HET_M1070_Tansmission_SOW_.docx

SCOPE OF WORK

REBUILD AND REPAIR OF THE

HET M1070 Transmission Allison CLT754 with Container

NSN 2520-01-354-6915

I. GENERAL

This scope of work covers the information required to rebuild the Allison CLT 754 Transmission with Container NSN 2520-01-354-6915, Part Number 57K3048. This transmission is used in the M1070 Heavy Equipment Transport (HET) vehicle and will be mounted to the Detroit Diesel DDEC III/IV engine. Scope for rebuilding and repairing these transmissions and containers includes receipt, inspection, test, repair, and like activities necessary to bring the transmission and container to a like new condition. No transmission 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 transmissions 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) TM 43-0139 Painting Instructions for Army Material

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

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

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

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

h) Final Assembly Testing (Attachment 1)

i) Item Unique Item Identification (Attachment 2)

j) Bill of Materials (Attachment 3)

k) Final Test Checklist Table E-1 (Appendix E)

l) Final Inspection Record (Appendix F)

m) Control Test (Appendix G)

n) Test Malfunction Deficiency Sheet Table E-2 (Appendix H)

IV. DEFINITIONS

1) Rebuild: Consist of those services/actions necessary for the restoration of unserviceable Allison CLT 754 Transmissions to a like new condition transmission 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 transmission 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 transmission 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) Transmission Assembly Rebuild and Repair:

a. Transmission Rebuild and Repair: Government will provide transmission assemblies, NSN 2520-01-354-6915 in various states of disrepair. Center of Excellence will rebuild the transmissions adhering to the information contained in Technical Manual Series 9-2320-360.

b. You the Center of Excellence shall rebuild All Het M1070 transmission assemblies IAW this Scope of Work and all references listed above in Section III 2

c. Each rebuilt transmission 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 transmission 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 transmission assembly must maintain the same transmission to vehicle interface as the original equipment transmission 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 cases or component assemblies when repairing or rebuilding other transmission 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 transmission assembly showing obvious signs of imminent failure or damage/deterioration with a fully serviceable or new item

h. The transmission provided will be in a container, NSN 8145-01-373-1592. 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 transmission assembly. Please note that the TM contains mandatory replacement parts for all aspects of repairing the HET, not just the transmission. 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 transmission cases, any crack are cause for disposal. Center of Excellence may use serviceable or repairable parts from cracked cases/assemblies when repairing or rebuilding other transmission assemblies, except mandatory replacement parts

2) DATA PLATE

a. Center of Excellence will include a “Rebuilt Transmission” data plate with each rebuilt transmission. Attach the data plate to the transmission 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 Transmission Number:

Rebuild Date:

Rebuild Location/Address:

NSN:

3) Accountable Records

a. Center of Excellence shall maintain up-to-date records of transmission assembly rebuild status. The Center of Excellence shall keep a tracking sheet of all transmission 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 Transmission Final Assembly Testing status. When requested, the Center of Excellence shall provide (in PDF format) a completed Transmission Final Test Checklist (Appendix E) and a Final Inspection Record (FIR) (Appendix F) for every rebuilt transmission 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 transmission 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 Transmission Assemblies will undergo a Final Assembly Test IAW Attachment 1. Transmission Run-In Performance Test will be conducted on every rebuilt transmission. A quality assurance representative must certify this testing. As part of the test, the Center of Excellence will complete the Transmission Final Test Checklist (Appendix E) and the Final Inspection Record (FIR) (Appendix F).

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

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

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 transmission assemblies.

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

4) The transmission 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 transmission 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 transmission 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 transmission assembly shall be assembled, subjected to acceptance inspection requirements and processed as a regular overhauled transmission 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 transmissions 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 transmission shall be cleaned and prepared for painting. The entire transmission assembly shall be painted IAW OEM specification, except for the areas and items listed below:

1) Bores in end yoke.

2) Air passages of breather.

3) Data plates.

4) Threads of fittings.

5) Flywheel and mounting flange of torque converter housing.

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

XIII. PACKAGING

All rebuilt Transmission 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 Test Malfunction Deficiency Sheet Table E-2 image1.emf

Final Assembly Testing.pdf image2.emf

HET M1070 Transmission IUID location.pptx HET M1070 Transmission IUID Location image1.jpeg image3.emf

Transmission BOM.pdf image4.emf

Final Test Checklist.pdf image5.emf

Final Inspection Record.pdf image6.emf

Control Test.pdf image7.emf

Test Malfunction and Deficiency Sheet.pdf