W6 Specification.docx

Specification Number P-233-0588 dtd 11/08

MTU FRIEDRICHSHAFEN

DIESEL ENGINE 8 V 396 TE 94

W6 ENGINE OVERHAUL

1. SCOPE

0. This describes the requirements with which the Contractor shall comply completing the W6 Maintenance Echelon on Motoren-und-Turbinen-Union Friedrichshafen MTU 8V 396 TE 94 Diesel Engine(s) and ZF 255 reduction gear. Two (2) engines and reduction gears are currently installed on each 87’ Coast Guard cutter nation wide.

0. CLASSIFICATION: This sets forth the requirements for the following equipment:

0. MTU 8V 396 TE 94 Diesel Engine (NSN 2815-12-348-2440)

0. ZF 255 Reduction Gear (NSN 2010-12-347-4887)

0. Gieslinger Coupling (NSN 3010-12-345-0397)

0. GOVERNMANT FURNISHED MATERIAL:

1. MTU 8V 396 TE 94 Diesel Engine (NSN 2815-12-348-2440)

1. ZF 255 Reduction Gear (NSN 2010-12-347-4887)

1. Geislinger Coupling (NSN 3010-12-345-0397)

1. APPLICABLE DOCUMENTS

1. DOCUMENT AVAILABILITY - For the methods and conditions for obtaining the referenced documents refer to section 6.0.

1. GOVERNMENT DOCUMENTS - The following specifications and standards form a part of this specification to the extent specified herein.

0. MIL-C-104-C Dated 24 June 93, Crates Type II, Class II, Style A.

1. COMMERCIAL DOCUMENTS - The following documents form a part of this specification to the extent specified herein. The documents shall be the 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).

0. ASTM-D-975-08a, Rev A, 2008.10.01, Diesel Fuel #2.

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

0. ANSI/ASQC Q90003-1994, dtd 18 July 94, Inspection System.

0. SFLC Specification D-000-0100, Rev G, Change 1, Feb 06, Bar Code Requirements.

0. ZF TP 4522, Reduction Gears, dtd 19 January 2004, 87 FT Predator Class Patrol Boat.

0. ZF Work Shop Manual (3082 751 105b) dtd December 1997, 255 Marine Reduction Gears.

0. MTU Workshop Manual (M020046/21E) dtd 2004, Diesel Engine 8V396TE94

1. 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 within 1 (one) week in writing of any perceived conflicts contained herein.

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

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

0. 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.

1. REQUIREMENTS

2. GENERAL - Technical publications as referenced in section 2.0 (Applicable Documents), shall be utilized to complete the W6 echelon overhaul. The Contractor shall be required to complete the following requirements. These requirements shall be required on all the units classified herein.

2. The Contractor shall provide all labor, equipment, special tools, materials, and parts, including Appendix D, required to clean, inspect, disassemble/reassemble, test components, test engine, and commission engine.

0. The engine overhaul shall be performed only by an authorized MTU certified facility.

0. The Contractor shall be able to provide, when requested by the Contracting Officer, detailed evidence of their experience with MTU 396 series diesel engines.

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

0. The Contractors lead technician shall be trained and certified to the level of MTU’s standards meeting CM3/CE3.

0. The overhauls and all component inspections shall be completed using only OEM unique parts, components, processes, and practices.

0. The engine dynamometer testing shall be conducted on-site at the Contractor’s facility in accordance with MTU procedures. The USCG reserves the right to witness all testing.

0. The Contractor shall be responsible to provide the USCG, when requested by the Contracting Officer, a Technical Representative to complete the engine commissioning in accordance with MTU specifications.

0. The Contractor shall be responsible to provide the USCG all up-dated data in regards to engine configuration, service bulletins, TP changes/revisions, parts, and part number changes.

0. Upon receipt of any engine, regardless of condition, the Contractor shall store propulsion units inside and kept from all weather.

2. REQUIRED REPORTS – The Contractor shall submit the following reports within the time lines set herein:

0. Receiving Inspection Report (Appendix A). The Contractor shall submit Appendix A to the Contracting Officer for approval within seven (7) days after receiving the engine. No further work shall be accomplished until approval from the Contracting Officer.

0. Upon approval of Appendix A, the reduction gear shall be separated and transported to an authorized ZF Marine Gear repair facility.

0. The Contractor shall ensure ZF completes the open and inspect criteria per ZF Work Shop Manual (3082 751 105b).

0. ZF’s findings and recommendations shall be documented and submitted via the Prime Contractor to the Contracting Officer. The format of the report will be left to the discretion of the Contractor but shall capture at the minimum, serial number, missing parts, description of any unusual wear patterns, broken parts, and recommendation.

0. The Prime Contractor shall ensure the report is submitted within fourteen (14) days of receipt of the gear.

0. No further work shall be accomplished until approval from the Contracting Officer.

0. Within forty-five (45) days after notice to proceed; ZF shall complete the repairs, if needed, per OEM specifications and spin-testing requirement per Appendix H.

0. It shall be the Contractor’s responsibility to facilitate the requirements of the Sub-Contractors.

0. Condition Found Report (Appendix B). The Contractor shall disassemble the engine and submit Appendix B to the Contracting Officer for approval within fourteen (14) days of receiving written approval of the Receiving Inspection Report. No further work shall be accomplished until approval from the Contracting Officer.

0. Reassembly Critical Dimension Report (Appendix C). The Contractor shall summit Appendix C to the Contracting Officer within fourteen (14) days of receiving written approval of the Condition Found Report. The report shall capture all MTU recommended critical dimensions and required parameters including testing component(s) results.

0. Cumulative Tracking Report (Appendix F). The Contractor shall submit Appendix F to the Contracting Officer quarterly no later than the 15th calendar day of the respective month.

0. Geislinger Coupling Inspection Report (Appendix G). The Contractor shall develop, and submit to the Contracting Officer for approval, a detailed inspection report for each Geislinger Coupling capturing all critical dimensions and recommended repairs in accordance with Technical Publication 4520 MTU Geislinger Coupling. Appendix G is due within fourteen (14) days of removal of Geislinger Coupling. No further work shall be accomplished until approval from the Contracting Officer.

2. GENERAL TEST REQUIREMENTS

d. Any unusual noises, external leakage, or any other noncompliance to this specification, as determined by the COTR, shall be cause for the propulsion unit to be found unacceptable.

2. NOTIFICATIONS & INSPECTIONS - The Contractor shall be responsible for notifying the Contracting Officer at least seven (7) working days prior to being ready for any inspections or testing.

0. Prior to notification of testing, ensure the engine is installed on the dyno, test operated, and engine warmed up prior to COTR arrival.

2. WARRANTY - A warranty of one year from installation or 1800 operating hours, whichever occurs first and 24 months of storage is required covering the entire marine propulsion units. Storage commences upon receipt of engine at the designated Coast Guard facility. The Contractor shall provide a Project Manager who shall be responsible for all Contractor warranty work performed under this specification.

1. The name of the Project Manager, and the name of any alternate who shall act for the Contractor in the absence of the Project Manager, shall be provided to the Contracting Officer. The Project Manager or alternate shall have full authority on all warranty matters relating to the requirements of this specification.

1. The Project Manager shall be available via telephone between the hours of 0800 and 1630 EST, Monday through Friday, and shall respond to a request for discussion or resolution of technical problems within twenty-four (24) hours of notification.

1. The Project Manager shall contact SFLC’s Contracting Officers Technical Representative (COTR) to evaluate the Contractor’s proposed duration of warranty repair time.

1. 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.

1. The Contractor shall provide OEM certified personnel to perform all requirements specified in this specification.

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

1. The Contractor shall repair/rebuild the failed engine including painting and preservation to the condition level necessary for the contractor to honor a new full warranty (to be funded by the CG). 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.

1. QUALITY ASSURANCE

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

0. RECORDS - The Contractor shall 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 COTR.

0. 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 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 Government review.

0. 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 ensure that supplies or services conform to the prescribed requirements.

0. REQUIRED TESTS - Each engine provided under this contract should be operationally tested in accordance with Appendix E. Each reduction gear provided under this contract should be operationally tested in accordance with Appendix I.

0. The equipment used to record/provide the dyno-meter test readings shall have the capability to print required parameters in a computerized format. During the final acceptance test the COTR shall have the capability to visually monitor all required parameters simultaneously.

0. TEST REPORT - The Contractor shall summit the final test reports in accordance with Appendix E and Appendix H of this specification.

0. 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.

1. PRESERVATION, PACKAGING, PACKING, & MARKING

0. PRESERVATION (Internal) - The engine shall be preserved as per the requirements of MTU Technical Publication A001061/33E (Series), Fluids and Lubricants Specification after acceptance by the Government.

0. PRESERVATION (External) - After completion of the final test run and internal preservation the engine will be prepared in accordance with MTU Technical Publication A001061/33E (Series), Fluids and Lubricants Specification.

0. All surfaces shall be cleaned of grease and oil

0. All loose scale and paint shall be removed

0. MTU white paint P/N 50291 shall be sprayed on all surfaces 3-5 mils thick, allow a minimum of seven (7) hours drying for primed surfaces.

0. When all paint is dry, the masking shall be removed including from the engine data plate.

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

0. Plug or cap any fittings/flanges or openings that will allow seepage.

0. The Contractor shall attach to the fuel oil pump, in a plastic envelope, a completed copy of the final test report (APPENDIX E) and ATTACHMENT 1 (WARRANTY INFORMATION).

0. The Contractor shall attach to the transportation locking device, a red tag with the following printed on it.

**DANGER: DO NOT ATTEMPT TO ROTATE ENGINE CRANKSHAFT OR GEAR OUTPUT SHAFT UNTIL LOCKING DEVICE IS REMOVED**

0. PACKING - The shipping container, if missing or damaged, shall be constructed and mounted to the metal base skidded pallet as per MIL-C-104C. The engine shall be packaged per MTU Technical Publication A001061/33E (Series), Fluids and Lubricants Specification

1. The Contractor shall securely fasten the engine into the approved shipping container. It shall be fastened in a manner that adequately ensures protection during multiple common carrier practices.

1. The Contractor shall ensure the refurbished electronic modules (EDM, PDM, and MIM modules) are safely secured in each engine’s X10 box.

0. 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.

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

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

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

NATIONAL STOCK NUMBER 2815-12-348-2440

PART NUMBER 5560028101TE94

ITEM NAME Diesel Engine

MODEL NUMBER 8V396TE94

SERIAL NUMBER “As per Enclosed Engine” 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 STACK.

1. 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

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

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

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

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

1. GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

0. GOVERNMENT DOCUMENTS

0. USCG Surface Forces Logistics Center

0. COMMERCIAL DOCUMENTS

0. International Organization for Standardization

0. ENCLOSURES – The following enclosures apply:

0. Appendix A Receiving Inspection Report

0. Appendix B Condition Found Report

0. Appendix C Reassembly Critical Dimensions Report

0. Appendix D Mandatory Parts List

0. Appendix E Engine Test Report

0. Appendix F Cumulative Tracking Report

0. Appendix G Geislinger Coupling Inspection Report

0. Appendix H Reduction Gear Test Report

0. Appendix I Technical Representative Condition Found Report

0. Attachment # 1 Warranty Information

0. Information