42 FT • Twin Cummins 6BTA5.9 M3 Diamond Series Diesel Engines • ZF 80A Marine Transmissions
Marine Engine Survey
Conducted by: Jeff Lendall & Sons — 805 Marine Diesel Mechanic
This survey documents the visual inspection, operational testing, sea-trial performance, cooling-system condition, ZF 80A transmission operation, turbocharger observations, Northern Lights generator information, oil-analysis sampling, minor port heat-exchanger leakage, control-cable condition, and final machinery assessment for the propulsion systems aboard this 2003 Ocean Alexander 42 Sport Sedan.
Cummins 6BTA5.9 M3
ZF 80A
Sea Trial
Oil Analysis
Executive Survey Summary
As a result of my investigation, marine engine survey, visual inspection, operational testing, oil-analysis sampling, and sea trial, my opinion is that the overall machinery rating is VERY GOOD.
The twin Cummins 6BTA5.9 M3 Diamond Series engines have exceptionally low operating hours for machinery of this age and demonstrated smooth starting, strong oil pressure, minimal exhaust smoke, satisfactory turbocharger response, smooth ZF transmission engagement, and clean high-load operation.
VERY GOOD
1,353 Port / 1,355 Starboard
Replace aging Morse throttle and shifter cables
Important Finding:
Both Cummins engines are more than 20 years old yet have approximately 1,355 operating hours. During the survey it was difficult to identify significant leaks, malfunctions, or evidence of excessive mechanical wear. The engines appear to have been very well maintained.
Vessel Identification
| Vessel | Ocean Alexander 42 Sport Sedan |
|---|---|
| Official Number | 1143754 |
| Length Overall | 42 FT |
| Year | 2003 |
| Propulsion | Twin Cummins 6BTA5.9 M3 Diamond Series Marine Diesel Engines |
| Marine Transmissions | Twin ZF 80A |
Main Propulsion Engines
The vessel is powered by twin Cummins 6BTA5.9 M3 Diamond Series marine diesel engines rated at 370 horsepower each.
PORT ENGINE
Very good overall operating condition.
STARBOARD ENGINE
Very good overall operating condition.
Northern Lights 8KW Generator
GENERATOR IDENTIFICATION
Generator ran fine under load.
Seawater-pump pressure was adequate and no leaks were observed.
Water temperatures at the heat exchanger, expansion tank, and exhaust mixing elbow appeared normal.
System Condition Matrix
| System | Survey Condition |
|---|---|
| Fuel Filtration System | Very Good |
| Lubrication System | Very Good |
| Cooling System | Very Good — minor port heat-exchanger hose leak noted |
| Seawater Pumps | Very Good |
| Turbochargers | Very Good |
| Engine Alignment | Very Good |
| ZF 80A Marine Transmissions | Very Good |
| Throttle & Shifter Controls | Operational — cable replacement recommended due to age |
| Bow & Stern Thrusters | Operational |
| Northern Lights Generator | Included in survey and oil-analysis review |
Operational & Visual Inspection Findings
Racor Twin Fuel Filter/Water Separator 10-micron port and starboard assemblies appeared serviceable with no water present.
Morse cable shifters worked properly at flybridge and main cabin locations. The older red-jacket control cables should be replaced to improve smoothness and long-term reliability.
Seals were not leaking, no water was present, and adequate seawater pressure was observed.
Inlet and outlet temperatures remained within operating parameters.
Inlet and outlet temperatures remained within acceptable operating range.
Working properly with no leaks observed.
Main engine beds consist of heavy longitudinal stringers inboard and outboard. Engine mounts appeared satisfactory.
At 100% engine load and approximately 2,800 RPM, oil pressure measured approximately 62 PSI port and 63 PSI starboard.
Freshwater reservoir cooling with seawater-cooled wet exhaust operated satisfactorily.
2-inch Groco bronze-alloy strainers with sight glass appeared serviceable and maintained.
Double clamped where sighted.
Belt and pulley condition appeared serviceable.
Appeared smooth and without vibration.
Turbochargers appeared to spool around 1,200 RPM and operated satisfactorily.
Both transmissions shifted adequately with no excessive vibration or abnormal noise underway.
Operated smoothly during port and starboard operation.
Sea Trial Performance Report
Both propulsion engines were operated through normal maneuvering, cruising, and high-load conditions during the sea trial. Engine instrumentation, cooling performance, oil pressure, transmission operation, steering response, exhaust appearance, and wide-open-throttle performance were observed.
| Sea Trial Item | Observation |
|---|---|
| Engine Start | Both Cummins engines started without excessive cranking. |
| Exhaust Appearance | Very minimal smoke observed for engines of this age. |
| Cooling Water Discharge | Cooling-water discharge appeared adequate and normal. |
| Instrumentation | All gauges operated within normal operating limits at idle, cruise, and WOT. |
| Oil Pressure | Approximately 62 PSI port and 63 PSI starboard at 2,800 RPM under full load. |
| Steering System | Steering system was very responsive underway. |
| Transmission Operation | Both ZF 80A transmissions shifted smoothly with no excessive noise. |
| Backdown Test | Backdown test was satisfactory. |
| Rudder Linkage | Rudder linkage operated smoothly underway with no leaks observed. |
| Wide Open Throttle | Both engines reached approximately 2,800 RPM with no visible smoke. |
Wide Open Throttle Test:
Both Cummins 6BTA5.9 M3 Diamond Series engines reached approximately 2,800 RPM. Port oil pressure remained approximately 62 PSI and starboard approximately 63 PSI. No visible smoke was observed and the propulsion system operated smoothly under high load.
Survey Recommendations & Observations
Both Cummins 6BTA5.9 M3 marine engines have very low hours — approximately 1,353 and 1,355 hours — considering that the machinery is more than 20 years old.
During the survey I was hard pressed to identify significant leaks, malfunctions, or excessive wear. The engines and related propulsion systems appear to have been very well maintained.
Primary Recommendation:
The Morse throttle and shifter control cables are older red-jacket style cables. Although they operated during the survey, replacement is recommended to provide smoother operation and improved long-term reliability.
For additional information on marine diesel engine diagnosis and system inspection, visit the
Master Marine Diesel Troubleshooting Guide
.
Engine Operation — Video Documentation
Video documentation was recorded during high-load engine operation to preserve visual evidence of engine behavior, vibration, visible leakage, and general machinery condition during the survey.
Starboard Engine — 2700 RPM
Starboard Cummins 6BTA5.9 M3 observed at approximately 2,700 RPM. No leaks were detected and everything appeared to operate very smoothly.
Port Engine — 2700 RPM
Port Cummins 6BTA5.9 M3 observed at approximately 2,700 RPM. One small leak was detected; everything else appeared to operate very smoothly.
Port Engine Heat Exchanger Finding
A small leak was observed at the port heat exchanger. Based on the visual inspection, the leak appears minor and may be corrected by slightly tightening the hose clamp.
Recommended Follow-Up:
Inspect the hose and clamp connection and correct the minor leak. The hose itself should also be inspected for deterioration before determining whether clamp adjustment alone is sufficient.
Laboratory Oil Analysis Samples
The following laboratory oil-analysis samples are included as part of the machinery survey record. Fluid analysis provides additional information about internal wear, contamination, lubricant condition, and possible developing mechanical problems that may not be visible during a conventional inspection.
| Component | Oil Analysis Report |
|---|---|
| Port Cummins 6BTA5.9 Engine |
View Port Cummins Engine Oil Analysis |
| Starboard Cummins 6BTA5.9 Engine |
View Starboard Cummins Engine Oil Analysis |
| Port ZF 80A Marine Transmission |
View Port ZF Transmission Oil Analysis |
| Starboard ZF 80A Marine Transmission |
View Starboard ZF Transmission Oil Analysis |
| Northern Lights 8KW Generator | Sample lost in shipping |
Generator Oil Sample:
The Northern Lights generator sample was lost in shipping. A replacement sample should be obtained if laboratory analysis of the generator lubricant is desired.
Documented Survey Evidence
2,700 RPM operation documented with no leaks detected.
2,700 RPM operation documented with one small leak observed.
Minor hose-connection leak photographically documented for follow-up service.
Priority Recommendations
1. Replace Morse Throttle & Shifter Cables
The existing red-jacket Morse cables are older equipment. Replacement is recommended for smoother control operation and improved long-term reliability.
2. Correct Port Heat-Exchanger Leak
Inspect the hose and clamp connection. The leak appears minor and may be corrected through clamp adjustment or minor hose service.
3. Continue Preventive Maintenance
Continue normal fuel filtration, engine lubrication, cooling-system, turbocharger, transmission, and generator maintenance schedules.
4. Continue Periodic Oil Analysis
Periodic fluid sampling can establish long-term wear trends for both Cummins engines and both ZF marine transmissions. A new generator oil sample should be obtained because the previous sample was lost in shipping.
Final Machinery Assessment
The twin Cummins 6BTA5.9 M3 Diamond Series engines demonstrated favorable operational characteristics throughout the inspection and sea trial.
Smooth and without excessive cranking
62 PSI port / 63 PSI starboard at approximately 2,800 RPM
Minimal smoke observed
Satisfactory operation
Smooth engagement and operation
Approximately 2,800 RPM with no visible smoke
Final Surveyor Conclusion
Based on visual inspection findings, operational testing, oil-analysis sampling, and sea-trial observations, the propulsion systems aboard this 2003 Ocean Alexander 42 Sport Sedan appear mechanically sound and generally well maintained for engine age and operating hours.
The engines demonstrated favorable operational characteristics including smooth starting, strong oil pressure, stable fuel delivery, minimal exhaust smoke, smooth transmission engagement, satisfactory turbocharger operation, and clean wide-open-throttle performance.
The primary negative observation was the age of the Morse throttle and shifter control cables. Replacement is recommended to improve control smoothness and long-term reliability.
A small leak was also observed at the port heat-exchanger hose connection. The condition appears minor and should be inspected and corrected.
Professional Survey Notes
NOTICE:
The following statements limit the liability of the undersigned and set ethical standards associated with this report. Use of this report for any purpose constitutes acceptance of the following:
NOTE A:
This report is issued without prejudice and is the property of the Requestor as listed above. Any use or distribution by another party is prohibited and shall render this report invalid.
NOTE B:
This report is issued subject to the understanding that the undersigned surveyor is not responsible for error, omission, negligence, or misstatement. This report is a statement of my opinion based on the conditions as I found them. It is not a warranty, express or implied.
Professional Marine Engine Surveys
805 Marine Diesel Mechanic provides professional marine engine surveys, pre-purchase diesel inspections, sea trials, cooling-system evaluations, oil analysis, transmission inspections, fuel-system diagnostics, and marine diesel troubleshooting throughout Ventura, Oxnard, Channel Islands Harbor, Santa Barbara, Marina del Rey, and surrounding Southern California harbors.
Survey Conducted By
Owner / Surveyor: Jeff Lendall
Jeff Lendall & Sons
805 Marine Diesel Mechanic