Attachment-1_34PB0803.docx

ATTACHMENT-1_34PB0803

1. SCOPE:

1.1. TITLE: Reconditioned Main Propulsion Diesel Engines (MPDEs); Brand: Cummins; Model: QSB 5.9L, Horse Power: 420; procure and configure

1.2. LOCATION:

1.2.1. Contractor Facility

1.3. IDENTIFICATION:

1.3.1. Quantity (one each); Port MPDE; Model: QSB 5.9L 425GS; Horse Power: 420; Manufacturer: Cummins; 6 Cylinder; Serial Number: 46917750; CPL: 8732

1.3.2. Quantity (one each); Starboard MPDE; Model: QSB 5.9L 425GS; Horse Power: 420; Manufacturer: Cummins; 6 Cylinder; Serial Number: 46917755; CPL: 8732

2. REFERENCES:

2.1. NAVSEA Standard Items (Current Fiscal Year)

2.2. QSB 5.9 380 & 425 HP (Current-Quick Serve On-Line) Service manual is a two part manual; P/N 4021271 & P/N 4021416

2.3. QSB 5.9 380 & 425 HP, Parts Manual. (Quick Serve On-Line updated parts manual per serial number)

2.4. S9AA0-AB-GOS-010/GSO, General Specifications for Overhaul of Surface Ships.

2.5. SUPSHIP San Diego Reference 276; Cleaning Procedures dated 18 April 1988.

2.6. T9074-AS-GIB-010/271, Requirements for Nondestructive Testing Methods.

2.7. MIL-STD-2035; Non-Destructive Testing Acceptance Criteria.

2.8. S9086-HB-STM-000/CH-233; NSTM, Diesel Engines.

2.9. BoatAlt 34PB/55B; Fuel Cooler Modification

2.10. BoatAlt GEN/55A; Cummins QSB-Series Engines-Starter Magnetic Switch Bracket Modification

2.10.1. DWG. No. 57311-180-5109418 REV A; Cummins QSB-Series Engines-Starter Magnetic Switch Bracket Modification (GEN/55A)

2.11. LAR 34PB-1312; 34PB Salt Water Pump Inlet Fitting Systemic High Failure Item

2.12. LAR 34PB-14123; Replacement Oil Lines On the Cummins 5.9L Engine

3. REQUIREMENTS:

3.1. Accomplish the Requirements of Ref 2.1 Section 009-90 Cummins OEM for all sections listed.

3.2. Contractor is responsible for all shipping costs of all materials including, secure storage, providing engine stands/shipping containers with adequate protection to ensure that material is not lost or damaged during transit or laydown for each MPDE listed 1.3.1 and 1.3.2 to and from the Diesel Engine OEM contractor’s facility.

3.2.1. All supplies, components, materials, tools and hardware necessary to accomplish the requirements of this task order, that are not specifically identified as GFM, shall be supplied by the contractor.

3.2.2. Contractor shall be responsible for all MPDE shipping costs (if required) including, but not limited to, providing engine stands/shipping containers with adequate protection to ensure that the engine is not damaged during transit.

3.2.3. Provide services and materials to properly remove and dispose of all engine oils, gear oils, and engine coolants.

3.3. Procure and install new (one each) reconditioned MPDE to replace MPDEs identified in section 1.3.1 and 1.3.2 with regards to provided S/N & CPL.

3.3.1. MPDEs shall be 24VDC including ECM 1.0 Smartcraft Architecture, to include wiring harnesses, SIM Cards and fuses using S/N & CPL provided in 1.3.1 and 1.3.2 IAW Ref (s) 2.2 and 2.3.

3.3.1.1. Template from existing, using S/N & CPL provided in 1.3.1 & 1.3.2, procure and install new 24VDC starter motors, starter motor magnetic switches, alternators

3.4. Fabricated Motor Mount Foundations; remove, template from existing from MPDEs identified in 1.3.1 and 1.3.2. Degrease, preserve, and install aboard reconditioned MPDEs including new mounting hardware IAW Ref (s) 2.2 and 2.3.

3.5. Procure and install new, engine belt guard assembly including cushion mounts and mounting hardware.

3.6. BoatAlt 34PB/55B; Fuel Cooler Modification, accomplish the requirements of Ref 2.9

3.7. BoatAlt GEN/55A; Cummins QSB-Series Engines-Starter Magnetic Switch Bracket Modification; accomplish the requirements of Ref 2.10

3.7.1. DWG. No. 57311-180-5109418; Cummins QSB-Series Engines-Starter Magnetic Switch Bracket Modification (GEN/55A), Ref 2.10.1

3.8. LAR 34PB-1312; 34PB Salt Water Pump Inlet Fitting Systematic High Failure Item; accomplish the requirements of Ref 2.11, 34PB Salt Water Pump Inlet Fitting Systemic High Failure Item.

3.9. LAR 34PB-14123; Replacement Oil Lines on the Cummins 5.9L Engine; accomplish the requirements of Ref 2.12

3.10. Special Configuration; Port Engine:

3.10.1. Pan, oil, front sump, Cummins P/N: 3958209; remove existing, procure and install new including required lube oil pick-up and all mounting hardware and gaskets.

3.10.2. Raw water cooling pump/HVAC Compressor mounting bracket; remove existing from MPDE identified in 1.3.1, and install on new procure MPDE IAW REF 2.2 and 2.3, including mounting hardware.

3.10.3. Air Conditioning fittings; remove existing materials from MPDE identified in 1.3.1, degrease, preserve, seal and install aboard reconditioned MPDE.

3.10.4. Oil Level Indication Dip Stick Assembly; procure and install new IAW REF 2.2 and 2.3. Oil level indication dip stick assembly shall be cylinder block mounted, calibrated WRT installation of front sump, shallow oil pans, and shall be installed on inboard side of MPDE IAW Oil Gauge Calibration IAW REF 2.3.

3.10.5. MPDE Vessel Adapter OEM Harness Extension; remove existing, procure new and install (1 each) Cummins P/N: 3999669, and (1 each) Terminating Resistors, Cummins P/N: 3972155 IAW REF 2.2 and 2.3.

3.11. Special Configuration; Starboard Engine:

3.11.1. Pan, oil, front sump, Cummins P/N: 3958209; remove existing, procure and install new including required lube oil pick-up and all mounting hardware and gaskets.

3.11.2. Oil Level Indication Dip Stick Assembly; procure and install new IAW REF 2.2 and 2.3. Oil level indication dip stick assembly shall be cylinder block mounted, calibrated WRT installation of front sump, shallow oil pans, and shall be installed on inboard side of MPDE IAW Oil Gauge Calibration IAW REF 2.3.

3.11.3. MPDE Vessel Adapter OEM Harness Extension; remove existing, procure new and install (1 each) Cummins P/N: 3999669, and (1 each) Terminating Resistors, Cummins P/N: 3972155 IAW REF 2.2 and 2.3.

3.12. Special Configuration; Port and Starboard Engine:

3.12.1. Procure new and install Propylene Glycol Coolant IAW original equipment manufacturer (OEM) specification.

3.12.2. Procure new, install and fill Engine to full mark with 15-40W oil specified IAW OEM specification for Oil Gauge Calibration IAW REF 2.3.

3.12.3. BoatAlt GEN/55A; Cummins QSB-Series Engines-Starter Magnetic Switch Bracket Modification; accomplish the requirements of REF 2.9

3.12.4. BoatAlt 34PB/55B; Fuel Cooler Modification; accomplish the requirements of REF 2.10

3.12.5. LAR 34PB-14123; Replacement Oil Lines on the Cummins 5.9L Engine; accomplish the requirements of REF 2.12

(V)(G) ‘Special Configurations’

3.13. Section(s) 3.0 thru 3.12 shall be accomplished and certified prior to accomplishment of section 3.14.

3.13.1. Submit legible copies, one in hard and one in electronic format, of a report listing the results of SECTION 3.13 to the SUPERVISOR within 24 hours of completion of test.

(V)(G) ‘Dynamometer Test’

3.14. Dynamometer Test: Perform dynamometer test; power output, MPDE’s pressures, and MPDE’s temperatures shall be monitored recorded to ensure engines are within the OEM specifications. OEM 009-90 shall be present with Cummins Insite Software; MPDE’s shall be delivered for installation and ready for unrestricted operation.

3.14.1. Submit legible copies, one in hard and one in electronic format, of a report listing the results of 3.14 to the SUPERVISOR within 24 hours of completion of test.

3.15. Post Dynamometer test sat and prior to the installation of the Port & Starboard MPDE’s into the craft all torques shall be verified and marked by the installing activity, Items such as pulleys, mounts, mounting foundations & flanges.

3.16. Provide services and materials to perform paint touch-up to each MPDE IAW manufacturer specifications.