4.02 FY26 CAT Maintenance SOW Rev 27AUG.pdf

STATEMENT OF WORK (SOW) FOR YT’S CATERPILLAR MAINTENANCE

1. INTRODUCTION.

1.1. Commander, Fleet Activities Yokosuka is the largest Naval installation outside of the U.S.

and its territories. We provide 24/7 mooring service. We are committed to providing the best service worldwide even on short notice. We coordinate the most suitable berthing arrangement according to your maintenance and operational needs. 7th Fleet Forces facilitate rapid response to natural and manmade crises in the region all the while ensuring security and stability. As per OPNAVINST 5090.4B Chapter 4, all Navy activities shall identity means and methods for the elimination or minimization of pollutants and, where possible, incorporate them at the earliest stages of planning, design, and procurement of facilities, ships, aircraft, weapon systems, equipment, and material. Fleet Activities Yokosuka maintains 4 Yard Tug boats. Without them, our abilities to conduct business in the harbor are significantly degraded.

1.2. This contract is for non-personal services. It does not create employment rights with the U.S. Government whether actual, inherent, or implied. By agreeing to perform the services described in these specifications, the Contractor acknowledges that he/she is not, and shall not become, an employee of the U.S. Government. The Contractor further agrees that he/she shall not bring any cause of action in any forum claiming that he/she has become an employee of the U.S. Government.

1.3. This contract extension is a “non-personal services contract” as defined in FAR 37.101. It is, therefore, understood and agreed that the Contractor and/or the Contractor’s employees or sub-contractor:

1.3.1. Shall perform the services specified herein as independent Contractors, not as employees of the Government.

1.3.2. Shall manage and administer the work required and bear sole responsibility for complying with any and all technical, schedule, or financial requirements or constraints attendant to the performance of this contract.

1.3.3. Shall be free from supervision or control by any government employee with respect to the manner or method of performance of the services specified; but

1.3.4. Shall, pursuant to the Government’s right and obligation to inspect, accept, or reject the work, comply with such general direction of the Contracting Officer, or the duly authorized representative of the Contracting Officer as is necessary to ensure accomplishment of the contract objectives.

2. DESCRIPTION OF REQUIREMENT AND REQUIRING ACTIVITY.

Maintenance performance requirement is in according with Caterpillar Operation and Maintenance Manual for 3500B series II and 3500C marine propulsion engines (SEBU7844-14), Maintenance Interval Schedule Pg. 58. Initial maintenance is to be completed within a 6 month period of receipt of contract and 6 month thereon to ensure the engine maintenance requirements for each YT is met on time. The requirement includes the periodic preventive maintenance for Caterpillar 3512C marine propulsion engines onboard of Navy Tug Yard YT-804, YT-805, YT- 806, and YT-807.

3. PLACE OF PERFORMANCE.

Port Operations, Bldg. 5203 or place will be determined by authorizing authority. Commander Fleet Activities Yokosuka, Japan

4. PERIOD OF PERFORMANCE.

1 September 2026 (or award date, whichever later) through 31 August 2027

5. PREVENTIVE/PERIODICAL MAINTENANCE SERVICES.

The Contractor shall perform the periodic preventive maintenance and on-call repairs in accordance with the manufacturer’s Maintenance manual. The services shall be performed on site depending on the operational hours of each propulsion engines during the performance period with mutually agreed upon schedule between the Contractor and the requiring activity.

Qualified technician personnel are authorized to perform periodic maintenance on propulsion engines. Such services shall include technical inspection, adjustment, cleaning, and replacement parts listed in Manufacturer’s manual and other service to keep the equipment in good condition.

6. LIST OF PREVENTIVE/PREDIODICAL MAINTENANCE FOR U.S. NAVY

HARBOR YARD TUG BOATS YT-804, YT-805, YT-806 AND YT-807.

The following list is the preventive/periodical maintenance for Caterpillar 3512C Marine Main Propulsion Diesel Engines onboard U.S. Navy Harbor Yard Tug Boats YT-804, YT-805, YT- 806, and YT-807. The contractor shall follow the maintenance procedures described in Caterpillar Operation and Maintenance Manual for 3500B series II and 3500C marine propulsion engines (SEBU7844-14) (hereinafter “the Maintenance Manual”), and the schedule found in the same document at Maintenance Interval Schedule Pg. 58.

a Every 6 months or 250 Hours, whichever comes first.

1. Conduct every 6-month Inspection as follows and in accordance with the Maintenance Manual:

a. Batteries

b. Battery Cables

c. Centrifugal Oil Filter

d. Engine Air Cleaner Element

1. Clean / Replace (if needed)

e. Belts-Inspect

1. Adjust/ Replace

f. Cooling System Coolant Sample (Level 1)

1. Attain

2. Provide condition report to Technical Liaison (TL)

g. Cooling System Supplemental Coolant Additive (SCA) – Test /Add

h. Air Shutoff-

1. Conduct Test

i. Heat Exchanger –

1. Inspect heat exchanger

2. Provide condition report to TL.

2. Zinc Rods/coolant freeze

a. Inspect /Replace as required

b. Cooling System Coolant Sample (Level 1) - Obtain

c. Cooling System Supplemental Coolant Additive (SCA) –

1. Test /Add as required

3. Engine Oil Sample

a. Obtain and report to TL

b. Change Engine Oil and Filter

4. Hoses and Clamps

a. Inspect /Replace

5. Fuel System –

a. Prime fuel system

b. Replace fuel filter

c. Fuel System Secondary Filter – Replace

6. Log errors

a. Inspect active log errors and clear from system as required

b. Report log errors to TL

7. Technical support

a. Provide training to Port Operations personnel

8. Engine performance test

a. Conduct engine performance test

b. Provide any discrepancies from test to TL

9. Technical transportation fee

b. Every 24 months or 1000 hours, whichever comes first

1. Inspect the following as provided in the Maintenance Manual:

a. Conduct all checks as listed in par 6.a

b. Engine

i. Inspect engine

ii. Clean engine

c. Engine Crankcase Breather –

i. Inspect crankcase breather

ii. Clean crankcase breather

d. Air Starting Motor Lubricator Bowl

i. Inspect and Clean

e. Engine Protective Devices –

i. Inspect and provide condition report to TL

f. Fuel System Primary Filter / Water Separator-

i. Inspect, Clean, and Replace as required.

g. Crankshaft Vibration Damper –

i. Inspect and provide condition report to TL

h. Auxiliary Water Pump –

i. Inspect and replace if required

ii. Provide condition report to TL

i. Driven Equipment

i. Inspect and provide condition report to TL.

j. Engine Mounts

i. Inspect and provide condition report to TL.

k. Air Shutoff Damper

i. Remove

ii. Clean

iii. Inspect and repair as required

iv. Provide condition report to TL

2. Turbocharger-

a. Inspect and replace if required.

b. Provide condition report to TL

3. Coolant (DEAC) –

a. Drain and clean the cooling system in accordance with maintenance manual.

Thoroughly clean the entire cooling system, including engine block, oil cooler, jacket water pump, jacket water expansion tank(s) and aftercooler expansion tank(s).

b. Restore the cooling system to operational condition

4. Engine Valve Lash –

a. Inspect

b. Adjust

5. Fuel Injector –

a. Inspect

b. Adjust

6. Air Shutoff Damper

a. Remove

b. Inspect and repair as required

c. Provide condition report to TL

7. Cooling System Water Temperature Regulator –

a. Remove and Replace

8. Heat exchanger cleaning and inspection

a. Conduct a complete heat exchanger cleaning, which includes all parts replacement and scale cleaning using an approved scale cleaner.

9. Replace jacket water pump

This requirement includes both the procurement of replacement parts and the execution of Caterpillar 3512C MPDE jacket water pump exchange work onboard of Navy Tug Yard. All equipment, tools, and materials necessary to complete this task shall be furnished and maintained by the contractor. The replacement parts per jacket water pump replacement are as follows:

PART NUMBER NOMENCLATURE QUANTITY

PUMP GP 416-0610 1

SEAL 271-4926 1

COVER 8N-6423 1

O-RING 5H-6734 1

BOLT 3B-1915 4

O-RING 235-3546 1

GASKET 5N-1940 1

SEAL 6V-3348 1

SEAL 8T-2903 2

SEAL 6V-6809 1

GASKET 1S-5772 1

GASKET 7N-4932 3

COOLANT (DRUM) 486-3023 2

OIL 15W40 (20 LITERS) 3E-9848 30

ELEMENT AS 1R-0726 4

The following depicts the maintenance requirements by boat per year that the Contractor is required to accomplish:

BOAT NO. SEP-FEB MAR-AUG

YT 804 A A

YT 805 A B

YT 806 A A

YT 807 A B

A 6 MONTH CHECKS

B 24 MONTH CHECKS

7. MAINTENANCE PART LIST.

The following list is the preventive/periodical maintenance parts for Caterpillar 3512C Marine Main Propulsion Diesel Engines onboard U.S. Navy Harbor Yard Tug Boats YT-804, YT-805, YT-806, and YT-807. The list contains the parts required to conduct preventive/periodical maintenances depending on the engine service hours. For more information and detail in reference of maintenance parts utilize Caterpillar Parts Manual for 3512C marine engine (SEBP4536). For more information and detail in reference of lubrication system, fuel system, and cooling system refill capacities, and recommendations utilize Caterpillar Operation and Maintenance Manual for 3500B series II and 3500C marine propulsion engines (SEBU7844-14), Maintenance Section, Page 52.

The following lists are parts required for YT’s 804, 805, 806 and 807 - 6 Months Checks.

Nomenclature Part Number Quantity Zinc Rod 116-7011 24 SOS Sample Kit AEZ05363 24 Oil Filter 1R-0726 48 O-Ring Seal 6V-9027 24 Seal 6V-3907 24 Element Assembly 1R-0756 84 Seal 5D-5957 24 RACOR Fuel Filter FB060328 24 Element 226-2779 24

The following lists are additional parts required for 24 Months Checks.

Nomenclature Part Number Quantity Zinc Rod 116-7011 4 SOS Sample Kit AEZ05363 4 Oil Filter 1R-0726 8 O-Ring Seal 6V-9027 4 Seal 6V-3907 4 Element Assembly 1R-0756 14 Seal 5D-5957 4 RACOR Fuel Filter FB060328 4 Element 226-2779 4 Element Assembly 354-1381 4 Seal O-ring 033-6031 8

Breather Assembly 4W-3027 8 Housing Gasket 7N-4927 2 Temperature Regulator 248-5513 8 Regulator Lip Seal 3S-9643 8 Coolant 18 liter can 486-3022 18

8 YT-806 CORRECTIVE MAINTENANCE

8.1 Port and Starboard heat exchanger cleaning, inspection, and overhaul

a. Conduct a complete heat exchanger cleaning and overhaul of each heat exchanger, which includes all parts replacement and scale cleaning using an approved scale cleaner.

b. Upon completion, conduct pressure and operational testing to validate the repair.

All equipment, tools, and materials necessary to complete this task shall be furnished and maintained by the contractor. The replacement parts per heat exchanger overhaul are as follows:

Heat Exchanger Liner 327-1099 6 Rubber Tube Seal 8L-8585 8 Heat Exchanger Gasket 449-3078 3 Heat Exchanger Ring Seal 449-3079 4 Plate Seal 149-2213 45 Coolant 4863-3022 3 O-Ring Seal 8T-7877 1 O-Ring Seal 6V-9027 2 Water Lines Gasket 161-6244 1 O-Ring Seal 110-7753 1 Retainer Ring 7E-7209 1 Heat Exchanger Transition Plate 327-1115 1 Scale Cleaner 999AOH8936 2 Engine Cover Gasket 7E-6016 1

8.2 Replace Port and Starboard MPDE jacket water pump

This requirement includes both the procurement of replacement parts and the execution of Caterpillar 3512C MPDE jacket water pump exchange work onboard of Navy Tug Yard. All equipment, tools, and materials necessary to complete this task shall be furnished and maintained by the contractor. The replacement parts per jacket water pump replacement are as follows:

PART NUMBER NOMENCLATURE QUANTITY

PUMP GP 416-0610 1

SEAL 271-4926 1

COVER 8N-6423 1

O-RING 5H-6734 1

BOLT 3B-1915 4

O-RING 235-3546 1

GASKET 5N-1940 1

SEAL 6V-3348 1

SEAL 8T-2903 2

SEAL 6V-6809 1

GASKET 1S-5772 1

GASKET 7N-4932 3

COOLANT (DRUM) 486-3023 2

OIL 15W40 (20 LITERS) 3E-9848 30

ELEMENT AS 1R-0726 4

9. REPLACEMENT PARTS.

The Contractor shall furnish replacement parts required for PM (already included in total cost of PM Service) at no additional cost to the Government. Parts outside of the normal PM will be negotiated separately either via OPR or separate contract pending Micro-purchase limits.

Consumable items, accessories, and items not connected electrically or mechanically to the equipment are excluded from such replacement parts.

10. EMERGENCY REPAIRS:

If repairs required due to unforeseen emergency situations, not covered under this SOW, shall be performed under a separate action. Separate action shall include a new contract, or using an approved Government Credit Card to purchase and fund the growth work repairs.

11. CONTRACTOR EXPERIENCE/TRAINING.

The Contractor shall provide all required applicable certification documentation that the service personnel are trained and experienced in repairing and/or maintaining the equipment covered herein.

12. REPORTING TO PORT OPERATIONS BEFORE AND AFTER SERVICE.

Inspection of the preventive maintenance and on-call repair services performed hereunder shall be made by the Port Ops Maintenance Officer or higher of the requiring activity. The Contractor shall report to the Port Operation Maintenance Officer or authorized YT crew personnel prior to and upon completion of each service. Upon completion of the service, the Contractor shall provide a copy of the service slip, signed by the Department Technician, certifying that the service has been performed and that the equipment is functioning at working condition. If the service is performed or completed outside the regular working hours, the Contractor shall present the certified service slip to the Command Duty Officer.

13. SERVICE SLIPS.

All Caterpillar marine propulsion engines service slips must contain the following minimal information:

A. Contract Number B. Plant Accounting Number of Unit C. Unit Malfunction D. Replacement Parts Number and Description E. Details of Preventive Maintenance or Emergency on-call service F. Service performance date and time G. Name of Technician

14. SERVICES PERFORMANCE TIME.

The scheduled Maintenance services shall be performed from 0800 to 1600, Monday through Friday. (Depending of ship job schedule and tug boat availability)

On Saturday, Sunday and Japanese holiday, contractor shall provide services from 0800 to 1600 but ‘Limited manpower’ is available. (Dependent of ship job schedule and tug boat availability)

Any other hours as mutually agreed upon between the Contractor and the requiring activity.

For phone call support during working operational hours (0800-1600, Monday through Friday):

CFAY Port Operations Port Control Dispatcher Office (after working hours)

CONUS: +81-46-816-7366

DSN: 243-7366

15. CONTROL AND DISPOSE OF WASTE.

The contractor will dispose of all waste/hazardous waste associated with this specification in accordance with the following standards and Japanese law.

a. Japan Environmental Governing Standards (JEGS) for the Overseas Environmental Baseline Guidance Document.

b. Japanese Law Relative to Disposal and Cleaning of waste (Haikibutu no Shori oyobi Seisou ni Kansuru Houritsu).

16. GENERAL REQUIREMENTS.

Unless otherwise specified, all work shall conform to the standards for overhauling work of this contract described below. However if a conflict between below publication and the specification of this contract is found, the specification of this contract precedes.

a. JIS (Japan Industrial Standard)

b. Technical Rules of Class NK (Nippon Kaiji Kyokai)

c. The Shipbuilding Association of Japan (Nihon Zosen Kogyo-kai)

d. Contractor furnished material and government furnished material. The contractor shall provide all facilities, equipment, materials, and services to perform the requirements of this contract. The Government will not provide the facility, equipment, material, and services under this contract.

17. TECHNICAL LIAISON (TL). - TBD

Will confirm work schedules with the contractor. Provides the technical direction, clarification, and guidance, the TLs have been identified below.

18. ACTIVITY REGULATIONS.

a. The Contractor will not schedule maintenance during Holidays. Contractor shall schedule all required maintenance during the Government's normal working hours are from 0800 to 1645, Mondays through Fridays except for the following Federal Holidays:

1. New Year’s Day (1 January, unless this day falls on a weekend)

2. Martin Luther King, Jr. Day (third Monday in January)

3. President's Day (third Monday in February)

4. Memorial Day (last Monday in May)

5. Independence Day (4 July, unless this day falls on a weekend)

6. Labor Day (first Monday in September)

7. Columbus Day (second Monday in October)

8. Veteran's Day (11 November unless this day falls on a weekend)

9. Thanksgiving Day (fourth Thursday in November)

10. Christmas Day (25 December, unless this day falls on a weekend)

19. SAFETY AND ENVIRONMENTAL REQUIREMENTS.

All work on Base shall be conducted in a safe manner and shall comply with the current safety and environmental requirements as indicated in EM385-1-1, Safety and Health Requirements Manual issued by the U.S. Army Corps of Engineers and JEGS, Japanese Environmental

Governing Standards issued by Headquarters, U.S. Forces Japan. EM385-1-1 is obtainable from Internet address http://www.usace.army.mil/CESO/Pages/Home.aspX, and a copy of the current JEGS will be made available for the contractor’s inspection and review upon request to MMO.

The Contractor shall brief the safety and environmental consideration at the pre-performance conference specified above, and submit the minutes in Japanese to MMO after the briefing immediately.

20. CONTRACTOR’S RESPONSIBILITY.

a. These requirements and responsibilities shall be considered to be a part of this work specification. Consideration shall be given to these requirements and responsibilities and shall be reflected in the Contractor's bid/offer. The Contractor shall comply with all National, prefecture and local environmental regulations. The Contractor shall assume these responsibilities and perform as required. Contractors unless otherwise specified, shall conform to the standards for overhauling work of this contract described below. However if a conflict between below publication and this work specification of this contract is found, the work specification of this contract precedes.

1. JIS (Japan Industrial Standard)

2. Technical Rules of Class NK (Nippon Kaiji Kyokai)

3. The Shipbuilding Association of Japan (Nihon Zosen Kogyo-kai)

b. The contractor’s appearance shall be neat, well-groomed, and professional at all times.

c. The contractor shall conduct himself/herself in an efficient and professional manner consistent with CFAY Port Operations business standards. The contractor shall interact with the CFAY Port Operations in a courteous, polite, and professional manner.

d. Alcohol/Drug use in the workplace will not be tolerated. Any Contractor/sub-contractor found to be under the influence of, consuming, or using alcohol or drugs while on duty will be subject to administrative action from the Contracting Officer, which may include contract termination.

e. The Contractor shall provide each employee with identification (ID) badge made of nonmetallic material that is easily readable, and includes employee's name, Contractor's name, and recent color photograph of the employee.

f. Display of ID Badges. Contractor personnel shall wear the ID badge at all times when performing work under this contract at a Government site, including while attending Government meetings and conferences that may take place outside the Government facility.

Unless otherwise specified in the contract, each Contractor employee shall wear the ID badge in a conspicuous place on the front of exterior clothing and above the waist except when safety or health reasons prohibit such placement.

g. The Contractor shall remove from the site any individual whose continued employment is deemed by the Contracting Officer to be contrary to the public interest or inconsistent with the best interests of National Security.

h. Work Permits. All contractors and sub-contractors who do not reside within Japan shall have a valid Work Permit/Working Visa prior to reporting to the CFAY. All contractors and sub-contractors shall be registered with the U.S. or Japan.

i. The Government shall monitor the contractor's performance under this contract using on-site inspections and customer feedback. The contractor shall be given the opportunity to correct or address any adverse findings resulting from observations and feedback consistent with the Inspection/Acceptance clause in the contract.

21. REPORTING.

Inspection of the preventive maintenance shall be made by the Port Operations Maintenance Officer or higher of the requiring activity. The Contractor shall report to the Port Operation Maintenance Officer or authorized crew personnel prior to and upon completion of each service.

Upon completion of the service, the Contractor shall provide a copy of the Quarter Maintenance Check List in English, signed by the Department Technician, certifying that the service has been performed and that the equipment is functioning at working condition.