CYLINDER KIT REPLACEMENT

REQUIREMENTS:

(1each) Series 60 MTU STBD Engine, NSN: 2815-01-590-7303 S/N: 06R1045765

DESCRIPTION:

A commercial diesel technician experienced in the overhaul and repair of the USCG Series 60 engines used on the 45’ Response Boat Medium Lifeboat shall provide labor and consumable parts to perform the repair of the Starboard engine for hull# 45652.  The technician shall provide the required credentials to access the US Government facility at:

REQUIREMENTS: This requirement is for the excessive oil leak repair of a USCG Series 60 Starboard Engine installed on the 45’ Response Boat Medium. The USCG shall remove the engine from the vessel and ship it to an MTU Authorized Service Center for repair. Upon completion of the repair, the USCG will ship the engine back to the Unit for re-installation on hull# 45652. 

All maintenance, repair, and overhaul services performed on the MTU S60 engine must be executed exclusively by MTU-certified technicians.

This policy is mandatory to ensure the highest standards of quality, performance, and reliability as intended by the manufacturer.

To uphold warranty conditions and ensure engine longevity, the following terms are non-negotiable:

• No Subcontracting: The engagement of any third-party or subcontracting entities for any portion of the work is strictly prohibited. The authorized MTU service provider is responsible for all work performed by its direct, certified staff. 

• Certified Technicians Only: All technicians must have completed extensive, official MTU training and be certified to perform work on the specified engine series. 

• Genuine Parts: Only genuine MTU Original Equipment Manufacturer (OEM) parts and consumables are to be used for any service or repair. 

 The use of non-genuine parts or service by unauthorized providers may void the engine's warranty. 

• Authorized Service Centers: All service must be conducted through an officially authorized MTU service outlet to guarantee adherence to factory-specified procedures and to maintain the validity of any existing warranties. 

• Dynamometer Testing: After completion of repairs, the engine shall be tested on a dynamometer owned and operated by the MTU Authorized Service Center. The duration of the testing shall be 1 hour with a full power pull at a minimum of 30 minutes. 

Failure to comply with these requirements may result in the voiding of the engine's warranty and could compromise the operational integrity and safety of the equipment. 

SCOPE OF WORK:

Series 60 Engine technician to provide labor and consumable parts for the following repair on the USCG Starboard Series 60 engine:

1. Drain the coolant from the engine.
2. Remove Heat Exchanger
3. Remove the valve cover and gasket.
4. Remove ECM.
5. Remove Exhaust Manifold and Exhaust Riser.
6. Remove Rocker Arm assembly
7. Remove Camshaft
8. Remove Injectors from Cylinder Head.
9. Remove Cylinder Head.
10. Drain Oil from Sump.
11. Remove Oil Pan.
12. Remove Oil Pump.
13. Remove Cylinder Liner Kits.
14. Thoroughly clean area of all debris.
15. Install New Cylinder Liner Kits with New Connecting Rods and Bearings.
16. Install Oil Pump.
17. Reinstall Oil Pan with new gasket.
18. Install Cylinder Head and Torque to MTU Specifications.
19. Re-install camshaft with new bearing.
20. Re-install rocker arm assemblies
21. Adjust Cylinder Head exhaust valves and injector timing IAW MTU requirements.
22. Reinstall Heat exchanger
23. Re-install all exhaust components
24. Re-install valve cover and gasket.
25. Add all required fluids for operating the engine.
26. Install engine on the dynamometer testing stand. Start Engine and check for leaks, vibrations, and proper operation.
27. After engine is up to operating temperatures perform the engine break IAW MTU specifications.
28. After completion of break-in perform complete dynamometer engine run operating the engine at full power for a minimum of 30 minutes.
29. After the successful dyno test, remove engine from the dyno test stand and reinstall the marine gear onto the engine. Torque all required hardware.
30. Perform touch up painting to all surfaces affected by the repair of the engine.
31. Re-install engine back into shipping container and secure with provided hardware.
32. Contact USCG to arrange shipping of the engine back to the USCG designated Unit.