ATTACHMENT 1 SPEC_MTU 20V4000M93L QL4 with appendix.pdf

REVISION No. 1 CHANGE No.

MTU 20V4000M93L QL4 OVERHAUL AND ANALYSIS

P-233-2044

ORIGINATED BY Richard Biagiotti DATE 02/2020

ORIGINATOR’S COMMAND SFLC PBPL

DEPARTMENT / DIVISION SFLC-PBPL-AMS1

INTERNAL REVIEWER Patrick Mulrooney DATE 02/2020

SWORB APPROVAL_______________________ __DATE________

1.0 SCOPE

1.1. This specification describes the requirements for the overhaul of non-ready for issue MTU 20V4000M93L marine diesel engine. The engines to be overhauled have reached the time interval, in accordance with (IAW) MTU Maintenance Schedule MA50075, in which 12,000 hour maintenance tasks are required, or may have experienced a catastrophic failure.

1.2. The specification describes the requirements for commissioning services of a newly installed overhauled MTU 20V4000M93L engine.

1.3. The specification describes the requirements for technical support for the MTU 20V4000M93L engine system.

1.4. This specification describes the requirements for wear analysis of the MTU 20V4000M93L engine to determine appropriateness of maintenance as applicable to a 1DS (continuous operation, variable, low load) engine.

1.5. This sets forth the requirements for the following equipment which will be issued to the contractor as Government Furnished Equipment (GFE);

a. ENGINE, DIESEL P/N 20V4000M93L, NSN 2815-12-392-7931, 26,900 lbs

b. CONTAINER, METAL ASSEMBLY, P/N 101PPI1001, NSN 8150-01-F18-5402, 6,640 lbs

c. FACTORY WOODED SKID, P/N None, 2,250 lb

2.0 APPLICABLE DOCUMENTS

2.1. APPLICABLE DOCUMENTS – The following documents form a part of this specification to the extent specified herein.

2.2. GOVERNMENT DOCUMENTS-

a. SFLC Specification- D-000-0100, Bar Coding for Coast Guard Material.

2.3. COMMERCIAL DOCUMENTS - The following documents form a part of this specification to the extent specified herein. The documents shall be the most current version listed by number and date from the referenced industry organization. Commercial documents may also be listed in the Department of Defense Index of Specifications and Standards (DODISS).

a. MTU 20V4000M93L Functional Description MA13029

b. MTU 20V4000M93L Operating Instructions MA15071

c. MTU 20V4000M93L Maintenance and Overhaul Manual MA22019

d. MTU 20V4000M93L Removal Spaces and Weights MS68001

e. MTU 20V4000M93L Maintenance Schedule MA50075

f. MTU 20V4000M93L Instruction for General Overhaul MA25014

g. MTU 20V4000M93L Instructions for Overhaul of Sub-Assemblies MA20011

h. MTU 20V4000M93L Spare Parts Manual MA30188

i. MTU Fluids and Lubricants Specification A001061

j. MTU Preservation and Re-preservation Specifications A001070

k. ANSI/NCSL Z540 3 2006.08.03, Requirements for the Calibration of Measuring and Test Equipment.

l. ANSI/ASQC Q90003-1994, Inspection System

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, unless otherwise specified herein. The Contractor shall notify the Contracting Officer in writing prior to continuing work of any perceived conflicts contained herein.

2.5. DEPARTUARE FROM SPECIFICATION – Departure from this specification shall not be allowed unless approved by the Contracting Officer.

a. If the Contractor finds it necessary to suggest implementing change or depart from applicable specifications they shall request permission.

b. Request for change shall clearly describe the changes proposed, the reason for change, advantages of the proposed changes, price increase or decrease (if any) resulting from the change.

3.0 REQUIREMENTS

3.1. GENERAL – The contractor shall overhaul the engine and components listed in MTU Maintenance Schedule MA50075. All 12,000 operating hour tasks shall be accomplished.

a. Contractors who possess a current MTU distributor agreement authorizing the service of their products shall provide proof of this agreement to the Contracting Officer. Any changes and/or modifications to the distributor agreement shall be forwarded immediately to the Contracting Officer. The Coast Guard reserves the right to request from the contractor proof of their distributor agreement at any time.

b. The contractor must have access to service bulletins applicable to the 20V4000M93L engine.

c. The contractor shall provide, when requested by the Contracting Officer, detailed evidence of their experience overhauling, repairing, and testing of the MTU 4000 03 marine diesel engine and components listed in this specification.

d. The Contractor shall have access to MTU’s secure MTU IT Business portal and the MTU Central Data Base.

e. All tools and test equipment shall be calibrated in accordance with section 4.3

f. The contractor shall ensure all work performed under this contract is by technicians possessing the training, qualifications, and MTU certifications (specified in the referenced manuals) to the level appropriate for the specific task they are performing.

Any work performed by un-certified/qualified, or under certified/qualified technicians will be subject to contractual remedies.

g. The overhaul and component inspections shall be completed using current MTU parts, components, processes, and practices.

h. Testing shall be conducted in accordance with run-in and acceptance test procedure.

i. The contractor shall notify the Contracting Officer fourteen (14) days prior to all testing. The Coast Guard reserves the right to witness all testing.

j. The overhauled engine shall be dynamometer tested to full load, 4,216KW, IAW MTU run-in/acceptance test procedures. When run-in and full load dynamometer testing cannot be conducted on-site, the engine shall be load tested to a minimum 2,700KW on-site with full load test completed at a remote facility when authorized by the Contracting Officer.

k. The contractor shall provide an electronic copy of the Engine Inspection Report (Birth Certificate) fourteen (14) days upon completion of testing.

l. Upon receipt of components, regardless of condition, the contractor shall store material inside in a secure area away from adverse weather.

m. The contractor shall be capable of overhauling a minimum of eight (8) engines per year.

n. The contractor shall submit for approval an acceptable wear analysis plan and conduct wear analysis on the MTU 20V4000M93L marine diesel engines using the approved wear analysis plan.

o. The contractor is solely responsible to facilitate and coordinate subcontractors’ performance requirements.

p. The contractor shall submit reports within the time line set forth in the delivery schedule.

q. The contractor shall submit resume’ of the following Key Personnel; Primary Project Manager (PM) and Alternate Project Manager (APM). Personnel shall be the single point of contact for the Contracting Officer and the Contracting Officers

Representative. The name, position, title, experience of these persons shall be stated in writing to the Contracting Officer prior to contract award. The PM and APM shall be abreast of all support the contractor is currently providing the USCG under this contract, and shall be able to address inquiries from the Contracting Officer and the Contracting Officers Representative regarding that support. The PM shall be able to read, write, speak and understand English fluently.

r. Disregard references to American Bureau of Shipping (ABS) certification. This not applicable to specification.

3.2. OVERHAUL/REPAIR ENGINE – When directed by the Contracting Officer, using the applicable MTU Technical Publications and Standards, the contractor shall provide all labor, equipment, special tools, materials, and parts to receive, inspect, overhaul, test, preserve, paint, package, and provide warranty for the engine and components listed in MTU Maintenance Schedule MA50075. All 12,000-hour maintenance tasks shall be accomplished. The contractor shall incorporate, at no cost to the Coast Guard, all applicable MTU engine service bulletin modifications. The contractor shall complete these requirements in accordance with the referenced delivery order.

a. The contractor shall receive a non-ready for issue engine, NSN 2815-12-392-7931 and shipping container(s), document the as-received condition, inspect shipping container(s), and submit Appendix (A) within the date specified in 1-0 of the Contract’s Delivery Schedule.

b. The contractor shall disassemble engine, inspect, and submit condition found report Appendix (B) within the date specified in 3-0 of the Contract’s Delivery Schedule.

Include cost estimate for any additional work.

c. Upon written approval from the Contracting Officer the contractor shall crate and ship to the Coast Guard, 2401 Baltimore, MD 21226, any engine found to be non-repairable. Engine to be free of hazardous material.

d. The contractor shall maintain critical dimensions documentation, as specified in Instruction for General Overhaul MA25014, and made available to Contracting Officer or Contracting Officer Representative (COR) upon request.

e. The contractor shall conduct a dynamometer test in accordance with the run-in and acceptance test procedure on overhauled engine per Appendix (C) and submit report within the date specified in 4-0 of the Contract’s Delivery Schedule.

f. The contractor shall preserve the engine IAW MTU Preservation and Re-preservation Specifications A001070. Freeze protection is required IAW, chapter 5.3.2, Storage with unfilled medium circuits. Use internal preservation corrosion inhibitor Glysacorr P133 antifreeze at 50% volume or equivalent. Submit to the Contracting Officer MTU Check Sheet for Preservation upon preservation completion.

g. The contractor shall paint the overhauled engine with Valspar LIC 50 general purpose polyurethane enamel RAL9010 white following all manufactures surface preparations, mixing ratios, and dry times. Paint shall be sprayed on all surfaces 3-5 mils thick.

h. The contractor shall package the overhauled engine in the GFE container IAW Preservation and Re-preservation Specifications A001070, chapter 8.2, Climate-compatible long term storage. Mark overhauled engine IAW section 5.4 of this specification.

i. The contractor shall submit a cumulative tracking report on the 15th of each month with status of all open delivery/task orders Appendix (D).

3.3. ENGINE ANALYSIS –In accordance with 5-0 of the Contract’s Delivery Schedule the contractor shall submit for Contracting Officer approval their in-depth analysis plan describing the nondestructive testing methodology to ascertain engine wear and appropriateness of the current maintenance schedule. At a minimum the plan shall include the following; indications of operator induced wear (for example low load conditions), indications of maintainer induced wear (for example improper valve lash adjustment), observed wear relative to anticipated wear, and internal corrosive wear.

Include in the plan which components to be analyzed, the quantity to be analyzed (for example all injectors, all cylinder liners), the level of testing (for example laboratory testing, comparative, measurements, etc.) to be completed, and how maintenance periodicity appropriateness to be determined. The analysis shall be conducted on an engine inducted for overhaul.

3.3.1- When directed by the Contracting Officer conduct wear analysis.

3.3.2- The contractor shall deliver to the Contracting Officer an electronic copy of Report of Engine Wear Analysis within the date specified in 5-0 of the Contract’s Delivery Schedule. At a minimum the report shall all include; all findings, operator recommendations, maintainer recommendations, and recommend new maintenance schedule based upon analysis findings.

3.4. COMMISSION ENGINE- When directed by the Contracting Officer the contractor shall provide a technical representative for two (2) days to provide start-up commissioning services on the overhauled 20V4000M93L engine(s) aboard a154’ WPC in accordance with MTU specifications. This shall be accomplished at a location designated by the Coast Guard seven (7) days after notification. The contractor shall submit a Commissioning Report, Appendix (E) within the date specified in 4-0 of the Contacts Delivery Schedule. When commissioning services cannot be completed because of an existing shipboard discrepancy, the contractor shall submit a condition found report and a cost estimate to correct discrepancies using rates section 3.5 of this specification.

3.5. TECHNICAL SUPPORT- When directed by the Contacting Officer the contractor shall provide technical support for the 20V4000M93L propulsion system to include; the Engine Control System (ECS), Machinery Control and Monitoring System (MCMS), and Remote Control System (RCS) at the location determined by the Coast Guard. This support includes, but is not limited to; phone support, on-site technical assistance to equipment diagnostics, troubleshooting, and repairing equipment faults. All requests for technical support will authorized by the Contracting Officer under a separate task order.

3.6. ROOT CAUSE FAILURE ANALYSIS- In the event of a catastrophic failure of a 20V4000M93L engine the Contracting Officer, on a separate task order, may send the failed engine to the contractor’s facility to determine the root failure. A report of findings shall be submitted to the Contracting Officer within the date specified in 7-0 of the Contract’s Delivery Schedule.

3.7. WARRANTY- The engines are being overhauled as system stock and will be placed into inventory and not for immediate installation. The Contractor shall provide a warranty for a period of one (1) year from installation or 1,000 operating hours, whichever comes first, following up to 24 months in storage. Storage commences upon receipt of the component at the designated Coast Guard facility. The warranty commences the date the engine is installed on a 154’ WPC. The warranty shall cover all parts and workmanship defects.

The contractor shall contact the 154’ WPC cutter within twenty –four (24) hours after receiving notification by the Coast Guard of a warranty claim.

3.8. TRAVEL- The contractor shall be required to travel to support this statement of work section 3.5 Technical Support. Costs for transportation, lodging, meals, and incidental expenses incurred shall be reimbursed using the current Federal Travel Regulations and not to exceed the maximum per diem and lodging rates for the time/location of performance. See Federal Acquisition Regulation (FAR) 31.205-46 (a)(2).

4.0 QUALITY ASSURANCE

4.1. GENERAL - The Contractor shall maintain an inspection system which shall ensure each item offered to the Coast Guard for acceptance conforms to contract requirements. The system shall be documented and in compliance with ANSI/ASQS Q90003.

4.2. RECORDS - The Contractor shall maintain records of all measurements, 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 request of Contractors Officers Representative (COR).

4.3. CONTRACTORS CALIBRATION SYSTEM - The Contractor as well as any Subcontractors shall be required to 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. The system shall include as a minimum, prescribed calibration intervals, source of calibration, and a monitoring system to ensure 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 Contractors Officers Representative (COR) 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 Coast

Guard. The Coast Guard 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 ensure that supplies or services conform to the prescribed requirements.

4.5. REQUIRED TESTS - Each component provided under this contract shall be operationally tested when required by MTU procedures.

4.6. TEST REPORT - The Contractor shall submit the final test reports in accordance with this specification.

a. One copy of the test reports shall be packed with each component delivered under this contract.

b. One electronic copy of the test reports shall be provided to the Contracting Officers Representative (COR).

4.7. PACKING INSPECTION - The Contracting Officer shall be notified after preservation seven (7) days prior to the packaging, and marking of the completed units. The Coast Guard reserves the right to perform an on-site inspection if deemed necessary.

5.0 PRESERVATION, PACKAGING, PACKING, & MARKING

5.1. PRESERVATION (Internal) – In accordance with section 3.2(e) of this specification.

5.2. PRESERVATION (External) - In accordance with section 3.2(e) of this specification.

5.3. PACKAGING– Each engine shall be packaged in accordance with MTU Preservation and Re-preservation Specifications A001070, section 8.2, in climate-compatible long term storage packaging in either the GFE issued re-usable skid mounted wooden box or steel shipping container (NSN 8150-01-F18-5402). The contractor shall notify the Contracting Officer of any damage to the GFE packaging. When the contractor is issued a skid mounted wooden box and also a steel a shipping container, the contractor shall package the engine in the steel shipping container and dispose of the now surplus skid mounted wooden box.

Each container shall be internally braced and cushioned to prevent movement of the assembly. The contractor shall ensure the internal is bracing capable of protecting the assembly while in storage and from rough handling during multiple shipments.

a. The Contractor shall place in a plastic envelope in each container, copies of all test and inspection results, caution tags, and coolant flush instructions to be completed prior to light off.

5.4. MARKING – Each preserved, packed, and packaged item shall be stenciled in the upper left-hand side of the two longest sides, (two opposite sides if square) of each box.

a. Machine made stencils shall be used for all marking.

b. All marking shall be in black print on a contrasting back ground (white paint) and at least 2” high.

c. The marking shall be in the format as follows:

NATIONAL STOCK NUMBER 2815-12-379-7231

ITEM NAME ENGINE, DIESEL

PART NUMBER 20V4000M93L

SERIAL NUMBER “As per Enclosed Item” CONTRACT NUMBER See Contract DELIVERY ORDER NUMBER As submitted on the Order SHIPPING WEIGHT As Determined by Contractor

QUANTITY & UNIT OF ISSUE 1- EA

PRESERVED FOR LONG TERM

STORAGE ON Date preserved

CONDITION CODE CONDITION A

OTHER DATA AS COAST GUARD SFLC MATERIAL

DIRECTED REUSABLE CONTAINER,

DO NOT DAMAGE.

DO NOT DESTROY.

d. The following marking shall be placed on all four sides and the top of each box, in stenciled black print at least 2” high.

Reusable Container- Do Not Damage Remove Bolts Prior To Removing Cover Use Forklift To Unload Do Not Lift By Cover

5.5. BAR CODING – Bar code labels shall be supplied on all crates.

a. All bar coded labels shall be in accordance with SFLC specification D-000-0100.

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

c. Each label shall contain encoded data for the Stock Number, Delivery Order Number and Contract Number.

6.0 GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

6.1. GOVERNMENT DOCUMENTS

a. USCG Surface Forces Logistics Center 707 Ordnance Road Baltimore, MD 21226 Attn: Technical Information Management Branch 410-762-6471

6.2. COMMERCIAL DOCUMENTS

a. Rolls-Royce Solutions Americas

39525 Mackenzie Drive Novi, MI 48377 248-560-8000 https://www.mtu-solutions.com/eu/en.regionselect.html_

b. International Organization for Standardization American National Standards Institute (ANSI) 1430 Broadway New York, NY 10018 212-642-4900

6.3. ENCLOSURES – The following enclosures apply;

a. Appendix A QL4 Receiving Inspection Report

b. Appendix B QL4 Condition Found Report

c. Appendix C QL4 Run-in and Acceptance Test Procedure

d. Appendix D QL4 Cumulative Tracking Report

e. Appendix E QL4 Commissioning Report

f. Attachment #1 Warranty Information https://www.mtu-solutions.com/eu/en.regionselect.html_

Appendix A QL4 Receiving Inspection Report

Delivery Order # __________________

Engine Serial # __________________ ECU7 Serial # __________________ EMU Serial # __________________ A1 Turbo Serial # __________________ A2 Turbo Serial # __________________ B1 Turbo Serial # __________________ B2 Turbo Serial # __________________ Jacket Water Pump Serial # ____________ Raw Water Pump Serial # __________________ HP Fuel Pump Serial # __________________

Remarks (missing parts):

Core Acceptance is based on the following;

a. Core must have no non-operational damage.

b. Core must be a complete unit and not disassembled.

1. Core acceptable__________, non-acceptable___________

2. Shipping crate: Serviceable_________ Needs Repair____________

Include photograph of engine front side, right side, left side, and rear views to include engine serial number in picture frame.

Appendix B QL4 CONDITION FOUND REPORT

Date

Delivery Order #

Engine Serial #

Nomenclature Part Number Condition Found QTY Price

Appendix C QL4 Run-in and Acceptance Test Procedure

USCG FRC MTU 20V4000M93L main propulsion diesel engine post QL4 engine run-in and acceptance testing shall be conducted in accordance with specification P-233-2044. The engine shall be tested on a dynamometer utilizing the following test schedule and record the results on the MTU 20V4000M93L Engine Inspection Report. The facility shall use a dynamometer rated for 4300 kW at 2100 rpm.

These tests will include operating the engine at various speeds and loads along with static demonstration of the safety shutdowns.

Any unusual noises, external leakage, or any other noncompliance to this specification, as determined by the U.S. Coast Guard representative, shall be cause for the propulsion engine to be found unacceptable.

1. General Test Requirements

a. Test requirements and readings of all required parameter values as detailed in this test plan are to be recorded during the test procedure at the times shown on the USCG FRC MTU 20V4000M93L Acceptance Test Diagram.

b. The overhaul engine shall produce 4,300 kW (25°C intake air and 25°C raw water) corrected value per ISO 3046 (Reciprocating Internal Combustion Engine Performance) and ISO 15550 (Measurement of Internal Combustion Engine Power). Relative humidity and altitude shall be recorded.

c. The U.S. Coast Guard representative shall witness the acceptance test.

d. ECU7 (Governor) and EMU (Ext. Monitoring Unit) serial numbers shall be included on the USCG FRC MTU 20V4000M93L Engine Inspection Report

e. The following contractor furnished equipment shall be fitted to the engine.

i. Lube oil priming pump

ii. Fuel Pre-filter

iii. Pre-warming coolant heater

iv. Coolant expansion tank

2. Pre-Test Requirements

a. Engine Coolant System

i. The engine shall be tested using coolant approved for the 20V4000M93L diesel engine as listed in the MTU Fluid and Lubricants Specification A001061/XX (Current edition).

ii. Fill engine cooling system ensuring vents are open and air is released from cooling system.

iii. Coolant temperature operating range is set by ECU7.

(1) Pre heater set point 40 °C

(2) Minimum permissible temperature for full load operation 60 °C

(3) Maximum permissible temperature 90 °C

iv. Coolant to be tested per MTU coolant test procedures prescribed in MTU coolant test kit prior to filling the engine. Coolant test readings shall be recorded on the checklist included in this document.

b. Lubricating Oil System

i. The engine shall be tested using lube oil that is MTU approved oil for the USCG FRC

MTU 20V4000M93L diesel engine as listed in the MTU Fluid and Lubricants Specification A001061/XX (Current edition).

ii. Any internal failures, including but not limited to; loss of lube oil pressure, lube oil cooler, head gasket, exhaust manifold, running gear, gear train failures or cases of high fuel oil dilution require the replacement of the automatic oil filter candles and the cleaning of the oil indicating filter.

iii. Two engine oil samples shall be taken. One before and one after the test run.

iv. Clean the oil indicating filter upon conclusion of acceptance test. Report findings.

v. Minimum permissible lube oil temperature for full load operation 60 °C

vi. Maximum permissible lube oil temperature 90 °C

c. Fuel Oil System

i. The engine shall be tested using fuel that conforms to MTU approved for the USCG FRC

MTU 20V4000M93L diesel engine as listed in the MTU Fluid and Lubricants Specification A001061/XX (Current edition).

ii. The contractor shall install new primary and secondary engine fuel filters for the engine tests.

iii. Prior to acceptance trial fuel must be approved for use.

iv. The contractor shall provide a fuel analysis spec sheet, tested using the following routine test slates and test methods outlined below verifying fuel used for testing meets or exceeds specifications.

Test Slate 1

Fuel Property Test Method Acid Number ASTM D664

Appearance (number rating and qualitative) @25°C

ASTM D4176

Ash ASTM D482 Biodiesel EN 14078 Carbon Residue (10% Bottoms) MCRT ASTM D4530 Cetane Index (4 variable) ASTM D4737 (1) Color (3) Report Density @15°C ASTM D4052 Flash Point (2) ASTM D93 Lubricity, HFRR ASTM D6079 Storage Stability ASTM D5304 Pour Point (2) ASTM D97 Sulfur ASTM D5453 Viscosity @40°C ASTM D445

Test Slate 2

Particle Count ISO 4406 Particulate Contamination ASTM D6217 Filter Blocking Tendency ASTM D2068 Water ASTM D6304

Test Slate 3

Particle Count ISO 4406 Particulate Contamination ASTM D6217 Filter Blocking Tendency ASTM D2068 Water ASTM D6304

Notes:

(1) Report of distillation temperatures as included in ASTM 4737 (90% recovery temperature, °C).

(2) All temperatures shall be reported in degrees Celsius (°C).

(3) Fuel may be dyed in accordance with government regulations. For dyed fuel, report color of fuel only (red, blue, green, etc.). An ASTM test method is not needed.

(4) Filtration time is included in ASTM D5452 test method for Particulate Matter.

Filtration time shall be reported separately

d. Air System

i. Air filtration must be authorized by MTU for the 20V4000M93L engine.

ii. Filtered air connections shall be made to the 4 turbocharger air inlet elbows

iii. Air temperature for the acceptance test shall be 38 ± 2 °C corrected IAW ISO 3046 and

ISO 15550.

iv. Intake air depression before the engine at full load for the acceptance test shall be 25 ± 1.5 mbar

v. Exhaust back pressure after engine at full load for the acceptance test shall be 34 ± 1.5 mbar

e. Raw Water System

i. Raw water temperature for the acceptance test shall be 32 ± 2 °C or corrected IAW ISO

3046 and ISO 15550.

3. Pre-Start Requirements

a. Connect MTU Diasys dialog unit to ECU7. Prepare to record all required parameters.

b. Lubricate the valve gear.

c. Fill and vent the engine cooling system and acknowledge on the checklist included in this document.

d. Connect fuel lines and prime fuel system and acknowledge on the checklist included in this

e. Fill and pre-lubricate the engine via the electric driven lube oil priming pump. Ensure a minimum of .4 bar is reached. Acknowledge on the checklist included in this document

f. Connect raw water source to engine. Prime and vent the raw water system and acknowledge on the checklist included in this document.

g. Connect the filtered air source to the engine air inlets and acknowledge on the checklist included in this document.

h. Conduct functional safety pre-tests.

i. Conduct static (non-running) “Overspeed” test and acknowledge on the checklist included in this document.

ii. Conduct static (non-running) “Emergency Stop” test and acknowledge on the checklist included in this document.

4. Initial Start-up

a. Start engine and idle with no load for approximately 1 minute. Conduct a general check for oil leaks, fuel leaks, coolant leaks, abnormal noises, and correct functioning of engine and the engine control system.

b. Secure engine.

c. Check engine oil level. If necessary top up oil. Record all oil added on the checklist included in this document.

d. Check for valve gear lubrication and acknowledge on the checklist included in this document.

5. Perform Engine Run-in Test

a. Perform the engine “run-in” in accordance with the USCG FRC MTU 20V4000M93L Post QL4 Run-In procedure. At the end of the run-in, verify oil and coolant temps are set for full load operation as noted above.

b. Secure the engine and prepare for the acceptance test.

6. Acceptance Test

c. Acceptance test to be conducted IAW USCG FRC MTU 20V4000M93L Acceptance Test Diagram and recorded on the USCG FRC MTU 20V4000M93L Engine Inspection Report.

7. Oil Consumption

a. The lubricating oil consumption shall be measured during the acceptance test and recorded on the checklist included in this document.

8. Oil Indicating Filter

a. Inspect and clean oil indicating filter and record findings on the checklist included in this

USCG FRC MTU 20v4000M93L Post QL4 Test Checklists

Pre-Start Checklist Technician Initials

Engine mounted to test stand, properly aligned, and connected to dynamometer

Cooling System is filled and vented and checked for leaks. Engine pre-heater energized.

Coolant Test Values

Make up Water Hardness (0 – 15 °D) _____________°D

Make up water pH (6.5 – 8.0) _____________pH

Make up water Chloride content (100 mg/lit max) __________mg/lit

Prepared Coolant Inhibitor Concentration (9 – 11% by volume) ______________%

Prepared coolant pH (7.0 – 9.0) _____________pH

Lube oil filled to full mark on engine dipstick and fresh oil sample taken

Valve covers removed; valve gear lubricated

Lube oil system pre-lubed and checked for leaks. During priming checked valve gear lubrication. Installed valve covers.

Pre-lube Oil Pressure (.4 bar min) ______________bar

New fuel pre-filters, primary filters, and secondary filters installed

Fuel system primed and checked for leaks

MTU Diasys dialog unit connected to ECU7 and data recording set-up

Pre-Start Checklist (continued) Technician

Raw water system connected and primed

Filtered inlet air connected to engine

Dyno Facility Ambient Temperature: ________ °C

Dyno facility control system and mechanical system alignment checked

MTU engine control system (ECS) operating properly

Static MTU ECS overspeed and E-stop tests performed

Initial Start Checklist Technician

Engine started and idled under no load for approximately 1 minute Engine secured General checks performed

Lube oil level checked and topped up to full on dipstick

Valve covers removed; valve gear lubrication verified

Acceptance test documents on hand

• USCG FRC MTU 20V4000M93L Acceptance Test Diagram

• USCG FRC MTU 20V4000M93L Engine Inspection Report

Acceptance Test Checklist Technician

Start MTU Diasys data recording

Start engine, check for leaks Acceptance Test Start Time ____________

Performed acceptance test:

• IAW the USCG FRC MTU 20V4000M93L Acceptance Test Diagram

• Document All required information on the USCG FRC MTU 20V4000M93L

Engine Inspection Report

Post Test Checklist Technician

Engine secured 10 minutes Lube oil topped-up Gallons Oil Consumed ____________

MTU 20V4000M93L Oil indicating filter cleaned and contents filtered Filtered contents checked for abnormal contamination

**Ensure USCG FRC MTU 20V4000M93L Engine Inspection Report is attached**

During the dyno-testing of this engine, the following personnel were in attendance:

Test Technician (print): _____________________________________ Date: ______________

Signature_______________________________________________

Shop Foreman (print): _____________________________________ Date: ______________

Signature_______________________________________________

Customer Rep (PBPL) (print): _____________________________________ Date: ______________

Signature_______________________________________________

RPM

Load (Nm) 500 800 1100 1350 1650 1750 1850 1995 2100

Time (mins) 10 5000 10 9460 10 12450 10 14615 10 17200 10 18000 10 19500 10 19552 20 19170 1hr 40 mins

USCG MTU 20V4000M93L Post QL4 Run-In Schedule

Notes:

This run-in combined with the acceptance trial will give the engine a total run time of approximately 4 hrs 40 mins.

USCG FRC MTU 20V4000M93L Acceptance Test Diagram

Data Recording

(Engine Stop)

(Idle) n =Idle

P = 0% PN

5 min n = 100% nN

P = 100% PN

60 min

4 TC

pe

PN = 100%

n = 57.1% nN

P = 16.8% PN

10 min

1 TC

n = 84.5% nN

P = 60% PN

30 min

10 min

3 TC

n = 100% nN

P = 100% PN

30 min

4 TC

nN = 2100 rpm PN = 4216 kW tcycle

10 min n = 100% nN

P = 85% PN

n = 75% nN

P = 50% PN

10 min

4 TC

2 TC

5 min n = 100% nN

P = 100% PN

4 TC

Ramp up time (0 kW /500 1/min to 4216 kW/ 2100 1/min): 40 s Ramp down time (4216 kW/ 2100 1/min to 0 kW /500 1/min): 23 s

400 m 0.82-0.86 g/cmᵌ 25°C >42700 KJ/kg 60% MTU Approved 25°C

Time Speed Torque Engine Power Pressure Temp. Pressure Pressure FSN Pressure Temp.

Consump Specific Injector Air Air Air (soot) Consump Factor before before before after before after before before before Turbo Turbo after after after before H.P. in before before after hr:min Engine Engine Engine Engine Pump Pump Engine Cyl. Cyl. A B Engine Engine Engine (how acq.) Engine Pump Rail Engine Pump Pump or (dyno?) (dyno?) (dyno?) (dyno?) (dyno?) ECS ECS ECS (dyno?) ECS (dyno?) ECS ECS ECS ECS ECS ECS A B (dyno?) (dyno?) ECS ECS (dyno?) (dyno?) EMU sec. rpm Nm kW kg/h g/kWh no. Unit bar degC degC degC bar bar degC degC bar abs. rpm rpm degC degC mbar - degC degC bar degC bar bar 06:30 Start 300 500 94 5 9.2 1885.4 35 2.5 75 75 77 0.7 1.1 39 64 0.98 0 0 208 159 0 0.54 32 59 600 32 0.7 0.8

1800↓ 2100 19172 4216 954.3 226.3 764 7.5 76 76 86 1.1 6.6 38 46 4.01 59869 58696 509 504 34 1.18 32 67 1850 32 0.5 4.0 2100 4216

600 1775 60% 600 1200 16.8% 300 500

1800 2100 4216 300 500 600 1575 50% 300 500 300 2100 85%

1800↓ 2100 4216 2100 4216

300 500 09:35 Stop

OK

Automatic Test Protocol /Measurements averaged/ also valid without signiture

Lube Oil Filter Check:

182539708

EMU Serial No.

No faults or deficiencies occurred during the acceptance test.

For authorized overhaul facility

Dataset No. XZ59654100226 In case of sensor value 0 no sensor system available.

Depending on intake air temperature the rated power as well as operation values can deviate from technical sales documentation (TSD)

Exhaust Gas Fuel System Raw Water Temperature Pressure

ECU7 ADEC Serial No.

182537665

Temperature Pressure Temperature Speed Temperature

Page Date Testbench Operator

11/4/2019 CG Yard Smith/Jones

Model No.

Serial No.

Order No.

20V4000M93L

528102984

750039 Barometric Pressure Direction of Rotatation

ISO 1204

ccw (counter clockwise)

960 mbarSite Altitude Above Sea Level Intake Air Temperature Relative Humidity Raw Water Temperature

--kW at --kW at

Fuel Stop Power 4300 kW at

-- rpm -- rpm

2100 rpm

USCG FRC MTU 20V4000M93L

Engine Inspection Report

Fuel Lube Oil Coolant Charge Air

Power Calculation

Py=2πM(n/60)/1000

Fuel Type Spec Desity at 15°C Calorific Value Lube Oil Type

DIN EN 590 Power Definition acc. ISO 3046 Continuous Power Overload Power

QL4 CUMULATIVE TRACKING REPORT

Appendix D

SUBMIT QUARTERLY BY THE 15TH OF THE MONTH

Engine Serial #

D/O # Date Received

Core Accepted Y/N

Completed

Appendix E QL4 COMMISSIONING REPORT

Delivery Order #

Engine Serial #

Ref: MA25014/03E INTRUCTIONS FOR GENERAL OVERHAUL

1. Ensure engine installation satisfactorily complete.

2. Prepare the engine to put into operation

3. Pre heat engine

4. Manually operate prelube pump for 30 minutes – verify oil pressure is at least 0.4 bar during this time

5. Manually operate fuel boost pump for 10 minutes

6. After both prelube and boost pumps have completed their runs, disconnect the X4 connector from the ECU and press the start button. The engine will run through one crank cycle, but will not start.

7. Repeat step 6 a second time

8. Reconnect X4 and start the engine at LOP

9. Allow engine to idle for 10 minutes

10. Conduct operational checks

11. Check monitoring system and ECU

12. Raise engine speed to 1000 RPM for 10 minutes

13. Raise engine speed to 1600 RPM for 10 minutes

14. Raise engine speed to 2100 RPM for 5 minutes

15. Lower back to idle speed for 10 minutes

16. Shut down engine at LOP

17. Request cutter sea trials and perform acceptance test run with DisSys recording.

18. Perform after shutdown service

19. Submit final commissioning report

Note: Throughout this process, there should be a diasys recording of the EMU, with all parameters. This recording shall be provided with final report.

Attachment # 1

Warranty Information

Warranty Period for this MTU 20V4000M93L Engine:

(1) Year from Date of Installation

****After installation scan and email this completed form to****

USCG SFLC PBPL AMS1

Richard.P.Biagotti@uscg.mil

410-590-7208

Unit Name: Engine Serial

Number

Hull Number:

Homeport: Date Received:

POC: Date Installed:

Telephone:

Upon Installation

Task Commanding Officer’s Signature Date

Verify Removal of Transportation Locking Device

Verify All Engine Monitoring, Alarm, and Safety Systems are Working Properly

Any discrepancies noted upon receipt/during warranty period mailto:Richard.P.Biagotti@uscg.mil

DO NOT REPAIR OR REPLACE!!!

Repairs are to be performed only after contacting Patrol Boat Product Line

OFFICE PHONE: (410) 590-7173.

AFTER HOURS Call your Asset Manager

!!Any unauthorized repairs could void the WARRANTY!!

• At 50 Hours check/adjust all valve clearances and record each. MPC A15015.D

• At 50, 250, and 500 hours of initial operation, engines shall have oil samples drawn and sampled. MPC A54020.O

• At 500 hours change oil, clean centrifuge filter, inspect oil indicator. MPC A54024.D, A54006.D, A54007.D

1. GENERAL CHECKS UPON RECEIPT OF ENGINE

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 CONNECTING

OF HOSES AND LINES.

E. INSURE THAT ALL LUBE OIL LINES LEFT ON BOARD ARE FLUSHED AND

ALL FILTERS ARE CHANGED.

F. INSURE PROPER SHAFT ALIGNMENT, IF ENGINE IS INSTALLED WHILE THE

CUTTER IS OUT OF THE WATER, YOU MUST WAIT 24 HOURS AFTER THE

CUTTER IS PLACED IN THE WATER BEFORE ALIGNING THE SHAFT. ALL

TANKS MUST BE TOPPED OFF.

G. CONFIRM THE CALIBRATION OF THE L/O DIPSTICK.

H. INSURE THE PROPULSION UNIT WILL BAR OVER BY HAND.

I. CHECK ENGINE MOUNTS.

J. ANY PROBLEMS DURING THE INSTALLATION WITH THE ENGINES SHOULD

BE REPORTED TO PATROL BOAT PRODUCT LINE IMMEDIATELY.

2. GENERAL WARRANTY PARAMETERS

A. THINGS THAT WILL NOT VOID THE WARRANTY.

1. Scheduled maintenance may be performed.

2. Troubleshooting the unit in accordance with TP 8019.

NOTE: Emergency repairs/replacement of parts may be performed, but notify the Patrol Boat Product Line Team immediately.

B. SOME THINGS THAT COULD VOID THE WARRANTY

1. Changing subassemblies without authorization.

2. Changing thermostat without authorization.

** CAUTION: OIL HAS BEEN DRAINED FROM ENGINE AND GEAR; DO NOT

OPERATE UNIT UNTIL FLUIDS ARE ADDED.

** CAUTION: FUEL SYSTEM HAS BEEN PRESERVED WITH INJECTION PUMP

TESTING OIL AND CORROSION INHIBITOR. FUEL SYSTEM MUST

BE FLUSHED COMPLETELY WITH DIESEL FUEL.

** CAUTION: JACKET WATER COOLANT SYSTEM HAS BEEN PRESERVED WITH

ANTIFREEZE OR COOLING SYSTEM CONDITIONER AND HAS

BEEN DRAINED. DO NOT OPERATE UNTIL FLUID HAS BEEN

ADDED.

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

INSTALL UNIT.

** CAUTION: REMOVE ALL COVERS, PLUGS AND TAPE COVERING OPENINGS.

NOTICE: FOR FURTHER INFORMATION REFER TO TP 8019 OR CALL

PATROL BOAT PRODUCT LINE TEAM

REPAIRS ARE TO BE PERFORMED ONLY AFTER CONTACTING THE

PATROL BOAT PRODUCT LINE (PBPL) TEAM

OFFICE PHONE: (410) 590-7173.

AFTER HOURS: Call your Asset Manager.