ATTACHMENT_1_SPEC_R-233-2031.docx

REVISION No. CHANGE No. 01

MTU FRIEDRICHSHAFEN

DIESEL ENGINE 8 V 396 TE 94

W6 ENGINE REMANUFACTURE

P-233-2031

ORGINATED BY Patrick R. Mulrooney DATE 10/2015 ___

ORIGINATOR’S COMMAND Surface Forces Logistics Center (SFLC) ________ _

DEPARTMENT / DIVISION Patrol Boat Product Line (PBPL) ________ _____

INTERNAL REVIEWER __________ __DATE_ ________

1.0 SCOPE

1.1. This describes the requirements with which the Contractor shall comply completing the W6 Maintenance Echelon on Motoren-und-Turbinen-Union (MTU)Friedrichshafen MTU 8V 396 TE 94 Diesel Engine(s). The Contractor shall also provide technical services including commissioning of new engines when requested by the Contracting officer. Two (2) propulsion units are currently installed on each of 73, 87’WPB Coast Guard cutters nationwide.

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

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

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

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

1.3. GOVERNMENT FURNISHED MATERIAL:

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

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

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

2.0 APPLICABLE DOCUMENTS

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

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

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

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

2.3. 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).

a. MTU 8V 396 TE.4 Maintenance Manual M020046/21E

b. MTU 8V 396 TE94 Parts Catalog M033971/00DE, Order #771903

c. MTU V396 TE.4 Tolerances & Wear Limits List M070026/00E

d. MTU Tool List M004021/20DE

e. MTU Exhaust Turbocharger ZR140 M040052/10E

f. MTU Bosch Fuel Injection Pump PE..ZWM 170/100RS 30.. Description, Assembly Instructions, Spare Parts List M040095/00E

g. MTU Solenoid Actuator, Description, Assembly Instructions M040082/10E

h. MTU Service Information 396-99/0562B Electric Governor Actuator with Oil Drain

i. Geislinger Coupling E56/7,5/90 Bearing Housing Description, Assembly Instructions N060558/00E

j. MTU Fluids and Lubricants Specification A001061/35E

k. MTU Engine management System Typ ECS 396/S Version E & F with ETB 4E/ETB 4F Document numbers; E 531 406/01 E, E 531 405/ 01E & E 531 403/02E

l. MTU Customer Connecting System CCS for ECS 396, E 531 416/00E

m. MTU Customer Connecting System CCS for ECS 396, E 531 415/00E

n. MTU Electrical Start Device SUE-ES for ECS 396, E 531 482/00E

o. MTU Engine Control System Illustrated Parts Catalog E 535 145/01ED

p. MTU Junction Box CCS-ECS 396E Illustrated Parts Catalog E 535 151/01ED

q. MTU Local Operating Panel for ECS E 531 301/01E

r. MTU Local Operating Panel LOP-ECS Illustrated Parts Catalog E 535 297/02ED

s. MTU Electrical Start Equipment SUE-ES Illustrated Parts Catalog E 535 187/00ED

t. MTU Monitoring & Control Unit Documentation E 535 164/00ED

u. Installation of MTU Electronic Systems E 530 606/06E

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

w. ZF Marine Transmissions BW 250 Series Operating Instructions 3082 758 103b

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

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

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

2.4. SPECIFICATION ORDER OF PRECEDENCE - In the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence, unless otherwise specified herein. The Contractor shall notify the Contracting Officer within 1 (one) week in writing of any perceived conflicts contained herein.

2.5. DEPARTUARE 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 suggest implementing change or depart from applicable specifications they shall request permission.

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

3.0 REQUIREMENTS

3.1. GENERAL – OEM technical publications shall be utilized to complete the W6 maintenance echelon. The Contractor shall be required to legally possess all OEM technical publications and have them available at the Contractor’s facility. The Contractor shall be required to complete the following requirements. These requirements shall be required on all the units classified herein. The Contractor shall complete these requirements in accordance with the attached Delivery Schedule.

q. Complete engine commissioning procedures and related technical services on newly installed engines.

r. Technical Support (optional)

s. Submit Appendix F (Technical Representative Report)

3.2. The Contractor shall provide all labor, equipment, special tools, materials, and parts required to clean, inspect, disassemble/reassemble, test components, test engine, and deliver at least two(2) engines simultaneously every 35 calendar days.

a. The Contractor shall provide & legally possess an authorized, up to date, MTU 1B service dongle to validate and update, as needed, the system parameters to match the current 87' WPB configuration.

b. The Contractor shall be able to provide, when requested by the Contracting Officer, detailed evidence of their experience successfully conducting the W6 maintenance echelon, performance and acceptance testing of MTU 396 TE94 series marine propulsion diesel engines.

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

d. The Contractors lead technicians shall be trained and certified to the level of MTU’s standards meeting CM3/CE3. Journeymen technicians shall be certified to the level of CM2/CE2.

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

f. The engine dynamometer testing shall be conducted on-site at the Contractor’s facility in accordance with MTU procedures. The dynamometer shall be designed to test salt water cooled 2000 KW marine engines at full load in all weather conditions. All dynamometer testing shall be conducted without the transmission attached. The Contractor’s dynamometer shall utilize MTU ECS-UNI/ADEC-UNI, LOP, bearing cage and all other MTU components required to complete testing. The USCG reserves the right to witness all testing.

g. 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. The contractor shall submit Appendix I “Technical Representative Condition Found Report” with a cost estimate to the Contracting Officer for approval for any repairs required that are beyond the scope of the pre-paid commissioning, in order to complete engine commissioning.

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

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

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

3.3. TECHNICAL SUPPORT- The Contractor shall provide technical support. These services shall include, but are not limited to the following:

a. Validate the gear(s) is operating within the manufacturer’s specifications.

b. Ensure the proper communication and interoperability of the system components.

c. Participate in dockside performance test, evaluation, and validation.

d. Participate in underway performance test, evaluation, and validation.

e. Perform lube oil analysis.

f. Repair, renew, adjust, calibrate, and test improperly functioning system components as required.

g. Provide maintenance recommendations based on data analysis and inspections.

3.4. FAILURE ANALYSIS – In the event of a catastrophic failure and at the discretion of the Government; on a separate task order the engine will be sent to the Contractor’s facility to determine the cause of the casualty. All parts & labor shall be priced separately and shall be negotiated under each task order. A report of the findings shall be submitted to the Contracting Officer within thirty (30) days of receipt of the gear.

3.5. USED PARTS - The Contractor shall request in writing to the Contracting Officer for the disposition of used parts.

3.6. CONTRACTOR PERSONNEL- The Contractor shall provide a Point of Contact

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

a. Receiving Inspection Report (Appendix A). The Contractor shall submit Appendix A to the Contracting Officer within seven (7) days after receiving the engine.

b. Upon submittal of Appendix A, the reduction gear shall be separated and returned to USCG SFLC Baltimore.

c. Condition Found/Disassembly Report (Appendix B). The Contractor shall disassemble the engine and submit Appendix B to the Contracting Officer for approval within twenty (20) days after receiving the engine. No further work shall be accomplished until approval is received from the Contracting Officer.

d. Reassembly Critical Dimension Report (Appendix C). The Contractor shall submit 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.

e. 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.

f. 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 MTU Geislinger Coupling E56/7,5/90 Bearing Housing Description, Assembly Instructions N060558/00E. Appendix G shall be submitted concurrently with Appendix B. No further work shall be accomplished until approval from the Contracting Officer.

3.8. GENERAL TEST REQUIREMENTS

3.9. 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.

a. Prior to notification of testing, ensure the engine is installed on the dyno, test operated, and engine warmed up prior to Coast Guard Representative’s arrival.

WARRANTY - A warranty of one year from installation or 1000 operating hours, whichever occurs first and up to 24 months of storage is required that covers workmanship, engine performance & all new parts installed by the Contractor or his sub-contractors. 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.

a. 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.

b. 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.

c. The Project Manager shall contact SFLC’s Contracting Officer’s Representative (COR) to evaluate the Contractor’s proposed duration of warranty repair time.

d. 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.

e. The Contractor shall provide OEM certified personnel, tooling, & software to perform the warranty requirements of this specification. The contractor shall be capable of providing the required warranty work and or parts at any geographic location the 87WPB fleet operates without affecting the contract’s delivery schedule.

f. 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.

g. 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. 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.

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 ANSI/ASQS Q90003.

4.2. 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 Coast Guard Representative.

4.3. CONTRACTORS CALIBRATION SYSTEM The Contractor as well as any Subcontractors shall be required to maintain a calibration and maintenance system to control the accuracy of measurement and test equipment used in the fulfillment of this contract in accordance with ANSI/NCSL Z540-3. The system shall include as a minimum, prescribed calibration intervals, source of calibration, and a monitoring system to ensure adherence to calibration schedules. Calibration standards shall be traceable to the National Institute of Standards and Technology (NIST). Documentation in support of this requirement shall be readily available for 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. 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.

b. REQUIRED TESTS - Each engine provided under this contract should be operationally tested in accordance with Appendix E.

c. 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 simultaneously.

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

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

5.0 PRESERVATION, PACKAGING, PACKING, & MARKING

5.1. PRESERVATION (Internal) - The engine shall be preserved as per the requirements of MTU Fluids and Lubricants Specification A001061/35E, Chapter 8 Preservation Specifications, after operational testing, and acceptance by the Government.

5.2. PRESERVATION (External) - After completion of the final test run and internal preservation the engine will be prepared in accordance with MTU Fluids and Lubricants Specification A001061/35E, Chapter 8 Preservation Specifications.

a. All surfaces shall be cleaned of grease and oil

b. All loose scale and paint shall be removed

c. 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.

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

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

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

g. 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).

h. 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**

5.3. PACKING - The shipping container if missing or damaged shall be constructed and mounted to the base skidded pallet as per MIL-C-104C. The engine shall be packaged as per MTU Fluids and Lubricants Specification A001061/35E Chapter 8 Preservation Specifications page 70, “Special Packing”.

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

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

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

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

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

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

NATIONAL STOCK NUMBER 2815-12-348-2440

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.

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

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

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

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

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

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

6.0 GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

6.1. GOVERNMENT DOCUMENTS

a. USCG Surface Forces Logistics Center

6.2. COMMERCIAL DOCUMENTS

a. MTU Detroit Diesel, INC 13400 Outer Drive West Detroit, Michigan 48239, USA 313-592-7000 www.mtudetroitdiesel.com

b. ASTM International 100 Barr Harbor Drive P.O. Box C700 West Conshohocken, PA 19428-2959, USA www.astm.org

c. International Organization for Standardization

6.3. ENCLOSURES – The following enclosures apply:

a. Appendix A Receiving Inspection Report

b. Appendix B Condition Found Report

c. Appendix C Reassembly Critical Dimensions Report

d. Appendix D Mandatory Parts List

e. Appendix E Engine Test Report

f. Appendix F Cumulative Tracking Report

g. Appendix G Geislinger Coupling Inspection Report

h. Appendix I Technical Representative Condition Found Report

i. Attachment # 1 Warranty Information

MTU 8V396 TE94 REMANUFACTURE SPECIFICATION

Appendix A Receiving Inspection Report

Work Order # ____________________ Delivery Order # __________________ Engine Serial # ___________________ Reduction Gear Serial # ____________

Core Acceptance is based on the following:

a. Core must have no non-operational damage.

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

1. Core acceptable__________, non-acceptable___________ Remarks: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

2. Shipping crate: Serviceable_________ Needs Repair____________

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

Appendix A Receiving Inspection Report Continued:

Condition Found

Repairs Required

Parts Required

Parts Expended

Recommendations

Appendix C

Reassembly Critical Dimensions Report

W-6

In order to prevent defective components from being reinstalled or sound parts from being scrapped, it is essential that testing and measurements are preformed on critical components.

The following components are deemed critical and require individual examination results. The Contractor shall record measurement IAW MTU 8V 396 TE.4 Maintenance Manual M020046/21E:

· Measuring Crankcase Bores

· Cylinder Liner (Installed)

· Axial Play and Backlash

· Crankshaft Data Sheets

· Crankshaft Bearings

· Conrods

· Conrod Bearing (Shells Installed)

· Timing and Injection Timing

· Piston Gap Settings

· Valve Guide Bushes

1.0 Requirements

1.1. General test parameters detailed in this Appendix shall be used during the test procedure and a test report in the format as per this Appendix that will be submitted after the COTR acceptance.

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

1.3. All engine testing will be verified and accepted by the USCG Representative.

1.4. Pre-Test Preparation Requirements

a. Each engine shall be fitted with new lube oil filters.

b. Each engine shall be filled with new OEM specified lube oil.

c. The fuel oil shall be as per ASTM-D-975 # 2 diesel and flow through a 20-micron filter/separator before entering pump.

d. The cooling system shall be filled with clean potable water.

e. Each engine shall be tested with all hang on attachments to include all those items listed in Appendix A.

1.5. Pre-Start Requirements

a. Fill engine-cooling system

b. Prime fuel system

c. Fill and pre-lube engine lube oil system

d. Energize engine block heater and allow engine to warm for a minimum of six (6) hours

1.6. Post Test Preparations Requirements

a. All engine lube oil filter elements shall be replaced with new filter elements after completion of engine test.

b. Old filter elements shall be cut open and inspected for foreign material in the presence of the USCG Representative.

c. Lube Oil consumption shall be calculated during final acceptance run.

2.0 Tests & Test Parameters

Basic Run-In:

Run in shall be conducted in accordance with OEM initial run-in procedures as outlined below. Basic Run-in shall be successfully completed prior to performing the Final Acceptance tests with a USCG representative. Results/readings of Run-In test shall be recorded and made available to USCG representative upon request.

Run-In Program BR 396

8V396TE

Engine Speed

(RPM)

(kW)

REMARKS: Engine measurements are only recorded at n = 1000 rpm and at final power (Full Power)

P= F x n (kW) X For load “F”, braking constant X= 10000

Final Acceptance Testing:

All readings and parameters taken during Final Acceptance run will be compared to engines “Birth Certificate” Dynamometer readings. This comparison will measure engine performance and will be used in determining Coast Guard acceptance. All defined parameters herein are based off of alarm set points.

ATMOSPHERIC PARAMETERS

NOTE - Readings shall be taken and recorded at the end of each phase. All line items with specific parameters are to be observed and actual readings recorded.

Phase 1: 5 Minutes Idling with Cylinder cut-out

GENERAL

TEMPERATURE

+30

PRESSURES

Phase 2: 15 Minutes at 600 rpm/30kW.

72,500

72,500

+30

Phase 3: 15 Minutes at 1260 rpm/ 275kW.

72,500

72,500

+30

Phase 4: 15 Minutes at 1590 rpm/ 550 kW.

+30

Phase 5: 15 Minutes at 1820 rpm/ 825 kW.

+30

Phase 6: 15 Minutes at 1930 rpm/ 990 kW.

+30

Phase 7: 15 Minutes at 2040 rpm/ 1000 kW.

+30

Phase 8: 15 Minutes at 2100 rpm/ 1100 kW.

+30

Phase 9: 1 Hour at 2000 rpm/ 1100 kW.

+30

EXHAUST

(Pyrometer) readings shall be recorded at completion of each phase of the dyno test. Differential temperatures between cylinders shall not exceed 86°(C).

EXHAUST

EXHAUST

CONDITION OF L/O FILTERS AND QUANITY OF L/O CONSUMED: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

FINDINGS/COMMENTS: __________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

SIGNATURE OF SHOP FOREMAN: ____________________________________ DATE: ________

SIGNATURE OF DYNO OPERATOR: ___________________________________ DATE: ________

SIGNATURE OF USCG REP: __________________________________________ DATE: ________

CUMULATIVE TRACKING REPORT SUBMIT QUARTERLY BY THE 15TH OF THE MONTH

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 MTU Geislinger Coupling E56/7,5/90 Bearing Housing Description, Assembly Instructions N060558/00E. 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.

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:

MTU Engine Model #:

Condition Found

Repairs Required

Parts Required

Parts Expended

Recommendations

Attachment # 1 Warranty Information Warranty Period for this MTU 8V396TE94 Engine:

1000 Hours of Operation OR (1) Year from Date of Installation

****After installation, return this completed sheet to the following****

USCG SFLC PBPL AMS 3

Attn: Pat Mulrooney/ patrick.r.mulrooney@uscg.mil Mail Stop 25, 2401 Hawkins Point Road Baltimore, MD 21226-5000

Unit Name:

Engine Serial Number

Hull Number:

R/G Serial Number

Homeport:

Date Received:

POC:

Date Installed:

Telephone:

Upon Installation

Verify Removal of Transportation Locking Device

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

Any discrepancies noted upon receipt/during warranty period

DO NOT REPAIR OR REPLACE!!!

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

OFFICE PHONE: (410) 590-7173.

AFTER HOURS Call your Asset Manager !!Any unauthorized repairs could void the WARRANTY!!

· At 50 Hours check/adjust all Valve Clearances and Record Each.

· At 50, 250, and 500 hours of initial operation, engines shall have oil samples drawn and sampled.

· At 500 hours, or 1 Year Change Oil and Clean Centrifuge Filter.

1. GENERAL CHECKS UPON RECEIPT OF ENGINE

A. A COMPLETE INSPECTION SHOULD BE MADE OF THE UNIT'S CONDITION.

B. INSPECT THE JACKET WATER, FUEL OIL, LUBE OIL, AND RAW WATER SYSTEMS FOR PRESERVATIVES REMAINING IN THESE SYSTEMS.

C. PRESERVATION TAGS ON THE ENGINE WILL TELL YOU TO WHAT EXTENT THE UNIT HAS BEEN PRESERVED AND WHAT SHOULD BE DONE BEFORE PLACING THE UNIT IN OPERATION.

D. UNCOVER ALL TAPED AND PLUGGED OPENINGS PRIOR TO CONNECTING OF HOSES AND LINES.

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

F. INSURE PROPER SHAFT ALIGNMENT, IF ENGINE IS INSTALLED WHILE THE CUTTER IS OUT OF THE WATER, YOU MUST WAIT 24 HOURS AFTER THE CUTTER IS PLACED IN THE WATER BEFORE ALIGNING THE SHAFT. ALL TANKS MUST BE TOPPED OFF.

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

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

I. CHECK ENGINE MOUNTS.

J. ANY PROBLEMS DURING THE INSTALLATION WITH THE ENGINES SHOULD BE REPORTED TO PATROL BOAT PRODUCT LINE IMMEDIATELY.

2. GENERAL WARRANTY PARAMETERS

A. THINGS THAT WILL NOT VOID THE WARRANTY.

1. Scheduled maintenance may be performed.

2. Troubleshooting the unit in accordance with TP 4531.

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

B. SOME THINGS THAT COULD VOID THE WARRANTY

1. Changing subassemblies without authorization.

2. Changing thermostat without authorization.

3. Removing the L/O cooler cores.

4. Changing the exhaust manifolds or turbocharger and assembly without authorization.

5. Removing gear housing.

** CAUTION: OIL HAS BEEN DRAINED FROM ENGINE AND GEAR; DO NOT OPERATE UNIT UNTIL FLUIDS ARE ADDED.

** CAUTION: FUEL SYSTEM HAS BEEN PRESERVED WITH INJECTION PUMP TESTING OIL AND CORROSION INHIBITOR. FUEL SYSTEM MUST BE FLUSHED COMPLETELY WITH DIESEL FUEL.

** CAUTION: JACKET WATER COOLANT SYSTEM HAS BEEN PRESERVED WITH ANTIFREEZE OR COOLING SYSTEM CONDITIONER AND HAS BEEN DRAINED. DO NOT OPERATE UNTIL FLUID HAS BEEN ADDED.

** CAUTION: DO NOT ROTATE THE ENGINE CRANKSHAFT OR GEAR OUTPUT SHAFT UNTIL READY TO INSTALL UNIT.

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

NOTICE: FOR FURTHER INFORMATION REFER TO TP 4531 OR CALL PATROL BOAT PRODUCT LINE TEAM REPAIRS ARE TO BE PERFORMED ONLY AFTER CONTACTING THE PATROL BOAT PRODUCT LINE (PBPL) TEAM

OFFICE PHONE: (410) 590-7173.

AFTER HOURS: Call your Asset Manager.

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