Mid-Life Overhaul Project for 8 Gillig Low Floor Transit Busses

Mid-Life Overhaul Project for 8 Gillig Low Floor Transit Busses

Scope

This project consists of repowering 8 Gillig Low Floor busses. These busses will be done one at a time with the collaboration of scheduling to be done by both NTS and the vendor providing the work. There will be time frames set in the contracts to provide NTS with assurance of limited down time of busses to protect the integrity of regularly scheduled route service.

The vendor will provide detailed warranty information for each part being installed. These items will be broken down by line item with all warranty time frames expressed in months and/or miles. Warranties expressed in engine hours will not be acceptable. If parts are procured by NTS and carry a; parts only,”Free from defects in workmanship” type warranty, NTS will hold that paper. Language for the installation only, will be negotiated at time of realization of parts availability to vendor.

The vendor will provide all newly installed parts with required fluids and lubricants as detailed below. The whole project has parts that tie together in the installation project, and the vendor will be expected to limit costing of fluids and lubricants to a one time instance. All fluids and lubricants other than those listed below must be approved by NTS.

Parts that cannot be procured by the vendor due to sole source/dealer regulations may be purchased by NTS and provided to the vendor. Pricing and shipping provisions must be agreed upon before starting the work on the bus. Some parts may be bought in entire quantities; some may have to be provided on a bus by bus basis, due to known delays that the sole source part vendors incur.

Overview

1.  Removal and reinstallation of reconditioned or rebuilt engines meeting OEM specifications. There are qty.7 Cummins ISL-250HP model engines residing in 29 ft. chassis. There is qty.1 Cummins ISM, EGR, 280HP model residing in a 35 ft. chassis.

2.  Removal and reinstallation of reconditioned transmissions meeting OEM specifications. There are qty.7 Allison B300R-5 models residing in 29 ft. chassis and qty.1 Allison B400R-5 model residing in a 35 ft. chassis.

3.  Removal and reinstallation of new driveshaft and U-joints. This stub shaft must meet or exceed OEM specifications. They are all Series 1710 ½ round shafts.

4.  Removal and reinstallation of remanufactured rear differentials meeting OEM specifications. There are qty. 7 Meritor model RS21-145‘s with a ratio of 5.13 residing in 29 ft. chassis. There is qty.1 Meritor model 71163 with a ratio of 5.38 residing in a 35 ft. chassis.

5.  Removal and reinstallation of new or approved reconditioned transmission cooler meeting or exceeding OEM specifications. They are all Modine brand units.

6.  Removal and reinstallation of new radiators. This part must meet or exceed OEM specifications. The OEM units were made by Modine with E-Coat. Re-cored units must be approved by NTS before being used.

7.  Removal and reinstallation of new rear bumper. This is a Romeo Rim bumper and only the aluminum extruded frame of the bumper must be new. The outer plastic modules may be re-used unless otherwise directed by NTS.

BREAKDOWN

1.  ENGINE

1.1.  The engines installed for this project must be approved by NTS. They must be Cummins reconditioned crate motors or motors rebuilt by an authorized Cummins service shop. They must be rated for Transit applications.

1.2.  The actual components for each new motor must be listed in the quoted price.The peripheral parts needed to complete repower project must be listed and agreed upon before each individual install is started.

1.2.1.  Some of the parts that might need consideration would be the hydraulic pump and filter assy .and the oil cooler assy. It is also understood that a different oil pan and pick-up will be required. This will also entail new gaskets and isolator type pan bolts.

1.2.2.  Belts, hoses, lines, fittings etc., must be looked at by rep for both NTS and vendor to ensure current condition of parts to be reused.

1.2.3.  If parts cannot be reused, it will then be determined who will provide which part and how it will be delivered to the vendor’s site in time for install.

1.3.  There are Qty. 7 2001 Cummins ISL ,250 HP engines to be replaced

1.4.  There is Qty. 1 2005 Cummins ISM,280 HP to be replaced

1.5.  The vendor will suggest the type of oil to be used for start up of newly installed engine. NTS uses Petro-Canada DURON-E 15W40 oil at time of this writing. Any and all warranties must accept this for future coverage. NTS reserves the right to change oil brands in the future and must consult with warranty before doing so.

1.5.1.  The coolant to be used must be DEXCOOL Extended life antifreeze/coolant. This will also be integrated with the replacement of the radiator.

1.6.  The ECM (Electronic Control Module) must be calibrated to meet exact specifications of the OEM motor as designated by the engine VIN. The vendor must verify and document this for each engine.

1.7.  The engine compartment will be power washed by NTS prior to delivery of bus to vendor’s shop for ease of inspection.

1.8.  A representative of NTS will be present upon delivery of bus. The vendor’s shop will run a quick diagnostic of the engine with Cummins INSITE Software to acknowledge if there are any current fault codes in the engine. All codes will be noted and agreed upon before bus is left for service.

1.8.1.  If the vendor needs NTS to provide a technician for the first of the busses to be worked on, that will be arranged. This will be for any questions, tips or helpful hints that might be useful to the vendor, in the case that they are not too familiar with any particular part of the bus.

1.9.  NTS will not deliver a bus to the vendor until all parts are verified that they are in the possession of the vendor. This should be done in advance as the scheduling of the work progresses from one bus to the next.

1.9.1.  NTS and the vendor will work together to implement a plan for making sure all parts are available as needed throughout the entire project. This process must be documented so as to try to prevent any problems that might arise throughout the term of the contract. Language must be written to help minimize delays and for recovery of costs incurred by both parties.

1.10  Upon completion of work, a printed version of the diagnostics must be presented and reviewed before acceptance of finished bus.

2  TRANSMISSION

2.1  All transmissions must be reconditioned and/or remanufactured by Allison or an authorized Allison service shop and must meet or exceed OEM specifications for heavy duty, inner city transit use.

2.2  The necessity for a new accumulator will be recommended by the vendor. The quote must include the cost and availability for a new accumulator. This might need to be decided upon at time of installation. Use of the original accumulator must not affect any warranty.

2.3  The lubrication must be new, unused, synthetic blend ATF, rated for heavy duty and sufficient enough to equal OEM specifications.

2.4  The vehicle will be test driven upon receipt for service by an authorized representative of the vendor. This to ensure that the retarder is currently engaged and operating properly. This must be recorded so as to protect NTS in case of newly acquired transmission problems after the receipt of bus, at beginning of warranty time frame.

2.5  NTS will upon completion of installation, require an Allison diagnostic report and a test drive, witnessed by both a NTS representative and one from the vendor. Any and all notations regarding the operation of the retarder will be recorded with the post install diagnostics.

3  DRIVESHAFT

3.1  The 1710 Series Stub driveshaft will be replaced with a new shaft and new U-joints. This unit may use reconditioned stub and slip yokes, but the u-joint kits, bearings and seals must be new, unused.

4  DIFFERENTIAL

4.1  The Meritor rear ends must be reconditioned or remanufactured by a Meritor authorized service shop. It must meet or exceed all OEM quality applications.

4.2  The gears will be matched to the OEM specifications. Qty. 7 is 5.13 and Qty. 1 is 5.38.

4.3  The housing will be inspected at time of delivery to the vendor to check for any apparent damage.

4.4  The axle shaft and spline will be inspected for any signs of fracture or weakening and technician recommendations will be noted. The need to replace axles must be authorized by NTS. The cost and availability for both axles and hubs should be noted on pricing quote to facilitate more accurate budgeting.

4.5  The gear lube will be 75W-90 full synthetic unless otherwise recommended by vendor.

5  TRANSMISSION OIL COOLER

5.1  The cooler will be replaced by a new Modine unit or a brand of equal or greater value and quality. This unit must meet all OEM specifications. The vendor must recommend and NTS must authorize any cooler other than OEM.

5.2  The unit must be inspected before uninstall and any need to use new plumbing for the cooler must be noted.

5.3  It is suggested that the vendor have cost and availability for replacement plumbing and fittings available to NTS in the case that a new part must be installed that was not previously noted at time of inspection. It is understood that some issues may arise during removal of fittings, lines and hoses.

6  RADIATOR

6.1  The radiator will be replaced with new unit that meets or exceeds OEM specifications.

6.2  It will be suggested by the vendor whether there should be a new core only, reusing all the current mounting parts. This practice versus the installation of an entire new assembly should be discussed prior to purchasing any radiator parts. The final decision will be rendered by NTS.

6.3  All units must be finished with E-Coat or electronically applied equivalent.

6.4  The coolant system will be flushed and the replacement coolant will be DEXCOOL Extended Life antifreeze.

6.5  The entire cooling system must be inspected before uninstall and any need to use new plumbing for the radiator must be noted. This includes current operating temp and proper thermostat operation at time of vehicle arrival to vendor’s shop.

6.6  It is suggested that the vendor have cost and availability for replacement of vehicle mounting parts, plumbing, and fittings. The vendor must make these available to NTS in case a new part must be installed that was not previously noted at time of inspection. It is understood that some issues may arise during removal of fittings, lines and hoses.

7  REAR BUMPER

7.1  The rear bumper will be replaced with a new Romeo Rim rear bumper. It must match exactly, the style that was provided by Gillig at time of manufacture.

7.2  The aluminum frame structure is prone to corroding at point of contact with the steel brackets to which it mounts. Most of the removable plastic modules are re-usable. NTS will decide on a bus to bus basis which ones might require a new module.

7.3  NTS should procure these bumpers from Gillig and provide them to the vendor at the time of engine replacement. The bumper must be removed for this part of the project and it might be seen that some of the aluminum extrusions are too far gone for reattachment.

7.3.1  The plastic modules can also be prone to corroding where the steel screws attach to the aluminum frame. These sometimes require heating and delicate removal so as not to damage the plastic modules.

7.4  When the vendor goes to re-install the new aluminum bumper to the existing steel brackets, some form of protective gasket must be used. NTS has used a thin sheet of rubber in the past. Language will be included in the contract after recommendation from vendor. This will prevent the problem of future corrosion.

All parts that do not need to be turned back to the vendors for a documented core charge, will remain the property of NTS. These parts may be recovered from the vendor on a bus by bus basis, or as a whole at the end of the project.