2. Specification_70Z08024RAG294_ALCO 251 Overhaul Parts Kits.docx

1.0. Scope: This specification describes the requirements for the manufacture, inspection, preservation, packaging and marking (PP&M), of 251 series ALCO engine overhaul parts kits in service onboard U. S. Coast Guard (USCG) WMEC 210’ and 270’ cutters and the WAGB 399’ class cutter.

1.1. Requirements: The Contractor shall provide all equipment, labor and materials to manufacture, inspect, preserve, package, pack, mark and ship the kits.

2.0. Applicable documents:

2.1. General: The documents listed in this section are specified in section 2 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, users are cautioned that they must meet all specified requirements of documents cited in sections of this specification, whether or not they are listed.

2.2. Document availability: To obtain the referenced documents see section 6 of this specification.

2.3. Government documents: The following documents form a part of this specification to the extent specified herein. The documents listed shall be by title and effective date, unless otherwise documented.

2.3.1. MIL-STD-129R(2) Military Marking for Military Shipment and Storage

2.3.2. MIL-STD-2073-1E(4) Standard Practice for Military Packaging

2.3.3 MIL-PRF-24636F Coating System, Weather-Resistant, Exterior Use

2.4. 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.

2.4.1. American Society for Testing and Materials, ASTM D6880/D6800M-19 Standard Specification for Wood Boxes

2.4.2. International Organization for Standardization (ISO), ISO 9001:2015, Quality Management Systems - Requirements

2.4.3. ISO/IEC 17025:2017(E) General Requirements for the Competence and Testing and Calibration Laboratories

2.4.4. International Organizations for Standardization (ISO), ISO/IEC-16388-2007, Dated 5/2007, Automatic Identification and Data Capture Techniques – Code 39 Bar Code Symbology

2.4.5. American Society for Testing and Materials, ASTM D3951-18, Standard Practice for Commercial Packaging

2.4.6. SAE-AMS-STD-595A, Colors Used in Government Procurement

2.5. Specification order of precedence: In the event of a conflict between the text of this specification and the references cited herein, this statement of work (SOW) shall take precedence. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0. Requirements:

3.1. General: The parts contained within each kit are defined as any items considered being repairable or consumable parts, components and assemblies that compose each kit contents for Alco Model 251; 16 and 18 cylinder diesel engine maintenance as used by the US Coast Guard and manufactured by the (OEM) Fairbanks Morse Defense (FMD). All parts shall be new OEM parts. Reclaimed, recycled, or aftermarket parts are not acceptable and shall not be used.

3.1.1 Workmanship - All workmanship shall be of highest quality in all respects with close attention paid to form, fit, material, dimensions, finish, etc. all to be in full conformance with the specifications and associated drawings and documents. All materials and components must be of highest quality in every respect and of new manufacture. No use of used materials or components will be permitted.

Any flaws detected in material or construction methods shall be resolved to the satisfaction of the Coast Guard before completing any kit. Welded parts shall be free of weld spatter, porosity, undercuts and other defects. All parts shall be free of burrs and sharp or ragged edges. The manufacture of all critical and or load bearing parts and assemblies shall only be performed by properly certified craftsmen. Commercial parts which are not manufactured by the diesel engine manufacturer shall be identified by their marking or through the use of the manufacturer’s technical documentation for identification purposes.

3.2. Certificate of Conformance: A signed, corporate level, Certificate of Conformance (COC) shall be supplied to the Contracting Officer, at the time of contract award. The COC shall state that all parts meet or exceed the salient characteristics of Fairbanks Morse Defense, the Original Equipment Manufacturer (OEM), and shall be signed by a corporate office of the OEM. See Section 5 for shelf life of consumable parts.

3.3. Surface preservation: Any part typically painted prior to installation shall be painted prior to delivery. Parts requiring surface preservation include, but are not limited to, pumps, intake side of turbochargers, cylinder heads, thermostats, and valves. Internal components, mating surfaces and rotating/moving components shall not be painted.

Exposed shafting and working machined surfaces, gear-trains, the inside of gearboxes and other finished surfaces dependent on lubrication for preservation shall be lubricated or coated with an appropriate preservative suitable for protection of equipment stowed in an unheated warehouse for up to one year. Preservatives shall be compatible with the intended working lubricants.

3.3.1. Primer coat shall be a High Build Epoxy suitable for use with the finish coat. Finish coat shall be in accordance with MIL-PRF-24635, Silicone Alkyd Enamel Type II Class 1. Color shall be “Machinery Gray” in accordance with Federal Standard 595 color number 16307 or match the OEM color. High Build Epoxy total paint thickness shall be a minimum of 5 to 6 mils Dry Film Thickness (DFT). Finish coat Silicone Alkyd Enamel Type II Class 1 total paint thickness shall be a minimum of 2 to 3 mils DFT. Total DFT shall be between 7 - 9 mils.

3.4. Storage Report: The Contractor shall maintain and submit to the Contracting Officer a plan for storing of CSO kits at contractor’s facility; providing how the kits will be stored and monitored to ensure protection and visibility of Government property.

The contractor shall store these CSO overhaul parts kits in a secure location until a kit is requisitioned by the Coast Guard for scheduled maintenance. At that time, the KO will provide authorization for the contractor to transfer the CSO kit to the cutter’s location and will provide a delivery address.

3.5. Warranty: If the item(s) required in the contract resulting from this solicitation are customarily warranted in the trade by a standard commercial warranty, such warranty shall be incorporated into this contract and thereby provided to the Government at no additional cost. Any standard commercial warranty provided shall be identical to the standard commercial warranty normally offered by the Contractor to the Contractor's most favored customer.

4.0. Quality assurance:

4.1. Quality Assurance Plan: 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, available for USCG QAR review and in compliance with International Organization for Standardization (ISO), ISO 9001:2015. The contractor shall maintain ISO 9001 certification.

The Coast Guard reserves the right to send a Coast Guard Quality Assurance representative (QAR), to witness or review all quality control procedures and tests. All testing will be accomplished on contractor supplied calibrated test equipment. All testing shall be accomplished IAW OEM specifications and procedures and shall be made available to the QAR upon request. It is the intention of the Government to conduct Quality Assurance Inspections for delivery order inspections for the PP&M, prior to delivery of any parts kits.

The contractor shall notify the Contract Administrator at least fifteen (15) days prior to readiness for inspection.

4.2. Quality system: The Contractor shall maintain an inspection system which shall insure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements in accordance with the International Organization for Standardization (ISO), ISO 9001:2015. The inspection system shall be documented and available for review by the QAR.

Conformance - The Contractor shall provide complete dimensional and technical data and criteria (including material composition certifications) with detailed parameters and min/max tolerances for use by the QAR in verifying conformance to OEM standards, specifications and drawings.

The contractor shall prepare and maintain an Equipment Unit Packaging and Marking Plan which shall be presented to the QAR upon request. It is the intention of the Government to conduct Quality Assurance inspections during the Preservation, Packaging, Packing and Marking prior to delivery of any parts kits.

The Marking Plan shall include examples of the parts container, packaging, markings, and bar codes. The QAR may verify that acceptable bar code and equipment unit shipping container markings have been applied, or are included as part of the Equipment Unit Marking Plan. The QAR inspector may also verify that the packaging, preservation, marking and bar coding are acceptable for the parts being supplied to the Coast Guard.

4.3. Contractor’s 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 ISO/IEC 17025:2017(E). 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. Quality Assurance Representative Inspection (QAR):

The contractor shall notify the Contract Administrator at least fifteen (15) days prior to readiness for inspection.

The following inspections will be conducted by a QAR and are the minimum necessary required. They are not intended to replace any controls, examinations or tests normally employed by the Contractor to assure the quality of the product.

a. Inventory, and verify condition of all kit line items and pieces prior to PP&M.

b. Each line item shall be marked/stamped by QAR to verify completion of inspection.

c. Contractor shall provide QAR with a Certificate of Conformance for all individual kit parts, components and assemblies in accordance with section 3.2 of this document.

d. Packing and enclosing of boxes/crates within the final wooden shipping crate(s) and securing of the wooden shipping crate sides to bottom skid sections.

e. Completion of final crate construction and packing of boxes/crates with installation of the final shipping crate top(s).

5.0. Preservation, Packaging & Marking (PP&M):

5.1. Preservation, Packaging and Marking (PP&M): The contractor shall package, mark, label all parts/part kits in accordance with all applicable Federal, State, Local, Environmental Protection Agency (EPA) and Department of Transportation (DOT) regulations. QA Inspection will be required. The KO or Contract Administrator shall be notified at least fourteen (14) calendar days prior to the preservation, packaging and marking of the completed kits.

PP&M shall be in accordance with ASTM D3951-18 and shall be verified and photographically documented by the Contractor for each kit. Photographs shall include completion of PP&M, required marking and barcode labels. The photographs shall be provided in a digital format.

Note: The Coast Guard reserves the right to have a Government QAR witness PP&M at the Government’s discretion. This inspection includes the following:

· Completion of PP&M for each box/crate with item marking labels attached.

· Packing and enclosing of boxes/crates within the final wooden shipping crate(s) and securing of the wooden shipping crate sides to bottom skid sections.

· Completion of final crate construction and packing of boxes/crates with installation of the final shipping crate top(s).

ACCEPTANCE OCCURS AT FINAL DESTINATION (Delivered to cutters location or to USCG SFLC Depot inventory location)

5.1.1 Preservation – Applicable methods of preservation and packing shall be applied to all kit components, parts and assemblies to ensure kit components are not degraded or damaged during shipment and storage. Methods of protection shall be applied in accordance with ASTM D3951-18, or in accordance with OEM standard preservation procedures when appropriate to protect an item during shipment, handling, indeterminate storage and distribution to Coast Guard cutters worldwide.

5.1.2. Packaging - Each item on the deliverable list shall be preserved, packaged and packed in its own container in accordance with ASTM D3951-18 packaging standards. All items in a kit shall be packaged as required, and packed together in one wooden crate or in multiple wooden crates; if multiple crates are required. Each crate shall be marked; Crate 1 of X, Crate 2 of X, etc.

In addition, the following shall apply:

(a) Each gasket, seal and O-ring line item shall be packed in either a hermetically sealed or Ziploc type plastic envelope / container and have the “manufacturers certified, cure date and shelf life” clearly indicated on the item label. The minimum remaining shelf life at procurement shall be 85 percent based upon a shelf life of 5 years. The shelf life expiration date of the applicable item(s) shall be displayed as part of the Exterior Marking Label of the item.

(b) Each gasket line item shall be packaged flat (Not Folded) with support backing cardboard sufficient to prevent bending, twisting or folding damage to gasket during packing or shipping. The use of heavy papers such as craft paper is unacceptable for this purpose. The use of single wall cardboard is the minimum acceptable material.

(c) Individual bearing shells and bushings shall be individually wrapped in water vapor and greaseproof paper per reference 2.3.4 of this specification.

(d) Individually packed and marked items which are combined within shipping containers, shall be placed, secured and blocked in the container in such a manner as to ensure safe arrival at destination when shipped by common carrier. When an intermediate pack contains two (2) or more unit packs, mark this container with the words: MULTIPAK, COAST GUARD SFLC MATERIAL.

(e) Particle Board or OSB shall not be used in the construction of any shipping containers or crates manufactured of wood. Only plywood or solid wood of sufficient thickness to provide the strength and protection required shall be used in the construction of shipping containers or crates for items requiring the use of a wooden shipping container or crate.

5.1.2.1. Kit materials shall be packed for shipment in such a manner as to afford adequate protection to the item from movement, corrosion, deterioration and physical damage during shipment from the supply source to, long term storage facility, USCG Surface Forces Logistic Center depot storage and/or individual cutter locations. Packaging shall also provide adequate preservation and protection for long term warehouse storage and multiple shipments.

Identical kit items with a quantity of more than one each (gaskets, seals, gasket kits, etc) may be packaged together in the same packaging, box or bag providing this packaging method will not result in any part damage, deformation or degradation.

5.1.3. Marking – Each preserved and packaged item shall include Identification Marking, Identification Bar Code Markings, Address Markings and Special Markings in accordance with ASTM D3951-18. Each preserved and packaged item shall be marked with pressure sensitive, weather resistant labels in the upper left-hand side of the two longest sides, (two opposite sides if square) of each box. The label lettering shall be ½ inches minimum height black characters on a white painted background. Marking shall also include instructions related to handling, unloading and lifting.

5.1.3.1. This marking shall consist of the STOCK NUMBER, ITEM NAME, SERIAL NUMBER, PART NUMBER, CONTRACT NUMBER, DELIVERY

ORDER NUMBER, GROSS WEIGHT (in lbs.), condition code CONDITION “A”, unit of issue with quantity (i.e. 1-EA), and the words U.S. COAST GUARD SFLC MATERIAL. If the kit is shipped in multiple crates, the crates shall be sequentially numbered along with the total number of crates (i.e. Box 1 of “X”, box 2 of “X”).

Marking Layout:

DELIVERY ORDER NUMBER SEE CONTRACT

STORAGE WARRANTY DATE "The Delivery Date to Storage or Designated Vessel"

SHIPPING WEIGHT AS DETERMINED

CONDITION CODE CONDITION “A”

QUANTITY & UNIT OF ISSUE SEE CONTRACT

BOX __ OF __ (If required)

U.S. COAST GUARD SFLC MATERIAL CONDITION A, 1 EA

5.1.3.2. If more than one kit per contract is ordered, each kit shall be marked with a Contractor provided serial number in addition to the applicable Coast Guard Contract Number to avoid ordering, inspection and storage confusion.

5.1.3.3. Gasket Kits shall be marked with a parts list label identifying the kit and the parts within the gasket kit. Items that are not physically marked with a part number for identification shall be marked with a label or tag attached to the part or the part container as applicable. Multiple identical items may be packaged together within the kit and shall have the part name, part number, barcode, quantity and unit of issue indicated on the line item label.

Individual kit items shall be individually packaged and similarly marked.

5.1.3.4. Each individual line item contained within the kit shall have the part number and quantity clearly indicated on the line item label.

5.2. Barcoding:

Bar code labels shall be supplied on all part packaging labels. Labels shall be in accordance with ISO/IEC-16388-2007 dated 5/2007, Code 39 bar code symbology requirements (reference 2.4.4.). The label shall be intended for long term indoor applications where labels will endure intermittent outdoor exposure. Each label shall contain encoded data for the National Stock Number (NSN) and delivery order/contract number and enclosed in clear plastic laminate. The stock number or numbers, and purchase order/contract number shall be bar coded with Human Readable Interpretation (HRI) immediately below the bar coding on unit and unitized packs.

5.3. Packing List - All material shipped to the US Coast Guard must be accompanied by an itemized packing list securely attached to the outside of the package or container. All packing lists shall cite the Contract and Order Number (when issued after award) with the package in such a manner to provide identification.

A packing list shall be prepared and enclosed for each box or shipping container, identifying all items included in the box or container with their part numbers, unit of issue, quantity and their National Stock Numbers if known. A copy of the packing list shall be posted inside a waterproof, clear plastic envelope or bag affixed on the outside of the shipping container. Documents and other enclosures shall be sealed in a zip lock or waterproof clear plastic envelope or bag, which shall be permanently affixed to the inside of the shipping container in a conspicuous location when the container is opened. Where the kit is packaged in more than one shipping container, or the shipping container consists of other boxes or shipping containers with other boxes or shipping containers, a Master Packing List shall be provided and include how many containers or boxes comprise one kit.

To ensure the parts in each kit match the parts identified on the packing list, the Packing List and the Bill of Materials shall also be similarly revised by the contractor whenever there are any changes to a kit part or its identifying information. These changes shall be documented and shall include part list additions or deletions and any item modifications with corresponding updates or changes to item part numbers, quantity required and unit cost. Technical documentation supporting or describing this change shall be provided to the Coast Guard KO or COR for notification and approval.

5.4. Shipping:

Large items (length + girth of box greater than 130 inches) and items over 70 lbs shall be packaged in skid mounted shipping containers, suitable for handling with a forklift. Shipping containers shall be completely enclosed and structurally suitable for stacking. Shipping containers shall be assembled with bolts or screws to permit ease of removal of the cover or lid from the base for inspection. Major components shall be bolted to the framing system. Loose components shall be intermediate boxed and shall be restrained within the shipping container. Suitable cribbing shall be provided to prevent part damage during shipment. Protrusions, projections, corners, sharp edges and fragile areas shall be cushioned to protect the equipment and to prevent rupture of shrink-wrap materials.

6.0. Government & commercial document sources:

6.1. Government documents:

a. Department of Defense Single Stock Point (DODSSP Documents) Building #4, Section D 700 Robbins Avenue Philadelphia, PA 19111-5094 FAX (215) 697-2664 http://www.documentservices.dla.mil/dso.html

b. DLA ASSIST Database

PH: (215) 737-8000

Public Website: https://quicksearch.dla.mil Public/Restricted Website: https://assist.dla.mil Private Website: https://assistca.dla.mil

c. Surface Forces Logistics Center (SFLC) Medium Endurance Cutter Product Line (MECPL) Supply Branch

6.2. Commercial documents:

a. American Society for Testing and Materials (ASTM) 100 Barr Harbor Drive

b. International Organization for Standardization (ISO) ISO Central Secretariat 1, ch. De la Voie-Creuse

CP 56

CH-1211 Geneva 20 Switzerland +41 22 749 01 11 http://iso.org

c. National Conference of Standards Laboratories (NCSL) 100 Bureau Drive, Stop 1070