Check/Adjust/Inspect valve rotators Fuel Ratio Control, Set Point, and Low Idle Check/Adjust Engine Mounts Inspect Crankshaft Vibration Damper Inspect Cooling System (Conventional Coolant/Antifreeze only) Clean/Flush/Change coolant Water Temperature Regulators (Thermostat) Replace PAR Analysis Obtain Cooling System (Long Life Coolant/Antifreeze only) Add extender

Daily
Walk-Around Inspection Inspect engine for leaks and loose connections Engine Crankcase Check oil level Cooling System Check coolant level Marine Gear Check oil level Air Starter (if equipped) Check lubricator bowl oil level Air Cleaner Check service indicator/Service air cleaner when necessary Clutch Shift Collar (if equipped) Lubricate

Every 3800 L (1000 gal) of Fuel or 50 Hours*


Zinc Rods Inspect/Replace

Every 379 000 L (100 000 gal) of Fuel or 5000 Hours*


Fuel Nozzles Test/Exchange Alternator Inspect/Rebuild or Exchange Air Compressor Inspect/Rebuild or Exchange Jacket Water Pump Inspect/Rebuild or Exchange Sea Water Pump Inspect/Rebuild or Exchange Turbocharger Inspect/Rebuild or Exchange Starting Motor Inspect/Rebuild or Exchange * First perform previous service hour items.

Every 9500 L (2500 gal) of Fuel or 125 Hours*


PTO Main Shaft, Shift Lever, and Pilot Bearing (if equipped) Lubricate Clutch (if equipped) Check/Adjust

First 19 000 L (5000 gal) of Fuel or 250 Hours*


Scheduled Oil Sampling Analysis (SOS) Obtain Engine Crankcase Replace oil and filters Crankcase Breather Clean Cooling System (Conventional Coolant/Antifreeze only) Test for coolant additive concentrations/ Add liquid coolant or replace coolant additive maintenance element (if equipped) Fuel System Clean primary filter/Replace final filter Batteries Clean/Inspect/Check electrolyte level Belts Check/Adjust/Replace Hoses and Clamps Inspect/Check Fuel Tank Drain water and sediment Valve Lash (at first oil change only) Check/Adjust

Every 76 000 L (20 000 gal) of Fuel or 1000 Hours*


Engine Protection Devices Inspect/Check

12

MARINE ENGINE MAINTENANCE SCHEDULES

3412 Marine Engines (all rated rpms) continued


OVERHAUL Every 1 520 000 L (400 000 gal) of Fuel for 1200 rated rpm, 1 310 000 L (345 000 gal) of Fuel for 1800 rated rpm, 760 000 L (200 000 gal) of Fuel for 2100 rated rpm
Cylinder Head, Connecting Rods, Pistons, Cylinder Liners, Turbocharger, Oil Pump, Spacer Plate, Fuel Ratio Control, Cam Followers, Fuel Transfer Pump, and Timing Advance Inspect/Rebuild or Exchange if necessary Piston Rings, Main Bearings, Rod Bearings, Valve Rotators, and Crankshaft Seals Install new Fuel Nozzles Test Fuel Injection Pump Test Crankshaft, Camshaft, Cam Bearings, Damper, Governor Inspect Oil Cooler Clean/Test Aftercooler Core Clean/Test Coolant Analysis Obtain Fuel amounts are based on an average fuel consumption of 76.29 liters/hour (20.13 gallons/ hour) for each maintenance interval. The liter quantity will not directly convert to the gallon quantity for the number of hours.

13

MARINE ENGINE MAINTENANCE SCHEDULES

3508 Marine Engines (rated up to 1300 rpm)


Use fuel consumption, service hours, or time interval, whichever occurs first.

Every 89 000 L (23 500 gal) of Fuel or 1000 Hours*


Engine Protective Devices Inspect/Check Engine Fuel Filters Replace Primary Fuel Filter Clean Crankcase Breather Clean Marine Gear Oil and Filter Replace Marine Gear Strainer and Breather Clean Marine Gear Output Shaft Seal Lubricate Governor Air Actuator (if equipped) Lubricate

When Required
Used Filter Inspection Inspect for debris

Daily
Walk-Around Inspection Inspect engine for leaks and loose connections Engine Crankcase Check oil level Cooling System Check coolant level Belts/Hoses Check/Inspect Marine Transmission Oil Check level Air Starter Lubricator (if equipped) Check level Air Tank Drain water Engine Air Cleaner Check/Replace element Engine Oil Filter Differential Pressure Check Engine Fuel Filter Differential Pressure Check Driven Equipment Inspect/Check/Lubricate Daily Engine Log Sheet Daily recordings

Every 178 000 L (47 000 gal) of Fuel or 2000 Hours*


Valve Lash/Bridge Adjustment Check/Adjust Turbochargers Inspect/Check Engine Mounts Inspect/Check Damper Inspect/Check

Every 4550 L (1200 gal) of Fuel or 50 Hours*


Zinc Rods Inspect/Replace Marine Gear Oil and Filter Change oil on new/ rebuilt at first 50 hrs. only, then at normal interval

Every 267 000 L (70 500 gal) of Fuel or 3000 Hours or 2 Years*
Cooling System (Engines Using Standard Type Antifreeze Only) Drain/Flush/Fill Cooling System (Engines Using LLCA Only) Add Extender

Every 11 350 L (3000 gal) of Fuel or 125 Hours*


Clutch Check/Adjust Clutch Bearing Lubricate

Every 356 000 L (94 000 gal) of Fuel or 4000 Hours*


Air Compressor (if equipped) Inspect/Rebuild or Exchange if necessary Electric Starter Inspect/Rebuild or Exchange if necessary * First perform previous service hour items.

Every 22 700 L (6000 gal) of Fuel or 250 Hours*


Scheduled Oil Sampling Analysis (SOS)** Obtain Engine Oil and Filters** Replace Cooling System (Engines Using Standard Type Antifreeze Only) Add conditioner Batteries Clean/Inspect/Check electrolyte level Alternator Belts Inspect/Check/Adjust Fuel Tank Drain water and sediment Initial Valve Lash/Bridge, and Injector Timing Check/Adjust (at first oil change only)

** For larger optional sump capacity of 224 L (59 gal), these items occur at 500 hours. For larger optional sump capacity of 425 L (112 gal), these items occur at 1000 hours. Refer to the Operation and Maintenance Manual for the correct oil change interval for your specific engine.

14

MARINE ENGINE MAINTENANCE SCHEDULES

3508 Marine Engines (rated up to 1300 rpm) continued


Every 535 000 L (141 000 gal) of Fuel or 6000 Hours*
Cooling System Drain/Flush/Fill Thermostats Replace Turbochargers Inspect/Rebuild or Exchange if necessary Water Pump Inspect/Rebuild or Exchange if necessary Sea Water Pump Inspect/Rebuild or Exchange if necessary Air Starter (if equipped) Inspect/Rebuild or Exchange if necessary Alternator Inspect/Rebuild or Exchange if necessary Piston Rings Install New Main Bearings Install New Rod Bearings Install New Crankshaft Seals Install New Crankshaft Inspect Camshaft Inspect Cam Bearings Inspect Damper Inspect Fuel System Linkage (if equipped) Inspect Gear Train Inspect Gear Train Bushings/Bearings Inspect Thrust Washers Inspect Driven Unit Alignment Inspect Oil Cooler Clean/Test Aftercooler Core Clean/Test Coolant Analysis Obtain PAR Analysis Obtain after Overhaul * First perform previous service hour items.

Top End Every 976 000 L (257 500 gal) of Fuel or 11 000 Hours*
Cylinder Head Assembly Rebuild or Exchange Injectors Replace PAR Analysis Obtain after Top End

OVERHAUL Every 1 952 000 L (515 000 gal) of Fuel or 22 000 Hours*
All Top End Items Connecting Rods Inspect/Rebuild or Exchange if necessary Cylinder Liners Inspect/Rebuild or Exchange if necessary Pistons Inspect/Rebuild or Exchange if necessary Piston Wrist Pins Inspect/Exchange if necessary Spacer Plate Inspect/Exchange if necessary Cam Follower Lifters Inspect/Exchange if necessary Fuel Transfer Pump Inspect/Rebuild or Exchange if necessary Prelube Pump (if equipped) Inspect/Rebuild or Exchange if necessary Mechanical Governor (if equipped) Inspect/ Rebuild or Exchange if necessary Mechanical Fuel Ratio Control (if equipped) Inspect/Rebuild or Exchange if necessary Oil Pumps Inspect/Rebuild or Exchange if necessary

15

MARINE ENGINE MAINTENANCE SCHEDULES

3508/3508B Marine Engines (rated 1301 to 1600 rpm)


Use fuel consumption, service hours, or time interval, whichever occurs first.

Every 109 000 L (28 800 gal) of Fuel or 1000 Hours*


Engine Protective Devices Inspect/Check Engine Fuel Filters Replace Primary Fuel Filter Clean Crankcase Breather Clean Marine Gear Oil and Filter Replace Marine Gear Strainer and Breather Clean Marine Gear Output Shaft Seal Lubricate Governor Air Actuator (if equipped) Lubricate

When Required
Used Filter Inspection Inspect for debris

Daily
Walk-Around Inspection Inspect engine for leaks and loose connections Engine Crankcase Check oil level Cooling System Check coolant level Belts/Hoses Check/Inspect Marine Transmission Oil Check level Air Starter Lubricator (if equipped) Check level Air Tank Drain water Engine Air Cleaner Check/Replace element Engine Oil Filter Differential Pressure Check Engine Fuel Filter Differential Pressure Check Driven Equipment Inspect/Check/Lubricate Daily Engine Log Sheet Daily recordings

Every 218 000 L (57 600 gal) of Fuel or 2000 Hours*


Valve Lash/Bridge Adjustment Check/Adjust Turbochargers Inspect/Check Engine Mounts Inspect/Check Damper Inspect/Check

Every 5450 L (1440 gal) of Fuel or 50 Hours*


Zinc Rods Inspect/Replace Marine Gear Oil and Filter Change oil on new/ rebuilt at first 50 hrs. only, then at normal interval

Every 327 500 L (86 400 gal) of Fuel or 3000 Hours or 2 Years*
Cooling System (Engines Using Standard Type Antifreeze Only) Drain/Flush/Fill Cooling System (Engines Using LLCA Only) Add Extender

Every 13 600 L (3600 gal) of Fuel or 125 Hours*


Clutch Check/Adjust Clutch Bearing Lubricate

Every 436 000 L (115 200 gal) of Fuel or 4000 Hours*


Air Compressor (if equipped) Inspect/Rebuild or Exchange if necessary Electric Starter Inspect/Rebuild or Exchange if necessary * First perform previous service hour items.

Every 27 200 L (7200 gal) of Fuel or 250 Hours*


Scheduled Oil Sampling Analysis (SOS)** Obtain Engine Oil and Filters** Replace Cooling System (Engines Using Standard Type Antifreeze Only) Add conditioner Batteries Clean/Inspect/Check electrolyte level Alternator Belt Inspect/Check/Adjust Fuel Tank Drain water & sediment Initial Valve Lash/Bridge, and Injector Timing Check/Adjust (at first oil change only)

** For larger optional sump capacity of 224 L (59 gal), these items occur at 500 hours. For larger optional sump capacity of 425 L (112 gal), these items occur at 1000 hours. Refer to the Operation and Maintenance Manual for the correct oil change interval for your specific engine.

16

MARINE ENGINE MAINTENANCE SCHEDULES

3508/3508B Marine Engines (rated 1300 to 1600 rpm) continued


Every 654 000 L (172 800 gal) of Fuel or 6000 Hours*
Cooling System Drain/Flush/Fill Thermostats Replace Turbochargers Inspect/Rebuild or Exchange if necessary Water Pump Inspect/Rebuild or Exchange if necessary Sea Water Pump Inspect/Rebuild or Exchange if necessary Air Starter (if equipped) Inspect/Rebuild or Exchange if necessary Alternator Inspect/Rebuild or Exchange if necessary Piston Rings Install New Main Bearings Install New Rod Bearings Install New Crankshaft Seals Install New Crankshaft Inspect Camshaft Inspect Cam Bearings Inspect Damper Inspect Fuel System Linkage (if equipped) Inspect Gear Train Inspect Gear Train Bushings/Bearings Inspect Thrust Washers Inspect Driven Unit Alignment Inspect Oil Cooler Clean/Test Aftercooler Core Clean/Test Coolant Analysis Obtain PAR Analysis Obtain after Overhaul * First perform previous service hour items.

Top End Every 976 000 L (257 500 gal) of Fuel or 9000 Hours*
Cylinder Head Assembly Rebuild or Exchange Injectors Replace PAR Analysis Obtain after Top End

OVERHAUL Every 1 952 000 L (515 000 gal) of Fuel or 18 000 Hours*
All Top End Items Connecting Rods Inspect/Rebuild or Exchange if necessary Cylinder Liners Inspect/Rebuild or Exchange if necessary Pistons Inspect/Rebuild or Exchange if necessary Piston Wrist Pins Inspect/Exchange if necessary Spacer Plate Inspect/Exchange if necessary Cam Follower Lifters Inspect/Exchange if necessary Fuel Transfer Pump Inspect/Rebuild or Exchange if necessary Prelube Pump (if equipped) Inspect/Rebuild or Exchange if necessary Mechanical Governor (if equipped) Inspect/Rebuild or Exchange if necessary Mechanical Fuel Ratio Control (if equipped) Inspect/Rebuild or Exchange if necessary Oil Pumps Inspect/Rebuild or Exchange if necessary

17

MARINE ENGINE MAINTENANCE SCHEDULES

3508/3508B Marine Engines (rated 1601 to 1800 rpm)


Use fuel consumption, service hours, or time interval, whichever occurs first.

Every 128 500 L (34 000 gal) of Fuel or 1000 Hours*


Engine Protective Devices Inspect/Check Engine Fuel Filters Replace Primary Fuel Filter Clean Crankcase Breather Clean Marine Gear Oil and Filter Replace Marine Gear Strainer and Breather Clean Marine Gear Output Shaft Seal Lubricate Governor Air Actuator (if equipped) Lubricate

When Required
Used Filter Inspection Inspect for debris

Daily
Walk-Around Inspection Inspect engine for leaks and loose connections Engine Crankcase Check oil level Cooling System Check coolant level Belts/Hoses Check/Inspect Marine Transmission Oil Check level Air Starter Lubricator (if equipped) Check level Air Tank Drain water Engine Air Cleaner Check/Replace element Engine Oil Filter Differential Pressure Check Engine Fuel Filter Differential Pressure Check Driven Equipment Inspect/Check/Lubricate Daily Engine Log Sheet Daily recordings

Every 257 000 L (68 000 gal) of Fuel or 2000 Hours*


Valve Lash/Bridge Adjustment Check/Adjust Turbochargers Inspect/Check Engine Mounts Inspect/Check Damper Inspect/Check

Every 6400 L (1650 gal) of Fuel or 50 Hours*


Zinc Rods Inspect/Replace Marine Gear Oil and Filter Change oil on new/ rebuilt at first 50 hrs. only, then at normal interval

Every 386 500 L (102 000 gal) of Fuel or 3000 Hours or 2 Years*
Cooling System (Engines Using Standard Type Antifreeze Only) Drain/Flush/Fill Cooling System (Engines Using LLCA Only) Add Extender

Every 16 000 L (4250 gal) of Fuel or 125 Hours*


Clutch Check/Adjust Clutch Bearing Lubricate

Every 514 000 L (136 000 gal) of Fuel or 4000 Hours*


Air Compressor (if equipped) Inspect/Rebuild or Exchange if necessary Electric Starter Inspect/Rebuild or Exchange if necessary * First perform previous service hour items.

Every 32 000 L (8500 gal) of Fuel or 250 Hours*


Scheduled Oil Sampling Analysis (SOS)** Obtain Engine Oil and Filters** Replace Cooling System (Engines Using Standard Type Antifreeze Only) Add conditioner Batteries Clean/Inspect/Check electrolyte level Alternator Belts Inspect/Check/Adjust Fuel Tank Drain water & sediment Initial Valve Lash/Bridge, and Injector Timing Check/Adjust (at first oil change only)

** For larger optional sump capacity of 224 L (59 gal), these items occur at 500 hours. For larger optional sump capacity of 425 L (112 gal), these items occur at 1000 hours. Refer to the Operation and Maintenance Manual for the correct oil change interval for your specific engine.

18

MARINE ENGINE MAINTENANCE SCHEDULES

3508/3508B Marine Engines (rated 1601 to 1800 rpm) continued


Every 771 000 L (204 000 gal) of Fuel or 6000 Hours*
Cooling System Drain/Flush/Fill Thermostats Replace Turbochargers Inspect/Rebuild or Exchange if necessary Water Pump Inspect/Rebuild or Exchange if necessary Sea Water Pump Inspect/Rebuild or Exchange if necessary Air Starter (if equipped) Inspect/Rebuild or Exchange if necessary Alternator Inspect/Rebuild or Exchange if necessary Mechanical Fuel Ratio Control (if equipped) Inspect/Rebuild or Exchange if necessary Oil Pumps Inspect/Rebuild or Exchange if necessary Piston Rings Install New Main Bearings Install New Rod Bearings Install New Crankshaft Seals Install New Crankshaft Inspect Camshaft Inspect Cam Bearings Inspect Damper Inspect Fuel System Linkage (if equipped) Inspect Gear Train Inspect Gear Train Bushings/Bearings Inspect Thrust Washers Inspect Driven Unit Alignment Inspect Oil Cooler Clean/Test Aftercooler Core Clean/Test Coolant Analysis Obtain PAR Analysis Obtain after Overhaul * First perform previous service hour items.

Top End Every 976 000 L (257 500 gal) of Fuel or 7500 Hours*
Cylinder Head Assembly Rebuild or Exchange Injectors Replace PAR Analysis Obtain after Top End

OVERHAUL Every 1 952 000 L (515 000 gal) of Fuel or 15 000 Hours*
All Top End Items Connecting Rods Inspect/Rebuild or Exchange if necessary Cylinder Liners Inspect/Rebuild or Exchange if necessary Pistons Inspect/Rebuild or Exchange if necessary Piston Wrist Pins Inspect/Exchange if necessary Spacer Plate Inspect/Exchange if necessary Cam Follower Lifters Inspect/Exchange if necessary Fuel Transfer Pump Inspect/Rebuild or Exchange if necessary Prelube Pump (if equipped) Inspect/Rebuild or Exchange if necessary Mechanical Governor (if equipped) Inspect/ Rebuild or Exchange if necessary

19

MARINE ENGINE MAINTENANCE SCHEDULES

3512 Marine Engines (rated up to 1300 rpm)


Use fuel consumption, service hours, or time interval, whichever occurs first.

Every 133 500 L (35 000 gal) of Fuel or 1000 Hours*


Engine Protective Devices Inspect/Check Engine Fuel Filters Replace Primary Fuel Filter Clean Crankcase Breather Clean Marine Gear Oil and Filter Replace Marine Gear Strainer and Breather Clean Marine Gear Output Shaft Seal Lubricate Governor Air Actuator (if equipped) Lubricate

When Required
Used Filter Inspection Inspect for debris

Daily
Walk-Around Inspection Inspect engine for leaks and loose connections Engine Crankcase Check oil level Cooling System Check coolant level Belts/Hoses Check/Inspect Marine Transmission Oil Check level Air Starter Lubricator (if equipped) Check level Air Tank Drain water Engine Air Cleaner Check/Replace element Engine Oil Filter Differential Pressure Check Engine Fuel Filter Differential Pressure Check Driven Equipment Inspect/Check/Lubricate Daily Engine Log Sheet Daily recordings

Every 267 000 L (70 000 gal) of Fuel or 2000 Hours*


Valve Lash/Bridge Adjustment Check/Adjust Turbochargers Inspect/Check Engine Mounts Inspect/Check Damper Inspect/Check

Every 6670 L (1760 gal) of Fuel or 50 Hours*


Zinc Rods Inspect/Replace Marine Gear Oil and Filter Change oil on new/ rebuilt at first 50 hrs. only, then at normal interval

Every 398 000 L (105 000 gal) of Fuel or 3000 Hours or 2 Years*
Cooling System (Engines Using Standard Type Antifreeze Only) Drain/Flush/Fill Cooling System (Engines Using LLCA Only) Add Extender

Every 16 700 L (4400 gal) of Fuel or 125 Hours*


Clutch Check/Adjust Clutch Bearing Lubricate

Every 534 000 L (140 000 gal) of Fuel or 4000 Hours*


Air Compressor (if equipped) Inspect/Rebuild or Exchange if necessary Electric Starter Inspect/Rebuild or Exchange if necessary * First perform previous service hour items.

Every 33 400 L (8800 gal) of Fuel or 250 Hours*


Scheduled Oil Sampling Analysis (SOS)** Obtain Engine Oil and Filters** Replace Cooling System (Engines Using Standard Type Antifreeze Only) Add conditioner Batteries Clean/Inspect/Check electrolyte level Alternator Belts Inspect/Check/Adjust Fuel Tank Drain water and sediment Initial Valve Lash/Bridge, and Injector Timing Check/Adjust (at first oil change only)

** For larger optional sump capacity of 300 L (81 gal), these items occur at 500 hours. For larger optional sump capacity of 600 L (162 gal), these items occur at 1000 hours. Refer to the Operation and Maintenance Manual for the correct oil change interval for your specific engine.

20

MARINE ENGINE MAINTENANCE SCHEDULES

3512 Marine Engines (rated up to 1300 rpm) continued


Every 796 000 L (210 000 gal) of Fuel or 6000 Hours*
Cooling System Drain/Flush/Fill Thermostats Replace Turbochargers Inspect/Rebuild or Exchange if necessary Water Pump Inspect/Rebuild or Exchange if necessary Sea Water Pump Inspect/Rebuild or Exchange if necessary Air Starter (if equipped) Inspect/Rebuild or Exchange if necessary Alternator Inspect/Rebuild or Exchange if necessary Piston Rings Install New Main Bearings Install New Rod Bearings Install New Crankshaft Seals Install New Crankshaft Inspect Camshaft Inspect Cam Bearings Inspect Damper Inspect Fuel System Linkage (if equipped) Inspect Gear Train Inspect Gear Train Bushings/Bearings Inspect Thrust Washers Inspect Driven Unit Alignment Inspect Oil Cooler Clean/Test Aftercooler Core Clean/Test Coolant Analysis Obtain PAR Analysis Obtain after Overhaul * First perform previous service hour items.

Top End Every 1 460 000 L (385 000 gal) of Fuel or 11 000 Hours*
Cylinder Head Assembly Rebuild or Exchange Injectors Replace PAR Analysis Obtain after Top End

OVERHAUL Every 2 920 000 L (770 000 gal) of Fuel or 22 000 Hours*
All Top End Items Connecting Rods Inspect/Rebuild or Exchange if necessary Cylinder Liners Inspect/Rebuild or Exchange if necessary Pistons Inspect/Rebuild or Exchange if necessary Piston Wrist Pins Inspect/Exchange if necessary Spacer Plate Inspect/Exchange if necessary Cam Follower Lifters Inspect/Exchange if necessary Fuel Transfer Pump Inspect/Rebuild or Exchange if necessary Prelube Pump (if equipped) Inspect/Rebuild or Exchange if necessary Mechanical Governor (if equipped) Inspect/Rebuild or Exchange if necessary Mechanical Fuel Ratio Control (if equipped) Inspect/Rebuild or Exchange if necessary Oil Pumps Inspect/Rebuild or Exchange if necessary

21

MARINE ENGINE MAINTENANCE SCHEDULES

3512/3512B Marine Engines (rated 1301 to 1600 rpm)


Use fuel consumption, service hours, or time interval, whichever occurs first.

Every 164 000 L (43 200 gal) of Fuel or 1000 Hours*


Engine Protective Devices Inspect/Check Engine Fuel Filters Replace Primary Fuel Filter Clean Crankcase Breather Clean Marine Gear Oil and Filter Replace Marine Gear Strainer and Breather Clean Marine Gear Output Shaft Seal Lubricate Governor Air Actuator (if equipped) Lubricate

When Required
Used Filter Inspection Inspect for debris

Daily
Walk-Around Inspection Inspect engine for leaks and loose connections Engine Crankcase Check oil level Cooling System Check coolant level Belts/Hoses Check/Inspect Marine Transmission Oil Check level Air Starter Lubricator (if equipped) Check level Air Tank Drain water Engine Air Cleaner Check/Replace element Engine Oil Filter Differential Pressure Check Engine Fuel Filter Differential Pressure Check Driven Equipment Inspect/Check/Lubricate Daily Engine Log Sheet Daily recordings

Every 328 000 L (86 400 gal) of Fuel or 2000 Hours*


Valve Lash/Bridge Adjustment Check/Adjust Turbochargers Inspect/Check Engine Mounts Inspect/Check Damper Inspect/Check

Every 8200 L (2160 gal) of Fuel or 50 Hours*


Zinc Rods Inspect/Replace Marine Gear Oil and Filter Change oil on new/ rebuilt at first 50 hrs. only, then at normal interval

Every 491 000 L (129 600 gal) of Fuel or 3000 Hours or 2 Years*
Cooling System (Engines Using Standard Type Antifreeze Only) Drain/Flush/Fill Cooling System (Engines Using LLCA Only) Add Extender

Every 20 500 L (5400 gal) of Fuel or 125 Hours*


Clutch Check/Adjust Clutch Bearing Lubricate

Every 654 000 L (172 800 gal) of Fuel or 4000 Hours*


Air Compressor (if equipped) Inspect/Rebuild or Exchange if necessary Electric Starter Inspect/Rebuild or Exchange if necessary * First perform previous service hour items.

Every 41 000 L (10 800 gal) of Fuel or 250 Hours*


Scheduled Oil Sampling Analysis (SOS)** Obtain Engine Oil and Filters** Replace Cooling System (Engines Using Standard Type Antifreeze Only) Add conditioner Batteries Clean/Inspect/Check electrolyte level Alternator Belts Inspect/Check/Adjust Fuel Tank Drain water and sediment Initial Valve Lash/Bridge, and Injector Timing Check/Adjust (at first oil change only)

** For larger optional sump capacity of 300 L (81 gal), these items occur at 500 hours. For larger optional sump capacity of 600 L (162 gal), these items occur at 1000 hours. Refer to the Operation and Maintenance Manual for the correct oil change interval for your specific engine.

22

MARINE ENGINE MAINTENANCE SCHEDULES

3512/3512B Marine Engines (rated 1301 to 1600 rpm) continued


Every 982 000 L (259 200 gal) of Fuel or 6000 Hours*
Cooling System Drain/Flush/Fill Thermostats Replace Turbochargers Inspect/Rebuild or Exchange if necessary Water Pump Inspect/Rebuild or Exchange if necessary Sea Water Pump Inspect/Rebuild or Exchange if necessary Air Starter (if equipped) Inspect/Rebuild or Exchange if necessary Alternator Inspect/Rebuild or Exchange if necessary Piston Rings Install New Main Bearings Install New Rod Bearings Install New Crankshaft Seals Install New Crankshaft Inspect Camshaft Inspect Cam Bearings Inspect Damper Inspect Fuel System Linkage (if equipped) Inspect Gear Train Inspect Gear Train Bushings/Bearings Inspect Thrust Washers Inspect Driven Unit Alignment Inspect Oil Cooler Clean/Test Aftercooler Core Clean/Test Coolant Analysis Obtain PAR Analysis Obtain after Overhaul * First perform previous service hour items.

Top End Every 1 460 000 L (385 000 gal) of Fuel or 9000 Hours*
Cylinder Head Assembly Rebuild or Exchange Injectors Replace PAR Analysis Obtain after Top End

OVERHAUL Every 2 920 000 L (770 000 gal) of Fuel or 18 000 Hours*
All Top End Items Connecting Rods Inspect/Rebuild or Exchange if necessary Cylinder Liners Inspect/Rebuild or Exchange if necessary Pistons Inspect/Rebuild or Exchange if necessary Piston Wrist Pins Inspect/Exchange if necessary Spacer Plate Inspect/Exchange if necessary Cam Follower Lifters Inspect/Exchange if necessary Fuel Transfer Pump Inspect/Rebuild or Exchange if necessary Prelube Pump (if equipped) Inspect/Rebuild or Exchange if necessary Mechanical Governor (if equipped) Inspect/Rebuild or Exchange if necessary Mechanical Fuel Ratio Control (if equipped) Inspect/Rebuild or Exchange if necessary Oil Pumps Inspect/Rebuild or Exchange if necessary

23

MARINE ENGINE MAINTENANCE SCHEDULES

3512/3512B Marine Engines (rated 1601 to 1800 rpm)


Use fuel consumption, service hours, or time interval, whichever occurs first.

Every 194 000 L (51 200 gal) of Fuel or 1000 Hours*


Engine Protective Devices Inspect/Check Engine Fuel Filters Replace Primary Fuel Filter Clean Crankcase Breather Clean Marine Gear Oil and Filter Replace Marine Gear Strainer and Breather Clean Marine Gear Output Shaft Seal Lubricate Governor Air Actuator (if equipped) Lubricate

When Required
Used Filter Inspection Inspect for debris

Daily
Walk-Around Inspection Inspect engine for leaks and loose connections Engine Crankcase Check oil level Cooling System Check coolant level Belts/Hoses Check/Inspect Marine Transmission Oil Check level Air Starter Lubricator (if equipped) Check level Air Tank Drain water Engine Air Cleaner Check/Replace element Engine Oil Filter Differential Pressure Check Engine Fuel Filter Differential Pressure Check Driven Equipment Inspect/Check/Lubricate Daily Engine Log Sheet Daily recordings

Every 388 000 L (102 400 gal) of Fuel or 2000 Hours*


Valve Lash/Bridge Adjustment Check/Adjust Turbochargers Inspect/Check Engine Mounts Inspect/Check Damper Inspect/Check

Every 9700 L (2560 gal) of Fuel or 50 Hours*


Zinc Rods Inspect/Replace Marine Gear Oil and Filter Change oil on new/ rebuilt at first 50 hrs. only, then at normal interval

Every 582 000 L (153 600 gal) of Fuel or 3000 Hours or 2 Years*
Cooling System (Engines Using Standard Type Antifreeze Only) Drain/Flush/Fill Cooling System (Engines Using LLCA Only) Add Extender

Every 24 250 L (6400 gal) of Fuel or 125 Hours*


Clutch Check/Adjust Clutch Bearing Lubricate

Every 776 000 L (204 800 gal) of Fuel or 4000 Hours*


Air Compressor (if equipped) Inspect/Rebuild or Exchange if necessary Electric Starter Inspect/Rebuild or Exchange if necessary * First perform previous service hour items.

Every 48 500 L (12 800 gal) of Fuel or 250 Hours*


Scheduled Oil Sampling Analysis (SOS)** Obtain Engine Oil and Filters** Replace Cooling System (Engines Using Standard Type Antifreeze Only) Add conditioner Batteries Clean/Inspect/Check electrolyte level Alternator Belts Inspect/Check/Adjust Fuel Tank Drain water and sediment Initial Valve Lash/Bridge, and Injector Timing Check/Adjust (at first oil change only)

** For larger optional sump capacity of 300 L (81 gal), these items occur at 500 hours. For larger optional sump capacity of 600 L (162 gal), these items occur at 1000 hours. Refer to the Operation and Maintenance Manual for the correct oil change interval for your specific engine.

24

MARINE ENGINE MAINTENANCE SCHEDULES

3512/3512B Marine Engines (rated 1601 to 1800 rpm) continued


Every 1 164 000 L (307 200 gal) of Fuel or 6000 Hours*
Cooling System Drain/Flush/Fill Thermostats Replace Turbochargers Inspect/Rebuild or Exchange if necessary Water Pump Inspect/Rebuild or Exchange if necessary Sea Water Pump Inspect/Rebuild or Exchange if necessary Air Starter (if equipped) Inspect/Rebuild or Exchange if necessary Alternator Inspect/Rebuild or Exchange if necessary Mechanical Governor (if equipped) Inspect/Rebuild or Exchange if necessary Mechanical Fuel Ratio Control (if equipped) Inspect/Rebuild or Exchange if necessary Oil Pumps Inspect/Rebuild or Exchange if necessary Piston Rings Install New Main Bearings Install New Rod Bearings Install New Crankshaft Seals Install New Crankshaft Inspect Camshaft Inspect Cam Bearings Inspect Damper Inspect Fuel System Linkage (if equipped) Inspect Gear Train Inspect Gear Train Bushings/Bearings Inspect Thrust Washers Inspect Driven Unit Alignment Inspect Oil Cooler Clean/Test Aftercooler Core Clean/Test Coolant Analysis Obtain PAR Analysis Obtain after Overhaul * First perform previous service hour items.

Top End Every 1 460 000 L (385 000 gal) of Fuel or 7500 Hours*
Cylinder Head Assembly Rebuild or Exchange Injectors Replace PAR Analysis Obtain after Top End

OVERHAUL Every 2 920 000 L (770 000 gal) of Fuel or 15 000 Hours*
All Top End Items Connecting Rods Inspect/Rebuild or Exchange if necessary Cylinder Liners Inspect/Rebuild or Exchange if necessary Pistons Inspect/Rebuild or Exchange if necessary Piston Wrist Pins Inspect/Exchange if necessary Spacer Plate Inspect/Exchange if necessary Cam Follower Lifters Inspect/Exchange if necessary Fuel Transfer Pump Inspect/Rebuild or Exchange if necessary Prelube Pump (if equipped) Inspect/Rebuild or Exchange if necessary

25

MARINE ENGINE MAINTENANCE SCHEDULES

3516 Marine Engines (rated up to 1300 rpm)


Use fuel consumption, service hours, or time interval, whichever occurs first.

Every 176 000 L (46 500 gal) of Fuel or 1000 Hours*


Engine Protective Devices Inspect/Check Engine Fuel Filters Replace Primary Fuel Filter Clean Crankcase Breather Clean Marine Gear Oil and Filter Replace Marine Gear Strainer and Breather Clean Marine Gear Output Shaft Seal Lubricate Governor Air Actuator (if equipped) Lubricate

When Required
Used Filter Inspection Inspect for debris

Daily
Walk-Around Inspection Inspect engine for leaks and loose connections Engine Crankcase Check oil level Cooling System Check coolant level Leaks and Loose Connections Check engine Belts/Hoses Check/Inspect Marine Transmission Oil Check level Air Starter Lubricator (if equipped) Check level Air Tank Drain water Engine Air Cleaner Check/Replace element Engine Oil Filter Differential Pressure Check Engine Fuel Filter Differential Pressure Check Driven Equipment Inspect/Check/Lubricate Daily Engine Log Sheet Daily recordings

Every 352 000 L (93 000 gal) of Fuel or 2000 Hours*


Valve Lash/Bridge Adjustment Check/Adjust Turbochargers Inspect/Check Engine Mounts Inspect/Check Damper Inspect/Check

Every 528 700 L (139 500 gal) of Fuel or 3000 Hours or 2 Years*
Cooling System (Engines Using Standard Type Antifreeze Only) Drain/Flush/Fill Cooling System (Engines Using LLCA Only) Add Extender

Every 8800 L (2300 gal) of Fuel or 50 Hours*


Zinc Rods Inspect/Replace Marine Gear Oil and Filter Change oil on new/ rebuilt at first 50 hrs. only, then at normal interval

Every 22 000 L (5800 gal) of Fuel or 125 Hours*


Clutch Check/Adjust Clutch Bearing Lubricate

Every 704 000 L (186 000 gal) of Fuel or 4000 Hours*


Air Compressor (if equipped) Inspect/Rebuild or Exchange if necessary Electric Starter Inspect/Rebuild or Exchange if necessary * First perform previous service hour items.

Every 44 000 L (11 600 gal) of Fuel or 250 Hours*


Scheduled Oil Sampling Analysis (SOS)** Obtain Engine Oil and Filters** Replace Cooling System (Engines Using Standard Type Antifreeze Only) Add conditioner Batteries Clean/Inspect/Check electrolyte level Alternator Belts Inspect/Check/Adjust Fuel Tank Drain water & sediment Initial Valve Lash/Bridge, and Injector Timing Check/Adjust (at first oil change only)

** For larger optional sump capacity of 400 L (l06 gal), these items occur at 500 hours. For larger optional sump capacity of 830 L (219 gal), these items occur at 1000 hours. Refer to the Operation and Maintenance Manual for the correct oil change interval for your specific engine.

26

MARINE ENGINE MAINTENANCE SCHEDULES

3516 Marine Engines (rated up to 1300 rpm) continued


Every 1 056 000 L (279 000 gal) of Fuel or 6000 Hours*
Cooling System Drain/Flush/Fill Thermostats Replace Turbochargers Inspect/Rebuild or Exchange if necessary Water Pump Inspect/Rebuild or Exchange if necessary Sea Water Pump Inspect/Rebuild or Exchange if necessary Air Starter (if equipped) Inspect/Rebuild or Exchange if necessary Alternator Inspect/Rebuild or Exchange if necessary Main Bearings Install New Rod Bearings Install New Crankshaft Seals Install New Crankshaft Inspect Camshaft Inspect Cam Bearings Inspect Damper Inspect Fuel System Linkage (if equipped) Inspect Gear Train Inspect Gear Train Bushings/Bearings Inspect Thrust Washers Inspect Driven Unit Alignment Inspect Oil Cooler Clean/Test Aftercooler Core Clean/Test Coolant Analysis Obtain PAR Analysis Obtain after Overhaul * First perform previous service hour items.

Top End Every 1 942 000 L (512 500 gal) of Fuel or 11 000 Hours*
Cylinder Head Assembly Rebuild or Exchange Injectors Replace PAR Analysis Obtain after Top End

OVERHAUL Every 3 844 000 L (1 025 000 gal) of Fuel or 22 000 Hours*
All Top End Items Connecting Rods Inspect/Rebuild or Exchange if necessary Cylinder Liners Inspect/Rebuild or Exchange if necessary Pistons Inspect/Rebuild or Exchange if necessary Piston Wrist Pins Inspect/Exchange if necessary Spacer Plate Inspect/Exchange if necessary Cam Follower Lifters Inspect/Exchange if necessary Fuel Transfer Pump Inspect/Rebuild or Exchange if necessary Prelube Pump (if equipped) Inspect/Rebuild or Exchange if necessary Mechanical Governor (if equipped) Inspect/Rebuild or Exchange if necessary Mechanical Fuel Ratio Control (if equipped) Inspect/Rebuild or Exchange if necessary Oil Pumps Inspect/Rebuild or Exchange if necessary Piston Rings Install New

27

MARINE ENGINE MAINTENANCE SCHEDULES

3516/3516B Marine Engines (rated 1301 to 1600 rpm)


Use fuel consumption, service hours, or time interval, whichever occurs first.

Every 212 000 L (56 000 gal) of Fuel or 1000 Hours*


Engine Protective Devices Inspect/Check Engine Fuel Filters Replace Primary Fuel Filter Clean Crankcase Breather Clean Marine Gear Oil and Filter Replace Marine Gear Strainer and Breather Clean Marine Gear Output Shaft Seal Lubricate Governor Air Actuator (if equipped) Lubricate

When Required
Used Filter Inspection Inspect for debris

Daily
Walk-Around Inspection Inspect engine for leaks and loose connections Engine Crankcase Check oil level Cooling System Check coolant level Belts/Hoses Check/Inspect Marine Transmission Oil Check level Air Starter Lubricator (if equipped) Check level Air Tank Drain water Engine Air Cleaner Check/Replace element Engine Oil Filter Differential Pressure Check Engine Fuel Filter Differential Pressure Check Driven Equipment Inspect/Check/Lubricate Daily Engine Log Sheet Daily recordings

Every 424 000 L (112 000 gal) of Fuel or 2000 Hours*


Valve Lash/Bridge Adjustment Check/Adjust Turbochargers Inspect/Check Engine Mounts Inspect/Check Damper Inspect/Check

Every 10 600 L (2800 gal) of Fuel or 50 Hours*


Zinc Rods Inspect/Replace Marine Gear Oil and Filter Change oil on new/ rebuilt at first 50 hrs. only, then at normal interval

Every 636 700 L (68 000 gal) of Fuel or 3000 Hours or 2 Years*
Cooling System (Engines Using Standard Type Antifreeze Only) Drain/Flush/Fill Cooling System (Engines Using LLCA Only) Add Extender

Every 26 500 L (7000 gal) of Fuel or 125 Hours*


Clutch Check/Adjust Clutch Bearing Lubricate

Every 848 000 L (168 000 gal) of Fuel or 4000 Hours*


Air Compressor (if equipped) Inspect/Rebuild or Exchange if necessary Electric Starter Inspect/Rebuild or Exchange if necessary * First perform previous service hour items.

Every 53 000 L (14 000 gal) of Fuel or 250 Hours*


Scheduled Oil Sampling Analysis (SOS)** Obtain Engine Oil and Filters** Replace Cooling System (Engines Using Standard Type Antifreeze Only) Add conditioner Batteries Clean/Inspect/Check electrolyte level Alternator Belts Inspect/Check/Adjust Fuel Tank Drain water and sediment Initial Valve Lash/Bridge, and Injector Timing Check/Adjust (at first oil change only)

** For larger optional sump capacity of 400 L (l06 gal), these items occur at 500 hours. For larger optional sump capacity of 830 L (219 gal), these items occur at 1000 hours. Refer to the Operation and Maintenance Manual for the correct oil change interval for your specific engine.

28

MARINE ENGINE MAINTENANCE SCHEDULES

3516/3516B Marine Engines (rated 1301 to 1600 rpm) continued


Every 1 272 000 L (336 000 gal) of Fuel or 6000 Hours*
Cooling System Drain/Flush/Fill Thermostats Replace Turbochargers Inspect/Rebuild or Exchange if necessary Water Pump Inspect/Rebuild or Exchange if necessary Sea Water Pump Inspect/Rebuild or Exchange if necessary Air Starter (if equipped) Inspect/Rebuild or Exchange if necessary Alternator Inspect/Rebuild or Exchange if necessary Oil Pumps Inspect/Rebuild or Exchange if necessary Piston Rings Install New Main Bearings Install New Rod Bearings Install New Crankshaft Seals Install New Crankshaft Inspect Camshaft Inspect Cam Bearings Inspect Damper Inspect Fuel System Linkage (if equipped) Inspect Gear Train Inspect Gear Train Bushings/Bearings Inspect Thrust Washers Inspect Driven Unit Alignment Inspect Oil Cooler Clean/Test Aftercooler Core Clean/Test Coolant Analysis Obtain PAR Analysis Obtain after Overhaul * First perform previous service hour items.

Top End Every 1 942 000 L (512 500 gal) of Fuel or 9000 Hours*
Cylinder Head Assembly Rebuild or Exchange Injectors Replace PAR Analysis Obtain after Top End

OVERHAUL Every 3 884 000 L (1 025 000 gal) of Fuel or 18 000 Hours*
All Top End Items Connecting Rods Inspect/Rebuild or Exchange if necessary Cylinder Liners Inspect/Rebuild or Exchange if necessary Pistons Inspect/Rebuild or Exchange if necessary Piston Wrist Pins Inspect/Exchange if necessary Spacer Plate Inspect/Exchange if necessary Cam Follower Lifters Inspect/Exchange if necessary Fuel Transfer Pump Inspect/Rebuild or Exchange if necessary Prelube Pump (if equipped) Inspect/Rebuild or Exchange if necessary Mechanical Governor (if equipped) Inspect/Rebuild or Exchange if necessary Mechanical Fuel Ratio Control (if equipped) Inspect/Rebuild or Exchange if necessary

29

MARINE ENGINE MAINTENANCE SCHEDULES

3516/3516B Marine Engines (rated 1601 to 1800 rpm)


Use fuel consumption, service hours, or time interval, whichever occurs first.

Every 258 000 L (68 000 gal) of Fuel or 1000 Hours*


Engine Protective Devices Inspect/Check Engine Fuel Filters Replace Primary Fuel Filter Clean Crankcase Breather Clean Marine Gear Oil and Filter Replace Marine Gear Strainer and Breather Clean Marine Gear Output Shaft Seal Lubricate Governor Air Actuator (if equipped) Lubricate

When Required
Used Filter Inspection Inspect for debris

Daily
Walk-Around Inspection Inspect engine for leaks and loose connections Engine Crankcase Check oil level Cooling System Check coolant level Belts/Hoses Check/Inspect Marine Transmission Oil Check level Air Starter Lubricator (if equipped) Check level Air Tank Drain water Engine Air Cleaner Check/Replace element Engine Oil Filter Differential Pressure Check Engine Fuel Filter Differential Pressure Check Driven Equipment Inspect/Check/Lubricate Daily Engine Log Sheet Daily recordings

Every 516 000 L (136 000 gal) of Fuel or 2000 Hours*


Valve Lash/Bridge Adjustment Check/Adjust Turbochargers Inspect/Check Engine Mounts Inspect/Check Damper Inspect/Check

Every 12 900 L (3400 gal) of Fuel or 50 Hours*


Zinc Rods Inspect/Replace Marine Gear Oil and Filter Change oil on new/ rebuilt at first 50 hrs. only, then at normal interval

Every 773 000 L (204 000 gal) of Fuel or 3000 Hours or 2 Years*
Cooling System (Engines Using Standard Type Antifreeze Only) Drain/Flush/Fill Cooling System (Engines Using LLCA Only) Add Extender

Every 32 250 L (8500 gal) of Fuel or 125 Hours*


Clutch Check/Adjust Clutch Bearing Lubricate

Every 1 032 000 L (272 000 gal) of Fuel or 4000 Hours*


Air Compressor (if equipped) Inspect/Rebuild or Exchange if necessary Electric Starter Inspect/Rebuild or Exchange if necessary * First perform previous service hour items.

Every 64 500 L (17 000 gal) of Fuel or 250 Hours*


Scheduled Oil Sampling Analysis (SOS)** Obtain Engine Oil and Filters** Replace Cooling System (Engines Using Standard Type Antifreeze Only) Add conditioner Batteries Clean/Inspect/Check electrolyte level Alternator Belts Inspect/Check/Adjust Fuel Tank Drain water and sediment Initial Valve Lash/Bridge, and Injector Timing Check/Adjust (at first oil change only)

** For larger optional sump capacity of 400 L (106 gal), these items occur at 500 hours. For larger optional sump capacity of 830 L (219 gal), these items occur at 1000 hours. Refer to the Operation and Maintenance Manual for the correct oil change interval for your specific engine.

30

MARINE ENGINE MAINTENANCE SCHEDULES

3516/3516B Marine Engines (rated 1601 to 1800 rpm) continued


Every 1 548 000 L (408 000 gal) of Fuel or 6000 Hours*
Cooling System Drain/Flush/Fill Thermostats Replace Turbochargers Inspect/Rebuild or Exchange if necessary Water Pump Inspect/Rebuild or Exchange if necessary Sea Water Pump Inspect/Rebuild or Exchange if necessary Air Starter (if equipped) Inspect/Rebuild or Exchange if necessary Alternator Inspect/Rebuild or Exchange if necessary Oil Pumps Inspect/Rebuild or Exchange if necessary Piston Rings Install New Main Bearings Install New Rod Bearings Install New Crankshaft Seals Install New Crankshaft Inspect Camshaft Inspect Cam Bearings Inspect Damper Inspect Fuel System Linkage (if equipped) Inspect Gear Train Inspect Gear Train Bushings/Bearings Inspect Thrust Washers Inspect Driven Unit Alignment Inspect Oil Cooler Clean/Test Aftercooler Core Clean/Test Coolant Analysis Obtain PAR Analysis Obtain after Overhaul * First perform previous service hour items.

Top End Every 1 942 000 L (512 500 gal) of Fuel or 7500 Hours*
Cylinder Head Assembly Rebuild or Exchange Injectors Replace PAR Analysis Obtain after Top End

OVERHAUL Every 3 884 000 L (1 025 000 gal) of Fuel or 15 000 Hours*
All Top End Items Connecting Rods Inspect/Rebuild or Exchange if necessary Cylinder Liners Inspect/Rebuild or Exchange if necessary Pistons Inspect/Rebuild or Exchange if necessary Piston Wrist Pins Inspect/Exchange if necessary Spacer Plate Inspect/Exchange if necessary Cam Follower Lifters Inspect/Exchange if necessary Fuel Transfer Pump Inspect/Rebuild or Exchange if necessary Prelube Pump (if equipped) Inspect/Rebuild or Exchange if necessary Mechanical Governor (if equipped) Inspect/Rebuild or Exchange if necessary Mechanical Fuel Ratio Control (if equipped) Inspect/Rebuild or Exchange if necessary

31

MARINE ENGINE MAINTENANCE SCHEDULES

3606 Marine Engines (all rated rpms)


Use fuel consumption, service hours, or time interval, whichever occurs first.

Every 568 000 L (150 000 gal) of Fuel or 2000 Hours*


Valve Lash, Injector Timing, Valve Bridge, and Injector Synchronization Check/Adjust

Daily
Walk-Around Inspection Inspect engine for leaks and loose connections Engine Oil, Engine Coolant, Marine Gear Oil***, Air Starter Lubricator Oil, Air Prelube Pump Lubricator Oil, and Woodward EGB29P Actuator Oil (if equipped) Check level Air Filter Differential Pressure, Oil Filter Differential Pressure, Fuel Filter Differential Pressure, and Driven Equipment Check Air Tank Drain water and sediment Fuel Tank (Day Tank if equipped) Drain water and sediment

Every 853 000 L (225 000 gal) of Fuel or 3000 Hours


Cooling System Clean/Flush

Every 1 705 000 L (450 000 gal) of Fuel or 6000 Hours or Yearly*
Water Temperature Regulators Replace Oil Temperature Regulators Replace PAR Analysis Obtain

Every 14 200 L (3700 gal) of Fuel or 50 Hours*


Zinc Rods Inspect/Replace

Every 2 130 000 L (562 500 gal) of Fuel or 7500 Hours or Yearly*
Sea Water Pump Rebuild or Exchange Water Pump Seals, Fuel Transfer Pump Seals, Crankshaft Seals, Prelube Pump Brushes, Exhaust Shield, and Damper for Leakage Inspect/Replace Woodward EGB29P Actuator Oil (if equipped) Replace Woodward EGB29P Actuator Operation (if equipped) Check for proper operation (reference SEBD9122)

Every 71 000 L (18 750 gal) of Fuel or 250 Hours*


Scheduled Oil Sampling Analysis (SOS)** Obtain Cooling System Test/Add supplemental coolant additive (conditioner) if necessary

Every 284 000 L (75 000 gal) of Fuel or 1000 Hours*


Valve Lash, Injector Timing, Valve Bridge, and Injector Synchronization (at initial 1000 hours only), Shutoff Controls and Alarms, 3161 Governor Oil Level (if equipped), Centrifugal Oil Filter Bearing, Exhaust System Leaks, and Air Filter Restriction Inspect/Check Oil Filters, Fuel Filters, Marine Gear Oil and Filter Replace Crankcase Breather System Clean Centrifugal Oil Filters Clean Manual Barring Device Lubricate Electric Prelube Pump (if equipped) Lubricate Fuel Control Linkage Lubricate Fuel Sample Obtain Coolant Sample Obtain Primary Fuel Filters Drain water Flywheel Ring Gear Lubricate with MPGM

TOP END OVERHAUL 5 500 000 L (1 500 000 gal) of Fuel or 20 000 Hours
Remanufacture or Rebuild: Cylinder Heads, Unit Injectors, Cylinder Head Intake and Exhaust Inserts, Cylinder Head Inner and Outer Valve Springs, Cylinder Head Valve Spring Guides, Cylinder Head Valve Locks, Cylinder Head Valve Rotocoils, Cylinder Head Intake Valves, Cylinder Head Exhaust Valves, Cylinder Head Dowels, Grind Valves and Seats (if not replaced), and Lap Valves and Seats (for full face contact)

32

MARINE ENGINE MAINTENANCE SCHEDULES

3606 Marine Engines (all rated rpms) continued


Replace: Cylinder Head Gaskets, Seals, O-Ring Seals and Plugs, Turbocharger Bearings, Bushings and Seals, Oil Pump Bushings and Seals, Fuel Transfer Pump Seals, Oil Cooler Seals and Regulators, Water Temperature Regulators and Seals, Oil Temperature Regulators and Seals, Exhaust Manifold Gaskets, Thermocouples (if equipped), Water Pump Bearing and Seals, Exhaust Shields, and Valve Lubricator Pump Clean and Inspect: Oil Cooler Core Inspect/Replace: Starter Brushes, Thrust Bearings (except crankshaft), Water Pump Idler Gear Bearings, and Camshaft Idler Gear Bearings Inspect/Replace: Pistons, Piston Rods, Cylinder Liners, Crankshaft, Camshafts, Valve Mechanism Group, Front Gear Group, Rear Gear Group, Exhaust Manifolds, Shutoff Controls and Alarms, and Priority Valve Replace Gaskets and Seals: Crankcase Side Cover Group, Central Structure Cover Group, Camshaft Front Cover Group, Camshaft Drive Gear Cover Group, Front Housing Group, Gear Inspection Group, Rear Housing Group, Rear Structure Cover Group, Power Take-Off Cover Group, Priority Valve Group, Crankshaft, Valve Mechanism Cover Group, Oil Lines, All Water Lines, Oil Cooler, and Vibration Damper and Fuel Lines * First perform previous service hour items.

OVERHAUL Every 11 000 000 L (3 000 000 gal) of Fuel or 40 000 Hours
Rebuild: Vibration Damper Bearings and Fluid, Centrifugal Filter Bearings, Starters, Cylinder Head and Woodward Actuator Replace: Piston Rings, Connecting Rod Bearings, Main Bearings, Camshaft Bearings, Rocker Arm Bearings, Injectors, Aftercooler Core, Accessory Group Bearings, Front and Rear Gear Train Bearings, Cylinder Head Valves and Valve Guides, Exhaust Manifold Seals and Bellows, Exhaust Shields, Intake Air Lines Seals, Inlet and Outlet Water Temperature Regulators and Seals, Oil Temperature Regulators and Seals, Fuel Rack Bearings, 3161 Governor, and Cylinder Head Valve Spring Guides Clean and Inspect: Oil Cooler Clean: Lube Oil Suction Screen

** Scheduled Oil Sampling or Oil Analysis (including infrared analysis) should be the determining factor for oil change intervals. *** See specifications of marine gear manufacturer for other maintenance.

33

MARINE ENGINE MAINTENANCE SCHEDULES

3608 Marine Engines (all rated rpms)


Use fuel consumption, service hours, or time interval, whichever occurs first.

Every 750 000 L (200 000 gal) of Fuel or 2000 Hours*


Valve Lash, Injector Timing, Valve Bridge, and Injector Synchronization Check/Adjust

Daily
Walk-Around Inspection Inspect engine for leaks and loose connections Engine Oil, Engine Coolant, Marine Gear Oiling*** Air Starter Lubricator Oil, Air Prelube Pump Lubricator Oil, and Woodward EGB29P Actuator Oil (if equipped) Check level Air Filter Differential Pressure, Oil Filter Differential Pressure, Fuel Filter Differential Pressure, and Driven Equipment Check Air Tank Drain water and sediment Fuel Tank (Day Tank if equipped) Drain water and sediment

Every 1 137 000 L (300 000 gal) of Fuel or 3000 Hours*


Cooling System Clean/Flush

Every 2 274 000 L (600 000 gal) of Fuel or 6000 Hours or Yearly*
Water Temperature Regulators Replace Oil Temperature Regulators Replace PAR Analysis Obtain

Every 38 000 L (10 000 gal) of Fuel or 50 Hours*


Zinc Rods Inspect/Replace

Every 2 800 000 L (750 000 gal) of Fuel or 7500 Hours or Yearly*
Sea Water Pump Rebuild or Exchange Water Pump Seals, Fuel Transfer Pump Seals, Crankshaft Seals, Prelube Pump Brushes, Exhaust Shield, and Damper for Leakage Inspect/Replace Woodward EGB29P Actuator Oil (if equipped) Replace Woodward EGB29P Actuator Operation (if equipped) Check for proper operation (reference SEBD9122)

Every 94 000 L (25 000 gal) of Fuel or 250 Hours*


Scheduled Oil Sampling Analysis (SOS)** Obtain Cooling System Test/Add supplemental coolant additive (conditioner) if necessary

Every 375 000 L (100 000 gal) of Fuel or 1000 Hours*


Valve Lash, Injector Timing, Valve Bridge, and Injector Synchronization (at initial 1000 hours only), Shutoff Controls and Alarms, 3161 Governor Oil Level (if equipped), Centrifugal Oil Filter Bearing, Exhaust System Leaks, and Air Filter Restriction Inspect/Check Oil Filters, Fuel Filters, Marine Gear Replace Crankcase Breather System Clean Centrifugal Oil Filters Clean Manual Barring Device Lubricate Electric Prelube Pump (if equipped) Lubricate Fuel Control Linkage Lubricate Fuel Sample Obtain Coolant Sample Obtain Primary Fuel Filters Drain water Flywheel Ring Gear Lubricate with MPGM

TOP END OVERHAUL 7 500 000 L (2 000 000 gal) of Fuel or 20 000 Hours
Remanufacture or Rebuild: Cylinder Heads, Unit Injectors, Cylinder Head Intake and Exhaust Inserts, Cylinder Head Inner and Outer Valve Springs, Cylinder Head Valve Spring Guides, Cylinder Head Valve Locks, Cylinder Head Valve Rotocoils, Cylinder Head Intake Valves, Cylinder Head Exhaust Valves, Cylinder Head Dowels, Grind Valves and Seats (if not replaced), and Lap Valves and Seats (for full face contact)

34

MARINE ENGINE MAINTENANCE SCHEDULES

3608 Marine Engines (all rated rpms) continued


Replace: Cylinder Head Gaskets, Seals, O-Ring Seals and Plugs, Turbocharger Bearings, Bushings and Seals, Oil Pump Bushings and Seals, Fuel Transfer Pump Seals, Oil Cooler Seals and Regulators, Water Temperature Regulators and Seals, Oil Temperature Regulators and Seals, Exhaust Manifold Gaskets, Thermocouples (if equipped), Water Pump Bearing and Seals, Exhaust Shields, and Valve Lubricator Pump Clean and Inspect: Oil Cooler Core Inspect/Replace: Starter Brushes, Thrust Bearings (except Crankshaft), Water Pump Idler Gear Bearings, and Camshaft Idler Gear Bearings Inspect/Replace: Pistons, Piston Rods, Cylinder Liners, Crankshaft, Camshafts, Valve Mechanism Group, Front Gear Group, Rear Gear Group, Exhaust Manifolds, Shutoff Controls and Alarms, and Priority Valve Replace Gaskets and Seals: Crankcase Side Cover Group, Central Structure Cover Group, Camshaft Front Cover Group, Camshaft Drive Gear Cover Group, Front Housing Group, Gear Inspection Group, Rear Housing Group, Rear Structure Cover Group, Power TakeOff Cover Group, Priority Valve Group, Crankshaft, Valve Mechanism Cover Group, Oil Lines, All Water Lines, Oil Cooler, and Vibration Damper and Fuel Lines * First perform previous service hour items.

OVERHAUL Every 15 000 000 L (4 000 000 gal) of Fuel or 40 000 Hours
Rebuild: Vibration Damper Bearings and Fluid, Centrifugal Filter Bearings, Starters, Cylinder Head, and Woodward Actuator Replace: Piston Rings, Connecting Rod Bearings, Main Bearings, Camshaft Bearings, Rocker Arm Bearings, Injectors, Aftercooler Core, Accessory Group Bearings, Front and Rear Gear Train Bearings, Cylinder Head Valves and Valve Guides, Exhaust Manifold Seals and Bellows, Exhaust Shields, Intake Air Lines Seals, Inlet and Outlet Water Temperature Regulators and Seals, Oil Temperature Regulators and Seals, Fuel Rack Bearings, 3161 Governor, and Cylinder Head Valve Spring Guides Clean and Inspect: Oil Cooler Clean: Lube Oil Suction Screen

** Scheduled Oil Sampling or Oil Analysis (including infrared analysis) should be the determining factor for oil change intervals. *** See specifications of marine gear manufacturer for other maintenance.

35

MARINE ENGINE MAINTENANCE SCHEDULES

3612 Marine Engines (all rated rpms)


Use fuel consumption, service hours, or time interval, whichever occurs first.

Every 1 136 000 L (300 000 gal) of Fuel or 2000 Hours*


Valve Lash, Injector Timing, Valve Bridge, and Injector Synchronization Check/Adjust

Daily
Walk-Around Inspection Inspect engine for leaks and loose connections Engine Oil, Engine Coolant, Marine Gear Oil***, Air Starter Lubricator Oil, Air Prelube Pump Lubricator Oil and Woodward EGB29P Actuator Oil (if equipped) Check level Air Filter Differential Pressure, Oil Filter Differential Pressure, Fuel Filter Differential Pressure, and Driven Equipment Check Air Tank Drain water and sediment Fuel Tank (Day Tank if equipped) Drain water and sediment

Every 1 705 500 L (450 000 gal) of Fuel or 3000 Hours*


Cooling System Clean/Flush

Every 3 411 000 L (900 000 gal) of Fuel or 6000 Hours or Yearly
Water Temperature Regulators Replace Oil Temperature Regulators Replace PAR Analysis Obtain

Every 28 400 L (7500 gal) of Fuel or 50 Hours*


Zinc Rods Inspect/Replace

Every 4 260 000 L (1 125 000 gal) of Fuel or 7500 Hours or Yearly
Sea Water Pump Rebuild or Exchange Water Pump Seals, Fuel Transfer Pump Seals, Crankshaft Seals, Prelube Pump Brushes, Exhaust Shield, and Damper for Leakage Inspect/Replace Woodward EGB29P Actuator Oil (if equipped) Replace Woodward EGB29P Actuator Operation (if equipped) Check for proper operation (reference SEBD9122)

Every 142 000 L (37 500 gal) of Fuel or 250 Hours*


Scheduled Oil Sampling Analysis (SOS)** Obtain Cooling System Test/Add supplemental coolant additive (conditioner) if necessary

Every 568 000 L (150 000 gal) of Fuel or 1000 Hours*


Valve Lash, Injector Timing, Valve Bridge, and Injector Synchronization (at initial 1000 hours only), Shutoff Controls and Alarms, 3161 Governor Oil Level (if equipped), Centrifugal Oil Filter Bearing, Exhaust System Leaks, and Air Filter Restriction Inspect/Check Oil Filters, Fuel Filters, Marine Gear Oil and Filter Replace Crankcase Breather System Clean Centrifugal Oil Filters Clean Manual Barring Device Lubricate Electric Prelube Pump (if equipped) Lubricate Fuel Control Linkage Lubricate Fuel Sample Obtain Coolant Sample Obtain Primary Fuel Filters Drain water Flywheel Ring Gear Lubricate with MPGM

TOP END OVERHAUL 11 000 000 L (3 000 000 gal) of Fuel or 20 000 Hours
Remanufacture or Rebuild: Cylinder Heads, Unit Injectors, Cylinder Head Intake and Exhaust Inserts, Cylinder Head Inner and Outer Valve Springs, Cylinder Head Valve Spring Guides, Cylinder Head Valve Locks, Cylinder Head Valve Rotocoils, Cylinder Head Intake Valves, Cylinder Head Exhaust Valves, Cylinder Head Dowels, Grind Valves and Seats (if not replaced), and Lap Valves and Seats (for full face contact)

36

MARINE ENGINE MAINTENANCE SCHEDULES

3612 Marine Engines (all rated rpms) continued


Replace: Cylinder Head Gaskets, Seals, O-Ring Seals and Plugs, Turbocharger Bearings, Bushings and Seals, Oil Pump Bushings and Seals, Fuel Transfer Pump Seals, Oil Cooler Seals and Regulators, Water Temperature Regulators and Seals, Oil Temperature Regulators and Seals, Exhaust Manifold Gaskets, Thermocouples (if equipped), Water Pump Bearing and Seals, Exhaust Shields, and Valve Lubricator Pump Clean and Inspect: Oil Cooler Core Inspect/Replace: Starter Brushes, Thrust Bearings (except Crankshaft), Water Pump Idler Gear Bearings, and Camshaft Idler Gear Bearings Inspect/Replace: Pistons, Piston Rods, Cylinder Liners, Crankshaft, Camshafts, Valve Mechanism Group, Front Gear Group, Rear Gear Group, Exhaust Manifolds, Shutoff Controls and Alarms, and Priority Valve Replace Gaskets and Seals: Crankcase Side Cover Group, Central Structure Cover Group, Camshaft Front Cover Group, Camshaft Drive Gear Cover Group, Front Housing Group, Gear Inspection Group, Rear Housing Group, Rear Structure Cover Group, Power Take-Off Cover Group, Priority Valve Group, Crankshaft, Valve Mechanism Cover Group, Oil Lines, All Water Lines, Oil Cooler, and Vibration Damper and Fuel Lines * First perform previous service hour items.

OVERHAUL Every 23 000 000 L (6 000 000 gal) of Fuel or 40 000 Hours
Rebuild: Vibration Damper Bearings and Fluid, Centrifugal Filter Bearings, Starters, Cylinder Head, and Woodward Actuator Replace: Piston Rings, Connecting Rod Bearings, Main Bearings, Camshaft Bearings, Rocker Arm Bearings, Injectors, Aftercooler Core, Accessory Group Bearings, Front and Rear Gear Train Bearings, Cylinder Head Valves and Valve Guides, Exhaust Manifold Seals and Bellows, Exhaust Shields, Intake Air Lines Seals, Inlet and Outlet Water Temperature Regulators and Seals, Oil Temperature Regulators and Seals, Fuel Rack Bearings, 3161 Governor, and Cylinder Head Valve Spring Guides Clean and Inspect: Oil Cooler Clean: Lube Oil Suction Screen

** Scheduled Oil Sampling or Oil Analysis (including infrared analysis) should be the determining factor for oil change intervals. *** See specifications of marine gear manufacturer for other maintenance.

37

MARINE ENGINE MAINTENANCE SCHEDULES

3616 Marine Engines (all rated rpms)


Use fuel consumption, service hours, or time interval, whichever occurs first.

Every 1 520 000 L (400 000 gal) of Fuel or 2000 Hours*


Valve Lash, Injector Timing, Valve Bridge, and Injector Synchronization Check/Adjust

Daily
Walk-Around Inspection Inspect engine for leaks and loose connections Engine Oil, Engine Coolant, Marine Gear Oil***, Air Starter Lubricator Oil, Air Prelube Pump Lubricator Oil, and Woodward EGB29P Actuator Oil (if equipped) Check level Air Filter Differential Pressure, Oil Filter Differential Pressure, Fuel Filter Differential Pressure, and Driven Equipment Check Air Tank Drain water and sediment Fuel Tank (Day Tank if equipped) Drain water and sediment

Every 2 274 000 L (400 000 gal) of Fuel or 3000 Hours*


Cooling System Clean/Flush

Every 4 548 000 L (1 200 000 gal) of Fuel or 6000 Hours or Yearly*
Water Temperature Regulators Replace Oil Temperature Regulators Replace PAR Analysis Obtain

Every 37 900 L (10 000 gal) of Fuel or 50 Hours*


Zinc Rods Inspect/Replace

Every 5 700 000 L (1 500 000 gal) of Fuel or 7500 Hours or Yearly*
Sea Water Pump Rebuild or Exchange Water Pump Seals, Fuel Transfer Pump Seals, Crankshaft Seals, Prelube Pump Brushes, Exhaust Shield, and Damper for Leakage Inspect/Replace Woodward EGB29P Actuator Oil (if equipped) Replace Woodward EGB29P Actuator Operation (if equipped) Check for proper operation (reference SEBD9122)

Every 190 000 L (50 000 gal) of Fuel or 250 Hours*


Scheduled Oil Sampling Analysis (SOS)** Obtain Cooling System Test/Add supplemental coolant additive (conditioner) if necessary

Every 760 000 L (200 000 gal) of Fuel or 1000 Hours*


Valve Lash, Injector Timing, Valve Bridge, and Injector Synchronization (at Initial 1000 Hours Only), Shutoff Controls and Alarms, 3161 Governor Oil Level (if equipped), Centrifugal Oil Filter Bearing, Exhaust System Leaks, and Air Filter Restriction Inspect/Check Oil Filters, Fuel Filters, Marine Gear Oil and Filter Replace Crankcase Breather System Clean Centrifugal Oil Filters Clean Manual Barring Device Lubricate Electric Prelube Pump (if equipped) Lubricate Fuel Control Linkage Lubricate Fuel Sample Obtain Coolant Sample Obtain Primary Fuel Filters Drain water Flywheel Ring Gear Lubricate with MPGM

TOP END OVERHAUL 15 000 000 L (4 000 000 gal) of Fuel or 20 000 Hours
Remanufacture or Rebuild: Cylinder Heads, Unit Injectors, Cylinder Head Intake and Exhaust Inserts, Cylinder Head Inner and Outer Valve Springs, Cylinder Head Valve Spring Guides, Cylinder Head Valve Locks, Cylinder Head Valve Rotocoils, Cylinder Head Intake Valves, Cylinder Head Exhaust Valves, Cylinder Head Dowels, Grind Valves and Seats (if not replaced), and Lap Valves and Seats (for full face contact)

38

MARINE ENGINE MAINTENANCE SCHEDULES

3616 Marine Engines (all rated rpms) continued


Replace: Cylinder Head Gaskets, Seals, O-Ring Seals and Plugs, Turbocharger Bearings, Bushings and Seals, Oil Pump Bushings and Seals, Fuel Transfer Pump Seals, Oil Cooler Seals and Regulators, Water Temperature Regulators and Seals, Oil Temperature Regulators and Seals, Exhaust Manifold Gaskets, Thermocouples (if equipped), Water Pump Bearing and Seals, Exhaust Shields, and Valve Lubricator Pump Clean and Inspect: Oil Cooler Core Inspect/Replace: Starter Brushes, Thrust Bearings (except crankshaft), Water Pump Idler Gear Bearings, and Camshaft Idler Gear Bearings Inspect/Replace: Pistons, Piston Rods, Cylinder Liners, Crankshaft, Camshafts, Valve Mechanism Group, Front Gear Group, Rear Gear Group, Exhaust Manifolds, Shutoff Controls and Alarms, and Priority Valve Replace Gaskets and Seals: Crankcase Side Cover Group, Central Structure Cover Group, Camshaft Front Cover Group, Camshaft Drive Gear Cover Group, Front Housing Group, Gear Inspection Group, Rear Housing Group, Rear Structure Cover Group, Power Take-Off Cover Group, Priority Valve Group, Crankshaft, Valve Mechanism Cover Group, Oil Lines, All Water Lines, Oil Cooler, and Vibration Damper and Fuel Lines * First perform previous service hour items.

OVERHAUL Every 30 000 000 L (8 000 000 gal) of Fuel or 40 000 Hours
Rebuild: Vibration Damper Bearings and Fluid, Centrifugal Filter Bearings, Starters, Cylinder Head, and Woodward Actuator Replace: Piston Rings, Connecting Rod Bearings, Main Bearings, Camshaft Bearings, Rocker Arm Bearings, Injectors, Aftercooler Core, Accessory Group Bearings, Front and Rear Gear Train Bearings, Cylinder Head Valves and Valve Guides, Exhaust Manifold Seals and Bellows, Exhaust Shields, Intake Air Lines Seals, Inlet and Outlet Water Temperature Regulators and Seals, Oil Temperature Regulators and Seals, Fuel Rack Bearings, 3161 Governor, and Cylinder Head Valve Spring Guides Clean and Inspect: Oil Cooler Clean: Lube Oil Suction Screen

** Scheduled Oil Sampling or Oil Analysis (including infrared analysis) should be the determining factor for oil change intervals. *** See specifications of marine gear manufacturer for other maintenance.

39

LEXM6231-01 1996 Caterpillar Inc.

Printed in U.S.A. All rights reserved.

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