3.c. Reintjes Gear SOW.pdf

REVISION NO. CHANGE NO.

TITLE

OVERHAUL SPECIFICATION

REINTJES WVS 234 UP REDUCTION GEAR

PURCHASE NEW GEARS

SPECIFICATION NUMBER

R-241-0595

ORIGINATED BY: JOHN DUNHAM DATE: 20OCT20

ORIGINATOR’S COMMAND: SURFACE FORCES LOGISTICS CENTER (SFLC)

DEPARTMENT / DIVISION: SMALL BOAT PRODUCT LINE (SBPL)

INTERNAL REVIEWER: DATE:

SWORB APPROVAL: DATE:

1.0 SCOPE

1.1 Requirements

a. Complete overhaul to include: disassembly, inspect, reassembly, operation testing, painting/preservation, and packaging of Reintjes WVS 234 UP Marine Reduction

Gears. These gears are attached to the main propulsion units installed on the U.S. Coast

Guard’s (117) 47’ MLBs. The Original Equipment Manufacturer (OEM) is Reintjes

GmbH (Eugen-Reintjes-Strabe 7) Germany.

b. Purchasing of new Reintjes WVS 234 UP Marine Reduction Gears.

c. Technical assistance for both Warranty and Non-Warranty items.

1.2 Classification

a. Reintjes WVS 234UP Marine Gear (NSN 3010-12-344-0596)

2.0 APPLICABLE DOCUMENTS

2.1 Document Availability

For the methods and conditions for obtaining the referenced documents refer to section

6.0.

2.2 Government Documents

a. ASTM-D7478/D7478M - Standard Spec. For Heavy Duty Sheathed Wood Crates

b. MIL-DTL-15090E - Enamel, Equipment, Light Gray

c. MIL-PRF-2104M - Lubricating Oil

d. MIL-STD-129R - Military Marking For Shipment And Storage

e. MIL-STD-2073 - Standard Practice For Military Packaging

f. ISO9001-2015 - Quality Management Systems

2.3 Commercial Documents

a. Reintjes Operating Manual (Marine Reverse Reduction Gear) Type WVS 234-334-004

b. ANSI/NCSL Z540 3 2006.08.03, Requirements for the Calibration of Measuring.

c. ASQC-Q9003 - QS Model for Quality Assurance in Final Inspection and Test

2.4 Specification Order Of Precedence

In the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence, unless otherwise specified herein. The

Contractor shall notify the Contracting Officer in writing of any perceived conflicts contained herein.

2.5 Departure From Specification

a. Departure from this specification shall not be allowed unless approved by the USCG

Contracting Officer.

b. If the Contractor finds it necessary to suggest implementing change or depart from applicable specifications they shall request permission.

c. Request for change shall clearly describe the changes proposed, the reason for change, advantages of the proposed changes, price increase or decrease (if any) resulting from the change.

3.0 REQUIREMENTS

3.1 General

The Contractor shall complete the following requirements in accordance with the attached Delivery

Schedule:

a. Fifteen (15) days, upon receipt of gear, to accept gear and notify the Contracting officer.

b. Thirty (30) days, upon receipt of gear, to disassemble gear and submit Appendix A

(condition found report) to Contracting Officer IAW paragraph 3.5a.

c. Sixty (60) days to overhaul gear after Contracting Officers review of CFR and sends contractor notice to proceed IAW paragraph 3.5b.

1. Within the above sixty (60) day period, the contractor shall submit Appendix C

(spin-test report) to the Contracting Officer IAW paragraph 3.5b and 3.6b.

2. Within the above sixty (60) day period, the contractor shall paint and preserve the gear IAW section 5.0.

3. Within the above sixty (60) day period, the contractor shall perform the correct packaging and marking procedures IAW section 5.0.

d. A “Cumulative Tracking Report”, (Appendix D), shall be submitted according to the periodicities set forth in paragraph 3.5.c.

e. The contractor has seven (7) business days after completion of overhaul, preservation and packing, to ship the gear to the appropriate USCG facility.

3.2 Contractor Responsibilities

a. The Contractor shall provide all labor, parts, equipment, special tools and materials required to complete the requirements.

b. The gear overhaul shall be performed by a Reintjes Certified Facility. The definition of

“Certified Facility” is the Contractor has provided legible documentation from Reintjes

GmbH (Eugen-Reintjes-Strabe 7) Germany (OEM) acknowledging the Contractor is authorized to meet the requirements of this specification.

c. The Contractor’s Technician(s) for all requirements of this specification shall be certified and trained with a Reintjes certification for the WVS 234 UP model gear.

Copies shall be provided to the Contracting Officer.

d. The Contractor shall legally possess all OEM Technical Publications.

e. The Contractor shall ensure all tools and test equipment are calibrated in accordance with Section 4.3.

f. The Contractor shall provide all special tooling, jigs and fixtures to accomplish the overhaul.

g. The overhauls and all component inspections shall be completed using only genuine

OEM parts, OEM components, processes, and practices.

h. The contractor shall use the parts listed in Appendix B and shall be new genuine OEM parts or factory reconditioned conforming to OEM specifications for reusable parts, with the approval of the Contracting Officer.

i. The Contractor shall have the capabilities to conduct all testing on-site at the

Contractor’s facility in accordance with Reintjes procedures.

j. The USCG reserves the right to witness all testing.

k. The Contractor shall be responsible to provide the USCG all updated data in regards to gear configuration, service bulletins, TP changes/revisions, parts, and part number changes.

l. Upon receipt of any gear, regardless of condition, the Contractor shall store the gear inside and keep from exposure to weather that may degrade or compromise the gear.

m. In the event, contingency parts and/or labor is/are required, in order to accomplish the overhaul, the contingency parts and/or labor shall be priced separately and shall be negotiated under each task order as required.

3.3 Failure Analysis

In the event of a catastrophic failure, and at the discretion of the Government on a separate task order, the gear will be sent to the Contractor’s facility to determine the cause of the casualty. All parts & labor shall be priced separately and shall be negotiated under each task order. A report of the findings shall be submitted to the

Contracting Officer within thirty (30) days of receipt of the gear.

3.4 Disposition

The Contractor shall submit a request to the Contracting Officer for the disposition of used parts.

3.5 Required Reports

a. The Contractor shall disassemble the gear and submit Appendix A to the Contracting

Officer for approval within thirty (30) days of receiving the gear.

b. Within sixty (60) days after notice to proceed, the contractor shall complete the approved work per OEM specifications and spin-testing requirement per Appendix C.

c. The Contractor shall submit the Cumulative Tracking Report Appendix D to the

Contracting Officer quarterly no later than the 15th calendar day of the month. The report shall capture the progress of each task order, and or delivery orders annotated in the previous months report.

d. Failure Analysis Report, as per paragraph 3.3, shall be submitted to the Contracting

Officer within (30) days of receipt of the gear.

e. Government Property Report. The Contractor shall provide a report IAW FAR 52-245-

1 upon request.

file:///C:/Users/MPMcHale/AppData/Local/Microsoft/Windows/DOCUMENT_SAMPLES_AND_TOOLS/FAR.pdf file:///C:/Users/MPMcHale/AppData/Local/Microsoft/Windows/DOCUMENT_SAMPLES_AND_TOOLS/FAR.pdf

3.6 General Test Requirements:

a. The Contractor shall give the Contracting Officer seven (7) business days’ notice prior to scheduling a reduction gear Spin Test.

b. The Reduction Gear spin test shall be completed and the pass/fail criteria detailed in

Appendix C and shall be recorded and submitted to the Contracting Officer.

c. Final acceptance testing of the gear shall be verified and accepted by a USCG

Representative.

d. During the final acceptance test, the USCG Representative shall have the capability to visually monitor all required parameters.

b. Any unusual noise, external leakage or any other noncompliance to this specification determined by the USCG Representative shall be cause for the gear to be found unacceptable.

3.7 Notifications & Inspections

a. The Contractor shall be responsible for notifying the Contracting Officer at least seven (7) business days prior to being ready for any inspections or testing.

b. Prior to notification the USCG of final testing, the gears shall be pretested with all the test results documented and made available upon the USCG representative’s arrival.

3.8 Warranty

a. A warranty of one year from installation or 1000 operating hours, whichever occurs first, as well as 24 months of storage, is required for the entire marine gear. Storage commences upon receipt of marine gear at the designated USCG facility.

b. In the event of a warranty claim, the contractor shall contact the prospective field unit to arrange a resolution of such claim within 24 (twenty-four) hours after receiving notification by the Coast Guard.

c. The contractor shall contact the Contracting Officer to evaluate the proposed duration of warranty repair time.

d. The contractor shall repair each gear to the condition level necessary for the contractor to honor a new full warranty at the expense of the contractor.

e. The contractor shall submit for approval, to the Contracting Officer, an inspection report containing any parts and/or pricing containing any work/repair(s) that is/are required that was/were not a result of the discrepancy reported by the prospective field unit.

f. To properly adhere to the warranty outlined in this contract, the government will ensure each designated Coast Guard facility complies with the warranty guidelines stated herein, and will be required to submit a Warranty Notice (Appendix E) to the

Contracting Officer if, or when, a discrepancy is found with a gear.

3.9 Technical Assistance

a. Then contractor shall assign a representative to support the USCG Contracting

Officer or the Contracting Officer Representative (COR).

b. The contractor shall respond to a formal technical assistance (TECH Assist) request within a 24 hour period (during normal working hours).

4.0 QUALITY ASSURANCE

4.1 General

The Contractor shall maintain an inspection system, which shall ensure each item offered to the USCG for acceptance conforms to contract requirements. The system shall be documented and in compliance with in accordance with reference 2.3.c.

4.2 Records

The Contractor shall maintain records of all inspections and tests. The records shall indicate the nature and number of observations made, type of deficiencies found and the corrective action taken.

4.3 Contractors Calibration System

The Contractor, as well as any Subcontractors, shall be required to maintain a calibration and maintenance system to control the accuracy of measurement and test equipment used in the fulfillment of this contract in accordance with reference 2.3.b.

The system shall include, at a minimum, prescribed calibration intervals, source of calibration and a monitoring system to ensure adherence to calibration schedules.

Calibration standards shall be traceable to the National Institute of Standards and

Technology (NIST).

4.4 Responsibility For Inspection

The Contractor shall be responsible for all inspections/test requirements specified herein. The Contractor shall provide space, personnel, and test equipment to conduct all inspection requirements. All testing and inspection shall be at the Contractors facility acceptable to the USCG. The USCG reserves the right to verify or have performed any of the inspection/tests set forth in this specification where such inspections are deemed necessary.

4.5 Packing Inspection

The USCG reserves the right to perform an on-site inspection of the preservation and marking requirements if deemed necessary.

5.0 PRESERVATION, PACKAGING, PACKING, & MARKING

5.1 Internal PRESERVATION

After operational testing and acceptance by the USCG, the gear shall be preserved in accordance with references 2.3a.

5.2 External PRESERVATION

a. After completion of the final test run and internal preservation the gear shall be prepared in accordance with Reintjes Marine Gears Anti-Corrosion Protection

Guidelines.

b. All loose scale and paint shall be removed prior to priming and painting.

c. The gear shall be painted in accordance with 2.2b.

d. Coat all unpainted metal surfaces with an anitcorosive metal preservitive, except for hot surfaces.

e. Plug or cap any fittings/flanges or openings that will allow seepage.

f. The Contractor shall attach to the gear, in a plastic envelope, a completed copy of the final test report (Appendix D) and warranty information (Appendix E).

5.3 Packing

a. The shipping container, if damaged, shall be constructed and mounted to the base skidded pallet in accordance with reference 2.2a. The gear shall be packaged in accordance with Reintjes Marine Gears Preservation Guidelines for corrosion proofing, types of packaging, storage conditions/storage periods.

b. The Contractor shall securely fasten the gear into the approved shipping container. It shall be fastened in a manner that adequately ensures protection during multiple common carrier practices.

5.4 Marking

a. Each preserved, packed, and packaged item shall be stenciled in the upper left-hand side of the two longest sides, (two opposite sides if square) of each box.

b. Machine made stencils shall be used for all marking.

c. All marking shall be in black print on a contrasting back ground (white paint) and at least 2” high.

d. The marking shall be in the format as follows:

NATIONAL STOCK NUMBER ...... 3010-12-344-0596

PART NUMBER ............................... WVS 234 UP

ITEM NAME ..................................... Transmission

MODEL NUMBER ........................... WVS 234 UP

SERIAL NUMBER ........................... “As per Enclosed Gear”

CONTRACT NUMBER .................... See Contract

DELIVERY ORDER NUMBER ....... As submitted on the Order

SHIPPING WEIGHT ......................... As Determined by Contractor

QUANTITY & UNIT OF ISSUE ...... 1- EA

DATE OF PRESERVATION............ Date preserved

CONDITION CODE ......................... CONDITION A

OTHER DATA AS ............................ COAST GUARD SFLC MATERIAL

DIRECTED ........................................ REUSABLE CONTAINER,

DO NOT DAMAGE

DO NOT STACK

e. The following marking shall be placed on all four sides and the top of each box, in stenciled black print at least 2” high:

Reusable Container- Do Not Damage

Remove Fasteners Prior To Removing Cover

Use Forklift to Unload

Do Not Lift By Cover

6.0 GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

6.1 Government Documents

USCG Surface Forces Logistics Center

2401 Hawkins Point Road

Baltimore, MD 21226

410-762-6112

6.2 Commercial Documents

International Organization for Standardization

American National Standards Institute (ANSI)

1430 Broadway

New York, NY 10018

212-642-4900

6.3 Enclosures

a. Appendix A Condition Found Report

b. Appendix B Mandatory Parts List

c. Appendix C Gear Spin Test Report

d. Appendix D Cumulative Tracking Report

e. Appendix E Warranty Information

Appendix A

Condition Found Report

Task Order #:_____________________________

Delivery Order #:__________________________

Engine Serial #:___________________________

Reduction Gear Serial #:____________________

Condition Found

Repairs Required

Parts Required

Parts Expended

Recommendations

Appendix B Mandatory Parts List

As part numbers are superseded, the new part numbers shall be used as the given part numbers for this specification. ALL part numbers shall be verified prior to ordering. Any part number changes shall be forwarded in writing to the COR

Mandatory Replacement Parts

No Item Number Description Qty

1 170054 E13 Bearing 1

2 170054 E15 Bearing 1

3 81391 E16 Bearing 2

4 170054 E122 Bearing 2

5 81391 E123 Bearing 2

6 77016 P20 Bearing 1

7 738654 P21 Bearing 1

8 738662 P22 Bearing 1

9 738670 P74 Bearing 1

10 603350 E11 Shaft Seal 1

11 SS1851 E219 Shaft Seal 1

12 21903 E1501 O-Ring 1

13 21903 E1502 O-Ring 1

14 705526 W12 Bush 1

15 800147 K7 Piston Ring 2

16 8850 K13 Allen Head Bolt 36

17 20753 K18 Piston Ring 2

18 469947 K22 Inner Disc 22

19 23K3602 K23 Outer Disc, Waffle 24

20 170038 W162 Screw Plug 12

21 572721 W163 Allen Bolt 12

22 550515 W164 Spring 12

23 8850 W166 Allen Head Bolt 44

24 28G2352 E203 Spring 4

25 301361 E714 Seal Set, Oil Pump 1

26 301167 E725 Bearing, Oil Pump 1

27 411396-01 A283 Seal Set Oil Filter 1

28 282987 A282 Seal Set Oil Cooler 1

29 300632-12 V223 Seal Set, Control Valve 1

30 705500 V422 Seal Set, Pressure Valve 1

31 659304 V351 Sinter Filter 1

32 395803 A37 Filter Element 2

33 171948 K8 hex Bolt 12

34 45128 K61 Locking Wire Kit 1

35 800039 R43 Retaining Ring 2

36 800175 R44 Circlip Seeger AW 2

Appendix B (cont’) Mandatory Parts List

37 4710111 P159 Circlip 1

38 4710135 P172 Circlip 2

39 GS51580 51580 Sealant 1

40 158186 A28 SHUTOFF VALVE 1

41 0594-32 KARL SENNER LLC TAG 1

42 14782 PIPE CLAMP 1

43 246018 E711 SHIM 4

44 800241 E711 SHIM 4

45 800263 E711 SHIM 4

46 246034 E712 SHIM 4

47 211303 E712 SHIM 4

48 246042 E712 SHIM 4

49 234012 HOSE (IN FEET) 6

50 395510 R3 FITTED DISC 2

51 410090 zV338 O-RING KIT, INTERMEDIATE PLATE 1

52 10703 #110 COMPRESSION SPRING, PRESSURE VALVE 1

53 93310018 PRESSURE ADJUSTMENT BOLT, PRESSURE VALVE 1

54 506834 PIPE CLAMP M12 2

55 506844 PIPE CLAMP M28 1

56 934010 HEX NUT 16

57 12092 FLAT WASHER 16

58 395803 A37 FILTER ELEMENT 1

59 659657 E19 OIL PUMP KF 1/11 RIGHT 1

60 1006516 V1 CONTROL VALVE 1

61 403067 K30 CARRIER 1

62 RI11/2EDX1/2CF REDUCER, 1-1/2 MBSPPX 1/2 FBSPP 2

63 991130 A1 OIL COOLER 1

64 21156 A35 OIL PRESSURE GAUGE 1

65 2406-20-16SS STAINLESS HOSE 2

66 SS9002-16-16 ADAPTER, MBSPP X MJ, SS 2

67 991137 SUPPORT, COOLER BRKT. 2

Appendix C Gear Spin Test Report

Repair Order # Date:

Model: Ratio:

Serial Number: Spec Number:

Tested By: (print name)

Time Start: Time Finished:

Pass Fail

Procedure All tests must be completed and data recorded.

1 Start motor at 650 RPM and verify the presence of oil pressure in forward and reverse. Note pressure below.

Increase the motor speed to 1800 RPM and maintain it until the internal oil temperature is 140-176 F

Reduce speed to 650 RPM. Perform 10 forward/reversing cycles. Insure that the engagement is instantaneous but soft. Confirm that the control lever moves without binding.

4 Confirm that the pump pressure is steady (max variation 20 bar). Note pressure below.

5 Confirm that gear will obtain full RPM in forward and reverse.

6 Record individual bearing temperatures.

Operational Test

TEST

RANGE

RPM

TEST

PORT

MAIN PSI FORWARD

CLUTCH PSI

REVERSE

CLUTCH PSI

Bearing Temperatures *

NEU N/A N/A Input

FWD

Input

AFT

Output

FWD

Output

AFT

650 FWD N/A N/A

1800 FWD N/A N/A

650 REV N/A N/A

1800 REV N/A N/A

7 Unusual Noise (Pass/Fail)

8 Pressures (Refer to transmission manual for pressure specifications and monitoring points.)

9 Visual check of unit for leaks. (No leakage should be detected.)

10 Record Oil Temperature at end of test: (F)

11 Remove oil and inspect filter. Clean suction filter and install new lubrication filter (if applicable).

NOTE – (*) The FWD and AFT bearing temperatures on any common shaft shall not have a temperature differential of greater than 15 Degrees F. If the temperature differential exceeds 15 Degrees F, the test will be stopped. This requirement is for spin tests only. The maximum temperature differential of 15 Degrees F is not applicable once the gear is installed.

Appendix C (cont’) Gear Spin Test Report

Description of failures and corrective actions:

Technician Signature

Date:

Contractor Manager Signature

USCG Representative Signature

Appendix D Cumulative Tracking Report

Gear Serial # D/O # Core Accepted Y/N

Percentage Complete

Date Completed

Appendix E Warranty Information

Warranty Period for Reintjes WVS 234 UP Marine Gears

1000 Hours of Operation OR One (1) Year from Date of Installation

****After installation, return this completed sheet to the following****

USCG SFLC SBPL

2401 Hawkins Point Road

Baltimore, MD 21226-5000

Unit Name: Engine Serial Number

Hull Number: R/G Serial Number

Homeport: Date Received:

POC: Date Installed:

Telephone:

Any discrepancies noted upon receipt/during warranty period

DO NOT REPAIR OR REPLACE!!!

Repairs are to be performed only after contacting John Dunham, Small Boat Product Line

OFFICE PHONE: (410) 762-6112; EMAIL: JOHN.M.DUNHAM@USCG.MIL

!!Any unauthorized repairs could void the WARRANTY!!

Appendix E (CONT’)

1. GENERAL CHECKS UPON RECEIPT OF GEAR

A. A COMPLETE INSPECTION SHOULD BE MADE OF THE UNIT'S CONDITION.

B. PRESERVATION TAGS ON THE GEAR WILL TELL YOU TO WHAT EXTENT THE

UNIT HAS BEEN PRESERVED AND WHAT SHOULD BE DONE BEFORE PLACING

THE UNIT IN OPERATION.

C. UNCOVER ALL TAPED AND PLUGGED OPENINGS PRIOR TO CONNECTING OF

HOSES AND LINES.

D. INSURE THAT ALL LUBE OIL LINES LEFT ON BOARD ARE FLUSHED AND ALL

FILTERS ARE CHANGED.

E. ENSURE PROPER SHAFT ALIGNMENT. IF REDUCTION GEAR IS INSTALLED WHILE

THE VESSEL IS OUT OF THE WATER, YOU MUST WAIT 24 HOURS AFTER THE

VESSEL IS PLACED IN THE WATER BEFORE ALIGNING THE SHAFT. ALL TANKS

MUST BE TOPPED OFF.

F. CONFIRM THE CALIBRATION OF THE L/O DIPSTICK.

G. ENSURE THE REDUCTION GEAR WILL BAR OVER BY HAND.

H. CHECK REDUCTION GEAR MOUNTS.

I. ANY PROBLEMS DURING THE INSTALLATION SHOULD BE REPORTED TO SMALL

BOAT PRODUCT LINE IMMEDIATELY.

2. GENERAL WARRANTY PARAMETERS

A. THINGS THAT WILL NOT VOID THE WARRANTY.

1. Preventive maintenance may be performed.

2. Troubleshooting the gear in accordance with your Type Manual.

NOTE: Emergency repairs/replacement of parts may be performed, but notify the Small Boat

Product Line Team immediately.

Appendix E (CONT’)

B. SOME THINGS THAT COULD VOID THE WARRANTY

1. Changing subassemblies without authorization.

2. Removing the L/O cooler cores.

3. Removing gear housing.

** CAUTION: DO NOT ROTATE THE OUTPUT OR INPUT SHAFT UNTIL READY TO

INSTALL UNIT.

** CAUTION: REMOVE ALL COVERS, PLUGS AND TAPE COVERING OPENINGS.

NOTICE: FOR FURTHER INFORMATION CALL SMALL BOAT PRODUCT LINE TEAM

REPAIRS ARE TO BE PERFORMED ONLY AFTER CONTACTING THE SMALL BOAT

PRODUCT LINE (SBPL) TEAM

OFFICE PHONE: (410) 762-6112