ATTACHMENT 2 Specification.docx

Appendix F Warranty Information

REVISION No. CHANGE No.

TITLE

OVERHAUL SPECIFICATION

ZF REDUCTION GEARS

TECHNICAL REPRESENTITIVE SUPPORT

PURCHASE NEW GEARS

SPECIFICATION NUMBER

D-233-0421

ORGINATED BY Mark Lacey DATE 11/09/12_________

ORIGINATOR’S COMMAND Surface Forces Logistics Center (SFLC) _____________

DEPARTMENT / DIVISION Patrol Boat Product Line (PBPL) ___________________

INTERNAL REVIEWER____________________________DATE___________________

SWORB APPROVAL__________________________DATE_________________

1.0 SCOPE

1.1.

a. This specification sets forth the requirements for receiving, disassembly, overhaul reassembly, testing, painting, and preservation and packaging of ZF Marine Reduction Gears. These gears are attached to the main propulsion units installed on the U.S. Coast Guard’s 110’ WPCs, 87’ WPBs and 154’ FRCs. The Original Equipment Manufacturer (OEM) is Zahnradfabrik Friedrichshafen AG (ZF) Germany.

b. This specification sets forth the requirements for Technical Representative to support casualties and maintenance repairs.

c. This specification sets forth the requirements for purchasing new gears.

1.2. CLASSIFICATION: This sets forth the requirements for the following equipment:

a. ZF BW1500 Reduction Gear (NSN 3010-99-741-9566)

b. ZF ZF23560C Reduction Gear (NSN 3010-12-389-2758)

c. ZF BW255 Reduction Gear (NSN 2010-12-347-4887)

1.3. GOVERNMENT FURNISHED MATERIAL:

a. ZF BW1500 Reduction Gear (NSN 3010-99-741-9566)

b. ZF ZF23560C Reduction Gear (NSN 3010-12-389-2758)

c. ZF BW255 Reduction Gear (NSN 2010-12-347-4887)

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 - The following specifications and standards form a part of this specification to the extent specified herein.

a. MIL-C-104-C Dated 24 June 93, Crates Type II, Class II, Style A.

b. MIL-DTL-C Dated 19 May 99, Coating, Primer Alkyd.

c. MIL-PRF-2104-G Dated 10 February 97, Lubricating Oil.

d. MIL-D-3464-E Dated 21 April 87, Desiccant, Activated Bag.

e. D-000-0100-G Dated February 06, Bar Coding

2.3. COMMERCIAL DOCUMENTS - The following documents form a part of this specification to the extent specified herein. The documents shall be the version listed by number and date from the referenced industry organization. Commercial documents may also be listed in the Department of Defense Index of Specifications and Standards (DODISS).

a. ZF Work Shop Manual 3052 751 110b Dated 1990, 1500 Marine Reduction Gears.

b. ZF Work Shop Manual 3082 751 105b Dated 1997, 255 Marine Reduction Gears.

c. ZF Marine Transmissions BW 250 Series Operating Instructions 3082 758 103b.

d. ZF Work Shop Manual 3090 751 101b Dated 1999, 23560C Marine Reduction Gears.

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

f. ANSI/ASQC Q90003-1994 Dated July 94, Inspection System.

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 – Departure from this specification shall not be allowed unless approved by the USCG Contracting Officer.

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

b. 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 be required to complete the following requirements in accordance with the attached Delivery Schedule.

a. Receive Gear

b. Disassemble Gear

c. Submit Appendix A (Condition Found Report)

d. Overhaul Gear

e. Submit Appendix C (Spin-Test Report)

f. Preserve

g. Paint Packaging and Marking

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

a. The gear overhaul shall be performed by a ZF Certified Facility. The definition of “Certified Facility” is the Contractor has provided legible documentation from ZF Zahnradfabrik Friedrichshafen AG (OEM) acknowledging the Contractor is authorized to meet the requirements of this specification.

b. The Contractor’s Technician for all requirements of this specification shall be certified and trained with a Friedrichshafen certification for ZF BW1500, ZF23560C and BW255 model gears. Copies shall be provided to the Contracting Officer.

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

d. All tools and test equipment shall be calibrated in accordance with Section 4.3.

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

f. The overhauls and all component inspections shall be completed using only genuine OEM parts, OEM components, processes, and practices.

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

h. The Contractor shall have the capabilities to conduct all testing on-site at the Contractor’s facility in accordance with ZF procedures. The USCG reserves the right to witness all testing.

i. 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.

j. Upon receipt of any gear, regardless of condition, the Contractor shall store the gear inside.

k. In the event, contingency parts & labor are required in order to accomplish the overhaul, the contingency parts & labor shall be priced separately and shall be negotiated under each delivery order as required.

3.3. TECHNICAL SUPPORT - The Contractor shall provide technical support. These services shall include, but are not limited to the following:

a. Validate the gear(s) is operating within the manufacturer’s specifications.

b. Ensure the proper communication and interoperability of the system components.

c. Participate in dockside performance test, evaluation, and validation.

d. Participate in underway performance test, evaluation, and validation.

e. Provide lube oil analysis recommendations and represervation inspections.

f. Repair, renew, adjust, calibrate, and test improperly functioning system components as required.

g. Provide maintenance recommendations based on data analysis and inspections.

3.4. FAILURE ANALYSIS - In the event of a catastrophic failure and at the discretion of the Government; on a separate delivery 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 delivery order. A report of the findings shall be submitted to the Contracting Officer within thirty (30) days of receipt of the gear.

3.5. The Contractor shall request in writing when submitting the Condition Found Report to the Contracting Officer for the disposition of used parts.

3.6. For those casualty repairs that cannot be accomplished on board, the Contractor shall provide a detailed recommendation in writing to the Contracting Officer.

3.7. CONTRACTOR PERSONNEL – The Contractor shall provide a Point of Contact (POC) who shall be responsible for all contractor work performed under this specification.

a. The name of the POC, and the name of any alternate who shall act for the Contractor in the absence of the POC, shall be provided to the Contracting Officer. The POC or alternate shall have full authority on all matters relating to the requirements of this specification.

b. The POC shall be available via telephone between the hours of 0800 and 1630 EST, Monday through Friday, and shall respond to a request for discussion or resolution of technical problems, refer to section 3.11.

c. The Contractor employees visiting Government facilities shall wear an identification badge that, at minimum, displays the Contractor’s name, the employee’s photo, name, and badge expiration date.

d. The Contractor employees shall comply with all applicable Government regulations, policies, and procedures (e.g. fire, safety, sanitation, environmental protection, security, “off limits” areas, the wearing of parts of military uniforms, and possession of weapons) while on Government property. The Contractor shall ensure contractor employees present a professional appearance at all times. Contractor employee’s conduct shall not reflect discredit on the United States, the Department of Homeland Security or the USCG.

e. The USCG reserves the right to direct the Contractor to remove any Contractor employee from USCG property for any reason deemed necessary. Removal does not relieve the Contractor of the responsibility to continue providing service required. The Contracting Officer will provide written explanation to support any request to remove an employee.

3.8. 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 as deemed necessary by the USCG.

3.9. COST FOR TECHNICAL REPRESENTATIVE – The services of the Technical Representative shall be based on the contractor’s flat hourly rate plus expenses.

a. The costs for transportation, lodging, meals, and incidental expenses incurred by the contractor’s personnel while performing under any contract referencing this specification shall be reimbursed in accordance with the Federal Acquisition Regulation (FAR) Part 31.205-46.

b. The costs incurred for lodging, meals, and incidental expenses shall be considered to be reasonable and allowable only to the extent they do not exceed on a daily basis the maximum per diem rates in effect at the time of travel IAW Joint Travel Regulation.

c. In the event of problems arising in the availability of parts or logistical problems (such as shipyard availability, sub-contractor problems, crane service problems), the Technical Representative may be required to provide the services in stages requiring additional travel, lodging, etc.

3.10. CONTRACTOR RESPONSE – The Contractor shall be required to supply the Technical Representative to the designated location within Thirty-Six (36) hours after receipt of the delivery order. The Contractor shall submit to the Contracting Officer a detailed report of the Technicians finding within Thirty-Six (36) hours of arrival (Appendix E).

3.11. DELIVERY ORDERS – Surface Forces Logistics Center (SFLC) will issue a Delivery Order for technical representative services 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 from the USCG Unit. The Contractor shall be responsible to contact the POC within twelve (12) hours after receipt of delivery order. In addition, delivery orders will be issued for the overhaul of reduction gears. Delivery orders will be issued for the purchase of new reduction gears.

3.12. REQUIRED REPORTS – The Contractor shall submit the following reports within the time lines set herein:

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. Cumulative Tracking Report (Appendix D). The Contractor shall submit Appendix E to the Contracting Officer quarterly no later than the 15th calendar day of the month. The report shall capture the progress of each delivery order, and or delivery orders annotated in the previous months report.

d. Failure Analysis Report.

e. Technical Representative’s Report (Appendix E). The report shall be submitted within thirty-six (36) hours upon arrival to the cutter.

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

ZF Marine Reduction Gear Overhaul Specification

3.13. GENERAL TEST REQUIREMENTS:

a. The Reduction Gear spin test shall be completed and the pass/fail criteria detailed in Appendix C shall be recorded and submitted to the Contracting Officer.

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

c. All gear testing shall be verified and accepted by a USCG Representative.

d. 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.

3.14. NOTIFICATIONS & INSPECTIONS - The Contractor shall be responsible for notifying the Contracting Officer and COR at least seven (7) working days prior to being ready for any inspections or testing

a. 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.

3.15. WARRANTY - A warranty of one year from installation or 1800 operating hours, whichever occurs first and 24 months of storage is required covering the entire marine gear. Storage commences upon receipt of engine at the designated USCG facility.

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 ANSI/ASQS Q90003.

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 ANSI/NCSL Z540-3. The system include as 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. PRESERVATION (Internal) - The gear shall be preserved as per the requirements of the ZF Workshop Manuals after operational testing, and acceptance by the USCG.

5.2. PRESERVATION (External) - After completion of the final test run and internal preservation the gear shall be prepared in accordance with ZF Marine Gears Anti-Corrosion Protection Guidelines (Stage II) for corrosion proofing.

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

b. The gear shall be sprayed enamel white paint (P/N 4C-4187) on all surfaces 3-5 mils thick, allow a minimum of seven (7) hours drying for primed surfaces.

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

d. Coat all unpainted metal surfaces with a light amount of grease, 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 - The shipping container if damaged shall be constructed and mounted to the base skidded pallet as per MIL-C-104C. The gear shall be packaged in accordance with ZF Marine Gears Anti-Corrosion Protection Guidelines (Stage II) for corrosion proofing, types of packaging, storage conditions/storage periods.

a. 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 – 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.

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

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

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

NATIONAL STOCK NUMBER “As per Enclosed Gear”

PART NUMBER

ITEM NAME Transmission MODEL NUMBER “As per Enclosed Gear” 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

PRESERVED FOR LONG TERM

STORAGE ON Date preserved

CONDITION CODE CONDITION A

OTHER DATA AS COAST GUARD SFLC MATERIAL

DIRECTED REUSABLE CONTAINER,

DO NOT DAMAGE.

DO NOT STACK.

d. 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 Bolts Prior To Removing Cover Use Forklift to Unload Do Not Lift By Cover

5.5. BAR CODING – Bar code labels shall be supplied on all Contract Line Item Numbers (CLIN), except for those that require data submissions only.

a. All bar coded labels shall be in accordance with SFLC specification D-000-0100.

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

c. Each label shall contain encoded data for the Stock Number, Delivery Order Number and Contract Number.

6.0 GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

6.1. GOVERNMENT DOCUMENTS

a. USCG Surface Forces Logistics Center

6.2. COMMERCIAL DOCUMENTS

a. International Organization for Standardization

6.3. ENCLOSURES – The following enclosures apply:

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 Technical Representative Condition Found Report

f. Appendix F Warranty Information

Delivery Order #:_____________________________ Delivery Order #:__________________________ Engine Serial #:___________________________ Reduction Gear Serial #:____________________

Condition Found

Repairs Required

Parts Required

Parts Expended

Recommendations

Appendix A Condition Found Report

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 COTR

Overhaul Kit Contains

Overhaul Kit Contains

Overhaul Kit Contains

Appendix B Mandatory Parts List

Repair Order #

Date:

Model:

Ratio:

Serial Number:

Spec Number:

Tested By: (print name)

Time Start:

Time Finished:

All tests must be completed and data recorded.

Operational Test

(Bar) Pump Pressure (Bar) Bearing Temperatures *

AFT

AFT

Record Oil Temperature at end of test: (F)

(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.

Description of failures and corrective actions:

Technician Signature

Date:

Contractor Manager Signature

Date:

USCG Representative Signature

Date:

Appendix C Gear Spin Test Report

Y/N

Appendix D Cumulative Tracking Report

Representative Name:

Date:

Time Arrival:

Time Departure:

Unit:

POC:

City:

State:

Address:

Zip:

Hull Number:

Tel #:

Gear Serial Number:

Stbd/Port:

Date Installed:

Hours:

Contract #:

Delivery Order #:

Contractor Name:

Contracting Officer:

ZF Model #:

Condition Found

Repairs Required

Parts Required

Parts Expended

Recommendations

Technician Signature

Date:

Appendix E Technical Representative Condition Found Report

Warranty Period for ZF Marine Gears

1800 Hours of Operation OR (1) Year from Date of Installation

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

USCG SFLC PBPL

Mail Stop 25, 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 Patrol Boat Product Line

OFFICE PHONE: (410) 590-7017

CELL PHONE AFTER HOURS: (443) 271-4026

!!Any unauthorized repairs could void the WARRANTY!!

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 CUTTER IS OUT OF THE WATER, YOU MUST WAIT 24 HOURS AFTER THE CUTTER 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 PATROL 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 Patrol Boat Product Line Team immediately.

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: THE LUBE OIL SYSTEM HAS BEEN PRESERVED WITH VOLATILE CORROSION INHIBITOR OIL. DO NOT OPERATE UNIT UNTIL FLUIDS ARE ADDED.

** CAUTION: FUEL SYSTEM HAS BEEN PRESERVED WITH INJECTION PUMP TESTING OIL AND CORROSION INHIBITOR. FUEL SYSTEM MUST BE FLUSHED COMPLETELY WITH DIESEL FUEL.

** CAUTION: JACKET WATER COOLANT SYSTEM HAS BEEN PRESERVED WITH ANTIFREEZE OR COOLING SYSTEM CONDITIONER AND HAS BEEN DRAINED. DO NOT OPERATE UNTIL FLUID HAS BEEN ADDED.

** 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 PATROL BOAT PRODUCT LINE TEAM

REPAIRS ARE TO BE PERFORMED ONLY AFTER CONTACTING THE PATROL BOAT PRODUCT LINE (PBPL) TEAM

OFFICE PHONE: (410) 590-7017

AFTER HOURS: (443) 271-4026

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