Cover of Marine Diesel Basics 1
  • 300+ illustrations
  • 222 pages
  • Maintenance – how and why to service all parts of diesel system
  • Lay-up – how to "winterize" direct & indirect cooled engines, and prepare for tropical storage (heat & humidity)
  • Recommission - everything to do to get the system going again
  • available in paperback
  • available in ebook format

Download the full Table of Contents

Table of Contents – Marine Diesel Basics 1

Introduction viii
What is the Value of this Book? viii
Disclaimer viii
From the Author viii
Words – Canadian, American, Australian & British Equivalents ix

Maintenance 1

Value of the Maintenance Log 1

1  Maintenance – Engine Essentials 2

Main Concerns 2
Task List 2
1  Visual Engine Room Inspection 3
2  Check Engine Oil Level 4
3  Check Belt Tension 4
4  Check Coolant/Antifreeze & Top Up as Needed 6
5  Check Transmission Fluid Level 7
6  Inspect Hoses and Hose Clamps 7
7  Fit & Inspect Chafe Protection 8
8  Inspect Wires and Wiring Terminals 9
9  Inspect Belts – Alternator, Coolant & Raw Water Pump 11
10  Inspect Pulleys (Sheaves) 12
11  Check Alignment of Belts & Pulleys 13
12  Adjust Pulley Alignment 15
13  Tighten Alternator and Water Pump Belts 16
14  Inspect & Repair Sound Insulation 17
15  Start Engine 17
Cautionary Tale 18

2  Maintenance – Diesel Fuel 19

Main Concerns 19
Task List 19
Importance of Scrupulously Clean Fuel 19
Three Ways to Contaminate Diesel Fuel & Tanks 20
Preventing Fuel Contamination 21
1  Inspect Fuel Deck Fill 21
2  Add Biocide to the Fuel Tank(s) 22
Diesel Fuel Primary Fuel Filter 23
How Small is Small? 23
3  Change the Primary Fuel Filter 24
4  Change the Secondary Fuel Filter 26
5  Bleed the Diesel System 29
6  Check Diesel Tank(s) for Contamination 33
7  Inspect Injection Pump and Injectors 34
Cautionary Tale 35

3  Maintenance – Lubrication 36

Main Concerns 36
Task List 36
1  Check Engine Oil Level 37
2  Dipstick Diagnostics – Engine Oil 38
3  Check Transmission Fluid 41
4  Dipstick Diagnostics – Transmission Fluid 41
5  Change the Engine Oil & Filter 45
6  Change the Transmission Fluid (Engine Oil) 52
7  Grease the Control Cable Ends and Engine Mount Threads 54
8  Lubricate Ignition Key Slot 55
9  Check Injection Pump & Governor Dipsticks 55
Cautionary Tale 56

4  Maintenance – Raw Water Cooling 57

Main Concerns 57
Task List 57
Indirect Cooling (Fresh Water Cooled) 58
Direct Cooling 59
Keel Cooling 60
1  Clean Thruhull of Anti-Foul Paint and Marine Growth 61
2  Check Emergency Plug Tied to Every Seacock 61
3  Check Seacock Opens/Closes Smoothly 62
4  Inspect Raw Water Strainer 62
5  Service Raw Water Pump & Impeller 63
6  Check and Change Heat Exchanger Anode(s) 68
7  Flush and Clean the Syphon Break 70
Cautionary Tale 71

5  Maintenance – Coolant/Antifreeze 72

Task List 72
Ethylene Glycol Coolant/Antifreeze 72
1  Check Coolant/Antifreeze Level in Header Tank or Overflow Bottle 73
2  Inspect Condition of Coolant 74
3  Drain and Replace Worn-out Coolant/Antifreeze 74
Cautionary Tale 76

6  Maintenance – Breathing 77

Main Concerns 77
Task List 77
Why Clean the Air Filter? 77
1  Clean the Air Filter 78
2  Check Adequate Air Flow Through Engine Room 80
3  Inspect & Repair Sound Insulation 81
Cautionary Tale 81

7  Maintenance – Electrical 82

Main Concerns 82
Task List 82
Sulphation 82
1  Keep Battery(s) Charged 83
2  Check Battery Open Circuit Voltage with a Multimeter 84
3  Keep Battery Terminal Connections Tight 84
4  Clean Battery Tops & Terminals 85
5  Check Electrolyte Levels in Wet-Cell Batteries 87
6  Add Water to Unsealed Wet-Cell Battery 89
7  Check Specific Gravity of a Wet-Cell Battery 90
8  Load Testing a 12 Volt Battery 92
Cautionary Tale 94

8  Maintenance – Drive Train 95

Main Concerns 95
Task List 95
1  Check Coupling Between Transmission & Prop Shaft 95
2  Inspect the Propeller Shaft 97
3  Inspect the Stern Gland (Stuffing Box) 98
4  Inspect the Strut 101
5  Inspect the Cutlass Bearing 102
6  Inspect the Propeller Anode 103
7  Clean the Propeller, Strut & Shaft 103
8  Inspect the Propeller 104
9  Inspect the Propeller Nuts and Cotter Pin 104
10  Inspect a Folding Propeller 105
11  Inspect the Anode on a Feathering Propeller 105
12  Grease a Feathering Propeller 105
Cautionary Tale 107

9  Saildrives Maintenance, Lay-Up & Recommission 108

Main Concerns 108

Maintenance Task List 108

Servicing a Saildrive 108
1  Check Gear Oil Level & Top Up 109
2  Change the Saildrive Gear Oil 109
3  Burp Air from Saildrive Gear Oil Dipstick 112
4  Inspect Exterior Rubber Fairing Flange 113
5  Inspect Interior Rubber Sealing Ring & Water Sensor Alarm 114
6  Inspect Saildrive Anodes 115
7  Inspect and Repair Paint Protection 116
8  Clean Raw Water Intakes 116
9  Inspect the Propeller 117
10  Grease a Feathering Propeller 117

Lay-up Task List 117

1 – 9 Lay-up Tasks 117
10  Drain Raw Water from Saildrive 117
11  (In Water) Protect Lower Unit from Marine Growth 118

Recommission Task List 119

1  Check Level of Gear Oil 119
2  Inspect Interior Rubber Sealing Ring & Water Sensor Alarm 119
3  Inspect Exterior Rubber Fairing Flange 119
4  Inspect and repair paint protection 119
5  Remove Covering from Propeller and Shaft 120
6  Inspect Saildrive Anodes 120
7  Inspect and repair paint protection 120
8  Clean Raw Water Intake 120
Main Concerns 121

Lay-Up – Winter Protection & Tropical Storage 121

10  Lay-Up – Engine Essentials 122

Main Concerns 122
Task List 122
1  Change Engine Oil & Filter 122
2  Change Transmission Fluid 122
3  Slacken Tension off Belts 123
4  Clean the Bilge 124
5  Wipe Down the Engine 125
6  Protect Engine Mounts 125
7  Write Up Good Notes in Maintenance Log 125

11  Lay-Up – Diesel Fuel 126

Main Concerns 126
Task List 126
1  Add Biocide to Last Fuel Fill 126
2  Check Deck Fill Fuel Cap is Closed 126
3  Change Primary Fuel Filter 126
4  Bleed Fuel System 127
5  Close All Fuel Valves – Supply & Return 127
6  Check Fuel Vent Cannot Back Flood 127

12  Lay-Up – Lubrication 128

Main Concerns 128
Task List 128
1  Change Engine Oil & Filter 128
2  Change Transmission Fluid 128
3  Grease Control Cable Ends & Engine Mount Threads 128
4  Lubricate Ignition Key Slot 128
5  Check Injection Pump & Governor Dipsticks (if fitted) 128
6  Fill the Transmission with ATF (or Engine Oil) 128

13  Lay-Up – Raw Water Cooling 129

Main Concerns 129
Laying-up the Raw Water Cooling Circuit 129
Indirect Cooling Task List 130
Direct Cooling Task List 131
1  Inspect Hoses and Hose Clamps 131
2  Drain Raw Water from the Engine Block 131
3  Check and Change Engine Block Anode(s) 133
4  Remove the Engine Thermostat 134
5  Fill the Block with Propylene Glycol Antifreeze 135
6  Re-install the Engine Thermostat 136
7  Add Propylene Glycol Antifreeze to Header Tank 137
8  Add Propylene Glycol Antifreeze to Raw Water Circuit 137
9  Run Engine to Flush Raw Water Circuit 139
10  Drain Raw Water Hoses 139
11  Drain the Raw Water Strainer 140
12  Service Raw Water Pump & Impeller 140
13  Drain the Heat Exchanger(s) 141
14  Check Heat Exchanger Anode 142
15  Protect Raw Water Thruhull from Marine Growth 142
16  Service the Exhaust Riser 143
17  Clean the Raw Water Syphon Break 145
18  Drain the Water-lift Muffler 145
Cautionary Tale 146

14  Lay-Up – Coolant/Antifreeze 147

Main Concerns 147
Task List 147
1  Check Coolant Level in Header Tank or Overflow Bottle 147
2  Drain and Refill Coolant/Antifreeze 147
3  Test Frost Protection of Coolant/Antifreeze 147

15  Lay-Up – Breathing 149

Main Concerns 149
Task List 149
1  Clean Air Filter/Air Intake 149
2  Seal Air Intake with Plastic 149
3  Disconnect Exhaust Riser & Hose from Exhaust Manifold 150
4  Drain Water-lift Muffler 150
5  Prevent Rodents Entering via Exhaust Thruhull 151

16  Lay-Up – Electrical 152

Main Concerns 152
Task List 152
Battery Self Discharge 152
Freezing 153
1  Clean Battery Top and Terminals 153
2  Check Electrolyte Levels 153
3  Add Water to Unsealed Wet-Cell Battery 153
4  Charge Battery 153
5  Load Test a Questionable Battery 153
6  Trickle Charge Battery 154
7  Disconnect Terminals from Battery 154
Storage in Freezing or Cold Conditions 154

17  Lay-Up – Drive Train 155

Main Concerns 155
Task List 155
1  Check Coupling Between Transmission & Prop Shaft 155
2  Inspect the Propeller Shaft 155
3  Inspect the Stern Gland 156
4  Inspect the Strut 156
5  Inspect the Cutlass Bearing 156
6  Inspect the Propeller Shaft Anode 156
7  Clean the Propeller, Strut and Shaft 156
8  Inspect the Propeller 156
9  Inspect the Propeller Nuts & Cotter Pin 156
10  Inspect a Folding Propeller 156
11  Inspect the Anode of a Feathering Prop 156
12  Grease a Feathering Propeller 157
13  Lay-Up a Traditional Stuffing Box In Water 157
14  Protect the Propeller & Shaft from Marine Growth 158

Recommissioning 159

Main Concerns 159

18  Recommission – Engine Essentials 159

Main Concerns 159
Task List 159
1  Visual Engine Inspection 159
2  Check Hoses and Hose Clamps 159
3  Inspect Wires and Wiring Terminals 159
4  Check Pulley and Belt Alignment 159
5  Tighten Alternator and Water Pump Belts 159

19  Recommission – Diesel Fuel 160

Main Concerns 160
Task List 160
1  Check Diesel Tank(s) for Contamination 160
2  Open Fuel Valve(s) 160

20  Recommission – Lubrication 161

Main Concerns 161
Task List 161
1  Rotate Engine Without Starting 161
2  Drain Transmission Fluid to Maximum Level on Dipstick 162

21  Recommission – Raw Water Cooling 163

Main Concerns 163
Task List 163
1  Check Seacocks Open/Close Smoothly 163
2  Check the Raw Water Strainer 163
3  Check Engine and Heat Exchanger Anodes 164
4  Re-Install the Raw Water Pump Impeller & Face Plate 164
5  Open Raw Water Seacock for Engine  166
6  Remove Plugs from Exhaust & Raw Water Intake Thruhulls 166

22  Recommission – Coolant/Antifreeze 167

Main Concerns 167
Task List 167
1  Check Coolant Level in Header Tank or Overflow Bottle 167

23  Recommission – Breathing 168

Main Concerns 168
Task List 168
1  Open Engine Room Ventilators 168
2  Unseal Air Intake on Engine 168
3  Re-Connect Exhaust Riser and Hoses 169
4  Close Drain on Water-lift Muffler or Reconnect Hose 170
Cautionary Tale 170

24  Recommission – Electrical 171

Main Concerns 171
Task List 171
1  Check Exterior Condition of Battery – Signs of a Frozen Battery 171
2  Top-up Battery Water Levels (unsealed wet-cell only) 171
3  Charge Battery(s) 172
4  Load Test a 12 Volt Battery
5  Reconnect Battery Terminals (Lugs) 172

25  Recommission – Drive Train 173

Main Concerns 173
Task List 173
1  Check Control Cables are Securely Attached to Lever 173
2  Check Throttle Cable Movement 174
3  Check Transmission Control Cable 174
4  Check Stop Cable or Solenoid 175
5  Grease Rubber Cup on Dripless Shaft Seal 176
6  Hand Tighten & Lock Packing Gland on Traditional Stuffing Box 177
7  Check Hose(s) on Dripless Shaft Seal 177

26  Recommission – In Water 178

Main Concerns 178

Task List 178
1 Remove Wrap Around Propeller and Shaft 178
2  Prime Raw Water Strainer 179
3  Start Engine 180
4  Check Raw Water Being Expelled with Exhaust 180
5  Burp Raw Water Strainer to Release Trapped Air 181
6  Check Oil Pressure Is Normal 181
7  Check Alternator Is Charging 182
8  Check Seacocks, Raw Water Strainer & Exhaust for Leaks 182
9  Check Vessel Moves in Gear 183
10  Re-adjust Packing in Traditional Stuffing Box 184
11  Burp Air from Dripless Shaft Seal 185

Task Lists 187

Tools & Supplies Required 203

Acknowledgements 205

Marine Diesel Basics 206

Purpose of the Series 206

About the Author 207

Index 208

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