RD_2815-01-423-4546.pdf

OVERHAUL DESCRIPTION

FOR OFFICIAL USE ONLY

ITEM NAME PARTS KIT,DIESEL ENGINE

STOCK NUMBER 2815-01-423-4546

PART NUMBER 40111777

USED ON WHEC 378 AND WAGB 420

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 REQUIREMENTS:

1.0. SCOPE:

1.1. This document sets forth the requirements for the exchange/purchase, packaging, packing, preservation, marking and shipping of Electro Motive Diesel (EMD) Blade and Fork Power Pack Kits for the EMD 8-567-RC POST-FRAM Diesel Engine onboard the U.S. Coast Guard (USCG) 378 foot High Endurance Cutter (WHEC).

1.2. Government Furnished Property (GFP) - The USCG reserves the right to provide, at its option, the following, to exchange, store and maintain:

1.2.1. Fork Power Pack Kit part number 40111777, NSN 2815-01-423-4546

1.2.2. Blade Power Pack Kit part number 40111778, NSN 2815-01-423-4752

2.0. APPLICABLE DOCUMENTS :

2.1. General - The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

2.2. Commercial Documents - The following documents form a part of this specification to the extent specified herein. The documents shall be the version listed by number and date from the referenced industry organization.

2.2.1. American Society for Quality (ASQ) Q90001-2008, dated 2008, Quality Management Systems-Requirements

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

2.3. Specification Order of Precedence - In the event of a conflict between the text of this specification and the references cited herein, the text of this specification shall take precedence. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0. REQUIREMENTS:

3.1. General - Upon receipt of a delivery order from the Coast Guard Contracting Officer, the Contractor shall exchange/purchase the specified quantities of EMD Blade and Fork Power Pack Kits.

3.1.1. The EMD Power Pack Kit, Unit Exchange (UTEX) shall be equipped with a Diamond 6 cylinder head, laser hardened upper bore liner, pre-stressed stainless steel top piston ring, resistance-hardened top piston ring groove, and tin-plated piston skirt.

3.1.2. The words "New" or "Utex" following the power pack component item name below are intended to indicate the origin of the item as delivered. A "Utex" designation indicates the Contractor may provide a unit exchanged/repaired/refurbished part. A "New" designation indicates that the Contractor shall provide a new part. All unit exchange parts provided shall be manufactured/exchanged/repaired/refurbished by EMD or an authorized distributor in accordance with EMD specifications, standards and technical requirements and shall meet the dimensional, material and performance specifications of an identical new EMD factory part.

3.1.3. Fork Power Pack Kit part number 40111777, NSN 2815-01-423-4546 shall include the following part numbers and quantities.

Qty Part # Description New/Utex 1 EA 9318833 Cylinder Liner Assembly New 1 EA 40109398 Cylinder Head Assembly Utex 1 EA 9572817 Piston New 1 EA 40077230 Piston Carrier Utex 1 EA 40077232 Piston Pin Utex 1 EA 40037114 Fork Connecting Rod Utex 1 EA 8442226 Bearing Insert New 1 EA 40102453 Thrust Washer New 1 EA 40082478 Ring Set New 1 EA 8059699 Snap Ring New 2 EA 8159340 Bolt ASM New 8 EA 8060089 Liner Nut New 8 EA 8059699 Liner Washer New 1 EA 40099569 Head Gasket New 1 EA 9583686 Installation Gasket Kit New 1 EA 40039256 Bolt Kit New 1 EA 40039257 Retainer Insert Bearing New

3.1.4. Blade Power Pack Kit part number 40111778, NSN 2815-01-423-4752 shall include the following part numbers and quantities.

Qty Part # Description New/Utex 1 EA 9318833 Cylinder Liner Assembly New 1 EA 40109398 Cylinder Head Assembly Utex 1 EA 9572817 Piston New 1 EA 40077230 Piston Carrier Utex 1 EA 40077232 Piston Pin Utex 1 EA 9569742 Blade Connecting Rod Utex 1 EA 8442226 Bearing Insert New 1 EA 40102453 Thrust Washer New 1 EA 40082478 Ring Set New 1 EA 8059699 Snap Ring New 2 EA 8159340 Bolt ASM New 8 EA 8060089 Liner Nut New 8 EA 8059699 Liner Washer New 1 EA 40099569 Head Gasket New

SHELF LIFE CD 0

1.0. SCOPE:

1.1. This document sets forth the requirements for the exchange/purchase, packaging, packing, preservation, marking and shipping of Electro Motive Diesel (EMD) Blade and Fork Power Pack Kits for the EMD 8-567-RC POST-FRAM Diesel Engine onboard the U.S. Coast Guard (USCG) 378 foot High Endurance Cutter (WHEC).

1.2. Government Furnished Property (GFP) - The USCG reserves the right to provide, at its option, the following, to exchange, store and maintain:

1.2.1. Fork Power Pack Kit part number 40111777, NSN 2815-01-423-4546

1.2.2. Blade Power Pack Kit part number 40111778, NSN 2815-01-423-4752

2.0. APPLICABLE DOCUMENTS :

2.1. General - The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

2.2. Commercial Documents - The following documents form a part of this specification to the extent specified herein. The documents shall be the version listed by number and date from the referenced industry organization.

2.2.1. American Society for Quality (ASQ) Q90001-2008, dated 2008, Quality Management Systems-Requirements

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

2.3. Specification Order of Precedence - In the event of a conflict between the text of this specification and the references cited herein, the text of this specification shall take precedence. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0. REQUIREMENTS:

3.1. General - Upon receipt of a delivery order from the Coast Guard Contracting Officer, the Contractor shall exchange/purchase the specified quantities of EMD Blade and Fork Power Pack Kits.

3.1.1. The EMD Power Pack Kit, Unit Exchange (UTEX) shall be equipped with a Diamond 6 cylinder head, laser hardened upper bore liner, pre-stressed stainless steel top piston ring, resistance-hardened top piston ring groove, and tin-plated piston skirt.

3.1.2. The words "New" or "Utex" following the power pack component item name below are intended to indicate the origin of the item as delivered. A "Utex" designation indicates the Contractor may provide a unit exchanged/repaired/refurbished part. A "New" designation indicates that the Contractor shall provide a new part. All unit exchange parts provided shall be manufactured/exchanged/repaired/refurbished by EMD or an authorized distributor in accordance with EMD specifications, standards and technical requirements and shall meet the dimensional, material and performance specifications of an identical new EMD factory part.

3.1.3. Fork Power Pack Kit part number 40111777, NSN 2815-01-423-4546 shall include the following part numbers and quantities.

Qty Part # Description New/Utex 1 EA 9318833 Cylinder Liner Assembly New 1 EA 40109398 Cylinder Head Assembly Utex 1 EA 9572817 Piston New 1 EA 40077230 Piston Carrier Utex 1 EA 40077232 Piston Pin Utex 1 EA 40037114 Fork Connecting Rod Utex 1 EA 8442226 Bearing Insert New 1 EA 40102453 Thrust Washer New 1 EA 40082478 Ring Set New 1 EA 8059699 Snap Ring New 2 EA 8159340 Bolt ASM New 8 EA 8060089 Liner Nut New 8 EA 8059699 Liner Washer New 1 EA 40099569 Head Gasket New 1 EA 9583686 Installation Gasket Kit New 1 EA 40039256 Bolt Kit New 1 EA 40039257 Retainer Insert Bearing New

3.1.4. Blade Power Pack Kit part number 40111778, NSN 2815-01-423-4752 shall include the following part numbers and quantities.

Qty Part # Description New/Utex 1 EA 9318833 Cylinder Liner Assembly New 1 EA 40109398 Cylinder Head Assembly Utex 1 EA 9572817 Piston New 1 EA 40077230 Piston Carrier Utex 1 EA 40077232 Piston Pin Utex 1 EA 9569742 Blade Connecting Rod Utex 1 EA 8442226 Bearing Insert New 1 EA 40102453 Thrust Washer New 1 EA 40082478 Ring Set New 1 EA 8059699 Snap Ring New 2 EA 8159340 Bolt ASM New 8 EA 8060089 Liner Nut New 8 EA 8059699 Liner Washer New 1 EA 40099569 Head Gasket New

1 EA 9583686 Installation Gasket Kit New 1 EA 40039256 Bolt Kit New 1 EA 40039257 Retainer Insert Bearing New

3.1.5. Receipt- Upon receipt of USCG owned EMD Blade and Fork Power Pack Kits from the manufacturer (or supplied as GFP), the Contractor shall implement the following steps:

a. Stage in a predetermined area

b. Validate material to ensure count and identification matches documentation attached i.e.; purchase order/contract number, shipping documents.

1. This shall include an itemized listing of each item by part number and quantity contained in each Blade and Fork Power Pack Kit.

c. Visually inspect for in-transit damage. If a discrepancy is found, notify USCG SFLC immediately upon discovery (a point of contact (POC) will be provided upon contract award).

d. Submit receipt confirmation via e-mail to the USCG SFLC within 3 days of receipt (a POC will be provided upon contract award).

3.2. Reports - The Contractor shall provide an annual audit of material and an inventory listing of stock on hand to the USCG Inventory Accuracy POC no later than 01 July of each year (a POC will be provided upon contract award).

3.3. Inspections - The Contractor shall allow on-site inspections of all USCG stock by SFLC representatives at any time during the contract period.

3.4. Release - The release of USCG owned material is only authorized upon receipt of a DD-1348 (Material Release Order) from the SFLC Item Manager.

4.0. QUALITY ASSURANCE

4.1. Records - The Contractor shall maintain records of all inspections and tests. The records, at a minimum, shall indicate the nature and number of observations made, the number and type of deficiencies found, and the corrective action taken.

4.2. Responsibility for Compliance - All items shall meet the provisions of sections 3 & 5 of this specification. The inspections set forth in this specification shall become part of the Contractor's overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the Contractor of the responsibility of assuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

4.3. Quality System - The Contractor shall maintain an inspection system which shall insure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements in accordance with section

2.2.1. of this specification. The inspection system shall be documented and available for review by the Coast Guard.

4.4. Tests & Inspections - The inspections/tests required here and in the appropriate subsection in section 3.0. of this specification, are the minimum required and are not intended to supplant any controls, examination, inspections or tests normally employed by the Contractor to assure the quality of the item in question.

5.0. PRESERVATION, PACKAGING, PACKING, MARKING & SHIPPING:

5.1. Preservation - Each Blade and Fork Power Pack Kit shall be preserved to prevent rust and corrosion during storage at the Contractor's facility, during transit by common carrier and short term storage (60 days) in a non-climate controlled facility.

5.2. Packaging and Packing - Each Blade and Fork Power Pack Kit shall be packaged and packed in an EMD metal reusable shipping container specifically made for this purpose. Each individual part contained in the kit shall be secured and cushioned as necessary, inside the metal shipping container, to prevent damage during multiple shipments by common carrier.

5.2.1. Each metal shipping container shall be securely attached to and supported on a skid mounted base, in the upright position, in a manner that would prevent it from being tipped over during multiple shipments via common carrier.

5.3. Marking - Each preserved, packed and packaged Blade and Fork Power Pack Kit reusable metal shipping container shall be neatly stenciled on two sides with 3/4 inch white painted characters on a blue contrasting background.

All previous markings and stenciling shall be removed from the reusable shipping container prior to the application of any new markings.

Stock Number: See contract delivery order Item Name: See contract delivery order Part Number: See contract delivery order Serial Number: As per name plate data Contract Number: Furnished at time of award Delivery Order: Furnished for each individual delivery order Shipping Weight: "As determined" Date Shipped: "Furnished by the Contractor" Unit of Issue: 1 Kit Coast Guard SFLC Material - Condition "A" Reusable Shipping Container, Do Not Destroy "This Side Up" with a corresponding arrow pointing up

5.4. Shipping - Coordinate the exact date and time for pick-up with the designated shipping agent within five (05) calendar days after receipt of the Commercial Bill of Lading (CBL). Note: The SFLC Transportation Office will

1 EA 9583686 Installation Gasket Kit New 1 EA 40039256 Bolt Kit New 1 EA 40039257 Retainer Insert Bearing New

3.1.5. Receipt- Upon receipt of USCG owned EMD Blade and Fork Power Pack Kits from the manufacturer (or supplied as GFP), the Contractor shall implement the following steps:

a. Stage in a predetermined area

b. Validate material to ensure count and identification matches documentation attached i.e.; purchase order/contract number, shipping documents.

1. This shall include an itemized listing of each item by part number and quantity contained in each Blade and Fork Power Pack Kit.

c. Visually inspect for in-transit damage. If a discrepancy is found, notify USCG SFLC immediately upon discovery (a point of contact (POC) will be provided upon contract award).

d. Submit receipt confirmation via e-mail to the USCG SFLC within 3 days of receipt (a POC will be provided upon contract award).

3.2. Reports - The Contractor shall provide an annual audit of material and an inventory listing of stock on hand to the USCG Inventory Accuracy POC no later than 01 July of each year (a POC will be provided upon contract award).

3.3. Inspections - The Contractor shall allow on-site inspections of all USCG stock by SFLC representatives at any time during the contract period.

3.4. Release - The release of USCG owned material is only authorized upon receipt of a DD-1348 (Material Release Order) from the SFLC Item Manager.

4.0. QUALITY ASSURANCE

4.1. Records - The Contractor shall maintain records of all inspections and tests. The records, at a minimum, shall indicate the nature and number of observations made, the number and type of deficiencies found, and the corrective action taken.

4.2. Responsibility for Compliance - All items shall meet the provisions of sections 3 & 5 of this specification. The inspections set forth in this specification shall become part of the Contractor's overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the Contractor of the responsibility of assuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

4.3. Quality System - The Contractor shall maintain an inspection system which shall insure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements in accordance with section

2.2.1. of this specification. The inspection system shall be documented and available for review by the Coast Guard.

4.4. Tests & Inspections - The inspections/tests required here and in the appropriate subsection in section 3.0. of this specification, are the minimum required and are not intended to supplant any controls, examination, inspections or tests normally employed by the Contractor to assure the quality of the item in question.

5.0. PRESERVATION, PACKAGING, PACKING, MARKING & SHIPPING:

5.1. Preservation - Each Blade and Fork Power Pack Kit shall be preserved to prevent rust and corrosion during storage at the Contractor's facility, during transit by common carrier and short term storage (60 days) in a non-climate controlled facility.

5.2. Packaging and Packing - Each Blade and Fork Power Pack Kit shall be packaged and packed in an EMD metal reusable shipping container specifically made for this purpose. Each individual part contained in the kit shall be secured and cushioned as necessary, inside the metal shipping container, to prevent damage during multiple shipments by common carrier.

5.2.1. Each metal shipping container shall be securely attached to and supported on a skid mounted base, in the upright position, in a manner that would prevent it from being tipped over during multiple shipments via common carrier.

5.3. Marking - Each preserved, packed and packaged Blade and Fork Power Pack Kit reusable metal shipping container shall be neatly stenciled on two sides with 3/4 inch white painted characters on a blue contrasting background.

All previous markings and stenciling shall be removed from the reusable shipping container prior to the application of any new markings.

Stock Number: See contract delivery order Item Name: See contract delivery order Part Number: See contract delivery order Serial Number: As per name plate data Contract Number: Furnished at time of award Delivery Order: Furnished for each individual delivery order Shipping Weight: "As determined" Date Shipped: "Furnished by the Contractor" Unit of Issue: 1 Kit Coast Guard SFLC Material - Condition "A" Reusable Shipping Container, Do Not Destroy "This Side Up" with a corresponding arrow pointing up

5.4. Shipping - Coordinate the exact date and time for pick-up with the designated shipping agent within five (05) calendar days after receipt of the Commercial Bill of Lading (CBL). Note: The SFLC Transportation Office will contract the shipment of Blade and Fork Power Pack Kits to the end user and provide a CBL to the Contractor.

5.4.1. Ensure proper documents, including the Material Release Order (MRO), are securely attached to each Blade and Fork Power Pack Kit prior to departure from the Contractor's facility.

5.4.2. Forward copies of all shipping documents and tracking information to the designated USCG SFLC point of contact.

6.0. NOTES

6.1. Commercial Documents

6.1.1. American Society for Testing & Materials (ASTM)

1916 Race Street Philadelphia PA. 19103-1187 215-299-5585

FAX 215-977-9679

www.astm.org

6.1.2. American Society for Quality (ASQ)

P.O. Box 3005 Milwaukee, WI 53201-3005 800-248-1946 www.asq,org

WARRANTY:

X A. Standard Manufacturer's Warranty

B. Item being repaired as an "onboard repair" or a "system stock" item and will be put into inventory. NOT FOR IMMEDIATE INSTALLATION.

Contractor must guarantee item against defects that lead to failure for days after installation for a period of up to two (2) years after delivery to Coast Guard.

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 and marking requirements.

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 and marking requirements.

PACKAGING AND MARKING FOR SHIPMENT:

X

A. Each unit shall be packed individually in it's own wooden box which shall be capable of providing adequate protection to the item during multiple shipments. Mark each box in legible black print lettering with the following information:

NATIONAL STOCK NUMBER

ITEM NAME

PART NUMBER

GOVERNMENT ORDER NUMBER

2815-01-423-4546

PARTS KIT,DIESEL ENGINE

40111777

PRESERVATION / PACKAGING:

A. Each unit shall be individually preserved and wrapped for protection against deterioration for a period of two (2) years minimum.

X B. See Attachments

B. See Attachments

And the words: "Coast Guard SFLC Material, Condition "A"

RECOMMENDED SOURCES:

WRITTEN BY:

DATE :

BRANDON ANDREWS

02 JUN 17

Cost Estimate for Overhaul NOT TO EXCEED: