Attachment_1_-_Specification_Number_P-260-0460.docx

REVISION No. C CHANGE No.

COMPONENT OVERHAUL

& PARTS PURCHASE FOR

MTU PROPULSION ENGINES

8V396 TE 94

P-260-0460

ORGINATED BY Patrick Mulrooney DATE 03/2016____

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

DEPARTMENT / DIVISION Patrol Boat Product Line (PBPL) _AMS-3 ______

INTERNAL REVIEWER_ ______DATE___ __ __

SWORB APPROVAL___________________________DATE___________

1.0 SCOPE

1.1. This specification describes the requirements for the preliminary inspection, reporting, overhaul, painting, testing, final inspection, preservation/packaging, packing marking and bar coding of various assemblies as described below and the purchase of any parts for the 8V396 TE 94 diesel engine & its control & monitoring systems.

1.2. CLASSIFICATION & Government Furnished Equipment: This sets forth the requirements for the following equipment & assemblies which will be issued to the contractor as Government Furnished Equipment in less than serviceable condition:

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. ASTM D7478/D7478M, Dated 01 Nov 2011, Standard Specification for Heavy Duty Sheathed Wood Crates, Type II, Class II, Style A.

b. MIL-STD-129R, dated 02/18/2014, entitled “Department of Defense Standard Practice, Military Marking for Shipment and Storage,” available at http://quicksearch.dla.mil/qsDocDetails.aspx?ident_number=35520, except bar coding in accordance with ISO/IEC-16388-2007, Code 39 Symbology. See MIL-STD-129R for details on how to obtain a copy of ISO/IEC-16388-2007, Code 39 Symbology.

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 Fluids and Lubricants Specification A001061/32E

h. 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

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

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

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

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

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

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

o. ANSI/NCSL Z540 3-2006(R2013), Requirements for the Calibration of Measuring and Test Equipment.

p. 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 – MTU technical publications shall be utilized to complete the component overhaul. The Contractor shall be required to legally possess all MTU technical publications and have them available at the Contractor’s facility. The Contractor shall complete the following requirements. These requirements shall be completed on all the components classified herein.

3.1.1. Receive component in less than serviceable condition. Disassemble, inspect & submit for approval to the Contracting Officer a detailed report on each component. The report shall be submitted within 30 days of receipt of each component.

3.1.2. No further work shall be accomplished until the Contracting Officer approves the report. Each report shall consist of the following data:

a. Date of inspection.

b. Name of inspector.

c. Identification of assembly/component by serial number, part number & national stock number.

d. Condition of the shipping crate and any cost to repair.

e. List of repair parts required, with prices.

f. Labor rate and labor hours required to complete overhaul and or repairs.

g. Comments if any pertaining to unusual observations during inspection.

3.1.3. Sample detailed inspection reports shall be submitted to the Contracting Officer within 30 days following contract award.

3.2. The Contractor shall provide all labor, equipment, special tools, materials, and parts required to clean, inspect, disassemble/reassemble, repair & test components.

a. The Contractor shall be able to provide, when requested by the Contracting Officer, detailed evidence of their experience overhauling, repairing and testing the MTU 8V 396 TE94 series diesel engine system components listed in this specification.

b. 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.

c. The Contractor shall have access to MTU’s secure FTP in order to access project software and calibration files.

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

e. The Contractors lead technician shall be trained and certified to the level of MTU’s standards meeting M3 & E3.

f. The overhauls/repairs, and all component inspections shall be completed using only OEM unique parts, components, processes, and practices.

g. The testing shall be conducted in accordance with MTU procedures. The Contractor’s electronic component testing shall utilize MTU ECS-UNI/ADEC-UNI, ROS, LOP, and all other MTU components required to complete testing. The USCG reserves the right to witness all testing.

h. The Contractor shall be responsible to provide the USCG all up-dated data in regards to configuration, service bulletins, and Tech Pub changes/revisions for the components classified in this specification.

i. The Contractor shall provide a quarterly cross reference describing all part number changes to any parts of listed in the 8V396 TE 94 Catalog, to include any electronic control system parts catalogs.

j. The Contractor shall submit to the Contracting Officer a parts price list at least annually that contains all parts of the MTU Propulsion system as installed on the 87WPB Cutters. The Coast Guard may use this price list to purchase parts for inventory to support maintenance and casualties.

k. Upon receipt of any components, regardless of condition, the Contractor shall store them inside in a secure area and kept from all weather.

3.3. GENERAL TEST REQUIREMENTS

1. Time and date of test or inspection

2. Step by step test/inspection procedures for test configuration and pass/fail criteria.

3. A chronological listing of the tests and inspections to be performed.

4. Test data sheets to be used to record observed performance data and any deficiencies found with corrective actions taken.

5. Dimensional inspection reports with tolerances.

6. Complete listing of all test equipment to be used with serial numbers.

7. Date and signatures of test/inspection personnel.

8. Signature of government witness if any.

3.4. 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. The Contractor shall maintain and submit to the Contracting Officer by the 15th of each month, for the previous month a cumulative tracking report for all components. All components shall be assigned serial numbers if not already marked for the purpose of managing the warranty requirements in section 3.5. The Contractor shall develop the format and submit to the Contracting Officer for approval.

3.5. WARRANTY – The components 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 six (6) months of operation, following up to one (1) year in storage. Storage commences upon receipt of the component at the designated Coast Guard facility. The warranty commences the date the component is installed on a Coast Guard Unit. The warranty shall cover all parts and workmanship defects.

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. All 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.

4.5. REQUIRED TESTS - Each component provided under this contract shall be operationally tested when required by MTU procedures.

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

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) – Each Component shall be internally preserved when appropriate. Preservation shall provide adequate protection to the assembly during long term storage of at least one year. All openings shall be plugged or blanked.

5.2. PRESERVATION (External) - . Each assembly shall be cleaned externally. Each assembly shall be painted to preserve the painted surfaces and to present a new appearance. Paint and color shall be in accordance with the OEM’s original specifications. Electronic control system components & fuel injection nozzles shall not be painted.

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 component 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.

g. Each component shall be wrapped in water vapor resistant paper when appropriate.

5.3. PACKING - Each assembly shall be packaged in a re-usable skid mounted, wooden box. Each box shall be internally braced to and cushioned to prevent movement of the assembly. The box and internal bracing shall be 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 for that component.

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 2950-12-347-2009

ITEM NAME TURBO, A BANK

PART NUMBER 5100205005

SERIAL NUMBER “As per Enclosed Item” 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 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. All bar coded labels shall be in accordance with ISO/IEC-16388-2007, Code 39 Symbology.

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. International Organization for Standardization