Overhaul Description 7692.pdf

OVERHAUL DESCRIPTION

FOR OFFICIAL USE ONLY

ITEM NAME PARTS KIT,CYLINDER HEAD,DIESEL ENGINE

STOCK NUMBER 2815-01-653-7692

PART NUMBER WDI002093-001

USED ON CGC HEALY

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 receipt, disassembly, inspections, condition/test reports, overhaul/repair, reassembly, testing, preservation, packaging, packing, and marking of Cylinder Heads with start air valves used on USCG Cutter HEALY.

1.2 Government Furnished Property

NSN Part Number Nomenclature 2815-01-653-7692 WDI002093-001 Cylinder Head, W/Start Air Valve

1.2.1 The Contractor shall immediately notify the Coast Guard Contracting Officer if the make, model or part number delivered for overhaul does not conform to the cylinder head cited above.

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

2.3. Government Documents - The following specifications and standards form a part of this specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the current Department of Defense Single Stock Point of Specification and Standards (DODSSP) and supplements thereto.

2.3.1 MIL-PRF-16173E(SH) W/Int. Amendment 1, dated 09/07/2006, Corrosion preventive compounds, solvent cutback, cold-application

2.3.2 MIL-PRF-131K, dated 08/18/2005, Barrier Materials, Water vapor proof, Greaseproof, Flexible, Heat-Sealable

2.3.3 MIL-STD-2073-1E w/Change4, Standard Practice for Military Packaging;

dated 04/22/2019

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

2.4.1 National Conference of Standards Laboratories (NCSL) Z540-3-2006, dated 2006, Requirement for the Calibration of Measuring and Test Equipment.

2.4.2 American Society for Quality (ASQ) Q90001-2015, dated 22015, Quality Management Systems-Requirements

2.4.3 American Society for Testing & Materials (ASTM) D3951-18, dated 2018, Standard Practice for Commercial Packaging

2.4.4 American Society for Testing & Materials (ASTM) D6880/D6880M-11, dated 2011, Standard Specification for Wood Boxes

2.4.5 Steel Structure Painting Council, SSPC-SP 3, Power Tool Cleaning

2.4.6 ISPM-15 Regulation of Packaging Material in International Trade; Dated

2.4.7 ISO/IEC 16388:2017- Automatic Identification and Data Capture Techniques-Code 39 Bar Code Symbology Specification

2.4.8 SAE-AMS-STD-595 Colors Used in Government Procurement, 2/14/2017

3.0 REQUIREMENTS

3.1 The Contractor shall receive, inspect and overhaul Government furnished Cylinder Heads with starting valve option. It is the intent of the Government to return these Cylinder Heads to a like-new condition. The overhaul requirements described herein are considered the minimum necessary and are not intended to replace any procedures, controls, examinations, or tests normally employed by the Contractor to assure the quality of the product.

3.2 The Contractor shall disassemble and conduct a Condition Found inspection of the cylinder head in accordance with the OEM procedures, specifications, references, and standard practices to determine the total estimated cost to repair the cylinder head including labor, materials, testing, preservation, packaging, packing, and marking.

3.2.1 Based on the findings from the Condition Found inspection, the Contractor shall prepare an individual Condition Found Report (CFR) detailing the condition of each cylinder head to be repaired. The CFR shall include, but not limited to, the following:

3.2.1a.The part number, NSN, and serial number of the cylinder head;

3.2.1.b. The contract number and delivery order number for each cylinder head;

3.2.1.c. A listing of individual (Mandatory & Contingency) parts by part number, cost, and quantity;

3.2.1.d. At a minimum, mandatory replacement parts shall include all bushings, seals, and gaskets. All parts that are worn, have an improper fit and or damaged beyond the OEM tolerances, shall be repaired or replaced as determined by the Contractor.

3.2.1.e. A listing of the labor hours and labor rate to perform the overhaul, testing, and preservation, packaging, packing, and marking (PPP&M).

3.2.1.f. It is assumed that the cylinder head will arrive in a re-usable container. The Contractor shall conduct a thorough inspection of the shipping crate to ascertain any needed repairs up to and including a complete replacement of the shipping container. If the as received condition allows for re-use with minimal repairs, the Contractor shall confirm that the shipping crate and packaging conforms to the Phyto-sanitary Requirements for Wood Packaging Material (WPM) in accordance with paragraph 2.4.6.

3.2.1.g. Comments, if any, pertaining to any unusual observations during inspection and disassembly.

3.2.1.h. The Contractor shall inspect a cylinder head to determine if the cylinder head is beyond economical repair (BER). The Contractor shall notify, via email, the Contracting Officer and COR within the CFR with the

SHELF LIFE CD 0

1.0 SCOPE

1.1 This document sets forth the requirements for the receipt, disassembly, inspections, condition/test reports, overhaul/repair, reassembly, testing, preservation, packaging, packing, and marking of Cylinder Heads with start air valves used on USCG Cutter HEALY.

1.2 Government Furnished Property

NSN Part Number Nomenclature 2815-01-653-7692 WDI002093-001 Cylinder Head, W/Start Air Valve

1.2.1 The Contractor shall immediately notify the Coast Guard Contracting Officer if the make, model or part number delivered for overhaul does not conform to the cylinder head cited above.

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

2.3. Government Documents - The following specifications and standards form a part of this specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the current Department of Defense Single Stock Point of Specification and Standards (DODSSP) and supplements thereto.

2.3.1 MIL-PRF-16173E(SH) W/Int. Amendment 1, dated 09/07/2006, Corrosion preventive compounds, solvent cutback, cold-application

2.3.2 MIL-PRF-131K, dated 08/18/2005, Barrier Materials, Water vapor proof, Greaseproof, Flexible, Heat-Sealable

2.3.3 MIL-STD-2073-1E w/Change4, Standard Practice for Military Packaging;

dated 04/22/2019

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

2.4.1 National Conference of Standards Laboratories (NCSL) Z540-3-2006, dated 2006, Requirement for the Calibration of Measuring and Test Equipment.

2.4.2 American Society for Quality (ASQ) Q90001-2015, dated 22015, Quality Management Systems-Requirements

2.4.3 American Society for Testing & Materials (ASTM) D3951-18, dated 2018, Standard Practice for Commercial Packaging

2.4.4 American Society for Testing & Materials (ASTM) D6880/D6880M-11, dated 2011, Standard Specification for Wood Boxes

2.4.5 Steel Structure Painting Council, SSPC-SP 3, Power Tool Cleaning

2.4.6 ISPM-15 Regulation of Packaging Material in International Trade; Dated

2.4.7 ISO/IEC 16388:2017- Automatic Identification and Data Capture Techniques-Code 39 Bar Code Symbology Specification

2.4.8 SAE-AMS-STD-595 Colors Used in Government Procurement, 2/14/2017

3.0 REQUIREMENTS

3.1 The Contractor shall receive, inspect and overhaul Government furnished Cylinder Heads with starting valve option. It is the intent of the Government to return these Cylinder Heads to a like-new condition. The overhaul requirements described herein are considered the minimum necessary and are not intended to replace any procedures, controls, examinations, or tests normally employed by the Contractor to assure the quality of the product.

3.2 The Contractor shall disassemble and conduct a Condition Found inspection of the cylinder head in accordance with the OEM procedures, specifications, references, and standard practices to determine the total estimated cost to repair the cylinder head including labor, materials, testing, preservation, packaging, packing, and marking.

3.2.1 Based on the findings from the Condition Found inspection, the Contractor shall prepare an individual Condition Found Report (CFR) detailing the condition of each cylinder head to be repaired. The CFR shall include, but not limited to, the following:

3.2.1a.The part number, NSN, and serial number of the cylinder head;

3.2.1.b. The contract number and delivery order number for each cylinder head;

3.2.1.c. A listing of individual (Mandatory & Contingency) parts by part number, cost, and quantity;

3.2.1.d. At a minimum, mandatory replacement parts shall include all bushings, seals, and gaskets. All parts that are worn, have an improper fit and or damaged beyond the OEM tolerances, shall be repaired or replaced as determined by the Contractor.

3.2.1.e. A listing of the labor hours and labor rate to perform the overhaul, testing, and preservation, packaging, packing, and marking (PPP&M).

3.2.1.f. It is assumed that the cylinder head will arrive in a re-usable container. The Contractor shall conduct a thorough inspection of the shipping crate to ascertain any needed repairs up to and including a complete replacement of the shipping container. If the as received condition allows for re-use with minimal repairs, the Contractor shall confirm that the shipping crate and packaging conforms to the Phyto-sanitary Requirements for Wood Packaging Material (WPM) in accordance with paragraph 2.4.6.

3.2.1.g. Comments, if any, pertaining to any unusual observations during inspection and disassembly.

3.2.1.h. The Contractor shall inspect a cylinder head to determine if the cylinder head is beyond economical repair (BER). The Contractor shall notify, via email, the Contracting Officer and COR within the CFR with the recommendation that the cylinder head is BER. Final determination of BER will be made by the KO. If the cylinder head is determined BER, the Government may purchase an identical new cylinder head from the Contractor on a separate order.

3.2.1.i. The cost of an identical new cylinder head, if a cylinder head is determined beyond economical repair.

3.3 Submit CFR-The Contractor shall submit a CFR with digital pictures showing the condition of the cylinder head and cylinder head parts. The CFR shall also have a repair plan that outlines proposed repairs to the Contracting Officer and Contracting Officer's Representative for review and approval, when applicable.

3.4 Overhaul Cylinder Head-The Contractor shall overhaul the Government furnished cylinder head including the start air valve with new OEM parts, replacing all parts cited as mandatory in paragraph 3.4.4. Commercial parts (materials), not manufactured by the OEM, such as seals, ball/roller type bearings, and couplings are acceptable but the Contractor shall identify them by their markings or through the use of the technical manual for identification purposes?. Commercial parts such as seals, ball/roller type bearings, and couplings are generally interchangeable between different manufacturers and may be substituted for cylinder head repairs as long as they are equal in all respects. Only in the case where the part cannot be identified shall it be ordered directly through the OEM and by their part number. Cylinder head parts that are reclaimed, recycled, or aftermarket are not acceptable and shall not be used.

3.4.1.a Remove Existing Paint: All surface coatings shall be removed. The Cylinder Head shall be mechanically cleaned by hand Tool Cleaning SSPC-SP2 (SSI-St3), Power Tool Cleaning SSPC-SP3 (SSI-St3), White Metal Blast SSPC-5 (SSI-Sa3) or Commercial Blast SSPC-SP6 (SSI-Sa2). An equal method of paint removal is acceptable where power tool cleaning may pose a risk of damage to internal components.

3.4.2.b Paint Cylinder Head: The Cylinder Head shall be painted with primer and finish coats of paint (excluding flange faces, internal surfaces). The base coat (primer) shall be a high build epoxy 5.0-6.0 mils dry film thickness (DFT) compatible with the finish coat. The finish coat shall be in accordance with MIL-PRF-24635 Silicone Alkyd, Type II Class 1, 2.0-3.0 mils DFT. The color shall be machinery gray, color number 16307 (or match the OEM color, Sulzer Green), in accordance with paragraph 2.2.3. Total paint thickness shall be 7.0-9.0 mils DFT.

3.4.3 Test Cylinder Head- All testing shall be accomplished on contractor supplied calibrated test equipment. If an item fails, it shall be repaired and re-tested as necessary until a successful test is achieved. All repairs and tests shall be in accordance with OEM specifications. After completion of an overhaul the Contractor shall, at a minimum, conduct the following described tests.

3.4.3.a Valve Seat visual inspection and NTD.

3.4.3.b Hydrostatic test.

3.4.3.c Assembly Tolerances and Clearances

3.4.4 Mandatory Parts- The part numbers and quantities listed below are mandatory replacement parts on every cylinder head deemed repairable.

3.4.4.a KS27130 O-ring Qty 1 3.4.4.b KS27119 O-ring Qty 4 3.4.4.c KS27131 O-ring Qty 4 3.4.4.d KS27135 Joint Qty 2 3.4.4.e KS27240 Nozzle with Needle and Coupling Qty 1 3.4.4.f KS27025 O-ring Qty 3 3.4.4.g KS27027 O-ring Qty 1 3.4.4.h KS27256 Dowel Pin Qty 2 3.4.4.i KS27266 Sealing Kit Qty 1 3.4.4.j KS27270 Compression Spring Qty 1 3.4.4.k KS27284 Hex Head Bolt Qty 6 3.4.4.l KS27540 Start Air Valve Overhaul Kit Qty 1

3.4.5 Cylinder Head Test Report- The test results shall be documented on a report and provided to the Contracting Officer and COR. The test results shall be reviewed by the COR and must be approved by the Contracting Officer prior preservation and packaging. A copy of the test report shall be packed with each cylinder head. The report shall contain the following information at a minimum:

3.4.5.a Contractor's Name 3.4.5.b Contract number, delivery order number, and/ or contract line item number 3.4.5.c Cylinder head model number, part number, and serial number 3.4.5.d Date of test 3.4.5.e Description of each test conducted and test results 3.4.5.f Name of the person conducting the testing

3.6 Cylinder Head Seal Kit- Each cylinder head shall be provided with the installation seal kit part number WDI100293-005 included in the shipping container.

3.7 Photo Documentation-The Contractor shall provide digital photo documentation to the Contracting Officer & COR for overhauled cylinder heads as follows:

3.7.1. During initial opening of the cylinder head after receipt.

3.7.2. When significant findings that will affect cost of repair/overhaul or time are discovered.

3.7.3. When other significant or unusual findings such as failed parts or damage are discovered

3.7.4. When the cylinder head is tested to document configuration.

3.7.5. When the cylinder head is prepared for shipment to document "as shipped" configuration to include images of the PPP&M.

3.7.6. The photo documentation shall be color digital and shall be sent to the Contracting Officer and the Contracting. Officer's Representative via email.

recommendation that the cylinder head is BER. Final determination of BER will be made by the KO. If the cylinder head is determined BER, the Government may purchase an identical new cylinder head from the Contractor on a separate order.

3.2.1.i. The cost of an identical new cylinder head, if a cylinder head is determined beyond economical repair.

3.3 Submit CFR-The Contractor shall submit a CFR with digital pictures showing the condition of the cylinder head and cylinder head parts. The CFR shall also have a repair plan that outlines proposed repairs to the Contracting Officer and Contracting Officer's Representative for review and approval, when applicable.

3.4 Overhaul Cylinder Head-The Contractor shall overhaul the Government furnished cylinder head including the start air valve with new OEM parts, replacing all parts cited as mandatory in paragraph 3.4.4. Commercial parts (materials), not manufactured by the OEM, such as seals, ball/roller type bearings, and couplings are acceptable but the Contractor shall identify them by their markings or through the use of the technical manual for identification purposes?. Commercial parts such as seals, ball/roller type bearings, and couplings are generally interchangeable between different manufacturers and may be substituted for cylinder head repairs as long as they are equal in all respects. Only in the case where the part cannot be identified shall it be ordered directly through the OEM and by their part number. Cylinder head parts that are reclaimed, recycled, or aftermarket are not acceptable and shall not be used.

3.4.1.a Remove Existing Paint: All surface coatings shall be removed. The Cylinder Head shall be mechanically cleaned by hand Tool Cleaning SSPC-SP2 (SSI-St3), Power Tool Cleaning SSPC-SP3 (SSI-St3), White Metal Blast SSPC-5 (SSI-Sa3) or Commercial Blast SSPC-SP6 (SSI-Sa2). An equal method of paint removal is acceptable where power tool cleaning may pose a risk of damage to internal components.

3.4.2.b Paint Cylinder Head: The Cylinder Head shall be painted with primer and finish coats of paint (excluding flange faces, internal surfaces). The base coat (primer) shall be a high build epoxy 5.0-6.0 mils dry film thickness (DFT) compatible with the finish coat. The finish coat shall be in accordance with MIL-PRF-24635 Silicone Alkyd, Type II Class 1, 2.0-3.0 mils DFT. The color shall be machinery gray, color number 16307 (or match the OEM color, Sulzer Green), in accordance with paragraph 2.2.3. Total paint thickness shall be 7.0-9.0 mils DFT.

3.4.3 Test Cylinder Head- All testing shall be accomplished on contractor supplied calibrated test equipment. If an item fails, it shall be repaired and re-tested as necessary until a successful test is achieved. All repairs and tests shall be in accordance with OEM specifications. After completion of an overhaul the Contractor shall, at a minimum, conduct the following described tests.

3.4.3.a Valve Seat visual inspection and NTD.

3.4.3.b Hydrostatic test.

3.4.3.c Assembly Tolerances and Clearances

3.4.4 Mandatory Parts- The part numbers and quantities listed below are mandatory replacement parts on every cylinder head deemed repairable.

3.4.4.a KS27130 O-ring Qty 1 3.4.4.b KS27119 O-ring Qty 4 3.4.4.c KS27131 O-ring Qty 4 3.4.4.d KS27135 Joint Qty 2 3.4.4.e KS27240 Nozzle with Needle and Coupling Qty 1 3.4.4.f KS27025 O-ring Qty 3 3.4.4.g KS27027 O-ring Qty 1 3.4.4.h KS27256 Dowel Pin Qty 2 3.4.4.i KS27266 Sealing Kit Qty 1 3.4.4.j KS27270 Compression Spring Qty 1 3.4.4.k KS27284 Hex Head Bolt Qty 6 3.4.4.l KS27540 Start Air Valve Overhaul Kit Qty 1

3.4.5 Cylinder Head Test Report- The test results shall be documented on a report and provided to the Contracting Officer and COR. The test results shall be reviewed by the COR and must be approved by the Contracting Officer prior preservation and packaging. A copy of the test report shall be packed with each cylinder head. The report shall contain the following information at a minimum:

3.4.5.a Contractor's Name 3.4.5.b Contract number, delivery order number, and/ or contract line item number 3.4.5.c Cylinder head model number, part number, and serial number 3.4.5.d Date of test 3.4.5.e Description of each test conducted and test results 3.4.5.f Name of the person conducting the testing

3.6 Cylinder Head Seal Kit- Each cylinder head shall be provided with the installation seal kit part number WDI100293-005 included in the shipping container.

3.7 Photo Documentation-The Contractor shall provide digital photo documentation to the Contracting Officer & COR for overhauled cylinder heads as follows:

3.7.1. During initial opening of the cylinder head after receipt.

3.7.2. When significant findings that will affect cost of repair/overhaul or time are discovered.

3.7.3. When other significant or unusual findings such as failed parts or damage are discovered

3.7.4. When the cylinder head is tested to document configuration.

3.7.5. When the cylinder head is prepared for shipment to document "as shipped" configuration to include images of the PPP&M.

3.7.6. The photo documentation shall be color digital and shall be sent to the Contracting Officer and the Contracting. Officer's Representative via email.

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 Calibration System - The Contractor, as well as any subcontractors, shall be required to maintain a test equipment calibration program in compliance with this SOW. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.3 Responsibility for Inspection - The Contractor shall be responsible for the performance of all inspection requirements specified herein. The Contractor shall provide space, personnel, and test equipment to conduct all required inspections. All inspection and testing shall be performed at the Contractor's plant or at other facilities acceptable to the Coast Guard.

The Coast Guard reserves the right to verify or have any of the inspections or tests performed that are deemed necessary to assure that supplies and services conform to the prescribed requirements as part of this SOW conducted in the presence of a Coast Guard Quality Assurance Representative or the COR,

4.4 Responsibility for Compliance-All items shall meet the provisions of this SOW. Inspections set forth in this SOW shall become part of the Contractor's overall inspection system or quality program. The absence of any inspection requirements in the SOW 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.

4.5 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 this SOW.

The inspection system shall be documented and available for review by the Coast Guard.

4.6 Tests & Inspections - The inspections/tests required here and in the appropriate subsection of this repair description, 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.

4.6.1 The following inspections are required and may be witnessed by the QAR:

4.6.1a. Verify installation of OEM parts 4.6.1.b. Verify paint requirement and paint thickness 4.6.1.c. Verify valve seat dimensions and NDT 4.6.1.d. Verify hydrostatic testing of cylinder head 4.6.1.e; Verify assembly tolerances and clearances 4.6.1.f. Verify PPP&M requirements

5.0 PRESERVATION, PACKAGING, PACKING AND MARKING

Upon completion of overhaul and testing each cylinder head shall be preserved, packaged, packed and marked as required in this section and the appropriate references.

5.1 Preserve Cylinder Head- An overhauled cylinder head is typically intended for warehouse storage and not for immediate installation. Therefore, it is critical that the Contractor ensure that the overhauled cylinder head undergo the following preservation requirements.

5.1.a The cylinder head shall be drained and dried of all testing and other fluids if present.

5.1.b All internal passages, components, and unpainted surfaces shall be coated with corrosion preventive compound that is completely miscible with lubricating oils and conforms to Grade 2, Class 2 of MIL-PRF-l6173E(SH).

5.1.c All open ports shall be sealed using waterproof caps or covers to prevent the intrusion of moisture and other contaminates.

5.1.d Any bare exposed threads and shafting shall be protected by a cardboard sleeve.

5.2 Package Cylinder Head- Each cylinder head shall be individually packaged in accordance with Method 30 of MIL-STD-2073-IE w/Change 1, with the following additions-

5.2.a Material for the protective envelope shall be Class 3 water vapor proof, grease proof, flexible, heat sealable barrier paper in accordance with

MIL-PRF-13IK.

5.2.b Desiccant of the proper type and quantity in accordance with Section

5.2.3.7 a. & b. of MIL-STD- 2073-1E w/Change I, shall be enclosed within the heat sealable envelope prior to sealing the bag.

5.2.c In the areas where the cylinder head shipping crate mounting bolts penetrate the protective envelope, a 1/8 inch thick rubber gasket(s) and RTV shall be used to seal the envelope from the entrance of moisture.

5.3 Pack Cylinder Head- After packaging, each cylinder head shall be individually packed in a reusable wooden box/ crate with a skid type base and totally enclosed as follows.

5.3.a The base shall be constructed of 2 inch by 6 inch solid wood lumber attached to 4 inch by 4 inch solid wood skids to facilitate lifting by a fork lift. The base shall be attached to the skids using lag bolts. Holes shall be predrilled in the 4 inch by 4 inch solid wood skids to prevent splitting and cracking when the lag bolts are inserted.

5.3.b The top, sides and ends that form the cover of the wooden container shall be constructed using 3/4 inch plywood (OSB and particle board are not acceptable), framed on the inside or outside using 2 inch by 4 inch solid wood lumber. CRES Philips head deck screws shall be utilized to assemble the individual pieces. Screws directly into the plywood without dimensional lumber backing are not acceptable.

5.3.c The cylinder head shall be securely through bolted to the skid base.

The cover shall be attached to the skid base using CRES Phillips head deck

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 Calibration System - The Contractor, as well as any subcontractors, shall be required to maintain a test equipment calibration program in compliance with this SOW. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.3 Responsibility for Inspection - The Contractor shall be responsible for the performance of all inspection requirements specified herein. The Contractor shall provide space, personnel, and test equipment to conduct all required inspections. All inspection and testing shall be performed at the Contractor's plant or at other facilities acceptable to the Coast Guard.

The Coast Guard reserves the right to verify or have any of the inspections or tests performed that are deemed necessary to assure that supplies and services conform to the prescribed requirements as part of this SOW conducted in the presence of a Coast Guard Quality Assurance Representative or the COR,

4.4 Responsibility for Compliance-All items shall meet the provisions of this SOW. Inspections set forth in this SOW shall become part of the Contractor's overall inspection system or quality program. The absence of any inspection requirements in the SOW 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.

4.5 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 this SOW.

The inspection system shall be documented and available for review by the Coast Guard.

4.6 Tests & Inspections - The inspections/tests required here and in the appropriate subsection of this repair description, 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.

4.6.1 The following inspections are required and may be witnessed by the QAR:

4.6.1a. Verify installation of OEM parts 4.6.1.b. Verify paint requirement and paint thickness 4.6.1.c. Verify valve seat dimensions and NDT 4.6.1.d. Verify hydrostatic testing of cylinder head 4.6.1.e; Verify assembly tolerances and clearances 4.6.1.f. Verify PPP&M requirements

5.0 PRESERVATION, PACKAGING, PACKING AND MARKING

Upon completion of overhaul and testing each cylinder head shall be preserved, packaged, packed and marked as required in this section and the appropriate references.

5.1 Preserve Cylinder Head- An overhauled cylinder head is typically intended for warehouse storage and not for immediate installation. Therefore, it is critical that the Contractor ensure that the overhauled cylinder head undergo the following preservation requirements.

5.1.a The cylinder head shall be drained and dried of all testing and other fluids if present.

5.1.b All internal passages, components, and unpainted surfaces shall be coated with corrosion preventive compound that is completely miscible with lubricating oils and conforms to Grade 2, Class 2 of MIL-PRF-l6173E(SH).

5.1.c All open ports shall be sealed using waterproof caps or covers to prevent the intrusion of moisture and other contaminates.

5.1.d Any bare exposed threads and shafting shall be protected by a cardboard sleeve.

5.2 Package Cylinder Head- Each cylinder head shall be individually packaged in accordance with Method 30 of MIL-STD-2073-IE w/Change 1, with the following additions-

5.2.a Material for the protective envelope shall be Class 3 water vapor proof, grease proof, flexible, heat sealable barrier paper in accordance with

MIL-PRF-13IK.

5.2.b Desiccant of the proper type and quantity in accordance with Section

5.2.3.7 a. & b. of MIL-STD- 2073-1E w/Change I, shall be enclosed within the heat sealable envelope prior to sealing the bag.

5.2.c In the areas where the cylinder head shipping crate mounting bolts penetrate the protective envelope, a 1/8 inch thick rubber gasket(s) and RTV shall be used to seal the envelope from the entrance of moisture.

5.3 Pack Cylinder Head- After packaging, each cylinder head shall be individually packed in a reusable wooden box/ crate with a skid type base and totally enclosed as follows.

5.3.a The base shall be constructed of 2 inch by 6 inch solid wood lumber attached to 4 inch by 4 inch solid wood skids to facilitate lifting by a fork lift. The base shall be attached to the skids using lag bolts. Holes shall be predrilled in the 4 inch by 4 inch solid wood skids to prevent splitting and cracking when the lag bolts are inserted.

5.3.b The top, sides and ends that form the cover of the wooden container shall be constructed using 3/4 inch plywood (OSB and particle board are not acceptable), framed on the inside or outside using 2 inch by 4 inch solid wood lumber. CRES Philips head deck screws shall be utilized to assemble the individual pieces. Screws directly into the plywood without dimensional lumber backing are not acceptable.

5.3.c The cylinder head shall be securely through bolted to the skid base.

The cover shall be attached to the skid base using CRES Phillips head deck screws with the head of the screws and a 2 inch surrounding area painted red to easily identify the screws. A 1/2 inch minimum Red stencil shall be painted on both sides with the words "REMOVE RED PAINTED SCREWS TO REMOVE

COVER".

5.3.d The wooden container shall be capable of protecting the cylinder head unit from damage during multiple shipments by commercial carrier.

5.4 Mark Cylinder Head- Each preserved, packaged, and packed cylinder head crate shall be stenciled in the upper left hand side of the two longest sides (two opposite sides if square) of each box. The stenciling shall be 3/4 inches minimum height black characters on a white "painted" background.

PLEASE NOTE: ALL PREVIOUS MARKINGS AND QUALITY ASSURANCE DECALS SHALL BE

REMOVED FROM A REUSABLE SHIPPING CONTAINER PRIOR TO THE APPLICATION OF ANY

NEW MARKINGS.

This marking shall consist of the STOCK NUMBER, ITEM NAME, PART NUMBER, SERIAL NUMBER, CONTRACT NUMBER, DELIVERY ORDER or CLIN NUMBER, GROSS WEIGHT in (LBS.), condition code CONDITION "A" and unit of issue with quantity (i.e. 1- EA), and the words COAST GUARD SFLC MATERIAL.

A. See below for marking lay out cylinder heads:

STOCK NUMBER 2815-01-653-7692

ITEM NAME CYLINDER HEAD WITH START AIR

PART NUMBER WDI002093-002

SERIAL NUMBER SEE CONTRACT

CONTRACT NUMBER SEE CONTRACT

SHIPPING WEIGHT AS DETERMINED BY CONTRACTOR

CONDITION CODE CONDTION "A"

QUANTITY AND UNIT OF ISSUE 1 EACH

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER- DO NOT DESTROY

5.5 Bar Coding- The Contractor shall supply bar code labels on all CLIN's except for those that require data submissions only. All bar code labels shall be in accordance with SFLC specification D-000-0100, Rev G: The actual labels shall be Type "V". Grade "a", Style "2", Composition "b" with plastic laminate. Each label shall contain encoded data for the Stock Number.

6.0 NOTES

None screws with the head of the screws and a 2 inch surrounding area painted red to easily identify the screws. A 1/2 inch minimum Red stencil shall be painted on both sides with the words "REMOVE RED PAINTED SCREWS TO REMOVE

COVER".

5.3.d The wooden container shall be capable of protecting the cylinder head unit from damage during multiple shipments by commercial carrier.

5.4 Mark Cylinder Head- Each preserved, packaged, and packed cylinder head crate shall be stenciled in the upper left hand side of the two longest sides (two opposite sides if square) of each box. The stenciling shall be 3/4 inches minimum height black characters on a white "painted" background.

PLEASE NOTE: ALL PREVIOUS MARKINGS AND QUALITY ASSURANCE DECALS SHALL BE

REMOVED FROM A REUSABLE SHIPPING CONTAINER PRIOR TO THE APPLICATION OF ANY

NEW MARKINGS.

This marking shall consist of the STOCK NUMBER, ITEM NAME, PART NUMBER, SERIAL NUMBER, CONTRACT NUMBER, DELIVERY ORDER or CLIN NUMBER, GROSS WEIGHT in (LBS.), condition code CONDITION "A" and unit of issue with quantity (i.e. 1- EA), and the words COAST GUARD SFLC MATERIAL.

A. See below for marking lay out cylinder heads:

STOCK NUMBER 2815-01-653-7692

ITEM NAME CYLINDER HEAD WITH START AIR

PART NUMBER WDI002093-002

SERIAL NUMBER SEE CONTRACT

CONTRACT NUMBER SEE CONTRACT

SHIPPING WEIGHT AS DETERMINED BY CONTRACTOR

CONDITION CODE CONDTION "A"

QUANTITY AND UNIT OF ISSUE 1 EACH

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER- DO NOT DESTROY

5.5 Bar Coding- The Contractor shall supply bar code labels on all CLIN's except for those that require data submissions only. All bar code labels shall be in accordance with SFLC specification D-000-0100, Rev G: The actual labels shall be Type "V". Grade "a", Style "2", Composition "b" with plastic laminate. Each label shall contain encoded data for the Stock Number.

6.0 NOTES

None

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.

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

2815-01-653-7692

PARTS KIT,CYLINDER HEAD,DIESEL ENGINE

WDI002093-001

PRESERVATION / PACKAGING:

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

B. See Attachments

B. See Attachments

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