PWS_W911N2-18-R-0003.pdf

PERFORMANCE WORK STATEMENT (PWS)

FOR

SERVICES PERTAINING THE REQUALIFICATION OF ENGINES 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 engine 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 engines 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) engine configurations, typical engines received from LEAD may include flexplate assemblies, air compressors, alternators, starters, and fans/clutch assemblies 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 CLIN Option Description XX01 Overhaul of RCV Engines

XX01AA 1 Overhaul Cummins ISL 8.0L Engine IAW Para. 5.1 XX01AB 2 Overhaul Cat C13 Engine IAW Para. 5.2 XX01AC 3 Overhaul Cummins QSB 6.7L Eng. IAW Para. 5.3 XX01AD 4 Overhaul Mercedes OM906LA Eng. IAW Para. 5.4

XX02 Life Cycle Tasks

XX02AA 5 Cummins ISL 8.0L Life Cycle Tasks Para. 5.5 XX02AB 6 Cat C13 Engine Life Cycle Tasks Para. 5.6 XX02AC 7 Cummins QSB 6.7L Life Cycle Tasks Para. 5.7 XX02AD 8 Mercedes OM906LA Life Cycle Tasks Para. 5.8

XX03 Minor Repair

XX03AA 9 Minor Repair of Cummins ISL 8.0L IAW Para. 5.9 XX03AB 10 Minor Repair of Cat C13 Engine IAW Para. 5.10 XX03AC 11 Minor Repair of Cummins QSB 6.7L IAW Para. 5.11 XX03AD 12 Minor Repair of Mercedes OM906LA IAW Para. 5.12

XX04 13 Painting of Engines 5.13 XX05 14 ECM Programming (Flashing) IAW Para. 5.14

XX06 Requalification Testing Engines

XX06AA 15 Test Cummins ISL 8.0L Engines IAW Para. 5.15.

XX06AB 16 Test Cat C13 Engines IAW Para. 5.15 XX06AC 17 Test Cummins QSB 6.7L Engines IAW Para. 5.15.

XX06AD 18 Test Mercedes OM906LA Engines IAW Para. 5.15

XX07 19 Test Alternator IAW Para. 5.16 XX08 20 Repair Alternator IAW Para. 5.17 XX09 21 Starter Rebuild IAW Para. 5.7.2 and 5.18 XX10 22 Supply Repair Parts for RCV Engines IAW 5.20.2

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 engines 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 four 12-month option years. The Period of Performance reads as follows:

1.3.1 Base Year: 30 Nov 2017 to 29 Nov 2018

1.3.2 Option Year One: 30 Nov 2018 to 29 Nov 2019

1.3.3 Option Year Two: 30 Nov 2019 to 29 Nov 2020

1.3.4 Option Year Three: 30 Nov 2020 to 29 Nov 2021

1.3.5 Option Year Four: 30 Nov 2021 to 29 Nov 2022

1.4 General Information:

1.4.1 Quality Control (QC): The contractor shall be certified by an accredited certification body to conform to ISO 9001:2008 (or newer) 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 perform services 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.

1.4.6 Special Qualifications: This program requires the requalifying of engines from vendor sources who are designated by the various engine 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. 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 Contracting Officer (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 contractor 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. Beyond what is listed in Table 2, if needed one set of the Charge Air Cooler (CAC) and Radiator parts that are listed in Table 3 can be provided to assist with requalification testing. At the end of the contract these aforementioned powerpack components shall be returned back to LEAD. (Note: The contractor shall sign and account for all components that are received as GFE):

Table 2 Nomenclature Model Model Used On NSN / Part Number Qty. per

Engine Engine ISL 8.0L 450 NSN 2815-01-618-1602 Engine CAT C13 NSN 2815-01-595-5789 Engine QSB 6.7L/409CI NSN 2815-01-659-4931 Engine OM 906 LA/6.4L NSN 2815-01-567-5163

Alternator C.E. Niehoff, N1609

ISL 8.0L 450 NSN 2920-01-566-9918

Alternator C.E. Niehoff, N1313-6

NSN 2920-01-537-2704

Alternator C.E. Niehoff, N1601-4

CAT C13 NSN 2920-01-595-6726

Alternator C.E. Niehoff, N1609-1

QSB 6.7L/409CI NSN 2920-01-560-3613

Alternator C.E. Niehoff, N1127-3

OM 906

LA/6.4L

NSN 6115-01-560-1929

Starter Cummins, 5284106

ISL 8.0L 450 NSN 6110-01-563-8609,

NSN 2920-01-627-1082

Starter (CAT, 2071556 or 190-9051) or

(Denso, R5)

CAT C13 NSN 2920-01-053-4675

Starter Cummins, 3965282

QSB 6.7L/409CI NSN 2920-01-481-6537

Starter Diamler AG, 0061512201

NSN 2920-12-367-8159

AC Tensioner QSB 6.7L/409CI NSN 2990-01-650-9474 1 Spacer, Plate QSB 6.7L/409CI NSN 5365-01-650-9468 1

Nut, Self-Locking, Hex.

QSB 6.7L/409CI NSN 5310-01-653-3155 1

Screw, Cap, Hex.

Head

QSB 6.7L/409CI NSN 5305-01-547-6220 1

Washer, Flat QSB 6.7L/409CI NSN 5310-01-557-6797 1 Screw Hexagon Head QSB 6.7L/409CI ISO4017-M16X60-8.8-

A2R

Washer, Flat QSB 6.7L/409CI NSN 5310-01-557-6579 2 Starter Boot C.E. Niehoff, N1609-1

NSN 5340-01-650-9442 1

Temperature Sensor QSB 6.7L/409CI NSN 6685-12-324-1181 1

Table 3 Nomenclature Model Model Used On NSN / Part Number Qty. per

Engine CAC Plumbing –

Hose Clamp

ISL 8.0L 450 NSN 4730-01-571-5938 2

CAC Plumbing – Insulation, Thermal

ISL 8.0L 450 NSN 2540-01-557-0503 1

CAC Plumbing – Tube, Bent, Metallic

ISL 8.0L 450 NSN 4710-01-563-8829 1

CAC Plumbing – Hose Clamp

ISL 8.0L 450 NSN 4730-01-576-0517 8

CAC Plumbing – Hose Nonmetallic

ISL 8.0L 450 NSN 4720-01-555-4799 4

CAC Plumbing – Tube, Bent, Metallic

ISL 8.0L 450 NSN 4710-01-563-8830 1

CAC Plumbing – Hose Clamp

CAT C13 NSN 4730-01-546-0254 4

CAC Plumbing – Hose Nonmetallic

CAT C13 NSN 4720-01-584-3792 1

CAC Plumbing – Tube, Bent, Metallic

CAT C13 NSN 4710-01-583-5534 1

CAC Plumbing – Hose, Preformed

CAT C13 NSN 4720-01-5854562 1

CAC Plumbing – Tube, Bent, Metallic

CAT C13 NSN 4710-01-583-3063 1

CAC Plumbing – Hose Clamp

CAT C13 NSN 4730-01-544-0153 3

CAC Plumbing – Hose, Air Duct

CAT C13 NSN 4720-01-596-7610 1

CAC Plumbing – Hose Clamp

CAT C13 NSN 4730-01-546-0254 1

CAC Plumbing – Hose Nonmetallic

CAT C13 NSN 4720-01-584-3801 1

CAC Plumbing – Hose Clamp

QSB 6.7L/409CI NSN 5340-01-575-8992 2

CAC Plumbing – Hose Nonmetallic

QSB 6.7L/409CI NSN 4720-01-557-6699 1

CAC Plumbing – Tube, Bent, Metallic

QSB 6.7L/409CI NSN 4710-01-575-9042 1

CAC Plumbing – Hose Clamp

QSB 6.7L/409CI NSN 4730-33-208-0341 2

CAC Plumbing – Hose Nonmetallic

QSB 6.7L/409CI NSN 4720-01-557-6645 1

CAC Plumbing – Tube, Bent, Metallic

QSB 6.7L/409CI NSN 4710-01-575-9073 1

CAC Plumbing – Hose Clamp

QSB 6.7L/409CI NSN 4730-33-208-0341 4

CAC Plumbing – Hose Nonmetallic

QSB 6.7L/409CI NSN 4720-01-557-6645 1

CAC Plumbing – Nut Self-Locking, Hex.

QSB 6.7L/409CI NSN 5310-01-563-8042 1

CAC Plumbing – Hose Clamp

QSB 6.7L/409CI NSN 4730-01-481-3773 1

CAC Plumbing – O-Ring

QSB 6.7L/409CI NSN 5331-01-424-6568 1

CAC OM 906

LA/6.4L

NSN 1660-01-598-6563 1

CAC Plumbing – Hose Clamp

OM 906

LA/6.4L

NSN 4730-01-554-5507 8

CAC Plumbing – Hose Nonmetallic

OM 906

LA/6.4L

Part# FP1380-120

(CAGE 1N5S7)

CAC Plumbing – Tube, Bent, Metallic

OM 906

LA/6.4L

NSN 4710-01-554-3995 1

CAC Plumbing – Tube, Bent, Metallic

OM 906

LA/6.4L

NSN 4710-01-554-4422 1

CAC Plumbing – Tube, Metallic

OM 906

LA/6.4L

NSN 4710-01-559-9302 1

CAC Plumbing – Bolt, Machine

OM 906

LA/6.4L

NSN 5306-12-353-5510 2

CAC Plumbing – Hose Clamp

OM 906

LA/6.4L

NSN 5342-12-300-8258 1

CAC Plumbing – Tube, Metallic

OM 906

LA/6.4L

Part# 0115-06075-26

(CAGE 1N5S7)

CAC Plumbing – O-Ring

OM 906

LA/6.4L

NSN 5331-01-572-8291 1

CAC Plumbing – Hose Clamp

OM 906

LA/6.4L

NSN 5340-01-572-5550 1

Radiator and CAC Assembly

ISL 8.0L 450 NSN 2930-01-555-4797 1

Radiator Plumbing – Outlet Formed Pipe

ISL 8.0L 450 NSN 2930-01-563-8725 1

Radiator Plumbing – Hose Clamp

ISL 8.0L 450 NSN 4730-01-546-0227 2

Radiator Plumbing – Nonmetallic Hose

ISL 8.0L 450 Part# 2454-FF2-040

(CAGE 36MV0)

Radiator and CAC Assembly

CAT C13 NSN 2990-01-610-7529 1

Radiator Plumbing – Hose Clamp

CAT C13 NSN 5340-01-557-0472 12

Radiator Plumbing – Nonmetallic Hose

CAT C13 NSN 4720-01-580-6169 4

Radiator Plumbing – Tube, Bent, Metallic

CAT C13 NSN 4710-01-583-5550 1

Radiator Plumbing – Preformed Hose

CAT C13 NSN 4720-01-543-5548 1

Radiator Plumbing – Tube, Bent, Metallic

CAT C13 NSN 4710-01-596-1293 1

Radiator Plumbing – Tube, Bent, Metallic

CAT C13 NSN 4710-01-596-1304 1

Radiator Plumbing – Hose Clamp

QSB 6.7L/409CI NSN 5340-01-584-9191 10

Radiator Plumbing – Hose Nonmetallic

QSB 6.7L/409CI NSN 4720-01-600-6250 5

Radiator Plumbing – Tube, Bent, Metallic

QSB 6.7L/409CI NSN 4710-01-605-7963 1

Radiator Plumbing – Hose Clamp

QSB 6.7L/409CI NSN 5340-01-652-8481 2

Radiator Plumbing – Hose Nonmetallic

QSB 6.7L/409CI NSN 4720-01-557-5644 1

Radiator OM 906

LA/6.4L

NSN 2930-01-561-7584 1

Radiator Plumbing – Tube, Bent, Metallic

OM 906

LA/6.4L

NSN 4710-01-554-5620 1

Radiator Plumbing – Tube, Bent, Metallic

OM 906

LA/6.4L

NSN 4710-01-568-7339 1

Radiator Plumbing – Hose Clamp

OM 906

LA/6.4L

NSN 4730-01-570-2454 8

Radiator Plumbing – Hose Nonmetallic

OM 906

LA/6.4L

NSN 4720-01-554-4415 4

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 engines for the following RCVs: MMPV/RG-33L Plus, Buffalo A2, RG-31Mk5E, and Husky MkII. The engines used in each particular platform are referenced in Appendix A of this PWS. Unless otherwise specified by LEAD the contractor shall subject all engines received to a requalification test.

If LEAD has determined an engine to be unserviceable, depending on the type of engine, either Option 1, 2, 3, or 4 shall be exercised.

5.1 Option-1 (CLIN XX01AA), Complete Overhaul of Cummins ISL8.0L 450 Engines: Option 1 shall be exercised where it has been determined by either LEAD, the contractor, or from the requalification test results, that a complete overhaul is needed. The costs of performing a second Requalification Test, as well as the cost for any components that were installed as part of the Life Cycle or Requalification options that would need to be re-placed in accordance with the respective engine OEM standards as a process of remanufacturing the engines shall be included in this CLIN. The costs for all other components that were previously accounted for by the Life Cycle and Requalification Options, and are not recommended to be replaced by the respective engine OEMs shall be excluded from CLIN; these previously installed components shall be inspected and serviced per the respective engine OEM service manuals. The cylinder heads and engine blocks shall be checked for warping/cracks. If warping or cracks are identified the affected cylinder head/block shall be replaced with a new assembly. The engines shall be rebuilt to “zero-hour” OEM standards/tolerances in accordance with Cummins shop manuals P/N 4021418 (base engine) and P/N 4021553 (electronic). For engines that utilize sleeves within the cylinder, the sleeve is to be replaced and the same original size piston and rings are to be used. For engines that do not utilize sleeves, the overhauled engine’s cylinders/pistons/rings shall conform to the next standard size over the piston removed from that engine. The contractor shall ensure that an overhauled engine’s performance meets or exceeds the performance as designated by the serial number on each of the engines received from LEAD. All overhauled engines shall be run through another three hour minimum engine requalification test. The contractor shall ensure that engines that pass the requalification test meet the Specific Repair Requirements of paragraph 5.20. For engines that fail the requalification test after being overhauled, the dynamometer test results shall be faxed or emailed to the LEAD COR within 24 hrs. The contractor shall specify potential causes for the failure. Engines that have been overhauled but have failed requalification testing are to be sent back to LEAD.

5.2 Option-2 (CLIN XX01AB), Complete Overhaul of CAT C13 Engines: Option 2 shall be exercised where it has been determined by either LEAD, the contractor, or from the requalification test results, that a complete overhaul is needed. The costs of performing a second Requalification Test, as well as the cost for any components that were installed as part of the Life Cycle or Requalification options that would need to be re-placed in accordance with the respective engine OEM standards as a process of remanufacturing the engines shall be included in this CLIN. The costs for all other components that were previously accounted for by the Life Cycle and Requalification Options, and are not recommended to be replaced by the respective engine OEMs shall be excluded from CLIN; these previously installed components shall be inspected and serviced per the respective engine OEM service manuals.

The cylinder heads and engine blocks shall be checked for warping/cracks. If warping or cracks are identified the affected cylinder head/block shall be replaced with a new assembly. The engines shall be rebuilt to “zero-hour” OEM standards/tolerances in accordance with CAT shop manuals P/N KENR381 (specification manual) and P/N KENR3834 (Disassembly/Assembly Manual), and P/N SEBU8568 (Operation and Maintenance Manual). For engines that utilize sleeves within the cylinder, the sleeve is to be replaced and the same original size piston and rings are to be used. For engines that do not utilize sleeves, the overhauled engine’s cylinders/pistons/rings shall conform to the next standard size over the piston removed from that engine. The contractor shall ensure that an overhauled engine’s performance meets or exceeds the performance as designated by the serial number on each of the engines received from LEAD. All overhauled engines shall be run through another three hour minimum engine requalification test. The contractor shall ensure that engines that pass the requalification test meet the Specific Repair Requirements of paragraph 5.20. For engines that fail the requalification test after being overhauled, the dynamometer test results shall be faxed or emailed to the LEAD COR within 24 hrs. The contractor shall specify potential causes for the failure. Engines that have been overhauled but have failed requalification testing are to be sent back to LEAD.

5.3 Option-3 (CLIN XX01AC), Complete Overhaul of Cummins QSB 6.7L/409CI Engines: Option 3 shall be exercised where it has been determined by either LEAD, the contractor, or from the requalification test results, that a complete overhaul is needed. The costs of performing a second Requalification Test, as well as the cost for any components that were installed as part of the Life Cycle or Requalification options that would need to be re-placed in accordance with the respective engine OEM standards as a process of remanufacturing the engines shall be included in this CLIN. The costs for all other components that were previously accounted for by the Life Cycle and Requalification Options, and are not recommended to be replaced by the respective engine OEMs shall be excluded from CLIN; these previously installed components shall be inspected and serviced per the respective engine OEM service manuals. The cylinder heads and engine blocks shall be checked for warping/cracks. If warping or cracks are identified the affected cylinder head/block shall be replaced with a new assembly. The engines shall be rebuilt to “zero-hour” OEM standards/tolerances in accordance with Cummins shop manuals P/N 4021418 (base engine) and P/N 4021553 (electronic). For engines that utilize sleeves within the cylinder, the sleeve is to be replaced and the same original size piston and rings are to be used. For engines that do not utilize sleeves, the overhauled engine’s cylinders/pistons/rings shall conform to the next standard size over the piston removed from that engine. The contractor shall ensure that an overhauled engine’s performance meets or exceeds the performance as designated by the serial number on each of the engines received from LEAD. All overhauled engines shall be run through another three hour minimum engine requalification test. The contractor shall ensure that engines that pass the requalification test meet the Specific Repair Requirements of paragraph 5.20. For engines that fail the requalification test after being overhauled, the dynamometer test results shall be faxed or emailed to the LEAD COR within 24 hrs. The contractor shall specify potential causes for the failure. Engines that have been overhauled but have failed requalification testing are to be sent back to LEAD.

5.4 Option-4 (CLIN XX01AD), Complete Overhaul of Mercedes OM 906 LA/6.4L Engines: Option 4 shall be exercised where it has been determined by either LEAD, the contractor, or from the requalification test results, that a complete overhaul is needed. The costs of performing a second Requalification Test, as well as the cost for any components that were installed as part of the Life Cycle or Requalification options that would need to be re-placed in accordance with the respective engine OEM standards as a process of remanufacturing the engines shall be included in this CLIN. The costs for all other components that were previously accounted for by the Life Cycle and Requalification Options, and are not recommended to be replaced by the respective engine OEMs shall be excluded from CLIN; these previously installed components shall be inspected and serviced per the respective engine OEM service manuals. The cylinder heads and engine blocks shall be checked for warping/cracks. If warping or cracks are identified the affected cylinder head/block shall be replaced with a new assembly. For engines that utilize sleeves within the cylinder, the sleeve is to be replaced and the same original size piston and rings are to be used.

For engines that do not utilize sleeves, the engines shall be rebuilt to “zero-hour” OEM standards/tolerances with the engine cylinders/pistons/rings conforming to the next standard size. The contractor shall ensure that an overhauled engine’s performance meets or exceeds the performance as designated by the serial number on each of the engines received from LEAD. All overhauled engines shall be run through another three hour minimum engine requalification test. The contractor shall ensure that engines that pass the requalification test meet the Specific Repair Requirements of paragraph 5.20. For engines that fail the requalification test after being overhauled, the dynamometer test results shall be faxed or emailed to the LEAD COR within 24 hrs. The contractor shall specify potential causes for the failure. Engines that have been overhauled but have failed requalification testing are to be sent back to LEAD.

5.5 Option-5 (CLIN XX02AA), Cummins ISL 8.0L Engine Life Cycle Tasks: This option shall be used to address components on the Cummins 8.0 ISL engines where high failure rates have been experienced. The scope of components that shall be replaced under this option are listed in Table 4 as well as the subsequent paragraphs of this section. When this option is exercised it shall be performed before performing the requalification test that is referenced in paragraph 5.15 of this PWS.

Table 4

Nomenclature NIIN Part Number Qty. Estimates

Water Pump 015138133 4309418 1

Fuel Gear Pump 015702430 4088866 1

Fuel Gear Pump, Gasket 015702434 4902780 1

High Pressure Fuel Pump Seal 014246586 5272819 1

Fuel Pump O-Ring 014844727 3040817 2

Turbo Charger 015669837 4090053 1

Turbo Core

Turbo Mounting Gasket 012137649 3755843 1

Turbo Control Valve 016260884 3770743 1

Fuel Filter 015300044 FF5488 1

Fuel Tube 015638663 3966130 1

Fuel Tube 015638673 3979330 1

Fuel Tube 015638570 3966128 1

Fuel Tube 015638579 3979403 1

Adapter Assembly 016226751 4921433NX 1

Adapter Assembly Core

Fuel Pump Bracket 015847696 3979337 1

IMV Adapter Mounting Bolt 014729328 3928873 7

Bracket, Bolt A 012716448 3081346 4

Bracket, Bolt B 012744404 3902116 1

Gasket, Exhaust Manifold 015563338 5269779 6

5.5.1 Water Pump: A new water pump shall be installed.

5.5.2 Common Rail High Pressure Pump: The common rail high pressure pump associated with the engine shall be requalified to include: fuel gear pump, pump actuator assembly, cam housing, and high pressure fuel pump head.

(NOTE: High pressure pump is to be updated IAW TSB100717 when and as needed.)

5.5.3 Front Engine Cover: The front engine cover shall be removed and resealed.

5.5.4 Turbo Exhaust Manifold: The turbo exhaust manifold shall be removed, cleaned, and inspected. The cylinder head exhaust ports shall be inspected for carbon and valve condition.

5.5.5 Turbocharger: A new or requalified turbocharger is to be installed on the engine.

5.5.6 Variable Geometry Turbocharger Control Valve (VGTC): A new VGTC is to be installed on the engine.

5.5.7 Fuel Filter: A new fuel filter shall be installed on the engine

5.5.8 Quick Disconnect Fuel Tubes: New quick disconnect fuel tubes are to be installed onto the engine.

5.5.9 Overhead Valve Train: The overhead valve train shall be adjusted as required to meet OEM specifications.

5.5.10 Water and Sediment within the Fuel System: Whenever signs of water and sediment are shown to be prevalent throughout an engines fuel system, filter elements, applicable fuel screens, and applicable fuel inlet connections shall be cleaned or changed if they are dirty.

5.6 Option-6 (CLIN XX02AB)-Cat C13 Engine Life Cycle Tasks: The contractor shall replace the parts referenced in Table 4 before performing requalification testing. This option shall be used to address components on the Cat C13 engines that need to be replaced to accommodate the new configuration requirements of the recapitalized vehicles that they are to be installed into. 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 5.15 of this PWS.

Table 5

Nomenclature NIIN Part Number Qty. Estimates

ROCKER COVER

Flat washer 00-432-4064 9M-1974:11083 14

Flat washer 01-051-2360 5P0537:11083 5

Bolt 01-360-1002 6V3918:11083 8

Retaining clip 01-429-3243 2V3216:11083 4

Spacer 01-466-8232 4P8525:11083 4

Bolt 01-470-9585 6V-7728:11083 4

Bolt 01-471-0429 6V-5221:11083 6

Tension clip 01-555-3628 2379960:11083 1

Bolt 01-563-2459 6V-8836:11083 1

Gasket 01-583-1093 10022033:1EFH8 1

Rocker spacer 015638663 332-3706:11083 1

ENGINE SENSORS

O-ring 00-020-0186 6V-5049:11083 1

O-ring 00-020-0203 6V-5048:11083 2

O-ring 00-973-8301 8L-2786:11083 1

Air temperature sensor 01-555-5134 256-6453:11083 1

Oil pressure sensor 01-564-7128 274-6719:11083 1

Atmospheric sensor 01-565-1589 274-6717:11083 1

Air pressure sensor 01-565-3187 276-6793:11083 1

ENGINE HARNESS

Engine wiring harness 01-587-6336 348-8676:11083 1

ENGINE THERMOSTAT

Seal 00-246-6380 3S9643 2

O-rings 00-297-6320 4F7389:11083 2

Flat washer 00-432-4064 9M-1974:11083 9

Plug 00-478-2920 9S4183:11083 1

Fitting 01-007-5232 SAE F514 4-4:81343 1

Male-to-female adapter 01-065-9356 LT-202-7:46717 1

Elbow adapter 01-106-0313 269HB-10-8:93061 1

O-ring 01-317-9506 6V9027:11083 1

O-ring 01-334-8574 6V5063:11083 2

O-ring 01-413-2754 6V-6609:11083 1

Bolt 01-468-0660 8T0292:11083 4

Regulator 01-533-1759 2485513:11083 2

O-ring 01-536-9831 166-2340:11083 1

Flow control fitting 01-555-3433 2398135:11083 1

O-ring 01-555-5083 2246361:11083 1

Sensor 01-555-5134 256-6453:11083 1

Bolt 01-568-0660 8T-0292:11083 5

Lower thermostat housing 01-601-7070 342-9827:11083 1

Tube/pipe assembly 01-608-5640 346-6219:11083 1

Top thermostat housing 01-612-5326 343-7202:11083 1

CRANK CASE BREATHER AND VALVE COVER

Clamp 01-165-5721 9M-2904:11083 1

Flat washers 01-359-8806 8T-4224:11083 10

Bolt 01-438-9854 7X2534:11083 4

Flat washer 01-439-0845 9X-8267:11083 4

Gasket 01-466-9290 9Y1758:11083 1

Mounts 01-555-7407 2127728:11083 10

Valve cover gasket 01-583-1093 272-03899:11083 1

Hose 01-587-6467 250-2300:11083 1

Breather 01-587-7469 247-7169:11083 1

Studs 01-588-0793 211-3445:11083 10

Valve cover 01-619-9881 342-7923:11083 1

FAN CLUTCH

Bolt 01-551-6466 0154002:0Y3H3 4

Flat washer 01-557-0524 40359:49181 4

Fan clutch 01-587-9960 10002122:1EFH8 1

1/8 NPT to 1/4 inch air fitting 01-591-9260 68PMT-4-2:93061 1

HOSE REPLACEMENT AND LIFTING BRACKET

Hose 01-587-6523 272-6668:11083 1

Bolt 01-448-1550 6V3668:11083 8

Flat washer 01-557-0524 40359:49181 8

Lifting bracket 01-589-4603 10026462:1EFH8 1

Hose 01-601-1117 337-7452:11083 2

5.7 Option-7 (CLIN XX02AC), Cummins QSB 6.7L Life Cycle Tasks Para. 5.7: This option shall be used to address components on the Cummins QSB 6.7L engines that need to be either newly installed or replaced to meet the new configuration requirements of the recapitalized vehicles that they are to be installed into. The scope of components that shall be installed/replaced under this option are listed in Table 6. When this option is exercised, unless otherwise stated in the subparagraphs of Section 5.7 of this PWS, the tasks specified for this option shall be performed before performing the requalification test that is referenced in paragraph 5.15 of this PWS.

Table 6

Nomenclature NSN Part Number Qty. Est.

Replacement of Defroster Quick Disconnects

Coupling Half, Quick Disconnect 4730-01-598-9187 R0120964 (CAGE SZ177) 1

Coupling Half, Quick Disconnect 4730-01-598-9188 R0120963 (CAGE SZ177) 1

Installation of AC Tensioner

AC Tensioner 2990-01-650-9474 R0162871 (CAGE SZ177) GFM

Spacer, Plate 5365-01-650-9468 R0161726 (CAGE SZ177) GFM

Nut, Self-Locking, Hex. 5310-01-653-3155 ISO10511-M16-8.8-A2R (CAGE 19008) GFM

Screw, Cap, Hex. Head 5305-01-547-6220 ISO4017-M8X35-8.8-A2D (CAGE 19008) GFM

Washer, Flat 5310-01-557-6797 R2003015 (CAGE SZ177) GFM

Screw Hexagon Head ISO4017-M16X60-8.8-A2R (CAGE 19008) GFM

Washer, Flat 5310-01-557-6579 R2003046 (CAGE SZ177) GFM

Replacement of Temperature Sensor

Temperature Sensor 6685-12-324-1181 323-803-004-007 (CAGE D4276) GFM

Installation of Starter Boot

5.7.1 Replacement of Defroster Quick Disconnects: These are direct replacement components that will already be installed on the engines. These components shall be replaced prior to performing the Requalification Test that is referenced in paragraph 5.15.

5.7.2 Installation of Starter Boot onto Starter: LEAD will provide the contractor with Work Instructions detailing how to perform this task. At the discretion of the contractor the starter boot can be installed during the most ideal process of rebuilding the starters.

5.7.3 Installation of AC Tensioner: LEAD will provide the contractor with Work Instructions detailing how to perform this task. At the discretion of the contractor the tensioner can either be installed before performing the Requalification Test that is referenced in paragraph 5.15, or afterwards, prior to shipping the engine back to LEAD.

5.7.4 Replacement of Temperature Sensor: The temperature sensor replaces a similar temperature sensor that is already installed on the engine. This component shall be replaced prior to performing the Requalification Test that is referenced in paragraph 5.15.

5.8 Option-8 (CLIN XX02AD), Mercedes OM 906 LA/6.4L Engine Life Cycle Tasks Para. 5.8: This option shall be used to address components on the Mercedes OM 906 LA/6.4L engines that need to be replaced to accommodate the new configuration requirements of the recapitalized vehicles that they are to be installed into. The scope of components that shall be replaced under this option are listed in Table 7. When this option is exercised it shall be performed before performing the requalification test that is referenced in paragraph 5.15 of this PWS.

Table 7

Nomenclature NIIN Part Number Qty. Est.

Capacitor, Fixed, Quartz, Dielectric 01-554-2221 3134901:1N5S7 1

Seal, Body 12-373-0830 2900400104: D8086 1

5.9 Option-9 (CLIN XX03AA), Minor Repair of Cummins ISL 8.0L 450 Engines: Option 9 shall be exercised where it has been determined by the contractor, and agreed upon by LEAD, that minor repair work can correct the deficiency observed from the engine requalification test (paragraph 5.15). Minor repairs shall be limited to replacing sensors, adjusting valves, and adjusting timing. For cost estimating purposes regarding minor repairs, labor hours shall be limited to sixteen hours totals. The cost of parts shall not exceed $3,000.00. After minor repairs have been completed on an engine, it shall be run through another three hour minimum engine requalification test.

The contractor shall ensure that engines that pass the requalification test meet the Specific Repair Requirements of paragraph 5.20. For engines that fail the requalification test for the second time, dynamometer test results shall be faxed or emailed to the LEAD Contracting Officer Representative (COR) within 24 hrs. The LEAD COR will notify the vendor if they are to proceed with the overhaul of the engine (Option 1).

5.10 Option-10 (CLIN XX03AB), Minor Repair of CAT C13 Engines: Option 10 shall be exercised where it has been determined by the contractor, and agreed upon by LEAD, that minor repair work can correct the deficiency observed from the engine requalification test (paragraph 5.10). Minor repairs shall be limited to replacing sensors, adjusting valves, and adjusting timing. For cost estimating purposes regarding minor repairs, labor hours shall be limited to sixteen hours totals. The cost of parts shall not exceed $3,000.00. After minor repairs have been completed on an engine, it shall be run through another three hour minimum engine requalification test. The contractor shall ensure that engines that pass the requalification test meet the Specific Repair Requirements of paragraph 5.20. For engines that fail the requalification test for the second time, dynamometer test results shall be faxed or emailed to the LEAD COR within 24 hrs. The LEAD COR will notify the vendor if they are to proceed with the overhaul of the engine (Option 2).

5.11 Option-11 (CLIN XX03AC), Minor Repair of Cummins QSB 6.7L/409 CI Engines: Option 11 shall be exercised where it has been determined by the contractor, and agreed upon by LEAD, that minor repair work can correct the deficiency observed from the engine requalification test (paragraph 5.15). Minor repairs shall be limited to replacing sensors, adjusting valves, and adjusting timing. For cost estimating purposes regarding minor repairs, labor hours shall be limited to sixteen hours totals. The cost of parts shall not exceed $3,000.00.After minor repairs have been completed on an engine, it shall be run through another three hour minimum engine requalification test.

The contractor shall ensure that engines that pass the requalification test meet the Specific Repair Requirements of paragraph 5.20. For engines that fail the requalification test for the second time, dynamometer test results shall be faxed or emailed to the LEAD COR within 24 hrs. The LEAD COR will notify the vendor if they are to proceed with the overhaul of the engine (Option 3).

5.12 Option-12 (CLIN XX03AD), Minor Repair of Mercedes OM 906 LA/6.4L Engines: Option 12 shall be exercised where it has been determined by the contractor, and agreed upon by LEAD, that minor repair work can correct the deficiency observed from the engine requalification test (paragraph 5.15). Minor repairs shall be limited to replacing sensors, adjusting valves, and adjusting timing. For cost estimating purposes regarding minor repairs, labor hours shall be limited to sixteen hours totals. The cost of parts shall not exceed $3,000.00. After minor repairs have been completed on an engine, it shall be run through another three hour minimum engine requalification test.

The contractor shall ensure that engines that pass the requalification test meet the Specific Repair Requirements of paragraph 5.20. For engines that fail the requalification test for the second time, dynamometer test results shall be faxed or emailed to the LEAD COR within 24 hrs. The LEAD COR will notify the vendor if they are to proceed with the overhaul of the engine (Option 4).

5.13 Option-13 (CLIN XX04), Painting of Engines: The contractor shall be required to paint engines that are received whenever Option 13 is exercised. LEAD will list the serial numbers of each engine that this requirement pertains to. The engine is not required to be completely disassembled for this option. The contractor shall however be required to remove the alternator from the engine before painting. The contractor shall cover all hoses and fittings not standardly painted by the OEM of the engine 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 engines. 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 engines. If rust or chipped/flaking paint is present on an area of the engine the contractor is required to hand sand the area and feather the surrounding edges before applying primer and paint. The contractor shall paint the engines with the original respective OEM colors used.

5.14 Option-14 (CLIN XX05), Electronic Control Module (ECM) Programming (Flashing): After the award of the contract LEAD will provide the contractor with access to sample ECMs 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 ECMs that may or may not already have programs flashed into them. LEAD will also provide the contractor with ECM 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 ECMs have the latest calibration updates in accordance with (IAW) OEM recommendations. The contractor shall ensure that an ECM has the latest calibration. 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 Cummins ISL8.0L 450, the Cummins QSB 6.7L/409CI, the CAT C13, and the Mercedes OM 906 LA/6.4L engine ECMs.

5.15 Engine Requalification Tests: For each of the engines referenced in Table 8, the contractor shall perform a basic tune-up, and where applicable to an engines configuration per its OEM serial number the contractor shall replace all of the items referenced in Table 9 with new components if they have not been specifically already replaced as part of a Life Cycle Option as referenced in this PWS. All vacuum lines shall be replaced with new lines.

All rubber hoses that connect to ports and fittings on the engine and are use directly for circulating fuel, air, oil, and coolant throughout the engine shall be replaced with new hoses. This includes the rubber couplings connecting all of the hard lines as well as the O-rings and seals associated with any crankcase breathers. Unless specifically referenced in this PWS this excludes any hoses that would connect to any auxiliary components such as surge tanks and additional fuel filters. Any crankcase breather assembly is to be cleaned for re-use. The contractor shall ensure that all engines for the same platform have the latest pulley configuration in accordance with the respective OEM specifications. After performing a basic tune-up, replacing hoses, and replacing the items from Table 9, the contractor shall then perform a three-hour minimum Dynamometer Requalification Performance Test on the engines. At a minimum the engines must meet or exceed 95% of the rated HP as designated by the Original Equipment Manufacturer (OEM) engine serial number on the engine block for given speeds, loads, and oil pressures. During the requalification test the performance of the injectors, injection pump, and fuel pump shall be monitored and tested. The injectors, injection pump, and fuel pump are considered amongst the listing of core components with regards to this PWS and are referenced in Table 12. If any of these core components fail however can be replaced with a minimum amount of effort with the engine still on the dynamometer, the contractor shall notify LEAD’s COR with a listing of the core components needed at which point LEAD’s COR may decide to utilize funds from CLIN XX10 to cover the parts. LEAD’s COR will make a decision within two business days of notification as to whether or not to replace the core component(s) through this means. If any of these core components fail and it has been determined by the contractor that an extensive amount of effort would be needed to replace/repair an issue observed, the contractor shall notify LEAD at which point LEAD may choose to exercise either Option 9, 10, 11, or 12 so that the failed components can be replaced with requalified or new components.

The contractor shall also measure the output of the air compressor attached to the engines to ensure that it is operating within OEM specifications. The air compressor is considered amongst the listing of core components with regards to this PWS and is referenced in Table 12. If an air compressor is not operating within OEM specifications however can be replaced with a minimum amount of effort with the engine still on the dynamometer, the contractor shall notify LEAD’s COR at which point LEAD’s COR may decide to utilize funds from CLIN XX10 to pay for the component. LEAD’s COR will make a decision within two business days of notification as to whether or not to replace the component(s) through this means. If the contractor has determined that it will take an extensive amount of effort to make the repair regarding the air compressor, the contract shall notify LEAD at which point LEAD may choose to exercise either Option 9, 10, 11, or 12 so that the compressor can be replaced with either a requalified or new component. Engines that pass requalification testing must meet the Specific Repair Requirements of paragraph

5.20. All rubber components on the engine block assembly shall be replaced with new components. The contractor shall clean all requalified engines (i.e. via steam, or pressure wash, etc.) to remove excessive grime and engine fluid residue. The Engine Requalification Test Options are referenced in Table 8 of this PWS.

Table 8 Option CLIN Task

15 XX06AA Perform Requalification Test on Cummins ISL 8.0L Engine 16 XX06AB Perform Requalification Test on Cat C13 Engine 17 XX06AC Perform Requalification Test on Cummins QSB 6.7L Engine 18 XX06AD Perform Requalification Test on OM906LA Engine

5.15.1 Minor Engine Repair: For engines that fail the requalification test, however either from evaluating the test results or reading from the Electronic Control Unit (ECU) it has been determined that minor repairs can be accomplished that will allow them to pass, depending on the type of engine, LEAD may choose to exercise either Option 9, 10, 11, or 12. Minor repairs shall be limited to replacing sensors, adjusting valves, and adjusting timing.

For cost estimating purposes regarding minor repairs, labor hours shall be limited to sixteen hours totals. The cost of parts shall not exceed $3,000.00. The contractor shall provide requalification performance test results, along with the respective engine serial numbers for which they correspond, back to LEAD.

5.15.2 Mandated Overhaul: For engines that fail the requalification test due to excessive blow-by, or crankcase pressure, as referenced by OEM standards, depending on the type of engine, LEAD may choose to exercise either Option 1, 2, 3, or 4. Contractors shall reference OEM shop manuals for each of the engines regarding what is considered an acceptable amount of blow-by. Shop manual part numbers for some of the engines are provided in Table 15 of this PWS for reference. For engines that exhibit signs of oil or coolant consumption such as either “blue” or “white” smoke being emitted from the exhaust, depending on the type of engine, LEAD may choose to exercise either Option 1, 2, 3, or 4. If it has been determined that an engine has previously run “hot” or runs hot during the requalification test, depending on the type of engine, LEAD may choose to exercise either Option 1, 2, 3, or 4. The contractor shall provide requalification performance test results, along with the respective engine serial numbers for which the tests were performed on, back to LEAD in the form of a test report as referenced by paragraph 5.20.4.

(Note: LEAD reserves the right to have another independent facility perform additional dynamometer testing on any engine received back from the awardee of the contract for this PWS.)

Table 9: Replacement Items for the Dynamometer Requalification Test

ITEM # NOMENCLATURE

1 Engine oil filter

2 Glow…