REVISED_SPEC_SPEC_R_233_2012.pdf

REVISION NUMBER _______

DETROIT DIESEL REMANUFACTURE SPECIFICATION

FOR

DETROIT DIESEL 6-71 MAIN DIESEL ENGINE P/N / MODEL 6072A

(PORT) AND 6071A (STBD) WITH ATTACHED ALLISON REDUCTION

GEAR AND GENERAL MOTORS POWER TAKE OFF

R-233-2012

ORGINATED BY: MKC THOMAS ANDERSON DATE: 18SEPT2014

DEPARTMENT / DIVISION: SBPL-CEO

INTERNAL REVIEWER_____________________________ DATE____________

SOWRB APPROVAL____________________________ DATE____________

USCG-SFLC

30SEPT2014

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DETROIT DIESEL OVERHAUL/RECONDITION SPECIFICATION

1.0 SCOPE

1.1 General -This document sets forth the requirements for the recondition / overhaul of the following assets to Original Equipment Material (OEM) specifications, parts, and standards:

a. Detroit Diesel Engine, P/N 6072A With Attachments (Section 1.2)

b. Detroit Diesel Engine, P/N 6071A With Attachments (Section 1.2)

These Detroit Engines with attached power take off (PTO) and Allison Reduction Gears shall be opened, disassembled, inspected, reported, reconditioned / overhauled, tested, preserved, packaged, marked and shipped back to the U.S. Coast Guard Yard, Baltimore.

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

a. Detroit Diesel (PORT) Model 6-71, P/N 6072A (NSN: 2815-00-892-5088)

b. Allison (PORT) Model MH30L P/N 6759696 (NSN: 2010-00-934-7885)

c. General Motors PTO (PORT) PTA-3811, DD# 5185573

d. Detroit Diesel (STBD) Model 6-71, P/N 6071A (NSN: 2815-00-892-5084)

e. Allison (STBD) Model MH30R P/N 6759695 (NSN: 2010-00-934-7882)

f. General Motors PTO (STBD) Model PTA-3811, DD# 5185573

2.0 APPLICABLE DOCUMENTS

2.1. Document Availability – To obtain the referenced documents see section 8.0.

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

2.2.1. Military Specifications

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

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

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

Application by the Dip Process

d. MIL-STD-2073-1E, Dated May 2008, Standard for Military Packaging

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

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industry organization. Commercial documents may be listed in the Department of Defense Single

Stock Point (DODSSP)

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

Laboratories (NCSL)

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

Equipment

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

Final Inspection and Test

2.3.2. American Society for Testing and Materials (ASTM)

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

2.3.3. Detroit Diesel Engine Company

a. Detroit Diesel 6-71 Service Manual No. S41, Dated Sept 1951

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

2.4.1. Departure from Specification - Departure from this specification shall not be allowed unless approved by the Contracting Officer (CO).

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

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

3.0 REQUIREMENTS

3.1. General - The contractor shall open, disassemble, inspect, report, remanufacture, test, preserve, package, mark and ship each engine with attached Twin Disc Reduction Gear if applicable. The contractor shall provide all labor, equipment, special tools, parts and materials required to accomplish the following in accordance with this specification.

a. Receive the engine with attached components

b. Submit a Core Condition Report (Appendix A)

c. Submit a Disassembly Report (Appendix B)

d. Recondition / Overhaul the engine with attached components

e. Perform Dynamometer Testing

f. Perform Internal Preservation

g. Perform External Preservation and Painting of engine with attached components

h. Package engine with attached components in Shipping Container

i. Preserve and Properly Label Shipping Container

j. Ship back to U.S. Coast Guard

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

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

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

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

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

a. Detroit Diesel 6-71 Model 6072A, Serial No. 06A0071600

b. Detroit Diesel 6-71 Model 6071A Serial No. 06A0090172

c. Allison R/G Model MH30L Serial No. 23495

d. Allison R/G Model MH30R Serial No. 47010

e. General Motors PTO (PORT) PTA-3811, DD # 5185573 Ser # 184005

f. General Motors PTO (STBD) PTA-3811, DD# 5185573 Ser # 192986

3.4. 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 parts not listed in the Mandatory Parts List that require replacement. These parts will be identified as for the reason for replacement & cost.

3.5. Recondition / Overhaul Parts – The contractor shall use only Detroit Diesel Engine Company /

Allison / General Motors OEM parts which meet the OEM specifications and standards. At a minimum, all parts listed under “mandatory replacement parts list” shall be replaced during the remanufacture of the engine. All other parts not listed shall be inspected for critical dimensions and wear limits and replaced as authorized, by the Contracting Officer to meet OEM recondition specification and parameters. The Government reserves the right to supply parts as Government

Furnished Property at any time during this contact.

3.6. Engine and Reduction Gears – The Detroit Diesel 6-71 PORT and STBD Engines may have

Allison Reduction Gears and General Motors PTO’s attached that are to be included in the overhaul process. Those components are identified above. These attachments will be primed and painted according to the same standards and color set forth in this specification for the engine. All equipment in this specification shall be remanufactured, tested and preserved in accordance with OEM specifications, OEM parts and OEM standards, restoring equipment to a like- new condition.

3.7. 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 671 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:

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

U. S. Coast Guard vessel unless otherwise directed by the Contracting Officer.

Locations – The services will primarily be required in vessel homeports located in

Warrenton, OR, Ilwaco, WA and Westport, WA.

Contractor Response – The Contractor shall be required to supply a Technical Representative to the designated location within 36 hours after notification by the Contracting Officer. The

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

The results of the Representative's findings shall be provided in writing within 24 hours of arrival. Approval to perform repairs will be made by the CO after COTR evaluation and approval.

3.8. Core Acceptance Criteria – The contractor shall accept the core based on a complete internal inspection and submit written notification and reasoning of non-acceptance for machinery not acceptable for remanufacture to the Contracting Officer.

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

a. Appendix A: Core Condition Report

b. Appendix B: Disassembly Report

c. Appendix C: Cumulative Tracking Report

d. Appendix D: Warranty Report for U.S. Coast Guard unit

e. Appendix E: “F” Condition U.S. Coast Guard unit Shipping Report

f. Appendix F: Mandatory Replacement Parts

g. Appendix G: Reduction Gear Spin Test

h. Appendix H: Engine Dynamometer Test Report

3.10. Core Condition and Disassembly Reports – The contractor shall submit a completed Appendix

A and B to the Contracting Officer for approval. A complete listing of contingency parts and their prices shall be identified by the Disassembly Report for negotiations with the Contracting

Officer. The contractor shall provide full supporting data with submission of each report to substantiate claim for material. The government further reserves the right to provide any of the parts, materials and components as government furnished property.

3.11. Cumulative Tracking Report – The contractor shall maintain and submit, by the 15 th of each month, the Cumulative Tracking Report, Appendix C, for all machinery included in this contract.

3.12. Warranty - A warranty of one year from date of installation, or 1000 operating hours, whichever occurs first is required under this contract. In addition to these warranty terms, the contractor will allow an extension to the inception date of the warranty by a maximum of 24 months of storage at a designated Coast Guard facility at the Coast Guard’s option. Storage date commences upon receipt of unit at the designated facility.

The contractor shall contact the field unit to arrange the resolution of a claim within 24 hours after receiving notification by the Contracting Officer. The contractor shall notify the

Contracting Officer of the proposed duration of warranty repair time. In the event that the work is not covered under warranty, the contractor shall obtain Contracting Officer’s approval before commencing any work.

In the event of a catastrophic failure that requires the machinery to be completely remanufactured, or where the Contracting Officer has determined that the proposed warranty repair time will compromise the operational schedule of the affected asset, such repair/overhaul will be at the Coast Guard’s option. The Contracting Officer shall negotiate repair pricing and warranty coverage at that time. At no time will machinery be removed from Coast Guard units without the written consent of the Contracting Officer.

3.13. Notifications & Inspections – The contractor shall be responsible for notifying the Contracting

Officer at least 7 calendar days prior to inspections or monitored testing required herein. At this time, prior to the arrival for inspection and testing, the contractor shall provide the exact inspection-testing sheet with O.E.M. specifications and parameters to the Contracting Officer via email.

3.14. Failure Analysis - In the event of a failure, the Contractor shall determine the cause of the casualty and corrective action. A report of the findings shall be submitted to the Contracting Officer.

4.0 QUALITY ASSURANCE

4.1. General – The contractor shall maintain an inspection system, which shall insure that each item offered to the U.S. Coast Guard for acceptance, or approval conforms to the contract requirements.

The inspection system shall be documented, meet the requirements of ASQC-Q9003-1994 and be available for review by the U.S. Coast Guard.

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

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

4.4. Responsibility for Inspection – The contractor shall be responsible for the performance of all inspection requirements specified herein. The contractor shall provide space, personnel, and test equipment for conducting all inspection requirements. All inspection and testing shall be performed at the contractor’s location, or at other facilities acceptable to the Coast Guard. The Coast Guard reserves the right to verify or witness, any of the inspections that are deemed necessary to assure that supplies and services conform to the prescribed requirements.

4.5. Responsibility for Compliance – The inspections set forth in this specification shall become part of the contractor’s overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the contractor of the responsibility of assuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract. Quality assurance based on sampling is not recommended and will not excuse poor performance.

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

Coast Guard.

4.7. Tests & Inspections – The inspection / test listed in 4.7.1. is the minimum required to meet OEM specification, parameters and standards. This inspection / test is not intended to replace any controls, examination, inspections or tests normally employed by the contractor or by the industry as required by commercially reasonable standards to assure the quality of the recondition / overhaul.

4.7.1. Each engine remanufature provided under this contract shall be tested / inspected on an approved dynamometer, under load, to ensure the performance is in accordance with the manufacturer’s OEM requirements and parameters. Prior to the final inspection / test, OEM data name plate with required information, including but not limited to, recondition / overhaul date, model number and item serial number, shall be affixed to machinery.

4.8. Dynamometer Test Reports – The contractor shall submit a signed dynamometer test report

(Appendix G & H) to the Contracting Officer within 7 calendar days after completion of the dynamometer test. The report shall consist of the data obtained during the dynamometer test along with any discrepancies outside of a satisfactory OEM recondition / overhaul specification. One copy of the report shall be packed and delivered with the piece of machinery. One copy of the report shall be provided by the contractor to the quality assurance representative and or COR at time of final testing.

4.9. Failure Responsibility – Any of the following conditions, if found to exist, represent a test failure:

a. Does not meet full power requirements as per O.E.M. standards

b. Has any fluid leaks Examples: oil, fuel, coolant, water

c. Does not meet recommended pressures and / or temperatures as per O.E.M. standards Examples:

oil, fuel, coolant.

d. Any O.E.M. parameter for that reconditioned / overhauled piece of machinery not meeting minimum requirements.

4.10. Failure Corrective Actions – The contractor shall report the failure and the recommended solution to the Contracting Officer. If approved, the corrective action shall be taken in accordance with this section.

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

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

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

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

5.0 PRESERVATION

5.1. Internal Preservation – Preservation in accordance with O.E.M. Policy shall not be started until all tests and inspections have been completed and accepted by the Contracting Officer. Preservation tags and pre-installation instructions shall be affixed to tested machinery.

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

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

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

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

1. Rubber hoses and wires

2. Alternator, Water Valves, Fuel Sight Glass

3. “Hot” surface areas of the turbocharger

4. All identification plates

5. The engine drive shaft output flange

6. The flywheel and rear bolt face

7. The front and rear seals

d. All exposed metal surfaces shall be primed with one coat (2-3 mils) of primer in accordance with

OEM instruction.

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

f. For the engine, reduction gear and PTO the paint color shall be Detroit Diesel Alpine Green.

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

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

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

j. A completed Appendix “D”, “E”, “G” and “H” shall be attached to the top of the engine in a plastic page protector and sealed.

k. The contractor shall place a total of 80 units of desiccant conforming to MIL-D-3464E (activated bag: 1 ounce equals 1 unit), in the interior of the shipping container in the receptacle provided.

l. The contractor shall install and secure from movement the reconditioned/ overhauled machinery into the shipping container.

6.0 MARKING

6.1. Marking – Each preserved and packaged item shall be marked in the upper left-hand side and end of each wooden crate or metal shipping container. The lettering shall be stenciled and at least 1” high, in black print lettering on a highly contrasting background. All other marking not required in this specification shall be painted over or made unreadable.

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

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

LABELED; COAST GUARD SFLC MATERIAL.

Stock Number (As per section 1.2, Example: 2815-00-892-5088)

Model Number (As per section 1.2)

Item Name (Example: Engine, Diesel)

Serial Number See Engine

Contract Number See Contract

Delivery Order Number See Delivery Order

Shipping Weight As Determined By Contractor

Condition Code Condition “A”

Quantity & Unit of Issue 1 – Each

And the Following:

Reusable Shipping Container – Do Not Damage. Do Not Stack. Use Forklift To Unload – Do

Not Lift By Cover. Machinery Has Been Preserved For Long Term Storage.

FINAL PICTURES

6.2. Pictures- Once sections of this document from 4.0 to 6.0 have been completed; pictures of the following shall be sent by the contractor to the Contracting Officer by email prior to shipping. This is to verify proper external preservation of machinery has been completed and properly identified, and that the crate or shipping container has been properly preserved as per this contract, and that the machinery and shipping container information match.

a. Pictures of each piece of machinery reconditioned / overhauled showing external preservation has been completed as per this specification.

b. Pictures clearly showing machinery with affixed data pate including serial number is in place and match, labeled and bar coded shipping container or crate.

c. Pictures showing attached Appendix “D”, “E”, “G” and “H” is affixed to machinery

d. Picture showing preservation tags and instructions affixed to machinery

e. Pictures showing crate marking as per 6.0 of this specification

7.0 NOTES

7.1. Government & Commercial Document Sources

7.1.1. Government Documents

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

Related Publications (DODSSP Documents)

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

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

Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia, PA 19120

215-697-2000

c. USCG Surface Forces Logistics Center

2401 Hawkins Point Road

Baltimore, MD 21226-5000

410-762-6472 ATTN: SBPL, KO

7.1.2. Commercial Documents

a. Society of Automotive Engineers INC. (SAE)

400 Common wealth Drive

Warrendale, PA 15096

412-776-4841

FAX 412-776-5760

b. American Society for Testing & Materials (ASTM)

1916 Race Street

Philadelphia, PA 19103-1187

215-299-5585

FAX 215-977-9679

c. American National Standards Institute (ANSI)

1430 Broadway

New York, NY 10018

212-642-4900

d. American Society for Quality Control (ASQC)

611 East Wisconsin Avenue

Milwaukee, Wisconsin 53202

e. MTU America, Inc

39525 Mackenzie Drive

Novi, MI 48377

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

Appendix A: Core Condition Report

Appendix B: Disassembly Report

Appendix C: Cumulative Tracking Report

Appendix D: Warranty Report for U.S. Coast Guard Unit

Appendix E: “F” Condition U.S. Coast Guard Unit Shipping Report

Appendix F: Mandatory Replacement Parts

Appendix G: Reduction Gear Spin Test

Appendix H: Engine Dynamometer Test Report

7.3. Glossary

a. C.P.L. – Control Parts List

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

Appendix A.

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

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

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

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

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

APPENDIX A

Core Condition Report

Work Order #____________

Delivery Order #__________

Engine Serial # _______________

Reduction Gear Serial # (If applicable) ___________________

Core Acceptance is based on the following:

a. Core must be in the configuration of Master Serial Numbers listed above (Section 3.3).

b. Core must have no non-operational damage.

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

1. Core Acceptable__________, Non Acceptable___________

Remarks _______________________________________________________________________________

2. Condition of shipping container;

Serviceable_______________________

Requires Repair_____________________

3. Photographs of machinery being reconditioned / overhauled; front, right side, left side, and rear views to include serial number in picture frame. These pictures shall then be emailed to the Contracting Officer.

Appendix B

Disassembly Report

Delivery Order Number: ___________________

Date: ___________________________________

Engine Model Number: ____________________

Engine Serial Number: ____________________

Reason for

Replacement Qty Part No. Part Description Unit Price Amount

Total

APPENDIX C

CUMULATIVE TRACKING REPORT

SUBMIT BY THE 15TH OF THE MONTH

Engine In

SER. #

Work # Delivery

Order #

Date

Received

Core

Accepted

Y/N

Eng Out

Ser. #

APPENDIX D

WARRANTY NOTICE

This item has a warranty for whichever comes first:

1 year of operation from installation

Or

1000 hours of operation

Or*

Two years storage from date SFLC received machinery from contractor

(*If required. Warranty period begins at installation if 24 months or less)

If any discrepancies are noted upon receipt

1. DO NOT REPAIR OR REPLACE!

2. CALL: USCG SURFACE FORCES LOGISTICS CENTER

CENTRAL ENGINE OVERHAUL

SMALL BOAT PRODUCT LINE (SBPL)

COMMERCIAL (410) 762-6089 / 6237

Have the following information ready when calling the (SBPL)

________ Date Received ________ Date Installed

________ Serial Number ________ Vessel Home Port

________ Hours on Machinery ________ Vessel Hull No

NOTES:

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

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

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

APPENDIX E

FOR COAST GUARD UNITS ONLY

SHIPPING REQUIREMENTS FOR "F" CONDITION RETURNS

(“F” Condition = Broken, Not ready for issue)

1. Call SFLC Shipping Supervisor Earl Gephardt at 410-762-6297 to receive shipping CBL or visit http://10.38.65.78/WarehouseShipping/ApplicationHome.aspx for instructions.

2. Returned machinery shall be crated and secured properly in the same crate the new engine came in.

3. Crate is to be securely fastened with crate seal intact before shipping.

4. Change Crate Marking from "A" Condition to "F" Condition (Stencil).

5. Change serial number marking on the crate / container from the new engine or gear to the old engine or gear being shipped back

6. Fuel and or oil filters are to be removed and discarded before crating engine or gear “if applicable”.

7. Ensure all fuel lines are to be drained before shipping “if applicable”.

8. Ensure oil and coolant is removed and properly disposed of before shipping “if applicable”.

9. Ensure any parts removed or swapped are reinstalled on the old machinery before shipping. (Make the “F”

Condition machinery complete as possible)

10. Any questions on these requirements please call the Central Engine Overhaul Warranty Phone Line @ 410-

762-6089 / 6237 http://10.38.65.78/WarehouseShipping/ApplicationHome.aspx

APPENDIX F

MANDATORY REPLACEMENT PARTS LIST

Note: Contractor shall be required to provide part numbers by engine serial numbers.

Manufacturer Detroit Diesel

Engine Model # 6-71

Description Main Propulsion Engine

Engine Serial Number 6A90170

6A90172

6FA2644

6A98500

6A98496

6A70363

6A98495

6A90170

6A41344

6A98499

No. Description Part No. Qty.

1 Cylinder Head 01

2 Injectors 06

3 Main Bearings 07

4 Main Bearing Bolt 14

5 Thrust Washer 04

6 Thrust Pin 04

7 Vibration Dampner 01

8 Connecting Rod Bearings 06

9 Connecting Rod Bolt 12

10 Connecting Rod Nut 12

11 Crosshead Bolt 12

12 Crosshead Bolt Spacer 12

13 Cylinder Kits STD 6

14 Liner Shim/Insert 6

15 Cam Bearing Int STD 05

16 Cam Bearing Front STD 04

17 Cam Bearing Rear STD 04

18 Idler Gear Bushing/Bearing 01

19 Cylinder Head Bolt 14

20 Cylinder Head Washer 14

21 Oil Pump Assembly 01

22 Oil Pressure Regulator Valve 01

23 Oil Filter 01

24 Oil Cooler Core 01

25 Fresh Water Pump Assy 01

26 Thermostat 01

27 Raw Water Pump 01

28 All Hoses Various

29 All Gaskets, Seals & O rings Various

30 Injector Jumper Line, Long 06

31 Injector Jumper Line, Short 06

32 Fuel Pump 01

33 Fuel Filter Primary 01

34 Fuel Filter Secondary 01

35 Blower Assembly 01

36 Air Filter 01

37 Clean Heat Exchanger 01

38 Clean Fuel Cooler 01

39 All Hoses

APPENDIX G

Allison MH30L and MH30R General Test Requirements

These recordings of the test procedure shall be filled out and submitted as part of the required test report. The contractor may use a similar test report in lieu of this report as long as the same information contained in this document is included.

Allison MH30L and MH30R Reduction Gear Parameters

a. Operating pressures of the transmission shall be recorded while spin testing at a minimum of the test Range RPM. All readings shall fall between the specified pressures or the transmission is not acceptable.

b. Any external leakage shall deem the transmission unacceptable.

c. Oil temperature shall be maintained between 85 and 95 degrees F at all times during the test.

Test Range Test Main

RPM Port PSI

1800 FWD 130-155

1800 NEU 130-155

1800 REV 110-155

**FWD- Less than 130 PSI indicates leakage

**REV- Less than 110 PSI indicates leakage

Date: Time: Facility:

Position Main PSI

1800 RPM

FWD

NEU

REV

Remarks: Passed Failed

Test completed by: Date:

Facility Representative Signature Date:

Coast Guard Representative Signature Date:

APPENDIX H