Performance_Work_Statement_RCV_Transmissions_03August17.pdf

PERFORMANCE WORK STATEMENT (PWS)

FOR

SERVICES PERTAINING THE REQUALIFICATION OF TRANSMISSIONS FOR USE IN RECAPITALIZED

ROUTE CLEARANCE VEHICLES (RCV)S

1.0 General:

1.1 Scope: The contractor shall provide all personnel, equipment, tools, materials, supervision, quality control and other items and non-personal services necessary to perform transmission requalification services as defined in this PWS, except as specified in Paragraph 3.0 as Government Furnished. The contractor shall perform to the standards in this contract. The contractor shall be required to pick-up the transmissions referenced in this PWS from Letterkenny Army Depot (LEAD) for the purpose of requalifying them and returning them back to LEAD. Beyond the standard Original Equipment Manufacturer (OEM) transmission configurations, typical transmissions received from LEAD may include flexplate assemblies, torque converters, and starters, still installed onto them. This PWS is structured to include various government-selected options for the level of service to be performed based on the type and condition of the component, as follows:

Table 1 Option Description

1 Initial Evaluation of Transmissions IAW Para 5.1 2 General Servicing of Transmissions IAW Para 5.2 3 Transmission Control Module Flashing Para 5.3 4 Modification Tasks – CAT CX31 Para 5.4 5 Modification Tasks – Allison 3000SP Para 5.5 6 Requalification Tests of Transmissions IAW Para 5.6 7 Remanufacture CAT CX31 6-Spd Transmission IAW Para 5.7 8 Remanufacture Allison 2500SP Transmission IAW Para 5.8 9 Remanufacture of Allison S-35C-602 (3200SP) & 3000SP Transmission IAW Para 5.9

10 Remanufacture/Replacement of CAT CX31 (S/N EBW00302) Torque Converter IAW Para 5.10 11 Remanufacture/Replacement of 2500SP Torque Converter P/N 29549520 IAW Para 5.11 12 Remanufacture/Replacement of 3000SP Torque Converter TC-418 IAW Para 5.12 13 Remanufacture/Replacement of 3200SP Torque Converter TC-421 IAW Para 5.13 14 Painting of Transmissions IAW Para 5.14 15 Supply Repair Parts for RCV Transmissions IAW 5.15.2 16 Manpower IAW 5.20

1.2 Background: Tank-Automotive and Armaments Command (TACOM) is planning to recapitalize Operational Need Statement (ONS) RCVs and reconfigure them to meet Program of Record (POR) standards. TACOM is requiring that the transmissions removed from the ONS RCVs are tested and requalified to meet original performance requirements.

1.3 Period of Performance (PoP): The Period of Performance shall be one Base Year of 12 months and three 12-month option years. The Period of Performance reads as follows:

1.3.1 Base Year: 01 September 2017 to 31 August 2018

1.3.2 Option Year One: 01 September 2018 to 31 August 2019

1.3.3 Option Year Two: 01 September 2019 to 31 August 2020

1.3.4 Option Year Three: 01 September 2020 to 31 August 2021

1.4 General Information:

1.4.1 Quality Control (QC): The contractor shall be certified to conform to ISO 9001 standards. The contractor shall develop and maintain an effective QC program to ensure services are performed in accordance with this PWS. The contractor shall develop and implement procedures to identify, prevent, and ensure non-recurrence of defective services. The contractor’s QC program is the means by which it assures itself that its work complies with the requirements of the contract. As a minimum, the contractor shall develop QC procedures that address the areas identified in Technical Exhibit 1, Performance Requirements Summary.

1.4.2 Quality Assurance (QA): The Government shall evaluate the contractor’s performance under this contract in accordance with the Quality Assurance Surveillance Plan (QASP). This plan is primarily focused on what the Government must do to ensure that the contractor has performed in accordance with the performance standards. It defines how the performance standards will be applied, the frequency of surveillance, and acceptable quality level(s) (defect rate(s)).

1.4.3 Recognized Holidays: The following are recognized US holidays. The contractor shall not pick up or deliver on these days:

1.4.3.1 New Year’s Day: January 1st

1.4.3.2 Martin Luther King, Jr.’s Birthday: Third Monday in January

1.4.3.3 President’s Day: Third Monday in February

1.4.3.4 Memorial Day: Last Monday in May

1.4.3.5 Independence Day: July 4th

1.4.3.6 Labor Day: First Monday in September

1.4.3.7 Columbus Day: First Monday in October

1.4.3.8 Veteran’s Day: November 11th

1.4.3.9 Thanksgiving Day: Fourth Thursday in November

1.4.3.10 Christmas Day: 25th Day in December

1.4.4 Place and Performance of Services: The contractor shall pick up and deliver during LEAD’s normal business hours except on recognized US holidays or when the Government facility/installation is closed due to local or national emergencies, administrative closings, or similar Government-directed facility/installation closings.

Performance shall be at the contractor’s facility. The contractor shall at all times maintain an adequate work force for the uninterrupted performance of all tasks defined within this PWS.

1.4.5 Security Requirements: Contractor and all associated sub-contractor’s employees shall comply with applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative). The contractor shall also provide all information required for background checks to meet installation access requirements to be accomplished by installation Provost Marshal Office, Director of Emergency Services or Security Office. Contractor workforce shall comply with all personal identity verification requirements as directed by DOD, HQDA and/or local policy. Should the Force Protection Condition (FPCON) change, the Government may require changes in contractor security matters or processes.

1.4.5.1 Physical Security: The contractor shall safeguard all Government property provided for contractor use. At the close of each work period, Government facilities, equipment and materials shall be secured.

1.4.5.2 AT Level 1 Awareness Training: All contractor employees, to included subcontractor employees, requiring access to Army Installations, facilities, and controlled access areas shall complete AT Level 1 awareness training within 30 calendar days after contract start date and within 30 calendar days of new employees commencing performance. The contractor shall submit certificates of completion for each affected contractor employee and subcontractor employee, to the COR or to the contracting officer, if a COR is not assigned, within 15 calendar days after completion of training. AT level 1 awareness training is available on the Letterkenny Army Depot homepage – www.lead.army.mil.

1.4.5.3 iWATCH Training: The contractor and all associated sub-contractors with an area of performance within an Army-controlled installation, facilities or area shall brief all employees on the local iWATCH program. This local developed training will be used to inform employees of the types of behavior to watch for and instruct employees to report suspicious activity to the COR or contracting officer. This training shall be completed within 30 calendar days of contract award and within 30 calendar days of new employees commencing performance. The contractor shall report completion for each affected contractor employee and subcontractor employee, to the COR or to the contracting officer, if a COR is not assigned, within 15 calendar days after completion of training. iWATCH training is available on the Letterkenny Army Depot homepage – www.lead.army.mil.

1.4.5.4 OPSEC Training: Per AR 530-1, Operations Security, new contractor employees and associated sub-contractor employees shall complete Level I OPSEC training within 30 calendar days of their reporting for duty and annually thereafter. The contractor shall submit certificates of completion for each affected contractor employee and subcontractor employee, to the COR or to the contracting officer, if a COR is not assigned, within 15 calendar days after completion of training. Level 1 OPSEC training is available on the Letterkenny Army Depot homepage – www.lead.army.mil.

1.4.6 Special Qualifications: This program requires the requalifying of transmissions from vendor sources who are designated by the various transmission OEMs as authorized rebuild centers, or from vendors that can provide objective evidence that validates their rebuild process, parts, testing and service is equal to or exceeds that of the different OEM specifications and authorization standards. The contractor shall perform requalifying and testing that meets or exceeds OEM specifications. In addition, interested sources must be able to provide objective evidence such as a certificate of conformance or other documentation that validates they are authorized by the OEM as an approved rebuild center. The contractor must have experience in the repair, remanufacture, and testing of transmissions and power train components to OEM standards. The contractor shall provide evidence of performing these types of services within the last two years. The Contractor shall submit sample transmission test reports along with historical narratives to validate this experience. The contractor is also required to have any necessary licenses that would be needed. The contractor shall be responsible for ensuring that any software or license is up-to-date and valid in accordance with the OEM guidelines.

1.4.7 Post Award Conference/Periodic Progress Meetings: The contractor agrees to attend any post award conference convened by the KO in accordance with Federal Acquisition Regulations Subpart 42.5. The KO, Contracting Officer’s Representative (COR), and other Government personnel, as appropriate, may meet periodically with the contractor to review the contactor’s performance. At these meetings, the Contacting Officer will apprise the contractor of how the Government views the contractor’s performance and the contractor shall apprise the Government of problems, if any, being experienced The contractor shall resolve outstanding issues raised by the Government. Contractor attendance at these meetings shall be at no additional cost to the Government.

1.4.8 Contract Manager (CM): The contactor shall provide a CM who shall ensure performance under this contract.

The name of this person, and an alternate who shall act for the contractor when the CM is absent, shall be designated in writing to the KO. The CM or alternate shall have full authority to act for the contractor on all contract matters relating to daily operation of this contract.

1.4.9 Identification of Contractor Employees: All contact personnel attending meetings, answering Government telephones and working in other situations where their contractor status is not obvious to third parties are required to identify themselves as such to avoid creating an impression in the minds of members of the public that they are Government officials. The contractor shall also ensure that all documents or reports produced by contractor personnel are suitably marked as contractor products or that contractor participation is appropriately disclosed

2.0 Definitions and Acronyms:

2.1.1 CONTRACTOR. A supplier or vendor awarded a contract to provide specific supplies or service to the government. The term used in this contract refers to the prime.

2.1.2 CONTRACTING OFFICER (KO). A person with authority to enter into, administer, and or terminate contracts, and make related determinations and findings on behalf of the government. Note: The only individual who can legally bind the government.

2.1.3 CONTRACTING OFFICER'S REPRESENTATIVE (COR). An employee of the U.S. Government designated by the KO to monitor contractor performance. Such appointment shall be in writing and shall state the scope of authority and limitations. This individual has authority to provide technical direction to the Contractor as long as that direction is within the scope of the contract, does not constitute a change, and has no funding implications. This individual does NOT have authority to change the terms and conditions of the contract.

2.1.4 DEFECTIVE SERVICE. A service output that does not meet the standard of performance associated with the Performance Work Statement.

2.1.5 DELIVERABLE. Anything that can be physically delivered and includes non-manufactured things such as meeting minutes or reports.

2.1.6 KEY PERSONNEL. Contractor personnel that are evaluated in a source selection process and that may be required to be used in the performance of a contract by the Key Personnel listed in the PWS. When key personnel are used as an evaluation factor in best value procurement, an offer can be rejected if it does not have a firm commitment from the persons that are listed in the proposal.

2.1.7 PHYSICAL SECURITY. Actions that prevent the loss or damage of Government property.

2.1.8 QUALITY ASSURANCE. The government procedures to verify that services being performed by the Contractor are performed according to acceptable standards.

2.1.9 QUALITY ASSURANCE SURVEILLANCE PLAN (QASP). An organized written document specifying the surveillance methodology to be used for surveillance of contractor performance.

2.1.10 QUALITY CONTROL. All necessary measures taken by the Contractor to assure that the quality of an end product or service shall meet contract requirements.

2.1.11 SUBCONTRACTOR. One that enters into a contract with a prime contractor. The Government does not have privity of contract with the subcontractor.

2.1.12 WORK DAY. The number of hours per day the Contractor provides services in accordance with the contract.

2.1.13 WORK WEEK. Monday through Friday, unless specified otherwise.

2.2 ACRONYMS:

AFARS Army Federal Acquisition Regulation Supplement AR Army Regulation CFR Code of Federal Regulations CONUS Continental United States (excludes Alaska and Hawaii) COR Contracting Officer Representative COTS Commercial-Off-the-Shelf DA Department of the Army DD250 Department of Defense Form 250 (Receiving Report) DD254 Department of Defense Contract Security Requirement List DFARS Defense Federal Acquisition Regulation Supplement DOD Department of Defense FAR Federal Acquisition Regulation KO Contracting Officer OCI Organizational Conflict of Interest ODC Other Direct Costs PIPO Phase In/Phase Out POC Point of Contact PRS Performance Requirements Summary PWS Performance Work Statement QA Quality Assurance QAP Quality Assurance Program

QASP Quality Assurance Surveillance Plan QC Quality Control QCP Quality Control Program TE Technical Exhibit

3.0 Government Furnished Property, Material, Equipment and Services (GFP/M/E/S): The Government will provide the facilities, equipment, materials, and/or services listed below in Table 2:

Table 2 Equipment Type Model NSN

Transmission CAT CX31 / 6-Speed 2815-01-595-5789 Transmission Allison 2500SP 2520-01-557-6128 Transmission Allison 2500SP 2520-01-554-9545 Transmission Allison 3000SP 2520-01-574-0556 Transmission Allison 3200SP 2590-01-555-5441

Torque Converter CAT CX31 Torque Converter Allison P/N 29549520 2520-01-554-3479 Torque Converter Allison TC-418 Torque Converter Allison TC-421

4.0 Contractor Furnished Property, Materials, Equipment (CFP/M/E):

4.1 General: Except for those items specifically stated to be Government-Furnished in Paragraph 3.0, the contractor shall furnish everything required to perform these services as indicated in Paragraph 1.1.

5.0 Requirements: The contractor shall receive transmissions for the following RCVs: MMPV/RG-33L Plus, Buffalo A2, RG-31Mk5E, and Husky MkII. The transmissions used in each particular platform are referenced in Table 6 of this PWS. Unless otherwise specified by LEAD the contractor shall subject all transmissions received to a requalification test. If LEAD has determined a transmission to be unserviceable, depending on the type of transmission, either Option 7, 8, or 9 shall be exercised.

5.1 Option 1 (CLIN 1) – Initial Evaluation of Transmission: The contractor shall perform an initial evaluation on every transmission that is received to determine if it is serviceable. The initial evaluation shall consist of draining and inspecting the fluid to see if it shows any signs of contamination such as water, engine coolant, or significant pieces of metal beyond what would be normal. The contractor shall visually inspect the sump for signs of damage/contamination which in some case may require removing the transmission filters.

5.1.1 Transmissions Determined to be Unserviceable: All transmissions that have been determined to be unserviceable shall be sent back to LEAD. No additional options shall be utilized beyond Option 1 of this PWS which is meant to cover the labor cost involved with performing the initial evaluation.

5.1.2 Transmissions Determined to be Serviceable but Damaged/Contaminated: The contractor shall contact LEAD’s COR if after performing an Initial Evaluation of a transmission it has been determined that it is serviceable but shows signs of damage/contamination. LEAD shall make a determination if whether or not to proceed with either Option 7, 8, or 9 of this PWS depending on the type of transmission. The turnaround period for servicing a transmission shall be extended by a day for each business day while waiting on a response back from LEAD.

5.1.3 Transmissions Determined to be Serviceable: If a transmission has been determined to be serviceable a contractor is authorized to proceed directly to performing General Servicing of the transmission IAW with Option 2 of this PWS.

5.2 Option 2 (CLIN 2) - General Servicing of Transmissions: The contractor shall service transmissions that pass the requalification test in accordance with OEM standards for draining, flushing, and changing their filters. Also as part of performing general servicing the contractor shall replace the rear output seal associated with each transmission. Part numbers for the various output seals are referenced in Table 3 of this PWS. While changing the fluid and filter the contractor shall check for any signs that would indicate if a transmission may have over heated.

The contractor shall also check to see if a transmission exhibits excessive amounts of wear. If a transmission shows signs of overheating or an excessive amount of wear, the contractor shall take photos and fax or email them to the LEAD COR within 24 hrs. The contractor shall specify potential causes for the failure along with potential corrective actions. The LEAD COR will notify the vendor if they are to proceed with any corrective actions.

Depending on the type of transmission, the LEAD COR may choose to have the contractor exercise either Option 7, 8, or 9. If a transmission does not exhibit signs of overheating or excessive amounts of wear the contractor shall proceed with replacing the filter and fluid and shall proceed with performing the Transmission Requalification Test per paragraph 5.6 of this PWS.

Table 3

Nomenclature Transmission Model NIIN Part Number Qty.

OUTPUT SEAL CAT CX31 015877093 274-7437 1

O-RING CAT CX31 010584568 3P0653 1

OUTPUT SEAL Allison 2500SP 015549413 29536379 1

OUTPUT SEAL Allison 3000SP 016538768 29556870 1

OUTPUT SEAL Allison 3200SP 015677455 29546233 1

5.3 Option 1 (CLIN 1) -Transmission Control Module (TCM) Programming (Flashing): After the award of the contract LEAD will provide the contractor with access to sample TCMs to read template program codes from. The contractor shall be required to download the code and then program (“flash” when used in this regards) it onto TCMs that may or may not already have programs flashed into them. LEAD will also provide the contractor with TCM parameter data that will need to be manually programmed into the units. The contractor shall only use software approved by the OEM for performing the services detailed in this PWS. The contractor shall also be required to check to see if the TCMs have the latest calibration updates in accordance with (IAW) OEM recommendations. If a contractor does not have approved OEM software/equipment in-house to reflash a particular OEMs ECMs, they are only authorized to coordinate with a respective authorized OEM service center to perform the tasks detailed in this PWS. This option will be used for the Allison 3000SP, the Allison 3200SP, the Allison 2500SP, and the CAT CX31 transmission TCMs.

5.4 Option 2 (CLIN 2) - CAT CX31 Modification Tasks: This option shall be used to modify the CAT CX31 transmission by removing a Fail in Gear (FIG) feature associated with it. The scope of components that shall be used to perform the FIG modification under this option are listed in Table 4 of this PWS. The contractor shall adhere to Caterpillar’s instructions on how to properly remove the FIG. When this option is exercised it shall be performed before performing the requalification test that is referenced in paragraph 5.4 of this PWS.

Table 4

Nomenclature NIIN Part Number Qty.

CAP-SEAL - 374-7463 1

PLUG AS-STOR 015697026 183-3409 1

BOLT-HEX HEAD 015658908 285-9066 12

BOLT-HEX HEAD 013981282 8T-4908 4

GUARD AS - 391-1261 1

WASHER, FLAT 013598806 8T-4224 16

5.5 Option 3 (CLIN 3) - Allison 3000SP Transmission Modification Tasks: The contractor shall replace the parts referenced in Table 5 before performing requalification testing. This option shall be used to address components on the Allison 3000SP transmissions that need to be replaced to accommodate the new configuration requirements of the recapitalized vehicles that they are to be installed into. The contractor will be provided with Work Instructions from LEAD on how to perform this task. The scope of components that shall be replaced under this option are listed in Table 5. When this option is exercised it shall be performed before performing the requalification test that is referenced in paragraph 5.4 of this PWS.

Table 5

Nomenclature NIIN Part Number Qty.

Dip Stick Seal - 29546224 (CAGE 73342) 1

5.6 Option 6 (CLIN 6) -Transmission Requalification Test: The contractor shall receive transmissions for the following RCVs: MMPV/RG-33L Plus, Buffalo A2, RG-31Mk5E, and Husky MkII. The transmissions used in each particular platform are referenced in Table 8 of this PWS. Unless otherwise determined from observations while doing General Servicing of the transmissions per paragraph 5.4 of this PWS, or otherwise specified by LEAD, the contractor shall subject all transmissions received to a requalification test. If LEAD has pre-determined that a transmission does not function properly, the requalification test shall be excluded and depending on the type of transmission, either Option 7, 8, or 9 shall be exercised:

5.6.1. Transmission Requalification Test: The contractor shall subject all transmissions and their corresponding torque converters to a dynamometer test. Shop manual part numbers for some of the transmissions are provided in Table 8 for reference. The contractor shall first run the dynamometer test and make sure that the torque converter is functioning properly in accordance with OEM performance specifications. If the torque converter is not functioning properly the contractor shall substitute the torque converter with a torque converter known to be in good working condition in accordance with OEM performance specifications in order to complete the requalification test of the transmission. This substitute torque converter shall be one that the contractor only uses for requalification tests after it is determined that the original torque converter accompanying the transmission is not functioning properly. The substitute torque converter shall not be shipped out installed on a transmission. For torque converters that have been evaluated and determined not to be functioning properly, either option 10, 11, 12, or 13 may be exercised depending upon prior approval from LEAD. The dynamometer test shall be run evaluating the transmissions in all drive gears. During the test output torque, shifting points, as well as full/closed throttle upshifting/downshifting shall be monitored for each gear. Each drive gear shall be tested for a minimum of 30-minutes. When evaluating the shifting points, and full/closed throttle upshifting/downshifting, the contractor shall compare data measured against the performance specifications as referenced by the serial number on each of the transmissions. For all other performance specifications evaluated the contractor shall reference OEM shop manuals for what is deemed acceptable operating characteristics. During the testing the contractor shall monitor the transmissions for signs of leakage, vibration, and binding. All data gathered shall be evaluated and compared against OEM specifications for the transmission. For transmissions that meet the OEM standards the contractor shall ensure that the transmissions meet the Specific Repair Requirements of paragraph 5.15 and then return them back to LEAD. For transmissions that do not meet the OEM standards, the contractor shall first contact LEAD’s COR for further direction, depending on the type of transmission, either Option 7, 8, or 9 may be exercised. LEAD’s COR shall provide a response within 72 hours. The contractor shall provide the test results, along with the respective transmission serial numbers for which the test were performed on, back to LEAD.

5.7 Option 7 (CLIN 7) - Complete Remanufacture of CAT CX31 6-Speed Transmissions: Option 7 shall be exercised where it has been determined by either LEAD, the contractor, or from the requalification test results that a complete remanufacture is needed. The costs of performing a second Requalification Test, as well as the cost for any General Servicing task that would need to be re-performed as a process of remanufacturing the transmissions shall be included in this CLIN. Before remanufacturing a transmission, the contractor shall evaluate the unit to determine if it is serviceable. For transmissions determined to be unserviceable the Delivery Order that exercised the Remanufacture option would be modified to only account for the labor hours spent to perform the evaluation and not the entire cost specified for the CLIN. For transmissions determined to be unserviceable the contractor shall contact LEAD’s COR with their findings along with the hours spent performing the evaluation; afterwards LEAD’s COR will provide the contractor with further instructions with regards to returning the unit. Serviceable transmissions shall be remanufactured to “zero-hour” OEM standards/tolerances. In addition, where OEM criteria does not specifically specify, to meet "zero-hour" standards the following components are required to be replaced within the transmissions: all bearings, all bushings, all friction rings, all springs, all seals and O-rings. All remanufactured transmissions shall be run through another transmission requalification test in accordance with paragraph 5.6. The contractor shall ensure that transmissions that pass the requalification test meet the Specific Repair Requirements of paragraph 5.15. For transmissions that fail the requalification test after being remanufactured, the contractor shall fax or email dynamometer test results to the LEAD COR within 24 hrs. The contractor shall specify potential causes for the failure along with potential corrective actions. Transmissions that have been remanufactured but have failed requalification testing are to be sent back to LEAD.

5.8 Option 8 (CLIN 8) - Complete Remanufacture of Allison 2500SP Transmissions: Option 8 shall be exercised where it has been determined by either LEAD, the contractor, or from the requalification test results that a complete remanufacture is needed. The costs of performing a second Requalification Test, as well as the cost for any General Servicing task that would need to be re-performed as a process of remanufacturing the transmissions shall be included in this CLIN. Before remanufacturing a transmission, the contractor shall evaluate the unit to determine if it is serviceable. For transmissions determined to be unserviceable the Delivery Order that exercised the Remanufacture option would be modified to only account for the labor hours spent to perform the evaluation and not the entire cost specified for the CLIN. For transmissions determined to be unserviceable the contractor shall contact LEAD’s COR with their findings along with the hours spent performing the evaluation; afterwards LEAD’s COR will provide the contractor with further instructions with regards to returning the unit. Serviceable transmissions shall be remanufactured to “zero-hour” OEM standards/tolerances in accordance with Allison shop manual P/N SM3191EN (Pre Gen 4) or shop manual P/N SM4006EN (Gen 4) depending on which manual is applicable. In addition, where OEM criteria does not specifically specify, to meet "zero-hour" standards the following components are required to be replaced within the transmissions: all bearings, all bushings, all friction rings, all springs, all seals and O-rings. All remanufactured transmissions shall be run through another transmission requalification test in accordance with paragraph 5.6. The contractor shall ensure that transmissions that pass the requalification test meet the Specific Repair Requirements of paragraph 5.15. For transmissions that fail the requalification test after being remanufactured, the contractor shall fax or email dynamometer test results to the LEAD COR within 24 hrs. The contractor shall specify potential causes for the failure along with potential corrective actions. Transmissions that have been remanufactured but have failed requalification testing are to be sent back to LEAD.

5.9 Option 9 (CLIN 9) - Complete Remanufacture of Allison S-35C-602 (3200SP) and 3000SP Transmissions:

Option 8 shall be exercised where it has been determined by either LEAD, the contractor, or from the requalification test results that a complete remanufacture is needed. The costs of performing a second Requalification Test, as well as the cost for any General Servicing task that would need to be re-performed as a process of remanufacturing the transmissions shall be included in this CLIN. Before remanufacturing a transmission, the contractor shall evaluate the unit to determine if it is serviceable. For transmissions determined to be unserviceable the Delivery Order that exercised the Remanufacture option would be modified to only account for the labor hours spent to perform the evaluation and not the entire cost specified for the CLIN. For transmissions determined to be unserviceable the contractor shall contact LEAD’s COR with their findings along with the hours spent performing the evaluation;

afterwards LEAD’s COR will provide the contractor with further instructions with regards to returning the unit.

Serviceable transmissions shall be remanufactured to “zero-hour” OEM standards/tolerances in accordance with Allison shop manual P/N SM2148EN (Pre Gen 4) or shop manual P/N SM4013EN (Gen 4) depending on which manual is applicable. In addition, where OEM criteria does not specifically specify, to meet "zero-hour" standards the following components are required to be replaced within the transmissions: all bearings, all bushings, all friction rings, all springs, all seals and O-rings. All remanufactured transmissions shall be run through another transmission requalification test in accordance with paragraph 5.6. The contractor shall ensure that transmissions that pass the requalification test meet the Specific Repair Requirements of paragraph 5.15. For transmissions that fail the requalification test after being remanufactured, the contractor shall fax or email dynamometer test results to the LEAD COR within 24 hrs. The contractor shall specify potential causes for the failure along with potential corrective actions. Transmissions that have been remanufactured but have failed requalification testing are to be sent back to LEAD.

5.10 Option 10 (CLIN 10) - Remanufacture of CAT CX31 (S/N EBW00302) Torque Converter: The contractor shall contact LEAD’s COR for approval before proceeding with Option 10. Option 10 shall be exercised if after evaluating a torque converter during the Requalification Test it has been determined that the torque converter is not functioning properly. The contractor shall reference OEM standards and tolerances regarding remanufacture requirements for torque converters that fail the requalification test but can be rebuilt. In addition, where OEM criteria does not specifically specify, to meet "zero-hour" standards the following components are required to be replaced when applicable to the various types of torque converters: all bearings, all bushings, and all seals. Torque converters that cannot be manufactured shall be sent back to LEAD.

5.11 Option 11 (CLIN 11) - Remanufacture of 2500SP Torque Converter P/N 29549520: The contractor shall contact LEAD’s COR for approval before proceeding with Option 11. Option 11 shall be exercised if after evaluating a torque converter during the Requalification Test it has been determined that the torque converter is not functioning properly. The contractor shall reference OEM standards and tolerances regarding remanufacture requirements for torque converters that fail the requalification test but can be rebuilt. In addition, where OEM criteria does not specifically specify, to meet "zero-hour" standards the following components are required to be replaced when applicable to the various types of torque converters: all bearings, all bushings, and all seals. Torque converters that cannot be manufactured shall be sent back to LEAD.

5.12 Option 12 (CLIN 12) - Remanufacture of 3000SP Torque Converter TC-418: The contractor shall contact LEAD’s COR for approval before proceeding with Option 12. Option 12 shall be exercised if after evaluating a torque converter during the Requalification Test it has been determined that the torque converter is not functioning properly. The contractor shall reference OEM standards and tolerances regarding remanufacture requirements for torque converters that fail the requalification test but can be rebuilt. In addition, where OEM criteria does not specifically specify, to meet "zero-hour" standards the following components are required to be replaced when applicable to the various types of torque converters: all bearings, all bushings, and all seals. Torque converters that cannot be manufactured shall be sent back to LEAD.

5.13 Option 13 (CLIN 13) - Remanufacture of 3200SP Torque Converter TC-421: The contractor shall contact LEAD’s COR for approval before proceeding with Option 13. Option 13 shall be exercised if after evaluating a torque converter during the Requalification Test it has been determined that the torque converter is not functioning properly. The contractor shall reference OEM standards and tolerances regarding remanufacture requirements for torque converters that fail the requalification test but can be rebuilt. In addition, where OEM criteria does not specifically specify, to meet "zero-hour" standards the following components are required to be replaced when applicable to the various types of torque converters: all bearings, all bushings, and all seals. Torque converters that cannot be manufactured shall be sent back to LEAD.

5.14 Option 14 (CLIN 14) - Painting of Transmissions: The contractor shall be required to paint transmissions that are received whenever Option 14 is exercised. LEAD will list the serial numbers of each transmission that this requirement pertains to. The transmission is not required to be completely disassembled for this option. The contractor shall however be required to remove the alternator from the transmission before painting. The contractor shall cover all hoses and fittings not standardly painted by the OEM of the transmission with some type of foil to protect them from being painted during the process. The contractor shall mask/cover any pulley, roller, and tensioner surface that would be in direct contact with the belts associated with the transmissions. The contractor shall mask/cover any labels, data plates, grounding locations, and symbols to prevent them from being painted over.

If a stencil or label needs to be removed to properly paint an area the contractor is required to re-apply the stencil or label in the same location. Other than the aforementioned excluded components the contractor is required to clean, prime, and paint any bracketry and metal surfaces present on the transmissions. If rust or chipped/flaking paint is present on an area of the transmission the contractor is required to hand sand the area and feather the surrounding edges before applying primer and paint. The contractor shall paint the transmissions with the original respective OEM colors used.

5.15 Specific Repair Requirements:

5.15.1 Repaired Components: Where repaired components are allowed, the contractor shall provide components that are rebuilt to OEM standards. All mandatory replacement parts as specified in the OEM technical manuals and specifications shall be replaced. All mandatory replacement parts shall meet or exceed OEM specifications. All replacement/repair parts, seals, gaskets (Do not use cork gaskets on transmission oil pans), sealants (Do not use anaerobic sealant), adhesives and other materials that are utilized by the contractor in the rebuild process shall conform to or exceed OEM specifications. The transmission requalifying requirements shall include OEM standard inspection. The rebuilding and testing of transmission electrical components shall include OEM standard inspection.

5.15.2 Damaged Core Component Replacement (CLIN 15): The costs for core components (i.e. transmission housings, major gear assemblies, etc.) that are not otherwise designated in NMWRs/OEM technical manuals as mandatory replacement parts are to be excluded from the costs of CLINs 7, 8, and 9. A listing of what is considered as a core component as defined in this PWS is referenced in Table 6. If a core component needs to be replaced the contractor shall provide a cost estimate for the component(s) back to LEAD’s COR at which point LEAD may choose to exercise an option to draw the estimated funds needed from a CLIN dedicated for miscellaneous components. LEAD will consider several factors in deciding whether or not to proceed with this option to include looking at a 70% threshold limit when compared to the cost of a new transmission assembly from the OEM.

Table 6

Table 5: Core Components Transmission Models

CAT CX31 Allison

2500SP

Allison

3000SP

Allison

3200SP

ITEM # NOMENCLATURE

1 Planetary Gears Ref. S/N for Part Number

Ref. S/N for Part Number

Ref. S/N for Part Number

Ref. S/N for Part Number

2 Main Shaft Ref. S/N for Part Number

Ref. S/N for Part Number

Ref. S/N for Part Number

Ref. S/N for Part Number

3 Control Valve Assembly Ref. S/N for Part Number

Ref. S/N for Part Number

Ref. S/N for Part Number

Ref. S/N for Part Number

4 Main Housing Ref. S/N for Part Number

Ref. S/N for Part Number

Ref. S/N for Part Number

Ref. S/N for Part Number

5 Converter Housing Ref. S/N for Part Number

Ref. S/N for Part Number

Ref. S/N for Part Number

Ref. S/N for Part Number

6 Rear Cover Ref. S/N for Part Number

Ref. S/N for Part Number

Ref. S/N for Part Number

Ref. S/N for Part Number

7 Transmission Control Module Ref. S/N for Part Number

Ref. S/N for Part Number

Ref. S/N for Part Number

Ref. S/N for Part Number

Torque Converters damaged beyond repair

Ref. S/N for Part Number

Ref. S/N for Part Number

Ref. S/N for Part Number

Ref. S/N for Part Number

5.15.3 Transmission Condition and Fluids: All delivered transmissions shall consist of rebuilt or new components, and shall be in a ready to run configuration for direct installation into a vehicle. Society of Automotive Engineers (SAE) 15W-40 grade motor oil shall be utilized in the transmissions unless specified otherwise on a delivery order.

Transmission oil, utilized for testing of the components need not be drained unless such fluids present a leakage problem during shipment. If fluids are drained from the units the contractor shall attach a tag to each unit stating this –for example: Fluid drained. Refill before operating.

5.15.4 Testing: The contractor shall test each rebuilt transmission and component as specified by the OEM technical manuals and specifications and to OEM standards. All results, to include dynamometer test results, shall be recorded in a computer generated test report. The contractor shall submit the format of the test report that they will be using for each component to LEAD for initial approval. The test data, identified to the component by serial or part number, shall be annotated within the test report. The contractor shall provide all test reports with corresponding serial numbers to LEAD.

5.15.5 Cleaning & Painting: All repaired and remanufactured components/assemblies shall be cleaned and stripped of any/all paint, residue and corrosion for purposes of being re-painted. Paint colors shall match the OEM colors on the respective transmissions.

5.15.6 Protection: When component repair is complete, the contractor shall take adequate measures to ensure that components are protected from the elements to prevent deterioration/corrosion until delivered to LEAD facilities.

5.15.7 Marking: The contractor shall mark all transmissions with contractor job order number and delivery order number.

5.15.8 Transportation: The Contractor shall pickup and deliver to LEAD all components in accordance with the delivery schedule. Exchange of component assemblies will be arranged through the COR that will be assigned at contract award. The contractor shall supply a completed DD form 1149 invoice/shipping document for all deliveries.

5.15.9 Shipping Containers: The contractor shall be responsible for providing any crates or skids needed to safely transport the various drive train components referenced in this PWS. The Contractor shall ensure that enough crates/skids are available to meet the weekly program demand requirements. For instance, if the weekly program demand requirements call for two transmissions a week, the contractor shall have at least four skids available (i.e.

This would allow two of the skids to be available at LEAD so that transmissions can be placed on them for pick-up, and would allow two of the skids to be at the contractor’s facility to satisfy transport requirements). Table 7 reflects the estimated quantities of each transmission skid that would be needed.

Table 7 OEM Model Total Quantity of

Skids/Crates Required

Allison

2500SP 4

3200SP 3

3000SP 10

CAT CAT CX31 6-Speed 3

5.16 Contractor Delivered Defective Components: If a transmission or component item delivered by the contractor to LEAD is found to be defective the LEAD COR will notify the contractor within 2 business days of the discovery;

after receiving the notification the contractor will have 5 days to either repair the item at LEAD or replace it. If a transmission or component item is to be exchanged by the contractor with the concurrence of LEAD, the item being exchanged shall be the same part number and configuration as the defective transmission or component item. If the defective transmission or component is exchanged with another GFE remanufactured transmission or component the contractor shall ensure that the turnaround timeframe for any following GFE transmission or components in their possession are not delayed. The contractor may also choose to replace the defective unit with a new or rebuilt unit that they have procured at their own expense at which point no additional rework will need to be done to the defective unit and it will remain the property of LEAD. All replaced items shall meet or exceed OEM remanufacture specifications and the contractor shall provide Objective Evidence Records (OER)’s with serial numbers to validate conformance as specified in this PWS.

5.17 Quality: LEAD reserves the right to perform quality inspections at the contractor’s facility at any time to verify quality, equipment, material, testing, and acceptance/rejection percentages.

5.18 Warranty: The contractor shall furnish a 12 month warranty or the industry standard OEM commercial warranty; whichever is greater, on all parts and labor of each component with regards to remanufactured or repaired components. The warranty period shall begin whenever a component is returned back to LEAD.

5.19 Delivery & Schedule: At the peak of each program, LEAD anticipates a weekly program quantity of one each Allison 3200SP transmissions, a weekly program quantity of two each CAT CX31 6-Spd transmissions, a weekly program quantity of seven each 3000SP transmissions, and a weekly program quantity of one each Allison 2500SP transmissions. The turnaround period for testing and performing any remanufacturing of a transmission/torque converter is not to exceed 35 calendar days. A LEAD COR will notify the contractor whenever a unit is ready to be picked up. The contractor will be given five business days to pick up a unit after they receive this notification. The 35 calendar day turn around period will start either one day after a unit has been picked up or no later than the sixth day after initial notification. Table 8 reflects the estimated quantities of each transmission that are anticipated to be sent out for service each year. Table 8 also includes serial numbers that can be referenced for the types of transmissions that are to be serviced per this PWS.

Table 8

Transmission Model and Reference Serial Number

Base Yr.

Est. Qty.

FY18 Est.

Qty.

FY19 Est.

Qty.

FY20 Est.

Qty.

CAT CX31 6-Spd (Ref. S/N EBW00302) 4 36 4 - Allison 2500SP (Ref. S/N 6310803675) 34 3 - - Allison 3000SP (Ref. S/N 652012733) - 200 200 2- Allison 3200SP (Ref. S/N 6510838590) 5 - - -

5.20 CONTRACTOR MANPOWER REPORTING (CMR): The Office of the Assistant Secretary of the Army (Manpower & Reserve Affairs) operates and maintains a secure Army data collection site where the Contractor shall report ALL Contractor manpower (including subcontractor manpower) required for performance of this contract.

The contractor shall completely fill in all the information in the format using the following web address https://armycmra.dmdc.osd.mil/default.aspx?ReturnUrl=%2f. The required information includes: (1) Contracting Office, KO, Contracting Officer’s Technical Representative (COTR) or also known as the Contracting Officer’s Representative (COR); (2) Contract number, including task and delivery order number; (3) Beginning and ending dates covered by reporting period; (4) Contractor's name, address, phone number, e-mail address, identity of Contractor employee entering data; (5) Estimated direct labor hours (including sub-Contractors); (6) Estimated direct labor dollars paid this reporting period (including sub-Contractors); (7) Total payments (including sub- Contractors); (8) Predominant Federal Service Code (FSC) reflecting services provided by Contractor (and separate predominant FSC for each sub-Contractor if different); (9) Estimated data collection cost; (10) Organizational title associated with the Unit Identification Code (UIC) for the Army Requiring Activity (the Army Requiring Activity is responsible for providing the Contractor with its UIC for the purposes of reporting this information); (11) Locations where Contractor and sub-Contractors perform the work (specified by zip code in the United States and nearest city, country, when in an overseas location, using standardized nomenclature provided on website); (12) Presence of deployment or contingency contract language; and (13) Number of Contractor and sub-Contractor employees deployed in theater this reporting period (by country). As part of its submission, the Contractor shall provide the estimated total cost (if any) incurred to comply with this reporting requirement. Reporting period shall be the period of performance not to exceed 12 months ending September 30 of each government fiscal year and must be reported by 31 October of each calendar year. Contractors may use a direct XML data transfer to the database server or fill in the fields on the website. The XML direct transfer is a format for transferring files from a Contractor’s system to the secure website without the need for separate data entries for each required data element at the website. The specific formats for the XML direct transfer may be downloaded from the website.

6.0 Applicable Publications: Publications applicable to this PWS are listed in both Table 9 and Table 10 of this PWS. The contractor shall be responsible for obtaining the various OEM technical manuals, specifications, and other data that is required to conform to the inspection, remanufacture, and test requirements that are set forth in this PWS. Table 9 references some of the most current Army technical manuals and commercial bulletins for the different RCV platforms. Some OEM shop manuals are referenced in Table 10 of this PWS.

Table 9 RCV Platform Transmission Model

& NSN

Army Parts Manual Army Maintenance Manual

Panther MMPV Allison 3200SP 2590-01-555-5441

Please reference part number and serial number

Please reference part number and serial number

RG-33L Plus Please reference part number and serial number

Please reference part number and serial number

Buffalo A2 CAT CX31 / 6-Speed 2520-01-577-8296

Please reference part number and serial number

Please reference part number and serial number

RG-31 Mk5E, 2355- 01-552-5169, 2355-

01-572-7980 2355-01-568-7688

Allison 2500SP 2520-01-557-6128

Please reference part number and serial number

Please reference part number and serial number

Husky MkII & MkIII, 2420-01-538-8287

Allison 2500SP 2520-01-554-9545

Please reference part number and serial number

Please reference part number and serial number

Table 10: Transmission OEM Shop Manuals

OEM Model (Serial Ref. Number) Shop Manual Part Number

Allison

2500SP

(6510838590 and 6310803675)

Pre Gen 4 – SM3191EN Gen 4 – SM4006EN

3200SP (6510838590) Pre Gen 4 – SM2148EN Gen 4 – SM4013EN 3000SP (652012733)

CAT CAT CX31 6-Speed (EBW00302) SEBU8192 – Operation & Maintenance

KENR5087 – Service Manual

TE…