S1.12a ATTACHMENT 2 - 2019 ServiceReady Parts Purchase Specification.docx

REVISION No. _ CHANGE No.

UNITED STATES COAST GUARD (USCG)

SERVICE READY PARTS PURCHASE FOR

MTU PROPULSION ENGINES

8V396 TE94

P-260-XXXX

ORGINATED BY Patrick Mulrooney DATE 10/2018____

ORIGINATOR’S COMMAND Surface Forces Logistics Center (SFLC) ________

DEPARTMENT / DIVISION Patrol Boat Product Line (PBPL) _AMS-1 ______

INTERNAL REVIEWER_ ______DATE___ __ __

SWORB APPROVAL___________________________DATE___________

1.0 SCOPE

1.1. This specification describes the requirements for the purchase of Service Ready parts to support the 8V396 TE94 main diesel engine and its control and monitoring system. The parts shall be made service ready through the following as required: preliminary inspection, assembly, cleaning, painting, programming, testing, final inspection, preservation/packaging/crating, packing, marking and bar coding of various parts and assemblies. The following parts and components need to be made service ready before being supplied to the USCG: (This is not an exhaustive list and additional parts and components that need to be made service ready shall be identified by the contractor during the performance of the Contract.)

1.2. CLASSIFICATION of components that require preservation and packaging set forth in section 5.0.

2.0 APPLICABLE DOCUMENTS

2.1. DOCUMENT AVAILABILITY - For the methods and conditions for obtaining the referenced documents refer to section 6.0.

2.2. GOVERNMENT DOCUMENTS - The following specifications and standards form a part of this specification to the extent specified herein.

a. ASTM D7478/D7478M, Dated 01 Nov 2011, Standard Specification for Heavy Duty Sheathed Wood Crates, Type II, Class II, Style A.

b. MIL-STD-129R, dated 02/18/2014, entitled “Department of Defense Standard Practice, Military Marking for Shipment and Storage,” available at http://quicksearch.dla.mil/qsDocDetails.aspx?ident_number=35520, except bar coding in accordance with ISO/IEC-16388-2007, Code 39 Symbology. See MIL-STD-129R for details on how to obtain a copy of ISO/IEC-16388-2007, Code 39 Symbology.

2.3. 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. Commercial documents may also be listed in the Department of Defense Index of Specifications and Standards (DODISS).

a. MTU 8V 396 TE94 Maintenance Manual M020046/21E

b. MTU 8V 396 TE94 Parts Catalog M033971/00DE, Order #771903

c. MTU Tool List M004021/20DE

d. MTU Bosch Fuel Injection Pump PE..ZWM 170/100RS 30.. Description, Assembly Instructions, Spare Parts List M040095/00E

e. MTU Engine management System Typ ECS 396/S Version E & F with ETB 4E/ETB 4F Document numbers; E 531 406/01 E, E 531 405/ 01E & E 531 403/02E

f. MTU Engine Control System Illustrated Parts Catalog E 535 145/01ED

g. MTU Local Operating Panel LOP-ECS Illustrated Parts Catalog E 535 297/02ED

h. MTU Electrical Start Equipment SUE-ES Illustrated Parts Catalog E 535 187/00ED

i. MTU Monitoring & Control Unit Documentation E 535 164/00ED

j. Installation of MTU Electronic Systems E 530 606/06E

2.4. SPECIFICATION ORDER OF PRECEDENCE - In the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence, unless otherwise specified herein. The Contractor shall notify the Contracting Officer within 1 (one) week in writing of any perceived conflicts contained herein.

2.5. DEPARTUARE FROM SPECIFICATION – Departure from this specification shall not be allowed unless approved by the Coast Guard Contracting Officer.

a. If the Contractor finds it necessary to suggest implementing change or depart from applicable specifications they shall request permission.

b. Request for change shall clearly describe the changes proposed, the reason for change, advantages of the proposed changes, price increase or decrease (if any) resulting from the change.

3.0 REQUIREMENTS

3.1. GENERAL – MTU technical publications shall be utilized to make these parts Service Ready as required. The Contractor shall be required to legally possess all MTU technical publications and have them available at the Contractor’s facility. The contractor shall have access to the latest version of MTU DIASYS diagnostic and any programming software. The contractor shall have at least one technician that is assigned a current 1B service dongle.

3.2. The Contractor shall provide all labor, equipment, special tools, and materials required to make the parts Service Ready as required. The contractor shall deliver all parts in a service ready condition for immediate install, electronic parts shall be programmed or calibrated to the Coast Guard’s configuration as required. Major subassemblies such as turbochargers, pumps, starters, cylinder heads, etc. shall be cleaned, painted and ready for install.

a. The contractor shall be able to prepare and ship approximately 18,000 service ready MTU 8V396 TE94 series diesel engine system parts and components annually to the USCG’s central Warehouse in Baltimore, Maryland as well as direct ship these parts and components worldwide to various USCG units and cutters.

b. The Contractor shall have access to MTU’s secure FTP server in order to access project software and calibration files.

c. The Contractor shall be responsible to provide the USCG all up-dated data in regards to configuration, service bulletins, and Tech Pub changes/revisions for the parts and components described in this specification.

d. The Contractor shall submit to the Contracting Officer a parts price list annually that contains all parts of the MTU Propulsion system as installed on the 87WPB Cutters. The Coast Guard shall use this price list to purchase parts for inventory to support maintenance and casualties.

3.3. WARRANTY – These parts and components are being purchased as system stock and will be placed into inventory and not for immediate installation. The Contractor shall provide a warranty for a period of six (6) months of operation, following up to one (1) year in storage. Storage commences upon receipt of the component at the designated Coast Guard facility. The warranty commences the date the component is installed on a Coast Guard Unit.

4.0 QUALITY ASSURANCE

4.1. GENERAL - The Contractor shall maintain an inspection system, which shall ensure each item offered to the Government for acceptance conforms to contract requirements. The system shall be documented and in compliance with ANSI/ASQS Q90003.

4.2. RECORDS - The Contractor shall maintain records of all inspections and tests. The records shall indicate the nature and number of observations made, type of deficiencies found and the corrective action taken. Records shall be furnished upon arrival of the Coast Guard Representative.

4.3. CONTRACTORS CALIBRATION SYSTEM The Contractor as well as any Subcontractors shall be required to maintain a calibration and maintenance system to control the accuracy of measurement and test equipment used in the fulfillment of this contract in accordance with ANSI/NCSL Z540-3. The system shall include at a minimum, prescribed calibration intervals, source of calibration, and a monitoring system to ensure adherence to calibration schedules. Calibration standards shall be traceable to the National Institute of Standards and Technology (NIST). Documentation in support of this requirement shall be readily available for Government review.

4.4. RESPONSIBILITY FOR INSPECTION - The Contractor shall be responsible for all inspections/test requirements specified herein. The Contractor shall provide space, personnel, and test equipment to conduct all inspection requirements. All testing and inspection shall be at the Contractors facility or other facilities acceptable to the Government. The Government reserves the right to verify or have performed any of the inspection/tests set forth in this specification where such inspections are deemed necessary to ensure that supplies or services conform to the prescribed requirements.

4.5. PACKING INSPECTION- The contracting Officer shall be notified after preservation seven (7) days prior to the packaging and marking of any parts or components made service ready. The Coast Guard reserves the right to perform on-site inspections if deemed necessary.

5.0 PRESERVATION, PACKAGING, PACKING, & MARKING

5.1. PRESERVATION (Internal) – As required each Component shall be internally preserved when appropriate. Preservation shall provide adequate protection to the assembly during long term storage of at least one year. All openings shall be plugged or blanked.

5.2. PRESERVATION (External) - As required, each assembly shall be cleaned externally. Each assembly shall be painted to preserve the painted surfaces and to present a new appearance. Paint and color shall be in accordance with the OEM’s original specifications. Electronic control system components & fuel injection nozzles shall not be painted.

a. All surfaces shall be cleaned of grease and oil

b. All loose scale and paint shall be removed

c. MTU white paint P/N 50291 shall be sprayed on all surfaces 3-5 mils thick, allow a minimum of seven (7) hours drying for primed surfaces.

d. When all paint is dry, the masking shall be removed including from the component data plate.

e. Coat all unpainted metal surfaces with a light amount of grease, except for hot surfaces.

f. Plug or cap any fittings/flanges or openings.

g. Each component shall be wrapped in water vapor resistant paper when appropriate.

5.3. PACKING - Each assembly shall be packaged in a re-usable skid mounted, wooden box. Each box shall be internally braced to and cushioned to prevent movement of the assembly. The box and internal bracing shall be capable of protecting the assembly while in storage and from rough handling during multiple shipments. The Contractor shall place in a plastic envelope in each container, copies of all test and inspection results for that component.

5.4. MARKING – Each preserved, packed and packaged item shall be stenciled in the upper left-hand side of the two longest sides (two opposite sides if square) of each box.

a. Machine made stencils shall be used for all marking.

b. All marking shall be in black print on a contrasting back ground (white paint) and at least 2” high.

c. Markings shall follow the format of the example provided below:

NATIONAL STOCK NUMBER 2950-12-347-2009

ITEM NAME TURBO, A BANK

PART NUMBER 5100205005

SERIAL NUMBER “As per Enclosed Item” CONTRACT NUMBER See Contract DELIVERY ORDER NUMBER As submitted on the Order SHIPPING WEIGHT As Determined by Contractor

QUANTITY & UNIT OF ISSUE 1- EA

PRESERVED FOR LONG TERM

STORAGE ON Date preserved

CONDITION CODE CONDITION A

OTHER DATA AS

DIRECTED COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER,

DO NOT DAMAGE.

DO NOT DESTROY.

d. The following marking shall be placed on all four sides and the top of each box in stenciled black print at least 2” high.

Reusable Container- Do Not Damage Remove Bolts Prior To Removing Cover Use Forklift To Unload Do Not Lift By Cover

5.5. BAR CODING – Bar code labels shall be supplied on all crates.

a. All bar coded labels shall be in accordance with MIL-STD-129R.

b. The actual labels shall be Type “V”, Grade “A”, Style”2”, Composition “b” with plastic laminate.

c. Each label shall contain encoded data for the Stock Number, Delivery Order Number and Contract Number.

6.0 GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

6.1. GOVERNMENT DOCUMENTS

USCG Surface Forces Logistics Center

6.2. COMMERCIAL DOCUMENTS

a. MTU Detroit Diesel, INC 13400 Outer Drive West Detroit, Michigan 48239, USA 313-592-7000 www.mtudetroitdiesel.com

b. International Organization for Standardization