FINAL PWS.DOCX

Performance Work Statement (PWS) For Caterpillar 3456 Engine Overhaul and SR4B Alternator and Refurbishment January 7, 2021

Prepared by:

Albert Lyou – Mechanical Engineer Generator/ECO Special Operations Branch C5ISR Center, Product Realization Directorate (PRD) U.S. Army Combat Capabilities Development Command

1.0. Scope. This Performance Work Statement (PWS) defines the efforts required to render the services required by this solicitation in accordance with the documents listed below. The services being purchased are entitled “Caterpillar 3456 Engine Overhaul and SR4B Alternator Refurbishment”. This is a requirement to provide: manufacturing-specific overhaul of Caterpillar (CAT) 3456 diesel engines in all aspects to manufacturer warranty-level quality; the assembly and disassembly, physical and mechanical inspection, cleaning, maintenance, electrical load testing, and refurbishment of IPS Caterpillar SR4B alternators; the testing and validation of the complete power pack, packaging of the finished power pack; and shipment of the power pack. A “power pack” is the paired combination of a single CAT 3456 Engine and a single SR4B Alternator. Overhauls will be completed in accordance with the manufacturer’s specification. Overhauls will include engine/alternator decoupling and recoupling, engine disassembly, engine reassembly, cleaning of components, inspection of engines, disassembly and reassembly of alternators, physical and mechanical inspection of alternators, cleaning of alternators, maintenance of alternators, electrical testing of alternators, and refurbishment (dip and bake) of alternators.

Note: Alternator and generator are interchangeable terms used to reference the SR4B.

Packaging: The completed power packs will be packaged so that every component is secured and contained within a completely enclosed wooden crate capable of being reused and used for overseas shipment. All fasteners shall be of a thread type and capable of removal and reuse. All lumber/plywood used will be pressure treated (outdoor rated). All carriage bolts, screws, lag screws and associated nuts and washers will be outdoor rated. Screws (1 ¾” long) will be used to construct each component (i.e base, end, side, top). Lag screws (3/8” diameter, 4” long) with correct washers will be used to assembly the components together. All carriage bolts will have the appropriate nuts and washers included.

Shipping and Receiving: The contractor will pick up power packs identified for rebuild from Letterkenny Army Depot (LEAD), at 1 Overcash Avenue, Chambersburg, PA 17201, ATTN: DOCK 2, W90CGJ. Upon completion of the complete overhaul and refurbishment, testing and validation, and packaging, the contractor will deliver overhauled power packs back to LEAD. All contractors must include transportation costs as part of the quote. Contractors must complete the overhaul of each power pack in 45 working days, not including shipping time.

2.0. Applicable Documents. The following documents are applicable to the extent cited.

2.1. Reference Manuals

A. Service Manual SR4B SENR5359 01; ANSI/NETA MTS 2015 B. CAT Cleaning and Drying of Electric Set Generators SEHS 9124 C. Generator Service Manual – SENR5359

2.2. List of Contract Data Requirements Lists (CDRLs)

CDRL/

Data Item

3.0. Requirements. The items being serviced herein:

Engine & Alternator

Power Packs

The contractor shall provide all personnel, equipment, supplies, facilities, tools, materials, and other items necessary to overhaul, validate, and ship CAT 3456 engines, IPS (CAT) SR4B Alternators, and a complete “turn-key” power pack as defined in this Performance Work Statement. The Contractor shall perform to the standards in this contract.

These requirements listed may be expanded by mutual agreement between the Government and the Contractor by modification to the contract.

3.1 Receiving: Upon notification from ILSC PED, the contractor shall pick up the power packs identified for overhaul and refurbishment within seven business days from Letterkenny Army Depot (LEAD), at 1 Overcash Avenue, Chambersburg, PA 17201, ATTN: DOCK 2, W90CGJ. The contractor will identify their own logistic channel for delivery to and from LEAD (W90CGJ).

3.2 Pre-Shop Testing and Inspection: Upon receipt of a power pack provided for overhaul and refurbishment, the contractor shall perform an Initial Pre-Shop Test & Inspection (T&I) to determine the actions and costs necessary to return the item(s) to serviceability if the unit is not found to be in an acceptable state for overhaul and refurbishment. The contractor shall prepare and submit a Pre-Shop T&I Report to the Government IAW CDRL Exhibit A001. Units must be considered serviceable to begin the overhaul and refurbishment process.

3.3 Power Pack Decoupling/Recoupling: The Contractor shall pick up the power pack from LEAD (W90CGJ), with the engine and alternator still connected to each other. The contractor is responsible for decoupling the alternator from the engine prior to the performance of the overhauls and refurbishments. After completion of the services, the contractor will be responsible for recoupling the alternator to the engine prior to testing and crating.

3.4 Engine Disassembly/Reassembly: The Contractor shall be responsible for all assembly and disassembly inherent in performance of the cleaning, inspections, maintenance, and overhaul of engines. The ECM will be reset for zero (0) hours.

3.5 Engine Component Replacement: The Contractor shall at the minimum, replace the following items during the overhaul using Original Equipment Manufacturer (OEM) components from the manufacturer or acceptable alternative approved by Caterpillar:

· Cylinder liners

· Piston skirts

· Piston crowns

· Piston rings

· Cylinder head

· Thermostats

· Main bearings

· Rod bearings

· All front gear bearings

· Thrust plates

· Fuel injectors

· Turbo charger

· Water pump

· Oil pump

· All seals and gaskets

· Oil and fuel filters

· Any other component deemed out of tolerance IAW CAT specifications.

3.6 Alternator Assembly/Disassembly: Contractor shall be responsible for all assembly and disassembly inherent in performance of the cleaning, inspections, electrical testing, maintenance, and refurbishment (dip and bake) of alternators. The IPS Enduraseal process must remain intact.

3.7 Physical and Mechanical Inspection: The Contractor shall inspect the physical and mechanical condition of alternator housing, bolting connections, anchorage, alignment, grounding, rectifiers, all components of the rotating field assembly (RFA), main armature, terminal leads, bearing, cables, and space heaters. (Reference: Service Manual SR4B SENR5359-01; ANSI/NETA MTS-2015)

3.8 Cleaning: The Contractor shall perform “as found” test(s) to determine the condition of insulation (see also Section 3.10 “Electrical Testing”). Cleaning will be performed to remove all contaminants such as dirt, grease, salt, or oil. Cleaning will be accomplished either by washing with an approved solvent IAW manufacturer’s directions or with steam cleaning when justified by dirty and greasy windings. Windings shall be oven dried after cleaning. After the windings and insulation have dried, the windings should be “dipped and baked” in a suitable varnish. (Reference: CAT Cleaning and Drying of Electric Set Generators SEHS 9124).

3.9 Maintenance: The Contractor shall be responsible for checking and balancing the rotor, replacing the main rotor bearing, installing the complete rectifier and heat sink assembly, machine work to refurbish the ODE bearing housing, inspect PM exciter stator, identify any broken parts. Paint the alternator to match as closely as possible the original color (Caterpillar Yellow).

3.10 Electrical testing: Each alternator shall be tested in its “as found” and “as left” (i.e., after refurbishment) conditions. Test values will be adjusted for temperature and humidity IAW ANSI/NETA 2015 MTS standards. Testing results shall be submitted IAW CDRL Exhibit B001, DI-MISC-80711A.

3.11 Enduraseal Coils: The SR4B alternators each must have fully functioning Enduraseal Coils. Should the contractor receive an alternator with faulty Enduraseal Coils, the contractor will have to provide a cost estimate for repairs IAW CDRL Exhibit A001, DI-NDTI-80809B.

3.12 Power Pack Break-in Load Test: The Contractor shall perform a power pack break-in and load test on the complete power pack as a complete system on JP8 fuel. If the power pack break-in and load test is not performed on a MEP-810 chassis with all of its’ parasitic load present, then the procedure MUST include the 34 kW (46 bhp) consumed by the hydraulic pump at ALL points during the test. The report shall be submitted IAW CDRL Exhibit C001, DI-MISC-80711A.

3.13 Power Pack Crating: The completed power packs shall be packaged so that every component is secured and contained within a completely enclosed wooden crate capable of being reused for repeated shipment. All fasteners shall be of a thread type and capable of removal and reuse. All lumber/plywood used will be pressure treated (outdoor rated). All carriage bolts, screws lag screws and associated nuts and washers will be outdoor rated. Screws (1 ¾” long) will be used to construct each component (i.e base, end, side, top). Lag screws (3/8” diameter 4” long) with correct washes will be used to assemble the components together. All carrier bolts will have the appropriate nuts and washers included.

3.14 Warranty: Overhauled engines shall be warrantied against failure for one year starting from the date of return to Government, or 1000 operating hours. All refurbished Alternators will be warrantied for 5 years, from the date of return to the Government.

3.15 Shipping: The contractor shall pick up power packs identified for overhaul and refurbishment from LEAD (W90CGJ). Upon completion of the complete overhaul and refurbishment, testing, validation, and packaging, the contractor will deliver completed power packs back to LEAD. Contractors must complete the overhaul and refurbishment of a single power pack in 45 working days, not including shipping time to and from LEAD (W90CGJ).

3.16 Storage: The Contractor shall be able to store the power packs in various modes of operation between three to six months. The contractor shall submit quarterly inventory reports IAW CDRL Exhibit D001, DI-MGMT-82128.

3.17 Inventory: The Contractor shall submit annual inventory reports IAW CDRL Exhibit D002, DI-MGMT-80441C.

4.0. Government Furnished Equipment.

4.1 Introduction

A. Army Materiel Command (AMC) and its units use Total Asset Visibility – Contractor (TAV-C) capability in its Logistics Management Program (LMP) to account for Government Furnished Equipment, Materiel, or Property (GFE/M/P) placed in the possession of contractors to support contracts for: 1) repair, modification, or upgrade work; 2) materials held for Stock, Store and Issue (SSI), or 3) New Production. Accounting records within LMP for this inventory are subject to verifying physical inventories and audits by the Army to ensure accuracy. This section addresses contractor requirements for repair, modification and/or upgrade contracts.

4.2 System Overview and Portal Access Requirements

A. To use TAV-C, Contractors shall request one of two TAV-C access methods below to exchange required inventory data with LMP: 1) Defense Logistics Management Standards (DLMS) interface or 2) the Army TAV-C Portal. Approval of the contractor’s access method will be based first on the type of work being performed, second, the sufficiency of the contractor’s existing property accountability and connectivity to LMP, and third, request by the to use the portal based on economic factors.

B. Contractors can choose between the two methods for accounting for government property as further described below:

1. Defense Logistics Management Standards (DLMS) interfaces: Contractors that have accounting systems capable of using a DLMS interface (see: DLM 4000.25, Defense Logistics Management Standards (DLMS) on the Defense Logistics Agency (DLA) website) shall request to use their accounting system and interface to account for Government Furnished Equipment/Materiel/Property (GFE/M/P) using DLMS transactions.

NOTE: If a contractor does not currently have an established DLMS interchange with Defense Logistics Agency (DLA) Defense Automated Addressing System (DAAS), it will be the contractor’s responsibility to contact DAAS to establish access to DAAS messaging system to support the exchange of DLMS transactions with the Army. DAAS provides a value added service for standard Military Standards (MILS) transactions providing the ability to receive, edit and route logistics transactions for the Military Services and Federal Agencies. Information on DAAS can be found at https://www.dla.mil/HQ/InformationOperations/DAAS/

2. Army TAV-C Portal: Contractors who are determined to be allowed to use the TAV-C Portal, will comply with prescribed processes to provide qualified workers to access the system to exchange data with LMP.

C. Portal Access Requirements. Contractor personnel who input data into the TAV-C Portal, must meet qualification requirements specified in the TAV-C Portal Guide Detailed Procedures and requirements are detailed in the TAV-C Portal Guide. These requirements include:

1. Contractor provided computer system: The contractor shall provide a computer system and internet connectivity that meets acceptable standards as identified in the TAV-C Portal Guide.

2. Security Requirements.

(a) The government requires contractor personnel accessing the LMP system to possess either a United States Government Common Access Card (CAC) or a Department of the Defense approved External Certification Authority (EAC). To apply for these credentials, contractor personnel must possess a soft certification from a security credentialing firm.

(b) Contractors will coordinate with the Contracting Officer’s Representative or designated government representative to complete required forms to obtain the CAC/EAC. This will require the above certification, forms of identification, etc.

3. User Training Requirements: TAV-C Portal user training is government provided and varies by the function performed. The training is online and completion of the training by each operator is required before accessing and using TAV-C.

4. The on-line training site will be provided by the government after award and access to the system has been granted. Functional training required to begin work should take no more than 15 hours to complete.

D. Problem Resolution: LMP is a government owned and maintained system. The contractor shall notify the COR or designated government point of contact for system related issues and government resolution.

4.3 DLMS Transactions / Portal Data Requirements

A. For DLMS Transactions for repair, modification and/or upgrade contracts, the inventory management transactions to be provided to the government by DLMS interface are:

1. DLMS 527R Materiel Receipt Acknowledgement (MRA) Transactions (for GFM expected to be consumed).

The material receipt transactions to be provided to the contractor by the government via the DLMS interface are:

1. DLMS 527D Pre-positioned Material Receipt Document for stock in-transit to vendor.

B. Army TAV-C Portal: Contractors who are allowed to use the TAV-C Portal to exchange required data directly with LMP, will provide the following information via data inputs to LMP.

1. TAV-C Portal Requirements: Details on entry of the input into the LMP Portal will be provided as part of the government provided training.

2. The required data will be based upon the business process being performed. Inputs and input formats will be driven by the role performed for this work as directed in the contract.

3. The LMP Portal will provide to the contractor reports which will serve to inform the contractor and aid in work performance. Details on the various reports and how they can be used will be covered as part of the government provided LMP Portal training.

C. Consumption Reporting: Quarterly reports on the consumption of Government Furnished Material (GFM) will be provided to the government IAW CDRL exhibit D001, DI-MGMT-82128.