TECHNICAL SERVICE REPORT – AQUARIUS DG#2

CUSTOMER ROCKTREE
EQUIPMENT TYPE/MODEL AQUARIUS VESSEL / DG2
ENGINE MODEL NT855DM
EQUIPEMENT SERIAL NUMBER N/A
WORKING HOURS 3363
ESN 41288117
PURPOSE OF SERVICE ENGINE OVERHAULING
DATE 06/01/2024
REPAIRS DONE? YES OR NO YES
ENGINEER O’NEILL BROKOUA

COMPLAINT
To overhaul a broken-down engine.
REPORT COMMENTS
Upon arrival in the vessel, visual assessment of new parts provided by customer were
done. Cylinder Head, Liner, Piston & Ring Set, Con Rod & Bearing, Main Bearing,
Camshaft & Bushing, Turbocharger, Injectors, Upper & Lower Gasket, and accessories.

ENGINE DATA PLATE

The camshaft, piston, cylinder head, crankshaft and others were already disassembly
by the engineers onboard. We removed old and assembly new bushing, the
crankshaft was installed with new bearings and torques using QSOL. Crankshaft end
float was also checked with reading 0.36mm

OLD CAMSHAFT BUSHING (1 -7)

CRANKSHAFT INSTALLED AND TORQUED TO ITS SPECIFICATION

Checking for Crankshaft END FLOAT

The camshaft was installed, and engine timing done. The accessory drive was also timed
and coupled to camshaft gear following Cummins Quickserve Online as show below.

The engine block was coupled to the main alternator and torqued. Crankshaft end float was
checked again to confirm the value and engine rotation by hand.

CHECKING TO CONFIRM
CRANKSHAFT END
FLOAT EXISTENCE
AFTER COUPLING THE
ENGINE TO THE MAIN
ALTERNATOR

The 6 old liners were removed from engine block to install news with protrusion checked at
each installation. Piston and connecting rod were assembled with piston ring set and
installed in the liners with connecting rod bearings and torqued to their specifications
according to Quickserve Online procedures.
ALL LINERS REMOVED FROM ENGINE BLOCK

CHECKING FOR LINER PROTUSION AFTER

EACH INSTALLATION - READING FOUND
BETWEEN THE RANGE OF 0.10mm – 0.18mm
PISTON ASSEMBLED WITH CON ROD AND RING SET

PISTON INSTALLED IN THE LINER

 CONNECTING ROD AND CAP WITH BEARING
INSTALLED ACCORDING TO THE PROCEDURES
QUICKSERVE ONLINE
 All news cylinder heads and injectors were installed and torqued to their correct torque.

ALL INJECTORS INSTALLED

Exhaust manifold, intake air connection, new turbocharger, rocker housing, oil pan, starter,
oil pump and all attachments to the engine were assembled. Valve and injector adjustment
were also done after engine turned several times to ensure there were no restrictions.
 ALL ATTACHMENTS TO THE ENGINE DONE

All fluids levels were filled to their maximum levels and the engine was started. When engine
was started, it has shut down after few minutes due to overheating from front cover and
unusual noise. The front cover was again removed and realized some parts damaged as
shown the picture below.
 CAMSHAFT BEARING
SUPPORT WAS BENT
WITH GEAR

After removed the front cover, some particles from camshaft were seen at the face. So,
we decided to disassembly the camshaft and droop the oil sump for more investigation.

BUSHING N#1 REMOVED

FROM THE BORE OF
ENGINE BLOCK
 PARTICLES FOUND IN THE OIL SUMP

After inspection, new camshaft and number 1 bearing, new lubricating pump and oil
sump were installed and torqued following the procedures Quickserve Online.

After installation, valve and injector have been adjusted accordingly to the procedures.
Oil filled and new lube filter installed, the engine was started again while monitoring on
idle, rated with gradually load. The performance was good and taking load without issue.
After 2 days running, the engine was stopped to check the valve clearance and handed
over to the customer for use.
 DISPLAY PANEL FOR
GENERATOR NUMBER 2
WORKING

CONCLUSION
The overhauling was done following Cummins procedures while the parts have been
provided by Customer.
The engine is running in good condition, however; we must follow the maintenance practice
and periodic health checking to avoid major issue.