SPECIFICATION_NO._024-R-233-0307.pdf

Enclosure (3) 6V92 DDEC IV Overhaul Specification

REVISION No. F CHANGE No.

SPECIFICATION OR

STATEMENT OF WORK

COVER SHEET

TITLE

Detroit 6V92 DDEC IV ENGINE OVERHAUL

REMANUFACTURE SPECIFICATION

SPECIFICATION NUMBER

024-R-233-0307

ORIGINATED BY Michael McHale DATE 11/08

Revision (A) ORIGINATED BY DATE ______

Revision (B) ORIGINATED BY DATE _______

Revision (C) ORIGINATED BY DATE ______

Revision (D) ORIGINATED BY Michael McHale DATE 09/14

Revision (E) ORIGINATED BY Michael McHale DATE _11/08_

Revision (F) ORIGINATED BY Michael McHale DATE 07/2010

ORIGINATOR'S COMMAND SURFACE FORCES LOGISTICS CENTER (SFLC)

DEPARTMENT/DIVISION SMALL BOAT PRODUCT LINE ENGINEERING CELL

INTERNAL REVIEWER DATE ______

SOWRB APPROVAL DATE

1.0 Scope

1.1 Purpose - This specification is for the remanufacture of non-ready for issue 6V92 DDEC IV

Detroit Diesel marine engines for remanufactured ready for issue 6V92 DDEC IV Detroit Diesel marine engines and hang-on equipment.

The contractor will reassemble the remanufactured marine engine with only Detroit Diesel OEM equipment, using Master Serial #06VF-222697.

The marine engine with attached hang-ons with the exception of the alternator shall be dynamometer tested, preserved, painted, and packaged. The marine engine (one of a pair) is install in the U.S. Coast Guard 47 FT. M.L.B. The engine will be provided to the contractor in a metal shipping container.

1.2 Government Furnished Property - This specification sets

forth the requirements for the following equipment:

a. 6V92 DDECIV PORT ENGINE (NSN 2815-01-442-4541)

b. 6V92 DDECIV STBD ENGINE (NSN 2815-01-442-4549)

c. Metal Shipping Container (ACN 8145-01-F00-3805)

2.0 APPLICABLE DOCUMENTS

2.1 Applicable Documents - The follow in documents form a part of this specification to the extent specified herein.

2.2 Government Documents

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

b. MIL-D-3464E, 21 Apr 87, Desiccant, Activated bag

c. MIL-C-104C, 24 Jun 93, Crates Type II, Class II,Style A

2.3 Commercial Documents The following documents form a part of this specification to the extent specified here. The documents shall be the version listed by number and date from the referenced industry organization. Commercial documents may be listed in the Department of

Defense Single Stock Point (DODSSP).

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

Laboratories (NCSL)

b. ANSI/ASQC Q9001-2000, 13 Dec 2000, Inspection System

c. ANS/ISO/IEC 17025:2005 for Part 1 and ANSI/NCSL Z540.3-2007 for Part 2, General

Requirements for Calibration Laboratories and Measuring and Test Equipment

d. ASTM D 975-02 10 January 2002, Diesel Fuel Oils

e. International Chemtex Cooperation: Chemtex Product Bulletin for "Chemfilm MXP"

Dated 2/16/2011

f. Detroit Diesel Manual 6SE379 DATED SEP. 1999

g. Valvoline Oil Company: Tectyl International Product Bulletin for Tectyl International

Product Bulletin for “Tectyl 859B” Dated 07/10

2.4 Specification Precedence - Any conflict between this specification and applicable documents identified in this specification shall be resolved in this order:

a. This specification

b. Applicable documents

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

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

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

3.0 Requirements

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

a. Receive engine

b. Uncrate engine

c. Disassemble and clean engine

d. Submit Core Condition Report (Appendix A)

e. Submit Disassembly Report (Appendix B& DDEC Reports)

f. Remanufacture engine

g. Reassemble engine

h. Complete any future Time Compliance Technical Orders (TCTO’s) (presently none pending)

i. Perform dynamometer testing (Appendix C)

j. Preserve

k. Paint

l. Package and mark engine and crate

3.2 Engine - Marine engines shall be remanufactured approval of Core Condition Report, Appendix

A. The marine engines shall be stored inside and kept from all weather.

3.3 Parts, Engine – All Detroit 6V92 parts listed in Appendix G shall be a mandatory replacement.

All other components and parts listed in Appendix H 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 Contracting Officer.

The contractor shall use only Detroit Diesel O.E.M parts meeting O.E.M. specifications. All marine engines provided under this specification will utilize Detroit Diesel Remanufactured marine engine, using Master Serial #06VF222697 to affect the remanufacturing of the Detroit

Diesel 6V92DDECIV marine engine. All engines supplied to the contractor under this contract will be overhauled at an authorized Detroit Diesel facility. Engines shall not be exchanged under the Detroit REMAN program. The Government reserves the right to supply parts as Government

Furnished Property (G.F.P.) at any time during the contract. The Government Furnished

Property will be annotated on each delivery order as required.

After submitting the DDEC reports from the engine’s Electronic Control Module (ECM), all data contained in the ECM shall be cleared unless otherwise specified by the Contracting Officer.

This includes engine hours, fault codes, injector calibration codes etc. At the completion of the overhaul the ECM will be re-programmed at zero hours, correct injector calibration codes and the USCG K2 function.

3.4 Injectors – Fuel Injectors P/N 5237578 and Injector Jumper Line Seals P/N 8928676, shall be installed in the remanufactured 6V92 engines as per Appendix G

3.5 Secondary Fuel Filter - Only P/N 23518530 or P/N 23530645 are to be used on 6V92 engines.

3.6 Cylinder Heads - Detroit Diesels marine grade cylinder heads shall be utilized on 6V92 engines as per Appendix G.

3.7 Wiring Harness – Wiring Harnesses for the 6V92 engines shall be installed new in the remanufactured engines. Harness part numbers are for both 80627K90 and 80627K91 engines as per Appendix G.

a. EMIM Harness P/N 23517139

b. Engine Sensor Harness P/N 23517138

c. Left Bank Injector Harness P/N 23511307

d. Right Bank Injector Harness P/N 23511308

3.8 Oil Pressure – Oil pressure requirements shall meet the following criteria in sequence:

a. During the entire 30-minute full power trial portion of dyno testing the oil pressure shall be 60-PSI plus (+) or minus (-) 5%.

b. Immediately after the full power trial the engine RPM shall be reduced to 600 RPM with no load. At which time, the oil pressure shall be no lower than 8 PSI.

c. Increase the engines speed to 1950 RPM with 85% load for 10 minutes. The oil PSI shall be 55 PSI plus (+) or minus (-) 3 % during the entire 10 minutes. The DDEC PROLINK computer will be used to validate this requirement.

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

3.10 Core Condition Report - The contractor shall submit Appendix A to the Contracting Officer after receipt of the engine. The contractor shall also submit Appendix B to the contracting officer after receipt of the engine. Appendix B will also contain the DDEC reports off the engine Electronic

Control Module (ECM). Reports will be in .pdf format.

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

3.12 Cumulative Tracking Report - The contractor shall maintain and submit to the contracting officer, by the 15th of the month, for the previous month; the Cumulative Tracking Report

Appendix F, for all engines.

3.13 Documentation - This specification sets forth the requirements for the following documentation.

a. Core Condition Report, in accordance with Appendix A

b. Disassembly Report, in accordance with Appendix B

c. Dyno Test Report, in accordance with Appendix C

d. Cumulative Tracking Report, in accordance with Appendix F

3.14 Engineering Changes Time Compliance Technical Order (TCTO) – For future TCTO’s these will be incorporated as per Appendix E.

3.15 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 marine engine. Storage commences upon receipt of engine at the designated Coast Guard facility. The contractor shall contact the field unit to arrange a resolution of a claim within 24 (twenty-four) hours after receiving notification by the Coast Guard of a warranty claim.

The contractor shall contact SFLC’s Contracting Officers Representative (COR) to advise on the contractors proposed time for visiting the vessel to perform the warranty repairs.

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

The contractor shall repair/rebuild the failed engine to the condition level necessary for the contractor to honor a new full warranty (to be funded by the CG) including assigning a new serial number and the zeroing of hours on the ECM. The contractor shall submit to the

Contracting Officer an inspection report for approval containing any parts and pricing for any work/repairs that are required that were not a result of the specific casualty.

3.16 Failure Analysis – The contractor shall provide a failure analysis of the Detroit 6V92 and 12V71 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.

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

3.17 Technical Representative Services – When requested by the Contracting Officer the contractor shall provide OEM certified personnel to perform onsite troubleshooting and repairs to the

Detroit Diesel 6V92 engine. Troubleshooting and repair of technical problems may require contractor personnel to travel to U.S. Coast Guard units. In correcting technical problems the contractor shall abide by the following:

TECHNICAL SERVICES PERFORMED ONSITE – The Contractor shall perform all services onboard the USCG vessel unless otherwise directed by the Contracting Officer.

HOURS OF OPERATION – The Contractor employees shall generally perform all work between the hours of 0800 and 1630 local time, Monday through Friday. However, 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 – Surface Forces Logistics Center (SFLC) will issue a Delivery order

(DO) stating where and when the services are required. SFLC will supply the Contractor with the nature of the problem (if known) along with a POC and phone number. The Contractor shall be responsible to contact the POC within twenty-four (24) hours after notification by the

Contracting Officer.

The results of the Representative's findings shall be provided in writing within twenty-four (24) hours of arrival. Approval to perform repairs will be made by the Contracting Officer after evaluation from the USCG Contracting Officer’s Representative. The report shall be in the format of (APPENDIX I).

4.0 Quality Assurance

4.1 General - The contractor shall maintain an inspection system, which shall ensure each item, offered to the Government for acceptance conforms to contract requirements. The system shall be documented and in compliance with ASQC Q9001-2000.

4.2 Records - The contractor shall as a minimum maintain records of all inspections and tests. The records shall indicate the nature and number of observations made, type of deficiencies found, and the corrective action taken. Records shall be furnished upon arrival of the Contracting

Officer's Representative.

4.3 Contractors Calibration System - The contractor shall maintain a calibration and maintenance system to control the accuracy of measurement and test equipment used in the fulfillment of this contract in accordance with ANSI/NCSL Z540.3-2007 Part 2. The system shall include as a minimum, prescribed calibration intervals, source of calibration, and a monitoring system to insure adherence to calibration schedules. Calibration standards shall be traceable to the

National Institute of Standards and Technology (NIST). Documentation in support of this requirement shall be readily available for Government review.

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

4.5 Required Tests - Each marine engine 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 marine engines. 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

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 engine test. One copy of the test report shall be packed and delivered with each marine engine delivered under this contract.

5.0 PRESERVATION PACKAGING, AND MARKING

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

Manual 6SE379 for extended storage (Unless directed by contracting officer) with the following exceptions:

5.1.1 Detroit Diesel Manual 6SE379 - Section 14.4 procedure 3 Page 14-6 change to:

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

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

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

5.1.2 Detroit Diesel Manual 6SE379 - Section 14.4 Page 14-6 Procedures 12 and 13 change to:

a. Refill fuel system with enough Nox-Rust # 518, Type P-9 or Tectyl 859B preservative oil to permit the engine to operate for about ten minutes.

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

5.2.1 Surfaces shall be cleaned and free of grease/oil.

5.2.2 All loose scale and paint shall be removed; uneven paint layers shall be sanded smooth.

5.2.3 The following items will be masked and not painted:

a. Rubber hoses and wires

b. Glass and chrome gauge bezels and covers

c. Identification plates

d. Any discharge or breather openings

e. Flywheel rear bolt face

f. Front and rear seals

5.2.4 On all exposed metal surfaces the Contractor shall apply one coat of primer TT-P-664 Rev D

(2 to 3 mils MDFT) each to all components allowing primer to dry.

5.2.5 Two coats, IAW TT-E-489H approximately two (02) mils, total thickness 3-5 mils MDFT) shall be sprayed on all surfaces, allow a minimum of seven (07) hours drying time between coats. Color shall be DD workboat blue (gallon container) p/n 23530131 (spray can) p/n

23521542.

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

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

5.2.8 Plug or cap all fittings/flanges and openings that may allow seepage from the engine during storage.

5.2.10 The contractor shall attach to the base of the shipping crate 1 gallon bottle of "Cummins

Fleetguard RESTORE" (p/n CC2601) heavy duty cooling system cleaner. The bottle shall be padded and inserted in a separate container (5 gallon container) and secured to prevent spillage during shipping.

5.2.11 The contractor shall install the marine engine into the supplied metal shipping container.

5.3 MARKING - Each shipping container shall be stenciled on the top of the two longest sides (two opposite sides if square) in accordance with 5.3.1. The bottom side of the container shall be stenciled with the appropriate NSN, engine serial number and model number on the two longest sides. The contractor shall ensure that the serial number and model number on the bottom and top of the container sides match the actual engine serial number and model number in the container.

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

b. All markings shall be in white or black which ever are most contrasting print and at least

1/2" high

5.3.1 This marking shall be in the format as follows:

TYPE a. Port Unit

STOCK NUMBER 2815-01-442-4541

ITEM NAME Diesel Engine, PORT

MODEL NUMBER 8062-7K90

SERIAL NUMBER “As per Contract Delivery Order”

CONTRACT NUMBER HSCG40-15-D-XXXXX

DELIVERY ORDER NUMBER “As per Contract Delivery Order”

SHIPPING WEIGHT “Determined by Contractor”

CONDITION CODE CONDITION A

OTHER DATA AS DIRECTED COAST GUARDSFLC MATERIAL

DO NOT STACK MORE THAN TWO

HIGH

TYPE b. Starboard Unit:

STOCK NUMBER 2815-01-442-4549

ITEM NAME Diesel Engine, STBD

MODEL NUMBER 8062-7K91

SERIAL NUMBER “As per Contract Delivery Order”

CONTRACT NUMBER HSCG40-15-D-XXXXX

DELIVERY ORDER NUMBER “As per Contract Delivery Order”

SHIPPING WEIGHT “Determined by Contractor”

CONDITION CODE CONDITION A

OTHER DATA AS DIRECTED COAST GUARDSFLC MATERIAL

DO NOT STACK MORE THAN TWO

HIGH

5.3.2 The following marking shall be placed on all four sides and the top of each box, in stenciled white print at least 1/2" high.

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

To Unload Do Not Lift By Cover

b. The contractor shall paint over all other markings not outlined in 5.3.1 and 5.3.2

6.0 NOTES

6.1 GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

6.1.1 GOVERNMENT DOCUMENTS

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. Surface Forces Logistics Center

Small Boat Product Line, Bldg 31

2401 Hawkins Point Rd.

Baltimore, MD 21226-1792

410-762-6472

6.1.2 COMMERCIAL DOCUMENTS

a. MTU America Inc.

39525 Mackensie Drive

Novi, Michigan 48377

b. American Society for Testing Materials (ASTM)

100 Barr Harbor DR.

P.O. Box C700

West Conshohocken PA. 19428-2959

6.2 APPENDICES - The following appendices apply:

a. Appendix A: Core Condition Report

b. Appendix B: Disassembly Report (Extra Cost Requests)

c. Appendix C: Test Plan and Dyno Report

d. Appendix D: Warranty Information

e. Appendix E: TCTO’s & Engineering Changes

f. Appendix F: Cumulative Tracking Report

g. Appendix G: Mandatory Replacement Parts

h. Appendix H: Contingency Replacement Parts

i. Appendix I: Technical Representative Condition Found Report

6.3 GLOSSARY

a. CPL: - Control Parts List

b. Core: - Detroit Diesel 6V92 DDEC IV Marine Engine

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

States and its territories

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

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

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

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

Appendix A

Work Order #_________________________________

Port/Stbd ____________________________________

Delivery Order #_______________________________

Engine Serial # ________________________________

Core Acceptance is based on the following:

a. Core must be in the configuration of Master Serial Number

b. Core must have no non-operational damage

c. Core must be a complete unit and not disassembled

NOTE: Missing parts from Appendix A are to be replaced and priced as per section B of this contract.

a. Core acceptable_______________________, non-acceptable_____________

Remarks _______________________________________________________

b. Metal shipping crate: Acceptable__________, non-acceptable_____________

Remarks _______________________________________________________

The core condition report shall include photographs of engine; front, right side, left side, and rear views to include serial number in picture frame.

APPENDIX A (CONTINUED)

Name P/N Missing Comments

CYLINDER HEAD ASSY 5149877 (2EA)

BRACKET, ENGINE LIFTING 5137761 (2EA)

FLYWHEEL HOUSING 8922052

FLYWHEEL 5100534

OIL PAN 23519545

COOLER ASSY , 24 PLATE 8547237

COVER,OIL COOLER 5101742

COVER, OIL COOLER

HOUSING

5146505

ADAPTER ASSY, OIL FILTER 5104115

ROCKER COVER 5103694

ROCKER COVER 5103695

FUEL PUMP ASSY 5199735

FUEL FILTER ASSY 5148171

FUEL COOLER 23511219

AIR INLET HOUSING ASSY 23504124

BLOWER ASSY 23511026

TURBO CHARGER ASSY 23516040

AFTERCOOLER ASSY 8925149

AIR SHUTDOWN ASSY 23501164

AIR SHUTDOWN SOLENOID 23504197

FRESH WATER PUMP ASSY 23506602

HOUSING

ASSY,THERMOSTAT

5109652 (RIGHT)

HOUSING

ASSY,THERMOSTAT

5106003 (LEFT)

TANK,HEAT EXCHANGER

ASSY

23501986

CORE, HEAT EXCHANGER 8543803

RAW WATER PUMP 5115396

MANIFOLD, EXHAUST, 23519252 (LEFT)

MANIFOLD, EXHAUST, RIGHT 23519253

STARTER MOTOR 1993924

ALTERNATOR(NOT

REQUIRED)

2258AC

APPENDIX A (CONTINUED)

SENSOR, AIR PRESSURE 16070629

SENSOR, COOLANT LEVEL 23519175

SENSOR, OIL/FUEL PRESSURE 23511176 (2EA)

SENSOR, OIL/WATER/FUEL 23518092 (4EA)

MOUNT ASSY, FRONT

TRUNION

23517861

INJECTORS 5237578 (6EA)

INJECTOR, JUMPER LINE

SEAL

8928676 (12EA)

TACHOMETER ADAPTER

ASSY

5106763

Additional Comments

Appendix B

Delivery Order Number:_________________

Date:_________________________________

Unit Serial Number:_____________________

Reason for

Replacement Qty Part No. Part Description Unit Price Amount

Total

Appendix C

Each marine engine shall be tested by the contractor and shall be tested using an approved test plan and all requirements outlined in this specification for the marine engine as per Detroit Diesel Shop Manual 6SE379.

1.0 General Test Requirements

1.1 The equipment used to record/provide the dynamometer test readings shall have the capability to print required parameters in a computerized format. During the final acceptance test, the Coast

Guard Representative shall have the capability to visually monitor all required parameters as detailed in Detroit Diesel Manual 6SE379 simultaneously.

1.2 Each marine engine shall be fitted with all "engine" equipment, with the exception of the alternator.

This equipment shall be "Contractor Supplied" and used for each engine test.

1.3 The engine shall be tested as per the dyno test specifications on page 2 of Appendix C. After the final dyno test is accepted by a Coast Guard Representative, all filter elements shall be replaced.

1.4 Any unusual noises, external leakage, or if any other noncompliance to this specification, as determined by the Coast Guard Representative, shall be cause for the marine engine to be found unacceptable.

The Government reserves the right to witness any part of the overhaul and testing requirements set forth in this specification.

Upon final acceptance the contractor shall provide the Coast Guard copies of all test results.

DYNAMOMETER ENGINE TEST REPORT

Date Serial Number ______________

Delivery Order Number Model Number _______________

A. PRE-STARTING

Step 1

PRE LUBE OIL SYSTEM

Step 2

PRIME FUEL

SYSTEM

Step 3

ADJUST VALVES

Step 4

TIME INJECTORS

Step 5

ADJUST GOVERNOR

Step 6

ADJUST INJECTOR

RACKS

B. BASIC RUN-IN C. RUN-IN INPECTION

TIME

AT

SPEED

IN

MINUTES

TIME

R.P.M.

B.H.P.

WATER

TEMP.

LUBE

OIL

PRESS.

1. Check oil at rocker mechanism

START

STOP

2. Inspect for lube oil leaks

3. Inspect for fuel oil leaks

4. Inspect for water leaks

5. Check and tighten all external bolts

6. Check torque on all manifold/turbo fasteners

D. INSPECTION AFTER BASIC RUN-IN

1. Re-torque Cylinder Head & Rocker Shaft Bolts

4. Re-adjust Governor Cap

2. Re-adjust valves (hot)

5. Re-adjust Injector Racks

3. Re-time injectors

6. Re-torque fuel jumper lines

E. FINAL RUN-IN

TIME TOP 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

START

STOP

NO LOAD

Max

2200 RPM

FULL LOAD

Min 2050

RPM

Hg

Hg

H²º

BLOWER INTAKE

RES

12” Max

FUEL OIL

PRESSURE

RET. MAN.

50-70

WATER TEMP

210 Max

LUBE OIL TEMP

250 Max

LUBE OIL PRESSURE

IDLE SPEED

FULL LOAD

60 ± 5%

IDLE

55 ± 3%

H²º

Lbs

RPM

F. INSPECTION AFTER FINAL RUN-IN

Temperature of Dyno Test Cell Pyro Temperature (4” pass turbo exhaust ) ° Raw Water Pump Delivery pressure Oil Viscosity Test (Falling Ball – Less then 1.5%)

Water Temperature at oil cooler inlet

K-2 Throttle Interrupt

Final Run OK’D Dynamometer Operator : Date:

Appendix D

This item has a warranty for whichever comes first:

1 year of operation from installation

Or

1,000 hours of operation

If any discrepancies are noted upon receipt:

CALL THE WARRANTY HOTLINE:

USCG ENGINEERING LOGISTICS CENTER

SMALL BOAT PRODUCT LINE

CENTRAL ENGINE OVERHAUL PROGRAM

COMMERCIAL (410) 762-6237

AFTER HOURS (443) 306-4811

The following information is needed when calling the ELC:

Date Received

Date Installed

Engine Serial No.

Engine Hours

Port/Stbd

Vessel Hull No.

Appendix D (CONTINUED)

GENERAL CHECKS UPON RECEIPT OF ENGINE

1 A complete inspection should be made of the engine’s condition.

2 Inspect the jacket water, fuel oil, lube oil and raw water systems for preservations remaining in these systems.

o Jacket water system must be flushed with “Restore” cleaner provided.

o Fuel system must be flushed completely with diesel fuel.

o Do not operate engine until the appropriate fluids are added.

3. Preservation tags on the engine will tell you to what extent the unit has been preserved and what should be done before operating the engine.

4. Uncover all taped and plugged openings prior to connecting all hoses and lines.

5. Ensure that all lube oil lines left on board are flushed and all filters are changed.

6. Ensure the engine will bar over by hand.

7. Check engine mounts.

THINGS THAT WILL NOT VOID THE WARRANTY

1. Preventative maintenance as set forth in P.M.S. manual may be performed.

2. Troubleshooting is approved, as long as the troubleshooting is in accordance with Tech Pub No. 6SE379.

3. Repairs are to be performed only after contacting Surface Forces Logistics Center SBPL (410) 762-6237.

After hours call (443) 306-4811.

4. 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 manifold assembly

5. Removing gear housing

PAST INSTALLATION PROBLEMS

1. Cross connecting lube oil lines during installation

2. Failure to flush lube oil lines coming from the boat

3. Overfilling lube oil sump

Appendix E

Time Compliance Technical Orders (TCTO’s)

Note: This Appendix is reserved for future TCTO’s specifically for the Detroit Diesel 6V92 engine.

Appendix F

CUMULATIVE TRACKING REPORT SUBMIT BY THE 15TH OF THE MONTH

Date:

Engine in

Serial

Number

Port/Stbd

Work #

D/O #

Date

Received

Core

Accepted

Y/N

Remarks

Appendix G

6V92 Engine Mandatory Replacement Parts

No Part Number Description Qty

1 5117005 Washer 4

2 5117700 Bearing 2

3 5126326 Spring 1

4 5133431 Relief Valve 1

5 5136678 Gasket 1

6 5144846 Spacer 12

7 5144857 Spring 1

8 5145581 Gasket 1

9 5148373 Bolt 12

10 5149565 Shell-Set 4

11 5149572 Shell-Set 6

12 5154398 Washer 1

13 5163760 Gasket 2

14 5167745 Gland 1

15 5167746 Seal 2

16 5177777 Valve 1

17 5177778 Spring 1

18 5180314 Ring 2

19 5185318 Shim 3

20 5196026 Bearing Set 4

21 5197224 Recon Kit 1

22 7451948 Bearing Assembly 1

23 8921934 Fork Assembly 1

24 8923959 Seal 2

25 8926285 Lockwasher 1

26 8926293 Washer 1

27 8928676 Seal Ring 24

28 9410925 Bolt 6

29 9411981 Nut 4

30 8926247 Camshaft Keys 2

31 9414123 Nut 8

32 23501143 Bolt 1

33 23501231 Gasket 2

34 23503411 Stud 4

35 23503767 Spacer 1

36 23503769 Seal 1

37 23503826 Therm 170 2

38 23507226 Sleeve 1

39 23507233 Zinc 1

40 23508370 Valve Assembly 2

41 23512684 Engine O/H Kit 1

Mandatory Replacement Parts Continued:

42 23514608 Oil Seal 1

43 23515243 Harness Assembly(2PC) 1

44 23517138 Harness, Engine Sensor 1

45 23519078 Hose 2

46 23519508 Gasket 2

47 23524340 Cylinder Kit 6

48 25042692 Check Valve 2

49 5101138 Seal Ring 4

50 5103534 Bolt 6

51 5104018 Gasket RKR 2

52 5106831 Gasket 3

53 5106847 Gasket 2

54 5111424 Washer 4

55 5115395 Gasket 2

56 5116485 Spacer 2

57 5100532 Plate 1

58 5112143 Gasket 1

59 5126327 Spring 2

60 5130995 Gasket 1

61 5131433 Washer 4

62 5132155 Seal 2

63 5170468 Gasket 1

64 5177773 Gasket 1

65 5183323 Shim 3

66 5185319 Shim 1

67 5575086 Gasket 1

68 8515850 Electrode 1

69 8922740 Valve 2

70 8929529 Gasket 1

71 23501544 Seal CR/SHF 1

72 23513509 Sealant Gasket 1

73 23530707 Element 1

74 R0461128 Starter 1

75 R5104501 V92 CON ROD 6

76 R5111422 Rear Bearing 2

77 R5117984 Front End Bearing 2

78 5198840 Oil Pump 1

79 R5199735 LH Fuel Pump 1

80 R5237578 EUI (Injector) 6

81 R8547237 Oil Cooler 1

82 R23506602 Water Pump 1

83 R23511026 Blower 6V92 1

84 23516040 Turbo (new) 1

85 R23504270AM Cylinder Head 2

86 4401-6S Aeroquip FTG,STGHT,SWIV 10

87 4401-8S Aeroquip SAE 45 Swivel 2

88 FC234-06 Hose Fuel & Oil Aeroquip 15’

89 FC234-08 Hose, Aeroquip 6’

90 190302-6S Aeroquip FTG, 90Deg Elb SH 14

91 232S Aeroquip 2” Blue Silicone Hose 3’

92 240S Aeroquip 2 ½” Blue Silicone Hose 3’

93 244S Aeroquip 2 ¾” Silicone Hose 3’

94 2600 ¼” Valve 1

95 23519253R RB Exhaust Manifold 1

96 23519252 LB Exhaust Manifold 1

97 23512161 Turbo Tee 1

98 23532692R Exhaust Pipe Long 1

99 23526966 Exhaust Pipe Short 1

100 23517139 EMIM Harness 1

101 8925149 Aftercooler 1

102 23511307 Left Bank Injector Harness 1

103 23511308 Right Bank Injector Harness 1

104 2362448 Clip, fuel hoses 6

105 2419766 Clip, oil drain hose #16 1

106 3290459 Clip, ht ex drain tube 1

107 5101196 Bolt, aftercooler 1

108 5104507 Gasket, star plate 1

109 5106219 Clamp, blower drive 1

110 5107931 Seal, tac drive 1

111 KWI-8701 Stbd Engine Walker Airsep Kit. 1

112 KWI-8702 Port Engine Walker Airsep Kit 1

113 5117629 Nut, con rod 12

114 5123123 Gasket, cover, front cover 1

115 5123240 Gasket, oil pump sides 2

116 5126160 Gasket, oil pump inlet 1

117 5126161 Gasket, oil pump rear 2

118 5129867 Hose, ¼” FC 332 1

119 5143999 Clamp, oil cooler spl 1

120 5144703 Gasket, ht ex bottom plate 1

121 5148310 Washer, head bolt 16

122 5148324 Bolt, cylinder head 16

123 5151921 Washer, copper, abx drive 4

124 5155596 Washer, copper 5/16” 10

125 5189292 Fitting, brass pushlok 1

126 5196119 Spacer, turbo feed line 1

127 6410640 Cap, heat exchanger 1

128 8920764 Plate, blower drive 2

129 8922420 Hose, aftercooler 1

130 8922605 Snap ring, blower drive 1

131 8923313 Plug, ¾” flat square 1

132 8923847 Plug, ¼” 2

133 8924140 Valve, drain, ¼” 4

134 8924153 Fitting, 90, heat exhaust drain 1

135 8924272 Bolt, main bearing 8

136 8924380 Plug, 1/8” 2

137 8924436 Hose, blower bypass 2

138 8924517 Plug, 3/8” 2

139 8924998 Fitting, 90, 3/8fl x ¼” pipe 4

140 8925042 Fitting, rest R80 1

141 8925710 Valve, drain, 3/8” 1

142 8927579 Bolt, idler patch 6

143 8929833 Fitting, st, 3/8fl x ¼” pipe 2

144 8929837 Fitting, 45 3/8fl x ¼” pipe 4

145 8996207 Valve, check, 1psi 2

146 11504603 Bolt, 8mm cold plate 2

147 23501142 Bolt, C/S pulley 1

148 23501600 Clamp, 300 constant torque 10

149 23501941 Clamp, 350 constant torque 4

150 23502013 Decal, pulley bolt 1

151 23503066 Clamp, 250 constant torque 6

152 23504352 O-Ring, dipstick 1

153 23504358 Decal, series 92 2

154 23506478 Element, block heater 1

155 23507896 Clamp, turbo drain 2

156 23508028 Clamp, 1-1/4” plastic 10

157 23508029 Clamp, 175 constant torque 2

158 23509673 Decal, caution fluid psi 1

159 23509873 Decal, zinc anode 4

160 23511565 Stud, head to manifold 8

161 23512307 Isolator, ECM 8

162 23512308 Bolt, ECM mounting 4

163 23514774 Tube, oil feed, blower drive 1

164 23515571 Fitting, Tee spec 2 way 1

165 23517004 Label, ECM disconnect 1

166 23517962 Clamp, 400 air inlet hose 4

167 23518117 Isolator, MIM 4

168 23529226 Neck, heat exch radiator cap 1

169 23530408 Filter, oil 2

170 23530645 Filter, fuel 1

171 23536815 Harness, block heater 1

172 5240940042 Clamp, exhaust 4

173 CAHH0438 Port Fltr 1

174 CAHK0320 LB HD-Filter Port 1

175 CAHK0358 Port Only Filter 1

176 CAHP0083 Port & STBD 1

177 CAHP0129 Port & STBD 1

178 23512162 Turbo Tee (Port Eng) 1

179 23532694 Exhaust Pipe Long (Port Eng) 1

180 23526972 Exhaust Pipe Short (Port Eng) 1

178 CAHP0178 STBD Only 1

179 CAHP0309 STBD Only 1

180 CAHP0423 Port (Replaces 0392) 3

181 CAHP0559 STBD ECM to F/O Cooler 1

182 CBHH0574 Port & STBD 1

183 CC2610 Restore (Coolant cleaner) 1

184 CDNN0240 Port & STBD 1

185 WAHP0262 Port FOP to Filter 1

186 23511176 Sensor, Oil/Fuel Pressure 2

187 23518092 Sensor, oil/Water/Fuel 4

188 16070629 Sensor, Air Pressure 1

189 23519175 Sensor, Coolant Level 1

190 23511219 Cooler. Fuel 1

APPENDIX H

Detroit 6V92 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 Fuel Lines 6

9 Oil Lines 2

10 Water Line 2

11 Air box drain 4

12 Front End Plate 1

13 Rear End Plate 1

14 Crankshaft 1

15 Flywheel Housing 1

16 Flywheel Assembly 1

17 Vibration Damper 1

18 Crankshaft Pulley 1

19 Front Cover 1

20 Drive Gear 1

21 Driven Gear 1

22 Retaining Plate 1

23 LH Camshaft Gear 1

24 RH Camshaft Gear 1

25 Camshaft 2

26 Camshaft Pulley 1

27 Water Pump drive gear 1

28 Crankshaft Drive gear 1

29 Crankshaft Timing Gear 1

30 Pulse Wheel 1

APPENDIX I

Contractor’s Technical Representative

Condition Found Report

Condition Found

Repairs Required

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 #:

Parts Required

Parts Expended

Recommendations