CHICAGO TRANSIT AUTHORITY DETAIL SPECIFICATION FOR REPLACEMENT CUMMINS RECON BRAND DIESEL ENGINE PACKAGES WITH OR WITHOUT AN AUTOMATIC TRANSMISSION OR HYBRID DRIVE UNIT; PUBLIC TRANSIT BUS APPLICATIONS CTA SPECIFICATION NO. 1060-17 1. SCOPE 1.1 This specification will describe the requirements for a contractor to furnish and deliver various models and configurations of genuine Cummins ReCon Brand remanufactured diesel engines, with or without a genuine ZF Brand factory new or a genuine ZF Brand factory remanufactured automatic transmission attached, or with or without a genuine Allison Brand factory new or a genuine Allison Brand factory authorized rebuilt hybrid drive unit attached, to be used as replacement units in various brands of public transit buses that were originally delivered to the Chicago Transit Authority (CTA) with a Cummins Brand diesel engine and a ZF Brand automatic transmission combination, or a Cummins Brand diesel engine and an Allison Brand hybrid drive combination, by the original bus manufacturer. 2. GENERAL INFORMATION & REQUIREMENTS 2.1 Contractor shall furnish and deliver, as and if requested during the term of a given contract, various models and configurations of genuine Cummins ReCon Brand remanufactured diesel engines, with or without a genuine ZF Brand factory new or a genuine ZF Brand factory remanufactured automatic transmission attached, or with or without a genuine Allison Brand factory new or a genuine Allison Brand factory remanufactured hybrid drive attached, per the requirements presented in this specification, per the requirements presented in the Contract Documents, and possibly per any additional in scope, valid requirements presented on a given CTA Release Form issued against a given contract. 2.2 The CTA will furnish the contractor one (1) Cummins Brand engine core for each Cummins ReCon Brand engine that the contractor furnishes the CTA. The CTA will furnish Cummins Brand engine cores that meet the requirements for an acceptable engine core as stated in Cummins Engine Company issued current factory literature at the time a given Invitation for Bid (IFB) is posted. If a given engine core furnished by the CTA does not meet the previously stated requirement, then the contractor has the right to refuse acceptance of that core. Page 1 of 10 CTA 1060-17 2.3 The CTA will furnish the contractor one (1) ZF Brand automatic transmission core for each genuine ZF Brand factory new or genuine ZF Brand factory remanufactured automatic transmission that the contractor furnishes the CTA. ZF North America, Inc. defines an acceptable automatic transmission core as meeting all of the following requirements: 1) Housing must not be cracked or damaged. 2) Input and output must rotate independently of each other 3) Must not have been used without lubricant 4) Must include all of its parts If a given ZF Brand automatic transmission core furnished by the CTA does not meet all four (4) of the above stated requirements, then the contractor has the right to refuse acceptance of that core. 2.4 The CTA will furnish the contractor one (1) Allison Brand hybrid drive unit core for each genuine Allison Brand factory new or genuine Allison Brand factory authorized rebuilt hybrid drive unit that the contractor furnishes the CTA. 2.5 There will be a single CTA location for engine core or combination engine and transmission / hybrid drive core pick-up by the contractor, as well as engine delivery or combination engine and transmission / hybrid drive delivery by the contractor. See the Special Conditions section of the Contract Documents for CTA location declaration as well as acceptable days and hours for pick-up and / or delivery operations. 2.6 The Special Conditions section of the Contract Documents shall state product warranty requirements. Please see the Special Conditions section of the Contract Documents for warranty requirement details. 2.7 For warranty tracking purposes, the contractor shall furnish each applicable engine component, and any applicable ancillary components on the engine, sprayed with a unique paint color on its exterior surface for each specific contract. Actual paint color to be used shall be agreed upon by the CTA’s Bus Engineering & Technical Services Department and the contractor after award of contract. 2.8 Each engine control module (ECM), or the equivalent acronym for the same function, shall be furnished fully programmed, according to the template developed by the CTA and the applicable bus manufacturer of a given bus, prior to its delivery to the CTA. Additional details will be provided to the contractor on this subject matter by the CTA’s Bus Engineering & Technical Services Department after award of contract. 2.9 The CTA reserves the right to add or subtract Cummins ReCon Brand engine models, ZF Brand automatic transmission models, or Allison Brand hybrid drive unit models during the term of a given contract due to possible fleet revisions. Page 2 of 10 CTA 1060-17 2.10 The contractor is not allowed to deviate from any item stated in this specification unless each such deviation is first requested in writing to, and approved in writing by, the CTA’s Chief Bus Equipment Engineer, or designee. 3. DETAIL REQUIREMENTS – CUMMINS ISC ENGINES 3.1 Contractor shall furnish and deliver a Cummins ReCon Brand Model ISC remanufactured diesel engine in the possible configurations described below. The CTA will declare each configuration required, along with quantity requirements, on each applicable CTA Purchase Order, or CTA Release Form issued against a given CTA Purchase Order. 3.1.1 ISC Engine Configuration #1 - Basic Package - Cummins #DR25878RX. (For Novabus Brand, CTA Series 6400 buses). The engine shall include all ancillary engine components as stated in current Cummins Engine Company factory literature for a Cummins ReCon Brand Model ISC remanufactured engine at the time a given IFB is posted. 3.1.2 ISC Engine Configuration #2 – Basic Package Plus Specified Ancillary Items – Cummins #DR25878C250. (For Novabus Brand, CTA Series 6400 buses). All specified ancillary items, as stated in this section, shall be the genuine brand name stated, factory new, unless stated otherwise. Contractor shall furnish each engine as described in this section on a pooled CTA owned and CTA furnished transport frame. The CTA will also utilize a transport frame from the same pool when furnishing the contractor each engine core. Each ISC Engine Configuration #2 Package will include all of the listed items that follow. (1) Cummins ReCon ISC Engine - #DR25878RX (1) Cummins ReCon of a Delco 41MT Starter - #3675197RX (1) Sauer-Danfoss Hydraulic Pump - #550137982182165 (1) Nelson Muffler/Catalyst - #200031A (1) Niehoff Alternator - #C701 (1) Niehoff Voltage Regulator - #A2-322 (1) Novabus / Prevost Dipstick - #N8892113 (1) Novabus / Prevost Dipstick Tube - #N8892114 (1) Novabus / Prevost Belt Guard - #N27613 (1) Novabus / Prevost Oil Filler Pipe - #N30041 (1) Novabus / Prevost Probalyzer - #G1002386 (1) Novabus / Prevost Exhaust Heat Shield - #N26335 (1) Novabus / Prevost Exhaust Pipe - #N31853 (1) Novabus / Prevost Turbocharger Heat Shield - #N27528 (1) Novabus / Prevost Muffler Support Bracket - #N13816 (2) Novabus / Prevost Motor Mount Assembly - #N34877, N13967, N35140, N30973, and N13969-02 (1) Novabus / Prevost Muffler Heat Shield - #N31988 (1) Novabus / Prevost Front Engine Mount - #N21540 (1) Cummins Ring Gear - #3908546 Page 3 of 10 CTA 1060-17 (1) Cummins / Fleetguard Fuel-Water Separator - #FS1022 (4) Parker 919 Series Stainless Steel Braided over Teflon Brand Material Fuel, Air, Oil, and Coolant Lines – As Required (8) Nord-Lock Washers - #N32118 (20) Breeze CT Series Constant Torque Hose Clamps – Various Sizes (30) Umpco SS Series Stainless Steel P-Clamps – Various Sizes (15) Silicone Hose per SAE Standard J20R1 – Various Sizes 3.1.3 ISC Engine Configuration #3 – Basic Package Plus Specified Ancillary Items, Plus Genuine ZF Brand Factory New or ZF Brand Factory Remanufactured Automatic Transmission Mounted to Engine – Cummins #DR25878C250ZF. (For Novabus Brand, CTA Series 6400 buses). All specified ancillary items, as stated in this section, shall be the genuine brand name stated, factory new, unless stated otherwise. Contractor shall furnish each engine and transmission combination as described in this section on a pooled CTA owned and CTA furnished transport frame. The CTA will also utilize a transport frame from the same pool when furnishing the contractor each engine and transmission combination core. Each ISC Engine Configuration #3 Package will include all items listed in Section 3.1.2 above plus all of the listed items that follow. (1) ZF Brand Automatic Transmission - #4149 046 003 (10) Novabus / Prevost Mounting Hardware (Bolt) - #N21857 (10) Novabus / Prevost Mounting Hardware (Washer) - #N21858 (2) Novabus / Prevost Mounting Hardware (Screw) - #N21859 (8) Novabus / Prevost Mounting Hardware (Screw) - #N21997 Note: The hardware items listed above are used to attach the ring gear flange to the transmission’s torque converter as well as to attach the flex plate to the converter. 4. DETAIL REQUIREMENTS – CUMMINS ISB ENGINE 4.1 Contractor shall furnish and deliver a Cummins ReCon Brand Model ISB remanufactured diesel engine in the possible configuration(s) stated below. The CTA will declare each configuration required, along with quantity requirements, on each applicable CTA Purchase Order, or CTA Release Form issued against a given CTA Purchase Order. 5. DETAIL REQUIREMENTS – CUMMINS ISL ENGINES