Detroit Diesel 71 series SSDG SOW.pdf

DETROIT DIESEL ALLISON MODEL 3-71 ENGINE CENTER

SECTION OVERHAUL

SPECIFICATION FOR DOCKSIDE MAINTENANCE

Developed By: IBCT Product Line

(Rev-0, 05 September 3, 2024) ii (Rev-0)

TABLE OF CONTENTS

Revisions Record ......................................................................................................................................... iii Consolidated List of References ................................................................................................................... iv Consolidated List of Government-furnished Property .................................................................................. v Consolidated List of Critical Inspection Items ............................................................................................. vi General Requirements WORK ITEM 1: Disassemble, Clean, Inspect, Repair or Renew and Reassemble Engine Units and

Accessories (Center Section Overhauls) iii (Rev-0)

REVISIONS RECORD

This page is used to record specification revisions, which may have occurred subsequent to a Revision 0 (Rev-0) package. Information listed is intended to provide contractors and field unit personnel a means to ensure all the current specification revision pages are present when reviewing or utilizing this specification package.

DATE REV# WORK

ITEM#

CHANGES MADE

NOTE : All work item and paragraph numbers listed above for a given revision correspond to same numbers in the previous revision. This revised specification is self-contained with all of the above listed changes incorporated.

iv (Rev-0)

CONSOLIDATED LIST OF REFERENCES

The below-listed documents form a part of this specification to the extent specified herein. Approval/publication dates or revision dates/numbers are also identified, to ensure that same document versions are used at time of specification writing and during contract execution.

All Coast Guard drawings, technical publications, and standard specifications will be provided to contractors by the Coast Guard at an appropriate time, or upon request, free of charge. Other Government documents may be accessed – free of charge – as follows:

• MIL/DOD/CID Specifications: http://www.assistdocs.com/search/search_basic.cfm

• Commandant Instruction Manuals: http://www.uscg.mil/directives/default.asp

• Public Laws, Code of Federal Regulations, U.S Codes, and other Federal Government laws:: www.gpoaccess.gov

The Government is aware of the following internet web links where contractors may procure commercial specifications:

• American Welding Society (AWS): http://www.awspubs.com/index.php

• ANSI, ASTM, IEEEE, NFPA, ASME, SAE Standards: http://www.techstreet.com/

• NFPA: http://www.nfpa.org

• SSPC Standards and pictorial guides: http://shopping.netsuite.com/sspcmarketplace

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General

Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2022, Welding and

Allied Processes Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2022, Requirements for Preservation of Ship Structures

OTHER REFERENCES

Ship’s Service Diesel Engine – 71 Series Technical Manual, Technical Publication 1510 Detroit Diesel Allison Marine Model 3-71 Operating Manual Services and Parts Information Manuals and/or the latest original equipment manufacturer (OEM) technical bulletins specification manual as guidance.

http://www.assistdocs.com/search/search_basic.cfm http://www.uscg.mil/directives/default.asp http://www.gpoaccess.gov/ http://www.awspubs.com/index.php http://www.techstreet.com/ http://www.nfpa.org/ http://shopping.netsuite.com/sspcmarketplace v (Rev-0)

CONSOLIDATED LIST OF GOVERNMENT-FURNISHED PROPERTY

The following is a list of property, which the Government will furnish. This list supersedes any other material obligations indicated or implied by referenced drawings.

None vi (Rev-0)

CONSOLIDATED LIST OF CRITICAL INSPECTION ITEMS

The following is a list of work items, which contain Critical Inspection reports, which the Contractor must complete within the first 25% of the availability contract period (see SFLC Std Spec 0000, paragraph 3.2.6.5 (Inspection report particulars)):

Work Item Title

1 Disassemble, Clean, and Inspect, Engine Units and Accessories.

7 (Rev-0)

23300_SSDG #1 and #2Overhl_0819_IBCT

General Requirements

1. SCOPE

1.1 Intent. The work item describes the requirements for the contractor to perform a center section overhaul of engines described in Table 1.

TABLE 1. ENGINE(S) TO OVERHAUL

Engine Engine Model Engine Serial #

#1 Detroit Diesel 3-71 3A-59887

1.2 Government-furnished property.

None

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color

Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2022, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2022, Requirements for Preservation of Ship Structures

OTHER REFERENCES

Ship’s Service Diesel Engine – 71 Series Technical Manual, Technical Publication 1510

8 (Rev-0)

Detroit Diesel Allison Marine Model 3-71 Operating Manual Services and Parts Information Manuals and/or the latest original equipment manufacturer (OEM) technical bulletins specification manual as guidance.

3. REQUIREMENTS

3.1 General. The Contractor shall provide all parts, labor, and tools required which includes but not limited to (standard tools/specialty tools/test equipment/software/consumables). Additionally, Contractor shall cover all core charges and ensure all cores are returned to distributor.

3.1.1 General. The Contractor shall conform to all requirements specified in SFLC Std Spec 0000 and in this item, as applicable, during the performance of this availability.

NOTE

The requirements of paragraph 3.1 (General) applies to all work under the scope of this contract, whether explicitly stated in work items or not, and to all other work subsequently authorized by changes, modifications, or extensions to the contract.

3.2 Personnel.

3.2.1 Detroit Diesel. The Contractor shall provide the services of a qualified Tech Rep, who is familiar with the Detroit Diesel 3-71 series engine models listed in table 1 and Para 3.3.4, to accomplish the following tasks – on site:

• Accessing Original Equipment Manufacturer (OEM) proprietary information, software, and tools pertinent to tasking in accordance with the specification.

• Assisting with proper repair methods and ensuring compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system.

• Provide Performance Analysis Report with the diagnostic test data and recommendations for the diesel engines.

• Conducting Marine Engine Performance diagnostic testing (load bank testing), ensuring compliance with OEM, U.S. Coast Guard, OSHA, and other pertinent procedures and standards

• Providing genuine, OEM-approved parts

3.2.1.1 Ensure that the Tech Rep is a Qualified technician.

3.2.1.2 Ensure that Tech Rep is qualified to work on Detroit Diesel Allision 3-71 engines and submit qualification to Contracting for review.

3.2.2 Employee identification and access. At least seventy-two (72) hours prior to each ship visit to perform work under this contract, the Contractor shall submit a list of all employees who shall be performing that work to the COR. To gain access to the ship or other Government facilities to perform

9 (Rev-0) any work under this contract, each Contractor employee shall carry a picture identification card furnished by the Contractor, or other servicing agent authorized by the Contractor/Manufacturer. The employee shall prominently display this card on their person in the chest area at all times when on any Government facility, except when actively engaged in labor wherein the card might get caught in tools or operating machinery and represent a hazard to the employee.

3.2.3 Security clearances. Special security clearances are normally not required to perform any work under this contract. The Contractor shall supply a list of all employees who may be required to perform work and periodically update that list. Prior to each ship visit to perform work, the Contractor shall submit information on visiting employees. In event the cutter be berthed at a Department of Defense or foreign government military facility, the KO will provide instructions on the method by which the cutter crew will assist the Contractor’s representatives in meeting facility access requirements at the time the Contractor is tasked.

3.3 Scope of work.

3.3.1 Work. The Contractor shall provide all personnel, labor, materials, parts, tools (standard and special), test equipment, test fittings, supplies, consumables, and equipment required to accomplish tasking in accordance with the scope of work.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment, perform electrical tag-outs in support of maintenance, drain and dispose of oil and coolant, and be available to advise on rigging safety procedures as necessary. All other labor associated with maintenance tasks (i.e.

rigging, parts delivery, repairs, etc.) shall be provided by the Contractor.

3.3.2 Travel. The Contractor shall provide all travel necessary to support tasks necessary to remove/install engines onboard the vessel at the vessel’s homeport.

The place of performance for Contract Line Items (CLINs) covered by this solicitation will be performed pier-side on-board the vessel, at the vessel’s homeport in the Continental United States (CONUS) located at: USCGC AXE, 800 Youngs Rd STE 100, Morgan City LA 70380.

(1) Pricing Travel and Pier Diem will be included in each Task Order and for all personnel required to accomplish the work covered by this specification.

(2) The proposed Travel and Per Diem for each Task Order shall represent total compensation for employees’ transportation, lodgings, meals, and incidentals and shall not exceed on a daily basis the maximum rates as set forth in the Federal Travel Regulations, the Joint Travel Regulation, and in the case of foreign travel, the Standardized Regulations.

(i) Federal Travel Regulations, prescribed by the General Services Administration, for travel in the conterminous 48 United States, is available on a subscription basis from the Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402.

(ii) Joint Travel Regulation, Volume 2, DOD Civilian Personnel, Appendix A, prescribed by the Department of Defense, for travel in Alaska, Hawaii, The Commonwealth of Puerto Rico, and territories and possessions of the United States, is available on a subscription basis from the Superintendent of Documents, U.S.

Government Printing Office, Washington, DC 20402.

10 (Rev-0)

(iii) Standardized Regulations (Government Civilians, Foreign Areas), Section 925, "Maximum Travel Per Diem Allowances for Foreign Areas," prescribed by the Department of State, for travel in areas not covered in by (i) and (ii) of this paragraph, is available on a subscription basis from the Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402.

(3) All receipts for travel must be submitted with the invoice(s) for the associated Task Order. If there is a difference in costs from pricing established at the time of award for Travel and Pier Diem;

a modification will be issued based on receipts for actual costs.

(4) The place of performance for all work will be completed at the vessel’s homeport. If for any reason the homeport or pier location is changed, the Contracting Officer will request a Quote for Travel and Pier Diem to the new location. The Contractor will be compensated for the difference in cost from the vessel’s homeport and the new location.

3.3.3 Engine parts.

3.3.3.1 New parts. The Contractor shall use only new, OEM-approved parts for accomplishments of tasks.

3.3.3.2 Reused parts. The Contractor shall ensure all parts qualified for “reuse” meet the reusability of OEM guidelines.

3.3.4 Engine applicability. The Contractor shall be advised that tasking will include work associated with the following Detroit Diesel Allison Marine Model 3-71 engine (serial number listed in Table 1).

The Contracting Officer (KO) will identify the specific engine serial and arrangement numbers of engine units and accessories to be completed under this contract at time of tasking.

3.4 Documentation.

3.4.1 Inspections. For visual inspections and condition assessments (i.e. pass/fail), the use of digital pictures attesting to condition of components inspected is required. These, in conjunction with a narrative, will be used to document acceptability. Visual inspections shall be accomplished using the following guidelines and included in all CFR submissions:

• OEM’s relevant guidance and reference documents for inspection and assessment shall be utilized and referenced accordingly (including Publication Number, Publication Date, and Title).

• List of all instruments (make and model) of equipment used in support.

• List of all parts and components inspected, including part numbers and serial numbers (as applicable) for machinery history and configuration tracking purposes.

• All readings and measurements (clearances, tolerances, etc.) recorded and used in support of

OEM-reusability determinations.

• Recommendations for re-use, replacement, repair, or renewal of inspected components per

OEM-reusability guidelines.

11 (Rev-0)

3.4.2 Parts list. Upon completion of work, the Contractor shall submit an itemized parts list (including part number information and nomenclature) detailing any parts replaced during overhaul. This list shall be attached to a CFR.

3.5 Compliance. All work shall meet the requirements of this work specification. The inspections set forth shall become part of the Contractor's overall Inspection System or Quality Program. The absence of any inspection requirements shall not relieve the Contractor of the responsibility of ensuring that all work submitted to the Government for acceptance complies with all requirements of the contract.

3.5.1 Noncompliance. If any work fails to pass a test or inspection, the Contractor shall take action to correct the work.

3.6 Acceptance. Acceptance of the work shall be discontinued until corrective actions, acceptable to the Government, have been taken. After taking corrective action, repeat the inspection on the corrected work.

3.7 Final acceptance. Final acceptance shall be withheld until re-inspection shows the corrective action to be successful. In the event of failure after re-inspection, the Contractor shall submit to the Coast Guard Inspector a written report concerning the failure with recommended corrective actions.

3.8 Conformance. Quality conformance tests and inspections shall be the minimum test and inspection methods used to demonstrate compliance to the requirements set forth in this work specification.

3.9 Fire watch requirements. The Contractor shall refer to 3.3.1.3 (Fire watch requirements) of SFLC Std Spec 0000, in accomplishing the following task:

• Coast Guard fire watch is in lieu of contractor personnel during the hours of 0800-1600, Monday through Friday, and limited to two Coast Guard fire watch personnel.

3.10 Preservation requirements. The Contractor shall accomplish all preservation tasks, including touch-ups of affected engine components, in accordance with SFLC Std Spec 6310. All new parts replaced shall be preserved in accordance with OEM-standards (i.e. new blocks, cylinder heads, etc).

3.11 Welding and brazing requirements. The Contractor shall perform all welding and allied processes, and NDI in accordance with SFLC Std Spec 0740.

3.12 Environmental protection requirements. The Contractor shall adhere to the following environmental protection requirements in accordance with the SFLC Std Spec 0000:

3.12.1 USCG facilities. The Contractor shall provide and maintain environmental protection as defined in SFLC Std Spec 0000 Appendix B, Requirements for Environmental Protection at USCG Facilities, during the performance of this availability. Contractor shall plan for and provide environmental protective measures to control pollution that develops during normal practice, as well as plan for and provide environmental protective measures required to correct conditions that develop during the project.

Contractor shall comply with applicable Federal, state, and local laws, codes, ordinances, and regulations in their entirety. Any reference to a specific portion of a Federal, state, or local law, code, ordinance, or regulation in this or any other item shall not be construed to mean that relief is provided from any other sections of the law, code, ordinance, or regulation.

3.12.2 HW disposal. The Contractor shall comply with SFLC Std Spec 0000 Appendix B, Requirements For Environmental Protection At USCG Facilities for HW disposal, and ensure that waste removals are conducted during normal business hours (0800-1600) on Monday through Friday (excluding holidays).

12 (Rev-0)

3.13 Rigging. Contractor is responsible for rigging all machinery parts on and off the vessel. Assistance with rigging engine parts on and off vessel, or use of buoy deck for temporary tool and parts storage must be confirmed with vessel at least seventy-two (72) hours prior to start of contract or the Friday before the contract start date.

3.14 Period of Performance. The period of performance for this contract shall not exceed 14 calendar days from the date of award.

3.15 Place of Performance. The primary place of performance will be at USCGC AXE home port at 800 Youngs Rd, Morgan City, LA 70380 unless an alternate location is approved by the Coast Guard. Access to this installation will be coordinated with CGC AXE Engineering Petty Officer.

3.16 Hours of Operation. Contractor employees shall generally perform all work between the hours of 0730 and 1600 EST, Monday through Friday (except Federal holidays). However, there may be occasions when Contractor employees shall be required to work other than normal business hours, including weekends and holidays, to fulfill requirements under this SOW. Precise times may be negotiated with the cutter Engineering Petty Officer (EPO) as scheduling is subject to ship’s operations.

3.17 Daily Progress Reports. The Contractor shall hold a daily progress meeting with the Engineering Petty Officer and/or Commanding Officer upon arrival at the asset each morning of the visit. This report shall include a summary of all Contractor work performed, an assessment of technical progress, schedule status, and discuss any hazardous work conditions or necessary precautions the crew need to be made aware of prior to commencing work.

3.18 General Reporting Requirements. The Contractor shall provide all written reports in electronic format with read/write capability using applications that are compatible with DHS workstations (Windows and Microsoft Office Applications).

4. NOTES

4.1 Access to COMDTINST M10360.3. The COMDTINST M10360.3 may be accessed at the following URL address: http://www.uscg.mil/directives/cim.asp http://www.uscg.mil/directives/cim.asp

13 (Rev-0)

00000_0116_FLT

00000_CAT Engine Ovhl IDIQ_PJM_0116_IBCT

WORK ITEM 1: Disassemble, Clean, Inspect, Repair or Renew and Reassemble Engine Units and Accessories (Center Section

Overhauls)

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to disassemble, clean, inspect, repair and reassemble either onboard vessel or at OEM authorized repair facility (Center Section Overhaul) Detroit Diesel Allison Engine Unit and Accessories to include engine model 3-71’ Barge engine S/N 3A-59887 and provide genuine Detroit Diesel approved parts as necessary for repairs aboard WLIC cutter class vessels onboard the vessel at the vessel’s homeport.

1.2 Government-furnished property.

None

2. REFERNCES

COAST GUARD DRAWINGS

None.

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color

Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2022, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2022, Requirements for Preservation of Ship Structures

OTHER REFERENCES

Ship’s Service Diesel Engine – 71 Series Technical Manual, Technical Publication 1510 Detroit Diesel Allison Marine Model 3-71 Operating Manual Services and Parts Information

Manuals and/or the latest original equipment manufacturer (OEM) technical bulletins specification manual as guidance

14 (Rev-0)

3. REQUIREMENTS

3.1 General. The Contractor shall provide all parts, labor, tools required which includes but is not limited to (standard tools/special tools/Test Equipment/Consumables). Additionally, Contractor shall cover all core charges and ensure cores are returned to distributor.

3.1.1 CIR. The Contractor shall submit a CIR for the inspections listed in the following paragraph(s):

• 3.3 (Engine component cleaning and inspections).

3.1.2 Protective measures.

3.1.2.1 Ensure protective measures are in place IAW General Requirements.

3.1.3 Interferences.

3.1.3.1 Contractor shall be responsible for reinstalling all interferences.

3.1.3.2 Contractor shall be responsible for rigging engine parts into and out of vessel. CG assistance provided at discretion of each vessel’s command.

3.1.4 References. The Contractor/technicians shall disassemble, clean, inspect, repair or renew and reassemble the John Deere engine units and accessories in accordance with the references listed in Section 2 herein.

3.1.5 Authority to proceed. The Contractor/technicians shall not proceed with any additional growth work on the engine units or accessories described in this specification, until specific instructions are given by the KO on what additional work is to be accomplished.

NOTE

The Contracting Officer (KO) will provide a written response to the Contractor, after receipt of the CIR, regarding all work to be completed for repairs. Work may not proceed until this authorization is received.

3.1.6 Responsibility for inspection. The Contractor/technicians shall be responsible for all inspections and test requirements specified herein. The Contractor shall provide the necessary calibrated test equipment to conduct all of the inspection requirements. Be aware that the Government reserves the right to verify or perform any of the inspections or tests set forth in this specification where such inspections are deemed necessary to assure that supplies or services conform to the prescribed requirements.

3.2 Operational test – initial. Prior to commencement of work, the Contractor shall witness an operational pre-test (by Coast Guard personnel) of the engine to demonstrate existing operational condition. Submit a CFR documenting operational condition of engine.

3.2.1 Operational test – initial – Center Section Overhaul (CSO). When conducting a CSO, submit CFR to include web deflection readings and thrust measurements of engine in pre-overhaul condition.

15 (Rev-0)

3.3 Clean and Inspect Engine Components. The Contractor shall disassemble, clean, inspect and test the engine components listed below, (Refer to Table 1) utilizing the appropriate publications as outlined in Section 2 as guidance. Provide a CIR/CFR of these components to the KO for potential reuse determination.

TABLE 1 - ENGINE COMPONENTS TO BE DISASSEMBLED, CLEANED, INSPECTED OR

TESTED DURING THE PERFORMANCE OF A CENTER SECTION OVERHAUL

Aftercooler Camshaft Exhaust Manifold Crankshaft Rocker Shaft Assembly and Push Rods Turbocharger/Blower housing and any other components not renewed in Table 2. Cylinder Block

Water Manifold Driven Equipment (alignment)

Jacket Water Pump Oil Supply Lines

Sea Water Pump Flywheel Heat Exchanger – All. Front Gear Train (Gears) Governor Fuel Linkage Rear Gear Train (Gears) Oil Suction Screen Oil Cooler Core

3.3.1 Report. The Contractor shall record the appropriate inspection findings on a CFR (clearance and tolerance readings of the cylinder block and related components). Submit a written report of all findings and recommendations to the Coast Guard Inspector (CGI) and COR within 24 hours after inspection.

3.3.2 Government’s right for furnishing various components and parts. The Contractor shall be aware that the Government reserves the right, to furnish new or rebuilt components or parts for installation, in place of the existing parts, at no additional cost to the Government. If the Government exercises this right, the Contractor shall turn over all existing components or parts to the CGI or COR as Mandatory Turn-In (MTI) items.

3.4 Automatic renewal. The Contractor shall perform the following engine component renewals with genuine, remanufactured (or new) OEM components, (Refer to Table 2).

16 (Rev-0)

TABLE 2 - ENGINE COMPONENTS TO BE DISASSEMBLED AND AUTOMATICALLY

RENEWED DURING CENTER SECTION OVERHAUL

TOP END CENTER SECTION (INCLUDES TOP END)

Complete Cylinder Head Assemblies Camshaft Bearings Cylinder Head Gaskets and Seals Connecting Rod Bearings Inlet Air Line Seals Crankshaft Seals Turbocharger Bearings, Bushings and Seals Crankshaft Thrust Plates Valve Lubricator (If Equipped) Exhaust Manifold (Seals and Bellows) Water Pump Bearings and Seals Fuel Injection Pumps Water Temperature Regulators / Thermostats and Seals Fuel Transfer Pump Fuel Injectors Gear Train Bushings Turbocharger Cartridge/Blower Inlet Manifold (Gaskets and Seals) Head Studs Jacket Water Pump Fuel System (Primary and secondary filters) Lubricating Oil Pump Air Filters Main Bearings Lifter Roller Assemblies Piston rings Sea Water Pump Sea Water Pump Crankshaft Vibration Damper including hardware Software (Install new software when a new ECM is installed) Crankshaft Counterweight Hardware (as applicable) Piston Assembly Cylinder Liners Lifter Roller Assemblies Turbocharger/Blower Connecting Rods and Hardware

3.5 Discretionary renewal. If a modification has been authorized and released by the KO, the Contractor shall renew the specified engine components with genuine, remanufactured (or new) OEM components.

(Refer to Table 3).

3.5.1 Exceptional Circumstances. If the Coast Guard or the servicing element determine a long block or short block is required to return the ship to operational condition, the KO may authorize the contractor to complete repairs utilizing a long block or short block vice in-place overhaul of engine. KO may authorize assembly of long block offsite to accomplish repair.

TABLE 3 - ENGINE COMPONENTS TO BE RENEWED UPON INSPECTION AND WITH KO

AUTHORIZATION

TOP END CENTER SECTION (INCLUDES TOP END)

Aftercooler Crankshaft Exhaust Manifold Camshaft Rocker Shaft Assembly and Push Rods Cylinder Block Governor (Overhaul by authorized governor dealer) Driven Equipment (alignment) Water Manifold Oil Suction Screen Oil Cooler Core Flywheel

17 (Rev-0)

TABLE 4 - OPTIONAL SERVICES TO BE COMPLETED DURING AN ENGINE OVERHAUL

WITH KO AUTHORIZATION

OPTIONAL SERVICES

Machining of Engine Block

Cooler Clean Line bore

Block renewal

3.6 Gaskets and seal. The Contractor shall furnish and renew all gaskets and seals (consumables) associated with the engine reassembly in this contract.

3.7 Fluids and Filters. The Contractor shall furnish and renew all fluids and filters associated with the engine reassembly. Contractor will be advised of Coast Guard desired engine oil preference prior to arrival conference.

3.8 Reassemble Engine Units and Accessories. After any authorized repairs and renewals, the authorized Contractor/technician’s shall reassemble the engine units and accessories to its original configuration utilizing the appropriate publications as outlined in Section 2.1 as guidance.

3.8.1 Alignmnent Check. The Contractor shall perform an alignment check post overhaul to include but not limited to SSDG generator decoupling, engine mount repair, rear gear work, or disconnecting engine from shaft and/ or red gear.

3.9 Operational testing – post overhaul.

NOTE

The USCG considers the testing below to be separate testing evolutions. The Contractor and Ship’s Force should coordinate scheduling of the three to ensure optimum use of schedule.

3.9.1 Operational "light-off" test. After completion of work, the Contractor shall witness an operational "light-off" test (by Coast Guard personnel) of the diesel engine unit and accessories to prove satisfactory operating condition.

3.9.2 Engine break-in. Upon successful completion of operational "light-off testing", the Contractor shall conduct an engine test run (break-in), under various loads, in accordance with applicable John Deere/Onan and Coast Guard standards. This is to ensure all internal engine components have been properly tested (seating of piston rings, proper oil flow to internal parts, temperatures) and any discrepancies are resolved.

3.9.2. For SSDGs and EDGs, the Contractor shall provide and utilize an external load bank to accomplish the proper engine break-in (CSO only).

3.9.3 Computer Aided Marine Performance Analysis Report. OEM approved analysis report.

18 (Rev-0)

NOTES

1. The intent OEM analysis testing is to establish overall condition of the engine “post-overhaul” in support of engine performance-tracking initiatives. Testing shall be conducted in accordance with OEM standards and include all data elements recorded on the complete program (i.e. fuel rates, boost pressures, etc.).

2. Historically, test results provided to the USCG have omitted specifications (i.e. acceptable data ranges for recorded parameters, units of measure, and recorded data). Contractor shall annotate the submitted test data as necessary to provide this information.

3. Ship’s Force may assist in data collection efforts as requested by the Contractor. Additionally, data collection can be accomplished using installed ship’s instrumentation (i.e. local meters, gauges, MPCMS displays, etc.) provided locations are in agreement with PAR testing requirements. The Contractor shall be aware that all PAR testing locations are not monitored by the USCG and will require the Contractor to install additional gauges and/or meters (and associated test fittings) to accomplish tasking.

3.9.4 Adjustments. Based on the results of the operational testing, perform any additional adjustments (or readjustments) as required to ensure proper operation of the engine.

3.9.5 Testing data submittal. Upon completion of testing, the Contractor shall submit (as attachment to CFR) all data recorded during testing. This shall include the following:

• Operational logs during engine break-in, including electrical load information for SSDGs and EDGs.

• Complete Analysis report, including fuel demand curves and findings.

4. NOTES

4.1 Equipment operation. Coast Guard personnel will operate all shipboard machinery and equipment during all operational tests.

4.2 Coast Guard Inspector responsibilities. Although the Contractor is responsible for applying appropriate quality assurance measures, the Coast Guard will witness the accomplishment of these measures. Therefore, a Coast Guard Inspector will:

4.2.1 Monitor the assigned work items to keep informed of progress and to ensure that the specifications are being followed.

4.2.2 Witness all test as required by the specification.

4.2.3 Be guided by the work item and seek immediate clarification when necessary.

4.2.4 Immediately bring to the attention of the Availability Project Manager, Contracting Officer, Contracting Officer Technical Representative any work which appears to be contrary to the work item requirements.

4.2.5 Document all work performed in the Machinery History Log.

19 (Rev-0)

4.2.6 Ship’s force is responsible for post-overhaul verifications per Coast Guard instructions.

When there is overwhelming documentation to record. The Engineer Officer/Engineer Petty officer may state in the Machinery History Log, “All overhaul documentation is located (indicate where) for reference.

4.3 Definitions.

4.3.1 Tools - Common tools normally contained in a standard toolbox (screwdrivers, wrenches, pliers) etc.

4.3.2 Special Tools/Test Equipment - Such as torque wrenches, calibrated electronic meters, computer devices etc not normally found in a standard toolbox.

4.3.3 Consumables - A non-reusable item such as a rag, disposable gloves, paint, oil, grease, solvent, adhesive, sealant, corrosion preventive product, cleaner, jacket water, etc.

4.4 Contractor may purchase and install overhauled prime mover meeting all specifications in this work item. Contractor shall notify CG of intent. Contractor shall be responsible for all COR charges.

20 (Rev-0)