Attachment-2 Specification.pdf

(Rev-2)

USCGC POLAR CLASS ICEBREAKER

SPECIFICAITON TO REPAIR POLAR CLASS ICEBREAKER CONTROLLABLE PITCH

PROPELLER (CPP) HUB ASSEMBLY

Developed By: Brian Adornado

(Rev-2, 22 January 2024)

TABLE OF CONTENTS

TABLE OF CONTENTS

REVISIONS RECORD

CONSOLIDATED LIST OF REFERENCES

CONSOLIDATED LIST OF GOVERNMENT-FURNISHED PROPERTY

CONSOLIDATED LIST OF CRITICAL INSPECTION ITEMS

GENERAL REQUIREMENTS

WORK ITEM 1: Controllable Pitch Propeller (CPP) Hub Assembly, Overhaul WORK ITEM 2: Controllable Pitch Propeller (CPP) Trunnion, Overhaul WORK ITEM 3: Controllable Pitch Propeller (CPP) Adjusting Crank, Repair WORK ITEM 4: Controllable Pitch Propeller (CPP) Locknut, Renew WORK ITEM 5: Controllable Pitch Propeller (CPP) Adjusting Crank Drive Pin Bores, Renew WORK ITEM 6: Controllable Pitch Propeller (CPP) Link Pin, Renew WORK ITEM 7: Controllable Pitch Propeller (CPP) Hub Trunnion Bushing, Renew WORK ITEM 8: Hub O-ring Sealing Surface, Restore WORK ITEM 9: Controllable Pitch Propeller (CPP) Trunnion, Repair WORK ITEM 10: Hub Testing and Transport Equipment, Maintain

REVISIONS RECORD

This page is used to record specification revisions, which may have occurred subsequent to a Revision 0

(Rev-0) package. Information listed is intended to provide contractors and field unit personnel a means to ensure all the current specification revision pages are present when reviewing or utilizing this specification package.

DATE REV# WORK

ITEM#

CHANGES MADE

NOTE : All work item and paragraph numbers listed above for a given revision correspond to same numbers in the previous revision. This revised specification is self-contained with all of the above listed changes incorporated.

CONSOLIDATED LIST OF REFERENCES

COAST GUARD DRAWINGS

400-WAGB_4400_5, Rev -, CPP LH Propeller Blade:

400-WAGB_4400_6, Rev -, CPP RH Propeller Blade Design

400-WAGB_4400_7, Rev -, CPP LH Propeller Blade Design

400-WAGB_4400_26, Rev -, CPP Master Cross Reference Drawing List

400-WAGB_4400_27, Rev -, CPP Right Hand Hub Assembly (Elev Section-Side Profile)

400-WAGB_4400_28, Rev -, CPP Right Hand Propeller Blade

400-WAGB_4400_29, Rev -, CPP Right Hand Adjusting Crank Arm

400-WAGB_4400_30, Rev -, CPP Right Hand Adjusting Crank Arm Dowell Location And Drive Pin

Matrix

400-WAGB_4400_31, Rev -, CPP RH Operating Rod

400-WAGB_4400_32, Rev -, CPP RH Link Arm Assy

400-WAGB_4400_33, Rev -, CPP RH Propeller Blade Design

400-WAGB_4400_34, Rev -, CPP 69 Inch Dia LH Prop Hub Assy (Elev Sect)

400-WAGB_4400_35, Rev -, CPP LH Propeller Blade

400-WAGB_4400_36, Rev -, CPP LH Adjusting Crank Arm (Unsigned)

400-WAGB_4400_37, Rev -, CPP Left Hand Adjusting Crank Arm Dowel Location

400-WAGB_4400_38, Rev -, CPP Left Hand Operating Rod

400-WAGB_4400_39, Rev -, CPP Left Hand Link Arm Assembly

400-WAGB_4400_40, Rev -, CPP Left Hand Propeller Blade Design

400-WAGB_4400_41, Rev -, CPP Hub Cylinder (Common To LH & RH)

400-WAGB_4400_42, Rev -, CPP Propeller Hub (Common To LH & RH)

400-WAGB_4400_43, Rev -, CPP Piston (Common To LH & RH)

400-WAGB_4400_44, Rev -, CPP Guide Rod & Guide Flange (Common To LH & RH)

400-WAGB_4400_45, Rev -, CPP Locknut (Trunnion) (Common To LH & RH)

400-WAGB_4400_47, Rev -, CPP List of Material

400-WAGB_4400_63, Rev -, Shipping Head

400-WAGB_4400_64, Rev -, Shipping Head Assembly

400-WAGB_4400_65, Rev -, Shipping Frame

400-WAGB_4400_72, Rev -, Shipping Head Assy Bill of Materials

400-WAGB_4400_73, Rev -, Shipping Plug

400-WAGB_4400_74, Rev -, Shipping Head Assy Bill of Materials

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 4986, Controllable Pitch Propeller System, Modified, Coast Guard Technical Publication (TP) 4986A, 2016, Controllable Pitch Propeller System, Modified

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2022, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2022, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), 2022, Auxiliary Machine Systems

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2022, Requirements for Preservation of Ship Structures

OTHER REFERENCES

400-WAGB-T00001 Hub Orientation for Shipping Stand

ASTM D4304, Dec 2022, Standard Specification for Mineral and Synthetic Lubricating Oil

Used in Steam or Gas Turbines.

American Bureau of Shipping (ABS) Marine Vessel Rules Part 7, July 2023, Survey After

Construction

Hytorc Hydraulic Operating Instructions

Hydraulic CPP hub Test Unit

MIL-DTL-2845E (SH), August 1999, Propulsion Systems, Boat And Ship; Main Shafting, CPP hubs, Bearings, Gauges, Special Tools, And Associated Repair Parts; Preservation, Packaging, Packing and Storage Of

TT-C-490H, June 2023, Chemical Conversion Coatings and Pretreatments for Metallic

Substrates (Base for Organic Coatings)

Federal Specification TT-C-C490E type V, Zinc Phosphate Coating

American Bureau of Shipping, Generic Rules for Classification, Materials and Welding and

Survey After construction - Part 2, Rules for Materials and Welding, January 2024

CONSOLIDATED LIST OF GOVERNMENT-FURNISHED PROPERTY

The following is a list of property, which the Government will furnish. This list supersedes any other material obligations indicated or implied by referenced drawings.

WORK

ITEM

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

1 Y *Work (overhaul) Stands Coast Guard Tool 3 ea 5,000

1 Y *60 Ton Hydraulic Jack, Hollow Center Coast Guard Tool 1 ea 400

1 Y *Pin Puller Bolts Coast Guard Tool 2 ea 200

1 Y *Pin Puller Adapter Sleeve Coast Guard Tool 1 ea 100

1 Y *Lifting Plate w/8 ea. 1-1/2" hex head bolts

Coast Guard Tool 1 ea 750

1 Y *Pad Eye for Operating Rod Coast Guard Tool 1 ea 250

1 Y *Blade Lifting Clamp Coast Guard Tool 1 ea 400

1 Y *Eye Bolt for Lifting Cylinder Coast Guard Tool 1 ea 250

1 Y *Flat Wrenches (4", 6-1/4", 6-1/2", 6-

5/8")

Coast Guard Tool 4 ea 400

1 Y *Hydraulic Test Fixture (3 pieces + clamps)

Coast Guard Tool 1 ea 800

1 Y *Shipping Stands Coast Guard Tool 3 ea 1250

1 Y *Guide Rod Nut Wrench Coast Guard Tool 1 ea 450

1 Y *CPP hub Blade Edge Clamp Coast Guard Tool 2 ea 200

1 Y *Hydraulic Test Unit Coast Guard Tool 1 ea 12,000

1 Y *HYTORC hydraulic wrench Coast Guard Tool 1 ea 1,500

1 Y *HYTORC hydraulic pump unit Coast Guard Tool 1 ea 700

1 Y *Cylinder Assembly Guide Pins Coast Guard Tool 4 ea 300

1 Y *Pitch Measuring Device (for use in O-2) Coast Guard Tool 1 ea 550

1 Y *Mounting Assembly (Hub to Work stand hold down (assemblies)

Coast Guard Tool 4 set 450

1 Y *4 dummy link pin set Coast Guard Tool 6 ea 800

1 Y *Hub check valve test fixture Coast Guard Tool 1 ea 350

1 Y *Aluminum trunnion blade thread gage Coast Guard Tool 1 ea 200

1 Y *Blade holding/clamp fixture for machining

Coast Guard Tool 1 ea 550

1 Y *Piston ring compressor tool Coast Guard Tool 1 ea 250

1 Y *Blade dowel pin positioning fixture Coast Guard Tool 1 ea 750

1 Y *Link arm fixture for machining Coast Guard Tool 1 ea 500

1 Y *Adjustable Reamer Coast Guard Tool 2 ea 600

3 N Adjusting Cranks (Either RH set or LH set)

Escher Wyss 4 ea 40,000

3 N Adjusting Cranks link pins, Escher Wyss 4 ea 500

3 N Spherical Bearings Escher Wyss 8 ea 2,000

7 N Outer Trunnion Bushing (Rough Cut

Condition)

Escher Wyss 1 ea 1,250.00

7 N Inner Trunnion Bushing (Rough Cut

Condition)

Escher Wyss 1 ea 1,000.00

10 Y *Shipping Stands Coast Guard Tool 3 ea 1250

10 Y *Hydraulic Test Unit Coast Guard Tool 1 ea 12,000

CONSOLIDATED LIST OF CRITICAL INSPECTION ITEMS

The following is a list of work items, which contain Critical Inspection reports, which the Contractor must complete within the first 25% of the availability contract period (see SFLC Std Spec 0000_STD, paragraph 3.2.6.5 (Inspection report particulars)):

This section is not applicable to this package.

00000_0413_FLT

REC_00000_FLT_ Commercial Project @ Contractor’ Facility (1212)

GENERAL REQUIREMENTS

1. SCOPE

1.1 Intent. This standard specification invokes general requirements for conducting vessel repairs performed at a commercial contractor’s facility for Coast Guard vessels.

1.2 Term interchangeability. The terms 'Contractor', 'CG Yard', 'NAVSTA EVERETT', 'shipyard', 'Base', and 'Coast Guard Industrial' are used interchangeably in this specification. Where the primary service provider is Coast Guard personnel, references to contractor and other noted descriptors within this specification or within drawings, publications, SFLC Standard Specifications or other commercial and military references are deemed the same as prime service provider.

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2022, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 5550 (SFLC Std Spec 5550), 2022, Fire

Prevention and Response

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2022, Requirements for Preservation of Ship Structures

OTHER REFERENCES

Code of Federal Regulations (CFR) Title 29, Part 1915, Occupational Safety and Health

Standards for Shipyard Employment

NAVSEA Technical Publication T9074-AD-GIB-010/1688, (TP 1688), July 2012, Requirements for Fabrication, Welding, and Inspection of Submarine Structure

3. REQUIREMENTS

3.1 General. The Contractor must conform to all requirements specified in SFLC Std Spec 0000 and in this item, as applicable, during the performance of this availability. The requirements of this WI applies to all work under the scope of this contract, whether explicitly stated in all following work items or not, and to all other work subsequently authorized by changes, modifications, or extensions to the contract.

NOTE

NAVSEA drawings listed will be available FOR INSPECTION ONLY from the Coast Guard Port Engineer post-award. SFLC will not redistribute

NAVSEA documents. Contractors can apply to NAVSEA headquarters directly for copies.

3.2 Contractor-provided fire watch personnel. The Contractor must provide fire watch personnel and equipment.

3.3 Preservation requirements. The Contractor must accomplish all preservation tasks, including touch-ups, in accordance with SFLC Std Spec 6310.

3.4 Welding and brazing requirements. The Contractor must perform all welding and allied processes, and

NDE in accordance with SFLC Std Spec 0740.

3.5 Environmental protection requirements. The Contractor must adhere to the following environmental protection requirements in accordance with the SFLC Stand Spec 0000 Appendix B (Non USCG facilities).

3.6 Access. The Contractor must provide access to their facilities for up to ten USCG personnel anytime work is being done on the hubs.

4. NOTES

None.

24509_BJA_0723_400

24509_JPH_0511_400

WORK ITEM 1: Controllable Pitch Propeller (CPP) Hub Assembly, Overhaul

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to disassemble, inspect, overhaul, reassemble and test one right hand or one left hand Polar Class Icebreaker CPP hub assembly.

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

Y *Work (overhaul) Stands Coast Guard Tool 3 ea 5,000 Y *60 Ton Hydraulic Jack, Hollow Center Coast Guard Tool 1 ea 400 Y *Pin Puller Bolts Coast Guard Tool 2 ea 200 Y *Pin Puller Adapter Sleeve Coast Guard Tool 1 ea 100 Y *Lifting Plate w/8 ea. 1-1/2" hex head bolts Coast Guard Tool 1 ea 750

Y *Pad Eye for Operating Rod Coast Guard Tool 1 ea 250 Y *Blade Lifting Clamp Coast Guard Tool 1 ea 400 Y *Eye Bolt for Lifting Cylinder Coast Guard Tool 1 ea 250 Y *Flat Wrenches (4", 6-1/4", 6-1/2", 6-

5/8") Coast Guard Tool 4 ea 400

Y *Hydraulic Test Fixture (3 pieces + clamps) Coast Guard Tool 1 ea 800

Y *Shipping Stands Coast Guard Tool 3 ea 1250 Y *Guide Rod Nut Wrench Coast Guard Tool 1 ea 450 Y *CPP hub Blade Edge Clamp Coast Guard Tool 2 ea 200 Y *Hydraulic Test Unit Coast Guard Tool 1 ea 12,000 Y *HYTORC hydraulic wrench Coast Guard Tool 1 ea 1,500 Y *HYTORC hydraulic pump unit Coast Guard Tool 1 ea 700 Y *Cylinder Assembly Guide Pins Coast Guard Tool 4 ea 300 Y *Pitch Measuring Device (for use in O-2) Coast Guard Tool 1 ea 550 Y *Mounting Assembly (Hub to Work stand hold down (assemblies) Coast Guard Tool 4 set 450

Y *4 dummy link pin set Coast Guard Tool 6 ea 800 Y *Hub check valve test fixture Coast Guard Tool 1 ea 350 Y *Aluminum trunnion blade thread gage Coast Guard Tool 1 ea 200 Y *Blade holding/clamp fixture for machining Coast Guard Tool 1 ea 550

Y *Piston ring compressor tool Coast Guard Tool 1 ea 250 Y *Blade dowel pin positioning fixture Coast Guard Tool 1 ea 750

Y *Link arm fixture for machining Coast Guard Tool 1 ea 500 Y *Adjustable Reamer Coast Guard Tool 2 ea 600 *Government-loaned property, which must be returned to the vessel upon completion of the availability.

**New or refurbished equipment that the Government may provide for installation in place of existing equipment.

***Government-furnished property, which is to be supplied by either the vessel or the C4IT Service Center.

2. REFERENCES

COAST GUARD DRAWINGS

400-WAGB-4400-5, Rev -, CPP LH Propeller Blade:

400-WAGB-4400-6, Rev -, CPP RH Propeller Blade Design

400-WAGB-4400-7, Rev -, CPP LH Propeller Blade Design

400-WAGB-4400-26, Rev -, CPP Master Cross Reference Drawing List

400-WAGB-4400-27, Rev -, CPP Right Hand Hub Assembly (Elev Section-Side Profile)

400-WAGB-4400-28, Rev -, CPP Right Hand Propeller Blade

400-WAGB-4400-29, Rev -, CPP Right Hand Adjusting Crank Arm

400-WAGB-4400-30, Rev -, CPP Right Hand Adjusting Crank Arm Dowell Location And Drive

Pin Matrix

400-WAGB-4400-31, Rev -, CPP RH Operating Rod

400-WAGB-4400-32, Rev -, CPP RH Link Arm Assy

400-WAGB-4400-33, Rev -, CPP RH Propeller Blade Design

400-WAGB-4400-34, Rev -, CPP 69 Inch Dia LH Prop Hub Assy (Elev Sect)

400-WAGB-4400-35, Rev -, CPP LH Propeller Blade

400-WAGB-4400-36, Rev -, CPP LH Adjusting Crank Arm (Unsigned)

400-WAGB-4400-37, Rev -, CPP Left Hand Adjusting Crank Arm Dowel Location

400-WAGB-4400-38, Rev -, CPP Left Hand Operating Rod

400-WAGB-4400-39, Rev -, CPP Left Hand Link Arm Assembly

400-WAGB-4400-40, Rev -, CPP Left Hand Propeller Blade Design

400-WAGB-4400-41, Rev -, CPP Hub Cylinder (Common To LH & RH)

400-WAGB-4400-42, Rev -, CPP Propeller Hub (Common To LH & RH)

400-WAGB-4400-43, Rev -, CPP Piston (Common To LH & RH)

400-WAGB-4400-44, Rev -, CPP Guide Rod & Guide Flange (Common To LH & RH)

400-WAGB-4400-45, Rev -, CPP Locknut (Trunnion) (Common To LH & RH)

400-WAGB-4400-46, Rev -, CPP Propeller Tailshaft Assembly (Common To LH & RH)

400-WAGB-4400-47, Rev -, CPP List of Material

400-WAGB-4400-63, Rev -, Shipping Head 400-WAGB-4400-64, Rev -, Shipping Head Assembly

400-WAGB-4400-65, Rev -, Shipping Frame

400-WAGB-4400-72, Rev -, Shipping Head Assy Bill of Materials

400-WAGB-4400-73, Rev -, Shipping Plug 400-WAGB-4400-74, Rev -, Shipping Head Assy Bill of Materials

Coast Guard Technical Publication (TP) 4986A, 2016, Controllable Pitch Propeller System, Modified

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2022, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2022, Requirements for Preservation of Ship Structures

OTHER REFERENCES

400-WAGB-T00001 Hub Orientation for Shipping Stand

ASTM D4304, Dec 2022, Standard Specification for Mineral and Synthetic Lubricating Oil Used in Steam or Gas Turbines.

American Bureau of Shipping (ABS) Marine Vessel Rules Part 7, July 2023, Survey After

Construction

Hytorc Hydraulic Operating Instructions

Hydraulic CPP hub Test Unit

MIL-DTL-2845E (SH), August 1999, Propulsion Systems, Boat And Ship; Main Shafting, CPP hubs, Bearings, Gauges, Special Tools, And Associated Repair Parts; Preservation, Packaging, Packing and Storage Of

TT-C-490H, June 2023, Chemical Conversion Coatings and Pretreatments for Metallic Substrates

(Base for Organic Coatings)

Federal Specification TT-C-C490E type V, Zinc Phosphate Coating

Hub 18 dimensions

NOTE

The numbers referenced throughout this work item are as shown in Coast

Guard Drawing 400-WAGB-4400-27, 400-WAGB-4400-34 and 400- WAGB-

4400-47. The first number corresponds to the “MSTR NO” column in 400-

WAGB-4400-47 and the second number corresponds to the “POS NO” in that drawing. These numbers may differ for left hand CPP hubs.

For example PN 017-33 is a Ball Retainer

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Technical Representative.

Not applicable.

3.1.3 Protective measures. The Contractor shall furnish and install suitable covering to seal off and protect all non-affected surfaces/equipment and spaces in the vicinity of the work area against contamination during the performance of work. Upon completion of work, remove protective material and inspect for the presence of contamination. Clean all equipment and spaces, contaminated due to improper protection, to original condition of cleanliness.

3.1.4 Hydraulic Cleanliness. Cleanliness is of the utmost importance in hydraulic systems. The

Contractor shall ensure that cleanliness standards are maintained in accordance with ISO

Cleanliness Code of 17/14 per ISO 4406 during all phases of work.

NOTE

Be aware that plastic bags may be used only when arrangement or configuration prevents the use of the other sealing methods specified above.

3.1.5 Interferences. The Contractor must handle all interferences in accordance with SFLC Std

Spec 0000.

3.1.6. Hub U18. This hub is slightly different than the other hubs, and these changes are not relfected in the drawings. The piston has a different arrangement, and the piston is sealed with a polymer – turcon. Take all measurements as instructed herein, but do not remove any material from this hub without submitting a CFR. See Figure 1 for a picture of U18, and Hub 18 dimensions in other references above.

3.2 Shipping and Receipt.

3.2.1 The Contractor will be given 5 days of notice to pick up the CPP hub assembly from the shipyard that removes them and to drop off the completed hubs to the shipyard that will be installing them. Any costs incurred from a delay in picking up or dropping off the hubs (i.e. added crane service costs, overtime, etc) will be borne by the Contractor. See paragraph 3.13 herein for further information about storage and transport of completed CPP hubs.

3.2.2. The CPP hub assembly will be removed from the vessel by a commercial shipyard and placed in the shipping stand. Shipping apparatus is shown in CG Drawings 400-WAGB-4400-63, -64, -65, -72 and

-73. The shipyard will then load the CPP hub and shipping stand assembly onto a truck for transport to the Contractor’s overhaul facility.

3.2.2 The Contractor must arrange, furnish, and bear all costs for transportation of the CPP hub assembly from the shipyard to the overhaul facility. A shipyard point of contact will be supplied to aide and coordinate transportation details. The COR will provide the Contractor with at least 5 days advance notice prior to the desired shipping date for coordination efforts with the shipyard. For bidding purposes, assume that the shipyard is on the West Coast of the United States.

3.2.3 Upon receipt of the hub the Contractor must inspect the transport equipment, including the shipping frame, shipping head and shipping plug using CG Drawings 400-WAGB-4400-63, -64, -65, -72 and -73 as a configuration reference. Inspect the following items and submit a CFR.

• Paint condition

• Damaged or deformed components

• Weld conditions (a simple visual inspection is sufficient. Do not remove paint to inspect welds)

• Condition of hardware (including noting missing hardware)

NOTE

The approximate weight of each CPP hub assembly and shipping stand is 47 tons. Approximate dimensions of hub and shipping stand are 15 ft. wide, 15

ft. long and 9 ft. high.

3.4 Pre-Disassembly Hydraulic Testing.

3.4.1 Prior to disassembling the CPP hub, it must be mounted on a suitable stand and hydraulically tested in the presence of the Coast Guard Inspector.

3.4.2 The test must be performed using the GFP hydraulic test unit in accordance with the reference

“Hydraulic CPP Hub Test Unit.” It is the Contractor's responsibility to safely operate this equipment within the manufacturer's operating instructions. The Contractor must continuously monitor operation of the test unit for damage, unusual performance, or unsafe operation and notify the COR immediately of any discrepancies via CFR.

3.4.3 The Contractor must transfer hydraulic oil of ISO viscosity grade 32, meeting ASTM 4304

Rev A Type III, from barrels of oil provided with the hub to the hub itself (approximately 150 gallons). Filter this hydraulic oil through a 10 micron filter when loading it into the hub.

3.4.4 The Contractor must complete the pre-disassembly test data sheets (Figure 2) during testing.

Hydraulic testing includes the following procedures:

3.4.4.1 Hydraulically pitch the CPP hub, full stroke, in both directions, to determine the minimum pressure required to operate the CPP hub. Sufficient tests must be conducted to ensure repeatability of the data. There must be a minimum of two full tests conducted.

3.4.4.2 Once the minimum operating pressure is determined, increase the pump pressure to 250 psig and conduct a timed operation test. Sufficient tests must be conducted to ensure repeatability of the data.

There must be a minimum of two full tests conducted.

3.4.4.3 The hub must be hydrostatically tested for external leaks at 250 PSI astern pressure using system hydraulic oil. At least one manual valve and one relief valve must be provided to protect from overpressurization during the test.

3.4.4.4 Upon completion of test, pitch blade to hardstop ahead. Drain oil from hub back to the hydraulic test unit and remove hydraulic test equipment.

3.4.4.5 After removal of hydraulic test equipment, determine the X3 dimensions for design ahead, hard stop ahead, and hard stop astern using the GFP Measuring Bar. X3 is the distance from the face of the hub to the end of the operating rod, measured in at least four locations equally spaced around the hub perimeter and calculating the average reading as shown in Figure 3. Blade #1 pitch markings must be used for design ahead pitch reference.

NOTE

X3 dimensions are taken again at the conclusion of work and after final testing in paragraph 3.10. With hydraulics removed, blades are pitched to desired pitch angles by use of blade edge clamps and straps/chains connected to overhead crane.

3.5 Disassembly.

3.5.1 Completely disassemble the CPP hub including the removal of the operating rod and the CPP hub blades. Consult CG TP-4986 section 7 for additional information.

3.5.1.1 Clean each blade of marine growth prior to disassembly.

3.5.1.2 During removal of each hub blade, weigh each blade and record the measurement. Submit the weight of each blade via CFR.

3.5.1.3 Disassembly includes the removal of the following major components. See drawings 400-

WAGB-4400-24, -34,-47 for guidance. This is not meant to be an all inclusive list of all smaller piece parts:

TABLE 1: DISASSEMBLY COMPONENTS

PART

NUMBER

DESCRIPTION

1 396-15 Hub Cylinder Cover

2 019-1 Hub Cylinder

3 017-25 Lock Plate

4 017-9 Operating Rod Nut (more detail in 400-WAGB-4400-31, -38) 5 019-5 Piston (more detail in 400-WAGB-4400-43) 6 017-37 Operating Rod Link Pins

7 018-350 Operating Rod (more detail in 400-WAGB-4400-31, -38) 8 017-12 Guide Flange (more detail in 400-WAGB-4400-44)

9 017-8 Guide Rods (more detail in 400-WAGB-4400-44)

10 017-36 Adjusting Crank Link Pin (more detail in 400-WAGB-4400-29, -36) 11 017-49 Link Assembly

12 017-17 Locknut (more detail in 400-WAGB-4400-5)

13 017-35 Drive Pin

14 017-301 Adjusting Crank (more detail in 400-WAGB-4400-29, -36)

PART

NUMBER

DESCRIPTION

15 014-2 CPP hub Blade (more detail in 400-WAGB-4400-5, -6, -7, -28, -33, -35, -

40)

16 019-6 Piston rings (more detail in 400-WAGB-4400-43)

3.5.2 Use the GFP HYTORC hydraulic wrench and hydraulic power unit to remove/install the 24 each 2-

8UNC cylinder socket head cap screws (PN 019-7). The Contactor must use the GFP HYTORC hydraulic wrench for removing and installing these socket head cap screws. It remains the Contractor's sole responsibility to safely operate this tool within the manufacturer's operating instructions and guidelines (including printed safety instructions) in “Hytorc Hydraulic Operating Instructions.” The

Contractor must continuously monitor operation of the tool for damage, unusual performance, or unsafe operation and notify the COR immediately of any discrepancies via CFR.

3.6 Inspection And Measurement.

3.6.1 When disassembly is complete, inspect all accessible components of the CPP hub assembly, measure and record all dimensions, clearances, and runouts on the enclosed forms (see “Measurement, Data, and Procedure Sheets” at the end of this work item). Submit a CFR for any wear or damage found in the initial disassembly inspection, including recommendations for restoration/repair.

3.6.2 The initial inspections and measurements outlined above must be completed within 120 days of

CPP hub receipt.

3.6.3 If a CPP hub has been provided for an “Accelerated Overhaul,” disassembly, inspections and measurements must be completed within 14 days of CPP hub receipt.

3.6.4 Hub Dimensional Checks.

3.6.4.1 Concentricity of the small, large and seal bores of each hub blade port must be verified. This verification must be accomplished concurrent with collection of hub runout readings required by Figure 3.

The following mandatory procedure must be used to setup, measure, and record hub runout readings required by Figure 4. Other methods for verifying concentricity and collecting hub runout readings are not permitted. Once the hub is set up for measurements, it must not be moved from, or repositioned on, the machine table until all measurements for all four blade ports are complete.

3.6.4.2 The Contractor must use a horizontal, universal milling machine with universal milling head

(min. 3-axis). Milling machine must have a rotatable table capable of supporting the full hub weight.

3.6.4.3 Place the hub on the rotatable table with its face centered to this table. Use the spigot of the CPP hub shaft connection for centering to establish spindle on common vertical plane with the hub's axis of rotation.

3.6.4.4 Align the large thrust face perpendicular to the spindle axis.

3.6.4.5 Repeat this procedure with all other ports using the first one as zero and record differences.

3.6.4.6 Select the optimum one for zero. The spindle axis should not be adjusted from then on, the spindle axis is fixed.

3.6.4.7 With the table rotated so that the blade ports are centered and using each blade port's large bore as a reference, adjust the spindle centerline (vertical positioning of spindle). If the wear pattern (bushing not removed) indicates a larger weardown in a part of circumference this area must not be considered for this zeroing.

3.6.4.8 Perform runout readings for each blade port as necessary to complete Figure 4

3.6.5 Blade Dimensional Checks.

3.6.5.1 The following mandatory procedure must be used to setup, measure, and record blade runout readings required by Figure 5:

3.6.5.2 The Contractor must use a horizontal, universal milling machine with universal milling head

(min. 3-axis). Milling machine must have table capable of supporting weight of blade or hub.

3.6.5.3 Roughly align blade on table with the aid of water balance (level) on the larger seat (surface B1, B2 on Figure 5).

3.6.5.4 Align the axial face of the outer trunnion (E1) perpendicular to the spindle axis. Align by fine adjustment of the table (preferable), or if necessary by moving the blade with hydraulic jacks or similar.

3.6.5.5 Align the spindle centerline preferably with two gauges mounted to the same holder, one gauge on each radial seat, outer trunnion (B1, B2) and inner trunnion (A1, A2). This alignment should be made by fine adjustment of table (preferable), or if moving the table is impossible then by moving the entire blade.

NOTE

The intent of the above steps is to ensure the trunnion surface E1 and B1 are used for zeroing.

3.6.5.6 Perform runout readings necessary to complete Figure 5.

3.6.5.7 Measure blade trunnion diameter and length using Figure 6 for each blade.

3.6.6 O-ring Seating Surfaces Inspections.

3.6.6.1 Visually inspect all o-ring seating surfaces throughout the hub for any gouges, pitting, scratches, nicks, or other damage that would affect optimal sealing. Report all discovered deficiencies via CFR.

3.6.7 Miscellaneous Measurements.

3.6.7.1 Measure and take readings of the following pieces:

• Link Pin Diameters (Figure 7).

• Spherical Ball Bearing (Figure 8).

• Adjusting Cranks (Figure 9).

• Guide Rod (Figure 10).

• Op Rod (Figure 11).

• Piston (Figure 12).

• Op Rod Bushing (Figure 13).

• Hub, Cylinder Spigot (Figure 14).

• Cylinder, include O-ring depth (Figure 15).

• Link Arms (Figure 16).

• Drive Pins (Figure 17).

• Thread Diameter Measurements (Figure 18).

• Dowel Pins and Bores Op Rods (Figure 19).

3.6.7.2 Blade Weights

3.6.7.2.1 Measure and record the weights of each blade after conducting all required repairs and prior to reassembly. Submit via CFR.

3.6.8 Dye Penetrant Examinations.

3.6.8.1 The Contractor must perform a 100% liquid penetrant (PT) inspection per SFLCS Standard Spec

0740, of the surfaces detailed below. Analysis of discrepant areas must be evaluated against acceptance and rejection criteria detailed in Table 1 of reference American Bureau of Shipping (ABS) Marine Vessel

Rules, Part 2, Chapter 3, Section 14. Written results of the evaluation must be submitted via CFR.

• The entire propeller blade, including all trunnion surfaces. See 400-WAGB-4400-5, -

6, -7, -28, -33, -35, -40 for more information about the propeller blades

• Drive pin holes. See 400-WAGB-4400-30 for more information about drive pin holes

• Operating rod nut. See 400-WAGB-4400-31, -38 for more information about the operating rod.

• The eight removed spherical bearings. Perform NDT prior to recoating.

• The adjusting cranks' ring to ear transitions. See 400-WAGB-4400-29, -36.

• All 24 2-8UNC cylinder socket head cap screws (PN 019-7)

3.7 Repair/Modifications.

3.7.1 The Contractor must perform the following work and provide the required parts.

3.7.1.1 Renew the following parts utilizing the same materials as shown in CG TP-4986 section 7 titled

"Parts List":

TABLE 2: REPAIR PARTS LIST

ITEM

PART NUMBER QTY DESCRIPTION

1 017-10 4 ea o-ring for guide rods (some hubs require 8 ea)

2 017-14 1 ea 0.250" Dia. Bar X 60" Lg

3 017-27 1 ea 0.047" Dia. Lock-wire

4 017-41 8 ea 0.047" Dia. Lock-wire

5 018-4 1 ea o-ring for Inner Oil Pipe

6 019-3 1 ea o-ring for Hub to Cylinder Seal

7 014-3 4 ea o-rings for CPP hub Blade Seals

8 017-50 4 ea Link Pin Lock Plates (adjusting crank)

9 017-113 8 ea Flat Head Cap Screw (for adjusting crank's link pin lock plate)

3.7.1.2 When material information is not clear on drawings, material must be equivalent to existing. This is true for PN 017-50 and PN 017-113 above.

3.7.1.3 Lance with solvent, and wipe down all hub cavities and components to remove all traces of dirt, dust and other contaminants. Protect surfaces with a light coat of hydraulic oil of ISO viscosity grade

32, meeting ASTM 4304 Rev A Type III .

3.7.1.4 Renew the lubrication on the eight spherical bearings by applying one coat of zinc phosphate conforming to Federal spec TT-C-490H type V, followed by one coat of dry-film anti-friction coating.

Subject coating must be an organic binder, heat set product infused with Molydenum Di-sulfide particles.

Suitable coatings include, but are not limited to, Molykote 106, Berucoat AF 130 or 291, Technolubeseal

Spray Dry Moly.

3.7.1.5 Measure and report the average thickness of the bearing zinc phosphate and lubrication film with a dryfilm thickness gauge in accordance with Paragraph D7.1 of SFLC Standard Spec 6310. Dryfilm thickness gauge must be capable of measuring film thickness within 0.0005". Total average film thickness must not exceed 0.001".

3.7.1.6 Hand dress the CPP hub blade ports and trunnions with a fine emery cloth to restore the surface finishes in accordance with CG Dwg 400-WAGB-4400-28.

3.7.1.7 Polish the O-ring contact surfaces to a 32 micro-inch RMS finish with a fine Emery Cloth. Install four new GFP CPP hub blade seals (lubricate seals with MOLYKOTE #55 O-ring grease or equivalent).

3.7.1.8 Renew the four (4) drain plug o-rings.

3.7.1.9 Ball Retainer Seats (PN 017-33). Clean the metal to metal seated surface of all foreign matter. Lap and spot-in the seat to obtain 360 degree continuous contact between the ball and the seat.

3.7.1.10 After the retainer seat has been refaced, conduct pressure test of the four (04) ball retainer valves at 600 psi using system hydraulic oil as the test medium. Ensure that there is a manual valve and a relief valve in the hydraulic circuit to prevent overpressure. Acceptance criteria: no leakage in 10 minutes holding time. Document results via CFR.

3.8 Fit Test

3.8.1 A hub fit test must be conducted to determine if any additional work is required to re-assemble the hub. The test must be performed prior to final assembly.

3.8.2 The blades must, without link arms and without adjusting cranks, be inserted into their respective trunnion bushing in the hub one at a time while still attached to the blade lifting device.

3.8.3 Upon the completion of a fit test for each blade submit a CFR with results of test to the COR.

3.9 Reassembly.

3.9.1 The Contractor must demonstrate in the presence of the Coast Guard Inspector the proper fit of adjusting crank, drive pins, blade, and locknut for each individual blade set, per drawings, on the shop floor prior to final assembly in the CPP hub.

3.9.2 At the conclusion of any hand or machine work required to restore the flatness of the Inner

Trunnion Surface, G, (See Figure 6) on the blades and their respective crank rings, perform the following:

In the presence of the Coast Guard Inspector, conduct a blue-fit check of these mating surfaces between the crank ring and Trunnion in way of the drive pins. The locknut must be torqued similar to hub assembly procedure. Minimum allowed contact is 75%. Submit a CFR with results of blue-fit test.

3.9.3 Lock-wiring and securing wire by tack welds must be in accordance with drawing 400-WAGB

4400-25 and the notes within. Acceptable lock-wire practices are illustrated in Figure 20.

3.9.4 The COR must be notified 5 buisiness days prior to Contractor commencing final reassembly of components into the CPP hub. After all inspections and repairs have been completed, and hub internals have been cleaned, re-assemble the CPP hub in the presence of a Coast Guard Inspector. All tolerances, fits, and torque requirements must be in accordance with applicable references. Assembly check sheets in accordance with Figure 21, must be completed during the reassembly and testing of the CPP hub. The

Contractor and the COR blocks on the check sheet must be initialed at the completion of every step before work proceeds further.

3.9.5 Some crank rings have been modified to accept TWO locknut locking plates. Where configured, both must be installed.

3.9.6 Installation of the piston nut retainer, PN 017-25, must be accomplished utilizing the following procedure: After the nut, PN 017-9, has been torqued, install and torque PN 017-25 to 75ft‐lbs. Using feeler gages, verify the clearance between the retainer and the operating rod (min 0.005”). Install lock wire. See CG Drawing 400-WAGB-4400-43 for information about the piston.

3.9.7 The Contractor must use C5-A Copper anti seize on all threaded components.

3.9.8 The Contractor must use the four GFP cylinder assembly guide pins when lowering the cylinder onto the CPP hub. Guide pins temporarily thread into four of the 2-8UNC cylinder socket head cap screws (PN 019-7) holes and are removed once the cylinder is safely landed. Prior to installing the cylinder, validate freedom of movement of all internal components by physically moving the Op Rod.

3.9.9 In the presence of the Coast Guard Inspector, torque all socket head cap screws to the final torque value in a minimum three equal step process, 1000, 2000, 3000 ft/lb, following a star pattern using the

GFP HYTORC wrench.

3.10 CPP Hub Testing.

3.10.1 The Contractor must notify COR 72 hours prior to commencing filling or testing. All testing must be done in the presence of a Coast Guard Inspector or the COR.

3.10.2 All hydraulic testing must be performed using the GFP hydraulic test unit. It remains the

Contractor's sole responsibility to safely operate this equipment within the manufacturer's operating instructions. The Contractor must continuously monitor operation of tool for damage, unusual performance, or unsafe operation and notify the COR immediately in addition to submitting a CFR noting all discrepancies.

3.10.4 The Contractor must complete the post-assembly test data sheets during this completion testing

(Figure 2) to ensure that the following will happen:

3.10.4.1 Hydraulically pitch the CPP hub, full stroke, in both directions, to determine the minimum pressure required to operate the CPP hub. Sufficient test runs must be conducted to ensure repeatability of the data. There must be a minimum of two full test runs.

3.10.4.2 Once the minimum operating pressure is determined, increase the pump pressure to 250 psig and conduct a timed operation test. Sufficient test runs must be conducted to ensure repeatability of the data.

There must be a minimum of two full test runs.

3.10.4.3 The Contractor must determine the return oil pressure and return oil flow during a hard stop ahead in 100 psi increments up to 600 psi. Conduct the same test astern with 250 psi. Do not exceed 250 psi astern. Record in Figure 2.

3.10.4.4 The hub must be hydrostatically tested for external leaks at 250 PSI astern pressure using system hydraulic oil.

3.10.4.5 During the test, the Contractor must determine, by measuring, the stroke of the operating rod

(piston) from zero pitch to maximum ahead, from 0 degrees pitch to design ahead, and 3 from 0 degrees pitch to maximum ahead. Use Blade #1 pitch markings for pitch reference (Figure 3).

3.10.5 Upon completion of test drain oil from hub.

3.10.6 The drained oil from hubs and leftover oil from the test stand must be reclaimed and reinstalled using a 10-micron filter.

3.10.7 Upon satisfactory completion of testing, the Contractor must re-torque all head cap screws, using the HYTORC wrench, to the final torque value. The Contractor must tack weld external fasteners (end cap and hub cylinder bolts) with stainless steel lock-wire as per CG Dwgs 400-WAGB-4400-27 and 400-

WAGB-4400-34.

3.10.8 Polish the external surfaces of the hub and blades to a 63 micro inch RMS average finish.

3.11 Measurement.

3.11.1 After all required tests of paragraph 3.10 have been completed, the Contractor must take the following measurements in the presence of the Coast Guard Inspector. The measurement is to obtain the value of X1 as shown in Figure 3.

3.11.2 Pitch CPP hub to the design ahead position.

3.11.3 Measure and record X3 from the face of the hub to the end of the operating rod in at least 4 locations equally spaced around the hub, and calculate the average.

3.11.4 Measure and record X2 from the end of the operating rod to the end of the inner oil tube.

3.11.5 Calculate X1: X1 = X3 – X2

3.11.6 On a card, as well as on data sheet, record the following information (Figure 2):

• Hub # _________ LH or RH (circle one)

• Date

• X3(at design ahead)=

• X2 =

• X1 =

• X3 dim at hard stop astern=

• X3 dim at hard stop ahead =

• Signature of Contractor's test operator

• Signature of COR/QA Representative

3.11.7 The filled-out information card must be encased in plastic and securely fastened to the hub so that it does not fall off due to weather and/or normal CPP hub handling procedure. A duplicate copy with the measurements must be submitted via CFR.

3.12 Storage and Preparation.

3.12.1 After final tests and acceptance by the Coast Guard, the Contractor must protect the CPP hub against physical damage and contamination, and must load it back onto the shipping stand. Drain the

CPP hub completely prior to load onto the shipping stand. The CPP hub must be shipped empty of hydraulic fluid.

3.12.2 The Contractor must arrange for preparation and packaging for shipment of the CPP hub on its shipping stand. CPP hub must be oriented on stand IAW drawing 400-WAGB-T00001 to ensure blade 1 is down and to the left as viewed from the cap end while stand/hub is in the vertical install position. The

Contractor must prepare and package the CPP hub in accordance with MIL-DTL-2845E, Level A., and store the CPP hub at his facility until the shipping destination and delivery schedule is designated by the

Contracting Officer. Shipping apparatus is shown in CG Drawings 400-WAGB-4400-63, -64, -65, -72 and -73

3.12.3 Upon notice from the Coast Guard, the CPP hub Overhaul Contractor must package and transport/ship the overhauled hub assembly from their overhaul facility to a designated shipyard on the

West Coast of the US. The shipyard will then load the CPP hub and shipping stand assembly onto a truck for transport to the Contractor’s overhaul facility A shipyard point of contact will be supplied to aide and coordinate transportation details. The Coast Guard will provide at least 5 days advanced warning of desired shipping date, to allow for coordination between CPP hub Overhaul Contractor and shipyard. The

Contractor must obey all pertinent rules, regulations, and/or laws in safely and legally transporting CPP hubs along roadways to the shipyard. Any added costs for arrival delays must be borne by the

Contractor.

All figures below are shown for a single piece (one hub, one blade, one component, etc). Make as many copies as necessary to document all of the relevant pieces

Some of the figures below have multiple pages

FIGURE 1. PICTURES OF HUB U18

FIGURE 2. POLAR CPP OPERATIONAL TESTING DATA SHEET

FIGURE 3. HUB MEASUREMENTS

FIGURE 4. HUB RUNOUT AND BLADE PORT READINGS

HUB RUNOUT READINGS (OUTSIDE LOOKING IN Inspector:

Date:

BLADE PORT MEASUREMENTS Inspector:

FIGURE 5. BLADE RUNOUT

BLADE RUNOUT DATA SHEET Inspector:

FIGURE 6. BLADE TRUNNION DIAMETER & LENGTH MEASUREMENT

BLADE TRUNION DIAMETER & LENGTH MEASUREMENTS Inspector:

FIGURE 7. LINK PIN DIAMETERS

LINK PIN DIAMETERS Inspector:

OPERATING ROD END

PIN No. 90 DEGREE

POSITION

LONGITUDINAL POSITION

1 2 3 4

A

B

A

B

A

B

A

B

CRANK END

PIN No. 90 DEGREE

POSITION

LONGITUDINAL POSITION

1 2 3 4

A

B

A

B

A

B

OPERATING ROD END

PIN No. 90 DEGREE

POSITION

LONGITUDINAL POSITION

1 2 3 4

A

B

A

B

A

B

POSITION

LONGITUDINAL POSITION

1 2 3 4

A

B

A

B

A

B

OPERATING ROD END

PIN No. 90 DEGREE

POSITION

LONGITUDINAL POSITION

1 2 3 4

A

B

A

B

A

B

POSITION

LONGITUDINAL POSITION

1 2 3 4

A

B

A

B

A

B

OPERATING ROD END

PIN No. 90 DEGREE

POSITION

LONGITUDINAL POSITION

1 2 3 4

A

B

A

B

A

B

POSITION

LONGITUDINAL POSITION

1 2 3 4

A

B

A

B

A

B

FIGURE 8. SPHERICAL BEARING

Spherical Bearing Inspector:

SPHERICAL BEARING DATA SHEET

BLADE 1

LARGER SMALLER

OP-ROD END BEARING (B1A) CRANK END BEARING (B1B)

A B C A B C

0° O.D.

45° O.D.

90° O.D.

135° O.D

I.D.

BLADE 2

OP-ROD END BEARING (B2A) CRANK END BEARING (B2B)

A B C A B C

0° O.D.

45° O.D.

90° O.D.

135° O.D

BLADE 3

OP-ROD END BEARING (B3A) CRANK END BEARING (B3B)

A B C A B C

0° O.D.

45° O.D.

90° O.D.

135° O.D

BLADE 4

OP-ROD END BEARING (B4A) CRANK END BEARING (B4B)

A B C A B C

0° O.D.

45° O.D.

90° O.D.

135° O.D

FIGURE 9. ADJUSTING CRANK

ADJUSTING CRANK Inspector:

CRANK No. 1

DESCRIPTION MARK

POSITION MEASUREMENTS

AXIAL RADIAL DESIGN BEFORE AFTER

TRUNNION

BORE

A N/A

J-K

(2)

CRANK

THICKNESS

B N/A

J

7.000 6.995

(2)

K

(1)

LINK PIN BORE

C N/A

4.330 4.331

D N/A K

(1)

GAP E N/A

3.543 3.546

(1)

CRANK No. 2

DESCRIPTION MARK

POSITION MEASUREMENTS

AXIAL RADIAL DESIGN BEFORE AFTER

TRUNNION

BORE

A N/A

J-K

CRANK

THICKNESS

B N/A

(1)

LINK PIN BORE

C N/A

K

(1)

GAP E N/A

(1)

CRANK No. 3

POSITION MEASUREMENTS

AXIAL RADIAL DESIGN BEFORE AFTER

TRUNNION

BORE

THICKNESS

B N/A

(1)

LINK PIN BORE

C N/A

K

(1)

GAP E N/A

(1)

CRANK No. 4

DESCRIPTION MARK

POSITION MEASUREMENTS

AXIAL RADIAL DESIGN BEFORE AFTER

TRUNNION

BORE

THICKNESS

B N/A

(1)

LINK PIN BORE

C N/A

K

(1)

GAP E N/A

FIGURE 10. GUIDE ROD

GUIDE ROD Inspector:

FIGURE 11. OPERATING ROD

OPERATING ROD Inspector:

OPERATING ROD DIAMETERS

POSITION

DESIGN

DIAMETER

DIAMETER BETWEEN LINK PINS:

1-3 2-4

8.499

8.498

OPERATING ROD LINK PIN BORES:

BLADE No. 1 BLADE No. 2

POS.

DESIGN

MEASURE

ACTUAL MEASUREMENT ACTUAL MEASUREMENT

A B C A B C

1-3 4.330

4.331 N/A N/A

2-4 N/A N/A

3.543

3.546 N/A N/A

BLADE No. 3 BLADE No. 4

POS.

DESIGN

MEASURE

ACTUAL MEASUREMENT ACTUAL MEASUREMENT

A B C A B C

1-3 4.330

4.331

N/A N/A

2-4 N/A N/A

3.543

3.546

FIGURE 12. PISTON

PISTON Inspector:

FIGURE 13. OP ROD BUSHING

OP ROD BUSHING Inspector:

FIGURE 14. HUB & CYLINDER SPIGOT

HUB & CYLINDER SPIGOT

Inspector:

FIGURE 15. CYLINDER, INCLUDING O-RING DEPTH

CYLINDER

FIGURE 16. LINK ARMS

LINK ARMS Inspector:

FIGURE 17. DRIVE PIN MEASUREMENTS

DRIVE PIN MEASUREMENTS

FIGURE 18. THREAD PITCH DIAMETER

THREAD PITCH DIAMETER MEASUREMENTS Inspector:

FIGURE 19. DOWEL PINS AND BORES OP RODS

DOWEL PIN & BORE MEASUREMENTS Inspector:

FIGURE 20. LOCKWIRE ARRANGEMENTS

FIGURE 21. ASSEMBLY CHECK SHEET

HUB # .

ASSEMBLY CHECK SHEET

POLAR CLASS CONTROLLABLE PITCH PROPELLER ASSEMBLY

Contractor USCG

I. Cleanliness Satisfactory?

A. Before Assembly Commences

B. After Installation of Blades

C. Before Cylinder Installation

D. At Assembly Completion

II. Blade to Hub Assembly

A. Verify Installation of Check Valves

B. Crank Ring and Nut Prefitted

1. Blade #1

2. Blade #2

3. Blade #3

4. Blade #4

C. “O” Ring Contact Surfaces Polished

1. Blade #1

2. Blade #2

3. Blade #3

4. Blade #4

D. “O” Ring Installed Properly

1. Blade #1

2. Blade #2

3. Blade #3

4. Blade #4

E. Trunnion Nut Secured and Lockwired

1. Blade #1

2. Blade #2

3. Blade #3

4. Blade #4

III. Blade Operating Mechanism Assembly

A. Link Pins Installed and Locked Correctly

1. Blade #1

a) Crank Ring

b) Cross Head

2. Blade #2

a) Crank Ring

b) Cross Head

3. Blade #3

a) Crank Ring

b) Cross Head

4. Blade #4

a) Crank Ring

b) Cross Head

ASSEMBLY CHECK SHEET (CONTINUED)

B. Guide Flange Bolts coated Prior to Install

C. Guide Flange Installed Correctly

D. Verify Renewal of Guide Rod O-rings

E. Inner Oil Tube & O-ring installation correct

F. Control Rod/Crossead Orientation Correct

G. Piston Installation, Doweling and Lockwire Correct

H. Piston Ring Installation Correct

I. Cylinder Installation Correct

J. Securing of Cylinder Screws & Nuts

1. (3600 FT-LBS, 6000psi hytorq)

IV. Hydraulic Testing @ 600 psi

A. Full Stroke, No Binding

B. No Leaks, Cylinder Joint Guide Rod Nuts

C. No Blade Seal Leaks Visible

1. Blade #1

2. Blade #2

3. Blade #3

4. Blade #4

D. Plot of Pitch vs Pressure OK?

E. Hydraulic Test Satisfactory & Complete

V. D ½ Operating Rod

A. Verify Cleanliness

B. Verify Op Rod Bushing Lubricated

C. Verify Oil Manifold Attached, Lockwired, Clean

1. See detail SECT A-A on 400WAGB 4400-31

D. Make Note of Blade Number Oil Manifold Aligned

1. (i.e. U17, B4)

FIGURE 22. SUMMARY SHEET

SUMMARY SHEET Inspector:

BEFORE REPAIRS/OVERHAUL

Blade No.

OUTER PORT INNER PORT

POS TRUNNION

DIA.

BEARING

BORE

GAP POS TRUNNION

DIA.

BEARING

BORE

GAP

(DESIGN MEASUREMENT) (DESIGN MEASUREMENT)

23.000

22.998

23.005

23.006

0.005

0.008

13.000

12.998

13.006

13.007

0.006

0.009

0° 0°

90° 90°

0° 0°

90° 90°

0° 0°

90° 90°

0° 0°

90° 90°

AFTER REPAIRS/OVERHAUL

Blade No.

OUTER PORT INNER PORT

POS TRUNNION

DIA.

BEARING

BORE

GAP POS TRUNNION

DIA.

BEARING

BORE

GAP

(DESIGN MEASUREMENT) (DESIGN MEASUREMENT)

23.000

22.998

23.005

23.006

0.005

0.008

13.000

12.998

13.006

13.007

0.006

0.009

0° 0°

90° 90°

0° 0°

90° 90°

0° 0°

90° 90°

0° 0°

90° 90°

24501_BJA_0124_40024501_JPH_0511_400

WORK ITEM 2: Controllable Pitch Propeller (CPP) Trunnion, Overhaul

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to repair one propeller blade trunnion with weld overlay and machining the surfaces to original dimensions

NOTE

Invoking this work item will also require new bushings (Work Item 7) and possibly new drive pins (Work Item 5)

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

400-WAGB_4400_5, Rev -, CPP LH Propeller Blade:

400-WAGB_4400_6, Rev -, CPP RH Propeller Blade Design

400-WAGB_4400_7, Rev -, CPP LH Propeller Blade Design

400-WAGB_4400_27, Rev -, CPP Right Hand Hub Assembly (Elev Section-Side Profile)

400-WAGB_4400_28, Rev -, CPP Right Hand Propeller Blade

400-WAGB_4400_33, Rev -, CPP RH Propeller Blade Design

400-WAGB_4400_34, Rev -, CPP 69 Inch Dia LH Prop Hub Assy (Elev Sect)

400-WAGB_4400_35, Rev -, CPP LH Propeller Blade

400-WAGB_4400_40, Rev -, CPP Left Hand Propeller Blade Design

400-WAGB_4400_47, Rev -, CPP List of Material

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2022, Welding and Allied Processes

OTHER REFERENCES

American Bureau of Shipping, Generic Rules for Classification, Materials and Welding and

Survey After construction – Part 2, Rules for Materials and Welding, January 2024

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Technical Representative.

Not applicable.

3.1.3 Protective measures. The Contractor shall furnish and install suitable covering to seal off and protect all non-affected surfaces/equipment and spaces in the vicinity of the work area against contamination during the performance of work. Upon completion of work, remove protective material and inspect for the presence of contamination. Clean all equipment and spaces, contaminated due to improper protection, to original condition of cleanliness.

3.1.3.1 Cleanliness is of the utmost importance in hydraulic systems. The Contractor shall ensure that cleanliness standards are maintained in accordance with ISO Cleanliness Code of

17/14 per ISO 4406 during all phases of work.

3.1.4 Interferences. The Contractor shall handle all interferences in accordance with SFLC Std

Spec 0000, paragraph 3.3.5 (Interferences).

3.2 Trunion Restoration. Restore all surfaces of the trunnion from the o-ring sealing surface to the trunnion end as shown in Figure 1, including the locknut threads, to the standards shown in

CG Drawing 400-WAGB-4400-28 (right hand propeller blade) and 400-WAGB-4400-35 (left hand propeller blade). Excavate the metal to eliminate scratches,fretting damage, disruptions, surface irregularities and defects up to 0.050 inches, weld overlay to build material up…