A21 - (D) Caterpillar Engine Overhaul Specification for Dockside Maintenance FY2021-2025.pdf

CATERPILLAR® ENGINE OVERHAUL

SPECIFICATION FOR DOCKSIDE MAINTENANCE

FY2021-2025

Developed By: IBCT Product Line

(Rev-0, 05 March 2020)

USCG CATERPILLAR ENGINE OVERHAUL DOCKSIDE MAINTENANCE FY2021-2025

2 (Rev-0)

TABLE OF CONTENTS

Revisions Record........................................................................................................................................................... iii Consolidated List of References................................................................................................................................. iv Consolidated List of Government-furnished Property.......................................................................................... v Consolidated List of Critical Inspection Items........................................................................................................ vi General Requirements WORK ITEM 1: Disassemble, Clean, Inspect, Repair or Renew and Reassemble Engine Units and

Accessories (Top End and Center Section Overhauls) WORK ITEM 2: Perform Computer Aided Marine Performance Analysis Report (CAMPAR) Diagnostic

Testing for a Diesel Engine

3 (Rev-0)

REVISIONS RECORD

This page is used to record specification revisions, which may have occurred subsequent to a Revision 0 (Rev-0) package. Information listed is intended to provide contractors and field unit personnel a means to ensure all the current specification revision pages are present when reviewing or utilizing this specification package.

DATE REV# WORK

ITEM#

CHANGES MADE

NOTE : All work item and paragraph numbers listed above for a given revision correspond to same numbers in the previous revision. This revised specification is self-contained with all of the above listed changes incorporated.

4 (Rev-0)

CONSOLIDATED LIST OF REFERENCES

The below-listed documents form a part of this specification to the extent specified herein.

Approval/publication dates or revision dates/numbers are also identified, to ensure that same document versions are used at time of specification writing and during contract execution.

All Coast Guard drawings, technical publications, and standard specifications will be provided to contractors by the Coast Guard at an appropriate time, or upon request, free of charge. Other Government documents may be accessed – free of charge – as follows:

� MIL/DOD/CID Specifications: http://www.assistdocs.com/search/search_basic.cfm

� Commandant Instruction Manuals: http://www.uscg.mil/directives/default.asp

� Public Laws, Code of Federal Regulations, U.S Codes, and other Federal Government laws::

www.gpoaccess.gov

The Government is aware of the following internet web links where contractors may procure commercial specifications:

� American Welding Society (AWS): http://www.awspubs.com/index.php

� ANSI, ASTM, IEEEE, NFPA, ASME, SAE Standards: http://www.techstreet.com/

� NFPA: http://www.nfpa.org

� SSPC Standards and pictorial guides: http://shopping.netsuite.com/sspcmarketplace

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2018, General

Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2018, Welding and

Allied Processes Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2018, Requirements for Preservation of Ship Structures http://www.assistdocs.com/search/search_basic.cfm http://www.uscg.mil/directives/default.asp http://www.gpoaccess.gov http://www.awspubs.com/index.php http://www.techstreet.com/ http://www.nfpa.org http://shopping.netsuite.com/sspcmarketplace

5 (Rev-0)

OTHER REFERENCES

Caterpillar® Marine Model D353, D379, D3304, D3306, D3406, D3412, D3508, D3608 Disassembly and

Assembly (Series) Manuals and/or the latest original equipment manufacturer (OEM) technical bulletins and specifications manuals as guidance

Caterpillar® Guidelines for Reusability, “Index of Publications on Reusability or Salvage of Used Parts”, Caterpillar Publication SEBF8029 (series)

Caterpillar® Marine Service Handbook

6 (Rev-0)

CONSOLIDATED LIST OF GOVERNMENT-FURNISHED PROPERTY

The following is a list of property, which the Government will furnish. This list supersedes any other material obligations indicated or implied by referenced drawings.

None

7 (Rev-0)

CONSOLIDATED LIST OF CRITICAL INSPECTION ITEMS

The following is a list of work items, which contain Critical Inspection reports, which the Contractor must complete within the first 25% of the availability contract period (see SFLC Std Spec 0000, paragraph 3.2.6.5 (Inspection report particulars)):

Work Item Title

1 Disassemble, Clean, Inspect, Repair or Renew and Reassemble Engine Units and Accessories.

8 (Rev-0)

00000_1215_FLT

REC_00000_FLT_Commercial Project @ CG Facility (1212)

00000_CAT Engine Ovhl IDIQ_MWC_0116_IBCT

General Requirements

1. SCOPE

1.1 Intent. This standard specification invokes general requirements for accomplishment of tasks specified in this specification by commercial contractors at various geographically dispersed Coast Guard facilities for Coast Guard vessels in the continental United States and OCONUS states and territories.

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color

Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2018, General

Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2018, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2018, Requirements for Preservation of Ship Structures

OTHER REFERENCES

Caterpillar® Marine Model D353, D379, D3304, D3306, D3406, D3412, D3508, D3608 Disassembly and Assembly (Series) Manuals and/or the latest original equipment manufacturer (OEM) technical bulletins and specifications manuals as guidance

Caterpillar® Guidelines for Reusability, “Index of Publications on Reusability or Salvage of Used Parts”, Caterpillar Publication SEBF8029 (series)

9 (Rev-0)

3. REQUIREMENTS

3.1 General. The Contractor shall conform to all requirements specified in SFLC Std Spec 0000 and in this item, as applicable, during the performance of this availability.

NOTE

The requirements of paragraph 3.1 (General) applies to all work under the scope of this contract, whether explicitly stated in work items or not, and to all other work subsequently authorized by changes, modifications, or extensions to the contract.

3.2 Personnel.

3.2.1 Caterpillar Tech Rep. The Contractor shall provide the services of a certified Tech Rep, who is familiar with the Caterpillar marine diesel engine models listed in Para 3.3.4, to accomplish the following tasks – on site:

� Accessing Original Equipment Manufacturer (OEM) proprietary information, software, and tools pertinent to tasking in accordance with the specification.

� Assisting with proper repair methods, and ensuring compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system.

� Generating a Computer Aided Marine Performance Analysis Report (CAMPAR) with the diagnostic test data and recommendations for the diesel engines.

� Conducting Marine Engine Performance diagnostic testing (CAMPAR or load bank testing), ensuring compliance with OEM, U.S. Coast Guard, OSHA, and other pertinent procedures and standards.

� Providing genuine, OEM-approved parts

3.2.1.1 Ensure that the Tech Rep is a Certified Representative of Caterpillar, Inc.

3.2.1.2 Ensure that Tech Rep is certified and authorized by Caterpillar to perform work on the applicable Caterpillar model marine diesel engine.

10 (Rev-0)

3.2.2 Employee identification and access. At least seventy two (72) hours prior to each ship visit to perform work under this contract, the Contractor shall submit a list of all employees who shall be performing that work to the COR. To gain access to the ship or other Government facilities to perform any work under this contract, each Contractor employee shall carry a picture identification card furnished by the Contractor, or other servicing agent authorized by the Contractor/Manufacturer. The employee shall prominently display this card on their person in the chest area at all times when on any Government facility, except when actively engaged in labor wherein the card might get caught in tools or operating machinery and represent a hazard to the employee.

3.2.3 Security clearances. Special security clearances are normally not required to perform any work under this contract. The Contractor shall supply a list of all employees who may be required to perform work and periodically update that list. Prior to each ship visit to perform work, the Contractor shall submit information on visiting employees. In event the cutter be berthed at a Department of Defense or foreign government military facility, the KO will provide instructions on the method by which the cutter crew will assist the Contractor’s representatives in meeting facility access requirements at the time the Contractor is tasked.

3.3 Scope of work.

3.3.1 Work. The Contractor shall provide all personnel, labor, materials, parts, tools (standard and special), test equipment, test fittings, supplies, consumables, and equipment required to accomplish tasking in accordance with the scope of work.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment, perform electrical tag-outs in support of maintenance, and be available to advise on rigging safety procedures as necessary. All other labor associated with maintenance tasks (i.e. rigging, parts delivery, repairs, etc.) shall be provided by the Contractor.

3.3.2 Travel. The Contractor shall provide all travel necessary to support tasks onboard the vessel at the vessel’s homeport. Travel shall be estimated and submitted to the COR and KO before it is commenced and actual travel receipts shall be supplied within 96 hours after travel has been completed.

The place of performance for Contract Line Items (CLINs) covered by this solicitation will be performed pier-side on-board the vessel, at the vessel’s homeport in the Continental United States (CONUS) or Outside the Continental United States (OCONUS).

11 (Rev-0)

(1) Pricing Travel and Pier Diem will be included in each Task Order and for all personnel required to accomplish the work covered by this specification.

(2) The proposed Travel and Per Diem for each Task Order shall represent total compensation for employees’ transportation, lodgings, meals, and incidentals and shall not exceed on a daily basis the maximum rates as set forth in the Federal Travel Regulations, the Joint Travel Regulation, and in the case of foreign travel, the Standardized Regulations.

(i) Federal Travel Regulations, prescribed by the General Services Administration, for travel in the conterminous 48 United States, is available on a subscription basis from the Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402.

(ii) Joint Travel Regulation, Volume 2, DOD Civilian Personnel, Appendix A, prescribed by the Department of Defense, for travel in Alaska, Hawaii, The Commonwealth of Puerto Rico, and territories and possessions of the United States, is available on a subscription basis from the Superintendent of Documents, U.S.

Government Printing Office, Washington, DC 20402.

(iii) Standardized Regulations (Government Civilians, Foreign Areas), Section 925, "Maximum Travel Per Diem Allowances for Foreign Areas," prescribed by the Department of State, for travel in areas not covered in by (i) and (ii) of this paragraph, is available on a subscription basis from the Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402.

(3) All receipts for travel must be submitted with the invoice(s) for the associated Task Order. If there is a difference in costs from pricing established at the time of award for Travel and Pier Diem; a modification will be issued based on receipts for actual costs.

(4) The place of performance for all work will be completed at the vessel’s homeport. If for any reason the homeport or pier location is changed, the Contracting Officer will request a Quote for Travel and Pier Diem to the new location. The Contractor will be compensated for the difference in cost from the vessel’s homeport and the new location.

3.3.3 Engine parts.

3.3.3.1 New parts. The Contractor shall use only new, OEM-approved parts for accomplishments of tasks.

3.3.3.2 Reused parts. The Contractor shall ensure all parts qualified for “reuse” meet the reusability guidelines specified in the appropriate documents listed in the latest published version of Caterpillar Publication SEBF8029 “Index of Publications on Reusability or Salvage of Used Parts”.

12 (Rev-0)

3.3.4 Engine applicability. The Contractor shall be advised that tasking will include work associated with the following Caterpillar® engine models (serial number prefixes included in parentheses):

� D353 (47B), D379 (69B)

� D3304 (83Z), D3306 (6EG, 85Z)

� D3406 (2AM, 2WB, 4BM, 9PL), D3412 (5RL, 60M, 7HG)

� D3508 (8TL, BAG, 3HM, 9WN)

� D3608 (8LL)

NOTE

The Contracting Officer (KO) will identify the specific engine serial and arrangement numbers of engine units and accessories to be completed under this contract at time of tasking.

3.4 Documentation.

3.4.1 Inspections. For visual inspections and condition assessments (i.e. pass/fail), the use of digital pictures attesting to condition of components inspected is required. These, in conjunction with a narrative, will be used to document acceptability. Visual inspections shall be accomplished using the following guidelines and included in all CFR submissions:

� OEM’s relevant guidance and reference documents for inspection and assessment shall be utilized and referenced accordingly (including Publication Number, Publication Date, and Title). For Caterpillar applications, this would include the appropriate documents listed in the latest published version of Caterpillar Media SEBF8029 “Index of Publications on Reusability or Salvage of Used Parts”.

� List of all instruments (make and model) of equipment used in support.

� List of all parts and components inspected, including part numbers and serial numbers (as applicable) for machinery history and configuration tracking purposes.

� All readings and measurements (clearances, tolerances, etc.) recorded and used in support of OEM-reusability determinations.

� Recommendations for re-use, replacement, repair, or renewal of inspected components per OEM-reusability guidelines.

13 (Rev-0)

3.4.2 Parts list. Upon completion of work, the Contractor shall submit an itemized parts list (including part number information and nomenclature) detailing any parts replaced during overhaul. This list shall be attached to a CFR.

3.5 Compliance. All work shall meet the requirements of this work specification. The inspections set forth shall become part of the Contractor's overall Inspection System or Quality Program. The absence of any inspection requirements shall not relieve the Contractor of the responsibility of ensuring that all work submitted to the Government for acceptance complies with all requirements of the contract.

3.5.1 Noncompliance. If any work fails to pass a test or inspection, the Contractor shall take action to correct the work.

3.6 Acceptance. Acceptance of the work shall be discontinued until corrective actions, acceptable to the Government, have been taken. After taking corrective action, repeat the inspection on the corrected work.

3.7 Final acceptance. Final acceptance shall be withheld until re-inspection shows the corrective action to be successful. In the event of failure after re-inspection, the Contractor shall submit to the Coast Guard Inspector a written report concerning the failure with recommended corrective actions.

3.8 Conformance. Quality conformance tests and inspections shall be the minimum test and inspection methods used to demonstrate compliance to the requirements set forth in this work specification.

3.9 Fire watch requirements. The Contractor shall refer to 3.3.1.3 (Fire watch requirements) of SFLC Std Spec 0000, in accomplishing the following task:

� Coast Guard fire watch is in lieu of contractor personnel during the hours of 0800-1600, Monday through Friday, and limited to two Coast Guard fire watch personnel.

3.10 Preservation requirements. The Contractor shall accomplish all preservation tasks, including touch-ups of affected engine components, in accordance with SFLC Std Spec 6310. All new parts replaced shall be preserved in accordance with OEM-standards (i.e. new blocks, cylinder heads, etc). A

3.11 Welding and brazing requirements. The Contractor shall perform all welding and allied processes, and NDI in accordance with SFLC Std Spec 0740.

3.12 Environmental protection requirements. The Contractor shall adhere to the following environmental protection requirements in accordance with the SFLC Std Spec 0000:

3.12.1 USCG facilities. The Contractor shall provide and maintain environmental protection as defined in SFLC Std Spec 0000 Appendix B, Requirements for Environmental Protection at USCG Facilities, during the performance of this availability. Contractor shall plan for and provide environmental

14 (Rev-0) protective measures to control pollution that develops during normal practice, as well as plan for and provide environmental protective measures required to correct conditions that develop during the project. Contractor shall comply with applicable Federal, state, and local laws, codes, ordinances, and regulations in their entirety. Any reference to a specific portion of a Federal, state, or local law, code, ordinance, or regulation in this or any other item shall not be construed to mean that relief is provided from any other sections of the law, code, ordinance, or regulation.

3.12.2 HW disposal. The Contractor shall comply with SFLC Std Spec 0000 Appendix B, Requirements For Environmental Protection At USCG Facilities for HW disposal, and ensure that waste removals are conducted during normal business hours (0800-1600) on Monday through Friday (excluding holidays).

3.13 SFLC standard specification approved changes. The Contractor shall be aware that the following are approved changes to published SFLC 2014 Edition Standard Specifications and supersede published content:

3.13.1 SFLC Standard Specification 6310, Requirements for Preservation of Ship Structures.

3.13.1.1 SFLC Std Spec 6310, page C-2, Section C1.5.1. Change from "lead-containing paint as 0.06%" to "lead-containing paint as 0.009%".

3.13.1.2 SFLC Std Spec 6310, page 4, Section 2 References, Group- Other References. Add “The Society for Protective Coatings (SSPC) Paint Application Guide No. 11, 2008, Protecting Edges, Crevices, and Irregular Steel Surfaces by Stripe Coating”

3.13.1.3 SFLC Std Spec 6310, page Appendix C-6, add "Hempel Hempadur Multi-Strength GF 35870" with FED-STD-595 color "Black/Red" under ANTI-ABRASION COATING, ICE BREAKING CAPABLE VESSELS, <235’.

3.13.1.4 Standard Spec 6310, page Appendix A-7, Under "UNDERWATER (U/W) BODY/BOOT-TOP", Add line Column 1: Option for U/W Body and Boot-Top, Steel Hulls, <154', in Salt Water. Column 2: Blank.

Column 3: SSPC-SP 10/NACE NO. 2 using grit conforming to MIL-A-22262 / (1.5-3.5) - or - SSPC-SP WJ-2(M)/NACE WJ-2(M). Columns 4 and 5: Same as "U/W Body and Boot-Top, Aluminum Hull, High Speed (>30 knots)".

3.13.2 SFLC Standard Specification 0000 General Requirements.

3.13.2.1 SFLC Std Spec 0000, paragraph 1.3 ‘Acronyms and term definitions’, page 5, “PCL (Paint Containing Lead)” definition replaced by, “Any paint or coating containing lead in excess of 0.009 percent by weight (1.0 mg/cm2 or 90 ppm). Lead Based Paint (LBP) is an interchangeable term with

PCL.”

3.14 Rigging. Contractor is responsible for rigging all machinery parts on and off the vessel. Assistance with rigging engine parts on and off vessel, or use of buoy deck for temporary tool and parts storage

15 (Rev-0) must be confirmed with vessel at least seventy two (72) hours prior to start of contract or the Friday before the contract start date.

4. NOTES

4.1 Access to COMDTINST M10360.3. The COMDTINST M10360.3 may be accessed at the following URL address: http://www.uscg.mil/directives/cim.asp http://www.uscg.mil/directives/cim.asp

16 (Rev-0)

00000_0116_FLT

00000_CAT Engine Ovhl IDIQ_PJM_0116_IBCT

WORK ITEM 1: Disassemble, Clean, Inspect, Repair or Renew and Reassemble Engine Units and Accessories (Top End and Center

Section Overhauls)

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to disassemble, clean, inspect, repair and reassemble (Top End and Center Section Overhaul) Caterpillar Diesel Engine Units and Accessories, to include engine models D353, D379, D3304, D3306, D3406, D3412, D3508, and D3608 and provide genuine CAT OEM-approved parts as necessary for repairs aboard WLB, WLI, WLM, WLIC, WLR, WTGB, and WYTL cutter class vessels onboard the vessel at the vessel’s homeport.

1.2 Government-furnished property.

None

2. REFERNCES

COAST GUARD DRAWINGS

None.

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color

Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2018, General

Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2018, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2018, Requirements for Preservation of Ship Structures

17 (Rev-0)

OTHER REFERENCES

Caterpillar® Marine Model D353, D379, D3304, D3306, D3406, D3412, D3508, D3608 Disassembly and Assembly (Series) Manuals and/or the latest original equipment manufacturer (OEM) technical bulletins and specifications manuals as guidance

Caterpillar® Guidelines for Reusability, “Index of Publications on Reusability or Salvage of Used Parts”, Caterpillar Publication SEBF8029 (series)

3. REQUIREMENTS

3.1 General. The Contractor shall provide all parts, labor, tools required which includes but is not limited to (standard tools/special tools/Test Equipment/Consumables). Additionally, Contractor shall cover all core charges and ensure cores are returned to distributor.

NOTE

The Contracting Officer (KO) will identify the specific engine serial and arrangement numbers of engine units and accessories to be completed under this contract.

3.1.1 CIR. The Contractor shall submit a CIR for the inspections listed in the following paragraph(s):

� 3.3 (Engine component cleaning and inspections).

3.1.2 Protective measures.

3.1.2.1 Ensure protective measures are in place IAW General Requirements.

3.1.3 Interferences.

3.1.3.1 Contractor shall be responsible for reinstalling all interferences.

3.1.3.2 Contractor shall be responsible for rigging engine parts into and out of vessel. CG assistance provided at discretion of each vessel’s command.

3.1.4 References. The Contractor/technicians shall disassemble, clean, inspect, repair or renew and reassemble the Caterpillar engine units and accessories in accordance with the references listed in Section 2 herein.

3.1.5 Authority to proceed. The Contractor/technicians shall not proceed with any additional growth work on the engine units or accessories described in this specification, until specific instructions are given by the KO on what additional work is to be accomplished.

18 (Rev-0)

NOTE

The Contracting Officer (KO) will provide a written response to the Contractor, after receipt of the CIR, regarding all work to be completed for repairs. Work may not proceed until this authorization is received.

3.1.6 Responsibility for inspection. The Contractor/technicians shall be responsible for all inspections and test requirements specified herein. The Contractor shall provide the necessary calibrated test equipment to conduct all of the inspection requirements. Be aware that the Government reserves the right to verify or perform any of the inspections or tests set forth in this specification where such inspections are deemed necessary to assure that supplies or services conform to the prescribed requirements.

3.2 Operational test – initial. Prior to commencement of work, the Contractor shall witness an operational pre-test (by Coast Guard personnel) of the engine to demonstrate existing operational condition. Submit a CFR documenting operational condition of engine.

3.2.1 Operational test – initial – Center Section Overhaul (CSO). When conducting a CSO, submit CFR to include web deflection readings and thrust measurements of engine in pre-overhaul condition.

3.3 Clean and Inspect Engine Components. The Contractor shall disassemble, clean, inspect and test the engine components listed below, (Refer to Table 1) utilizing the appropriate publications as outlined in Section 2 as guidance. Provide a CIR/CFR of these components to the KO for potential reuse determination.

TABLE 1 - ENGINE COMPONENTS TO BE DISASSEMBLED, CLEANED, INSPECTED OR

TESTED DURING THE PERFORMANCE OF A TOP END/CENTER SECTION OVERHAUL

TOP END CENTER SECTION (INCLUDES TOP END)

Aftercooler Camshaft Exhaust Manifold Crankshaft Rocker Shaft Assembly and Push Rods Crankshaft Vibration Damper (all models except 3608) Turbocharger housing and any other components not renewed in Table 2. Cylinder Block

Water Manifold Driven Equipment (alignment) Jacket Water Pump Engine Mounts Sea Water Pump Flywheel Heat Exchanger – All. Front Gear Train (Gears) Cylinder Head Spacer Plate (3508 only) Rear Gear Train (Gears) Governor Fuel Linkage Oil Cooler Core Oil Supply Lines Oil Suction Screen Spacer Plates

19 (Rev-0)

3.3.1 Report. The Contractor shall record the appropriate inspection findings on a CFR (clearance and tolerance readings of the cylinder block and related components). Submit a written report of all findings and recommendations to the Coast Guard Inspector (CGI) and COR within 24 hours after inspection.

3.3.2 Government’s right for furnishing various components and parts. The Contractor shall be aware that the Government reserves the right, to furnish new or rebuilt components or parts for installation, in place of the existing parts, at no additional cost to the Government. If the Government exercises this right, the Contractor shall turn over all existing components or parts to the CGI or COR as Mandatory Turn-In (MTI) items.

3.4 Automatic renewal. The Contractor shall perform the following engine component renewals with genuine, remanufactured (or new) OEM components, (Refer to Table 2).

20 (Rev-0)

TABLE 2 - ENGINE COMPONENTS TO BE DISASSEMBLED AND AUTOMATICALLY

RENEWED DURING THE PERFORMANCE OF A TOP END/CENTER SECTION

OVERHAUL

TOP END CENTER SECTION (INCLUDES TOP END)

Complete Cylinder Head Assemblies Camshaft Bearings Cylinder Head Gaskets and Seals Connecting Rod Bearings Inlet Air Line Seals Crankshaft Seals Turbocharger Bearings, Bushings and Seals Crankshaft Thrust Plates Valve Lubricator (If Equipped) Exhaust Manifold (Seals and Bellows) Water Pump Bearings and Seals Fuel Injection Pumps Water Temperature Regulators / Thermostats and Seals

Fuel Transfer Pump

Fuel Injectors Gear Train Bushings Turbocharger Cartridge Inlet Manifold (Gaskets and Seals) Head Studs Jacket Water Pump Fuel System (Primary and secondary filters) Lubricating Oil Pump Air Filters Main Bearings Lifter Roller Assemblies (3608 only) Piston rings Sea Water Pump (3608 only) Sea Water Pump Software (Install new software when a new ECM is installed) Crankshaft Vibration Damper (3608 model engine ) including hardware Lifter Roller Assemblies Connecting Rods and Hardware Cylinder Liners Piston Assembly Crankshaft Counterweight Hardware (as applicable)

3.5 Discretionary renewal. If a modification has been authorized and released by the KO, the Contractor shall renew the specified engine components with genuine, remanufactured (or new) OEM components. (Refer to Table 3).

3.5.1 Exceptional Circumstances. If the Coast Guard or the servicing element determine a long block or short block is required to return the ship to operational condition, the KO may authorize the contractor to complete repairs utilizing a long block or short block vice in-place overhaul of engine. KO may authorize assembly of long block offsite to accomplish repair.

TABLE 3 - ENGINE COMPONENTS TO BE RENEWED UPON INSPECTION AND WITH

KO AUTHORIZATION

TOP END CENTER SECTION (INCLUDES TOP END)

21 (Rev-0)

Aftercooler Crankshaft Exhaust Manifold Camshaft Rocker Shaft Assembly and Push Rods Cylinder Block Turbocharger Driven Equipment (alignment) Water Manifold Engine Mounts (Caterpillar) Flywheel Oil Cooler Core Oil Suction Screen Governor (Overhaul by authorized governor dealer)

TABLE 4 - OPTIONAL SERVICES TO BE COMPLETED DURING AN ENGINE OVERHAUL

WITH KO AUTHORIZATION

OPTIONAL SERVICES

Machining of Engine Block

Cooler Clean Line bore

Long block renewal

3.6 Gaskets and seal. The Contractor shall furnish and renew all gaskets and seals (consumables) associated with the engine reassembly in this contract.

3.7 Fluids and Filters. The Contractor shall furnish and renew all fluids and filters associated with the engine reassembly. Contractor will be advised of Coast Guard desired engine oil preference prior to arrival conference.

3.8 Reassemble Engine Units and Accessories. After any authorized repairs and renewals, the authorized Caterpillar Contractor/technician’s shall reassemble the engine units and accessories to its original configuration utilizing the appropriate publications as outlined in Section 2.1 as guidance.

3.8.1 Alignmnent Check. The Contractor shall perform an alignment check post overhaul to include but not limited to SSDG generator decoupling, engine mount repair, rear gear work, or disconnecting engine from shaft and/ or red gear.

3.9 Operational testing – post overhaul.

NOTE

The USCG considers the testing below to be separate testing evolutions. The Contractor and Ship’s Force should coordinate scheduling of the three to ensure optimum use of schedule.

22 (Rev-0)

3.9.1 Operational "light-off" test. After completion of work, the Contractor shall witness an operational "light-off" test (by Coast Guard personnel) of the diesel engine unit and accessories to prove satisfactory operating condition.

3.9.2 Engine break-in. Upon successful completion of operational "light-off testing", the Contractor shall conduct an engine test run (break-in), under various loads, in accordance with applicable Caterpillar and Coast Guard standards. This is to ensure all internal engine components have been properly tested (seating of piston rings, proper oil flow to internal parts, temperatures) and any discrepancies are resolved.

3.9.2.1 For MDEs, this will include both pier-side and underway testing to ensure proper engine break-in.

3.9.2.2 For SSDGs and EDGs, the Contractor shall provide and utilize an external load bank to accomplish the proper engine break-in (CSO only).

3.9.3 Computer Aided Marine Performance Analysis Report (CAMPAR) testing. Upon successful operational testing and engine break-in, the Contractor shall perform a CAMPAR diagnostic test for the engine in accordance with Caterpillar’s instructions. The CAMPAR testing shall include all data points required by the CAMPAR program and includes the installation of external meters and gauges in support. The Contractor shall provide all diagnostic equipment, test fittings, test measurement devices, and any additional tooling required in support of CAMPAR testing (Refer to General Requirements – Paragraph 3.3.1 “Work”).

NOTES

1. The intent of the CAMPAR testing is to establish overall condition of the engine “post-overhaul” in support of engine performance-tracking initiatives. CAMPAR testing shall be conducted in accordance with Caterpillar standards and include all data elements recorded on the complete program (i.e. fuel rates, boost pressures, etc.).

2. Historically, the CAMPAR test results provided to the USCG have omitted specifications (i.e. acceptable data ranges for recorded parameters, units of measure, and recorded data). Contractor shall annotate the submitted test data as necessary to provide this information.

3. Ship’s Force may assist in data collection efforts as requested by the Contractor.

Additionally, data collection can be accomplished using installed ship’s instrumentation (i.e. local meters, gauges, MPCMS displays, etc.) provided locations are in agreement with PAR testing requirements. The Contractor shall be aware that all PAR testing locations are not monitored by the USCG and will require the Contractor to install additional gauges and/or meters (and associated test fittings) to accomplish tasking.

23 (Rev-0)

3.9.4 Adjustments. Based on the results of the operational testing, perform any additional adjustments (or readjustments) as required to ensure proper operation of the engine.

3.9.5 Testing data submittal. Upon completion of testing, the Contractor shall submit (as attachment to CFR) all data recorded during testing. This shall include the following:

� Operational logs during engine break-in, including electrical load information for SSDGs and EDGs.

� Complete CAMPAR report, including fuel demand curves and findings.

4. NOTES

4.1 Equipment operation. Coast Guard personnel will operate all shipboard machinery and equipment during all operational tests.

4.2 Coast Guard Inspector responsibilities. Although the Contractor is responsible for applying appropriate quality assurance measures, the Coast Guard will witness the accomplishment of these measures. Therefore, a Coast Guard Inspector will:

4.2.1 Monitor the assigned work items to keep informed of progress and to ensure that the specifications are being followed.

4.2.2 Witness all test as required by the specification.

4.2.3 Be guided by the work item and seek immediate clarification when necessary.

4.2.4 Immediately bring to the attention of the Contracting Officer any work which appears to be contrary to the work item requirements.

4.2.5 Document all work performed in the Machinery History Log.

4.2.6 Ship’s force is responsible for post-overhaul verifications per Coast Guard instructions.

NOTE

When there is overwhelming documentation to record. The Engineer Officer/Engineer Petty officer may state in the Machinery History Log, “All overhaul documentation is located (indicate where) for reference.

4.3 Definitions.

4.3.1 Tools - Common tools normally contained in a standard toolbox (screwdrivers, wrenches, pliers) etc.

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4.3.2 Special Tools/Test Equipment - Such as torque wrenches, calibrated electronic meters, computer devices etc not normally found in a standard toolbox.

4.3.3 Consumables - A non-reusable item such as a rag, disposable gloves, paint, oil, grease, solvent, adhesive, sealant, corrosion preventive product, cleaner, jacket water, etc.

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23300_MWC_CAMPAR

WORK ITEM 2: Perform Computer Aided Marine Performance Analysis Report (CAMPAR) Diagnostic Testing for a Diesel Engine

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform a Marine Engine Performance diagnostic test and generate a Computer Aided Marine Performance Analysis Report (CAMPAR®) for a designated diesel engine, onboard the vessel at the vessel’s homeport.

NOTE

The intent of this work item is to accomplish a CAMPAR® test on a single diesel engine as requested by the USCG. This work item will be utilized independent of a planned overhaul.

1.2 Government-furnished property.

None.

2. APPLICABLE DOCUMENTS

Caterpillar® Marine Service Handbook

3. REQUIREMENTS

3.1 Computer Aided Marine Performance Analysis Report (CAMPAR) testing. The Contractor shall perform a CAMPAR diagnostic test for a designated engine in accordance with Caterpillar’s instructions. The CAMPAR testing shall include all data points required by the CAMPAR program and includes the installation of external meters and gauges in support. The Contractor shall provide all diagnostic equipment, test fittings, test measurement devices, and any additional tooling required in support of CAMPAR testing (Refer to General Requirements – Paragraph 3.3.1 “Work”).

NOTES

1. CAMPAR testing shall be conducted in accordance with Caterpillar standards and include all data elements recorded on the complete program (i.e. fuel rates, boost pressures, etc.).

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2. Historically, the CAMPAR test results provided to the USCG have omitted specifications (i.e. acceptable data ranges for recorded parameters, units of measure, and recorded data). Contractor shall annotate the submitted test data as necessary to provide this information.

3. Ship’s Force may assist in data collection efforts as requested by the Contractor.

Additionally, data collection can be accomplished using installed ship’s instrumentation (i.e. local meters, gauges, MPCMS displays, etc.) provided locations are in agreement with PAR testing requirements. The Contractor shall be aware that all PAR testing locations are not monitored by the USCG and will require the Contractor to install additional gauges and/or meters (and associated test fittings) to accomplish tasking.

4. Testing shall be accomplished both pier-side and underway as indicated in the proposed test plan.

3.2 Computer Aided Marine Performance Analysis Report (CAMPAR). The Contractor shall generate and provide the CAMPAR report to the COR within 2 weeks of completion of testing. The report shall include all testing data, results, analysis, recommendations and diesel engine identifiers (serial number and vessel designation).

3.3 Recommended adjustments. If a Change Request has been authorized and released by the KO, the Contractor shall accomplish any recommended adjustments based upon the results of the diagnostic test, prior to departure.

4. NOTES

4.1 Documentation. The Coast Guard Inspector will document the accomplishment of testing in the Engine's History Log.