Spec.doc

AMERICAN AERO

OCEANMASTER CG300 MARINE CRANE

SPECIFICATIONS FOR OVERHAUL

Commander (v) Maintenance and Logistics Command, Atlantic 300 E. Main Street, Suite (600) Norfolk, VA 23510-9102

TABLE OF CONTENTS

Work Item Title Page iiList of Sketches

Revisions ReCOTRd iii List of Applicable References iv List of Government-furnished Property vi List of Critical Inspection Items vii General Requirements Principal Characteristics Overhaul Oceanmaster CG300 Marine Crane Upperworks Overhaul GFE Box and Components Inspect and Renew Hydraulic System Components Overhaul Boom

List of Sketches

Work

Item Sketch Number Page

This section is not applicable to this package.

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.

NOTE: All work item numbers, page numbers, paragraph numbers, etc listed above for a given revision Correspond to what they were in the previous revision. This revised specification is self-contained with all of the above listed changes incorporated.

List of Applicable References

The following documents form a part of this specification to the extent specified herein. Specific approval dates and the dates of any applicable amendments and revisions are identified by the below listing and are applicable to all parts of this specification to the extent specified herein. All required documents maintained by the Coast Guard and listed in this specification are not marked with approval dates and dates of all amendments and revisions. They are, however, marked with approval dates or amendment dates or revision dates that specifically or uniquely identify them in the Coast Guard. The 2001 Edition, dated Sept. 12, 2001, is the applicable version for MLCA Standard Specifications referenced herein. Electronic versions of MLCA Standard Specifications are available on the Internet and may be found by utilizing the following Internet Uniform Resource Locator (URL) address: http://www.uscg.mil/mlclant/vdiv/standard_specs/default.htm. Refer to section L of the contract documents, Instructions, Conditions and Notices to Bidders for guidance in obtaining copies of documents referenced herein.

Order of precedence. In the event of conflicts between text of this specification and the applicable references cited herein, order of precedence shall be in accordance with MLCA Standard Specification 0000_STD, paragraph 3.2 (Order of precedence), unless otherwise specified by the Contracting Officer (KO). The Contractor shall immediately notify the Contracting Officer in writing of any perceived conflicts contained herein. Nothing in these documents, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

FEDERAL AND MILITARY SPECIFICATIONS AND STANDARDS

MIL-C-81309, Nov 1997, Corrosion Preventive Compounds, Water Displacing, Ultra-Thin Film

MIL-PRF-16173, Jan 1993, Corrosion Prevention Compound, Solvent Cut-back, Cold-Application

DOCUMENTS

Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0000_STD, 2001 Edition, General Requirements

Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0740_STD, Welding and Allied Processes, 2001 Edition

Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 6300_STD, 2001 Edition, Preserve Ship Structures

DRAWINGS

Coast Guard Drawing FL 9210-1, Rev -, Fleet Weatherford Marine CG 300 Crane

PUBLICATIONS

Coast Guard Technical Publication (TP) 1952-A, Construction Crane, Oceanmaster CG300

Caterpillar/Perkins, Series 1106 Engine Service Manual, 8 April 2003

INDUSTRY STANDARDS

American Society for Testing and Materials (ASTM) E1003, Reapproved 2000, Standard Test Method for Hydrostatic Leak Testing

American Society for Testing and Materials (ASTM) E114, Reapproved 2001, Standard Practice for Ultrasonic Pulse-Echo Straight-Beam Examination by the Contact Method

American Society for Testing and Materials (ASTM) E1417, 1999, Standard Practice for Liquid Penetrant Examination

American Society for Testing and Materials (ASTM) E1444, 2001, Standard Practice for Magnetic Particle Examination

American Society for Testing and Materials (ASTM) E165, 2002, Standard Test Method for Liquid Penetrant Examination

American Society for Testing and Materials (ASTM) E587, 2000, Standard Practice for Ultrasonic Angle-Beam Examination by the Contact Method

American Society for Testing and Materials (ASTM) E709, 2001, Standard Guide for Magnetic Particle Examination

National Fire Protection Association (NFPA), 306, 2001 Edition, Standard for the Control of Gas Hazards on Vessels 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.

($/UNIT)

*Government-loaned Property which shall be returned to the vessel upon completing the availability.

**Government-furnished property for which the Government reserves the right to provide as indicated in the work item.

***Government-furnished property which is to be supplied by either the vessel or local Electronics Maintenance Division.

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 MLCA Standard Specification 0000_STD, paragraph 3.11 (Reports)):

Work Item Title

This section is not applicable to this package.

00000N_FLT (24 Aug 2003)

General Requirements

1. SCOPE

1.1 Scope. This item describes the general requirements to be followed by the Contractor while conducting this availability.

2. APPLICABLE DOCUMENTS

Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0000_STD, 2001 Edition, General Requirements

Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0740_STD, 2001 Edition, Welding and Allied Processes

Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 6300_STD, 2001 Edition, Preserve Ship Structures

American Society for Testing and Materials (ASTM), D3951, 10 Nov 1998, Standard Practice for Commercial Packaging

National Fire Protection Association (NFPA), 306, 2001 Edition, Standard for the Control of Gas Hazards on Vessels

The Society for Protective Coatings (SSPC)/NACE International 2000 Edition, Joint Standard VIS 4/NACE No. 7, Visual Reference Photographs for Steel Cleaned by Waterjetting

The Society for Protective Coatings (SSPC)/NACE Int’l, Joint Surface Preparation Std SSPC-SP 12/NACE No.5, 2002, Surface Prep and Cleaning of Steel and Other Hard Materials by High and Ultrahigh-Pressure Water Jetting Prior to Recoating

3. REQUIREMENTS

3.1 General. The Contractor shall conform to all requirements specified in Std Spec 0000_STD and in this item, as applicable, during the performance of this availability.

NOTICE!

The requirements of paragraph 3.1 (General) apply not only to all work under the scope of this contract, whether explicitly stated in work items or not, but also to all other work subsequently authorized by changes, modifications, or extensions to the contract.

3.2 Gas-freeing requirements. The Contractor shall certify all spaces and components “ATMOSPHERE SAFE FOR WORKERS” and “SAFE FOR HOT WORK”, as applicable, in accordance with NFPA 306, in lieu of what is specified in Std Spec 0000_STD, paragraph 3.4 (Gas-freeing). Be aware that work necessary to certify spaces and components includes, but is not limited to opening, ventilating, cleaning, and maintaining the safe conditions for the duration of the work being performed.

3.3 Welding and brazing requirements.

3.3.1 General. The Contractor shall accomplish all welding and allied processes, including non-destructive testing (NDT), in accordance with Std Spec 0740_STD and the following deviations:

· Disregard paragraph 20.1.3.2 of Appendix A (Commercial Welding Standards).

· Replace paragraph 20.2.2 of Appendix A (Commercial Welding Standards) with the following:

20.2.2 Prequalified welding procedures. The Contractor shall not use welding procedures identified by AWS as “Prequalified Welding Procedure Specifications” on critical welds. For these noted critical applications, all weld procedures must be qualified by testing in accordance with the chosen regulatory code.

3.3.2 Weld inspection. When inspecting welds using visual inspection (VT), liquid penetrant inspection (PT) and magnetic particle inspection (MT); the weld surface should be clearly visible, i.e. free of paint, grease, etc.

3.3.3 Electronic equipment protection. The Contractor shall work with the COTR to safeguard electronic equipment before welding to prevent damage from stray current and electromagnetic interference. Electrically isolate or disconnect ungrounded or sensitive equipment as necessary. Locate all welder ground connections as close to the work area as possible.

3.4 Quality assurance requirements for preservation of “critically-coated” surfaces.

3.4.1 Inspection form submission. When preserving surfaces deemed “critically-coated” surfaces, as defined in Std Spec 6300_STD, and revised below in paragraph 5.1 (Critically-coated surfaces)), the Contractor shall complete all applicable Quality Assurance (QA) Inspection Forms provided in Std Spec 6300_STD. Submit the completed forms to the COTR upon completion of work.

3.4.2 Soluble salt level or conductivity measurements. In addition, as part of the preservation of “critically-coated” surfaces, with the exception of potable water tanks, the Contractor shall measure soluble salt levels or conductivity due to soluble salts, randomly over the prepared surfaces (take 5 measurements every 1,000 ft2, or 5 total measurements for surfaces less than 1,000 ft2), using a suitable surface contamination analysis equipment. If levels of soluble salts or conductivity due to soluble salts exceed the requirements specified in Table I (Soluble Salt Threshold), wash down the affected areas, using fresh water at a pressure of 2000-3000 psi, paying particular attention to crevices, pits, welds, and reverse faces of beams. Remove all standing water and dry all affected areas, as applicable. Repeat testing and wash down procedures, until satisfactory levels are obtained.

TABLE I. SOLUBLE SALT THRESHOLD.

(microgram/cm2)

CONDUCTIVITY

(microsiemens/cm)

4. QUALITY ASSURANCE

4.1 Operational testing. The Contractor shall thoroughly test and prove satisfactory all disturbed shipboard equipment, in accordance with Std Spec 0000_STD, paragraph 3.20 (Operational testing) and 5.2 (Equipment operation).

5. NOTES

5.1 Critically-coated surfaces. Critically-coated surfaces are defined as follows:

· All surfaces exposed to salt contamination.

Principal Characteristics

American Aero Oceanmaster CG300 Marine Crane

I. Crane

Design Max. Boom Length:

70’

Standard Boom Length:

60’

Extension Lengths 10’/20’

Height (turntable base to top of gantry):

11’

Length:

10’ 6”

Width 9’ 3”

Tail Swing (from center line of turntable):

7’ 4”

Vertical Center of Gravity (above the pedestal ring):

3’ 7-7/8”

Gross Weight (lbs.)

II. Prime Mover

Manufacturer:

Caterpillar/Perkins

Model:

Series 1100, Model VK

Size:

365 Cu. In.

Rated:

150 BHP @ 2500 RPM

III. Pumps Type:

Commercial, 3-Stage

Pressure:

2800 PSI (Max.)

Overhaul Oceanmaster CG300 Marine Crane Upperworks

1. SCOPE

1.1 Scope. This work item describes the requirements for the Contractor to overhaul the Upperworks for the Oceanmaster CG300 Marine crane.

2. APPLICABLE DOCUMENTS

Coast Guard Drawing FL 9210-1, Rev -, Fleet Weatherford Marine CG 300 Crane

Coast Guard Technical Publication (TP) 1952-A, Construction Crane, Oceanmaster CG300

Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0740_STD, Welding and Allied Processes, 2001 Edition

Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 6300_STD, 2001 Edition, Preserve Ship Structures

Caterpillar/Perkins, Series 1106 Engine Service Manual, 8 April 2003

American Society for Testing and Materials (ASTM) E114, Reapproved 2001, Standard Practice for Ultrasonic Pulse-Echo Straight-Beam Examination by the Contact Method

American Society for Testing and Materials (ASTM) E165, 2002, Standard Test Method for Liquid Penetrant Examination

American Society for Testing and Materials (ASTM) E587, 2000, Standard Practice for Ultrasonic Angle-Beam Examination by the Contact Method

American Society for Testing and Materials (ASTM) E709, 2001, Standard Guide for Magnetic Particle Examination

American Society for Testing and Materials (ASTM) E1417, 1999, Standard Practice for Liquid Penetrant Examination

American Society for Testing and Materials (ASTM) E1444, 2001, Standard Practice for Magnetic Particle Examination

3. REQUIREMENTS

3.1 General. The Contractor shall overhaul the cab equipment for the Oceanmaster CG300 Crane (by American Aero), in accordance with TP 1952-A, and as specified herein.

3.2 Rip-outs and removals. The Contractor shall:

3.2.1 Rip-outs. Remove and dispose of the following cab assembly components shown on Coast Guard Fleet Drawing FL-9210-1 and the drawings in TP 1952-A:

· Fluid filters, strainers, and associated mounting hardware.

· Flex hoses.

· Cab controls: operators console assembly, meters and gauges, associated wiring, breaker panels, cabling, battery charger (if applicable), and mounting brackets/harnesses.

· Diesel engine and associated components, including the hot starts, flanged exhaust flex pipe (3-inch stainless steel), muffler, engine mounts, and associated mounting hardware.

· seat assembly and associated mounting hardware.

3.2.2 Removal, cleaning , and inspection. Remove, disassemble, clean, and inspect all other cab assembly components shown on Coast Guard Fleet Drawing FL-9210-1 and the drawings in TP 1952-A and submit a written condition found report to COTR within 24 hours after the inspection. These components include but are not limited to:

· Navigation Light Mast (if applicable).

· All slewing gear, gear-box, and associated components.

· All hydraulic winches, pumps, heat exchanger, associated piping, valves, and fittings.

· AC unit (include any repair recommendation in CFR).

· Electric swivel assembly

· Load cell, load cell gauge, and associated components.

NOTICE!

For cranes with load cell gauge mounted outside of the crew cab, remove gauge from mounting bracket on boom base post. Crop gauge mounting bracket from boom and grind flush all welds.

· All doors (operator cab & access spaces), cab windows, and associated mounting hardware.

· Cab deck plates

· Ball ring and associated components.

· All pins, sheaves, keepers, shafts, plates, spacers, rollers, and associated mounting hardware.

3.3 Nondestructive inspection. The Contractor shall nondestructively inspect the following components and surfaces using either the ultrasonic (UT), magnetic particle (MT), or liquid penetrant (PT) inspection method. UT inspect in accordance with ASTM E114 and ASTM E587. MT inspect in accordance with ASTM E709 and ASTM E1444. PT inspect in accordance with ASTM E165 and ASTM E1417. Submit a written condition found report, including any recommended repairs, to the COTR within 24 hours of completing the inspection.

· All winch foundations.

· All boom pins and pin-holes.

· Ratchet and pawl assembly foundation and pins.

· Lifting eyes of crane upper works.

· All sheave foundations.

· Boom foot mount.

3.4 Navigation light mast bracket modification. Fabricate and fit three stuffing tubes, stanchion brackets and supports so that the cab will be suitable for either cutter class application (WLIC 75 or WLIC 160). Perform all welding and non-destructive testing (NDT) in accordance with Std Spec 0740_STD.

3.5 Fuel and hydraulic tank cleaning. The Contractor shall clean the following tanks until all areas are free of grease, oil, flux, scale, dirt, loose particles or loose Corrosion products, and any other contamination foreign to the base material.

Type of tank Capacity Cleaning

(gallons) (Method)

Fuel Oil Supply Hot Water Hydraulic Steam

3.6 Component renewal and installations. Renew all tank internal filters, filler caps, drain, ball valve, 1½” fuel oil fill pipe, hydraulic tank sight glass, and fuel oil tank float, prior to closing the tanks. Renew all crane cab controls, operator’s seat, and insulate cab in accordance with ANSI and API standards.

3.7 Door overhaul. The Contractor shall overhaul the designated doors and associated door frames, as shown on Drawings CG3002B and CG3002B1 contained in TP 1952-A, in accordance with the door manufacturer’s instructions.

Part Number Size (inches)

Description

80607 26” x 66”, Steel, Operator’s Access Door

2-dog, RH with renewed oval window

80609 24” x 30”, Steel, Engine Compartment Door

1-dog, LH

80608 20” x 30”, Steel, Hydraulic Machinery

2-dog, LH Compartment Door

80609 24” x 30”, Steel, Hydraulic Machinery

1-dog, LH Compartment Door

80609 24” x 30”, Steel, Heat Exchanger/Radiator

2-dog, LH Access Door

3.8 Propulsion engine performance verification/inspection. The Engine shall be inspected and placed on dynamometer pass manufacturer performance requirements, provide CFR to the COTR.

3.9 Hydraulic Oil Heat Exchanger (P/N # 480058). The Contractor shall perform Backflushing, per subsection 3.4 (Backflushing) and as follows:

3.9.1 Reassembly. Reassemble the heat exchangers to their original configurations, with new gaskets, mounting hardware, and fasteners.

3.9.2 Fill jacket water cooling systems. For testing, refill the jacket water cooling systems with a mixture of distilled water, anti-freeze and/or Corrosion inhibitor, as specified by the Coast Guard Inspector.

3.10 Ball ring overhaul. The Contractor shall disassemble, clean, inspect, and reassemble the ball ring assembly, shown on Drawing CG300-6-80 (Assembly Bearing), in accordance with TP 1952-A, and as specified herein.

3.10.1 Nondestructive inspection. The Contractor shall nondestructively inspect on all other ball ring components, including the spacer ring, using either the ultrasonic (UT), magnetic particle (MT), or liquid penetrant (PT) inspection method. UT inspect in accordance with ASTM E114 and ASTM E587. MT inspect in accordance with ASTM E709 and ASTM E1444. PT inspect in accordance with ASTM E165 and ASTM E1417. Submit a written condition found report, including any recommended repairs, to the COTR within 24 hours of completing the inspection.

3.10.2 Reassembly. When authorized reassemble the ball ring assembly.

3.10.3 Final reinstallation. After final inspection, the Contractor shall reinstall the ball ring assembly with new bolts and Type 316L Stainless Steel washers, which must be “Sharpie Tested”, in accordance with TP 1952-A (Bolt Torque and Installation Procedure).

3.11 Boom stops. The Contractor shall overhaul and lubricate two boom stop assemblies, in accordance with TP 1952-A, and as specified herein. Cut a notch on both sides of the boom stop bases so that the boom stop clears the new operator cab when lowered to 0 degrees and the topping lift wire rope clears on the other side.

3.12 Calibrate meters and gages. The Contractor shall provide qualified technicians, portable instrument standards and all necessary equipment to calibrate all meters and gauges identified below, shown in TP 1952-A. The Contractor shall remove the meters and gauges from the crane to a shore-side calibration facility. If this is done the Contractor shall exercise extreme care in transporting and reinstalling the meters and gauges to ensure they remain in calibration.

NOTICE!

Meters and gauges may be portable or permanently mounted in control panels.

Meter/Gauge Servicing Range Pressure Main and Whip 0-3000 psig Pressure Boom Hoist 0-3000 psig Pressure Slewing(Swing) Drive 0-3000 psig Temperature Lube Oil 100-220 deg. F Level Fuel Oil (E)mpty - (F)ull Pressure Lube Oil 5-100 psig Temperature Engine Jacket Water 100-265 deg. F Ammeter Electrical -30 - +30 Amps Tachometer/Hour Engine RPM/Hours

0-4000 RPM/HR.

3.12.1 Post-calibration. After calibration, the instruments must perform within the manufacturer's original specifications for accuracy over the entire range for that instrument.

3.12.1.1 Failure. Those that fail to meet this requirement shall be disassembled, cleaned, adjusted, reassembled with new gaskets, and calibrated again at a shoreside calibration facility. At no additional cost to the Government, the Contractor may, renew and test gauges designated for repair.

3.12.2 Standards. The Contractor shall calibrate meters and gauges using standards whose calibration is certified as being traceable to the National Standards and as follows:

3.12.2.1 Derivation. These calibration standards must have been derived from accepted values of natural physical constants or by the ratio type of self-calibration techniques.

3.12.2.2 Support. Support all Contractor-used standards by certificates, reports, or data sheets attesting the date, accuracy, and environmental or other conditions under which the furnished results were obtained. Certificates or reports from other than the National Bureau of Standards shall attest the comparison of the standards used, to the National Standard, at planned intervals, either directly or through a controlled system using the above methods.

3.12.2.3 Accuracy level. Utilize standards which have an accuracy level at least four times that of the instrument being calibrated.

3.12.3 Labeling. Affix a calibration label to the face (over the calibration screw, if so equipped) of the instrument successfully calibrated. The label installed shall remain legible for the entire calibration period and shall indicate the calibration date, the re-calibration date (re-calibration due date shall be two years unless otherwise notified by the Coast Guard Inspector), and the code or initials of the calibrating individual.

3.12.4 Certificate. Provide a certificate of calibration for each instrument that includes the date, manufacturer, model and serial number, full name of the individual performing the calibration, and the traceability number of the standard used in the calibration.

3.12.5 Report. Provide a written report listing each instrument on the crane that was calibrated with its nomenclature, manufacturer, model and serial number, date of calibration, and specific location on the vessel.

3.13 Upper-works preparation. The Contractor shall:

3.13.1 Cab preparation. Prior to surface preparation, remove visible oil, grease, soil, soluble welding residues, and salts from the surfaces.

3.13.2 Surface preservation. The Contractor shall prepare and coat all upper-works surfaces in accordance with Std Spec 6300_STD, using the coating system specified in Table IA (Exterior Coating Systems) for “Machinery Exposed To Weather, Option I”. Select spar (10371) as the top coating color.

3.14 Reassembly. After all authorized repairs, the Contractor shall reassemble the Upper-works assembly to the original configuration in accordance with TP 1952-A.

3.14.1 Renew all gaskets, O-rings, seals, plugs, cotter pins, and fasteners during reassembly.

WARNING!

ALL Winch Mounting Bolts are Grade 8 bolts.

3.14.2 Renew, tag, and test all flex hose assemblies.

3.14.3 Renew winch control assemblies.

3.14.4 Renew and label all electrical panels and their associated equipment as required, provide CFR to COTR.

3.14.5 Renew operator cab seat as needed, provide CFR to COTR.

3.14.6 Lubricate all moving components as required with manufacturer's recommended lubricants.

3.15 Failure responsibility. If any inspection or test fails to meet the requirements herein, the Contractor shall take corrective procedures and/or furnish materials to correct each deficiency.

4. QUALITY ASSURANCE

No additional requirements.

5. NOTES

This Section is not applicable to this work item.

Overhaul GFE Box and Components

1. SCOPE

1.1 Scope. This work item describes the requirements for the Contractor to overhaul a designated GFE Box and associated components.

2. APPLICABLE DOCUMENTS

Coast Guard Technical Publication (TP) 1952-A, Construction Crane, Oceanmaster CG300

Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 6300_STD, 2001 Edition, Preserve Ship Structures

MIL-PRF-16173, Jan 1993, Corrosion Prevention Compound, Solvent Cut-back, Cold-Application

MIL-C-81309, Nov 1997, Corrosion Preventive Compounds, Water Displacing, Ultra-Thin Film

American Society for Testing and Materials (ASTM) E1003, Reapproved 2000, Standard Test Method for Hydrostatic Leak Testing

3. REQUIREMENTS

3.1 GFE Box. The Contractor shall remove GFE Box components, overhaul/renew components and box, and reinstall the components in the box as specified herein and the Contract Line Items (CLINs) specified in the SECTION B of this specification.

3.2 Disassembly. Upon receipt of the GFE Box at the Contractor’s facility, the Contractor shall do the following:

3.2.1 Open the GFE Box and compare contents to the “USCG CG-300 GFE Parts” listing provided with the GFE Box, in the presence of the Coast Guard Inspector.

3.2.2 Remove all components from the GFE Box.

3.3 Load cell gauge. When authorized, the Contractor overhaul the load cell assembly in accordance with TP 1952-A (Load Cell Maintenance), and the requirements herein.

3.3.1 Label. The Contractor shall affix a calibration label to the face of the load cell gauge. The label shall be able to remain legible for the entire calibration period and shall indicate the following:

3.3.1.1 The calibration date.

3.3.1.2 The re-calibration due date (one year unless otherwise notified by the Coast Guard Inspector).

3.3.1.3 Code or initial of the calibrating individual and name of company.

3.3.2 Certificate. The Contractor shall provide a certificate of calibration for the load cell gauge which shall include the date, manufacturer, model, serial number, and the full name of the individual & company performing the calibration.

3.4 Swing drive overhaul. The Contractor shall overhaul, lubricate, and test the swing drive assembly, shown in Figures 1 and 2 below, in accordance with the requirements herein.

Figure 1

Figure 2

3.5. Furnish swivel assembly. When authorized by the KO, the Contractor shall furnish a new, 10-conductor, 50 amp for 110VAC Swivel, similar to the one removed.

3.6 Winch overhaul. The Contractor shall overhaul and test the hydraulic winch assemblies, in accordance with TP 1952-A, (Winches) and as follows:

3.6.1 Type. Braden Winch, PD12C Series Planetary Winches. Three types:

· Two (2) regular.

· One (1) counterbalance.

· One (1) ratchet & pawl.

· Winch Motor

· All steel discs

· Cam clutches

· All friction discs

· Needle valves

· Mounting bolts

· Two speed solenoid valve

3.6.2 Inspections and testing. Contractor shall perform a dynamic load test to rating (12,000 lbs) and provide tag.

3.6.3 Winch assembly non-working surface preservation. The Contractor shall prepare and coat all upper-works surfaces in accordance with Std Spec 6300_STD, using the coating system specified in Table IA (Exterior Coating Systems) for “Machinery Exposed To Weather, Option I”. Select spar (10371) as the top coating color.

3.6.4 Winch assembly working surfaces preservation. Coat all working surfaces, which includes the winch drum, with Solvent Cutback Corrosion Preventative Compound, conforming to MIL-PRF-16173, Type II, Grade 3, or Thin Film Corrosion Preventative Compound, conforming to MIL-C-81309, Type II, Class I.

3.6.5 Label plate. The Contractor shall provide and install an anodized-hydrated aluminum label plate on the tested winch assembly. The label plate shall state the date of overhaul, date of operational and weight test, and name of the Contractor performing the overhaul and test.

3.7 Valve overhaul. The Contractor shall overhaul the below listed hydraulic control valves for the Oceanmaster CG300 Crane by American Aero, in accordance with TP 1952-A, and as specified herein. Each valve consists of a control valve portion and a relief valve portion.

Valve Part/Drawing No.

Two-Speed Control Valve 488289-001 Dual Main and Whip Line Control Valve 480585 Slewing Drive Control Valve 480917 Boom Hoist Control Valve 480432

3.7.1 Disassemble and inspect. Completely disassemble each valve, match and mark all components, and visually inspect all parts for defects and deterioration. Submit a written report of all findings and recommendations to the COTR within 24 hours after inspecting.

3.7.2 Component renewals. Renew the following components, per the valve manufacturer’s recommendations:

· O-Rings and backup rings.

3.7.3 Reassembly. Reassemble each valve.

3.7.4 Tests. The Contractor shall perform the following test:

3.7.4.1 Hydrostatic test. Hydrostatically test each relief valve to its’ rate test pressure, using system fluid in accordance with ASTM E1003. After a satisfactory hydrostatic test, perform a lifting test on each relief portion of the valve, listed in 3.1 herein. Each valve shall seat cleanly after pressure relief without simmering. The test shall be accomplished using the appropriate test media. The Contractor shall adjust the relief pressure as necessary to obtain the specified lifting pressure. After adjustment, the Contractor shall perform a final test to confirm each relief valve's lifting pressure.

3.7.5 Coating. After all authorized repairs and tests are completed, the Contractor shall prepare and coat the valve exterior surfaces in accordance with the manufacturer’s recommended procedures.

3.7.6 Documentation. The Contractor shall attach a copper tag (1-inch by 2-inches by 1/16-inch) with wire to each valve, engraved with 1/8-inch letters stating valve number, test pressure, flow rate, date of test, and name of testing facility. The Contractor shall certify in writing for each valve tested the date of the test, test pressure, and place of test; a separate letter shall be provided to the COTR for each valve tested within 72 hours of the completion of the test.

3.8 New hydraulic pump. The Contractor shall furnish a new three-stage hydraulic pump (P/N 483305-084) for the Oceanmaster CG300 Crane by American Aero, shown in TP 1952-A, with new mounting hardware.

3.9 Component reinstallation. After overhauling and/or renewing the components and GFE Box, the Contractor shall install the components, in their proper locations using new Type 316L Stainless Steel fasteners. Fill out and sign the “GFE Parts” listing and provide the original and one (1) copy to the COTR.

3.10 Pre-shipment inspection. The Contractor shall conduct a pre-shipment inspection of the GFE Box and installed components, in the presence of the COTR/Coast Guard Inspector, to verify all components are installed and in “A” Condition.

3.11 Secure GFE Box. The Contractor shall secure the GFE Box lid to the box, using new, Type 316L Stainless Steel Fasteners and rubber Tie-downs.

4. QUALITY ASSURANCE

4.1 Winch operational and weight test. The Contractor shall install each hydraulic winch on a test rig and perform a dynamic load test of (12,000 pounds)prior to installing them in the GFE Box.

· Suspend the static load from a rope attached to the winch drum for 10 minutes and verify the brake holds without slipping.

· Raise and lower the dynamic load a minimum of 10 feet through 3 complete cycles using a rope attached to the winch drum.

· Raise and lower the working load a minimum of 10 feet through 10 complete cycles using a rope attached to the winch drum.

5. NOTES

5.1 Documentation. A copy of the signed “GFE Parts List” will be included in the GFE Box, along with the Load Cell Calibration Certification, in a reusable, waterproof sleeve.

Inspect and Renew Hydraulic System Components

1. SCOPE

1.1 Scope. This work item describes the requirements for the Contractor to renew designated components for the Oceanmaster CG300 Marine crane hydraulic system.

2. APPLICABLE DOCUMENTS

Coast Guard Technical Publication (TP), 1952, Construction Crane, Oceanmaster CG300

3. REQUIREMENTS

3.1 Inspection. The Contractor shall inspect all system hydraulic components and submit a written condition found report to COTR within 24 hours after the inspection.

3.2 Renew hydraulic components. Once a change request has been released by the COTR, the Contractor shall renew the designated hydraulic components listed in TP 1952-A (pages 226 through 228 “Hydraulic Fittings, Adapters, Flanges, Etc.” and “U.S.C.G. Hose List”).

4. QUALITY ASSURANCE

No additional requirements.

5. NOTES

This section is not applicable to this work item.

WORK ITEM 1: Overhaul Boom

1. SCOPE

1.1 Scope. This work item describes the requirements for the Contractor to overhaul the boom.

2. APPLICABLE DOCUMENTS

Coast Guard Technical Publication (TP) 1952, Construction Crane, Oceanmaster CG300

Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 6300_STD, 2001 Edition, Preserve Ship Structures

3. REQUIREMENTS

3.1 The Contractor shall perform American Aero Quality Control Procedure (QCP) #12.11 Rev 6 in Part 4 (Operations and Maintenance Addendum) of TP 1952-A and submit a written condition found report to the COTR within 24 hours after completing the inspection.

3.2 After a change request has been released by the COTR, the Contractor shall perform all designated weld repairs and non-destructive testing (NDT) in accordance with Std Spec 0740_STD.

3.3 Surface preservation. The Contractor shall prepare and coat the boom surfaces in accordance with Std Spec 6300_STD, using the coating system specified in Table IA (Exterior Coating Systems) for “Machinery Exposed To Weather, Option I”. Select spar (10371) as the top coating color.

4. QUALITY ASSURANCE

No additional requirements.

5. NOTES

This section is not applicable to this work item.

(March 16, 2009 Rev 0)