HET_Engine_SOW_Rev_5_(2).docx

SCOPE OF WORK

REBUILD AND REPAIR OF THE HET M1070

DDEC II AND DDEC III/IV ENGINE ASSEMBLIES AND CONTAINER

NSN 2815-01-452-6354

I. GENERAL

This scope of work covers the information required to rebuild and convert the Detroit DDEC II, Dressed Engine Assembly, NSN 2815-01-354-2911, Part Number 12436583 (19207), and rebuild the DDEC III/IV Dressed Engine Assembly NSN 2815-01-450-4014, Part Number 12472145 (19207) leaving as a DDEC III/IV engine, NSN 2815-01-452-6354 Part Number 57k4728 (19207). This engine is used in the M1070 Heavy Equipment Transport (HET) vehicle and will be mounted to the Allison CLT 754 Transmission. Scope for rebuilding and repairing these engines and containers includes receipt, inspection, test, repair, and like activities necessary to bring the engine and container to a like new condition. No engine will be accepted without a container.

II. ACCEPTABLE STANDARD

Rebuild/repair instructions, mandatory replacement parts, tolerances and wear limits in the National Maintenance Work Requirements (NMWR), Technical Manuals (TM) and this Scope of Work (SOW) are the minimum acceptable standards. Components found to be worn or defective beyond repair limits shall be disposed of in accordance with current directives. Before performing any rebuild or repair activity, the Center of Excellence shall be familiar with the procedures in the applicable NMWR, Technical Manual, MIL Standard and this SOW.

III. APPLICABLE DOCUMENTS

1) The rebuild and repair of the engines are to be accomplished, in accordance with the National Maintenance Work Requirements, Technical Manuals and Military Standards listed below. In the event of a conflict between the documents referenced herein and the contents of this SOW, the contents of this SOW shall be the superseding requirement. You can receive copies of the applicable documents by calling the TACOM Heavy Tactical Vehicle PSID at (586) 282-9293or e-mailing the TACOM Heavy Truck Group HET Team at: dami_het@conus.army.mil, or by sending a written request to:

U.S. Army TACOM Life Cycle Management Command

HET TEAM

(MS# 420)

ATTN: AMSTA-LCC-HH

6501 E. 11 Mile Rd.

Warren, MI 48397-5000

2) The following documents form a part of this scope of work:

a) Technical Manuals Series 9-2320-360

b) IETM 9-2320-360-13&P Heavy Equipment Transporter (HET)

c) DDEC II to DDEC III/IV Dressed Engine Conversion Procedures (TM 9-2320-360-13&P)

d) TM 43-0139 Painting Instructions for Army Material

e) TB 9-289 Reconditioning of Type I and Type II Reusable Metal Containers

f) MIL-STD-129 DOD Standard Practice for Military Marking for Shipment and Storage

g) MIL-STD-2073-1 Standard Practice for Military Packaging

h) MIL-STD-130N Identification Marking of U.S. Military Property

i) Final Assembly Testing (Attachment 1)

j) Item Unique Item Identification (Attachment 2)

k) Bill of Materials (Attachment 3)

l) Final Test Checklist (Appendix E)

m) Final Inspection Record (Appendix F)

n) Control Test (Appendix G)

o) Horsepower and Altitude Compensation (Appendix H)

p) Test Malfunction Deficiency Sheet Table E-2 (Appendix I)

IV. DEFINITIONS

1) Rebuild: Consist of those services/actions necessary for the restoration of unserviceable HET DDEC II and DDEC III/IV, 8V92TA engines to a like new condition engine in accordance with Technical Manual Series 9-2320-360. The rebuild operation includes the act of returning to zero those age measurements (hours/miles, etc.) considered in classifying Army equipment.

2) Repair: Restoring a component to its original performance condition, replacing parts if necessary.

3) OEM: The original equipment manufacturer. The company that originally manufacture fabricated or supplied the DDEC, engine or part. OEM may include items manufactured by a subcontractor for an original equipment manufacturer, provided that the name or trademark of the OEM is shown on the item, label, or container.

4) After Market Part: Any part or component that has been manufactured or fabricated by a company other than the original equipment manufacturer their approved subcontractors and sold as a replacement part for an OEM part or component.

5) Serviceable Part: Any part that is capable of meeting or exceeding the minimum OEM standards for performing the function for which it was originally designed.

6) Non serviceable part: Any part that no longer meets minimum OEM standards.

7) Mandatory Replacement Parts: Parts/Components identified for mandatory replacement are considered unserviceable after removal (during disassembly) and must be replaced on each dressed engine assembly that is rebuilt or repaired. The mandatory replacement parts list is found within Technical Manual Series 9-2320-360. When using other than OEM parts, the parts used must be able to be repaired or replaced using the existing procedures, tools and repair parts specified within HET technical manuals.

V. REQUIREMENTS

1) Engine Assembly Rebuild and Repair:

a. DDEC II/III/IV Engine Rebuild and Repair: Government will provide engine assemblies, NSN 2815-01-354-2911, (DDECII) and NSN 2815-01-450-4014 (DDECIII/IV), in various states of disrepair. Center of Excellence will rebuild the engines adhering to the information contained in Technical Manual Series 9-2320-360.

b. You the Center of Excellence shall rebuild All Het M1070 DDEC II, III/IV engine assemblies IAW this Scope of Work and all references listed above in Section III 2

c. Each rebuilt engine assembly must meet the performance testing described in paragraph VI below. Passing this testing will provide a serviceable component(s) that can be issued to users without restriction (i.e., condition of rebuilt engine assembly shall be such that the utility and performance are equal to that of a condition code A item as defined in AR 725-50). Parts that are requisitioned through the Army Wholesale System and do not conform to the original OEM requirements, Center of Excellence shall initiate a PQDR. Use of other than OEM parts is authorized when the following conditions are met. You must be able to repair or replace those parts using the procedures, tools and repair parts currently specified in the HET technical manuals. Each rebuilt engine assembly must maintain the same engine to vehicle interface as the original equipment engine assembly. You must supply the technical data for both the OEM part and the other than OEM part to the Government for comparison and written authorization to use.

d. Center of Excellence may use serviceable or repairable parts from cracked blocks or component assemblies when repairing or rebuilding other engine assemblies, except mandatory replacement parts.

e. Inspect all previously used parts in accordance with procedures found in the technical manuals before reusing. These parts must meet the requirements specified therein, as a minimum, or be replaced with new parts. NSN’s for new parts may be found in TM 9-2320-360-13&P

f. Replace damaged or worn bolts, washers, retainers and other locking hardware, and any parts required to be discarded or items failing to meet minimum prescribed tolerances

g. Replace any sub-components/parts of the engine assembly showing obvious signs of imminent failure or damage/deterioration with a fully serviceable or new item

h. The engine provided will be in a container, NSN 8145-01-373-1579. To ensure it meets performance specifications, all containers will be inspected and repaired in accordance with TB 9-289 or SB 725-92-1.

i. Mandatory replacement parts are listed in TM 9-2320-360 series and shall be 100% replaced on each rebuilt engine assembly. Please note that the TM contains mandatory replacement parts for all aspects of repairing the HET, not just the engine. In addition to the mandatory replacements parts listed within the TM, we the requestor have added items to a Bill of Materials (BOM) which are to be replaced.

j. Center of Excellence will not repair or rebuild cracked engine blocks or heads. Any crack is cause for disposal of the block or head. Center of Excellence may use serviceable or repairable parts from cracked blocks or head assemblies when repairing or rebuilding other engine assemblies, except mandatory replacement parts

2) DATA PLATE

a. Center of Excellence will include a “Rebuilt Engine” data plate with each rebuilt engine. Attach the data plate to the engine near the original serial number data plate.

b. Center of Excellence may determine the format of the data plate. However, as a minimum, the following information must be included:

Serial Number:

Rebuilt Engine Number:

Rebuild Date:

Rebuild Location/Address:

NSN:

3) Accountable Records

a. Center of Excellence shall maintain up-to-date records of engine assembly rebuild status. The Center of Excellence shall keep a tracking sheet of all engines rebuilt and will include at a minimum the serial numbers and date of acceptance by the Government. This data will be provided on a monthly basis.

b. Center of Excellence shall maintain up-to-date records of rebuilt Engine Final Assembly Testing status. When requested, the Center of Excellence shall provide (in PDF format) a completed Engine Final Test Checklist (Appendix E) and a Final Inspection Record (FIR) (Appendix F) for every rebuilt engine assembly.

c. Return the completed (PDF) Final Test Checklist and Final Inspection Record sheets by e-mailing the TACOM Heavy Truck Group HET Team at: dami_het@conus.army.mil, or mailing to:

U.S. Army TACOM Life Cycle Management Command HET Team

(MS# 420)

ATTN: AMSTA-LCC-HH

6501 E. 11 Mile Rd.

Warren, MI 48397-5000

4) FACILITIES AND SUPPORT

The Center of Excellence for repair is responsible for providing all facilities, equipment, and tooling required to perform engine rebuild operations contained within this SOW. This includes, but is not limited to, handling equipment, disassembly and re-assembly of equipment, quality and tolerance checking equipment, equipment required for identification and marking of components, cleaning and processing equipment, and testing equipment.

VI. PERFORMANCE TEST

1) All DDEC IV Engine Assemblies will undergo a Final Assembly Test IAW Attachment 1. An Engine Run-In Performance Test will be conducted on every rebuilt engine. A quality assurance representative must certify this testing. As part of the test, the Center of Excellence will complete the Engine Final Test Checklist (Appendix E) and the Final Inspection Record (FIR) (Appendix F).

a. Selected rebuilt engine assemblies shall undergo Control Test and Inspection, based on Center of Excellence production quantity, in accordance with (Appendix G).

b. The engine must operate satisfactorily in an ambient temperature range of –50 Degrees F to 120 Degrees F.

Engine Performance Specifications:

c. Horsepower and Torque Requirements:

Engine should operate at 2300 rpm, increase load until engine speed decreases to 2100 rpm. Verify that brake horsepower is 500 minimum.

2) After testing, return the completed (PDF) Final Test Checklist and Final Inspection Record sheets by e-mailing the TACOM Heavy Truck Group HET Team at: dami_het@conus.army.mil,, or mailing to:

U.S. Army TACOM Life Cycle Management Command HET Team

(MS# 420)

ATTN: AMSTA-LC-HH

6501 E. 11 Mile Rd.

Warren, MI 48397-5000

VII. QUALITY ASSURANCE

1) The Center of Excellence shall develop, administer, and maintain a Quality Assurance (QA) program fulfilling the requirements of ISO 9001: 2008, Quality Management Systems Requirements or ISO 9001: 2008, Quality Management Systems Guidelines for Performance Improvement. The Quality Assurance/Quality Control (QA/QC) plan shall be made available to the Procuring Authority/Commodity Manager (PA/CM) for review prior to the start of work and through the life of the program. The contractor shall notify the PA/CM in writing of any change. The basic plan and changes thereto are subject to disapproval by the PA/CM.

2) A Control Test and Inspection shall be performed on overhauled, tested and accepted engine assemblies.

3) The Government shall select engine assemblies for control test and inspection in accordance with (Appendix G).

4) The engine assemblies subjected to control test and inspection must meet the following requirements:

a. The Testing/Performance Check in (Attachment 1) shall be performed.

b. During the control test, the engine must meet the test requirements in accordance with (Appendix G).

5) Any discrepancy found shall be cause for control test or inspection failure. Failure may result in discontinuance of acceptance of the engine assemblies by the Government until the Center of Excellence has demonstrated to the Government that corrective action to eliminate the cause(s) for failure has been taken. When the cause(s) for failure is determined, necessary corrections must be made and proved by testing and/or inspecting three randomly selected units from the production quantity. One of the three units must be subjected to all specified tests and inspections. Control test and inspection for the other units in the production period shall be limited to the parameters related to the failure cause(s) and to the parameters affected by the corrective action taken.

6) Failures shall be reported to USA TACOM, ATTN: AMSTA-LCC-HH within 48 working hours. After correction of discrepancies found during control test and inspection, the engine assembly shall be assembled, subjected to acceptance inspection requirements and processed as a regular overhauled engine assembly, if all requirements are met.

VIII. INSPECTION EQUIPMENT

1) The Center of Excellence QA activity shall ensure that test and measurement equipment is properly maintained and in current calibration status. Unless otherwise specified, the Center of Excellence shall be responsible for maintenance, calibration, surveillance, and disposition of acceptance inspection and test equipment prescribed herein. Inspection and test equipment used in conjunction with the program shall be controlled in accordance with requirements of ISO 9000 and ISO 10012:2003. All inspection and test equipment shall be made available to the representative from the procuring activity, when required, for verification purposes.

2) The Center of Excellence QA activity shall ensure that inspection and test equipment used in conjunction with the program will be maintained and controlled in accordance with ISO 9001: 2008 or ISO 9009: 2009. The depot's current quality system may be used until the current certification has expired after which, current certification shall satisfy the requirements of the latest ISO 9001/9004: 2000 revision.

IX. FABRICATION

Fabrication of parts is authorized (with prior approval of TACOM) as a work-around due to lack of needed parts in the supply system.

X. DISPOSAL

Disposal of non repairable DDEC II and DDEC III/IV Engines and their sub-components will be the responsibility of the rebuilding contractor and must be in accordance with all federal, state, local laws and ordinances.

XI. IUID CODING

IUID markings and readability requirements shall comply with MIL-STD-130N or latest version. The human readable characters and the machine readable IUID symbology will be marked on the hardware. First priority for IUID marking location will be any pre-existing data plate that currently reflects part number, manufacturer, etc. If the technical data has not specified the marking location, IUID tag, Template “B” shall be placed IAW Attachment 3 IUID location. IUID tags can be ordered using the Letterkenny UID Works site;

http://www.letterkenny.army.mil/UIDworks/howto.html

XII. PAINTING

a. Each rebuilt engine shall be cleaned and prepared for painting. The entire engine assembly shall be painted IAW OEM specification, except for the areas and items listed below:

1) Rubber hoses and belts

2) Electrical wires and connectors

3) Engine electrical control components

4) Flex plate

5) Flywheel housing mounting flange

b. Painting shall be accomplished IAW MIL-T-704, AR 750-58 and TM 43-0139.

XIII. PACKAGING

All rebuilt DDEC III/IV Dressed Engine Assemblies will be preserved and packaged in IAW instructions contained in TM 9-2320-360.

XIV. CONTAINER REPAIR

To ensure containers meet performance specifications, Center of Excellence will inspect and repair the container in accordance with TB 9-289 or SB 725-92-1. OEM or equivalent parts can be use when repairing the container. When using these parts, Center of Excellence must ensure they meet the requirements specified on the OEM part’s drawing.

XV. SUPPORT ITEMS

a. Special Tools that are listed in TM 9-2320-360-13&P and can be requisitioned through the Army Supply System. The cost of these tools will be borne by the repair site. Fabrication of any necessary fabricated support items listed in the NMWR or TM is the repair site’s responsibility.

b. When using other than OEM parts, the parts used must be able to be repaired or replaced using the existing procedures, tools and repair parts specified in the HET technical manuals.

Attachment 1 Final Assembly Testing

Attachment 2 Item Unique Item Identification

Attachment 3 Bill of Materials

Appendix E Final Test Checklist

Appendix F Final Inspection Record

Appendix G Control Test

Appendix H Horsepower and Altitude Compensation

Appendix I Test Malfunction Deficiency Sheet Table E-2 image1.emf

Final Assembly Testing Attachment 1.pdf image2.emf

Item Unique Item Identification Attachment 2.pdf image3.emf

Final Test Checklist Appendix E.pdf image4.emf

Final Inspection Record Appendix F.pdf image5.emf

Control Test Appendix G.pdf image6.emf

Horsepower and Altitude Compensation(Appendix H).pdf image7.emf

Test Malfunction Deficency Sheet Table E2 Appendix I.pdf