Attachment 1-MTU_parts_ovhl_SOW.pdf

UNITED STATES COAST GUARD

SURFACE FORCES LOGISTICS CENTER

Repair Description MTU1163TB93 Components

CWO John Kane

10/14/22

OVERHAUL/ REPAIR DESCRIPTION

This document sets forth the requirements for the overhaul services, receipt, storage, inspection, repair, testing, preservation, packaging, packing, and marking of MTU1163TB93 overhaul components, the following items. Items as received by the contractor must be complete and of the proper cited part number. Discrepancies shall be reported to the Coast Guard Contracting Officer.

OVERHAUL/ REPAIR REQUIREMENTS:

INSPECTION AND OVERHAUL DISCRIPTION

1. SCOPE: U.S. Coast Guard SFLC requires complete overhaul/ repair services for the following item(s):

CLIN DESCRIPTION PART NUMBER NSN

R.1 TURBO, LOW PSI 584-LPTURBO-RPLM 2990-01-619-4969

R.2 TURBO, HIGH PSI 584-HPTURBO-RPLM 2950-01-620-0381

R.3 PRELUBE PUMP UNIT

X00015763

2815-12-380-7429

R.4 OIL PUMP,CW 584-LO-PMP-KIT 4320-01-619-2729

R.5 Jacket Water Pump Kit 584-JWPMPRS-RPLM 4320-01-619-2545

R.6 SEAWATER PUMP (CW TURNING) 584-SWPMPCW-RPLM 4320-01-619-2696

R.7 SEA WATER PUMP 584-SWPMP-RPLM 4320-01-619-2264

R.8 FUEL INJECTION ASSY 584-INJ-RPL-KIT 2910-01-591-1763

R.9 Fuel Delivery Pump

584-FUELDLPMP-

RPLM 2910-01-619-3107

R.10 HEAD, CYLINDER, w/valves 584-CYL-HD-RPLM-3 2815-01-695-5551 R.11 Jacket Water thermostat LS 584-THERMLS-RPLM 2815-01-619-3818 R.12 Jacket Water thermostat RS 584-THERMRS-RPLM 6685-01-619-2848 R.13 Temperature Control Valve 584-TCVLV-RPLM 2815-01-619-2215

R.14 INJECTION PUMP 584-FL-INJ-PMP-KIT 2910-01-619-2228

R.15 Jacket Water pre-heater

584-PREHTRPMP-

RPLM 2815-01-619-2234

R.16 EXHAUST MANIFOLD 5841404818 2815-01-F19-5828

R.17 GOVERNOR 5080606798/MR 2910-01-629-0769

R.18 COOLER LUBRICATING OIL ENGINE 5841800665/32 2930-12-384-6858

R.19 COUPLING ALIGNMENT X00033903/32 4730-01-592-7538

R.20 COOLER, CHARGE AIR 0020984020/32 2950-12-384-7694

R.21 RADIATOR ENGINE COOLANT 5840900114/32 2930-12-384-2070

R.22

PREHEATER, INSERT HEAT

EXCHANGER 0020984220/87 2815-12-384-3754

R.23 LEVER, CONTROL PROPULSION B00E50207659 2010-01-616-1468

R.24 PISTON, SKIRT 5840300615 2815-12-381-5442

R.25 CYLINDER, SLEEVE 5840112610 2815-12-358-0491

R.26 Camshaft (A-Bank) (Drive End) 5840515401 2815-12-384-5520 R.27 Camshaft Kit (A-Bank) (Center Section) 5840504001 2815-12-385-0947 R.28 Camshaft Kit (A-Bank) (Non-Drive End) 5840504101 2815-12-385-0964

R.29 Camshaft Kit (B-Bank) (Drive End) 5840504201 2815-12-385-0965 R.30 Camshaft Kit (B-Bank) (Center Section) 5840504301 2815-12-385-0988 R.31 Camshaft (B-Side) (Non-Drive End) 5840515901 2815-12-384-5403

R.32 CRANKSHAFT X51403100006/32 2815-01-F20-6056

R.33 COUPLING, POWER TAKE OFF X58425100019/32 3010-01-682-7264

R.34 CW, GEAR CASE X58402400004 2815-01-F22-6576

Application: 418 FT WMSL Original Equipment Manufacturer (OEM): MTU America Inc.

1.1 All references to items herein shall be inclusive to the part number. Estimate and overhaul/ repair shall include the entire assembly.

1.2 Descriptive Data: VARIOUS

1.3 Contractor shall notify the Coast Guard Contract Administrator of any missing components or, otherwise, questionable condition that may hinder the overhaul/ repair process.

1.4 The overhaul requirements described herein are considered minimum and are not intended to replace any procedures, controls, examinations or tests normally employed by the contractor to assure the quality of the product. Overhaul/ repair is intended to return the item to a condition equal to that of an identical new unit.

2. Applicable Documents:

a. ANSI/NCSL Z540.3-2006 Requirements for the Calibration of Measuring and Test Equipment.

b. COMDTINST M10360.3C, Coating & Color Manual, Appendix B, Cutters and Boats interior Painting System.

c. Federal Standard, FED-STD-595 Colors Used In Government Procurement.

d. ASTM A-276-06 Standard specification for stainless steel bars and shapes, 2006 edition.

e. U.S. COAST GUARD SPECIFICATION D-000-0100 REV G. (dated 06/2006) bar coding For U.S.C.G. ELC Material.

f. Packaging and Labeling MIL-STD-2073

g. ASTM-D-3951 Standard Practice for Commercial Packaging

h. MTU Spare parts catalog EA535000/02DE

i. MTU Engine Service manual M020078/11E

j. MTU Fuel Injection Pump maintenance M040112/00E

k. MTU Exhaust Turbocharger ZR210, M040059/10E

l. MTU Exhaust Turbocharger ZR170, M040055/10E

m. American Society for Quality (ASQ) Q90001-2008, dated 2008, Quality Management System-Requirements

m. American Society for Testing and Materials (ASTM) D3951-98, dated 2004, Standard Practice for Commercial Packaging

2.1 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. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained

3. Requirements: The contractor shall provide all labor and materials to perform overhaul services on the MTU America parts. Overhaul services shall cover the entire assembly.

3.1 Preliminary disassembly and inspection shall be conducted in accordance with OEM procedures, specifications, references and standard practices to determine estimated cost of overhaul including material, labor, testing, packing, preservation, and packaging.. A detailed estimate shall be submitted to the Coast Guard Contracting Officer for approval prior to the start of overhaul work. Estimate shall include overhaul, testing, packaging, preservation, and marking. Overhaul is intended to restore the item to a condition that is equal to that of a new item. Contractor shall immediately notify the Coast Guard Contracting Officer if an item delivered for overhaul services does not conform to the intended item cited in section 1.0 above, or is questionable for any reason.

Cost Estimate- A detailed cost estimate shall be submitted to the Coast Guard’s Contracting Officer for review and approval prior to the start of any repair or order of material. The Contractor shall also provide the replacement cost of an identical new item for comparison to the overhaul cost. The detailed cost estimate shall contain the following as a minimum:

a. The part number, NSN and serial number of the component

b. The contract number for the component

c. A listing of individual parts by part number, cost and quantity

d. A listing of labor hours and labor rate to perform the overhaul, testing, and

PPP&M

e. The cost of an identical new component

Beyond Economical Repair (BER) - the Coast Guard Contracting Officer will determine the disposition of any component delivered for overhaul that is BER. If a component is BER, the government reserves the right to purchase an identical new component from the contractor.

3.2 Replacement Parts: All replacement parts used in the overhaul shall be new original OEM parts. Reclaimed, recycled or aftermarket parts are not acceptable and shall not be used. Parts not normally manufactured by the OEM, such as seals and ball / roller type bearings, shall be equal to the quality of such parts originally installed by the OEM, but are not required to be supplied by the OEM.

3.2.1 Decal: A decal or permanent type label shall be affixed to the side of the unit informing the user of the manufactures recommended amount and type of grease to be used.

3.2.2 Pipe Plugs: All pipe plugs shall be replaced with new grade 316 stainless steel pipe plugs. The stainless steel grade shall conform to ASTM A 276 or equal standard. Plugs shall be installed using Teflon tape or equal thread sealer unless any sealer is specifically prohibited.

3.2.3 Label Plates (if applicable): Remove any label plates and replace at the conclusion of painting. New label plates shall be used if the original plate is not legible or in poor condition. Label plate shall contain unit make, model and serial numbers as well as all performance information as a minimum requirement if applicable. Label plates for Coolers. The Contractor shall attach an anodized aluminum test data plate to each cooler using epoxy resin cement. Ensure that each plate is engraved with ¼-inch high letters, stating the following:

a. Hydrostatic test pressure.

b. Test date.

c. Testing facility.

3.3 Disposition: The Coast Guard shall determine the disposition of any item delivered for repair that is found to be not suitable for repair for whatever reason.

3.4 Painting (if applicable): an item shall be painted with primer and finish coats. Primer coat shall be any rust preventive metal primer suitable for use with the finish coat. Finish coat shall be Silicone Alkyd Enamel Type III Class 1. Color shall be “Machinery Gray” in accordance with Federal Standard 595 color number 16376. Total paint thickness shall be a minimum of 4 to 6 mils dry film thickness, not to exceed 12 mils dry thickness.

3.5 Testing:

3.5.1 Testing Requirements: After completion of an overhaul, contractor shall conduct the following described tests in the presence of a Coast Guard Quality Assurance Rep (QAR). Coast Guard Quality Assurance Representative (QAR) shall be provided an opportunity to witness or review any testing highlighted in 3.5 testing. All testing shall be accomplished on contractor supplied calibrated test equipment. If an item fails, it shall be repaired and re-tested as necessary until a successful test is achieved. All repairs shall be in accordance with OEM specifications and procedures and shall be made available to the QAR.

3.5.2 Rotational Test for pumps: To ensure the pump turns freely and without bind, the pump shaft assembly shall be rotated 10 times by the use of a strap wrench or other non-damaging tool. The QAR shall inspect for smoothness of rotation and check for signs of binding. The contractor shall also make available a machinists’ stethoscope to listen for noises as the shaft assembly is being turned. Contractor shall investigate any questionable test results and correct as necessary.

3.5.2.1 Pump Testing: The pump shall be tested in accordance with the OEM recommendation. If a new pump is hydro-tested or operational tested, the overhauled pump shall require the same identical testing and procedure prior to acceptance.

3.5.3 Turbochargers: any rotating part must rotate freely without any abnormal noise and vibration. Clearances and tolerances shall be verified as per OEM specifications. The passageways shall be clean and free of debris and the proper preservation applied. Verify the rotor assembly rotates freely without any abnormal rubbing noises using a Machinists Stethoscope. Verify the correct rotor assembly is installed.

3.5.4 Fuel Injection Pump: The pump shall be tested and calibrated utilizing procedure and settings prescribed in reference 2.i as per the OEM specifications. QAR will witness pressure testing on a calibrated test stand.

3.5.5 Operational Test: Any binding or unusual noise such as squealing coming from the item during this test shall be corrected and retested after corrective work is complete.

3.5.6 Test Report: Test results shall be documented on a report. A copy of the test report shall be packed with the tested item and a copy shall be turned over to the Coast Guard Quality Assurance Representative. Report shall contain the following information as a minimum:

a. Contractor name.

b. Contract number.

c. Item Model & Serial Numbers

d. Date of test.

e. Description of each test conducted and results of each test.

f. Name of the person conducting the testing.

3.6 Calibration: All test equipment and attached gages shall be calibrated and have a current calibration sticker. Calibration shall be traceable to National standards.

3.7 Assembly: Overhauled items shall be delivered to the Coast Guard completely assembled and ready for installation. Overhauled items shall have a complete set of installation gaskets installed inside a large translucent zip lock bag and stapled to the inside of each shipping crate along with the test results. Contractor shall preserve, package and mark the pump and motor unit in accordance with part 5 below.

3.8 Responsibility for Inspection: The Contractor shall be responsible for the performance of all inspection requirements specified herein. The Contractor shall provide space, personnel and test equipment for the conduct of all inspection requirements. All inspection and testing shall be performed at the Contractors facility prior to the Coast Guard’s acceptance of the contracted items. The Coast Guard reserves the right to verify or have performed any of the inspections set forth herein where such inspections are deemed necessary to assure that supplies and services conform to prescribed requirements.

3.9 Notifications & Inspections: The contractor is responsible for notifying the Contracting Officer no less than ten (10) calendar days prior to the contractor being ready for any Quality Assurance (Q.A.) inspections or testing required herein.

4. Quality Assurance:

4.1 General: The Contractor is responsible for the conformance and overall quality of each item offered to the Coast Guard for acceptance or approval

4.2 Inspections & Tests: The inspections & tests required herein are the minimum necessary and are not intended to replace any controls, examinations, or tests normally employed by the contractor to assure the quality of the product. The following are required:

a. Test requirements described in part 3.5.

b. Paint thickness as specified in 3.4 Inspection of preservation, packaging, packing, marking and bar-coding in accordance with section 5

c. Verify OEM installation of parts in part 3.2

d. Verify label/name plate installation in part 3.2.3

e. Final inspection and test reports as required in section 3.5.4

4.3 Calibration System: The Contractor shall be required to maintain a test equipment calibration program in compliance with ANSI/NCSL Z540-1. The program shall be documented and traceable to the National Institute of Standards (NIST). The calibration system records shall be maintained for inspection for the duration of any contract referencing this specification.

4.4 Test & Inspection Reports: A copy of any standard contractor test or inspection report shall be turned over to the Coast Guard Q.A. Inspector upon his arrival at the contractor's plant.

4.5 Warranty. Contractor’s standard new unit warranty applies.

4.6 Failure Responsibility – If a component fails to pass any inspection/test the contractor shall report the failure and the recommended fix to the Coast Guard Contract Officer.

5. Preservation Packaging and Marking:

5.1 Preservation: Any overhauled item is intended for warehouse storage for up to two

(2) year minimum and not for immediate installation. Therefore, it is critical that the contractor ensures that the overhauled unit undergo the below preservation requirements:

a. Any fluid shall be drained and the unit must be dry.

b. Intake and discharge ports shall have plastic cap inserts or wood covers installed with a desiccant pouch stapled to the inside of each cap or cover.

c. Any grease fittings must be capped with red zirc caps.

d. The item shall be bagged in an 8 mil minimum thickness translucent polyurethane bag with at least four (4) 4 ounce desiccant packs in the bag.

Bag opening shall be sealed closed with a plastic tie wrap.

5.2 Packing: The overhauled and preserved item shall be individually packaged in its own framed in wooden crate, totally enclosed, with a skid mount to facilitate handling by a fork lift. The crate shall be assembled with wood screws. The item shall be bolted to the inside of the crate or wooden blocking shall be incorporated and shall be constructed in such a manner as to prevent the item from shifting within. Crates shall be capable of protecting the item from damage during multiple shipments by commercial carrier.

5.3 Packaging:

All open ports shall be sealed using waterproof caps or covers to prevent the intrusions of moisture and other contaminates. A copy of the material certifications shall be packaged inside a protective envelope. Each overhauled items shall be packaged in a moisture resistant protective envelop using MIL-PRF-131K Class 1. Just before the package is sealed, add the appropriate amount of desiccant shall be placed inside each item as per MIL-D-3464D. A vacuum shall be used to remove all excess air and the package sealed.

Packaging of the injectors/fuel pump assemblies shall be done using individual double-walled boxes. Each box shall have either protective fitted foam or the injectors/fuel pump assemblies shall be spray formed in order to protect the injector/assembly from moving. Sealed bags and desiccant is required.

5.4 Marking: Shipping container shall be stenciled with black enamel paint with the information as laid out below. Stencil shall be applied directly on the container and be 1/2 inch minimum height black characters on a white painted contrasting background in the upper left-hand side of the two longest sides (two opposite sides if square) of each box. NOTE: ALL PREVIOUS MARKINGS AND / OR QUALITY ASSURANCE

DECALS SHALL BE COMPLETELY REMOVED FROM A REUSABLE SHIPPING

CONTAINER PRIOR TO THE APPLICATION OF ANY NEW MARKINGS. The following information shall be included in the markings:

NSN:

Item Name:

P/N:

S/N: If applicable Shipping Weight:

Government Contract No.

Coast Guard SFLC Material Condition A, 1 ea."

5.5 BAR CODING: The stock number shall also be bar coded in addition to the numerical marking.

a. All bar coded labels shall be in accordance with SFLC Bar Coding specification number D-000-100 Rev. G.

1. The actual labels shall be Type “V”, Grade “C”, Style 2”, and Composition

“a”.

2. The Bar Code Label can be applied separately or as part of the marking required in 5.3.

Acceptance: Acceptance will be made at destination by a government representative.

Acceptance will be contingent upon representative's verification of no damage in transit, correctness and completeness of order and contractors conformance to preservation, packing and marking requirements.

6. Notes:

Source of Documents:

Commercial:

Steel Structures Painting Council 40 24th Street Pittsburgh, PA 15222

(412) 281-2331

Naval Publication and Forms Center 5801 Tabor Ave.

Philadelphia Pa. 19120 215-697-2000 / 2626

American National Standards Institute (ANSI) 1430 Broadway New York, NY 10018 212-642-4900

MTU America Inc.

13400 Outer Drive West Detroit, MI. 48239

WARRANTY:

__x___ A. Standard Manufacturer’s Warranty

GOVERNMENT ACCEPTANCE:

Acceptance will be made at destination by a Government representative. Acceptance will be contingent upon the representative’s verification of no damage in transit, correctness and completeness of order and contractor’s conformance to preservation/packaging, packing, marking requirements.

Shipping Weight: