ENGINE REBUILD

SERVICE REPORT

Vessel Name : TB P III - 615

Engine Model : C-18 ( ME )
Engine AREA : PORTSIDE
Arrangement : 020/MNTC/OH/VII/2021
Scope of Work : General Overhaul (Inframe)
Job No. : 020

Pemberitahuan :
1. Pastikan seluruh data / keterangan dalam keadaan tercatat dan
didokumentasikan dalam foto. Apabila lembaran pada Laporan ini
tidak mencukupi, silahkan menambahkan data / keterangan pada
lembaran lain dan sertakan dalam laporan ini.

Notification :
1. Make sure all data / information is recorded on writing or photo
documentation. If provided shests are not adequate, please ask data /
information to other sheets and attach to this report.
 PT. PANCARAN MARITIM TRANSPORTINDO
Vessel Name : TB P III - 615 Engine Model : C-18 Cert Ditta
Unit Location Engine : PORT
Application TB Arrangement : 020/MNTC
Service Meter :

REPORT CONTENT :

• IMAGE DOCUMENT ( photos )

• VISUAL INSPECTION DISASSEMBLE AREA ..........................................................................................................

o NOT INSTALLED / MISSING PARTS LIST ...................................................................................................
o DAMAGE PARTS LIST ..............................................................................................................................
o REPAIRED PART LIST ................................................................................................................................
• LEAK TEST ............................................................................................................................................................

• SUMMARY OF INSPECTION ................................................................................................................................

• INJECTOR TEST RECORD .....................................................................................................................................

• NOZZLE TEST RECORD .........................................................................................................................................

• CRANKSHAFT INSPECTION FORM ......................................................................................................................

• CONNECTING ROD JOURNAL INSPECTION MEASURE .....................................................................................

• PISTON INSPECTION ...........................................................................................................................................

• LINERS INSPECTION ............................................................................................................................................

• ENGINE ASSEMBLY AND QUALITY ASSURANCE CHECK ..................................................................................

• CONNECTING ROD INSPECTION .......................................................................................................................

• ENGINE REBUILD SERVICE ..................................................................................................................................

o ENGINE MECHANICAL SUB-ASSEMBLY INSPECTION ...........................................................................
o ENGINE ELECTRICAL SUB-ASSEMBLY INSPECTION ...............................................................................
• CRITICAL ENGINE ASSEMBLY CHECKLIST ..........................................................................................................

• COMPLETION ......................................................................................................................................................
 PT. PANCARAN MARITIM TRANSPORTINDO
Vessel Name : TB P III - 615 Engine Model : C-18 Cert Ditta
Unit Location Engine : PORT
Application TB Arrangement : 020/MNTC
Service Meter :

VISUAL INSPECTION DISASSEMBLE AREA

ENGINE HARUS DALAM KEADAAN BERSIH SEBELUM DIBONGKAR
MAKE SURE THE ENGINE GROUP IS COMPLETELY CLEANED BEFORE DISASSEMBLED
FOTO HARUS LENGKAP MEWAKILI KEADAAN ENGINE / KOMPONEN
PHOTO MUST REPRESEN ENGINE/COMPONENT CONDITION COMPLETELY
Dilakukan/Done Tidak/No
1. Photo Engine : Sisi Depan, Sisi Belakang, Sisi Kanan, Sisi Kiri, Nama Plate, Damage/Missing
V
(Photo Front Side, Rear Side, Right Side, Left Side, Engine Name Plate, Damage/Missing)

2. Contoh Oli SOS / SOS Oil Sample V

3. Photo kondosI Damage/Repair & Missing part (isi Form Damage, Missing, Repair Part List)
(photo for Damage/repaire & Missing part (Fill Damage, Missing, Repaire Part List) V
Tambahan untuk Engine Problem ( Additional or Engine Problem) :
4. Pemeriksaan filter yang dipotong & Photo / Inspect & Photo cut filter V
5. Pemeriksaan backlash clearance seluruh valve sebelum pembongkaran
Check all valve backlashclerance before disassemble
V
6. Download ECM Unit dan diserahkan ke F`man/Supv
V
Download ECM Unit and handed to F`man/Supv
7. Memeriksa keberadaan Oli/Air pada Air Intake
Inspect Air-Intakes For Oil / Enty or Water Present
V
8. Memeriksa keberadaan oli/air akibat kebocoran/kerusakan
Inspect for oil / water present damage leaks etc. V
9. Memeriksa torque dari Retaining Bolt Cyl. Head
V
Inspecte The Torque Of The Head Retaining Bolts
10. Berikan Catatan yang mewakili kondisi aktual engine saat dibongkar (Note for actual conditon) V
..........................................................................................................................................................................................

Engine overhaul by on schedule time.

SELURUH COMPONENT DIBERSIHKAN, DIKERINGKAN DAN DIBERI ANTI RUST

SERTA DILETAKKAN PADA KERAJANG/RAK/CABINET DAN DIBERIKAN KETERANGAN JOB
Make Sure All Components Are Cleaned, Dried And Coated With Anti_Rust Proved Warned Correctly
And Place Into The Back Cabinets Correct Are is

DATA DIATAS MERUPAKAN HASIL INSPEKSI SELAMA PEMBONGKARAN

The above data is actual inspected during dismanting

Inspected by, Acknowledge by, Approved By,

( SURYANA ) ( DEDI SUSANTO ) ( ANGGA ANDI A )

 PT. PANCARAN MARITIM TRANSPORTINDO
Vessel Name : TB P III - 615 Engine Model : C-18 Cert Ditta
Unit Location Engine : PORT
Application TB Arrangement : 020/MNTC
Service Meter :

VISUAL INSPECTION DISASSEMBLE AREA

DAFTAR PARTS YANG TIDAK ADA / HILANG

NOT INSTALLED / MISSING PARTS LIST

PHOTO Inspected
No P/N Qty PARTS GROUP/LOCATION
YES NO by

Inspected by, Acknowledge by, Approved By,

( SURYANA ) ( DEDI SUSANTO ) ( ANGGA ANDI A )

 PT. PANCARAN MARITIM TRANSPORTINDO
Vessel Name : TB P III - 615 Engine Model : C-18 Cert Ditta
Unit Location : Engine : PORT
Application TB Arrangement : 020/MNTC
Service Meter :

VISUAL INSPECTION DISASSEMBLE AREA

DAFTAR PARTS YANG DIGANTI

REPLACE PARTS LIST

PHOT Inspected by
O
GROUP/LOCATI DAMAGE
No P/N Qty PARTS Y
ON TYPE N
E
O
S
SINGLE FUEL
1 248-1394 5 GASKET KIT Worn out MCH
INJECTOR
2 358-0837 1 WATER PUMP INST GASKET KIT Worn out MCH
AFTERCOOLER & MCH
3 453-2309 1 GASKET KIT Worn out
LINES
SINGLE CYLINDER MCH
4 456-0005 1 GASKET KIT Worn out
HEAD
TURBOCHARGER MCH
5 360-7481 1 GASKET KIT Worn out
INST
OIL COOLER & MCH
6 453-2315 1 GASKET KIT Worn out
LINES
7 456-0003 1 CENTRAL & LOWER GASKET KIT Worn out MCH
8 1 GP CYLINDER HEAD CYLINDER HEAD Worn out MCH
9 166-2904 6 SEAL-O-RING CYLINDER HEAD Worn out MCH
10 9X-7430 1 SEAL-O-RING CYLINDER HEAD Worn out MCH
11 6V-1197 1 SEAL-O-RING CYLINDER HEAD Worn out MCH
12 160-7271 2 SEAL CYLINDER HEAD Worn out MCH
13 329-4509 6 BODY AS PISTON BASIC ENGINE Worn out MCH
14 223-9159 6 RING TOP BASIC ENGINE Worn out MCH
15 238-2707 6 RING INTER BASIC ENGINE Worn out MCH
16 246-5659 6 RING OIL BASIC ENGINE Worn out MCH
17 224-3246 6 BEARING CON-ROD BASIC ENGINE Worn out MCH
18 317-8766 7 MAIN BEARING BASIC ENGINE Worn out MCH
19 253-8766 6 CYLINDER LINER BASIC ENGINE Worn out MCH
20 155-0809 6 SEAL LINER BASIC ENGINE Worn out MCH
21 155-0810 6 SEAL LINER BASIC ENGINE Worn out MCH
22 155-2793 6 SEAL LINER BASIC ENGINE Worn out MCH
23 9L-5854 6 SEAL BAND BASIC ENGINE Worn out MCH
24 1 REGULATOR TEMP COOLING Worn out MCH
SYSTEM
25 10R-2772 6 FUEL INJECTOR FUEL SYSTEM Low MCH
perform

Inspected by, Acknowledge by, Approved By,

( SURYANA ) ( DEDI SUSANTO ) ( ANGGA ANDI A )

 PT. PANCARAN MARITIM TRANSPORTINDO
Vessel Name : TB P III - 615 Engine Model : C-18 Cert Ditta
Unit Location Engine : PORT
Application : TB Arrangement : 020/MNTC
Service Meter :

VISUAL INSPECTION DISASSEMBLE AREA

DAFTAR PARTS SISA

REMAINING PARTS LIST

GROUP/ PHOTO Inspected by
PART
No P/N Qty PARTS LOCATIO
CONDITION YES NO
N
return to Akhmad N
1 253-1752 5 Thrust plate
warehouse
return to Akhmad N
2 329-4509 4 Body as piston
warehouse
return to Akhmad N
3 155-5271 2 Piston skirt
warehouse
return to Akhmad N
4 172-0919 2 Crown piston
warehouse
1 pc spare for Akhmad N
4 110-6994 3 Spacer plate
vessel
return to Akhmad N
5 131-0420 9 Fastener
warehouse
return to Akhmad N
6 131-0421 3 Fastener
warehouse
return to Akhmad N
7 7N-2405 63 Conrod bolt 3516
warehouse
72 Conrod bolt C-18 return to Akhmad N
8
warehouse
4w-2646 1 Contactor 1 pc spare for Akhmad N
9
vessel
8N-7296 8 Retainer return to Akhmad N
10
warehouse
230-2569 36 Retainer return to Akhmad N
11
warehouse
107-7954 4 Spacer return to Akhmad N
12
warehouse
4P-7680 6 Spacer return to Akhmad N
13
warehouse
379-3359 1 ESS return to Akhmad N
14
warehouse

Inspected by, Acknowledge by, Approved By,

( SURYANA ) ( DEDI SUSANTO ) ( ANGGA ANDI A ))

 PT. PANCARAN MARITIM TRANSPORTINDO
Vessel Name : TB P III - 615 Engine Model : C-18 Cert Ditta
Unit Location Engine : PORT
Application TB Arrangement : 020/MNTC
Service Meter :

Summary of Inspection

No Component Reuse Replace Checked By

1 Cylinder Block
2 Crankshaft
3 Cylinder Liner
4 Connecting Rod
5 Piston Group
6 Camshaft
7 Injector
8 Ring Piston Kit
V MCH
V MCH
V MCH
V MCH
V MCH
V MCH
V MCH
V MCH

Summary of Repair/Rebuild

No Component Reuse Replace Repair Checked By

1 Cylinder Head
2 Oil Pump
3 Fresh Water Pump
4 Aux Water Pump
5 Cartridge Turbo
6 Starting Motor
7 Alternator
V MCH
V MCH
V MCH
V MCH
V MCH
V MCH
V MCH

Inspected by, Acknowledge by, Approved By,

( SURYANA ) ( DEDI SUSANTO ) ( ANGGA ANDI A )

 PT. PANCARAN MARITIM TRANSPORTINDO
Vessel Name : TB P III - 615 Engine Model : C-18 Cert Ditta
Unit Location Engine : PORT
Application TB Arrangement : 020/MNTC
Service Meter :

LEAK TEST
Date of test :
Tested by :
Supervised by :

Part No. Qty Description Condotion Picture Remark

AFTER Good Leak Yes No
315-0047 1 GOOD
COOLER
Good Leak Yes No
7C-0145 1 OIL COOLER GOOD
Good Leak Yes No

Procedure :
1. Tutup salah satu ujung core (aftercooler atau cooler) dengan plat/plug
Close one end of core (aftercooler or cooler) tube with blanking plate.plug, etc
2. Hubungkan ujung lainnya dengan udara bertekanan
Connect the other tub with pressurized air
3. Pastikan tidak ada kebocoran dengan udara bertekanan
Make sure there`s no leak at all connectins
4. Atur tekanan udara pada regulator
15 psi untuk aftercooler ( tekanan pada cooling system )
100 psi untuk oilcooler ( tekanan pada oil pressure )
Dilarang melebihi tekanan di atas, untuk menghindari kerusakan pada core
Set the air pressure regilator at :
15 psi for aftercooler ( pressure at cooling system )
100 psi for oilcooler ( pressure at oil pressure )
To avoid damage for core, do not exceed the pressure above the limit
5. Selama pemberian udara bertekanan, core direndam dalam air selama 30 menit.
Pemeriksaan apakah ada gelembung udara yang mengindikasikan adanya kebocoran
During pressurising the core, submerge the core into the water for 30 menutes
Check for air bubbles appearance that indicate leaking
 PT. PANCARAN MARITIM TRANSPORTINDO
Vessel Name : TB P III - 615 Engine Model : C-18 Cert Ditta
Unit Location : Engine : PORT
Application TB Arrangement : 020/MNTC
Service Meter :

6. Memberikan tekanan pada gauge 20 kpa (3 psi) lebih tinggi dari tekanan pada presseure cap
Get pressure reading on the gauge to 20 kpa (3 psi )more then pressure on the pressure cap
7. Cek kebocoran pada bagian luar radiator
Check the radiator for outside leakage
8. Cek semua sambungan dan hose dari kebocoran
Check all connections and hoses for the cooling system for outside leakage
9. Jika tidak terjadi kebocoran, dan tekanan pada gauge tetap sama selama 5 menit, maka Radiator dan cooling system
tidak terjadi kebocoran
If you do not see any outside leakage and the pressure reading on the gauge is still the same after 5 minutes, the
radiator and cooling system does not have leakage
10. Dokementasikan photo kebocoran
Take picture of leaking
 PT. PANCARAN MARITIM TRANSPORTINDO
Vessel Name : TB P III - 615 Engine Model : C-18 Cert Ditta
Unit Location Engine : PORT
Application TB Arrangement : 020/MNTC
Service Meter :

INJECTOR INSPECTION
Injector No. 1 2 3 4 5 6
NOT GOOD Visual NOT NOT NOT NOT NOT GOOD
Inspection GOOD GOOD GOOD GOOD GOOD
Comments
Injector YES YES YES YES NO
YES
Replacement

E-trim Code N/A N/A N/A N/A N/A N/A

CONCLUSION REPLACED REPLACED REPLACED REPLACED REPLACED REPLACED

Inspected By :
Comment:

BASE ON VISUAL INSPECTION, THE BODY INJECTORS STILL GOOD. BUT AFTER
PERFORM INJECTOR CUT OUT, FOUND THE INJECTOR NO 1-6 IS NOT GOOD
ENGINE REBUILD SERVICE
CYLINDER BLOCK INSPECTION

MAIN BEARING BORE

Specification 5.1138” ± 0.0005” Initial
Dial Bore Gauge set to 5.1138” After Line Boring
No. C B A
Alignment
Front Rear Front Rear Front Rear

1
2
3
4
5
6
7
Reusability Reason / Comment Action Required
 CRANKSHAFT INSPECTION FORM

FORGING NUMBER .................. ASSEMBLY .............................

INSPECTED BY :
DATE : ...................................................................................
ENGINE MODEL S/N:
COMMENTS : Crankshaft can be reuse again FORGING HEAT CODE (OPTIONAL) ...............................................

MAIN JOURNAL INSPECTION MEASUREMENTS

MEASURED JURNAL DIAMETERS HARD
OUT-OF-ROUND TAPER NESS
MAIN Spect : 120.650 ± 0.020 mm (4.7500 ± 0.0008 inch) FILLET (Rc) PROVILE SURFACE FINISH VISUAL
RADIUS Spect
JURNAL FRONT 1 CENTER 3 CHECK CHECK CHECK
CHECK :
..................................................................
REAR (2) (1) MINUS (3) (1) MINUS (2)
O
90 TO (1) AND (2) ........
1 ............... ........
........
2
........
3 ........
4 ........
5 ........
6 ..
7
DISPOTION JURNAL BEND MEASUREMENTS JOURNAL BEND MEASUREMENT POSITIONS
ROD JOURNAL MEASURING
LOCATIONS BEFORE AFTER
POLISH STRAIGHTENING STRAIGHTENING
3 COMMENTS AND RECOMMENDATION:
2 1-2
1 GRIND
1
CORE FOR EXCHANGE 2-3

HOLD FOR ....................... 3-4

SCARP
4-5
..........................................
5-6

6-7

DATE
By ROTATION : STANDARD-ccw cw
(VIEW FROM FLYWHEEL)
 PT. PANCARAN MARITIM TRANSPORTINDO
Vessel Name : TB P III - 615 Engine Model : C-18 Cert Ditta
Unit Location Engine : PORT
Application TB Arrangement : 020/MNTC
Service Meter :

CONNECTING ROD JOURNAL INSPECTION MEASUREMENT

MEASURE JURNAL DIAMETERS OUT-OF- HARDNESS (Rc)
TAPER FILLET SURFACE
ROD Spect : . 97.028 ± 0.020 mm (3.8189 ± 0.0008 inch) ROUND Sepect : PROVILE VISUAL
RADIUS FINISH
JOURNAL ....................... CHECK CHECK
CENTER 3 CHECK CHECK
FRONT 1 REAR 2 1 MINUS 3 1 MINUS 2 ......66 min.....
90O TO 1 AND 2
 PT. PANCARAN MARITIM TRANSPORTINDO
Vessel Name : TB P III - 615 Engine Model : C-18 Cert Ditta
Unit Location Engine : PORT
Application TB Arrangement : 020/MNTC
Service Meter :

ROD JOURNAL MEASURING

LOCATIONS
1 3 2 COMMENTS AND RECCOMENDATION :
Use connecting rod
 PT. PANCARAN MARITIM TRANSPORTINDO
Vessel Name : TB P III - 615 Engine Model : C-18 Cert Ditta
Unit Location Engine : PORT
Application TB Arrangement : 020/MNTC
Service Meter :

END PLAY

Specification : 0.11mm – 0.57mm

Actual : 0.21mm

Checked By :
 PT. PANCARAN MARITIM TRANSPORTINDO
Vessel Name : TB P III - 615 Engine Model : C-18 Cert Ditta
Unit Location Engine : PORT
Application TB Arrangement : 020/MNTC
Service Meter :

PISTON INSPECTION

Reusability
If parts are reusable, put “√” in the box.
If parts are worn normally but are out of the specification, pu “X” in the box
Piston No →
1 Crown
2 Ring Grooves
3 Top ring Lands
4 Skirt
5 Pin Bore
6 Snap Ring
Reusability(Y/N)
Grooves
Note: Refer to GRPTS SEBF8059-16 for Correct Specification

Number of replaced :6
Number of reuse :0

COMMENT AND RECOMMENDATION

Date of inspection :
Inspected by :

If rod/Pin is good put √ in rod reusability column and put X if rod is bad.
 PT. PANCARAN MARITIM TRANSPORTINDO
Vessel Name : TB P III - 615 Engine Model : C-18 Cert Ditta
Unit Location Engine : PORT
Application TB Arrangement : 020/MNTC
Service Meter :

LINERS INSPECTION

* Dial Bore gauge set to: 145.000 ± 0.025 mm (5.7086 ± 0.001”)

Cylinder Flange Liner
Upper end bore size Lower End Bore Size Visual Condition
Position Thickness Reusability

Number of replaced :6
Number of reuse :0

COMMENT AND RECOMMENDATION

All cylinder liner have been wear out

................................................................................................................................................................................................................
................................................................................................................................................................................................................
................................................................................................................................................................................................................

Date of inspection :
Inspected by :
 PT. PANCARAN MARITIM TRANSPORTINDO
Vessel Name : TB P III - 615 Engine Model : C-18 Cert Ditta
Unit Location Engine : PORT
Application TB Arrangement : 020/MNTC
Service Meter :

CONNECTING ROD INSPECTION

Table of specification :

A
B Date of inspection: ……...........
A+B
2 Inspected by:.
A-B
C
D

Rod no A B A+B A-B C D Reusability

2
1
2
3
4
5
6

COMMENT AND RECOMMENDATION

.....All connecting rod can be used again................................................................................................................

......................................................................................................................................................................................

.......................................................................................................................................................................................
 PT. PANCARAN MARITIM TRANSPORTINDO
Vessel Name : TB P III - 615 Engine Model : C-18 Cert Ditta
Unit Location Engine : PORT
Application TB Arrangement : 020/MNTC
Service Meter :

ENGINE REBUILD SERVICE

CRITICAL ENGINE ASSEMBLY CHECKLIST

CHECKED
No. OPERATION DATE MECHANIC INCHARGE REMARKS
BY

1 Cylinder Block Clean

2 Block Plugs Installed
3 Install Cylinder Liner
4 Crankshaft Plugs Torqued
5 Install new main bearing
6 Piston / Ring / Conrod Installation
Cooling Jet Clean,
7
Clearence & Torqued (Spec, torque : 22 lb.ft)
8 Camshaft Instalation
Camshaft Timing (Include Torque, Spec : 177
9
lbft )
10 Gear Marked / Engrave with W/O
11 Install Front Housing (included Fastener Check)
12 Install flywheel
13 Install Auxiliary Water Pump
Install Rear Housing
14
(included Fastener Check)
15 Install Cylinder Head
16 Cylinder Head Torque (Spec, torque : 450 Nm)
17 Install Exhaust Manifold
18 Install Oil Pump (included Fastener Check)
19 Install Heat Exchanger
20 Install Oil Pan (include Fastener Check)
21 Crankshaft Front Seal Installation
22 Crankshaft Rear Seal Installation
23 Install Damper (Spec. Torque : 200 lbft...)
24 Fuel Injection Pump Timing
25 Install turbo charger
26 Valve Clearance Setting (Spec. Clearance :
0.015 in, 0.030 ex )
 PT. PANCARAN MARITIM TRANSPORTINDO
Vessel Name : TB P III - 615 Engine Model : C-18 Cert Ditta
Unit Location Engine : PORT
Application TB Arrangement : 020/MNTC
Service Meter :

PHOTO TAG

Aftercooler after tested Install oil pan New crankshaft seal

View of condition new New ring piston Timing gear camshaft

cylinder liner

Turbo charger clean up New cyl liner and piston has The new ring piston and conrod
been installed bearing has been assembly
 PT. PANCARAN MARITIM TRANSPORTINDO
Vessel Name : TB P III - 615 Engine Model : C-18 Cert Ditta
Unit Location Engine : PORT
Application TB Arrangement : 020/MNTC
Service Meter :

Replace Main bearing and Jet spray has been installed Conrod bolt has been torqued
thrust plate

New reman injectors ready to Valve lash adjustment Setting fuel injector
installed

View of AE after completion Install new rear crankshaft seal Re-clean up cylinder head
PT. PANCARAN MARITIM TRANSPORTINDO
Vessel Name : TB P III - 615 Engine Model : C-18 Cert Ditta
Unit Location Engine : PORT
Application TB Arrangement : 020/MNTC
Service Meter :