6V92 OVHL SPEC_22_Oct_25.doc

Enclosure (3) MTU 6V92 Marine Engine Overhaul Specification

REVISION No. H

CHANGE No.

SPECIFICATION OR

STATEMENT OF WORK

COVER SHEET

TITLE

MTU 6V92 Marine Engine OVERHAUL

OVERHAUL SPECIFICATION

SPECIFICATION NUMBER

024-R-233-0307

ORIGINATED BY

Michael McHale

DATE

11/08 Revision (A) ORIGINATED BY

DATE

Revision (B) ORIGINATED BY

DATE _______

Revision (C) ORIGINATED BY

DATE ______

Revision (D) ORIGINATED BY Michael McHale

DATE 09/14

Revision (E) ORIGINATED BY Michael McHale

DATE

_11/08_ Revision (F) ORIGINATED BY Michael McHale

DATE

07/2010

Revision (G) ORIGINATED BY Michael McHale

DATE

09/2023 Revision (H) ORIGINATED BY Michael McHale

DATE

06/2024

ORIGINATOR'S COMMAND

SURFACE FORCES LOGISTICS CENTER (SFLC)

DEPARTMENT/DIVISION SMALL BOAT PRODUCT LINE ENGINEERING CELL

INTERNAL REVIEWER

DATE ______

SOWRB APPROVAL

DATE

1.0 Scope

Purpose - This specification is for the overhaul of non-ready for issue (F Condition) MTU 6V92 Marine Engines for ready for issue (A Condition) MTU 6V92 Marine Engines and hang-on equipment.

It also provides the requirement for the minor repair of unserviceable (E condition) MTU 6V92 Marine Engines for serviceable ready for issue (B condition) MTU 6V92 Marine Engines.

The contractor will reassemble the overhauled marine engine with MTU OEM parts unless otherwise noted in this specification using Master Serial #06VF-222697.

In the event MTU parts are not available either through the OEM or through aftermarket sources, the USCG reserves the right to provide GFE that may need to be recertified to meet OEM standards for use on the overhaul of the USCG MTU 6V92 Marine Engine engines.

The marine engine with attached hang-ons with the exception of the alternator shall be dynamometer tested, preserved, painted, and packaged. The marine engine (one of a pair) is installed on the U.S. Coast Guard 47 FT. Motor Lifeboat (MLB). The engine will be provided to the contractor in a metal shipping container.

1.2 Government Furnished Property - This specification sets

forth the requirements for the following equipment:

a.

6V92 DDECIV PORT ENGINE (NSN 2815-01-442-4541)

b.

6V92 DDECIV STBD ENGINE (NSN 2815-01-442-4549)

c.

Metal Shipping Container (ACN 8145-01-F00-3805)

2.0

APPLICABLE DOCUMENTS

2.1 Applicable Documents - The follow in documents form a part of this specification to the extent specified herein.

2.2 Government Documents

a.

MIL-L-2104F, 28 Sep 92, Lubricating O, Grade 40

b. MIL-D-3464E, 21 Apr 87, Desiccant, Activated bag

c. MIL-C-104C, 24 Jun 93, Crates Type II, Class II, Style A

2.3 Commercial Documents The following documents form a part of this specification to the extent specified here. The documents shall be the version listed by number and date from the referenced industry organization. Commercial documents may be listed in the Department of Defense Single Stock Point (DODSSP).

a. American National Standards Institute (ANSI) / National Conference of Standards Laboratories (NCSL)

b. ANSI/ASQC Q9001-2000, 13 Dec 2000, Inspection System

c. ANS/ISO/IEC 17025:2005 for Part 1 and ANSI/NCSL Z540.3-2007 for Part 2, General Requirements for Calibration Laboratories and Measuring and Test Equipment

d. ASTM D 975-02 10 January 2002, Diesel Fuel Oils

e. International Chemtex Cooperation: Chemtex Product Bulletin for "Chemfilm MXP" Dated 2/16/2011

f. Detroit Diesel Manual 6SE379 DATED SEP. 1999

g. Valvoline Oil Company: Tectyl International Product Bulletin for Tectyl International Product Bulletin for “Tectyl 859B” Dated 07/10

2.4 Specification Precedence - Any conflict between this specification and applicable documents identified in this specification shall be resolved in this order:

a. This specification

b. Applicable documents

2.4.1 Departure from Specification - Departure from this specification shall not be allowed unless approved by the Coast Guard Contracting Officer.

a. If the contractor finds it necessary to implement change or depart from applicable specifications, they shall request permission.

b. Request by contractors for change shall clearly describe the changes proposed, the reasons for and advantages of the changes proposed, and the contract’s price increase or decrease (if any) that would result.

3.0 Requirements

3.1 General - The contractor shall provide all labor, equipment, special tools and materials required to accomplish the following sequence of activities:

Condition “F” MTU 6V92 Marine Engine Engines Received a.

Receive engine

a. Uncrate engine

c. Disassemble and clean engine

d. Submit Core Condition Report (Appendix A)

e. Submit Disassembly Report (Appendix B & DDEC Reports)

f. Overhaul engine

g. Reassemble engine h.

Perform dynamometer testing (Appendix C)

i. Preserve, Paint, Package and Mark engine & container

Condition “E” MTU 6V92 Marine Engine Engines Received a.

Receive engine

b. Uncrate engine

c. Submit Core Condition Report (Appendix A)

d. Perform dynamometer testing

e. Submit Condition Found Report (Appendix B & Dyno Report)

f. Repair engine

g. Preserve, Paint, Package & Mark engine & crate.

3.2 Engine - Marine engines shall be overhauled upon approval of Core Condition Report, Appendix A. The marine engines shall be stored inside and kept from all weather.

3.3 Parts, Engine – All MTU 6V92 Marine Engine parts listed in Appendix G shall be a mandatory replacement. All other components and parts listed in Appendix H shall be replaced upon the contingency of inspection. Contingent parts shall be inspected for critical dimensions and wear limits and replaced as authorized by the Contracting Officer.

Any minor parts including, but not limited to, hardware, gaskets, seals, retainer clips, that are not separately priced in the base contract’s Appendix H Contingency Parts List, shall be listed under a Miscellaneous Parts list that is categorized separately on the Appendix B report. The miscellaneous parts list shall not exceed a cap of $1000 per engine.

The contractor shall use only MTU OEM parts meeting OEM specifications. For OEM parts no longer available and rendered obsolete by the OEM, the contractor shall be permitted to use aftermarket parts as denoted in Appendix G and Appendix H parts listing. All marine engines provided under this specification will utilize Master Serial #06VF222697 to affect the overhauling of the MTU 6V92 Marine Engine. All engines supplied to the contractor under this contract will be overhauled at an authorized MTU facility. Engines shall not be exchanged under the Detroit REMAN program. The Government reserves the right to supply parts as Government Furnished Property (G.F.P.) at any time during the contract. The Government Furnished Property will be annotated on each delivery order as required.

For engines being completely overhauled from an F condition to A condition engine and after submitting the DDEC reports from the engine’s Electronic Control Module (ECM) to the Contracting Officer, all data contained in the ECM shall be cleared unless otherwise specified.

This includes engine hours, fault codes, injector calibration codes etc. At the completion of the overhaul the ECM will be re-programmed at zero hours, correct injector calibration codes and the USCG K2 function The following components of the MTU 6V92 Marine Engine may be overhauled at a Certified MTU/Daimler Distributor’s facility versus replaced by an authorized MTU/Daimler Distributor as annotated in Appendix G:

· Cylinder heads p/n R23504270AM

· Rotary Blower p/n R23511026

· EUI Injector(s) p/n R5237578

3.4 Injectors – Fuel Injectors P/N R5237578 and Injector Jumper Line Seals P/N 8928676, shall be installed in the overhauled MTU 6V92 Marine Engine engines as per Appendix G

3.5 Hoses & Fittings – All hoses and hose fittings listed in Appendix G will be replaced as new. The contractor is authorized to manufacture and assemble all hoses & fittings on the MTU 6V92 Marine Engine at the contractor’s facility. The contractor shall not deviate from the manufacturer or sizes of the hoses & fittings listed in the MRP list.

3.6 Secondary Fuel Filter - Only P/N 23518530 or P/N 23530645 are to be used on MTU 6V92 Marine Engine engines.

3.7 Wiring Harness – Wiring Harnesses for the MTU 6V92 Marine Engines shall be installed new in the overhauled engines. Harness part numbers are for both 80627K90 and 80627K91 engines as per Appendix G.

a. EMIM Harness

P/N 23517139

b. Engine Sensor Harness P/N 23517138

c. Left Bank Injector Harness P/N 23511307

d. Right Bank Injector Harness P/N 23511308

3.8 Oil Pressure – Oil pressure requirements shall meet the following criteria in sequence:

a. During the entire 30-minute full power trial portion of dyno testing the oil pressure shall be 60-PSI plus (+) or minus (-) 5%.

b. Immediately after the full power trial the engine RPM shall be reduced to 600 RPM with no load. At which time, the oil pressure shall be no lower than 8 PSI.

c. Increase the engines speed to 1950 RPM with 85% load for 10 minutes. The oil PSI shall be 55 PSI plus (+) or minus (-) 3 % during the entire 10 minutes. The DDEC PROLINK computer will be used to validate this requirement.

3.9 Labor - All labor is to be performed by MTU certified and authorized machinists and mechanics.

3.10 Core Condition Report - The contractor shall submit Appendix A to the Contracting Officer after receipt of the engine. The contractor shall also submit Appendix B to the contracting officer after receipt of the engine. Appendix B will also contain the DDEC reports off the engine Electronic Control Module (ECM). Reports will be in .pdf format.

3.11 Core Acceptance Criteria - The contractor shall accept the core based on a visual walk around inspection as per Appendix A.

3.12 Cumulative Tracking Report - The contractor shall maintain and submit to the contracting officer, by the 15th of the month, for the previous month; the Cumulative Tracking Report Appendix F, for all engines.

3.13 Documentation - This specification sets forth the requirements for the following documentation.

Core Condition Report, in accordance with Appendix A

Disassembly Report, in accordance with Appendix B

Dyno Test Report, in accordance with Appendix C d.

Cumulative Tracking Report, in accordance with Appendix F

3.14 Warranty – (A Condition Engines Only) A warranty of one year from installation or 1000 operating hours, whichever occurs first and 24 months of storage is required covering the entire marine engine. Storage commences upon receipt of engine at the designated Coast Guard Inventory Control Point (ICP) facility. The contractor shall contact the field unit to arrange a resolution of a claim within 24 (twenty-four) hours after receiving notification by the Coast Guard of a warranty claim.

The contractor shall contact SFLC’s Contracting Officers Representative (COR) to advise on the contractors proposed time for visiting the vessel to perform the warranty repairs.

In the event the Coast Guard decides the proposed warranty repair time compromises the Coast Guards mission and decides on removal/replacement, the contractor shall coordinate and fund all necessary shipping arrangements for the failed engine to be returned to the origin of the overhauled facility for repairs and returned to a designated Coast Guard facility after repairs have been completed.

The contractor shall repair/rebuild the failed warranty engine to the condition level necessary for the contractor to honor a new full warranty (to be funded by the CG) including assigning a new serial number and the zeroing of hours on the ECM. The contractor shall submit to the Contracting Officer an inspection report for approval containing any parts and pricing for any work/repairs that are required that were not a result of the specific casualty.

3.15 Failure Analysis – The contractor shall provide a failure analysis of the MTU 6V92 Marine Engine upon request from the Contracting Officer. The test shall include but is not limited to the following objectives:

a. Dyno of the engine in an effort to emulate the failure cause.

b. Witness of engine disassembly at the Contractor’s facility by COR.

c. Visual inspection of engine and observance of any indication of failure.

d. Measurements of major engine components, bearings and bushings. Measurements will include critical dimensions and surface profilometry.

Component measurements and related data shall be recorded as necessary.

e. The inspection shall include removing all components necessary to conduct the investigation and to recover evidence of failure.

f. The suspected inferior parts/components and the inspection itself shall be performed using a high resolution digital camera.

3.16 Technical Representative Services – When requested by the Contracting Officer the contractor shall provide OEM certified personnel to perform onsite troubleshooting and repairs to the MTU 6V92 Marine Engine. Troubleshooting and repair of technical problems may require contractor personnel to travel to U.S. Coast Guard units. In correcting technical problems the contractor shall abide by the following:

TECHNICAL SERVICES PERFORMED ONSITE – The Contractor shall perform all services onboard the USCG vessel. Removal of the engine from the vessel to the contractor’s facility will only be authorized by the Contracting Officer. In this event USCG personnel shall provide labor to remove & install the engine from the vessel.

LOCATIONS – The services will primarily be required in vessel homeports located throughout the continental United States, Hawaii and Alaska.

CONTRACTOR RESPONSE – The Contractor shall be required to supply the Technical Representative to the designated location within Thirty-Six (36) hours after notification by the Contracting Officer. The Contractor is authorized to sub-contract the technical services to other local OEM distributors & dealers.

The Contracting Officer shall establish the dates the Technical Representative is required.

DELIVERY ORDERS – Surface Forces Logistics Center (SFLC) will issue a Delivery order (DO) stating where and when the services are required. SFLC will supply the Contractor with the nature of the problem (if known) along with a POC and phone number. The Contractor shall be responsible to contact the POC within twenty-four (24) hours after notification by the Contracting Officer.

The results of the Representative's findings shall be provided in writing within twenty-four (24) hours of arrival. Approval to perform repairs will be made by the Contracting Officer after evaluation from the USCG Contracting Officer’s Representative. The report shall be in the format of (APPENDIX I).

4.0 Quality Assurance

4.1 General - The contractor shall maintain an inspection system, which shall ensure each item, offered to the Government for acceptance conforms to contract requirements. The system shall be documented and in compliance with ASQC Q9001-2000.

4.2 Records - The contractor shall as a minimum maintain records of all inspections and tests. The records shall indicate the nature and number of observations made, type of deficiencies found, and the corrective action taken. Records shall be furnished upon arrival of the Contracting Officer's Representative.

4.3 Contractors Calibration System - The contractor shall maintain a calibration and maintenance system to control the accuracy of measurement and test equipment used in the fulfillment of this contract in accordance with ANSI/NCSL Z540.3-2007 Part 2. The system shall include as a minimum, prescribed calibration intervals, source of calibration, and a monitoring system to insure adherence to calibration schedules. Calibration standards shall be traceable to the National Institute of Standards and Technology (NIST). Documentation in support of this requirement shall be readily available for Government review.

4.4 Responsibility For Inspection - The Contractor shall be responsible for all inspections/test requirements specified herein. The contractor shall provide space, personnel, and test equipment to conduct all inspection requirements. All testing and inspection shall be at the Contractors facility or other facilities acceptable to the Government. The Government reserves the right to verify or have performed any of the inspection/tests set forth in this specification where such inspections are deemed necessary to assure that supplies or services conform to the prescribed requirements. The contractor shall notify the Contracting Officer seven (7) working days prior to all inspections and tests.

4.5 Required Tests - Each marine engine provided under this contract shall be operationally tested under load to assure minimum performance prior to acceptance. A test plan shall be submitted to the Contracting Officer thirty days after contract award addressing the final testing, inspection, and preservation to be accomplished by the contractor on all marine engines. The test plan shall address the manufacture's requirements outlined in Appendix C and all other testing, inspection, and preservation requirements covered in this specification.

a.

4.6 Test Report

5.2 Engine preservation (internal)

5.3 Engine preservation (external)

5.4 Marking

4.6 Test Report - The contractor shall deliver a test report, APPENDIX C, within seven (7) calendar days after completion of tests. The test report shall consist of the data obtained during the engine test. One copy of the test report shall be packed and delivered with each marine engine delivered under this contract.

5.0

PRESERVATION PACKAGING, AND MARKING

5.1 ENGINE PRESERVATION (Internal) - Preservation shall be completed as per MTU Manual 6SE379 for extended storage (Unless directed by contracting officer) with the following exceptions:

5.1.1 Detroit Diesel Manual 6SE379 - Section 14.4 procedure 3 Page 14-6 change to:

Refill with clean, soft water/ethylene glycol antifreeze mixture and add Corrosion Inhibitor Adjunct Molykote XP (as per the product information directions).

b.

All preservative oil and cooling fluids shall be drained after 48 hours of set time at ambient temperature.

5.1.2 Detroit Diesel Manual 6SE379 - Section 14.4 Page 14-6 Procedures 12 and 13 change to:

Refill fuel system with enough Nox-Rust # 518, Type P-9 or Tectyl 859B preservative oil to permit the engine to operate for about ten minutes.

5.2 ENGINE PRESERVATION (External) - Upon completion of final run-in, the marine engine shall be prepared as follows:

5.2.1 Surfaces shall be cleaned and free of grease/oil.

5.2.2 All loose scale and paint shall be removed; uneven paint layers shall be sanded smooth.

5.2.3 The following items will be masked and not painted:

Rubber hoses and wires

Glass and chrome gauge bezels and covers

Identification plates

Any discharge or breather openings e.

Flywheel rear bolt face f.

Front and rear seals

5.2.4 On all exposed metal surfaces the Contractor shall apply one coat of primer TT-P-664 Rev D (2 to 3 mils MDFT) each to all components allowing primer to dry.

5.2.5 Two coats, IAW TT-E-489H approximately two (02) mils, total thickness 3-5 mils MDFT) shall be sprayed on all surfaces, allow a minimum of seven (07) hours drying time between coats. Color shall be DD workboat blue (gallon container) p/n 23530131 (spray can) p/n 23521542.

5.2.6 When all paint is dry, all masking shall be removed.

5.2.7 All unpainted metal surfaces shall be coated with a light film of grease (except for hot surfaces).

5.2.8 Plug or cap all fittings/flanges and openings that may allow seepage from the engine during storage.

5.2.10 The contractor shall attach to the base of the shipping crate 1 gallon bottle of "Cummins Fleetguard RESTORE" (p/n CC2601) heavy duty cooling system cleaner. The bottle shall be padded and inserted in a separate container (5 gallon container) and secured to prevent spillage during shipping.

5.2.11 The contractor shall install the marine engine into the supplied metal shipping container.

5.3 MARKING - Each shipping container shall be stenciled on the top of the two longest sides (two opposite sides if square) in accordance with 5.3.1. The bottom side of the container shall be stenciled with the appropriate NSN, engine serial number and model number on the two longest sides. The contractor shall ensure that the serial number and model number on the bottom and top of the container sides match the actual engine serial number and model number in the container.

Machine made stencils shall be used for all markings not on the bar code labels

All markings shall be in white or black which ever are most contrasting print and at least 1/2" high

5.3.1 This marking shall be in the format as follows:

TYPE a.

Port Unit

DO NOT STACK MORE THAN TWO HIGH

TYPE b.

Starboard Unit:

DO NOT STACK MORE THAN TWO HIGH

5.3.2 The following marking shall be placed on all four sides and the top of each box, in stenciled white print at least 1/2" high.

Reusable Crate, Do Not Damage, Remove Bolts Prior To Removing Cover, Use Forklift To Unload Do Not Lift By Cover

The contractor shall paint over all other markings not outlined in 5.3.1 and 5.3.2

6.0

NOTES

6.1

GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

6.1.1

GOVERNMENT DOCUMENTS

Specifications and Standards (DODISS Documents)

Standardization Document Order Desk

700 Robbins Avenue

Building #4, Section D

Philadelphia, PA 19111-5094

215-697-1187

DOD & Navy Publications & Forms (NOT DODISS)

Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia, PA 19120

215-697-2000

Surface Forces Logistics Center

Small Boat Product Line, Bldg 31 2401 Hawkins Point Rd.

Baltimore, MD 21226-1792

410-762-6472

6.1.2

COMMERCIAL DOCUMENTS

MTU America Inc.

39525 Mackensie Drive Novi, Michigan 48377 b.

American Society for Testing Materials (ASTM)

100 Barr Harbor DR.

P.O. Box C700 West Conshohocken PA. 19428-2959

6.2 APPENDICES - The following appendices apply:

Appendix A:

Core Condition Report b.

Appendix B:

Disassembly Report (Extra Cost Requests)

Appendix C:

Test Plan and Dyno Report d.

Appendix D:

Warranty Information e.

Appendix E:

TCTO’s & Engineering Changes f.

Appendix F:

Cumulative Tracking Report g.

Appendix G:

Mandatory Replacement Parts

Appendix G.1: Mandatory Replacement Parts (Minor Repair) h.

Appendix H:

Contingency Replacement Parts

i. Appendix I:

Technical Representative Condition Found Report

6.3

GLOSSARY

a. CPL: - Control Parts List

b. Core: - MTU 6V92 Marine Engine

c. Field Unit: - United States Coast Guard units located throughout the fifty (50) United States and its territories

d. OEM - Original Equipment Manufacturer

e. Engine: - MTU 6V92 Marine Engine

f. Exchange: - Exchange of used parts for original equipment manufacture (OEM) parts

g. Overhauled: - Overhauled components with OEM parts to OEM new specifications

h. Condition Code A – Serviceable: New, used, repaired, or reconditioned materiel which is serviceable and issuable to all customers without limitation or restriction.

i. Condition Code B – Serviceable (Issuable With Qualification): New, used, repaired, or reconditioned materiel which is serviceable and issuable for intended purpose, but which is restricted from issue to specific units, activities, or geographical areas by reason of limited usefulness or short life expectancy.

j. Condition Code E – Unserviceable (Limited Restoration): Materiel which involves only limited expense of effort to restore to serviceable condition.

k. Condition Code F – (Reparable): Economically reparable materiel which requires repair, overhaul, or reconditioning.

Appendix A Work Order #_________________________________

Port/Stbd ____________________________________

Delivery Order #_______________________________

Engine Serial # ________________________________

Core Acceptance is based on the following:

a. Core must be in the configuration of Master Serial Number

b. Core must have no non-operational damage

c. Core must be a complete unit and not disassembled

NOTE: Missing parts from Appendix A are to be replaced and priced as per section B of this contract.

a. Core acceptable_______________________, non-acceptable_____________

Remarks _______________________________________________________

b. Metal shipping crate: Acceptable__________, non-acceptable_____________

Remarks _______________________________________________________

The core condition report shall include photographs of engine; front, right side, left side, and rear views to include serial number in picture frame.

APPENDIX A (CONTINUED)

APPENDIX A (CONTINUED)

Additional Comments ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Appendix B Delivery Order Number:_________________

Date:_________________________________

Unit Serial Number:_____________________

Total

Appendix C Each marine engine shall be tested by the contractor and shall be tested using an approved test plan and all requirements outlined in this specification for the marine engine as per Detroit Diesel Shop Manual 6SE379. Prior to the Coast Guard Representative arriving for the final Dyno witness, a four hour break-in shall be performed as per the Detroit Diesel Shop Manual 6SE379.

1.0 General Test Requirements

1.1 The equipment used to record/provide the dynamometer test readings shall have the capability to print required parameters in a computerized format. During the final acceptance test, the Coast Guard Representative shall be present at the Contractor’s facility and have the capability to visually monitor all required parameters as detailed in Detroit Diesel Manual 6SE379 simultaneously. Engine acceptable parameters are listed in the table below and the enclosed Dynamometer Engine Test Report.

1.2 Each marine engine shall be fitted with all "engine" equipment, with the exception of the alternator. This equipment shall be "Contractor Supplied" and used for each engine test.

1.3 The engine shall be tested as per the dyno test specifications on page 2 of Appendix C. After the final dyno test is accepted by a Coast Guard Representative, all filter elements shall be replaced.

1.4 Any unusual noises, external leakage, or if any other noncompliance to this specification, as determined by the Coast Guard Representative, shall be cause for the marine engine to be found unacceptable.

The Government reserves the right to witness any part of the overhaul and testing requirements set forth in this specification.

Upon final acceptance the contractor shall provide the Coast Guard copies of all test results.

Dyno/Manometer

DDEC

Crankcase Pressure

DYNAMOMETER ENGINE TEST REPORT

Date Serial Number ______________ Delivery Order Number Model Number _______________

A. PRE-STARTING

Step 1

PRE LUBE OIL SYSTEM

Step 2

PRIME FUEL

SYSTEM

Step 3

ADJUST VALVES

Step 4

TIME INJECTORS

Step 5

ADJUST GOVERNOR

Step 6

ADJUST INJECTOR RACKS

TIME

AT

SPEED

IN

MINUTES

B.H.P.

WATER

TEMP.

LUBE

OIL

PRESS.

1. Check oil at rocker mechanism

START

STOP

2. Inspect for lube oil leaks

3. Inspect for fuel oil leaks

4. Inspect for water leaks

5. Check and tighten all external bolts

6. Check torque on all manifold/turbo fasteners

D. INSPECTION AFTER BASIC RUN-IN

1. Re-torque Cylinder Head & Rocker Shaft Bolts

4. Re-adjust Governor Cap

2. Re-adjust valves (hot)

5. Re-adjust Injector Racks

3. Re-time injectors

6. Re-torque fuel jumper lines

E. FINAL RUN-IN

435 Plus 5%

AIR BOX PRESSURE

FULL LOAD

46.6 Min

EXHAUST BACK

PRESSURE F/L

2.5” Max

CRANKCASE

PRESSURE F/L

2.5” Max

Max

2200 RPM

FULL LOAD

Min 2050 RPM

Hg

BLOWER INTAKE

RES

12” Max

FUEL OIL PRESSURE

RET. MAN.

50-70

WATER TEMP

193 Max

LUBE OIL TEMP

250 Max

FULL LOAD

60 ± 5%

IDLE

6-9

RPM

F. INSPECTION AFTER FINAL RUN-IN

Temperature of Dyno Test Cell

Raw Water Pump Delivery pressure

Oil Viscosity Test (Falling Ball – Less then 1.5%)

Water Temperature at oil cooler inlet

K-2 Throttle Interrupt

Final Run OK’D Dynamometer Operator : Date:

Appendix D

(TO BE ATTACHED TO COMPLETED OVERHAULED ENGINE BEFORE SHIPMENT BACK TO SFLC BALTIMORE) This MTU 6V92 Marine Engine has a warranty for whichever comes first:

1 year of operation from installation

Or

1,000 hours of operation

If any discrepancies are noted upon receipt:

CALL FOR WARRANTY!

USCG SURFACE FORCE LOGISTICS CENTER

SMALL BOAT PRODUCT LINE (SBPL-SES)

CENTRAL ENGINE OVERHAUL PROGRAM

TEAMS (571) 607-2111

AFTER HOURS (443) 306-4811

The following information is needed when calling the SBPL-SES:

Date Received

Date Installed

Engine Serial No.

Engine Hours

Port/Stbd

Vessel Hull No.

Appendix D (CONTINUED) (TO BE ATTACHED TO COMPLETED OVERHAULED ENGINE BEFORE SHIPMENT BACK TO SFLC BALTIMORE)

GENERAL CHECKS UPON RECEIPT OF ENGINE

1 A complete inspection should be made of the engine’s condition.

2 Inspect the jacket water, fuel oil, lube oil and raw water systems for preservations remaining in these systems.

· Jacket water system must be flushed with “Restore” cleaner provided.

· Fuel system must be flushed completely with diesel fuel.

· Do not operate engine until the appropriate fluids are added.

3. Preservation tags on the engine will tell you to what extent the unit has been preserved and what should be done before operating the engine.

4. Uncover all taped and plugged openings prior to connecting all hoses and lines.

5. Ensure that all lube oil lines left on board are flushed and all filters are changed.

6. Ensure the engine will bar over by hand.

7. Check engine mounts.

THINGS THAT WILL NOT VOID THE WARRANTY

1. Preventative maintenance as set forth in P.M.S. manual may be performed.

2. Troubleshooting is approved, as long as the troubleshooting is in accordance with Tech Pub No. 6SE379.

3. Repairs are to be performed only after contacting Surface Forces Logistics Center SBPL (410) 762-6237. After hours call (443) 306-4811.

4. Emergency repairs/replacement of parts may be performed, but notify Engineering Logistics Center as soon as possible afterwards.

SOME THINGS THAT WILL VOID THE WARRANTY

1. Changing subassemblies

2. Changing thermostat

3. Removing the L/O cooler cores

4. Changing the exhaust manifold assembly

5. Removing gear housing

PAST INSTALLATION PROBLEMS

1. Cross connecting lube oil lines during installation

2. Failure to flush lube oil lines coming from the boat

3. Overfilling lube oil sump Appendix F

CUMULATIVE TRACKING REPORT SUBMIT BY THE 15TH OF THE MONTH

Date:

Appendix G

MTU 6V92 Marine Engine Mandatory Replacement Parts (Condition A Engines Only)

SOURCE

APPENDIX G.1

MTU 6V92 Marine Engine Mandatory Replacement Parts for Minor Repair

The use of OEM Overhauled parts is authorized. If the OEM part/component is obsolete through the OEM the contractor is authorized to overhaul the part/component at the contractors facility using OEM overhaul parts/kits.

Appendix H MTU 6V92 Marine Engine Contingency Parts List