3.c. Twin Disc Overhaul SOW_04OCT21.pdf

REVISION NO. CHANGE NO.

TITLE

OVERHAUL SPECIFICATION

TWIN DISC REDUCTION GEAR

TWIN DISC MG-507A1

TWIN DISC MG-5114SC

ORIGINATED BY: JOHN DUNHAM DATE: 04OCT21

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 General

a. Complete overhaul to include: disassembly, inspection, reassembly, operation testing, painting/preservation, and packaging of Twin Disc reduction gear models: MG-507A1 and MG-5114SC. These gears are attached to the main propulsion units installed on the

U.S. Coast Guard vessels 49’ BUSL’s and the 45’ RB-M’s.

b. Purchasing of new Twin Disc reduction gear models: MG-507A1 and MG-5114SC.

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

1.2 Classification

a. The below listed items are property of, and managed by the USCG Surface Forces

Logistic Center (SFLC) Baltimore, MD.

1. Twin Disc MG507A1 Ratio 2.54:1 (NSN 2010-01-450-5801)

2. Twin Disc MG5114SC Ratio 1.02:1 (NSN 3010-01-590-4163)

1.3 Government Furnished Property

a. The Government reserves the right to supply Government Furnished Property (GFP) at any time during the existence of this contract. The contractor shall provide protective storage for the GFP when not in use, and safe handling when in use.

b. In the event a furnished Reduction Gear is determined to be beyond economical repair

(BER) during the inspection process, the contractor shall contact the Contracting Officer

Representative. in accordance with section 3.1a2i.

2.0 APPLICABLE DOCUMENTS

2.1 Document Availability

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

7.0

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. Twin Disc MG-5114SC Service Manual

b. Twin Disc MG-507A1 Service Manual

c. Twin Disc MG Assembly Instruction / Production Testing-S570DY

d. Twin Disc MG Assembly Instruction / Production Testing-B2408G

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

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

2.4 Specification Order Of Precedence

a. 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 from the USCG Contracting

Officer.

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

a. The Contractor shall complete the following requirements in accordance with the

Delivery Schedule:

1. Fifteen (15) calendar days, upon receipt of gear, to accept gear and notify the

Contracting officer Representative (COR) of acceptance.

2. Thirty (30) calendar days, upon receipt of gear, to disassemble gear and submit

Appendix A (Condition Found Report) to COR, IAW paragraph 3.4a.

i. If repairs are expected to exceed 65% of the replacement cost of the reduction gear, the reduction gear shall be considered “BER” and either properly disposed of by the contractor or returned to the USCG at the expense of the contractor. The COR may then initiate a request to exercise the CLIN for a new reduction gear.

1. In the event a reduction gear is deemed “BER”, and the contractor will dispose of the shaftreduction gear, the contractor shall not use any portion of the reduction gear deemed “BER” in conjunction with a new reduction gears without the direct authorization from the COR.

3. Sixty (60) calendar days to overhaul gear after Contracting Officers’ review of

Condition Found Report and sends contractor notice to proceed, IAW paragraph

3.4b.

i.Within the above sixty (60) calendar day period, but after overhaul, the contractor shall submit Appendix D (spin-test report) to the COR, IAW paragraph 3.5 and 3.6.

ii.Within the above sixty (60) calendar day period, but after overhaul, the contractor shall paint and preserve the gear IAW section 5.0.

iii.Within the above sixty (60) calendar day period, but after overhaul, painting and preservation, the contractor shall perform the correct packaging and marking procedures IAW section 5.0.

4. A “Cumulative Tracking Report”, (Appendix E), shall be submitted according to the periodicities set forth in paragraph 3.4.c.

5. 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 Twin Disc Certified Facility. The definition of “Certified Facility” is the Contractor has provided legible documentation from Twin

Disc of Racine, Wisconsin (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 Twin Disc certification for both MG-507A1 and MG-5114SC reduction gear models. Copies shall be provided to the Contracting Officer upon request.

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 Twin Disc 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 (Appendix C) 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 Disposition

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

3.4 Required Reports

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

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

1. For any part included on the Condition Found Report (Appendix A) that is considered a contingency part, the Contractor shall supply the Contracting

Officer’s Representative (COR) with pictures of the faulty part, clearly displaying the part failure, and if the part can be rebuilt or reconditioned.

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

1. The contractor shall submit a signed spin test report to the COR within 10 calendar days after completion of the spin test. The report shall consist of the data obtained during the spin test along with any discrepancies outside of a satisfactory

OEM recondition / overhaul specification. One copy of the report shall also be packed and delivered with each reduction gear under this contract.

c. The Contractor shall submit the Cumulative Tracking Report Appendix E to the COR bi-weekly. The report shall capture the progress of each task order, and or delivery orders annotated in the previous report.

d. Government Property Report. The Contractor shall provide a report IAW FAR 52-245-1 upon request.

3.5 General Test Requirements:

a. The Reduction Gear spin test shall be completed in accordance with Appendix D and shall be recorded and submitted to the COR.

b. These recordings of the test procedure shall be filled out and submitted as part of the required test report.

https://www.acquisition.gov/far/52.245-1

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

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

Representative.

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

f. 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.

3.6 Test Failure Guidance:

a. If the Reduction Gear fails to pass any inspection/test due to any of the following reasons, the contractor shall report the failure and the recommended solution to the COR:

1. Does not meet rated RPM (Revoltions Per Minute) as per OEM standards.

2. Has any oil leaks or abnormal noise

3. Does not meet recommended pressures as per OEM

4. Any parameter for that reconditioned / overhauled reduction gear not meeting

OEM requirements.

b. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

c. The inspection/test shall be discontinued until all corrective action has been taken.

d. After all corrective actions have been taken; the inspection/test shall be continued or repeated at the option of the Contracting Officer.

e. Acceptance shall be withheld until re-inspection has been shown that the corrective action was successful and the item satisfactorily passes all inspections and tests.

f. All corrective actions shall be documented as part of the contractor’s inspection system and submitted for approval to the Contracting Officer.

3.7 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 COR to evaluate the proposed duration of warranty repair time within 48 (forty-eight) hours.

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 COR, 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 F) to the

COR if, or when, a discrepancy is found with a gear.

3.8 Non-Warranty Technical Assistance

a. Non-Warranty technical services shall primarily be required in vessel homeports located throughout the continental United States, Hawaii and Alaska.

b. Then contractor shall assign a representative to support the USCG Contracting Officer and/or the COR.

c. The contractor shall respond to a formal non-warranty technical assistance (TECH

Assist) request within a 24 hour period (during normal working hours).

d. Approval to perform repairs will be made by the Contracting Officer after evaluation from the COR.

e. The results of the Representative's findings shall be provided to the COR in writing within 24 hours of arrival of the TECH Assist.

4.0 QUALITY ASSURANCE

4.1 General

a. 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.f.

4.2 Records

a. 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

a. 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.e. 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

a. 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.

b. 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

a. 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

a. After operational testing and acceptance by the USCG, the gear shall be preserved in accordance with references 2.3a and 2.3b in conjunction with paragraph 5.2.

b. Preservation in accordance with O.E.M. Policy shall not be started until a successful dynamometer (spin test) has been completed and accepted by the COR.

c. The contractor shall take into account that preconditioned units may be stored in a controlled temperature warehouse for up to 24 months before installation.

5.2 External Preservation

a. After completion of the final test run and internal preservation the gear shall be prepared in accordance with Twin Disc 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 as follows depending on the model.

1. MG-507A1 Cummins White P/N 3885912

2. MG-5114SC Alpine Green Kimball # 80943

d. Coat all unpainted metal surfaces with an anticorrosive metal preservative; except for hot surfaces.

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

5.3 Packing

a. The contractor shall inspect each wooden crate to determine crates condition. This inspection shall be documented on the Reduction Gears Condition Found Report with the crates discrepancies, plan of repairs or replacement, and cost.

b. 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

Twin Disc Marine Gears Preservation Guidelines for corrosion proofing, types of packaging, storage conditions/storage periods.

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

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

Shipping Instructions (Appendix G).

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 (i.e. white paint) and at least 2” high.

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

NATIONAL STOCK NUMBER .......2010-01-450-5801

PART NUMBER ...............................MG-507A1

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

MODEL NUMBER ...........................MG-507A1

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,

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:

6.0 FINAL PICTURES

6.1 Picture Verification

a. Once sections of this document from 3.0 to 5.4e have been completed; pictures of the following shall be sent by the contractor, to the COR by email prior to shipping. This is to verify proper external preservation of the reduction gear has been completed and properly identified by serial number, and that the crate or shipping container, reduction gear, and shipping container information match correspondingly:

Reusable Container- Do Not Damage

Remove Fasteners Prior To Removing Cover

Use Forklift to Unload

Do Not Lift By Cover

1. Pictures of each reduction gear reconditioned / overhauled showing external preservation has been completed as per this specification.

2. Pictures clearly showing reduction gear with affixed data pate including serial number is in place and match labeled shipping crate.

3. Pictures showing final spin test report Appendix D is affixed to reduction gear.

4. Pictures showing attached warranty sheet Appendix F is affixed to reduction gear.

5. Picture showing unit shipping instruction Appendix G is affixed to reduction gear.

7.0 GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

7.1 Government Documents

USCG Surface Forces Logistics Center

2401 Hawkins Point Road

Baltimore, MD 21226

410-762-6112

7.2 Commercial Documents

International Organization for Standardization

American National Standards Institute (ANSI)

1430 Broadway

New York, NY 10018

212-642-4900

7.3 Enclosures

a. Appendix A Condition Found Report

b. Appendix B Mandatory Parts List

c. Appendix C Contingency Parts List

d. Appendix D Gear Spin Test Report

e. Appendix E Cumulative Tracking Report

f. Appendix F Warranty Information

g. Appendix G Unit Shipping Instructions

Appendix A

Condition Found Report

Date: __________________

Task Order #: __________________

Delivery Order #: __________________

Reduction Gear Model #: __________________

Reduction Gear Serial #: __________________

Condition Found

Repairs Required

Parts Required

Parts Expended

Recommendations

Appendix B

Mandatory Parts List

MG-507A1

No. Part No. Description QTYU /I

1 K964 BRG KIT 1 EA

2 K961 GASKET AND SEAL KIT 1 EA

3 M2280 BREATHER 1 EA

4 PX4917B OIL PUMP 1 EA

5 A2916DK O-RING 2 EA

6 B2130A STRAINER 1 EA

7 P5081 SHIM 3 EA

8 P5081A SHIM 3 EA

9 P5710 SHIM 2 EA

10 P5710A SHIM 2 EA

11 P5136 SHIM 2 EA

12 P5158 SHIM 2 EA

13 P5136A SHIM 2 EA

14 P5136B SHIM 2 EA

15 A2704BS SPRING 1 EA

16 A2703AP SPRING 1 EA

17 XB2134 DETENT PLATE 1 EA

18 B3357 SHIM 3 EA

19 B3357A SHIM 3 EA

20 A3905B RUBBER BLOCK 26 EA

21 P3924C CLUTCH PLATES SINTERED 14 EA

22 P5389 CLUTCH PLATE STEEL 12 EA

23 A2669K SNAP RING 2 EA

24 PM5108A SNAP RING 2 EA

25 P5146 CLUTCH SPRING 2 EA

26 PM5729A LOCK WASHER 1 EA

Appendix B

Mandatory Parts List (cont’)

MG-5114SC

No. Part No. Description QTY U /I

1 KS2227 Gasket & Seal Kit 1 EA

2 K1151 BEARING KIT 1 EA

3 P12122 FACED CLUTCH PLATES 22 EA

4 P12235 STEEL CLUTCH PLATES 20 EA

5 M1945AG PLUG 1 EA

6 M1945AM PLUG 1 EA

7 P-10532 COUPLING 1 EA

8 M1841P PLUG 1 EA

9 PM1677N SNAP RING 2 EA

10 1039030 SOLENOID 2 EA

11 1001425 SEAL 4 EA

12 PM4177 CONNECTOR 2 EA

13 PM10667B BREATHER 1 EA

14 PX9330 PUMP 1 EA

15 B2509 SHIM .005" 3 EA

16 B2509A SHIM .007" 2 EA

17 B2509B SHIM .010" 1 EA

18 B2509C SHIM .020" 1 EA

19 P11493 SHIM 2 EA

20 B2423 SHIM .005" 3 EA

21 B2423A SHIM .007" 2 EA

22 B2423B SHIM .020" 1 EA

23 M1841AL EXPANSION PLUG 1 EA

24 PM8455C SNAP RING 1 EA

25 B3637 SHIM .005" 2 EA

26 B3637A SHIM .007" 2 EA

27 B3637C SHIM .020" 1 EA

28 B3637D SHIM 1 EA

29 M1990H BALL 1 EA

30 M2067X CLOSURE PLASTIC 4 EA

31 P10228 GASKET 1 EA

32 P10479 PLATE 1 EA

33 A2916H O-RING 1 EA

34 1020005 SHIM 3 EA

35 PM2057AE SHIM 3 EA

36 B2334 SHIM 5 EA

37 XA2707AX SPRING 1 EA

38 PM1349M WASHER 1 EA

39 A2702T SPRING 1 EA

Appendix C

Contingency Parts List

MG-5114SC

No. Part No. Description QTY U /I

1 P9802 OUTPUT FLANGE 1 EA

2 PX9788A MANIFOLD 1 EA

3 P10115A OUTPUT GEAR 1 EA

4 PX10116A FORWARD PINION 1 EA

5 PX10118A REVERSE PINION 1 EA

6 PX9831 DRIVE COUPLING HUB 1 EA

7 B3477B BACK PLATE CLUTCH 1 EA

8 P10980 CLUTCH PISTON 1 EA

9 PX9791 INPUT SHAFTV 1 EA

10 PX9792 REVERSE SHAFT 1 EA

11 A2708AX CLUTCH SPRING 1 EA

12 PX9784A MAIN HOUSING 1 EA

13 P9803A OUTPUT SHAFT 1 EA

Appendix D

Spin Testing and Report

MG-507A1 General Test Requirements

The contractor shall create and submit a spin test report to the COR which will include, but not limited to, the following:

1. Facility’s Testing Representative name and signature.

2. Testing date and times

3. Gear model, serial number, and Job Order Number (as assigned by contractor)

4. Parameter readings as outlined below.

5. Pass or Fail

6. Details of Failure and recommendations to rectify any issues (if applicable).

All readings shall fall between the below outlined pressures and temperatures. Any deviation from these parameters constitutes a test “Failure”.

If the reduction gear shows any signs of leaking transmission oil, this constitutes a test “Failure”.

The oil used, and associated temperature and pressures during testing of the reduction gear shall be in accordance with references 2.2c and 2.3d or the manufacturer’s (Twin Disc) requirements.

Oil temperature shall be maintained between 85 and 100 degrees Fahrenheit at all times during the test.

Each marine gear provided under this contract shall be operationally tested to assure minimum performance prior to acceptance. Testing with the USCG representative shall be conducted as follows: (Pressure parameters will depend on the control valve installed. Defer to reference 2.3d)

1. Contractor shall have the reduction gear operating at the minimum operating temperature of 85-100°F (30-38°C) prior to starting test observation.

2. With clutch disengaged (neutral) and test motor at 735 RPM’s, the oil pressure should read between 1.7 and 2.8 BAR (25-40 PSI); temperature should be between 85-100°F

(30-38°C). Take record of the actual pressure, temperature and time.

3. With clutch engaged (ahead) and test motor at 735 RPM’s (idle), the oil pressure should read between 20.7 and 22.8 BAR (300-330 PSI); temperature should be between 85-

100°F (30-38°C). Take record of the actual pressure, temperature and time.

4. With clutch engaged (ahead) and test motor at 1470 RPM’s, the oil pressure should read between 22 and 24 BAR (325-350 PSI); temperature should be between 85-100°F (30-

38°C). Take record of the actual pressure, temperature and time after engaged for a minimum of 20 minutes.

5. After a minimum 20 minutes of ahead 1470 RPM, return to idle and disengage.

6. With clutch engaged (astern) and test motor at 735 RPM’s (idle), the oil pressure should read between 1.7 and 2.8 BAR (25-40 PSI); temperature should be between 85-100°F

(30-38°C). Take record of the actual pressure, temperature and time.

7. With clutch engaged (astern) and test motor at 1470 RPM’s, the oil pressure should read between 22 and 24 BAR (325-350 PSI); temperature should be between 85-100°F (30-

38°C). Take record of the actual pressure, temperature and time after engaged for a minimum of 20 minutes.

8. After a minimum 20 minutes of astern 1470 RPM, return to idle and disengage.

9. Secure from testing. Record any discrepancies and recommendations.

Appendix D

Spin Testing and Report (cont’)

MG-5114SC General Test Requirements

The contractor shall create and submit a spin test report to the COR which will include, but not limited to, the following:

1. Facility’s Testing Representative name and signature.

2. Testing date and times

3. Gear model, serial number, and Job Order Number (as assigned by contractor)

4. Parameter readings as outlined below.

5. Pass or Fail

6. Details of Failure and recommendations to rectify any issues (if applicable).

All readings shall fall between the below outlined pressures and temperatures. Any deviation from these parameters constitutes a test “Failure”.

If the reduction gear shows any signs of leaking transmission oil, this constitutes a test “Failure”.

The oil used during testing of the reduction gear shall be in accordance with references 2.2c and

2.3c and the manufacturer’s (Twin Disc) requirements.

Oil temperature shall be maintained between 85 and 100 degrees Fahrenheit at all times during the test.

Each marine gear provided under this contract shall be operationally tested to assure minimum performance prior to acceptance. Testing with the USCG representative shall be conducted as follows:

1. Contractor shall have the reduction gear operating at the minimum operating temperature of 85-100°F (30-38°C) prior to starting test observation.

2. With clutch disengaged (neutral) and test motor at 600 RPM’s, the oil pressure should read between 1.0 and 4.5 BAR (15-65 PSI); temperature should be between 85-100°F

(30-38°C). Take record of the actual pressure, temperature and time.

3. With clutch engaged (ahead) and test motor at 600 RPM’s (idle), the oil pressure should read between 14 and 18 BAR (205-265 PSI); temperature should be between 85-100°F

(30-38°C). Take record of the actual pressure, temperature and time.

4. With clutch engaged (ahead) and test motor at 1800 RPM’s, the oil pressure should read between 14 and 18 BAR (205-265 PSI); temperature should be between 85-100°F (30-

38°C). Take record of the actual pressure, temperature and time after engaged for a minimum of 5 minutes.

5. After a minimum 5 minutes of ahead 1800 RPM, return to idle and disengage.

6. With clutch engaged (astern) and test motor at 600 RPM’s (idle), the oil pressure should read between 14 and 18 BAR (205-265 PSI); temperature should be between 85-100°F

(30-38°C). Take record of the actual pressure, temperature and time.

7. With clutch engaged (astern) and test motor at 1800 RPM’s, the oil pressure should read between 14 and 18 BAR (205-265 PSI); temperature should be between 85-100°F (30-

38°C). Take record of the actual pressure, temperature and time after engaged for a minimum of 5 minutes.

8. After a minimum 5 minutes of astern 1800 RPM, return to idle and disengage.

9. Secure from testing. Record any discrepancies and recommendations.

Appendix E

Cumulative Tracking Report

REPORT DATE: ITEM #

GEAR

MODEL#

GEAR

SERIAL#

MOD

REQUIRED

ESTIMATED

DELIVERY DATE

CONTRACT NUMBER

CONTRACTOR NAME:

CONTRACTOR POC:

ORDER NUMBER:

ORDER DATE:

CURRENT MODIFICATION:

REQUIRED DELIVERY DATE

ADJUSTED DELIVERY DATE:

USCG POC's

CONTRACTING SPECIALIST:

COR:

APPENDIX A COMPLETE

COMMENTS

Appendix F

WARRANTY NOTICE

This item has a warranty for whichever comes first:

1 year of operation from installation

Or

1000 hours of operation

Or

Two years storage from date SFLC received machinery from contractor

If any discrepancies are noted upon receipt

1. DO NOT REPAIR OR REPLACE!

2. CALL: USCG SURFACE FORCES LOGISTICS CENTER

CENTRAL ENGINE OVERHAUL

SMALL BOAT PRODUCT LINE (SBPL-SES)

COMMERCIAL 410-762-6175 / 6237

Have the following information ready when calling the (SBPL)

________ Date Received ________ Date Installed

________ Serial Number ________ Vessel Home Port

________ Hours on Machinery ________ Vessel Hull No

NOTES:

(1) Preventative Maintenance (PMS) should still be performed as per applicable Maintenance

Procedure Cards (MPC’s). PMS does not void the warranty.

(2) If the above procedure is not followed, the warranty may be affected.

Appendix G

FOR COAST GUARD UNITS ONLY

SHIPPING REQUIREMENTS FOR "F" CONDITION RETURNS

(“F” Condition = Broken, Not ready for issue)

1. Login to SFLC Portal (ALD) to request a CBL using item document number.

2. Returned machinery shall be crated and secured properly in the same crate the new engine or gear came in.

3. Crate is to be securely fastened with crate seal intact before shipping.

4. Change Crate Marking from "A" Condition to "F" Condition (Stencil).

5. Change serial number marking on the crate / container from the new engine or gear to the old engine or gear being shipped back

6. Fuel and or oil filters are to be removed and discarded before crating engine or gear “if applicable”.

7. Ensure all fuel lines are to be drained before shipping “if applicable”.

8. Ensure oil and coolant is removed and properly disposed of before shipping “if applicable”.

9. Ensure any parts removed or swapped are reinstalled on the old machinery before shipping. (Make the

“F” Condition machinery complete as possible)