Attachment_2_Specification_Cummins_Eng_Reman.pdf

REVISION No. 3 (as of: 26 Nov 18)

CUMMINS REMANUFACTURE SPECIFICATION

FOR

CUMMINS / MERCRUISER QSD2.8L/220

CUMMINS 6CTA8.3M1

CUMMINS QSB6.7LM

ORGINATED BY: Kenneth Brickell DATE: June 23, 2016

ORIGINATOR’S COMMAND_SURFACE FORCES LOGISTICES CENTER

DEPARTMENT / DIVISION SMALL BOAT PRODUCT LINE

INTERNAL REVIEWER_____________________________ DATE____________

SWORB APPROVAL____________________________ DATE____________

USCG-SFLC

CUMMINS REMANUFACTURE SPECIFICATION

1.0 SCOPE

1.1 General -This document sets forth the requirements for the remanufacture of the following assets to

Original Equipment Material (OEM) specifications, parts, and standards:

a. Cummins/MerCruiser QSD 2.8L/220

b. Cummins 6CTA8.3M1

c. Cummins QSB6.7L

The Contractor shall inspect each wooden or metal crate to determine crates condition. This inspection shall be documented with the crates discrepancies, plan of remanufacture or replacement, and painting and marking, and all cost associated with.

These Cummins Engines, with attached hang-ons, shall be dynamometer and, preserved, painted, packaged, and shipped back to the Coast Guard Yard, Baltimore, MD. All of the machinery being remanufacture is to be used onboard various U.S. Coast Guard boats.

1.2 Government Furnished Property (GFP) – The below listed items are property of, and managed by the USCG Surface Forces Logistic Center (SFLC) Baltimore, MD.

a. Cummins/MerCruiser QSD 2.8L/220 (NSN: 2815-01-585-2703)

b. Cummins 6CTA8.3M1 (NSN: 2815-01-450-5653)

c. Cummins QSB 6.7L / (OTH) (NSN: 2815-01-649-8159)

d. Cummins QSB 6.7L / ZF 280-1 (LRI) (NSN: 2815-01-659-4809)

e. Shipping container for Cummins / Onan Generator Set (Wooden Crate)

f. Shipping container for Cummins / MerCruiser QSD 2.8L / 220 (NSN: 8145-01-F11-2100)

g. Shipping container for Cummins 6CTA8.3M1 (NSN: 2815-01-LG4-8745)

h. Shipping container for Cummins QSB 6.7L (NSN: N/A)

2.0 APPLICABLE DOCUMENTS

2.1. Document Availability – To obtain the referenced documents see section 6.1

2.2. Government Documents – The following specifications and standards form a part of this specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the current Department of Defense Single Stock Point (DODSSP) for military specifications, standards, and related publications.

a. USCG Drawing 49A BUSL-502-50, 4 Cylinder Engine Outline

b. USCG Surfaces Forces Logistics Center- D-000-0100 REV G, Dated 2/06, Bar Coding for

USCG SFLC Material

c. USCG SFLC Standard Specification 3101

2.2.1. Military Specifications

a. MIL-L-2104F, Dated 28 Sep 1992, Lubricating Oil

b. MIL-D-3464E, Dated 21 Apr 1987, Desiccant, Activated Bag

c. MIL-PRF-32295A, Dated 19 APR 2010, Cleaner, Non-Aqueous, Low-VOC, HAP-Free

d. MIL-I-24092D, Dated 21 Sep 1993, Insulating Varnishes and Solventless Resins for

Application by the Dip Process

e. MIL-STD-2073-1E, Dated May 2008, Standard for Military Packaging (Please use this

Mil-STD for marking and packing only)

f. Preservation in accordance with O.E.M. Policy.

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)

2.3.1. American National Standards Institute (ANSI)/ National Conference of Standards

Laboratories (NCSL)

a. ANSI/NCSL Z540, Dated 2006, Requirements for the Calibration of Measuring and Test

Equipment

b. ANSI/ASQC Q9003, Dated 1994, Quality Systems – Model for Quality Assurance in

Final Inspection and Test

c. ANSI/EASA AR100, Dated 2006, Recommended Practice for the Repair of Rotating

Electrical Apparatus

2.3.2. American Society for Testing and Materials (ASTM)

a. ASTM D 975, REV C, Dated 2010, Diesel Fuel #2

2.3.3. Cummins Engine Company

a. All Cummins Bulletins that are applicable to the Coast Guard

b. Cummins/MerCruiser QSD2.8 Engine Service Manual No. 90-866941, Dated Nov 2007

c. Cummins/MerCruiser QSD2.8 Parts Manual No. 90-898181001, Dated Aug 2009

d. All Cummins/MerCruiser Bulletins that are applicable to the Coast Guard QSD2.8L

Engine

e. Cummins 6CTA8.3M1 Shop Manual No. 3666008

f. Cummins 6CTA8.3M1 Parts Manual No. 3884333

g. All Cummins Bulletins that are applicable to the Coast Guard 6CTA8.3M1 Engine

h. Cummins QSB6.7M Shop Manual No. 4310612

i. Cummins QSB6.7M Parts Manual No. 4056622

2.4. Specification Order of Precedence – In the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence.

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 for change by contractors 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 remanufacture the Propulsion Engines within one hundred (100) calendar days after approval of the Core Condition report (Appendix B). The contractor shall provide all labor, equipment, special tools, parts and materials required to accomplish the following:

a. Receive the Propulsion Unit

b. Submit a Core Condition Report (Appendix A)

c. Submit a Disassembly Report (Appendix B)

d. Remanufacture the Propulsion or Generator Set

e. Perform Dynamometer Testing (Appendix D)

f. Perform Internal Preservation

g. Perform External Preservation and Painting of Propulsion

h. Package Propulsion or Generator Set in Shipping Container

i. Preserve and Properly Label Shipping Container

j. Cumulative Tracking Report (Appendix C)

3.2. Government Furnished Property – The Government reserves the right to supply Government

Furnished Property (GFP) at anytime during the existence of this contract. The Contractor shall provide protective storage for the GFP when not in use, and safe handling when in use.

3.2.1. The storage area shall at a minimum be closed on all sides, dry, and locked when unattended.

Uncrated engines shall be stored inside at all times. Empty containers may be stored outside in a covered area.

3.3. Equipment Configuration - The following Master Serial Numbers are provided to identify the correct Coast Guard specific configuration of the machinery to be remanufactured :

a. Cummins/Onan Prime Mover, Model 4B3.9G(M), Serial No. 45797460

b. Cummins Propulsion Engine, Model 6CTA8.3M1, Serial No. 45928899

c. Cummins/MerCruiser Propulsion Engine, Model QSD2.8L/220, Serial No. 88305719

d. Cummins Propulsion Engine, Model QSB 6.7L, Serial No. 73657526

e. Twin Disc Gear, MG-507 Serial No. 3E1281

f. ZF Reduction Gear, Model 280-1, Serial No. 20205142

3.4. Internal Inspection – For any part included on the Disassembly Report (Appendix B) the

Contractor shall supply the Contracting Officer’s Representative (COR) with pictures of the faulty part, clearly displaying the part failure.

3.5. Remanufacture Parts – The Contractor shall use only OEM parts for the remanufacturing of the

Cummins Engine Company/MerCruiser/Onan, Twin Disc, and ZF Reduction Gears.

3.6. Parts- All gaskets, seals, O-rings, copper seals, hoses, belts, and sensors shall be replaced with new regardless of condition. All parts listed for each asset in Appendix F shall be replaced during the remanufacturing. All other parts not listed shall be inspected for critical dimensions and wear limits and replaced as authorized by the Contracting Officer. The Government reserves the right to supply parts as Government Furnished Property at any time during this contact.

3.7. Propulsion Unit – The Cummins QSB 6.7L Engines will have ZF Model 280-1 Reduction Gears, or a Twin Disc Model MG-507 attached that are to be included in the remanufacture process. All

Propulsion units shall be remanufactured in accordance with OEM specifications and standards, restoring each Propulsion Unit to a like new condition with warranty.

3.8. Technical Representative Services – When requested by the Contracting Officer, the Contractor shall provide OEM certified personnel for discussion, resolution, of technical problems.

Troubleshooting of technical problems may require Contractor personnel to travel to Coast Guard units. In correcting technical problems the Contractor shall abide by the following:

3.8.1. Technical Services Performed Onsite – The Contractor shall perform all services onboard the

USCG vessel unless otherwise directed by the Contracting Officer.

Hours of Operation – The Contractor employees shall generally perform all work between the hours of 0800 and 1630 local time, Monday through Friday. However, the Contractor’s employees shall be required to work other than normal business hours, including weekends and holidays.

Locations – The services will primarily be required in vessel homeports located throughout the continental United States, Hawaii and Alaska. However, with the CG missions being worldwide there may be a need for Contractor employees to travel outside of the United

States boarders.

Contractor Response – The Contractor shall be required to supply a Technical Representative to the designated location within thirty-six (36) hours after notification by the Contracting

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

Delivery Orders (D.O.) – Surface Forces Logistics Center (SFLC) will issue a D.O. 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 Technical Representative

3.9. Paint Requirement for Metal Shipping Containers- All internal & external surfaces shall have all scale and loose paint removed. The containers will then be primed as per The Society for Protective

Coatings (SSCP) Paint 25 and painted with two coats of the corresponding colors mentioned below and sited in [FED STD 595 C with CHANGE NOTICE 1] using paint in accordance with

Commercial Item Description (CID) A-A-2962A.

a. Shipping container for Cummins, QSB 6.7L – Use color # 15123

b. Shipping container for Cummins/MerCruiser QSD 2.8L/220 – Use color # 686

c. Shipping container for Cummins/6CTA8.3M1 – Use color # 15123

d. Shipping container for Cummins/Onan Generator Set – Use color # 15123

3.10. Labor – Contractor shall perform all labor, and authorized machinists, mechanics and technicians.

3.11. Core Acceptance Criteria – The Contractor shall accept the core based on a complete internal inspection and submit written notification and reasoning of non-acceptance for propulsion units not acceptable for reconditioning within ten (10) calendar days after the receipt of a propulsion unit.

3.12. Documentation – This specification sets forth the requirements for the following documentation.

a. Core Condition Report, in accordance with Appendix A

b. Disassembly Report, in accordance with Appendix B

c. Cumulative Tracking Report, in accordance with Appendix C

d. Dynamometer Test Report, in accordance with Appendix D

e. Warranty Notice in accordance with Appendix E

f. Mandatory Replacement Parts List in accordance with Appendix F

g. Contingency Parts List in accordance with Appendix G

3.13. Core Condition and Disassembly Reports – The Contractor shall submit a completed Appendix A to the Contracting Officer within ten (10) calendar days after receipt of a propulsion unit. Appendix

B will be sent to the Contracting Officer (15) fifteen calendar days after Appendix A. One hundred

(100) calendar days after approval of the Core Condition report (Appendix B). The Contractor shall have engines ready for testing. The Contracting Officer must be notified if this time line cannot be kept.

3.14 Cumulative Tracking Report – The Contractor shall maintain and submit, by the 15th of each month, the Cumulative Tracking Report, Appendix C, for all propulsion units.

3.15. Warranty - A warranty of one (1) 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 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 evaluate the Contractor’s proposed duration of warranty time.

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 exchanged/ remanufacture facility for repairs and returned to a designated Coast Guard facility after repairs have been completed.

The Contractor shall repair/rebuild the failed engine to the condition level necessary for the contractor to honor a new full warranty (to be funded by the Coast Guard.) In the event that the work is found not to be warranted, the contractor shall stop work immediately and contact the Contracting

Officer.

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.

3.16. Notifications & Inspections – The Contractor shall be responsible for notifying the Contracting

Officer’s Contracting Officer Representative (COR) at least seven (7) calendar days prior to inspections or monitored testing required herein.

3.17. Failure Analysis - In the event of a failure, the Technical Representative shall determine the cause of casualty, systems, root cause, and corrective action, and a report of the findings shall be submitted to the Contracting Officer.

4.0 QUALITY ASSURANCE

4.1. General – The Contractor shall maintain an inspection system, which shall insure that each item offered to the Coast Guard for acceptance, or approval conforms to the contract requirements. The inspection system shall be documented, meet the requirements of ASQC-Q9003-1994 and be available for review by the Coast Guard.

4.2. Records – The Contractor shall maintain records of all inspections and tests. The records at a minimum shall indicate the nature and number of observations made, the number and type of deficiencies found, and the corrective action taken.

4.3. Calibration System – The Contractor, as well as any Subcontractors, shall be required to maintain a test equipment calibration program in compliance with ANSI/NCSL Z540, Dated 2006. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.4 Responsibility for Inspection – The Contractor shall be responsible for the performance of all inspection requirements specified herein. The contractor shall provide space, personnel, and test equipment for conducting all inspection requirements. All inspection and testing shall be performed at the contractor’s plant or at other facilities acceptable to the Coast Guard. The Coast Guard reserves the right to verify or have performed any of the inspections that are deemed necessary to assure that supplies and 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 Responsibility for Compliance – All items shall meet the provisions of sections 3 & 5. The inspections set forth in this specification shall become part of the contractor’s overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the contractor of the responsibility of assuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

4.6 Inspection System – The Contractor shall maintain an inspection system, which shall insure that each item offered to the Coast Guard for acceptance, or approval conforms to the contract requirements. The inspection system shall be documented and available for review by the Coast

Guard.

4.7 Tests & Inspections – The inspections/tests required here is the minimum required and are not intended to replace any controls, examination, inspections or tests normally employed by the contractor to assure the quality of the propulsion unit.

4.7.1 Each prime mover provided under this contract shall be tested / inspected on an approved dynamometer under load to ensure the propulsion unit performance is in accordance with the manufacturer’s requirements as per Appendix D. The contractor shall complete and submit the report required in Appendix D.

4.8 Dynamometer Test Reports – The Contractor shall submit a dynamometer test report, Appendix D, within seven (7) calendar days after completion of the dynamometer test. The report shall consist of the data obtained during the dynamometer prime unit test. One copy of the report shall be packed and delivered with each generator set under this contract.

4.9 Failure Responsibility – If the Engine fails to pass any inspection/test the contractor shall report the failure and the recommended solution to the Contracting Officer. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

a. The inspection/test shall be discontinued until all corrective action has been taken.

b. After all corrective actions have been taken the inspection/test shall be continued or repeated at the option of the Contracting Officer.

c. Acceptance shall be withheld until re-inspection has been shown that the corrective action was successful and the item satisfactorily passes all inspections and tests.

d. All corrective actions shall be documented as part of the contractor’s inspection system and submitted for approval to the Contracting Officer.

4.10 Packing Inspection – The Contracting Officer’s Representative (COR) shall be notified prior to the packaging, packing and marking of the completed units in accordance with section 3.17.

5.0 PRESERVATION, PACKAGING, PACKING, & MARKING

5.1. Internal Preservation – Preservation in accordance with O.E.M. Policy shall not be started until a successful dynamometer test has been completed and accepted by the Contracting Officer’s

Representative (COR).

5.2. External Preservation – After completion of the internal preservation, the propulsion unit shall be prepared in accordance with the following procedure.

a. All surfaces shall be cleaned of grease and oil.

b. All loose scale and paint shall be removed; areas feathered and brought to a smooth surface.

c. The following items shall be masked and not painted.

1. Rubber hoses and wires

2. Alternator, Water Valves, Fuel Sight Glass

3. Hot surface areas of the turbocharger

4. All identification plates

5. The engine drive shaft output flange

6. The flywheel and rear bolt face

7. The front and rear seals

d. All exposed metal surfaces shall be primed with one coat (2-3 mils) of primer in accordance with Cummins item number SS8061. Allow a minimum of seven (7) hours to dry.

e. Two color coats approximately (2 mils); total thickness (3-5 mils) shall be sprayed on all surfaces. Allow seven (7) hours drying time between coats. The color shall be Cummins

Marine Grey part number 3375379.

f. When all paint is dry, the masking shall be removed.

g. Coat all unpainted metal surfaces with a light amount of grease, except for hot surfaces.

h. Plug any fittings/flanges or openings that will allow foreign material to enter the engine during storage.

i. Open all jacket water and raw water-cooling system petcocks and drain any residual fluid into a portable container. Once drained, close all petcocks.

j. A completed Appendix D and Appendix E shall be attached to the top of the engine in a plastic bag.

k. The Contractor shall place a total of 80 units of desiccant conforming to MIL-D-3464E

(activated bag: 1 ounce equals 1 unit), in the interior of the shipping container in the receptacle provided.

l. The Contractor shall install the propulsion unit into the metal or wooden shipping container. The Contractor shall ensure that all of the container accessories (if applicable), such as rubber engine mounts, desiccant, humidity indicator, pressure valve, and sealing gasket are in place and in good working order. The container shall be sealed such that the cover makes 100% contact with the sealing gasket.

m. The Humidity Indicator (if applicable) shall have the inner retaining nut permanently attached to the inside of the container to allow for the removal and replacement of the indicator.

5.3. Marking – Each preserved and packaged item shall be marked in the upper left-hand side and end of each box. The lettering shall be stenciled and at least 1” high, in black print lettering on a highly contrasting background.

5.3.1. This marking shall consist of the STOCK NUMBER, MODEL NUMBER, ITEM NAME, SERIAL NUMBER, CONTRACT NUMBER, DELIVERY ORDER NUMBER, GROSS

WEIGHT (in lbs), CONDITION CODE, QUANTITY AND UNIT OF ISSUE, AND

LABELED; COAST GUARD SFLC MATERIAL.

Stock Number (As per section 1.2, Example: 2815-01-033-3050)

Model Number (As per section 1.2)

Item Name (Example: Engine, Diesel)

Serial Number See Engine

Contract Number See Contract

Delivery Order Number See Delivery Order

Shipping Weight As Determined By Contractor

Condition Code Condition “A”

Quantity & Unit of Issue 1 – Each

(And the Following):

Reusable Shipping Container – Do Not Damage. Do Not Stack More Than Two High.

Remove Bolts Prior To Removing Cover. Use Forklift To Unload – Do Not Lift By Cover.

Preserved For Long Term Storage.

5.3.2. Special Markings – (IF APPLICABLE) The container shall be marked with the following special markings:

a. LOCATING DOWEL (place above locating dowel, if applicable)

b. VENT: DO NOT BLOCK (place next to vent, if applicable)

c. HUMIDITY INDICATOR (place next to indicator, if applicable)

5.3.3. The Contractor shall paint over all other marking not required by paragraph 5.3.

5.4. Bar Coding – The Contractor shall supply bar code labels on all Contract Line Item Number’s

(CLIN) except for those that require data submissions only.

5.4.1. All bar coded labels shall be in accordance with SFLC specification D-000-0100 Rev G, FEB/06.

a. The actual labels shall be Type “V“. Grade “A“, Style “2“, Composition “B” with plastic laminate.

b. Each label shall contain encoded data for the Stock Number, Contract Number, and the

Delivery Order Number as applicable.

c. The marking required in 5.3 can be applied separately or as part of the Bar Code Label.

6.0 NOTES

6.1. Government & Commercial Document Sources

6.1.1. Government Documents

a. Department of Defense Single Stock Point for Military Specifications, Standards, and

Related Publications (DODSSP Documents)

Http://dodssp.daps.dla.mil/

b. DOD & Navy Publications and Forms (Other Than DODSSP)

Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia, PA 19120

215-697-2000

c. USCG Surface Forces Logistics Center

2401 Hawkins Point Road

Baltimore, MD 21226-5000

410-762-6229

ATTN: Contracting Officer SBPL

6.1.2. Commercial Documents

a. Society of Automotive Engineers INC. (SAE)

400 Commonwealth Drive

Warrendale, PA 15096

412-776-4841

FAX 412-776-5760

b. American Society for Testing & Materials (ASTM)

1916 Race Street

Philadelphia, PA 19103-1187

215-299-5585

FAX 215-977-9679

c. American National Standards Institute (ANSI)

1430 Broadway

New York, NY 10018

212-642-4900

d. American Society for Quality Control (ASQC)

611 East Wisconsin Avenue

Milwaukee, Wisconsin 53202

e. Cummins Engine Company, INC.

500 Jackson Street

Columbus, Indiana 47202

6.2. Appendices – The following Appendices form a part of this specification.

Appendix A: Core Condition

Appendix B: Disassembly Report

Appendix C: Cumulative Tracking Report

Appendix D: Engine Testing Report

Appendix E: Warranty Notice

Appendix F: Mandatory Replacement Parts List

Appendix G: Contingency Parts List

6.3. Glossary

a. C.P.L. – Control Parts List

b. Core – Either the engine block or the generator housing including the attachments mentioned in

Appendix A.

c. Field Unit – United States Coast Guard units located throughout the fifty (50) United States and it territories.

d. O.E.M. – Original Equipment Manufacturer

e. O.E.P.L. – Original Equipment Parts List

f. Prime Mover – An engine used to transfer power, in the form of a turning motion, to the generator or reduction gear.

g. Propulsion Unit – Main Propulsion Engines listed in section 1.2, B through E.

h. Exchange – Exchange of used parts for original equipment manufacturer (OEM) parts.

i. Recondition – To recondition parts with O.E.M. parts to O.E.M. new specifications.

APPENDIX A

Core Condition Report

(For QSB 6.7L, QSD 2.8/220, and 6CTA8.3M1)

Work Order #____________

Delivery Order #__________

Engine Serial # _______________

Reduction Gear Serial # (If applicable) ___________________

Core Acceptance is based on the following:

a. Core must be in the configuration of Master Serial Numbers listed above (Section 1.2).

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 Appendix B of this contract.

1. Core Acceptable__________, Non Acceptable___________

Remarks _______________________________________________________________________________

2. Condition of shipping container;

Serviceable_______________________

Needs Repair_____________________

3. Photograph of prime mover; front, right side, left side, and rear views to include serial number in picture frame.

(CONTINUED)

Engine Model (Circle one): QSB 6.7L, QSD 2.8/220, and 6CTA8.3M1

ITEM NAME P/N MISSING

1. COOLER, LUBE OIL

2. FUEL PUMP

3. MANIFOLD, EXH, PORT

4. MANIFOLD, EXH, STBD

5. HEAD, CYLINDER

6. MANIFOLDS, INTAKE

7. DAMPER, VIBRATION

8. STARTER

9. COOLER, GEAR OIL

10. AIRSEP, (WALKER)

11. HEATER, ENGINE

12. PUMP, SEA WATER

13. HOUSING HEAT EXCH

14. EXHAUST RISER

15. EXHAUST RISER

16. TURBOCHARGER

METAL SHIPPING CONTAINER:

ITEM NAME P/N MISSING

1. HUMIDITY INDICATOR

2. SEALING GASKET

3. VALVE, PRESSURE

4. RUBBER MOUNT

5. WOOD SKID

REMARKS:

PRIME MOVER:

ITEM NAME P/N MISSING

1. COOLER, LUBE OIL

2. FUEL INJECTION PUMP

3. MANIFOLD, EXHAUST

4. TURBOCHARGER

5. HEAD, CYLINDER

6. MANIFOLDS, INTAKE

7. DAMPER, VIBRATION

8. STARTER

9. COOLER, GEAR OIL

10. AIRSEP, (WALKER)

11. HEATER, ENGINE

12. PUMP, SEA WATER

13. EXPANSION TANK

14. EXHAUST ELBOW

15. ELECTRONIC GOVERNOR

16. AIR CLEANER

SHIPPING CONTAINER (if applicable):

ITEM NAME P/N MISSING

1. HUMIDITY INDICATOR

2. SEALING GASKET

3. VALVE, PRESSURE

4. RUBBER MOUNT

5. WOOD SKID

REMARKS:

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Appendix B

Disassembly Report

Delivery Order Number: ___________________

Date: ___________________________________

Engine Model Number: ____________________

Engine Serial Number: ____________________

Reason for

Replacement Qty Part No. Part Description Unit Price Amount

Total

APPENDIX C

CUMULATIVE TRACKING REPORT

SUBMIT BY THE 15TH OF THE MONTH

Engine In

SER. #

Work # Delivery

Order #

Date

Received

Core

Accepted

Y/N

Eng Out

Ser. #

APPENDIX D

Engine/Prime Mover Testing

1.0 General Test Requirements

1.1 Readings as detailed in this Appendix are to be followed as per OEM standards for dynamometer testing. These recordings of the test procedure shall be filled out and submitted as part of the required test report. The contractor may use a similar test report in lieu of this report as long as the same information contained in this appendix is included.

1.2 Each engine shall be fitted with a lube oil filter. The engine shall be filled with MIL-L- 2104F compatible grade lube oil particular to that piece of equipment. The fuel oil shall be as per ASTM D

975 Rev C # 2 diesel and flow through an OEM filter/separator before entering engine fuel pump.

The cooling system shall be filled with clean potable water. An outside clean potable water source shall be used as raw water-cooling. All engine lube oil filter elements shall be replaced with new after completion of engine dynamometer test. Old filter elements shall be cut open and inspected for foreign material.

1.3 The engine shall be dynamometer tested with all applicable hang on attachments. Exhaust blankets and transmission are not required to be attached during dynamometer test.

1.4 The horsepower reading is read as shaft horsepower at the prime mover output flange.

2.0 Engine Parameters

2.1 Basic Run-In, 5-10 Minutes

ENGINE

MIN ACTUAL MAX

SPEED RPM

LUBE OIL PRESSURE PSI

BLOW-BY IN-H20

JACKET WATER TEMP IN DEG F

JACKET WATER TEMP OUT DEG F

LUBE OIL TEMP DEG F

ACCEPTABLE______________

UNACCEPTABLE___________

STOP ENGINE: CHECK ALL FLUID LEVELS AND TOP OFF AS REQUIRED.

2.2 Phase 1, 15 Minutes

ENGINE

MIN ACTUAL MAX

SPEED RPM

HORSEPOWER SHP

LUBE OIL PRESSURE PSI

BLOW-BY IN-H20

JACKET WATER TEMP IN DEG F

JACKET WATER TEMP OUT DEG F

LUBE OIL TEMP DEG F

ACCEPTABLE______________

UNACCEPTABLE___________

STOP ENGINE: CHECK ALL FLUID LEVELS AND TOP OFF AS REQUIRED.

2.3 Phase 2, 15 Minutes

MIN ACTUAL MAX

SPEED RPM

HORSEPOWER SHP

LUBE OIL PRESSURE PSI

BLOW-BY IN-H20

JACKET WATER TEMP IN DEG F

JACKET WATER TEMP OUT DEG F

LUBE OIL TEMP DEG F

2.4 Phase 3, 15 Minutes

MIN ACTUAL MAX

SPEED RPM

HORSEPOWER SHP

LUBE OIL PRESSURE PSI

BLOW-BY IN-H20

JACKET WATER TEMP IN DEG F

JACKET WATER TEMP OUT DEG F

LUBE OIL TEMP DEG F

NOTE: Phase 3 and after, if blow-by is too high decrease the load by one phase and run for 30 minutes.

Return the engine to the original phase’s specification and continue the run-in period.

2.5 Phase 4, 15 Minutes

ENGINE

MIN ACTUAL MAX

SPEED RPM

HORSEPOWER SHP

LUBE OIL PRESSURE PSI

BLOW-BY IN-H20

JACKET WATER TEMP IN DEG F

JACKET WATER TEMP OUT DEG F

LUBE OIL TEMP DEG F

2.6 Final Run –In, Not To Exceed 5 Minutes

MIN ACTUAL MAX

SPEED RPM

HORSEPOWER SHP

FUEL RAIL PRESSURE PSI

FUEL RATE LB/HR

LUBE OIL PRESSURE PSI

BLOW-BY IN-H20

JACKET WATER TEMP IN DEG F

JACKET WATER TEMP OUT DEG F

LUBE OIL TEMP DEG F

MANIFOLD AIR PRESSURE IN-HG

2.7 Any unusual noises as determined by the Coast Guard representative, external leakage, or any other noncompliance to this specification, the propulsion unit will be found unacceptable.

2.8 All above test will be verified and accepted by the Coast Guard Representative.

APPENDIX E

CUMMINS QSB 6.7L, 6CTA8.3M1, QSD2.8/220

WARRANTY NOTICE

This item has a warranty for whichever comes first:

1 year of operation from installation

Or

1000 hours of operation

If any discrepancies are noted upon receipt

1. DO NOT REPAIR OR REPLACE!

2. CALL: USCG SURFACE FORCES LOGISTICS CENTER

CENTRAL ENGINE OVERHAUL

SMALL BOAT PRODUCT LINE (SBPL)

COMMERCIAL (410) 762-6237/6790/6089

Have the following information ready when calling the (SBPL)

________ Date Received ________ Date Installed

________ Serial No. ________ Vessel Home Port

________ Engine Hours ________ Vessel Hull No

3. A Report of Discrepancy (ROD) Form 364 must also be submitted to Surface Forces Logistics Center.

NOTES:

(1) Preventative Maintenance (PMS) should still be performed as per applicable Maintenance Procedure

Cards (MPC’s). PMS does not void the warranty.

(2) If the above procedure is not followed, the warranty may be affected.

CUMMINS QSB 6.7L, 6CTA8.3M1, QSD2.8/220 ENGINE INFORMATION

1. General Checks Upon Receipt Of Propulsion Unit

A. A Complete Inspection Should Be Made Of The Unit's Condition.

B. Inspect The Jacket Water, Fuel Oil, Lube Oil, And Raw Water Systems For Preservatives Remaining In

These Systems.

C. Preservation Tags On The Engine Will Tell You To What Extent The Unit Has Been Preserved And

What Should Be Done Before Placing The Unit In Operation.

D. Uncover All Taped And Plugged Openings Prior To The Connection Of Hoses And Lines.

E. Insure That All Lube Oil Lines Left On Board Are Flushed And All Filters Are Changed.

F. Confirm The Calibration Of The L/O Dipstick. The Dipstick Should Be Marked To Show A Low And

High Mark With Engine At Its Installed Angle. Refer To Service Manual For Quantity.

G. Insure The Prime Mover Will Bar Over By Hand.

H. Check Engine Mounts.

2. GENERAL WARRANTY PARAMETERS

A. THINGS THAT WILL NOT VOID THE WARRANTY.

a. Preventive maintenance as set forth in applicable Maintenance Procedure Cards may be performed.

b. Basic troubleshooting as per Cummins Service Manual.

c. Any Repairs must only be performed after contacting Central Engine Overhaul for approval.

(410) 762-6237/6790/6089

NOTE: Emergency repairs/replacement of parts may be performed, but notifying Central Engine Overhaul as soon as possible, in order to confirm your warranty status.

CAUTION: LUBE OIL HAS BEEN DRAINED FROM ENGINE; DO NOT OPERATE UNIT

UNTIL FLUIDS ARE ADDED.

CAUTION: FUEL SYSTEM HAS BEEN PRESERVED. FUEL SYSTEM MUST BE FLUSHED

COMPLETELY WITH DIESEL FUEL.

CAUTION: JACKET WATER COOLANT SYSTEM HAS BEEN PRESERVED. SYSTEM MUST

BE FLUSHED .

CAUTION: DO NOT ROTATE THE ENGINE CRANKSHAFT UNTIL READY TO INSTALL

UNIT

CAUTION: REMOVE ALL COVERS, PLUGS AND TAPE COVERING OPENINGS

ADDITIONAL QUESTIONS, CALL CENTRAL ENGINE OVERHAUL AT (410) 762-6237/6159

APPENDIX F

MANDATORY REPLACEMENT PARTS LIST

MACHINERY DESCRIPTION

Manufacturer Cummins / Cummins - MerCruiser

Engine Model # QSD-2.8L/220

Description Main Propulsion Engine

Item Serial Number

MANDATORY REPLACEMENT PARTS FOR EACH

No. Description Part No. Qty. Unit Price Total Price

1 Connecting Rods 898101584 4 $682.43 $2729.72

2 Cylinder Kit (incl. Pistons/Rings) 891726 4 $664.20 $2656.80

3 Main Bearings: Std Set 879194165 1 $214.78 $214.78

4 Piston Cooler Kit 879194188 1 $107.62 $107.62

5 Gasket Set, Engine 879194153 1 $991.15 $991.15

6 Rod Bearing Set: Std 898101414 4 $27.99 $111.96

7 Belt 57-898101624 1 $74.88 $74.88

8 Decal 37-8M0021526 1 $39.13 $39.13

9 Alternator 898101505 1 $962.01 $962.01

10 Oil Separator Blow-by Valve 898101751 1 $156.33 $156.33

11 Injector Assy 898101423 4 $1124.32 $4497.28

12 Injection Pump Assy 879194120 1 $3241.08 $3241.08

13 Fuel Regulating Valve 879172103 1 $767.43 $767.43

14 Fuel Cooler 896332110 1 $597.17 $597.17

15 Turbo Charger 896332158 1 $2990.00 $2990.00

16 Air Filter 855514002 1 $218.70 218.70

17 Cylinder Head (includes valves) 900-898101415 4 $694.35 $2777.40

18 Dip Stick, Oil 898101599 1 $15.68 $15.68

19 Oil Pump 896332186 1 $346.19 $346.19

20 Thermostat Valve 879194215 1 $373.32 $373.32

21 J/W Pump Assy 896332168 1 $511.81 $511.81

22 Starter Motor 879172259 1 $895.13 $895.13

23 R/W Pump 854179001 1 $2230.20 $2230.20

24 Steering Pump 898101502 1 $778.14 $778.14

25 Belt, Steering Pump 57-898101580 1 $34.02 $34.02

TOTAL: $ 28317.93

APPENDIX G

CONTINGENCY REPLACEMENT PARTS LIST

MACHINERY DESCRIPTION

Manufacturer Cummins / Cummins - MerCruiser

Engine Model # QSD-2.8L/220

Item Serial Number

No. Description Part No. Qty. Unit Price Total Price

1 Engine QSD-2.8L/220 1 $ 36,273.17 $36,273.17

2 Engine Control Module (ECM) 896332255 1 $1694.43 $1694.43

3 Intercooler 896332112 1 $4906.46 $4906.46

4 Oil Cooler Heat Exchanger 898101491 1 $7826.40 $7826.40

5 Heat Exchanger 879194181 1 $6144.07 $6144.07

6 $

7 $

TOTAL: $ 56844.53

Manufacturer Cummins

Engine Model # 6CTA8.3M1

Item Serial Number

MANDATORY REPLACEMENT PARTS FOR EACH

No. Description Part No. Qty. Unit Price Total Price

1 Connecting Rods 3901383RX 6 $205.23 $1231.38

2 Piston Kit (incl.

Pistons/Rings)

4020059 6 $273.33 $1639.98

3 Main Bearings: Std Set 3945917 1 $253.57 $253.57

4 Piston Pins 3934046 6 $34.27 $205.62

5 Gasket Set, Engine Upper 4025271 1 $447.82 $447.82

6 Rod Bearing Set: Std 3950661 12 $13.95 $167.40

7 Cylinder Liner Kit 3800328 6 $229.51 $1377.06

8 Starter Motor 3910646 1 $461.82 $461.82

9 Gasket Set, Engine Lower 3800558 1 $513.00 $513.00

10 Alternator V-Belt 3911562 1 $13.40 $13.40

11 Alterntor 4629JA 1 $539.00 $539.00

12 Injector Assy 3802202 6 $193.09 $1158.54

13 Vibration Damper 3914450 1 $179.39 $179.39

14 Fuel Shutoff SOL Valve 3928161 1 $355.45 $355.45

15 Aftercooler 3914502 1 $528.05 $528.05

16 Turbo Charger 3527017 1 $3293.50 $3293.50

17 Air Restriction Indicator CD210 1 $22.47 $22.47

18 Air Filter CD176 1 $118.48 $118.48

19 Oil Cooler T-Stat 3923477 1 $37.02 $37.02

20 Oil Cooler Core 3918175 1 $117.21 $117.21

21 Retaining Ring 3920692 12 $2.31 $27.72

22 Valve, Intake 3802463 6 $28.46 $170.76

23 Valve, Exhaust 3921444 6 $16.87 $101.22

24 Oil Pump Kit 3802278 1 $240.14 $240.14

25 Thermostat Valve 3928640 2 $48.15 $96.30

26 J/W Pump Assy 3920509 1 $99.81 $99.81

27 Fuel Inj Pump 3921123RX 1 $2804.17 $2804.17

28 Fuel Transfer Pump 4988749 1 $59.40 $59.40

29 Elbow Hose 3920762 1 $20.74 $20.74

30 Cam Bushing 5283368 7 $13.26 $92.82

31 Hose 3897107 1 $8.85 $8.85

32 Hose 3920994 1 $14.37 $14.37

33 Hose 63495-B 1 $17.16 $17.16

34 Hose 63241-N 1 $19.19 $19.19

35 Hose 67185 2 $17.04 $34.08

36 Hose 3905034 1 $11.42 $11.42

37 Hose 3924493 1 $19.92 $19.92

38 Elbow Hose 3918607 1 $20.03 $20.03

39 Hose 3918611 5 $19.13 $95.65

40 Hump Hose 3030763 1 $38.57 $38.57

41 Hose 3897502 1 $18.87 $18.87

42 Hose 3897507 1 $32.00 $32.00

43 Hose 3905082 1 $11.65 $11.65

44 Hose 3913724 1 $31.95 $31.95

45 Hose 3913751 1 $9.03 $9.03

46 Hose 3913752 1 $9.41 $9.41

47 Hose 3286499 2 $26.86 $53.72

48 Hose Clamp 3922844 12 $8.38 $100.56

49 Hose Clamp 3922843 12 $10.81 $129.72

TOTAL $ $17049.39

MACHINERY DESCRIPTION

Manufacturer Cummins

Engine Model # 6CTA8.3M1

1 Engine 6CTA8.3M1 1 $25,000.00 $25,000.00

2 Crankcase 3934900 1 $7000.00 $7000.00

3 Crankshaft 3917320 1 $1,114.77 $1,114.77

4 $

5 $

TOTAL: $ 32114.77

Manufacturer Cummins

Engine Model # QSB6.7L

Item Serial Number

MANDATORY REPLACEMENT PARTS FOR EACH

No. Description Part No. Qty. Unit Price Total Price

1 Piston Kit 4309259 6 $213.42 $1280.52

2 Rod Bearings 3969562 6 $7.01 $42.06

3 Rod Bearings 4892795 6 $5.49 $32.94

4 Main Bearings Upper STD 5287907 6 $134.20 $793.20

5 Main Bearings Lower STD 5287908 7 $134.20 $925.40

6 Thrust Bearing STD 3978822 1 $31.24 $31.24

7 Cam Bushings 4983253 2 $13.64 $27.28

8 Sea Water Pump 5268375 1 $1148.47 $1148.47

9 Major Kit 5268424 1 $873.02 $873.02

10 Drive Belt 5307825 1 $86.80 $86.80

11 Drive Belt 4946197 1 $172.21 $172.21

12 Molded Hoses 5270525 1 $18.17 $18.17

13 Molded Hoses 70458A 1 $22.02 $22.02

14 Molded Hoses 5270529 1 $96.77 $96.77

15 Molded Hoses 5270530 1 $145.13 $145.13

16 Plain Hose 63549A 1 $23.07 $23.07

17 Hose Clamp 3922846 2 $12.35 24.70

18 Hose Clamp 3922847 4 $13.11 $52.44

19 Hose Clamp 3922849 2 $14.18 $28.36

20 Hose Clamp 3819725 2 $7.59 $15.18

21 Flexible Hose 3918496 1 $73.24 $73.24

22 Idler Shaft 3935229 1 $33.29 $33.29

23 Drive Belt Idler Pulley 3978324 1 $70.21 $70.21

24 Water Pump 5294904 1 $180.42 $180.42

25 Lube Oil Section Tube 5291847 1 $44.83 $44.83

26 Zinc Anodes Plug 68241 2 $28.93 $57.86

27 Zinc Anodes Plug 3957921 1 $29.71 $29.71

28 Zinc Anodes Plug 5290511 2 $28.94 $57.88

29 Exhaust Discharge (Riser) 3978842 1 $2369.56 $2369.56

30 Lube Oil Cooler Core 3975818 1 $441.20 $441.20

31 Lube Oil Regulator Plunger 3918428 1 $23.70 $23.70

32 Lube Oil Regulator Spring 3925009 1 $3.11 $3.11

33 Lube Oil Pressure Relief Valve 5306512 1 $5.85 $5.85

34 Flexible Hose 5293165 1 $150.20 $150.20

35 Flexible Hose 5293166 1 $148.60 $148.60

36 Oil Filter Cartridge 3903264 1 $3.30 $3.30

37 Seal and Gasket Kit Lower 4309460 1 $355.40 $355.40

38 Seal and Gasket Kit Upper 4309459 1 $947.50 $947.50

39 Cylinder Heads (Recon) 5271171NX 1 $2485.50 $2485.50

40 Injectors

Recon Equivalent

5303101

5303101 NX

6 $701.68

$701.68

4210.08

41 Fuel Pressure Pump 4989266 1 $2207.79 $2207.79

Recon Equivalent 4989266 NX $1935.09 $1935.09

42 Turbocharger Kit

Recon Equivalent

4309148

4309148 NX

1 $3293.50 $3293.50

43 Lube Oil Pump 4983496 1 $112.59 $112.59

44 Raw Water Heat Exchanger Core 5273349 1 $4024.22 $4024.22

45 Starter 5290001 1 $711.33 $711.33

46 Alternator 5293213 1 $660.54 $660.54

47 Lube Oil Filter Head Assy 3979393 1 $130.84 $130.84

48 Thermostat 5292725 1 $35.43 $35.43

49 Thermostat Seal 3954829 1 $5.04 $5.04

50 Air Cleaner Element 5309235 1 $463.94 $463.94

Total $29,175.64

MACHINERY DESCRIPTION

Manufacturer Cummins

Engine Model # QSB6.7L

1 Engine QSB6.7L 1 $36,000.00 $36,000.00

2 Crankcase 3934900 1 $7000.00 $7000.00

3 Crankshaft 3917320 1 $ 1,114.77 $ 1,114.77

4 $

5 $

TOTAL: $ 44114.77

MACHINERY DESCRIPTION

Manufacturer Twin Disc

TWIN DISC

MG-507-A1, 2.54:1 RATIO

Engine Model # 6CTA8.3M1

Description REDUCTION GEAR

Item Serial Number

MANDATORY REPLACEMENT PARTS FOR EACH

No. Description Part No. Qty. Unit Price Total Price

1 BRG KIT K964 01 $657.14 $657.14

2 GASKET AND SEAL KIT K961 01 $89.00 $89.00

3 BREATHER M2280 01 $1.16 $1.16

4 PUMP PX4917B 01 $254.79 $254.79

5 O-RING A2916DK 02 $0.78 $1.56

6 SCREEN FILTER B2130A 01 $26.28 $26.28

7 SHIM P5081 03 $3.85 $11.55

8 SHIM P5081A 03 $3.85 $11.55

9 SHIM P5710 02 $3.85 $7.70

10 SHIM P5710A 02 $3.85 $7.70

11 SHIM P5136 02 $3.85 $7.70

12 SHIM P5158 02 $3.85 $7.70

13 SHIM P5136A 02 $3.85 $7.70

14 SHIM P5136B 02 $3.85 $7.70

15 SPRING A2704BS 01 $32.10 $32.10

16 SPRING A2703AP 01 $15.32 $15.32

17 DETENT PLATE XB2134 01 $123.21 $123.21

18 SHIM B3357 03 $4.02 $12.06

19 SHIM B3357A 03 $6.17 $18.51

20 RUBBER BLOCK A3905B 26 $2.08 $54.08

21 CLUTCH PLATES SINTERED P3924C 14 $29.27 $409.78

22 CLUTCH PLATE STEEL P5389 12 $12.23 $146.76

23 SNAP RING A2669K 02 $9.96 $19.92

24 SNAP RING PM5108A 02 $9.96 $19.92

25 CLUTCH SPRING P5146 02 $55.24 $110.48

26 LOCK WASHER PM5729A 01 $2.00 $2.00

TOTAL: $ 2063.37

MACHINERY DESCRIPTION

Manufacturer Z-F Reduction Gear

Z-F GEAR

280-1 1.39:1 RATIO

WITH 12V ELECTRIC SHIFT OPTION

Engine Model # For Cummins Engines QSB 6.7L

Description Main Propulsion Engine

Item Serial Number

MANDATORY REPLACEMENT PARTS FOR EACH

No. Description Part No. Qty. Unit Price Total Price

1 GASKET KIT IRM280A-1 3803207199513 1 $263.70 $263.70

2 CLUTCH KIT 20/22 ZF280PL-1 3803207199511 1 $1402.20 $1402.20

3 MAINTENANCE KIT 3803207199510 1 $90.90 $90.90

4 O-RING, OIL PUMP 3800634303746 1 $1.80 $1.80

5 O-RING, OIL PUMP 3800634303814 1 $1.80 $1.80

6 PUMP SUPPORT 3803207306002 1 $559.80 $559.80

7 FEED BUSHING 3803207301011 1 $448.20 $448.20

TOTAL: $ 2768.40

MACHINERY DESCRIPTION

Manufacturer Z-F Reduction Gear

Z-F GEAR

280-1 3.00:1 RATIO

WITH 12V ELECTRIC SHIFT OPTION

Engine Model # For Cummins Engines QSB 6.7L

Description Main Propulsion Engine

Item Serial Number

MANDATORY REPLACEMENT PARTS FOR EACH

No. Description Part No. Qty. Unit Price Total Price

1 GASKET KIT IRM280A-1 3803207199513 1 $263.70 $263.70

2 CLUTCH KIT 20/22 ZF280PL-1 3803207199511 1 $1402.20 $1402.20

3 MAINTENANCE KIT 3803207199510 1 $90.90 $90.90

4 O-RING, OIL PUMP 3800634303746 1 $1.80 $1.80

5 O-RING, OIL PUMP 3800634303814 1 $1.80 $1.80

6 PUMP SUPPORT 3803207306002 1 $559.80 $559.80

7 FEED BUSHING 3803207301011 1 $448.20 $448.20

TOTAL: $ 2768.40