Attachment 2 - Hamilton Jet Overhaul Spec Rev. 12-07-2024.docx

REVISION No. N/A___

HAMILTON JET DRIVE OVERHAUL SPECIFICATION

FOR

HJ 292 & HJ213

ORIGINATED BY: Thomas Taylor DATE: December 11, 2024

ORIGINATOR’S COMMAND SURFACE FORCES LOGISTICS CENTER

DEPARTMENT / DIVISION SMALL BOAT PRODUCT LINE

INTERNAL REVIEWER_____________________________ DATE____________

SWORB APPROVAL____________________________ DATE____________

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 HJ 292

b. Hamilton Jet HJ 213 Upon receipt, the contractor shall inspect each wooden or metal crate to determine crates condition. This inspection shall be documented with the crate’s 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 remanufactured is to be used onboard various U.S. Coast Guard boats.

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 Specification 3101.

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 remanufacture/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 always stored inside. 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 remanufactured in accordance with OEM specifications and standards, restoring each unit to a like- new condition.

3.7. Technical Representative Services – After the contractor overhauls the Jet Drives, within the warranty time frame, any troubleshooting and repair of technical problems may require Contractor personnel to travel to Coast Guard units. In correcting technical problems, the Contractor shall abide by the following:

3.7.1. Technical Services Performed Onsite – The Contractor shall perform all services onboard the USCG vessel unless otherwise directed by the Contracting Officer.

Hours of Operation – The Contractor employees shall generally perform all work between the hours of 0800 and 1630 local time, Monday through Friday. However, Contractor employees shall be required to work other than normal business hours, including weekends and holidays.

Locations – The services will primarily be required in vessel homeports located throughout the continental United States, Hawaii and Alaska.

Contractor Response – The Contractor shall be required to supply a Technical Representative to the designated location within thirty-six (36) hours after notification by the Contracting Officer. The Contracting Officer shall establish the dates the Technical Representative is required.

Task Orders (T.O.) – Surface Forces Logistics Center (SFLC) will issue a T.O. stating where and when the services are required. SFLC will supply the Contractor with the nature of the problem (if known) along with a POC and phone number. The Contractor shall be responsible to contact the POC within twenty-four (24) hours after notification by the Contracting Officer.

The results of the Representative's findings shall be provided in writing within twenty-four (24) hours of arrival. Approval to perform repairs will be made by the Contracting Officer after evaluation from the USCG Contracting Officer’s Technical Representative.

3.8. Paint Requirement for Metal Shipping Containers- All internal & external surfaces shall have all scale and loose paint removed. The containers will then be primed as per The Society for Protective Coatings (SSCP) Paint 25 and painted with two coats of the corresponding colors mentioned below and sited in [FED STD 595 C with CHANGE NOTICE 1] using paint in accordance with Commercial Item Description (CID) A-A-2962A.

a. Shipping container for Hamilton Jet, HJ 213 & HJ 292 – Use color number.

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

3.10. 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 overhaul within ten (10) calendar days after the receipt of the jet drive units.

3.11. 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. Contingency Replacement Parts List in accordance with Appendix D

f. Warranty Notice in accordance with Appendix E

3.12. 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.

3.13. 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 contractor’s 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.

3.0 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.

4.7.1 Each jet drive provided under this contract shall be tested/ inspected on an approved bench test under load to ensure the jet drive unit performance is in accordance with the manufacturer’s requirements. The contractor shall complete and submit the report required as per the Hamilton Jet Manual.

4.8 Bench Test Reports – The contractor shall submit a bench test report, per the manufacture manual, within seven (7) calendar days after completion of the bench test. The report shall consist of the data obtained during the prime unit test. One copy of the report shall be packed and delivered with each jet drive unit under this contract.

4.9 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 in accordance with O.E.M. Policy shall not be started until a successful dynamometer test has been completed and accepted by the Contracting Officer’s Representative (COR).

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 mil’s); total thickness (3-5 mil’s) 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.

l. The Humidity Indicator (if applicable) shall have the inner retaining nut permanently attached to the inside of the container to allow for the removal and replacement of the indicator.

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.

(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. DOD & Navy Publications and Forms (Other Than DODSSP) Naval Publication and Forms Center 5801 Tabor Ave.

Philadelphia, PA 19120 215-697-2000

c. 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: Contingency Replacement Parts List Appendix E: 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.

USCG-SFLC

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;

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

METAL SHIPPING CONTAINER:

REMARKS:

Disassembly Report B

Task Order Number: ___________________

Date: ___________________________________

Jet Drive Model Number: ____________________

Jet Drive Serial Number: ____________________

Total

APPENDIX C

MANDATORY REPLACEMENT PARTS LIST

MACHINERY DESCRIPTION

Item Serial Number

MANDATORY REPLACEMENT PARTS FOR EACH REMANUFACRURE

Item Serial Number

MANDATORY REPLACEMENT PARTS FOR EACH REMANUFACTURE

MACHINERY DESCRIPTION

Item Serial Number

MANDATORY REPLACEMENT PARTS FOR EACH REMANUFACTURE

Item Serial Number

MANDATORY REPLACEMENT PARTS FOR EACH REMANUFACTURE

APPENDIX D

Item Serial Number

MANDATORY REPLACEMENT PARTS FOR EACH REMANUFACTURE

Item Serial Number

MANDATORY REPLACEMENT PARTS FOR EACH REMANUFACTURE

Item Serial Number

MANDATORY REPLACEMENT PARTS FOR EACH REMANUFACTURE

APPENDIX E

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 REMANUFACTURE

SMALL BOAT PRODUCT LINE (SBPL)

COMMERCIAL (410) 762-6237/6159

Have the following information ready when calling the (SBPL)

NOTES: