D398 Overhaul Desc.pdf

SOW 31110 0417 270WMEC

Statement of Work: Ship Service Diesel Generator (SSDG) Prime Mover, Overhaul

1. SCOPE

1.1 Intent. This statement of work (SOW) describes the requirements for the Contractor to overhaul, test, package and ship a designated SSDG prime mover.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 901 WMEC 256-008, Rev B, SSDG Modification — Aux Sea Water Piping

Mod

Coast Guard Drawing 901 WMEC 256-009, Rev B, SSDG Jacket Water Cooling System and

Mods

Coast Guard Drawing 901 WMEC 310-016, Rev-, Cyl & Tchrgr Thermocpls Mods to SSDG

Wiring Dia & Arrgmt

Coast Guard Drawing 901 WMEC 320-045, Rev B, SSDG Modification — Power Modification

Coast Guard Drawing 901 WMEC 504-003, Rev-, SSDG Temperature Gauges

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2018, General Requirements

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2018, Requirements for Preservation of Ship Structures

Coast Guard Technical Publication (TP) 2703, Oct 2016, Ship Service Diesel Generator (Set), OTHER REFERENCES

ASTM International (ASTM) 1)3951, 2010, Standard Practice for Commercial Packaging

3. REQUIREMENTS

3.1 General. The Contractor shall accomplish all work in accordance with the requirements of SFLC Std

Spec 0000, and using the Coast Guard drawings and TP listed under Section 2 (References) as guidance.

3.1.1 CIR.

None.

3.1.2 Tech Rep. The Contractor shall provide the services of an OEM authorized/ licensed Tech Rep for the SSDG Prime Mover, (Model D398 Marine Engine), to accomplish the following tasks — on site at

Contractor's facility where SSDG engine is undergoing overhaul and test:

o Provide manufacturer's proprietary information, software, and tools pertinent to the equipment/system.

o Assist with and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, reassembly and final operational testing of the equipment/system.

3.1.2.1 Ensure the Tech Rep is an OEM Certified Representative for the system/equipment stated above and demonstrated on their résumé.

3.1.2.2 Submit the name and résumé of the Tech Rep to the COR prior to Contract start.

3.2 Overhaul requirements. The Contractor shall accomplish the following tasks for the designated

SSDG Prime Mover (Caterpillar PN: D398B-TA/ARGMT-3N1127), in accordance with TP 2703, and the

SSDG manufacturer's (Caterpillar) recommended procedures. The Contractor shall accomplish a complete overhaul of the Caterpillar engine to "like new" condition. The Contractor shall provide all labor and materials to accomplish the requirements within this SOW.

3.2. I Removal. Package and ship the engine assembly to the Contractor's facility.

3.2.2 Disassembly, cleaning and inspection. Disassemble, clean and inspect the engine components.

Submit a CFR.

3.2.3 Bore alignment check. Measure the size, straightness, and the clearances related to the main bearing journals and cylinder blocks. Compare all measurements against the engine factory specifications in TP 2703. Submit a CFR. The CFR shall contain the cost of repair, labor, parts/materials, testing, paint, preservation, packing and marking.

NOTE

Maximum allowable line bore clearance shall be 0.002-inches.

32.4 Parts renewal. Furnish and install all parts listed in paragraph 4.1 (Contractor-furnished parts list), in place of existing parts. Validate parts list with Tech Rep prior to purchase.

3.2.5 Reassembly. Reassemble the prime mover in accordance with the applicable sections of TP 2703.

32.6 Testing. Test overhauled engine assembly in accordance with TP 2703 and Tech Rep's recommendations. Test shall include a four-hour minimum dynamic test. Submit a CFR.

3.2.6.1 No-load testing. Prior to the dynamometer test, in the presence of the Coast Guard Inspector and in accordance with TP 2703, the Contractor shall run the engine for a period of 30 minutes under no load.

Check the engine and all sub-assemblies, tubing, hoses, flanges, lines, fittings, joints, and plugs for leaks.

Monitor the lube oil pressure and engine temperature. Submit a CFR. Correct any deficiencies and discrepancies found during testing and retest.

3.2.6.2 Dynamometer test. After all authorized repairs, the Contractor shall test the engine using an engine dynamometer in accordance with OEM recommendations. The Contractor shall correct any deficiencies and discrepancies found and retest. Submit a CFR of all test results; including RPM, torque, HI), oil pressure and temp, jacket water pressure and temp, fuel pressure and rate, and time of each reading. Test report shall include engine model number, serial number, date of testing, and signature of authorized tester.

3.2.6.3 Purging. After a successful Dynamometer test and acceptance by the Coast Guard Inspector; the

Contractor shall purge the engine sea water and jacket water systems. The Contractor shall open and vent the sea water and jacket water systems by using the engine's petcocks, fittings and flanges to allow trapped fluid to drain from the engine, to prevent expansion damage due to possible freezing in cold weather. After the engine is drained, all external openings shall be securely capped, plugged or closed to prevent contamination of the engine or the storage container.

3.2.7 Packaging and shipping. After all authorized repairs are complete, package and ship engine assembly in accordance with SFLC Std Spec 0000 to SFLC Baltimore. Preserve engine assembly prior to packaging in preparation for long-term storage in temperatures ranging from -20 to 120 degrees F. All exposed metal surfaces shall be prepared and preserved in accordance with SFLC Std Spec 6310. Coat all unpainted surfaces with a light amount of grease. Plug or cap fittings, flanges and openings that can allow foreign materials to enter the engine. Drain and protect all fluid systems with appropriate preservatives.

Shrink wrap engine.

A warning tag shall be attached to the engine stating the preservation action taken and method to place engine back into service.

The shipping crate shall have the following markings in 2-inch black enamel letters:

Caterpillar Engine, D398

Engine Serial Number #

U. S. Coast Guard Material

Gross Weight Cube

A Condition Code

Contract Number/Delivery Order Number

Do Not Stack More Than Two High

Do Not Lift By Cover

Contractor shall notify COR at least 24 hours prior to closing shipping container.

4. NOTES

4.1 Contractor-furnished parts list.

PART NUMBER PART NAME QTY

OR0804 (CORE) Pump water 1

OR2536 (CORE) Crankshaft 1

OR5521 (CORE) Oil Pump Assembly 1

OR5842 (CORE) Turbocharger 2

OR8125 (CORE) Camshaft Kit (with followers) 1

OR9851 (CORE) Motor 1

3N4364 (CORE) Aftercooler 1

3N4363 (CORE) Aftercooler 1

5N3392 (CORE) Shut off group 1

IOR7754 (CORE) Engine Kit (power packs) 1

3N2078 / 20R-0963 (CORE) Fuel Pump 1

0L1213 Gasket 2

0L1351 Cap screw 2

0S1588 Cap screw 6

1653929 Cap screw 7

0S1594 Cap screw 2

0S1595 Cap screw 4

0S1596 Bolt 10

0T0603 Bolt 10

1A2343 Bolt 1

1F7958 Nut 4

1F3278 Nut 6

1F4503 Bearing 2

1F6936 Gasket 2

1N8423 Gear 1

1P0436 Gasket 1

1P7325 Bearing 2

1W9201 Line 1

1W9202 Line 1

1W9203 Line 1

1W9204 Line 1

1W9205 Line 1

1W9206 Line 1

1W9207 Line 1

1W9208 Line 1

1W9209 Line 1

1W9210 Line 1

1W9211 Line 1

1W9212 Line 1

2D8153 Stud 4

2H7911 Pointer 1

2N1587 Gasket 1

2N2416 Gasket 1

2N4369 Plate 1

2N6737 Coupling 2

2N8613 Washer 4

2N9101 Shaft 1

2S7264 Pump assembly 12

2W4192 Gasket 1

2W5016 Motor 1

3B1915 Bolt 1

3B4506 Lock washer 4

3B4621 Cotter pin 1

3F7445 Bearing

3H5841 Cap screw 12

3H5939 Gasket 4

3J2903 Cover 1

3J5389 Plug 2

3J5390 Plug 2

3K8909 Lock washer 12

0S1588 Cap screw 4

0S1617 Bolt 9

IH5959 Seal 2

2N7519 Rotor 1

2N7520 Gasket 1

2N7521 Cover 1

2N7522 Kit, Gasket 1

2N7523 Idler 1

2N7524 Head 1

2N7525 Housing 1

5M6214 Plug 2

6D3910 Screw 1

6F2172 Key 1

3T3678 Motor 1

3N1242 Gasket 1

3N1442 Adapter 1

3N2004 Plate 1

3N2202 Elbow 1

3N3148 Tube 2

3N4057 Shaft 1

3N4059 Gear 1

3N5489 Plate 2

3N5490 Plate 2

3N5491 Damper 2

3N5492 Damper 2

3N5493 Spacer 2

3N7731 Gasket 1

3N8785 Adapter, damper 1

3N8920 Gasket 2

3N9075 Gasket 1

3P0649 Seal, O-ring 1

3P0651 Seal, O-ring 1

3P0656 Seal, O-ring 2

3P1155 Seal, O-ring 1

3P1156 Seal, O-ring 1

4B5271 Washer 6

458-9582 Primer 12

4H5952 Gasket 12

4L3756 Bearing 1

4L7820 Rod 24

4L7823 Lock 12

4L7854 Lock 1

4L7885 Gasket 3

4L8167 Pin 1

4M6953 Washer 10

4M4044 Gasket 2

4W2568 Seal 1

4W2569 Seal 1

4W4011 Regulator 4

5B2113 Bearing 1

5H1504 Washer 4

5H4475 Bushing 3

5H5553 Screw 12

5K9235 Fitting 4

5K9238 Fitttin 2

5K9244 Fitting 6

5L2660 Bearing 1

5L2806 Bearing 3

51.3773 Gasket 3

5L5263 Bearing 1

5L5276 Bearing 1

5L6620 Damper 3

5L6624 Damper 3

5L6745 Pointer 1

5M2894 Washer 14

5M5689 Clamp 6

5M5690 Damper 4

5M6213 Plug 2

5M7877 Lock nut 2

5N1615 Tube 1

5N1841 Flange 3

5N4213 Spacer 8

5N4411 Bolt 1

5N6159 Bearing 4

5N6162 Bearing 2

5N6165 Bearing 1

5N7849 Tee 1

5N7853 Tube 1

5N7856 Bracket 1

5N7857 Bracket 1

5N7858 Cover 1

5N7894 Pump 1

5P3860 Clamp 2

5P6672 Rod 1

5P8245 Washer 4

6B6684 Nut 24

6H7127 Lug 3

6K8079 Fitting 4

6L2142 Bushing 2

6L3005 Clamp 4

6L3401 Gasket 1

6L3458 Gasket 1

6L3528 Gasket 1

6L6489 Gasket 4

6L7817 Seal 24

6L8441 Bushing 1

6L8761 Sleeve 4

6V3736 Kit, Gasket 2

6V3737 Kit, Gasket 1

6V3739 Kit, Gasket 1

6V5428 Kit, Gasket 1

6V5429 Kit, Gasket 1

6V5467 Kit, Gasket 1

6V7834 Bolt 2

6V8801 Nut 4

6V9442 Bolt 2

7B9457 Lock 2

7B9514 Lock 2

7B9665 Plug 1

7L2905 Gasket 1

7L8841 Spring 1

7M6124 Spring 1

7M6842 Plunger 1

7M6843 Gasket 1

7M6844 Gasket 1

7M6856 Body 2

8F4610 Ring 2

8F6711 Seal 1

8F8682 Lock 1

8F8683 Lock 1

8F9206 Seal 2

8L3419 Cover 1

8L3562 Rack 1

8L3598 Gasket 8

8L5855 Coupling 1

8L6557 Adapter 1

8L9757 Gasket 2

8M4445 Seal, O-ring 1

8M4668 Clamp 4

8M4988 Seal, O-ring 1

8M7753 Bearing 1

8N1831 Nozzle 12

9F7283 Ring 1

9F8999 Cap screw 4

9L5125 Fitting 1

9S8858 Nut 1

162-3906 Pump 1

167-8133 Damper 1

9F6656 Ring 6

3J5390 Plug 2

3J5389 Plug 2

248-5513 Regulator 4

5H4488 Lifter 12

1A0744 Screw 24

9S8905 Nut 24

9F8254 Socket 24

1B4205 or 6B6684 Nut 24

6B6684 Nut 16

1F7603 Screw 2

1F7604 Ferrule 1

1L6939 Fitting 5

2N3385 Nut 12

2N2766 Lock nut 2

2N2765 Bolt 8

5R4630 Tube 1

0S1588 Cap screw 4

0S1617 Cap screw 9

6F2172 Key 1

0S1583 Cap screw 12

0S1587 Cap screw 12

1F7958 Nut 28

2N2766 Lock nut 10

4L8191 Gasket 1

3B4621 Cotter pin 12

3F9780 Washer 4

3H0510 Gasket 2

4L8176 Gasket 1

5L6943 Gasket 1

3N9075 Gasket 1

8L4855 Spacer 8

5N8184 Cable 1

9L2685 Ball joint 1

3N1344 Tube 1

2N3386 Support 2

0L1143 Bolt 12

5M2894 Washer 34

6V8801 Nut 16

5N2677 Washer 30

4F0411 Cap screw 3

9F8999 Cap screw 2

0S1590 Cap screw 4

1653931 Bolt 10

3S1252 Spring 12

1R0659 Filter, oil 4

2N3583 Gasket (oil filter housing ) 2

1R0724 Filter, fuel 4

2N3295 Gasket (fuel filter housing) 2

6L4714 Filter, air 2

5R3047 Filter, emission 1

4W2606 Front crankshaft seal 1

4W2607 Rear crankshaft seal 1

4L5816 Camshaft , fuel pump 1