SPEC 024R233224 FNAL.pdf

Enclosure (4) 12V71 Engine Remanufacture Specification

REVISION No.___B_____ CHANGE No.______

SPECIFICATION OR

STATEMENT OF WORK

COVER SHEET

TITLE

12V71 DIESEL ENGINE REMANUFACTURE SPECIFICATION

SPECIFICATION NUMBER

026-R-233-224

ORIGINATED BY PO J. Vial DATE 11/97_____

REVISION (B) ORIGINATED BY Michael McHale DATE_03/09_______

ORIGINATORS COMMAND ENGINEERING LOGISTICS CENTER (ELC)

DEPARTMENT/DIVISION SMALL BOAT PRODUCT LINE BRANCH

INTERNAL REVIEWER DATE

SOWRB APPROVAL DATE

1.0 SCOPE

1.1 Purpose - This specification is for the remanufacture of non-ready for issue 12V71 Detroit

Diesel marine engines, Twin Disc MG-514 transmissions and hang-on equipment.

The Coast Guard will require the contractor to overhaul a non ready for issue remanufactured marine engine assembly, using Master Serial #12VA66188 for the Port marine engine, and Master Serial #12VA80667 for the Starboard marine engine, provided by Detroit Diesel. The contractor will reassemble the remanufactured marine engine with Detroit Diesel and Twin Disc remanufactured OEM equipment.

The marine engine with attached transmission and hang-ons, referred to as a propulsion unit, must be dynamometer tested, preserved, painted, and packaged. The propulsion unit (one of a pair) is installed in the U.S. Coast Guard 55FT. A.N.B. The propulsion unit will be provided to the contractor in a reusable wooden shipping crate.

1.2 Government Furnished Property - This specification sets forth the requirements for the following equipment:

a. 12V71 PORT Propulsion Unit (NSN 2815-01-120-4016)

b. 12V71 STBD Propulsion Unit (NSN 2815-01-1200992)

c. Wooden Shipping Crate

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

b. MIL-L-21260D AMEND I, 11 OCT 90, Lubricating Oil, Grade 30

c. MIL-D-3464E 21 APR 87, Desiccant, Activated Bag

d. TT-P-664D 28 AUG 92, Coating, Primer Alkyd

e. D-000-100, Oct. 91, Bar Coding for Coast Guard Engineering Logistics Center Material

2.3 Commercial Documents

a. ASQC Q9003-1994, 18 JUL 94, Inspection System

b. ANSI/NCSL Z540-1-1994 DATED 1994, General Requirements for Calibration

Laboratories and Measuring and Test Equipment

c. ASTM D 975-02 DATED 10 Jan 2002, Diesel Fuel Oils

d. Chemtex Product Bulletin DATED DEC 1996 for "MOLYKOTE XP"

e. Detroit Diesel Manual 6SE193 DATED OCT 1989

f. Twin Disc Service Manual SM-190 DATED 0CT 1989 (MG-514)

2.4 Specification Precedence - Any conflict between this

specification and applicable documents identified in this specification shall be resolved in this order:

a. This specification

b. Applicable documents

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

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

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

3.0 REQUIREMENTS

3.1 General - The contractor shall remanufacture propulsion units within sixty (60) calendar days after approval of the Core Condition report (Appendix A) by the Contracting Officer. The contractor shall provide all labor, equipment, special tools, and materials required to accomplish the following sequence of activities:

a. Receive propulsion unit

b. Uncrate propulsion unit

c. Disassemble and clean engine

d. Submit Core Condition Report (Appendix A)

e. Submit Disassembly Report (Appendix B)

f. Remanufacture propulsion unit

g. Reassemble propulsion unit

h. Complete Boat Alterations (Appendix E)

i. Perform dynamometer testing (Appendix C)

j. Preserve

k. Paint

l. Package and mark propulsion unit and crate

3.2 Propulsion Unit - Propulsion units shall be remanufactured within SIXTY (60) calendar days after approval of Core Condition Report, Appendix A. The propulsion units shall be stored inside and kept from all weather.

3.3 Parts, Propulsion Unit - All Detroit 12V71 parts listed in Appendix G shall be a mandatory replacement. All other Detroit Diesel 12V71 components and parts listed in Appendix H shall be replaced upon the contingency of inspection. All Twin Disc parts listed in Appendix I shall be a mandatory replacement. All other Twin Disc components and parts listed in Appendix J shall be replaced upon the contingency of inspection. Contingent parts shall be inspected for critical dimensions and wear limits and replaced as authorized by the KO. All gaskets, seals, O rings and copper seals shall be replaced as new. The contractor shall use only Detroit Diesel and Twin Disc O.E.M parts meeting O.E.M. specifications. All propulsion units provided under this specification will utilize Detroit Diesel Remanufactured marine engine, using Master Serial #12VA66188 for the Port engine, and Master Serial #12VA80667 for the Starboard engine to affect the remanufacturing of the Detroit Diesel 12V71 marine engine.

The Twin Disc MG-514 transmission shall be reconditioned or new. 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.

3.4 Labor - All labor is to be performed by Detroit Diesel and Twin Disc certified and authorized machinists and mechanics.

3.5 Core Condition Report - The contractor shall submit to

the contracting officer in writing within ten (15) calendar days after receipt of the propulsion unit, a completed Appendix A.

3.6 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.

3.7 Cumulative Tracking Report - The contractor shall maintain and submit, by the 15th of the month, for the previous month; the Cumulative Tracking Report Appendix F, for all propulsion units.

3.8 Documentation - This specification sets forth the

requirements for the following documentation.

a. Core Condition Report, in accordance Appendix A

b. Disassembly Report, in accordance with Appendix B

c. Dyno Test Report, in accordance with Appendix C

d. Cumulative Tracking Report, in accordance with Appendix F

3.9 Boat Alterations and Engineering Changes - The Boat Alterations and Engineering Changes are required to be incorporated as per Appendix E.

3.10 Warranty - A warranty of one year from installation or 1000 operating hours, whichever occurs first and 24 months of storage is required covering the entire propulsion unit. Storage commences upon receipt of propulsion unit 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 Contracting Officer of a warranty claim.

The contractor shall contact ELC’s Contracting Officers Technical Representative (COTR) to evaluate the contractors proposed duration of warranty repair time.

In the event the Coast Guard decides the proposed warranty repair time compromises the Coast Guards mission and decides removal/replacement, the contractor shall coordinate and fund all necessary shipping arrangements for the failed engine to be returned to the origin of remanufactured facility for repairs and returned to a designed 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 CG) including assigning a new serial number and the zeroing of hours. 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.

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

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

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

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

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

Component measurements and related data shall be recorded as necessary.

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

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

3.12 Technical Representative Services – When requested by the Contracting Officer; the Contractor shall provide OEM certified personnel for discussion, resolution, and repair of technical problems. Troubleshooting and repair of technical problems may require Contractor personnel to travel to Coast Guard units. In correcting technical problems the Contractor shall abide by the following:

HOURS OF OPERATION – The Contractor employees shall generally perform all work between the hours of 0800 and 1630 local time, Monday through Friday. However, Contractor 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.

CONTRACTOR RESPONSE – The Contractor shall be required to supply the Technical Representative to the designated location within Thirty-Six (36) hours after notification by the Contracting Officer.

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

DELIVERY ORDERS – Engineering Logistics Center (ELC) will issue a D.O. stating where and when the services are required. ELC 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.

The report shall be in the format of (APPENDIX K).

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 with contract requirements. The system shall be documented and in compliance with ANSI/ASQC Q9003.

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 Z540-1. The system shall include as a minimum, prescribed calibration intervals, source of calibration, and a monitoring system to insure adherence to calibration schedules. Calibration standards shall be traceable to the National Institute of Standards and Technology (NIST). Documentation in support of this requirement shall be readily available for Government review.

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

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

a. 4.6 Test Report

b. 5.2 Engine preservation (internal)

c. 5.3 Engine preservation (external)

d. 5.4 Marking/Barcoding

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

5.0 PRESERVATION PACKAGING, AND MARKING

5.1 TRANSMISSION PRESERVATION - Fill transmission to max level with MIL-L-21260D SAE

30 oil. Rotate input and output shafts at least five revolutions, drain all oil completely, install drain plugs, and seal all openings that allow seepage from the transmission during storage.

5.2 ENGINE PRESERVATION (Internal) - Preservation shall be completed as per Detroit Diesel

Manual 6SE193 for extended storage (Unless directed by contracting officer) with the following exceptions:

5.2.1 Detroit Diesel Manual 6SE193 Section 15.3 Page 1 Procedure 1 Subparagraph change to:

a. Refill with clean, soft water/ethylene glycol antifreeze mixture and add Corrosion

Inhibitor Adjunct Molykote XP (as per product information directions).

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

5.2.2 Detroit Diesel Manual 6SE193 Section 15.3 Page 1 Procedure 8 Subparagraph change to:

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

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

5.3.1 Surfaces shall be cleaned and grease/oil free.

5.3.2 All loose scale and paint shall be removed, uneven paint layers shall be sanded smooth.

5.3.3 The following items will be masked and not painted:

a. Reduction Gear output flange and seal

b. Rubber hoses and wires

c. Glass and chrome gauge bezels and covers

d. Identification plates

e. Any discharge or breather openings

f. Flywheel rear bolt face

g. Front and rear seals

5.3.4 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.

5.3.5 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 p/n 5194975.

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

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

5.3.8 Plug or cap all fittings, flanges, and openings that allow seepage from the propulsion unit during storage.

5.3.9 Wrap propulsion unit as per ASTM D 4649-87 Packaging, Shrink Wrap.

5.3.10 The contractor shall attach to the base of the shipping container one (1) gallon bottle of

"RESTORE" 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.

5.3.11 The contractor shall install the propulsion unit into the supplied shipping crate.

5.4 MARKING - Each shipping crate shall be stenciled in the upper left-hand side of the two longest sides, (two opposite sides if square). 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.

a. Machine made stencils shall be used for all marking not on the bar code labels.

b. All markings shall be in white or black which ever is most contrasting print and at least 2" high. The contractor shall paint over all other marking not outlined in 5.4.1.

5.4.1 This marking shall be in the format as follows:

Port Unit

STOCK NUMBER 2815-01-120-4016

ITEM NAME Diesel Engine 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 (Date preserved)

CONDITION CODE CONDITION A

OTHER DATA AS DIRECTED COAST GUARD ELC MATERIAL DIRECTED

REUSABLE CRATE, DO NOT

DAMAGE. DO NOT STACK MORE THAN TWO HIGH

Starboard Unit

STOCK NUMBER 2815-01-120-0992

ITEM NAME Diesel Engine 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 (Date preserved)

CONDITION CODE CONDITION A

OTHER DATA AS Directed COAST GUARD ELC MATERIAL

REUSABLE CRATE, DO NOT

DAMAGE. DO NOT STACK MORE

THAN TWO HIGH

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

a. Reusable Crate- Do Not Damage, Remove Bolts Prior To Removing Cover, Use Forklift

To Unload Do Not Lift By Cover.

5.4.3 BAR CODING - Bar code labels shall be supplied on all Contract Line Item Numbers (CLIN), except for those that require data submissions only.

a. All bar coded labels shall be in accordance with ELC specification D-000-100.

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, the Contract Number, and the Delivery Order Number.

6.0 NOTES

6.1 GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

6.1.1 GOVERNMENT DOCUMENTS

a. Specifications and Standards (DODISS Documents)

Standardization Document Order Desk 700 Robbins Avenue Building #4, Section D Philadelphia, PA 19111-5094 215-697-1187

b. DOD & Navy Publications & Forms (NOT DODISS).

Naval Publication and Forms Center 5801 Tabor Ave.

Philadelphia, PA 19120 215-697-2000

c. Engineering Logistics Center

2401 Hawkins Point Rd.

Baltimore, MD 21226-1792 410-762-6473 Code 046

6.1.2 COMMERCIAL DOCUMENTS

a. Detroit Diesel Corp.

13400 Outers Drive Detroit, Michigan 48239-4001 313-592-5000

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 to this specification.

a. Appendix A

b. Appendix B

c. Appendix C

d. Appendix D

e. Appendix E

f. Appendix F

g. Appendix G

h. Appendix H

i. Appendix I

j. Appendix J

k. Appendix K

6.3 GLOSSARY

a. CPL: Control Parts List.

b. Core: Detroit Diesel 12V71 marine engine with attached Twin Disc marine gear.

c. Field Unit: United States Coast Guard units located through out the fifty (50) United

States and its territories.

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

e. PROPULSION UNIT: Detroit Diesel 12V71 Marine Diesel Engine with attached Twin

Disc MG-514 Transmission.

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

g. REMANUFACTURE: To remanufacture components with O.E.M parts to O.E.M new specifications.

Appendix A

Core Condition Report

Work Order #____________ Port/Stbd _________ Delivery Order #__________ Engine Serial # __________ Transmission 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.

1. Core acceptable__________, non acceptable___________ Remarks ___________________________________

2. Shipping crate; Serviceable_________ Needs Repair____________

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

NAME P/N MISSING

1. CYLINDER HEAD ASSEMBLY 5172759 (2EA) ________

2. BRACKET, ENGINE LIFTING 5128441 ________

3. BRACKET, ENGINE LIFTING 5137761 ________

4. FLYWHEEL HOUSING 5132454 ________

5. FLYWHEEL 5174748 ________

6. OIL PAN, UPPER 5128045 ________

7. OIL PAN, LOWER 5143994 ________

8. HOUSING, OIL COOLER 5122716 ________

9. COOLER ASSEMBLY, 12 PLATE 8547561 ________

10. COVER, OIL COOLER ADAPTER 5130998 ________

11. PUMP ASSEMBLY, FRESH WATER 23506763 ________

Appendix A (CONTINUED)

12. MANIFOLD, EXHAUST 5167140 (2EA) ________

13. AIR SILENCER ASSEMBLY 5134402 (2EA) ________

14. FUEL PUMP ASSEMBLY 5146343 ________

15. BLOWER ASSEMBLY, REAR 5103533 (2EA) ________

16. TURBO CHARGER ASSEMBLY 5103838 (2EA) ________

17. INTERCOOLER ASSEMBLY, FRONT 5124107 ________

18. INTERCOOLER ASSEMBLY, REAR 5144485 ________

19. FUEL FILTER ASSEMBLY 6436419 ________

20. FUEL STRAINER ASSEMBLY 6438518 ________

21. FUEL COOLER 5136348 ________

22. GOVERNOR ASSEMBLY 5144128 ________

23. BRACKET,ENGINE SUPPORT,REAR 5117533 (2EA) ________

24. BRACKET,ENGINE SUPPORT,FWD 5117460 (2EA) ________

25. BRACKET, REDUCTION GEAR 5117528 ________

26. BRACKET, REDUCTION GEAR 5117531 ________

27. PTO ASSEMBLY (PORT) C111HP3 ________

29. VALVE COVER 5196749 (2EA) ________

30. STARTER MOTOR (PORT) 1109979 ________

31. STARTER MOTOR (STARBOARD) 1109962 ________

32. REDUCTION GEAR MG-514 5102800 ________

33. TANK,HEAT EXCHANGER ASSY. 5117713 ________

34. ELEMENT, HEAT EXCHANGER 8532343 ________

35. RAW WATER PUMP 23507972 ________

36. ALTERNATOR 8SA3064PC ________

37. STRAP, ALTERNATOR ADJUSTING 5101370 ________

38. BRACKET, ALTERNATOR 5101371 ________

39. ADAPTER, TACHOMETER DRIVE 5136249 ________

40. VALVES, SHUT OFF 3116561 (2EA) ________

41. TURBO INSULATING BLANKET 5144640 (2EA) ________

42. INSULATING BLANKET 5144639 (2EA) ________

43. SWITCH 8923909 ________

44. SWITCH, WATER TEMPERATURE 5146080 ________

45. FUEL STRAINER 5575824 ________

46. SOLENOID, 24 VOLT SHUTDOWN 1118191 ________

47. SWITCH, OIL PRESSURE, 5 PSI 23520023 (1EA) ________

Appendix B

DISASSEMBLY INSPECTION REPORT

Delivery Order Number:_________________

Date:_________________________________

Unit Serial Number:_____________________

Reason for Replacement Qty Part No. Part Description Unit Price Amount

Total

Appendix C

ENGINE/TRANSMISSION TESTING

Each marine engine and transmission shall be tested by the contractor and shall be tested using an approved test plan and all requirements outlined in this specification for engine as per Detroit Diesel Shop Manual 6SE193 and for transmission as per Twin Disc MG-514 570M Dated 10/20/95, spin test.

1.0 General Test Requirements

1.1 The equipment used to record/provide the dynometer test readings shall have the capability to print required parameters in a computerized format. During the final acceptance test, the Coast Guard Representative shall have the capability to visually monitor all required parameters as detailed in Detroit Diesel Manual 6SE193 simultaneously.

1.2 Each engine shall be fitted with all "engine" equipment. This equipment shall be "Contractor Supplied" and used for each engine test. (ALL FILTER ELEMENTS SHALL BE REPLACED).

2.0 Operational run-in test stage one: The engine shall be tested separately as per dyno specifications.

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 propulsion unit to be found unacceptable.

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

DYNAMOMETER ENGINE TEST REPORT

Date Serial Number ______________

Delivery Order Number Model Number _______________

PRE-STARTING

ep 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

BASIC RUN-IN C. RUN-IN INPECTION

TIME

1. Check oil at rocker mechanism

TIME

AT

SPEED

IN

MINUTES

START

STOP

R.P.M.

B.H.P.

WATER

TEMP.

LUBE

OIL

PRESS.

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

INSPECTION AFTER BASIC RUN-IN

Re-torque Cylinder Head & Rocker Shaft Bolts

4. Re-adjust Governor Cap

Re-adjust valves (hot)

5. Re-adjust Injector Racks

Re-time injectors

6. Re-torque fuel jumper lines

FINAL RUN-IN

TIME TOP RPM

START

STOP

NO LOAD

Max

2200 RPM

FULL LOAD

Min 2050

RPM

B.H.P.

435 Plus 5%

AIR BOX PRESSURE

FULL LOAD

43” Min

EXHAUST BACK

PRESSURE F/L

2.5” Max

CRANKCASE

PRESSURE F/L

2.5” Max

Hg

Hg

H²º

LUBE OIL PRESSURE BLOWER INTAKE

RES

12” Max

FUEL OIL

PRESSURE

RET. MAN.

50-70

WATER TEMP

210 Max

LUBE OIL TEMP

250 Max

FULL LOAD

60 ± 5%

IDLE

55 ± 3%

IDLE SPEED

H²º

Lbs

RPM

INSPECTION AFTER FINAL RUN-IN

emperature of Dyno Test Cell Pyro Temperature (4” pass turbo exhaust ) ° aw Water Pump Delivery pressure Oil Viscosity Test (Falling Ball – Less then 1.5%) ater Temperature at oil cooler inlet

2 Throttle Interrupt nal Run OK’D Dynamometer Operator : Date:

Appendix D

WARRANTY NOTICE

This item has a warranty for whichever comes first:

1 year of operation from installation or

1,500 hours of operation

If any discrepancies are noted upon receipt:

DO NOT REPAIR OR REPLACE!

CALL THE WARRANTY HOTLINE:

USCG ENGINEERING LOGISTICS CENTER

Machinery Propulsion Branch (026)

CENTRAL ENGINE OVERHAUL PROGRAM

COMMERCIAL (410) 762-6229

CELL PHONE/AFTER HOURS (443) 306-4811 ALTERNATE (443) 790-2448

The following information is needed when calling the

ELC:

________ Date Received ________ Date Installed ________ Engine Serial No. ________ Port/Stbd.

________ Engine Hours ________ Vessel Hull No.

NOTES:

(1) Normal Preventative Maintenance (PMS) should still be performed. PMS does not void the warranty

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

Appendix D (CONTINUED)

DETROIT DIESEL ENGINE INFORMATION

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. ENSURE THAT ALL LUBE OIL LINES LEFT ON BOARD ARE

FLUSHED AND ALL FILTERS ARE CHANGED.

F. ENSURE THE PROPULSION UNIT WILL BAR OVER BY HAND.

G. CHECK ENGINE MOUNTS.

GENERAL WARRANTY PARAMETERS

THINGS THAT WILL NOT VOID THE WARRANTY

a. Preventative maintenance as set forth in P.M.S.

manual may be performed.

b. Troubleshooting the propulsion unit in accordance with

TECH. PUB. NO. 6SE193.

Appendix D (Continued)

Repairs are to be performed only after contacting Engineering Logistics Center (410)762-6237/6791/6790/6738/6796. After hours call the CEO cell phone (443) 306-4811 alternate (443) 443-790-2448.

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

SOME THINGS THAT WILL VOID THE WARRANTY

1. Changing subassemblies.

2. Changing thermostat.

3. Removing the L/O cooler cores.

4. Changing the exhaust manifolds or turbocharger assembly

5. Removing gear housing.

PAST INSTALLATION PROBLEMS

A. CROSS CONNECTED L/O LINES DURING INSTALLATION.

Causing an overheated condition and L/O pump failure.

B. FAILURE TO FLUSH INSTALLED L/O LINES.

Contaminating the propulsion units L/O system, causing engine failure.

C. OVER FILLING LUBE OIL SUMP.

Causing rear seal leaks.

D. FAILURE OF P.T.O.

Caused by improper disengagement, and running at excessive engine R.P.M.

Appendix D (CONTINUED)

CAUTION: LUBE OIL SYSTEM HAS BEEN PRESERVED WITH

MIL-L-21260D PRESERVATIVE OIL. LUBRICATING OIL

HAS BEEN DRAINED FROM ENGINE AND GEAR, DO NOT

OPERATE UNIT UNTIL FLUIDS ARE ADDED.

CAUTION: FUEL SYSTEM HAS BEEN PRESERVED WITH NOX-

RUST NO. 518. FUEL SYSTEM MUST BE

FLUSHED COMPLETELY WITH DIESEL FUEL.

CAUTION: JACKET WATER COOLANT SYSTEM HAS BEEN

PRESERVED WITH MOLYKOTE XP. SYSTEM MUST

BE FLUSHED WITH "RESTORE" CLEANER

PROVIDED. FOLLOW DIRECTIONS ON BOTTLE.

CAUTION: DO NOT ROTATE THE ENGINE CRANKSHAFT OR

GEAR OUTPUT SHAFT UNTIL READY TO

INSTALL UNIT

CAUTION: REMOVE ALL COVERS, PLUGS AND TAPE

COVERING OPENINGS

NOTICE: FOR FURTHER INFORMATION REFER TO DETROIT DIESEL

SERVICE MANUAL 6SE193 SECTION 15.3. ADDITIONAL

QUESTIONS, CALL CENTRAL ENGINE OVERHAUL AT

410-762-6237/6738/6790/6791/6796 after hours 443-865-2421

Appendix E

Boat Alterations/Engineering changes

a. 55’ANB fire Pump removal/Dated Aug 3, 2000

55 ANB-C-39

Appendix F

CUMULATIVE TRACKING REPORT

SUBMIT BY THE 15TH OF THE MONTH

Engine in Serial

Number

Trans in

Number

Work #

D/O #

Date

Received

Core Accepted

Y/N

Engine out Serial

Number

Trans out

Number

Appendix G 12V71 Engine Mandatory Replacement Parts

No Part Number Description Qty 1 0103361 Pin, cotter rack 2 2 0142583 Retainer, clip 3 3 181377 Bolt, turbo mount 8 4 181396 Bolt, damper 6 5 515596 Washer, copper 5/16” 10 6 5101914 Gasket, exhaust, wide round 1 7 05102374 Bolt, main brg 12 pt hd 4 8 5103534 Bolt, idler gear retainer 6 9 5103642 Screw, rkr cvr vent 6 10 5103646 Seal, rkr vent 2 11 05116353 Bolt, main brg 6 pt hd 10 12 05118060 Neck, filler 1 13 5118061 Gasket, filler neck 1 14 5131433 Washer, turbo mounting 8 15 5133245 Gasket, air 1 16 5133431 Valve, wood nickel 1 17 5143999 Clamp, special 1 18 5150941 Washer, gov 3 19 5152148 Washer, copper 3/8 10 20 5154637 Retainer, blower drive shaft 1 21 5157930 Washer, crank pulley bolt 1 22 5170468 Gasket, turbo drain sump 2 23 5177778 Spring, bypass 1 24 5183323 Shim, oil pump 6 25 5194974 Paint, alpine spray 2 26 5575080 Washer, aluminum 1 27 8920528 Gasket, oil cooler half 1 28 8920528 Gasket, oil cooler half 1 29 8920631 Bolt, air box cover 18 30 08922605 Clip, blower drive shaft 1 31 8923313 Plug, ¾” 1 32 8923847 Plug, ¼” 2 33 8924140 Valve, drain ¼” 4 34 8924380 Plug, 1/8” 2 35 8924517 Plug, 3/8” 2 36 8925710 Valve, drain 3/8” 2 37 8926285 Washer, lock blower drive 1 38 8927579 Bolt, patch 6 39 8927582 Bolt, patch, F/W housing 6 40 9411981 Nut, turbo mounting 8

Mandatory Replacement Parts Continued:

41 09424121 Bearing Governor Riser 1 42 09438907 Bearing governor wt. end 1 43 23501143 Bolt, crank pulley 1 44 23503769 Seal, front crankshaft 1 45 23504471 Hose, turbo, air out 3 46 23507296 Cone, front seal, long 1 47 23507296 Seal, front cone 1 48 23508028 Clamp 1 ¼” plastic 14 49 23511697 Gasket, intercooler end 4 50 23512188 Gasket, air inlet, graphite 4 51 23512189 Gasket, air inlet hsg end 2 52 23514609 Seal, rear crankshaft 1 53 23515243 Tube, blower drive 1 54 23516808 Clamp, turbo hose 6 55 55001000 Hose 1” 3 ft 56 55002000 Hose 2” 1 ft 57 55002500 Hose 2 ½” 1 ft 58 55002650 Hose 2 5/8” 1 ft 59 55002750 Hose 2 ¾” 1 ft 60 55003500 Hose 3 ½” 1 ft 61 #6 Aeroquip Hose end, male inv fl 45 1 62 #6 Aeroquip Hose end, male inv fl 90 4 63 #6 Aeroquip Hose end, male inv fl st 5 64 #6 push lok Hose end, male inv fl st 6 65 #6 push lok Hose end, SAE swivel 2 66 CC2610 Restore 1 67 FC234-16 Hose 5 ft 68 FC234-6 Hose 14 ft 69 FC234-8 Hose 5 ft 70 FC-300 Hose 4 ft 71 R23506763 Pump, fresh water 1 72 R23507281IM Cylinder Head Assy T/I/M 2 73 R5103533 Blower Assembly 2 74 R5103838 Turbocharger 2 75 R5111422 Bearing, cam rear 2 76 R5117984 Bearing, cam front 2 77 R5122233 Pump, oil 1 78 R5199735 Pump, fuel 1 79 R5228777 Injector N-75 12 80 R8547237 Core, oil cooler 1 81 R8547561 Core, oil cooler 1 82 R8922491 Damper, vibration 1 83 05196026 Bearing, cam intermediate 10 84 07451948 Bearing, idler gear 1 85 05132383 Bolt, con rod 24

Mandatory Replacement Parts Continued:

86 05117003 Bolt, cylinder head 28 87 09411631 Bolt, flywheel 8 88 08927579 Bolt, idler gear retainer 6 89 05148373 Bolt, piston crosshead 24 90 06410879 Cap, radiator 1 91 05103377 Coupling, blower drive 1 92 23522485 Cylinder Kit STD/OS TR/CH 12 93 05121714 Gasket, front cover, oil pump 1 94 05104019 Gasket, rocker cover, silicone 2 95 Hose end 16SAE fml swv 4 96 Hose end, 8 male inv flare 2 97 05104515 Isolator, rocker cover 8 98 05197222 Kit, reman, RW pump 1 99 05196378 Marine Supplemental Kit 1 100 05117629 Nut, con rod 24 101 23512681 OH Gasket Set 1 102 05194975 Paint, Alpine Green 1 103 TT-P-664 Paint, primer 1 104 05120753 Plate, flywheel scuff 1 105 05149572 Shell set, con rod std 12 106 05149556 Shell set, main brg std 7 107 05199569 Shim, liner 12 108 23507225 Sleeve, rear seal 1 109 05144846 Spacer, piston bolt 24 110 05126327 Spring, oil psi regulator 2 111 23503826 Thermostat 4 112 23533307 Tube, jumper line long 12 113 2353308 Tube, jumper line short 12 114 08922740 Valve, oil psi regulator 2 115 Washer, gov lok, end brg 1 116 Washer, lock gov end brg 1 117 05117005 Washer, Thrust 4 118 08515850 Zinc 2 119 08517479 Zinc 1

Appendix H Detroit 12V71 Contingency Replacement Parts

No Description Qty 1 Heat Exchanger 1 2 Raw Water Pump 1 3 Alternator 1 4 Cylinder Block 1 5 Idler Gear 1 6 Accessory Drive Gear 1 7 Blower Drive Gear 1 8 Aftercooler 1 9 Fuel Lines 6 10 Oil Lines 2 11 Water Line 2 12 Air box drain 4 13 Front End Plate 1 14 Rear End Plate 1 15 Crankshaft 1 16 Flywheel Housing 1 17 Flywheel Assembly 1 18 Vibration Damper 1 19 Crankshaft Pulley 1 20 Front Cover 1 21 Drive Gear 1 22 Driven Gear 1 23 Retaining Plate 1 24 LH Camshaft Gear 1 25 RH Camshaft Gear 1 26 Camshaft 2 27 Camshaft Pulley 1 28 Water Pump drive gear 1 29 Crankshaft Drive gear 1 30 Crankshaft Timing Gear 1 31 Pulse Wheel 1

Appendix I

Twin Disc Reduction Gear Model M-514 Mandatory Replacement Parts

No. Part Number Description Qty 1 K240 Bearing Kit 01 2 K497 Seal & Gasket Kit 01 3 M207 Bearing 01 4 M268 Fitting 02 5 A1663 Hose 01 6 A2836 Retainer 04 7 B2215 Plate, Locking 12 8 B1535C Cotter Key 04 9 B3073C Drive Block 26 10 M2188-1 Filter 01 11 A6566J Clutch Plate 08 12 A6567 Clutch Plate Steel 07 13 A2695T Spider Drive Stud 12 14 A2704AW Spring, Clutch Release 08 15 B1758 Spring 08 16 B5349A Oil Pump 01 17 A29587BV Drive Gear Pin 01 18 2409 Data Plate 01 19 M2065Q Suction Hose 01 20 M1853W Top Hose 01 21 B1251A Breather Assy 01

Appendix J Twin Disc Reduction Gear MG-514 Contingency Parts

1 B5997 Reverse Gear Drive 01 2 6614G Clutch plate As required 3 B1639 Pinion 02 4 B5552 Bull Gear 2.5-1 01 5 A7133 Shaft & Gear Fwd Drive 01

APPENDIX K

Contractor’s Technical Representative

Condition Found Report

Representative Name: Date:

Time Arrival: Time Departure:

Unit: POC:

City: State:

Address: Zip:

Hull Number: Tel #:

Engine Serial Number: Stbd/Port:

Date Installed: Hours:

Contract #: Delivery Order

Contractor Name: Contracting Officer:

Engine Model #:

Condition Found

Repairs Required

Parts Required

Parts Expended

Recommendations