Technical Specifications EEandQA-833 Bus Engine Re-Manufacture_111818.pdf

MASSACHUSETTS

BAY

TRANSPORTATION

AUTHORITY

TECHNICAL SPECIFICATION

EE&QA-833

REQUIREMENTS FOR THE

REMANUFACTURING OF ENGINES

ISSUED:

May 20, 2014

REVISIONS:

November 18, 2018

BUS OPERATIONS

Equipment Engineering and Quality Assurance

Technical Specification

Specification:

SUBJECT: Requirements For The

Remanufacturing Of Engines

Page: 2 o f 24

Date: May 20, 2014

Revised:

Revision: A

1.0 SCOPE

2.0 DESCRIPTION OF WORK

2.1 Basic Work

2.2 Additional Work

2.3 Cores………………………………………………………………………………………………….…………4, 6

3.0 GENERAL REQUIREMENTS

3.1 Intent and Purpose of Specification

3.2 Contractor's Responsibilities

3.3 First Article Inspection

3.3.1 Installation

3.3.2 Packaging

3.3.4 Delivery

3.4 Warranty and Guarantees

3.4.1 Warranty and guaranty

3.4.2 Units & Parts Not Specified

3.4.3 Labor costs

3.4.4 Returns

3.4.5 Product Defects

3.4.6 Written Terms of Warranty

3.5 Drug and Alcohol Free Workplace Requirement

3.6 Authority Access to Work

3.7 Bidder Requirements

3.7.1 Facilities

3.7.2 Drivers

3.7.3 Experience

3.7.4 Qualification

3.7.5 Disclosures

3.7.6 Responsibility

3.7.7 Supervision

3.7.8 Documentation

4.0 REMANUFACTURING OF ENGINES

4.1 Block

4.1.1 Basic Work

4.1.2 Additional Work

4.2 Head

4.2.1 Basic work

4.2.2 Extra Work

4.3 Crankshaft

4.4 Camshaft

Page: 3 o f 24

5.0 DELIVERY

6.0 APPROVALS

7.0 REVISION RECORD

8.0 APPENDIX A

1.0 SCOPE:

This specification establishes the general procedures and processes and the Contractor requirements for the remanufacturing of the following engines:

Detroit Diesel

Series 50 diesel—04R0017079—compatible with 1994/1995 Nova Transit buses

Series 50 CNG—04R0028480

Series 60 diesel—06R0754949

Series 60 CNG—06R0706065

Caterpillar

C-9 --- MTB01142

Cummins

8.3C --- 46363576

ISC CM850 --- 46682134

ISL CM2150 --- 46837220

ISL 330H --- 73051385

The work needed to remanufacture to OEM spec, will include but not limited to:

Block

Head

Crankshaft

Page: 4 o f 24

Camshaft

Connecting rods

2.0 DESCRIPTION OF WORK:

2.1 Basic Work

All Basic Work required on each engine turned over to the Contractor for remanufacturing shall include, but not limited to, work listed and summarized in the Basic Work sections

2.2 Additional Work

It shall be the responsibility of the Contractor to determine what part of the

Additional Work listed will be necessary to completely overhaul and repair the engine and restore it to an as-new condition.

The contractor shall indicate the charge for additional work as a separate line item on the invoice for that particular block.

2.3 Cores

The MBTA shall not be required to pay any charges for cores.

Used parts removed from all engines shall be used as cores.

The MBTA shall put the cores on pallets. The contractor shall inspect the core and pallet to ensure it is adequate for shipment. The pallets shall be returned to the

MBTA by the contractor with the remanufactured part.

If applicable, the contractor shall inspect the cores when they are picked up. The contractor shall identify any used part that is not an acceptable core, tag it with the reason it is not acceptable and notify the MBTA that it will not be taken. There

Page: 5 o f 24 shall be no charge backs for those parts picked up by the contractor.

The contractor shall inspect the packaging of the cores to determine if they can be handled and shipped.

The contractor shall produce, sign and provide a copy of a manifest indicating the part description, part serial number and quantity of used parts picked up to the

Supervisor of Component Exchange.

Residual fluids may remain in and on some cores. If applicable, the contractor shall be responsible for disposal of these fluids and the cleaning materials used to remove them.

All costs associated with the disposal are the responsibility of the contractor.

There shall be no additional charge to the MBTA for any of these costs.

The contractor shall be responsible for the disposal of all parts removed from the blocks and heads. This shall include, but not be limited to, freeze plugs, followers, rollers, locks, bridge assemblies, injector tubes, valve guides, valves, valve springs and valve keepers.

All engine blocks that are not repairable must be returned to MBTA’s engine shop foreperson.

All costs associated with the disposal are the responsibility of the contractor.

There shall be no additional charge to the MBTA for any of these costs.

Multiple pickups of cores shall be made by the contractor. Cores will become available as used engines are removed and disassembled. The contractor shall be responsible for all freight charges.

The contractor shall designate an individual to be responsible for coordinating activities with the MBTA. This individual shall contact the Engine Shop

Page: 6 o f 24

Foreperson, telephone # 617-222-5873, or their designee, regarding scheduling pickups. The contractor shall contact the Foreperson at Component Exchange at telephone # 617-222-5447 to arrange for pick up of cores. Pickups shall be made

Monday through Friday between the hours of 7:00 AM and 1:00 PM excluding holidays. The contractor shall be responsible for all freight charges for the pickup of cores from the following Address:

MBTA Main Repair Facility

Component Exchange

Building # 1, Door # 12

80 Broadway

Everett, MA 02149

The contractor shall identify, provide and prepare all applicable permits, certificates, manifests, restriction forms and any other forms required by Federal, State and local laws and regulations to safely handle and transport all items. All labor, material and other costs for this work shall be included in the bid. See

Form C.

BASIS OF AWARD – VALUE PROPOSAL

The MBTA shall not be bound to accept the lowest priced Response or the Response with the highest technical Proposal Score. The selection will be made on a best-value basis, evaluating price and warranty along with technical score.

After the determination of the Technical Proposal Score, the MBTA will evaluate the Price Evaluation

Criteria of the remaining Bidders and assign an overall Price Proposal Score. To determine the best value, the MBTA will then conduct a trade-off analysis determining whether the perceived benefits of the higher priced Response merit the additional cost.

The MBTA will not select any Bidder that receives a rating of fail on any Pass/Fail Evaluation Criteria or less than an average of 2 on any Technical Evaluation Criteria. The MBTA will not select any Bidder that the MBTA determines has submitted a non-responsive Technical or Price Proposal or to have submitted

Page: 7 o f 24 any pricing information that is not reasonable. The MBTA reserves the right to accept or reject, at its sole discretion, any or all Responses in full or in part.

3.0 GENERAL REQUIREMENTS:

3.1 Intent and Purpose of Specification

The intent of this Specification is to establish a minimum acceptable quality standard for the overhaul of engines, but not to rule out better or more economical materials or techniques, if such exists. If the Contractor wishes to use different materials or procedures, he shall apply, in writing, to the

Authority's Manager of Bus Operations for approval. If it is determined that it is in the best interest of the Authority, written approval for such alternates will be issued. Without such written approval, the Contractor shall not deviate from this

Specification. Such written approval will be appended to this Specification and made an integral part thereof.

3.2 Contractor's Responsibilities

Unless otherwise specified herein or in any contractual documents, the Contractor shall complete all work required on each engine and return within 3 business days after receipt of a notice to pick up said armature.

Workmanship for all remanufactured parts shall comply with the latest engine

OEM Service Information Letters, Bulletins, and Manuals. This shall include, but not be limited to, replacement, service parts, specifications, clearances, tolerances, adjustments, settings and work standards.

If applicable, the used part shall be completely disassembled, chemically cleaned, all internal parts inspected, replaced or replaced as required. All replacement parts shall be new and unused and meet or exceed OEM Specifications.

Page: 8 o f 24

The contractor shall identify all parts that are remanufactured by them. This identification shall be a permanent marking that does not interfere with the operation, maintenance or repair of the remanufactured part. The contractor shall describe the identification that will be used with their bid.

All remanufactured parts shall consist of parts produced using cores picked up from the MBTA, unless written authorization is received from the MBTA

Machine Shop Supervisor.

The remanufactured parts shall be complete and ready for service. Items not specifically mentioned but, necessary for service, shall be furnished and installed by the contractor. These items shall be considered incidental and included within the scope of the Specification. There shall be not additional cost to the MBTA.

The parts furnished and installed by the contractor shall be new and unused and meet or exceed OEM Specifications

3.3 First Article Inspection

3.3.1 Installation of the first remanufactured head, block, camshaft and crankshaft shall be evaluated by the MBTA. Items to be evaluated shall include, but not be limited to, the following:

- is the part complete and ready to install

- fit up to MBTA Engines and Transmissions

- ease of installation

- operational performance

3.3.2 The packaging of the remanufactured parts shall be evaluated.

3.3.3 If required, the contractor shall make all adjustments and component changes/additions required to provide for remanufactured parts and packaging that complies with Specification Requirements. In addition, all parts (both those already delivered and to be delivered) shall be modified to

Page: 9 o f 24 include any changes that are required. These modifications shall be completed at no additional expense to the MBTA Should the contractor fail to meet this requirement, the Authority may demand that the non-complying parts be removed at the contractor's expense and may cancel this contract.

3.3.4 All remanufactured parts delivered by the contractor shall conform to the

Requirements of this Section. Uniformity of all remanufactured parts and packaging is of vital importance to the Authority. The Authority may demand that the non-complying parts be removed at the contractor's expense and may cancel this contract

3.4 Warranty and Guarantees

3.4.1 All remanufactured parts shall be warranted and guaranteed from defects and related defects for one (l) year.

The warranty shall begin when the remanufactured parts are put into service at the MBTA. The warranty will NOT start at the time of delivery.

It is anticipated that installation of all parts will be completed within one year of delivery.

3.4.2 Units & Parts Not Specified

All units or parts not otherwise specified shall be the manufacturer's units or parts, and shall conform in material, design and workmanship to the best industry practices. The successful bidder shall assume all responsibilities for these specialties and parts, whether made by the manufacturer or purchased from another source.

3.4.3 The warranty shall cover labor costs incurred by the MBTA to remove and replace, or if applicable, package and ship the defective component. In addition, shipping costs to and from the manufacturer’s facility shall be

Page: 10 o f 24 covered by the warranty. Packing materials shall be furnished and delivered to the MBTA by the contractor. The contractor shall pick up defective components or arrange for a shipping company to pick them up.

3.4.4 A component that has been returned to the contractor for warranty repair shall be redelivered to the MBTA in no more than five (5) business days.

It is critical that the contractor have the materials and manpower to complete warranty repairs or provide replacement parts in timely fashion.

The contractor shall provide a written statement on compliance with this requirement and others that appear in this Section with their bid. The contractor may replace the MBTA Component with another from their stock provided it is equipped in the same way as MBTA Components, is a direct replacement and will have the same warranty.

3.4.5 Product Defects

A product defect is defined as cumulative failures of any kind in the same components or software in the same or similar application where such items covered by warranty and such failures occur in the warranty period in the specified proportion of the assemblies delivered. The proportion shall be twenty (20%) percent.

After identification of a product defect, the Authority and contractor shall mutually agree to and promptly undertake and complete a work program reasonably designed to prevent the occurrence of the same defect in all other systems. Where the specific defect can be solely attributed to particular identifiable parts) or software problem, the work program shall include redesign and/or replacement of the defectively designed and/or manufactured parts) and/or software in all systems. All costs shall be borne by the contractor.

Page: 11 o f 24

The contractor shall meet on-site with the MBTA to provide the following information and mutually agree to a work program that does the following:

- description of the defect or failure or reason for the hardware or software modification

- description of the proposed hardware or software modification

- documentation or drawings of the proposed modification

- test procedures for the modification

- progress reports or deployment plan for the modification

- testing/demonstration period on one part for the modification

3.4.6 Written Terms of Warranty

The bidder shall submit a written statement as to the terms of his warranty as part of his proposal and the extent of his compliance with the above requirements shall be taken into consideration by the Authority in evaluating the proposals received.

3.5 Drug and Alcohol Free Workplace Requirement

The Contractor, Contractor's employees, vendors, visitors, and volunteers are to be free of the effect of drugs, alcohol, controlled substances or other prohibitive substances when they are on MBTA property or performing MBTA business. In addition, all referenced parties are prohibited from using, possessing, selling or distributing any drugs, alcohol, controlled substances or other prohibited substances when they are on MBTA property or performing MBTA business. It is the responsibility of the Contractor to advise its employees of this requirement and to ensure that its employees meet this "fitness for duty" standard. Violators of this policy will not be allowed to remain on MBTA property or to continue conducting business for or with the MBTA. The Contractor will submit to the

Page: 12 o f 24

Authority within thirty (30) days of a Drug and Alcohol violation, a written report documenting the actions taken with regard to any of its employees who violate this policy. The Contractor will accept all liability arising from violation of this policy by his/her employees.

3.6 Authority Access to Work

The Authority shall have the right to witness and/or inspect any and all work, processes, methods, parts, materials, equipment, workmanship and tests that are furnished or used by the Contractor for this Contract and may reject, without cost or liability to the Authority, any of such that, in the opinion of the Authority, is defective or unsuitable for the use and purpose intended. The Contractor, at his own expense, shall reconstruct, replace or correct, as the case may be, any such defective or unsuitable items and work.

The presence of an Authority representative shall in no way alleviate the responsibility of the Contractor to perform such inspections, of both his product and processes and those of his subcontractors and vendors. In addition, such

Authority inspection shall not relieve the Contractor of his responsibility to perform the overhaul and repair work in a quality manner in accordance with the requirements of the Specification and shall not prejudice any claim, right or privilege that the Authority may have under the guarantees.

Representatives of the Authority shall be permitted full and free access to the

Contractor's facilities, as well as those of his subcontractors and vendors. The

Contractor shall furnish such facilities and give such assistance for inspection as the Authority's representative may require, at no cost to the Authority.

3.7 Bidder Requirements

3.7.1 The bidders shall, at the request of the MBTA, present evidence that they are fully competent and have the necessary facilities, equipment, and financial resources to fulfill the conditions of this specification. The

Page: 13 o f 24

MBTA reserves the right to determine whether or not said facilities are sufficiently adequate to supply the MBTA's requirement of the remanufactured parts.

3.7.2 Delivery vehicles and drivers shall comply with all applicable regulations.

These regulations shall include, but not be limited, to Federal Motor

Vehicle, Federal Motor Carrier, Commonwealth of Massachusetts

Registry of Motor Vehicles, Commonwealth of Massachusetts Department of Telecommunications, Department of Transportation (DOT) and local fire department regulations. This compliance is to include requirements for hazardous materials as specified in the DOT Hazardous Materials. The bidders shall, at the request of the MBTA, present evidence that they fully comply with the requirements of this paragraph.

3.7.3 Experience:

The bidder's shall have at least two years' experience relating to the specific work outlined in this proposal or of similar type diesel engines with a public/private transit company. Evidence of this experience shall be provided to the MBTA upon request.

3.7.4 Qualification:

In the procurement of products requiring qualifications, the MBTA reserves the right to reject bids on products for which the bidder is unable to furnish authenticated records of tests to satisfy the MBTA that the proposed remanufactured part has met all requirements of this specification.

3.7.5 If the contractor or any subcontractor has been cited or under investigation for noncompliance with Federal, State or local laws, ordinances, rules or regulations, the contractor shall notify the MBTA in writing immediately and provide suitable explanatory information. Failure to make such

Page: 14 o f 24 disclosures at the time of bidding shall be cause for rejection of the bidder's proposal or immediate termination of the contract after award.

Disclosures will be reviewed, evaluated and addressed by the MBTA with the contractor on a case-by-case basis.

3.7.6 The successful bidder shall assume responsibility for the remanufactured parts delivered whether provided by the bidder or by a subcontractor. The successful bidder shall be responsible for informing all subcontractors of specification requirements and ensuring compliance. Please note that this includes insurance requirements. An insurance binder for all subcontractors must be obtained by the successful bidder and provided to the. A written statement on fulfilling this requirement shall be supplied with their bid.

3.7.7 The contractor shall provide adequate supervision, oversight and training to maintain strict work discipline and perform all work in full compliance with all applicable laws and regulations, particularly those pertaining to occupational safety and health.

3.7.8 Before submitting a bid, each prospective contractor shall (1) examine

Specification Documents thoroughly, (2) become familiar with conditions that may in any manner effect cost, progress or performance of the work specified, (3) familiarize themselves with the configuration of the

MBTA’s bus fleet engines, (4) be familiar with Federal, State and local laws, ordinances, rules and regulations that may affect the cost, progress or performance of the work specified and (5) study and correlate information thus determined with the Specified Documents.

Therefore, submission of a bid shall indicate that the contractor is completely and thoroughly familiar with these.

Page: 15 o f 24

4.0 REMANUFACTURING OF ENGINES:

4.1 Block

4.1.1 Basic Work

The remanufacturing process used by the contractor shall comply with OEM

Specifications. It shall include, but not be limited to, the following:

All plug holes, cap plugs and cam bearings shall be removed to permit thorough inspection and cleaning of coolant, fuel and lubrication passages.

Thermal clean, shot peen, sand gasket surfaces. C1eaning shall remove accumulated dirt, rust and oxide buildup.

Inspect for cracks and leaks by both visual and magnaflux inspection. To include, but not be limited to, deck, counter bore areas, sides, mainlines and main caps.

Inspect flatness of top deck area

Inspect main crankshaft and camshaft intermediate bearing bores for evidence of turned or spun bearing shells, crank webs, scoring and other irregularities. Inspect all lubricating passages for obstructions. Repair as necessary.

Inspect main crankshaft caps for cracks, irregularities and damage. Replace as necessary. Burrs shall be removed from all machined surfaces. Where threads on bolt holes can be repaired to the quality standards of the OEM, such bolt holes threads may be cleaned with a tap and die as required. Threaded inserts

(Helicoils) shall not be used to repair bolt holes.

All studs and plate dowel pins shall be inspected for stretching, bending or other irregularities. All stretched and/or bent and/or damaged studs and pins shall be

Page: 16 o f 24 replaced.

New stainless steel plugs (freeze plugs) shall be furnished and installed by the contractor.

New cam bearings shall be furnished and installed by the contractor. The parts furnished and installed by the contractor shall be new and unused and meet or exceed OEM Specifications

4.1.2 Additional Work

When required, the following items shall be included in the remanufacturing process.

Cylinder cavitation damage repair: machine and install upper or lower repair sleeves

Bearing bore misalignment: perform align bore

Fire deck flatness out of spec, resurface fire deck and machine counter bores

Repair threaded holes with repair bushings

Repair casting

4.2 Head

4.2.1 Basic work

Head shall be completely disassembled to permit thorough inspection and

Page: 17 o f 24 cleaning of coolant, fuel and lubrication passages

Thermal clean, shot peen, sand gasket surfaces. Cleaning shall remove accumulated dirt, rust and oxide buildup.

Inspect flatness

Inspect all threaded holes and repair as necessary.

Inspect for cracks and leaks by both visual and magnaflux inspection.

Install all stainless steel expansion plugs. *

Pressure test

Remove, furnish and install all valve guides. *

Check valve seats and replace as necessary

Machine fire deck

Machine valve seats to OEM Specifications

Clean and inspect valves

Machine valves and replace as necessary

Final wash

Clean, test and replace as necessary valve springs to OEM Specifications

Clean, inspect and replace as necessary valve locks.

Page: 18 o f 24

Furnish and install new valve seals. *

Assemble head per OEM Specifications

* The parts furnished and installed by the contractor shall be new unused and meet or exceed OEM specifications.

4.2.2 Extra Work

Head casting damage: machine and repair as applicable

4.3 Crankshaft

Clean

Inspect for cracks by both visual and magnaflux inspection

Check all threaded holes.

Check snout and flywheel flange for True Indicator Run Out

Inspect for straightness

Measure journals and polish as required per OEM Specifications.

4.4 Camshaft:

Page: 19 o f 24

Clean

Inspect for cracks by both visual and magnaflux inspection

Inspect for straightness

Measure lobes and polish as required

Measure journals and polish as required per OEM Specifications.

4.5 Connecting Rods

Visual inspection

Remove wrist pin bushing and cap

Degrease

Check for straightness

Magnaflux rods, bolts, and nuts

Supply and install new wrist pin bushing

Machine rod and cap

Machine big end to OEM specs

Bore wrist pin bushing to correct center to center distance

Wash and bag connecting rod

Page: 20 o f 24

5.0 DELIVERY:

It is critical that the delivery of remanufactured parts be made as soon as possible after a core is picked up by the contractor. The length of time for this to occur shall not exceed three (3) working days. The contractor shall provide a written statement in their bid that indicates compliance with this Requirement.

The contractor shall deliver remanufactured parts to:

Engine Shop Foreperson

MBTA Main Repair Facility

Component Exchange

Building # 1, Door # 12

80 Broadway

Everett, MA 02149

Deliveries shall be made Monday through Friday between the hours of 7:00 AM and

1 :00 PM excluding holidays. The contractor shall prepare delivery tickets that indicate the types of remanufactured parts, serial numbers and quantities that are delivered. The contractor shall obtain the signature of MBTA Personnel making delivery of the parts on these delivery tickets. A copy of each delivery ticket shall be provided to the MBTA after they are signed.

The contractor shall be responsible for all freight charges for the delivery of remanufactured parts.

The contractor shall identify, provide and prepare all applicable permits, certificates, manifests, restriction forms and any other forms required by the Federal, State and local laws and regulations to safely handle and transport all items. All labor, material and other costs for this work shall be included in the bid. There shall be no additional charge to the MBTA for any of these costs.

Page: 21 o f 24

If at any time during the contract, the contractor fails to comply with the specified deliver requirements, the MBTA shall the right to cancel the contract.

The contractor shall submit an invoice having the cost for the number of parts delivered with each shipment. The MBTA shall pay for only those parts that have been delivered.

The MBTA shall have up to forty-five (45) days to process payment for all invoices.

6.0 APPROVAL

Michael Burrows – Supervisor

Everett Bus Main Repair Facility

Page: 22 o f 24

7.0 REVISION RECORD

Rev Description Date Approv

Original release 2014

Black lined use of Appendix A-price sheet.

Bidder is to use Price Form C – spreadsheet attachment Price Form for RFP-145-18 providing a more user friendly and seamless single page format which complies with the price proposal submission requirements.

11/18

Equipment Engineering and Quality Assurance

Page: Page 23 of 24

Date: September 28, 2011

Revision:

8.0 APPENDIX A Use FORM C – Pricing Sheet Attachment

Block

Motor Manufacturer ______________

Motor Serial Number ______________

Motor Model ______________

Price

Basic Work ______________

Additional Work ______________

Tighten main cap and align bore ______________

Resurface deck and machine counter bores ______________

Repair threaded holes with repair bushings ______________

Repair casting ______________

Head

Motor Serial Number ______________

Motor Model ______________

Price

Basic Work ______________

Additional Work ______________

Head casting damage: machine and repair as applicable ______________

Crankshaft

Motor Serial Number ______________

Motor Model ______________

Camshaft

Equipment Engineering and Quality Assurance

Page: Page 24 of 24

Date: September 28, 2011

Revision:

Motor Serial Number ______________

Motor Model ______________

Price

Basic Work ______________

Connecting Rods

Motor Manufacturer ______________

Motor Serial Number ______________

Motor Model ______________

Use FORM C – Pricing Sheet Attachment