Attachment 1-SOW_DGRC Engine and Wheel Set- Rev 2 7-13-2022.docx

LOCOMOTIVE EMD 645E ROOTS BLOWN ENGINE AND WHEEL / AXLE SET

FOR ANNISTON ARMY DEPOT (ANAD)

SCOPE OF WORK (SOW)

MAY 16, 2022

1.0 OBJECTIVE

The Government has a requirement to have 1 each Locomotive 645E Engine and 1 Wheel and Axle Assembly Set (4 axles make a set) rebuilt for Anniston Army Depot (ANAD). The Engine and the Wheel and Axle Assembly are described as:

1.1 EMD 645E Roots Blown Engine – Model 567C engine block (roots blown) upgraded to 645-E power pack assemblies. All work is to be performed in accordance with General Motors Electro Motive Division (EMD) Original Equipment Manufacturer (OEM) specifications.

1.2 Wheel and Axle Assembly Set (One set equals 4 axles and 8 wheels) – WHEELAXLE:72915: Locomotive Wheel and Axle Assembly, for use with a General Motors, Electro Motive Division, General Purpose (GP) 9 locomotive for Defense Generator and Rail Center at Anniston Army Depot located at 7 Frankford Ave Bldg. 121 Anniston AL 36201. The truck assemblies that these are to be used in are “Swing Hanger Design” One locomotive set quantity is 8 wheels and 4 axles. Government furnished equipment (GFE) will include used wheel and axle assemblies 4 each and used Hyatt bearing housings 8 each.

2.0 Requirements

2.1 EMD 645E Roots Blown Engine. The contractor shall perform the following actions as related to the engine rebuild to include but not limited to original equipment manufacture standards and specifications:

2.1.1 During engine rebuild all applicable EMDs’ MI engine upgrades will be applied. Upgrades are:

a) Stub Shaft Modification to replace obsolete components.

b) Vibration Dampener Modification for configuration management within the 120-ton fleet.

c) Oil Strainer Housing Upgrade, Industry recommended for improved reliability and optimum performance.

d) All governors will be replaced with a 12-pin style to include the 12-pin electrical cannon plug.

2.1.2 The contractor shall completely disassemble the engine and inspect and measure all components to determine if they can be used in rebuild. If engine block and/or crankshaft shall meet original manufactures specifications. Engine will be reconditioned in accordance with EMD Maintenance Manuals, and all applicable EMD Maintenance Instructions. Also refer to the following EMD MI's: #100, Crankcase Main Bearing Alignment Qualification; #315 Crankcase Lower Deck Repair; #926, Lube Oil Filtration.

2.1.3 General Instructions

a) Block and pan will be disassembled and chemically cleaned. All lube tubes re removed.

b) Block will be pressure tested at 60 psi for one (1) hour on oil galley and water galley.

c) Block will be none destructive testing mag particle checked and dimensional readings none on all areas.

d) All bolt holes shall be inspected and tapped; then qualified with a tread go-no-go gauge, class 2-B.

e) All bolt holes that do not qualify shall be inserted or welded and re-machined. Exhaust manifold mounting bolt holes must be repaired by keenserts or equivalent.

f) Lifting pad bold holes that fail to qualify are welded, drilled, and tapped.

g) A record of the inspection, measurements, and repairs performed shall be furnished to the customer.

h) After qualification and repair, the crankcase and oil pan shall be re-cleaned and sealed to remove all metal shaving and contaminants.

i) New lower liner inserts will be installed and measured for proper inside dimension and alignment after installation.

j) Clean and install head frames, covers, and fuel manifolds.

k) Clean and install water manifolds and water manifold braces.

l) Install backing plates for engine tags.

m) Install vendor engine tags, including engine serial number, vendor identification, date, and engine model.

n) Paint engine.

2.1.4 Power Unit Assemblies

The contractor shall perform the following actions as related to the engine components to include but not limited to original equipment manufacture standards and specifications.

a) Standard size cast iron liners

b) Circle 3 or better heads

c) New valves

d) New hardened valve guides

e) New keepers and locks

f) Head refinished to phonograph finish

g) New piston with upper hardened ring grove

h) Pre-stressed stainless-steel rings

i) New carrier bronze inserts/bearing

j) Remanufactured carriers and new pins

k) Qualified fork and remanufactured blade rods.

2.1.5 Main Bearing

The contractor shall perform the following actions as related to the engine components to include but not limited to original equipment manufacture standards and specifications.

a) Main bearing caps and A-frames will be deburred and checked with a serration gauge. Caps will be applied to the crankcase with qualified main bearing studs and stud stretched. Alignment of bores, bore sizes, thrust width, and location will be checked on GRANIT table along with “P” pip manifold and end sheet squareness to line bore and recorded.

b) Main bearing bore will be checked with laser.

c) Serrations shall be inspected and gauged and repaired, as necessary.

d) All main bearing caps shall be gauged for thickness and spot faced for hardened flat washer.

e) All crab studs qualified.

f) All spherical seats checked for cracks and pits and repaired, as necessary.

g) Crankshaft line fore will be welded and machined as necessary in accordance with Electro-Motive Division Maintenance Instruction 100 (May 1992). Line bore machine will put line bore back to center of OEM tolerances.

2.1.6 Oil Pan Repair

The contractor shall perform the following actions as related to the engine components to include but not limited to original equipment manufacture standards and specifications.

a) All fractures, excessive wear areas and areas of distortion will be recorded and corrected.

b) Oil pan shall be inspected for damage with NDT testing, with repairs made as necessary, pay particular attention to oil suction pipe.

c) Base rails will be inspected for straightness, with repairs to be made if out of tolerance.

d) All dowel holes in base are welded

e) Oil pan is fitted to case with OEM tolerances.

f) Oil pan will be sealed.

2.1.7 Crankcase Repair

The contractor shall perform the following actions as related to the engine components to include but not limited to original equipment manufacture standards and specifications.

a) All fractures, excessive wear areas and areas of distortion will be recorded and corrected.

b) Head seat surfaces that are not square are skim cut. Head seats that do not meet OEM standards shall be welded and machined.

c) Upper pilot bores shall be wire wheel brushed and diameters checked in two (2) positions, with repairs made as needed.

d) Water jumper bores will be reamed to 1.447”-1.448” and then measured and inspected for wear groove and excessive rust pitting.

e) Bore size not to exceed 1.450” if oversize shall be welded and machined.

f) Lower liner insert bores wired brushed and polished. Bores will be checked in two (2) locations, readings recorded, and bore size restored by welding/re-boring if oversized.

g) All cam pads and keyways checked for wear and alignment. The exhaust manifold surface will be machined. All bolt holes will be cleaned to the bottom of the hole, tapped and qualified by a go-no-go thread gauge.

h) End plates will be visually inspected for damage and squareness and repaired as necessary. Block will be doweled to the pan and checked for length and alignment by dial indicator. Dowels and dowel holes will be checked for fit.

i) Top deck frame surfaces shall be checked for damage and straightness, repairing as necessary. All latches and supports will be applied and the frame cut to length per OEM specifications.

j) Piston cooling brackets and manifolds will be checked on granite table for alignment and damage, with repairs made as indicated.

k) Water manifold sleeve bores will be checked, with bushings to be replaced 100%.

l) Block and over speed trip housing will have drain back modification.

m) All Cylinder Relief Valve tubes are dial bore checked and brought back to OEM standard size for new CRV seal.

n) All hand hole cover surfaces are dimensionally checked, and wear steps removed.

o) Case will be sealed.

2.1.8 Engine Misc.

The contractor shall perform the following actions as related to the engine components to include but not limited to original equipment manufacture standards and specifications.

a) Crankshaft will be Class “D” and modified for a bolt on stub shaft.

b) Install new OEM standard size main bearings

c) New hydraulic gear type damper.

d) Water pumps remanufactured to EMD M.I.

e) Lube oil pumps remanufactured to EMD M.I.

f) New hot oil detector.

g) Engine detector remanufactured to EMD M.I.

h) Remanufactured governor

i) Remanufactured engine blowers

j) Remanufactured governor drive

k) Remanufactured camshafts with new bearings

l) Remanufactured auxiliary drive

m) Remanufactured fuel filter assembly with new filters

n) A/C coupling with new rubber grommets

o) Power assemblies with new Viton head seat rings

p) Modify engine clock with drain back

q) New fuel lines

r) Environmental hose kit

s) Remanufactured lay shafts

t) All gears will be re-qualified

u) All gasket surfaces will be cleaned. Ensure counterweights match engine configuration

v) Install Engine Pre-lube system as per EMD 645E Blower-Type Engine Maintenance Manual.

2.1.9 ENGINE PROTECTIVE DEVICES

2.1.9.1 The contractor shall replace all protective devices Low water, temperature switches, low oil, etc.

2.1.9.2 The contractor shall replace any defective components.

2.1.9.3 The contractor shall test over speed devices to ensure OEM specifications are met.

2.1.9.4 The contractor shall follow commercial best practices found in EMD-MI's: #259-Low Water & Crankcase Pressure Detector.

2.1.10 LOAD TEST. The contractor shall perform Engine break in and load test in accordance with MI 6830.

2.2 Wheel and Axle Assembly Set.

The contractor shall perform the following actions as related to the Wheel and Axle Assembly Set rebuild to include but not limited to original equipment manufacture standards and specifications.

Contractor shall provide the following:

a) New 40-inch wheels having AAR 1-B Contour, wheels can be “fat 40’s or regular 40’s” to be mounted on axles with standard support bearing size and 8 wheels to accommodate 1each GP9 locomotive. Reference MI1518 for standard specification.

b) 6 ½ x 12-inch journals and axles with 62-15 gear ratio and new cartridge type tapered roller bearings, Class GG. Timken number E-34744-B or equivalent. The complete locomotive requires 4 axles. One axle will have one GG end cap assembly Timken K82329 or equivalent for a speedometer drive mounted on the gear side end of cap. Hyatt bearings housings modified to adapt to the Class GG bearings.

c) All wear plates will be replaced with new plates.

d) Association of American Railroad (AAR) Certification Statement identifying components, i.e., wheels, axles, and roller bearings, came from a certified AAR source shall be included with each shipment. Reference AAR Manual M-1003 (J), Standard Operating Procedure MQ-03.

2.3 PRODUCTION SCHEDULE/CONTROL

The contractor shall deliver 1 each 645E Engine no later than 22 weeks of receipt of core engine from ANAD. The contractor shall deliver 1 Wheel and Axle Set (4 axles and 8 wheels) no later than 9 weeks of receipt of core wheel and axle set from ANAD.

2.4 MATERIAL HANDLING

The contractor shall be responsible for material requirements needed to for the remanufacturing of the 645E engine and Wheel and Axle Set.

2.5 Facilities/Equipment

The contractor shall be responsible for the facilities, machinery, and test equipment necessary to meet all requirements listed in the SOW.

2.6 Shipping

The contractor shall provide shipping and cost of shipping of the cores to their location. The contractor shall also provide shipping and cost of the shipping for the completed 645 E Engine and Wheels and Axle Assembly Sets and bearing housings back to Anniston Army Depot.

3.0 REFERENCES AND SPECIFICATIONS

a.) Association of American Railroad Manual M-1003 (J), SOP MQ-03 b.) Electro-Motive Division Maintenance Instructions c.) Code of Federal Regulations (CFR), Title 49, Transportation d.) Electro-Motive Division Replacement Parts Catalog 190 e.) Electro-Motive Division Replacement Parts Catalog 300

4.0 Scope Changes

The Contractor shall not proceed with any verbal or written change(s) to the scope of work from sources other than the Contracting Officer, who will provide changes in writing.