6V92_SOW_Dyno_Repair_Paint.doc

Enclosure (3) 6V92 DDEC IV Repair Specification

REVISION No. H

CHANGE No.

SPECIFICATION OR

STATEMENT OF WORK

COVER SHEET

TITLE

Detroit 6V92 DDEC IV ENGINE

TROUBLESHOOT/REPAIR & DYNO

SPECIFICATION

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

1.1 Purpose - This specification is for the Dyno,minor repair, paint, preservation and packaging of non-ready for issue (E Condition) 6V92 DDEC IV Detroit Diesel marine engines for ready for issue (B Condition) 6V92 DDEC IV Detroit Diesel marine engines and hang-on equipment. .

The contractor will repair the CG 6V92 marine engine with Detroit Diesel OEM parts unless otherwise noted in this specification using Master Serial #06VF-222697.

In the event Detroit Diesel or 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 6V92 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:

a. This requirement is for the repair & dynamometer testing of the USCG MTU 6V92 engine(s) installed on the 47’ Motor Lifeboat (MLB).

All maintenance, repair, and overhaul services performed on the MTU 6V92 engine must be executed exclusively by MTU-certified technicians.

This policy is mandatory to ensure the highest standards of quality, performance, and reliability as intended by the manufacturer.

To uphold warranty conditions and ensure engine longevity, the following terms are non-negotiable:

· No Subcontracting: The engagement of any third-party or subcontracting entities for any portion of the work is strictly prohibited. The authorized MTU service provider is responsible for all work performed by its direct, certified staff.

· Certified Technicians Only: All technicians must have completed extensive, official MTU training and be certified to perform work on the specified engine series.

· Genuine Parts: Only genuine MTU Original Equipment Manufacturer (OEM) parts and consumables are to be used for any service or repair.

The use of non-genuine parts or service by unauthorized providers may void the engine's warranty.

· Authorized Service Centers: All service must be conducted through an officially authorized MTU service outlet to guarantee adherence to factory-specified procedures and to maintain the validity of any existing warranties.

· Dynamometer Testing: After completion of repairs, the engine shall be tested on a dynamometer owned and operated by the MTU Authorized Service Center. The duration of the testing shall be 1 hour with a full power pull at a minimum of 30 minutes.

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

Receive engine

b. Uncrate engine

c. Perform dynamometer testing (Appendix C)

d. Submit Repair Report (Appendix B)

e. Repair engine after receiving approved additional funding from Contracting Officer.

f. Reassemble engine

i. Perform dynamometer testing, if needed (Appendix C)

j. Preserve

k. Paint (touch up) l.

Package and mark engine and crate

3.2 Engine - The marine engines shall be stored inside and kept from all weather.

3.3 Parts, Engine

The contractor shall use only Detroit Diesel O.E.M parts meeting O.E.M. specifications. For O.E.M. parts no longer available and rendered obsolete by the O.E.M, the contractor shall request from the Contracting Officer Representative (COR) permission to use aftermarket parts. 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.

The following components of the 6V92 engine may be overhauled at a Certified MTU/Daimler Distributor’s facility versus replaced by an authorized MTU/Daimler Distributor as needed.

· 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 USCG 6V92 engine.

3.5 Hoses & Fittings – As needed, the contractor is authorized to manufacture and assemble all hoses & fittings on the 6V92 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 6V92 engines.

3.7 Wiring Harness – As needed, wiring Harnesses for the 6V92 engines shall be installed new in the remanufactured 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 Detroit Diesel 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.

3.11 Core Acceptance Criteria - The contractor shall accept the core based on a visual walk around inspection as per Appendix A. If during the internal core inspection the contractor identifies concerns with the core condition, conditions will be negotiated per paragraph 2.4.1.

3.12 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

3.13 Warranty - A warranty of one year from installation or 1000 operating hours, whichever occurs first and 24 months of storage is required covering any repairs of the marine engine. Storage commences upon receipt of engine at the designated Coast Guard 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.

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.

5.0

PRESERVATION PACKAGING, AND MARKING

5.1 ENGINE PRESERVATION (Internal) - Preservation shall be completed as per Detroit Diesel 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 d.

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

6.3

GLOSSARY

CPL: - Control Parts List

Core: - Detroit Diesel 6V92 DDEC IV Marine Engine

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

O.E.M.: - Original Equipment Manufacturer

e. Engine: - Detroit Diesel 6V92 DDEC IV Marine Diesel Engine f.

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

Remanufactured: - Remanufacture components with O.E.M parts to O.E.M new specifications

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 on the contractor’s onsite Dynamometer and shall not be sub-contracted to another entity. NO EXCEPTIONS! The engine 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 This item 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 THE WARRANTY HOTLINE:

USCG ENGINEERING LOGISTICS CENTER

SMALL BOAT PRODUCT LINE

CENTRAL ENGINE OVERHAUL PROGRAM

TEAMS (571) 607-2111

AFTER HOURS (443) 306-4811

The following information is needed when calling the SFLC:

Date Received

Date Installed

Engine Serial No.

Engine Hours

Port/Stbd

Vessel Hull No.