HJ_Overhaul_Specification_HJ_213_HJ_292_-_Final_Attachment_2.pdf

REVISION No. N/A___

HAMILTON JET DRIVE OVERHAUL SPECIFICATION

FOR

HJ 292 & HJ213

ORGINATED BY: MKC Nolet Antoine DATE: March 03, 2017

ORIGINATOR’S COMMAND_SURFACE FORCES LOGISTICES CENTER

DEPARTMENT / DIVISION SMALL BOAT PRODUCT LINE

INTERNAL REVIEWER_ Michael McHale _______ DATE__ July 25 2019 _

SWORB APPROVAL____________________________ DATE____________

ATTACHMENT 2

USCG-SFLC

HAMILTON JET DRIVES OVERHAUL SPECIFICATION

1.0 SCOPE

1.1 General -This document sets forth the requirements for the overhaul of the following assets to Original Equipment Material (OEM) specifications, parts, and standards:

a. Hamilton Jet HJ292

b. Hamilton Jet HJ213

Upon receipt, the contractor shall inspect each wooden or metal crate to determine crates condition.

This inspection shall be documented with the crates discrepancies, plan of repairs or replacement and cost associated with it.

These Hamilton Jet Drives, with attached hang-ons, shall be bench and/or load tested, preserved, painted, packaged, and shipped back to the Coast Guard Yard, Baltimore, MD. All of the machinery being overhauled is to be used onboard various U.S. Coast Guard boats.

1.2 Government Furnished Property (GFP) – The below listed items are property of, and managed by the USCG Surface Forces Logistic Center (SFLC) Baltimore, MD.

a. Hamilton Jet HJ 213 (NSN: 2010-98-206-2591).

b. Hamilton Jet HJ 292 (NSN: 4320-01-624-5473).

c. Shipping container for HJ 213 (NSN: N/A).

d. Shipping container for HJ 292 (NSN: N/A).

2.0 APPLICABLE DOCUMENTS

2.1. Document Availability – To obtain the referenced documents see section 6.1.

2.2. Government Documents – The following specifications and standards form a part of this specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the current Department of Defense Single Stock Point (DODSSP) for military specifications, standards, and related publications.

a. USCG Surfaces Forces Logistics Center- D-000-0100 REV G, Dated 2/06, Bar Coding for

USCG SFLC Material.

b. USCG SFLC Standard SpecificationD-084-0481 Engineering Change Equipment Unit, Preservation, Packaging and Marking, Standard Requirements for USCG SFLC-ESD- NAME (dated 20 April 2012).

c. USCG Technical Publication 4584B, Dated 25 Oct 2012. HJ 213 Installation and Service Manual R2A36.

d. USCG Technical Publication 6636, Dated 10 July 2015. HJ 213 Installation and Service Manual R1A12.

2.2.1. Military Specifications

a. MIL-L-2104F, Dated 28 Sep 1992, Lubricating Oil.

b. MIL-D-3464E, Dated 21 Apr 1987, Desiccant, Activated Bag.

c. MIL-PRF-32295A, Dated 19 APR 2010, Cleaner, Non-Aqueous, Low-VOC, HAP-Free.

d. MIL-I-24092D, Dated 21 Sep 1993, Insulating Varnishes and Solvent less Resins for

Application by the Dip Process.

e. MIL-STD-2073-1E, Dated May 2008, Standard for Military Packaging.

2.3. Commercial Documents – The Following documents form a part of this specification to the extent specified here. The documents shall be the version listed by number and date from the referenced industry organization. Commercial documents may be listed in the Department of Defense Single Stock Point (DODSSP).

2.3.1. American National Standards Institute (ANSI)/ National Conference of Standards Laboratories (NCSL).

a. ANSI/NCSL Z540, Dated 2006, Requirements for the Calibration of Measuring and Test Equipment.

b. ANSI/ASQC Q9003, Dated 1994, Quality Systems – Model for Quality Assurance in Final Inspection and Test.

2.3.2. American Society for Testing and Materials (ASTM).

2.3.3. Hamilton Jet Corporation.

a. HJ 213 Shop Manual No. HJ-213/HSRX.

b. HJ 213 Parts Manual No. HJ-213/HSRX.

c. HJ 292 Shop Manual No. HJ-292.

d. HJ 292 Parts Manual No. HJ-292.

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.

2.4.1. Departure from Specification - Departure from this specification shall not be allowed unless approved by the Coast Guard Contracting Officer.

a. If the contractor finds it necessary to implement changes or depart from applicable specifications, they shall be requested.

b. Request for changes by contractors shall clearly describe the changes proposed, the reasons for and advantages of the changes proposed, and the contract’s price increase or decrease (if any) that would result.

3.0 REQUIREMENTS

3.1. General - The contractor shall overhaul/recondition the jet drive units within sixty (60) calendar days after approval of the Core Condition report (Appendix A). The contractor shall provide all labor, equipment, special tools, parts and materials required to accomplish the following:

a. Submit a Core Condition Report (Appendix A).

b. Submit a Disassembly Report (Appendix B).

f. Perform Bench Testing.

g. Perform Internal Preservation.

j. Preserve and Properly Label Shipping Container.

3.2. Government Furnished Property – 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.

3.2.1.The storage area shall at a minimum be closed on all sides, dry, and locked when unattended.

Uncrated jet drives shall be stored inside at all times. Empty containers may be stored outside in a covered area.

3.3. Internal Inspection – For any part included on the Disassembly Report (Appendix B) the Contractor shall supply the Contracting Officer’s Representative (COR) with pictures of the faulty part, clearly displaying the part failure.

3.4. Overhaul Parts – The contractor shall use only OEM parts for the overhaul of the Hamilton Jet Drives.

3.5. All gaskets, seals, o- rings, copper seals, hoses, belts, and sensors shall be replaced with new regardless of condition. At a minimum, all parts listed in Appendix F shall be replaced during the remanufacturing. All other parts not listed shall be inspected for critical dimensions and wear limits and replaced as authorized by the KO. The Government reserves the right to supply parts as Government Furnished Property at any time during this contact.

3.6. Propulsion Unit – The Hamilton Jet HJ 213 & HJ 292 units shall be overhauled in accordance with OEM specifications and standards, restoring each unit to a like- new condition.

3.7. Labor – Contractor shall perform all labor, and authorized machinists, mechanics and technicians.

3.8. Core Acceptance Criteria – The contractor shall accept the core based on a complete internal inspection and submit written notification and reasoning of non-acceptance for jet drive units not acceptable for reconditioning/overhaul within ten (10) calendar days after the receipt of the jet drive units.

3.9. Documentation – This specification sets forth the requirements for the following documentation.

a. Core Condition Report, in accordance with Appendix A

b. Disassembly Report, in accordance with Appendix B

c. Bench Test Report, in accordance with Hamilton Jet

d. Mandatory Replacement Parts List in accordance with Appendix C

e. Warranty Notice in accordance with Appendix D

3.10. Core Condition and Disassembly Reports – The contractor shall submit a completed Appendix A to the contracting officer within ten (10) calendar days after receipt of a jet drive unit. Appendix B will be sent to the contracting officer (15) fifteen calendar days after Appendix A.

3.11. Warranty - A warranty of one year from installation or 1000 operating hours, whichever occurs first and 24 months of storage is required covering the entire jet drive unit. Storage commences upon receipt of engine at the designated Coast Guard facility. The contractor shall contact the field unit to arrange a resolution of a claim within 24 (twenty-four) hours after receiving notification by the Coast Guard of a warranty claim. The contractor shall contact SFLC’s Contracting Officers Representative (COR) to evaluate the contractors proposed duration of warranty repair time.

In the event the Coast Guard decides the proposed warranty repair time compromises the Coast Guards mission and decides on removal/replacement, the contractor shall coordinate and fund all necessary shipping arrangements for the failed jet drive to be returned to the origin of exchanged/overhaul facility for repairs and returned to a designated Coast Guard facility after repairs have been completed.

The contractor shall repair/rebuild the failed jet drive to the condition level necessary for the contractor to honor a new full warranty (to be funded by the Coast Guard.) In the event that the work is found not to be warranted, the contractor shall stop work immediately and contact the Contracting Officer.

The contractor shall submit to the Contracting Officer an inspection report for approval containing any parts and pricing for any work/repairs that are required that were not a result of the specific casualty.

3.14. Notifications & Inspections – The contractor shall be responsible for notifying the Contracting Officer’s Contracting Officer Representative (COR) at least seven (7) calendar days prior to inspections or monitored testing required herein.

3.15. Failure Analysis - In the event of a failure, the Technical Representative shall determine the cause of casualty, systems, root cause, and corrective action. And a report of the findings shall be submitted to the Contracting Officer.

4.0 QUALITY ASSURANCE

4.1. General – The contractor shall maintain an inspection system, which shall insure that each item offered to the Coast Guard for acceptance, or approval conforms to the contract requirements. The inspection system shall be documented, meet the requirements of ASQC-Q9003-1994 and be available for review by the Coast Guard.

4.2. Records – The contractor shall maintain records of all inspections and tests. The records at a minimum shall indicate the nature and number of observations made, the number and type of deficiencies found, and the corrective action taken.

4.3. Calibration System – The contractor, as well as any subcontractors, shall be required to maintain a test equipment calibration program in compliance with ANSI/NCSL Z540, Dated 2006. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.4 Responsibility for Inspection – The contractor shall be responsible for the performance of all inspection requirements specified herein. The contractor shall provide space, personnel, and test equipment for conducting all inspection requirements. All inspection and testing shall be performed at the contractor’s plant or at other facilities acceptable to the Coast Guard. The Coast Guard reserves the right to verify or have performed any of the inspections that are deemed necessary to assure that supplies and services conform to the prescribed requirements. The contractor shall notify the KO seven (7) working days prior to all inspections and tests.

4.5 Responsibility for Compliance – All items shall meet the provisions of sections 3 & 5. The inspections set forth in this specification shall become part of the contractor’s overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the contractor of the responsibility of assuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

4.6 Inspection System – The contractor shall maintain an inspection system, which shall insure that each item offered to the Coast Guard for acceptance, or approval conforms to the contract requirements. The inspection system shall be documented and available for review by the Coast Guard.

4.7 Tests & Inspections – The inspections/tests required here is the minimum required and are not intended to replace any controls, examination, inspections or tests normally employed by the contractor to assure the quality of the jet drive unit.

4.8 Failure Responsibility – If the jet drive unit fails to pass any inspection/test the contractor shall report the failure and the recommended solution to the Contracting Officer. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

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

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

c. 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.

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

5.0 PRESERVATION, PACKAGING, PACKING, & MARKING

5.1. Internal Preservation – Preservation (Pre-Installation) in accordance with 2.2.c and 2.2.d

5.2. External Preservation – After completion of the internal preservation, the jet drive unit shall be prepared in accordance with the following procedure.

a. All surfaces shall be cleaned of grease and oil.

b. All loose scale and paint shall be removed; areas feathered and brought to a smooth surface.

c. The following items shall be masked and not painted.

1. Rubber hoses and wires

2. All identification plates

3. The jet drive shaft output flange

4. The front and rear seals

d. All exposed metal surfaces shall be primed with one coat (2-3 mils) of primer in accordance with Hamilton Jet. Allow a minimum of seven (7) hours to dry.

e. Two color coats approximately (2 mils); total thickness (3-5 mils) shall be sprayed on all surfaces. Allow seven (7) hours drying time between coats. The color shall be Hamilton Marine Grey.

f. When all paint is dry, the masking shall be removed.

g. Coat all unpainted metal surfaces with a light amount of grease, except for hot surfaces.

h. Plug any fittings/flanges or openings that will allow foreign material to enter the engine during storage.

i. A completed Appendix D and Appendix E shall be attached to the top of the jet drive unit in a plastic bag.

j. The contractor shall place a total of 80 units of desiccant conforming to MIL-D-3464E

(activated bag: 1 ounce equals 1 unit), in the interior of the shipping container in the receptacle provided.

k. The contractor shall install the jet drive unit into the metal or wooden shipping container.

The contractor shall ensure that all of the container accessories (if applicable), such as rubber mounts, desiccant, humidity indicator, pressure valve, and sealing gasket are in place and in good working order. The container shall be sealed such that the cover makes 100% contact with the sealing gasket.

5.3. Marking – Each preserved and packaged item shall be marked in the upper left-hand side and end of each box. The lettering shall be stenciled and at least 1” high, in black print lettering on a highly contrasting background.

5.3.1. This marking shall consist of the STOCK NUMBER, MODEL NUMBER, ITEM NAME, SERIAL NUMBER, CONTRACT NUMBER, TASK ORDER NUMBER, GROSS

WEIGHT (in lbs), CONDITION CODE, QUANTITY AND UNIT OF ISSUE, AND

LABELED; COAST GUARD SFLC MATERIAL.

Stock Number 2010-98-206-2591 for HJ 213 & 2010-01-624-5473 for HJ 292 Model Number HJ 213 or HJ 292 Item Name Jet Drive Assembly Serial Number Jet Drive S/N: ___________ Contract Number See Contract Task Order Number See Task Order Shipping Weight As Determined By Contractor Condition Code Condition “A” Quantity & Unit of Issue 1 – Each

(And the Following):

Reusable Shipping Container – Do Not Damage. Do Not Stack More Than Two High.

Remove Bolts Prior To Removing Cover. Use Forklift To Unload – Do Not Lift By Cover.

Preserved For Long Term Storage.

5.3.2. Special Markings – (IF APPLICABLE) The container shall be marked with the following special markings:

a. LOCATING DOWEL (place above locating dowel, if applicable)

b. VENT: DO NOT BLOCK (place next to vent, if applicable)

c. HUMIDITY INDICATOR (place next to indicator, if applicable)

5.3.3. The contractor shall paint over all other marking not required by paragraph 5.3.

5.4. Bar Coding – The contractor shall supply bar code labels on all Contract Line Item Number’s (CLIN) except for those that require data submissions only.

5.4.1. All bar-coded labels shall be in accordance with SFLC specification D-000-0100 Rev G, FEB/06.

a. The actual labels shall be Type “V“. Grade “A“, Style “2“, Composition “B” with plastic laminate.

b. Each label shall contain encoded data for the Stock Number, Contract Number, and the Task Order Number as applicable.

c. The marking required in 5.3 can be applied separately or as part of the Bar Code Label.

6.0 NOTES

6.1. Government & Commercial Document Sources

6.1.1. Government Documents

a. Department of Defense Single Stock Point for Military Specifications, Standards, and Related Publications (DODSSP Documents) Http://dodssp.daps.dla.mil/

b. USCG Surface Forces Logistics Center 2401 Hawkins Point Road Baltimore, MD 21226-5000 410-762-6229 ATTN: Contracting Officer SBPL

6.1.2. Commercial Documents

a. Society of Automotive Engineers INC. (SAE) 400 Commonwealth Drive Warrendale, PA 15096 412-776-4841

FAX 412-776-5760

b. American Society for Testing & Materials (ASTM) 1916 Race Street Philadelphia, PA 19103-1187 215-299-5585

FAX 215-977-9679

c. American National Standards Institute (ANSI) 1430 Broadway New York, NY 10018 212-642-4900

d. American Society for Quality Control (ASQC)

611 East Wisconsin Avenue Milwaukee, Wisconsin 53202

6.2. Appendices – The following Appendices form a part of this specification.

Appendix A: Core Condition Appendix B: Disassembly Report Appendix C: Mandatory Replacement Parts List Appendix D: Warranty Notice

6.3. Glossary

a. C.P.L. – Control Parts List

b. Core – Either the engine block or the generator housing including the attachments mentioned in

Appendix A.

c. Field Unit – United States Coast Guard units located throughout the fifty (50) United States and it territories.

d. O.E.M. – Original Equipment Manufacturer

e. O.E.P.L. – Original Equipment Parts List

f. Prime Mover – An engine used to transfer power, in the form of a turning motion, to the generator or reduction gear.

g. Jet Drive Unit – Jet Drive Units listed in section 1.2, B through E.

h. Exchange – Exchange of used parts for original equipment manufacturer (OEM) parts.

i. Recondition – To recondition parts with O.E.M. parts to O.E.M. new specifications.

APPENDIX A

Core Condition Report (For HJ 213 & HJ 292)

Work Order #____________

Task Order #__________

Jet Drive Serial # _______________

Jet Drive Model # ___________________

Core Acceptance is based on the following:

a. Core must be in the configuration of Master Serial Numbers listed above (Section 1.2).

b. Core must have no non-operational damage.

c. Core must be a complete unit and not disassembled.

NOTE: Missing parts from Appendix A are to be replaced and priced as per Appendix B of this contract.

1. Core Acceptable__________, Non Acceptable___________

Remarks _______________________________________________________________________________

2. Condition of shipping container;

Serviceable_______________________

Needs Repair_____________________

3. Photograph of prime mover; front, right side, left side, and rear views to include serial number in picture frame.

APPENDIX A

(CONTINUED)

Jet Drive Model (Circle one): HJ 213 & HJ 292

ITEM NAME P/N MISSING

1. SAGINAW PUMP

2. REVERSE DUCK

3. STEERING NOZZLE

4. STEERING SHAFT

5. TAILPIPE

6. HSRX CYLINDER

7. IMPELLER

8. INTAKE GRATE

9. WEAR RING

10. DRIVE COUPLING

11. THRUST BEARING ASSY.

12. WATER BEARING

SLEEVE

13. DRIVE BELT

14. PIVOT PIN

15. PIVOT BUSHINGS

16. ROTARY SEAL

REMARKS:

Disassembly Report B

Task Order Number: ___________________

Date: ___________________________________

Jet Drive Model Number: ____________________

Jet Drive Serial Number: ____________________

Reason for Replacement

Qty Part No. Part Description Unit Price Amount

Total

APPENDIX C

MANDATORY REPLACEMENT PARTS LIST

MACHINERY DESCRIPTION

Manufacturer Hamilton Jet Jet Drive Model # HJ 213 Description Reverse and Forward Propulsion Repair Item Serial Number

MANDATORY REPLACEMENT PARTS FOR EACH REMANUFACRURE

No. Description Part No. Qty. Unit Price Total Price 1 Water Seal 213-241 HJ061483 1 2 O-ring 5.34x85.1x9508 340n70 HJ061488 1 3 Rotary Seal HJ061458 2 4 Seal Sleeve 211-241 HJ106004 2 5 Bearing (Thrust) HJ201439 1 6 Carrier Bearing HJ106005 1 7 Holder Seal Face MK2 213 241 HJ111717 1 8 Split Pin HJ201074 1 9 Bearing Marine HJ106011 1 10 Anode Aluminum 203123 1 11 Bearing Sleeve HJ110379 1 12 O-ring HJ200985 1 13 Wear Ring HJ107537 1 14 Insulator Wear Ring HJ107538 1 15 O-ring HJ200999 1 16 Anode Aluminum 212094 4 17 O-Ring 25.07 x 2.62 064726 3 18 V-Belt PJ559 10 HJ064430 2 19 O-Ring HJ200964 1 20 Bushing Steering HJ105998 2 21 Bearing 201466 1 22 Ball Joint Morse S.S. 201553 1 23 O-ring HJ200962 1 24 Clamp & Shim Assembly Morse 080934 1 25 Bush Flange Pivot Steering HJ111387 2 26 Seal, Bonded 064996 1 27 Seal, Bonded 201767 4 28 HSRX Kit HJ213 CTHSE12002 1 29 Nut Nyloc HJ201330 14 30 Washer Flat HJ201383 6 31 Bush Rod Cylinder Rev HJ111808 1 32 Anode mk3 203124 5 33 O-Ring 314 X 9.5 107618 1 34 Nut Nyloc 201331 4 35 Mobilux EP #2 Grease HJGREASE 2 36 Mobil ATF D/M sold in gallon HAM ATF 1 37 Relief Valve HJ202986 1 38 Kit Seal HSRX mk2 HJ112078 1 39 Hydraulic Pump Painted HJ206264 1

APPENDIX C

MANDATORY REPLACEMENT PARTS LIST

MACHINERY DESCRIPTION

Manufacturer Hamilton Jet Jet Drive Model # HJ 292 Description Reverse and Forward Propulsion Repair Item Serial Number

MANDATORY REPLACEMENT PARTS FOR EACH OVERHAUL

No. Description Part No. Qty. Unit Price Total Price 1 Anode Aluminum 203133 8 2 Anode Aluminum 203130 1 3 Anode Aluminum 203123 2 4 Anode Aluminum 203124 4 5 Anode Aluminum 203131 4 6 Belt HJ203969 2 7 Hydraulic Pump Assembly Painted HJ206264 2 8 Switch Pressure Assy HJ202993 2 9 Valve Assembly HJ111554 1 10 Parker Valve Spool Cover MK2 HJ209327 1 11 Parker Valve Spool Cover MK2 HJ209327-1 1 12 Insert Tube Plastic HJ208151 4 13 Nut Nyloc M8 SS316 201330 14 14 O-Ring 304x 1.78 104916 1 15 Bearing Marine 106265 1 16 Sleeve Bearing Marine 111202 1 17 O-Ring 132.72x 6.99 200991 1 18 Wear Ring 292 104211 1 19 Insulator Wear Ring 104674 1 20 Seal Impeller 104190 1 21 Bushing Shaft Steering 111124 2 22 Seal Oil 061362 1 23 Seal Scraper Wyclip 061353 1 24 Bush Pivot Steering 111480 2 25 Washer 105139 2 26 Lip Seal 111332 2 27 Kit, Seal Rev Cyl MK2 HJ292 112516 1 28 Bush Pivot 104610 2 29 Washer Poly 063955 2 30 Bearing 201447 1 31 Seal, Oil 201449 2 32 Sleeve Seal 104617 2 33 Seal Rotary 061528 1 34 O-Ring 113.89x 3.53 200978 1 35 Bearing Carrier 104621 1 36 O-Ring 66.27x 3.53 206347 1 37 Element Filter 063699 1 38 O-Ring 228.19x 3.53 200998 1 39 O-Ring 36.09x 3.53 200967 2 40 O-Ring 418x 9.5 111183 1 41 Seal Bonded 064996 2 42 Hose Kit CTHSE12019 1 43 Bearing 201457 1 44 End Rod 065072 1 45 Washer Lock Internal 065073 1

46 Clevis & Pin Kit SS316 106261 1 47 Pin Split 201077 2 48 Seal Bonded 201768 3 49 Seal Bonded 201767 1 50 Seal Bonded 201766 2 51 Rod End 201475 2 52 Clamp & Shim Assy Morse 080934 1

APPENDIX D

HAMILTON JET 213 & 292

WARRANTY NOTICE

This item has a warranty for whichever comes first:

1 year of operation from installation

Or

1000 hours of operation

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)

COMMERCIAL (410) 762-6237/6159

Have the following information ready when calling the (SBPL)

________ Date Received ________ Date Installed

________ Serial No. ________ Vessel Home Port

________ Engine Hours ________ Vessel Hull No

3. A Report of Discrepancy (ROD) Form 364 must also be submitted to Surface Forces Logistics Center.

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.