SOW SPEC MTU 20V4000M93L QL4 (UPDATED).pdf

REVISION No. 1 CHANGE No.

RRSA/MTU 20V4000M93L QL4 OVERHAUL AND ANALYSIS

P-233-2044

ORIGINATED BY Clayton Ward DATE 02/2026

ORIGINATOR’S COMMAND SFLC PBPL

DEPARTMENT / DIVISION SFLC-PBPL-AMS1

INTERNAL REVIEWER DATE

SWORB APPROVAL_______________________ DATE________

1.0 SCOPE

1.1. This specification describes the requirements for the overhaul of non-ready for issue RRSA/MTU 20V4000M93L marine diesel engine. The engines to be overhauled have reached the time interval, in accordance with (IAW) MTU Maintenance Schedule MA50075, in which 12,000 hour maintenance tasks are required, or may have experienced a catastrophic failure.

1.2. The specification describes the requirements for commissioning services of a newly installed overhauled RRSA/MTU 20V4000M93L engine.

1.3. The specification describes the requirements for technical support for the RRSA/MTU 20V4000M93L engine system.

1.4. This specification describes the requirements for wear analysis of the 20V4000M93L engine to determine appropriateness of maintenance as applicable to a 1DS (continuous operation, variable, low load) engine.

1.5. This sets forth the requirements for the following equipment which will be issued to the contractor as Government Furnished Equipment (GFE);

a. ENGINE, DIESEL P/N 20V4000M93L, NSN 2815-12-392-7931, 26,900 lbs

b. CONTAINER, METAL ASSEMBLY, P/N 101PPI1001, NSN 8150-01-F18-5402, 6,640 lbs

c. FACTORY WOODED SKID, P/N None, 2,250 lb

2.0 APPLICABLE DOCUMENTS

2.1. APPLICABLE DOCUMENTS – The following documents form a part of this specification to the extent specified herein.

2.2. GOVERNMENT DOCUMENTS-

a. None

2.3. COMMERCIAL DOCUMENTS - The following documents form a part of this specification to the extent specified herein. The documents shall be the most current 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. RRSA/MTU 20V4000M93L Functional Description MA13029

b. RRSA/MTU 20V4000M93L Operating Instructions MA15071

c. RRSA/MTU 20V4000M93L Maintenance and Overhaul Manual

MA22019

d. RRSA/MTU 20V4000M93L Removal Spaces and Weights MS68001

e. RRSA/MTU 20V4000M93L Maintenance Schedule MA50075

f. RRSA/MTU 20V4000M93L Instruction for General Overhaul MA25014

g. RRSA/MTU 20V4000M93L Instructions for Overhaul of Sub-Assemblies MA20011

h. RRSA/MTU 20V4000M93L Spare Parts Manual MA30188

i. RRSA/MTU Fluids and Lubricants Specification A001061

j. RRSA/MTU Preservation and Re-preservation Specifications A001070

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

l. ANSI/ASQC Q90003-1994, 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 in writing prior to continuing work of any perceived conflicts contained herein.

2.5. DEPARTUARE FROM SPECIFICATION – Departure from this specification shall not be allowed unless approved by the 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 – The contractor shall overhaul the engine and components listed in RRSA/MTU Maintenance Schedule MA50075. All 12,000 operating hour tasks shall be accomplished.

a. Contractors who possess a current RRSA/MTU distributor agreement authorizing the service of their products shall provide proof of this agreement to the Contracting Officer. Any changes and/or modifications to the distributor agreement shall be forwarded immediately to the Contracting Officer. The Coast Guard reserves the right to request from the contractor proof of their distributor agreement at any time.

b. The contractor must have access to service bulletins applicable to the 20V4000M93L engine.

c. The contractor shall provide, when requested by the Contracting Officer, detailed evidence of their experience overhauling, repairing, and testing of the RRSA/MTU 4000 03 marine diesel engine and components listed in this specification.

d. The Contractor shall have access to RRSA/MTU’s secure IT Business portal and the RRSA/MTU Central Data Base.

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

f. The contractor shall ensure all work performed under this contract is by technicians possessing the training, qualifications, and RRSA/MTU certifications (specified in the referenced manuals) to the level appropriate for the specific task they are performing.

Any work performed by un-certified/qualified, or under certified/qualified technicians will be subject to contractual remedies.

g. The overhaul and component inspections shall be completed using current RRSA/ MTU parts, components, processes, and practices.

h. Testing shall be conducted in accordance with run-in and acceptance test procedure.

i. The contractor shall notify the Contracting Officer fourteen (14) days prior to all testing. The Coast Guard reserves the right to witness all testing.

j. The overhauled engine shall be dynamometer tested to full load, 4,216KW, IAW MTU run-in/acceptance test procedures.

k. The contractor shall provide an electronic copy of the Engine Inspection Report (Birth Certificate) fourteen (14) days upon completion of testing.

l. Upon receipt of components, regardless of condition, the contractor shall store material inside in a secure area away from adverse weather.

m. The contractor shall be capable of overhauling a minimum of four (4) engines.

n. The contractor shall submit for approval an acceptable wear analysis plan and conduct wear analysis on the RRSA/MTU 20V4000M93L marine diesel engines using the approved wear analysis plan.

o. The contractor is solely responsible to facilitate and coordinate subcontractors’ performance requirements.

p. The contractor shall submit reports within the time line set forth in the delivery schedule.

r. Disregard references to American Bureau of Shipping (ABS) certification. This not applicable to specification.

3.2. OVERHAUL/REPAIR ENGINE – When directed by the Contracting Officer, using the applicable RRSA/MTU Technical Publications and Standards, the contractor shall provide all labor, equipment, special tools, materials, and parts to receive, inspect, overhaul, test, preserve, paint, package, and provide warranty for the engine and components listed in RRSA/MTU Maintenance Schedule MA50075. All 12,000-hour maintenance tasks shall be accomplished. The contractor shall incorporate, at no cost to the Coast Guard, all applicable RRSA/MTU engine service bulletin modifications.

The contractor shall complete these requirements in accordance with the referenced order.

a. The contractor shall receive a non-ready for issue engine, NSN 2815-12-392-7931 and shipping container(s), document the as-received condition, inspect shipping container(s), and submit Appendix (A) within the date specified in 1-0 of the Contract’s Delivery Schedule.

b. The contractor shall disassemble engine, inspect, and submit condition found report Appendix (B) within the date specified in 3-0 of the Contract’s Delivery Schedule.

Include cost estimate for any additional work.

c. Upon written approval from the Contracting Officer the contractor shall crate and ship to the Coast Guard, 2401 Baltimore, MD 21226, any engine found to be non-repairable. Engine to be free of hazardous material.

d. The contractor shall maintain critical dimensions documentation, as specified in Instruction for General Overhaul MA25014, and made available to Contracting Officer or Contracting Officer Representative (COR) upon request.

e. The contractor shall conduct a dynamometer test in accordance with the run-in and acceptance test procedure on overhauled engine per Appendix (C) and submit report within the date specified in 4-0 of the Contract’s Delivery Schedule.

f. The contractor shall preserve the engine IAW RRSA/MTU Preservation and Re-preservation Specifications A001070. Freeze protection is required IAW, chapter 5.3.2, Storage with unfilled medium circuits. Use internal preservation corrosion inhibitor Glysacorr P133 antifreeze at 50% volume or equivalent. Submit to the Contracting Officer RRSA/MTU Check Sheet for Preservation upon preservation completion.

g. The contractor shall paint the overhauled engine with Valspar LIC 50 general purpose polyurethane enamel RAL9010 white following all manufactures surface preparations, mixing ratios, and dry times. Paint shall be sprayed on all surfaces 3-5 mils thick.

h. The contractor shall package the overhauled engine in the GFE container IAW Preservation and Re-preservation Specifications A001070, chapter 8.2, Climate-compatible long term storage. Mark overhauled engine IAW section 5.4 of this specification.

i. The contractor shall submit a cumulative tracking report on the 15th of each month with status of all open delivery/task orders Appendix (D).

3.3. ENGINE ANALYSIS –In accordance with 5-0 of the Contract’s Delivery Schedule the contractor shall submit for Contracting Officer approval their in-depth analysis plan describing the nondestructive testing methodology to ascertain engine wear and appropriateness of the current maintenance schedule. At a minimum the plan shall include the following; indications of operator induced wear (for example low load conditions), indications of maintainer induced wear (for example improper valve lash adjustment), observed wear relative to anticipated wear, and internal corrosive wear.

Include in the plan which components to be analyzed, the quantity to be analyzed (for example all injectors, all cylinder liners), the level of testing (for example laboratory testing, comparative, measurements, etc.) to be completed, and how maintenance periodicity appropriateness to be determined. The analysis shall be conducted on an engine inducted for overhaul.

3.3.1- When directed by the Contracting Officer conduct wear analysis.

3.3.2- The contractor shall deliver to the Contracting Officer an electronic copy of Report of Engine Wear Analysis within the date specified in 5-0 of the Contract’s Delivery Schedule. At a minimum the report shall all include; all findings, operator recommendations, maintainer recommendations, and recommend new maintenance schedule based upon analysis findings.

3.4. COMMISSION ENGINE- None

3.5. TECHNICAL SUPPORT- None

3.6. ROOT CAUSE FAILURE ANALYSIS- None

3.7. WARRANTY- The engines are being overhauled as system stock and will be placed into inventory and not for immediate installation. The Contractor shall provide a warranty for a period of one (1) year from installation or 1,000 operating hours, whichever comes first, even if stored up to 24 months after overhaul. Storage commences upon receipt of the component at the designated Coast Guard facility. The warranty commences the date the engine is installed on a 154’ WPC. The warranty shall cover all parts and workmanship defects. The contractor shall contact the 154’ WPC cutter within twenty –four (24) hours after receiving notification by the Coast Guard of a warranty claim.

3.8. TRAVEL- None

4.0 QUALITY ASSURANCE

4.1. GENERAL - The Contractor shall maintain an inspection system which shall ensure each item offered to the Coast Guard 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 measurements, 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 request of Contractors Officers Representative (COR).

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 Contractors Officers Representative (COR) 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 Coast

Guard. The Coast Guard 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.

4.5. REQUIRED TESTS -• The overhauled engine shall be dynamometer tested to full load, 4,216KW, IAW MTU run-in/acceptance test procedures. Test shall be complete on sight.

4.6. TEST REPORT - The Contractor shall submit the final test reports in accordance with OEM as standard Birth Certificate.

a. One copy of the test reports shall be packed with each component delivered under this contract.

b. One electronic copy of the test reports shall be provided to the Contracting Officers Representative (COR).

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) – In accordance with section 3.2(e) of this specification.

5.2. PRESERVATION (External) - In accordance with section 3.2(e) of this specification. 5.3.

PACKAGING– Each engine shall be packaged in accordance with Preservation and Re-preservation Specifications A001070, section 8.2, in climate-compatible long term storage packaging in either the GFE issued re-usable skid mounted wooden box or steel shipping container (NSN 8150-01-F18-5402). The contractor shall notify the Contracting Officer of any damage to the GFE packaging. When the contractor is issued a skid mounted wooden box and also a steel a shipping container, the contractor shall package the engine in the steel shipping container and dispose of the now surplus skid mounted wooden box.

Each container shall be internally braced and cushioned to prevent movement of the assembly. The contractor shall ensure the internal is bracing capable of protecting the assembly while in storage and from rough handling during multiple shipments.

a. The Contractor shall place in a plastic envelope in each container, copies of all test and inspection results, caution tags, and coolant flush instructions to be completed prior to light off.

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 2815-12-379-7231

ITEM NAME ENGINE, DIESEL

PART NUMBER 20V4000M93L

SERIAL NUMBER “As per Enclosed Item”

CONTRACT NUMBER

DELIVERY ORDER NUMBER

SHIPPING WEIGHT

See Contract If Applicable 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 DESTROY.

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 crates.

a. None

6.0 GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

6.1. GOVERNMENT DOCUMENTS

6.2. COMMERCIAL DOCUMENTS

a. Rolls-Royce Solutions Americas/MTU 39525 Mackenzie Drive Novi, MI 48377 248-560-8000 https://www.mtu-solutions.com/eu/en.regionselect.html_

b. International Organization for Standardization American National Standards Institute (ANSI) 1430 Broadway New York, NY 10018 212-642-4900

6.3. ENCLOSURES – None

https://www.mtu-solutions.com/eu/en.regionselect.html_