When a marine engine suffers a catastrophic failure, every second counts. Performance Power Systems was contacted by a commercial client dependent on reliable engines to power their vessel. We immediately moved to replacing the failed engine and improving their power system by installing two new Leroy-Somer generator ends.

Assessing the Damage and Planning the Repair

Upon arrival, our technicians confirmed the extent of the damage. The thrown rod had caused irreparable damage to the engine block, making a complete long block replacement the best course of action. We immediately sourced a replacement and began the meticulous process of transferring usable components from the damaged engine. The unique challenge in this case was the need for a quick turnaround due to the vessel’s daily operations, which required us to work efficiently without compromising on quality.

The team’s commitment to preventing future issues was evident in our repair process. We meticulously removed, cleaned, and pressure-tested components, including the charge air cooler, oil cooler assembly, and fuel system parts. Some areas required extensive work to restore functionality, such as rebuilding the oil filter base assembly with a new spring, plunger, and gaskets. The technician also ensured the mounting surfaces were properly prepped for sealing to prevent any future leaks. We left no stone unturned in our repair process, ensuring the vehicle’s future performance and safety.

Executing the Long Block Replacement

With the replacement long block ready, our technicians executed a detailed swap, which included:

  • Removing and reinstalling major external components, including injectors, turbochargers, exhaust manifolds, and the aftercooler system.
  • Torque specifications were adhered to throughout the assembly, ensuring proper fit and longevity.
  • Installing a new oil pump, oil pan, and front gear housing and replacing damaged hardware.
  • Finalizing the installation of new seals, gaskets, and filters to optimize engine performance and reduce the risk of leaks.

One of the biggest challenges was the extensive corrosion in the cooling system piping and turbocharger components. The technician cleaned, resurfaced, or replaced parts to ensure optimal cooling and airflow.

Upgrading the Power System with New Generator Ends

In addition to the engine repair, the vessel’s power generation system required an upgrade. The existing gensets were fitted with new Leroy-Somer generator ends, which are known for their reliability and efficiency. This upgrade not only improved the vessel’s power generation capabilities but also ensured that auxiliary power demands, including lighting, HVAC, and onboard electronics, remained stable and uninterrupted during operations.

Final Checks and Sea Trial

Once we completed all repairs, our team conducted final torque checks, system inspections, and an end-play verification to confirm proper installation. The engine was tested for leaks, oil pressure stability, and smooth operation under load. The vessel’s crew then performed their final system connections, including the CCV system, oil drain piping, keel cooler, and expansion tank connections.

During a successful sea trial, the team confirmed that the CAT 3408 performed at peak operating condition, and the vessel could return to service, a testament to the reliability and effectiveness of our repair process.

Why Choose Performance Power Systems for Emergency Marine Repairs?

Having an experienced and responsive team makes all the difference when critical failures occur. At Performance Power Systems, we specialize in:

✔️ Emergency marine diesel repairs with quick turnaround times

✔️ Engine rebuilds, repowers, and component overhauls

✔️ Generator and auxiliary power upgrades

✔️ On-site and international service availability

With this CAT 3408 rebuild and generator replacement project, we again proved why vessel operators trust us to keep their fleets running strong. If you need expert marine diesel service, contact us today! Contact Performance Power Systems to schedule your engine maintenance. Please don’t wait until it’s too late; ensure your vessel’s power and reliability today.

Contact us!
email: info@performancepowersystems.com

Performance Power Systems
105 D Owens Industrial Drive, Suite D
Savannah, GA 31405
(912) 232-0300
Performance Power Systems of Florida
3241 SE Slater Street
Stuart, FL 34997
(772) 600-7359
Performance Power Systems of Florida
2200 NW 32nd Street
Pompano Beach, FL 33069
(561) 366-5643