Hydraulic Winch Overhaul Spec.doc

Spec

5/19/22

REVISION No. 1

Date:

SPECIFICATION FOR THE OVERHAUL OF HYDRAULIC WINCHES FOR U.S. COAST GUARD CUTTERS

SPECIFICATION NUMBER

R-573-2036 ORIGINATED BY: Charles D. Kane . DATE 12/20/2016

UPDATED BY: . DATE .

ORIGINATOR’S COMMAND: Surface Forces Logistics Center (SFLC) .

DEPARTMENT/DIVISION: Icebreaker, Buoy and Construction Tender (IBCTPL) .

INTERNAL RE-VIEWER: . DATE .

SWORB APPROVAL: . DATE .

SPECIFICATION FOR THE REPAIR AND PURCHASE OF HYDRAULIC

WINCHES FOR U.S. COAST GUARD CUTTERS

1.0. SCOPE:

1.1. This specification provides the requirements for the receipt, inspection & condition found reports, overhaul, testing/test reports, preservation, packaging, packing, and marking of hydraulic winches currently used on U. S. Coast Guard Vessels nationwide.

1.2. Classification - This sets forth the requirements for the following equipment:

1.2.1. Types of hydraulic winches: refer to appendix (A).

1.3. Government Furnished Property (GFP) – The listed items are managed by the U.S. Coast Guard Surface Forces Logistics Center at Baltimore, MD.

1.3.1. The hydraulic winches listed in appendix (A) constitute the GFP applicable to this specification. Individual hydraulic winches will be released to the Contractor as dictated by USCG requirements with the issuance of a delivery order.

1.3.2. Dimensional data and descriptive characteristics are listed on the applicable Data Sheets; refer to appendix (B) of this specification.

1.3.3. The Contractor shall immediately notify the Coast Guard Contracting Officer if the make, model, or part number received for overhaul does not conform to the hydraulic winches specified on the delivery order.

2.0. APPLICABLE DOCUMENTS:

2.1. General – The documents listed in this section are specified in sections 3.0, 4.0, or 5.0 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements cited in sections 3.0, 4.0, or 5.0 of this specification, whether or not they are listed.

2.2. Government Documents – The following specifications, standards, publications, and handbooks form a part of this repair description to the extent specified herein. Unless otherwise specified, the versions in effect are those listed in the GSA Index of Federal Specifications, Standards and Commercial Item Descriptions or the current Department of Defense Single Stock Point of Specifications and Standards, (DODSSP), and supplements thereto, cited in the solicitation or contract.

2.3. Military Specifications

2.3.1. DODD 4140.01-M-1, Dated 7 Sep 2007; Compliance for Defense Packaging: Phytosanitary Requirements for Wood Packaging Material (WPM).

2.3.2. MIL-D-3464E dated 04/1987, Desiccants, Activated, Bagged, Packaging Use and Static Dehumidification.

2.4. Other Government Documents - The following documents form a part of this specification to the extent specified herein. The documents listed shall be by title and effective date, unless otherwise documented.

2.4.1. MIL-STD-129R DOD Standard Practice Military Marking for Shipment and Storage

2.4.2. SAE AMS-STD-595 Revision A (2017), Colors used in government procurement

2.5. 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).

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

a. ANSI/NCSL Z540-3 (dtd. 8/2006) Requirements for the Calibration of Measuring and Test Equipment

b. ANSI/ASQC Q9001-2008 (dtd 2008) Quality Systems Management Systems -Requirements.

2.5.2. American Society of Mechanical Engineers (ASME).

a. ASME B30.7 (dtd. 09/16) Base Mounted Drum Hoists.

2.5.3. Steel Structures Painting Council (SPCC).

a. NACE No.2/SSPC-SP 10 Joint Surface Preparation Standard: Near-White Metal Blast Cleaning (dtd. 09-13-06) (Steel Structures Painting Manual, Ch 2 - Surface Preparation Specs.)

2.5.4. American Society for Testing and Materials.

a. ASTM D6039/6039M Standard Specification for Open and Covered Wood Crates

2.5.5. International Organization for Standardization / International Electrotechnical Commission

a. ISO ISO/IEC 16388 - Information technology - Automatic identification and data capture techniques - Code 39 bar code symbology specification.

2.5.6 Document Availability – To obtain the referenced documents see section 6.1 of this specification.

2.6. 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. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0. REQUIREMENTS:

3.1. General - The overhaul requirements described herein are the minimum necessary and are not intended to replace any procedures, controls, examinations or tests normally employed by the contractor to insure quality of the product. All work shall be performed in accordance with OEM standard procedures.

3.2. Storage – The Contractor shall provide a secured inside storage location for all GFP with complete protection from the weather elements.

3.3. Preliminary Inspection - Preliminary disassembly and inspection shall be conducted to evaluate the extent of repair required.

3.3.1. Upon receipt of the winch, the contractor shall note the condition of the shipping container and contents. If the container as received does not conform to section 5.2. Packaging requirements, a cost for repair or a new container shall be provided in accordance with the inspection report. Contractor is to include photo documentation of the crates as received with the inspection report. All shall be included in an inspection report and immediately reported to the Contracting Officer.

3.3.2. Each winch received shall be completely disassembled. All components shall be cleaned and inspected to OEM specifications. All removed components that are listed in 3.5.3 for mandatory replacement shall be disposed of at the contractor’s discretion.

3.3.3. The Coast Guards inventory of winches was originally manufactured with the Constant Tension (CT) function. The Coast Guard no longer requires the CT function and it is a requirement of this specification to have the contractor remove the CT function. The contractor is required to report the CT function and any addition to cost for parts modifications in writing as part of the inspection report.

3.3.4. Upon completion of all inspections, the contractor shall develop an individual written inspection report, which shall include, but not limited to the following information for each winch received:

a. Letterhead of Contractor.

b. Winch model and Serial numbers.

c. Shipping container condition.

d. Repair or replace the existing shipping container, if required per CLIN.

e. Signature of person performing inspections.

f. Disassembly and inspection summarized findings.

g. An itemized parts list including item name, quantity and cost of each part required for the overhaul.

h. Breakdown of labor costs.

i. Total overhaul cost.

j. Cost of new winch for comparison to cost of overhaul/repairs.

3.4. Authority to Proceed: Upon completion of the winch disassembly, inspection, and submittal of an inspection report, the contractor shall not begin any overhaul or component/part replacement until authorized in writing by the Contracting Officer. The authorization will give specific guidance on the type of work to proceed with, which may include, but not limited to; (a) overhaul, reassembly, and testing of the winches as a ready to operate assembly as detailed in the contractor inspection report, or (b) disposal of any winch deemed non-repairable as determined by the Contracting Officer.

3.4.1. The Coast Guard Contracting Officer will determine the disposition of any Hydraulic Winch delivered for overhaul that is Beyond Economical Repair (BER).

3.5. Overhaul Requirements - Upon the approval of the inspection report and authorization to proceed by the Contracting Officer, each winch shall be overhauled and tested in accordance with the Original Equipment Manufacturers (OEM) current design and requirements.

3.5.1. The winch shall be restored to the performance standards of a like-new condition winch.

3.5.2. Overhaul shall include a thorough cleaning of all parts. Renewal of parts worn beyond manufacturer’s tolerances or damaged shall be replaced. Overhaul procedure shall insure that all OEM specified clearances, procedures, calibrations, and torque values are applied.

3.5.3. Mandatory replacement parts: The following parts shall be replaced regardless of their condition.

a. O-rings

b. Backup rings

c. Seal (oil, washer, and ring)

d. Retaining rings (snap)

e. Springs

f. Pins (roll, split, and coiled)

g. Hose (replacement hose material shall be not more than 1 year old from date of mfr.)

h. Cap screws w/ lock washers

i. Plugs

j. Electric solenoid and wiring

k. Brake plate, primary group

l. Plate assembly

m. Data plate (see 3.8)

n. Hondu (Wire Rope Retainer)

3.6. Replacement Parts - All replacement parts unique to the winch assembly (i.e.: gears, shafts, housings, etc.) shall be genuine OEM parts. Common hardware items such as bearings (i.e.: roller or ball type) lip seals may be purchased from local suppliers. Any common hardware part not purchased through the OEM shall be of the required type and of equal or better quality as the removed part. The OEM shall supply all gaskets.

3.7. Winch Test - Each winch shall be tested as follows:

3.7.1. The hydraulics supplied to test these winches shall be capable of producing a minimum of 2,500 PSI at 40 GPM.

a. All preliminary pressure or relief valve adjustment shall be performed using calibrated gauges (see 4.4).

b. The winch shall be operated briefly to validate operability before being weight tested.

3.7.2. Pull Test - Each winch shall perform a working load line pull test at 125% of the maximum working load as per Hydraulic Winch Data Sheet, for a five (5) minute time period.

3.7.3. Brake Test - Each winch brake shall be tested to 150% of the maximum working load for as per Appendix B, Hydraulic Winch Data Sheet for ten (10) minute time period with no creep allowed.

3.7.4. Live Load Test – Upon completion and the passing of the Pull and Brake test, the winch will be required to perform a Live Load Test. The test will be performed by lifting and cycling at rated load and rated speed as per Appendix B, Hydraulic Winch Data Sheet, through several cycles. Then lifting rated load and holding for five (5) minutes time period with no creep allowed.

125% dynamic load test – Upon completion and passing of the Pull test, Brake test, and Rated load test the winch will be required to perform at 125% of rated load test at no specific speed as per Appendix B, Hydraulic Winch Data Sheet.

3.7.5. Oil Leaks - Any oil leaks observed during any phase of the testing shall constitute a failed test. If oil leaks occur, contractor shall immediately discontinue the test and make appropriate repairs. Winch shall be re-tested after the leak is corrected.

3.7.6. Test certification - Contractor shall provide a test certificate for each winch upon successful completion of all testing. Certificate shall include the following information as a minimum:

a. Contractors name and address.

b. Contract number.

c. Test date.

d. Model and serial numbers of the tested winch.

e. A detailed description (i.e.: system pressure, test pressure in PSI, Test time, etc.) of each test performed with results of the test.

f. Signature of the contractor official conducting or overseeing the testing.

3.7.7. Test certificate for each winch shall be turned over to the Coast Guard Quality Assurance Representative upon his arrival at the contractor’s facility. A second copy shall be packed with the tested winch.

3.8. Surface Preparation - Removal of existing paint shall be accomplished by abrasive blast to near white metal in accordance with SSPC SP-10/NACE No.2 using grit conforming to MIL-A-22262/ (1.5.-2.5). Equal means of paint removal is acceptable where grit blast poses a risk of damage to internal components and cannot be properly protected from blasting operation. Remove any label plates and replace at the conclusion of painting.

3.9. Paint Application:

3.9.1. All non- painted surfaces or openings shall be protected by masking or capping to protection during paint application.

a. The internal surface of the winch drum, where the cable rides, shall not be painted. It will only have one coat of "Zinc-Rich Primer-Polysiloxane System", at 3.0 to 4.0 mils DFT.

3.9.2. Paint application:

a. Abrasive-blast all steel surfaces to "Near White", in accordance with the Society of Protective Coatings (SSPC) Specification SSPC-SP 10, with angular abrasive to achieve a 1.5 to 2.5 mil anchor profile.

b. Prime all surfaces (the same day they are cleaned or before flash-rusting occurs), with one coat of "Zinc-Rich Primer-Polysiloxane System", at 3.0 to 4.0 mils DFT.

c. Apply a thin coat of "Polysiloxane" top coating, at 1.0 to 2.0 mils DFT.

d. Apply a full coat of "Polysiloxane" top coating, at 5.0 to 6.0 mils DFT.

3.9.3. Authorized Polysiloxane System suppliers are as provided in COMDTINST M10360.3 (Series) as follows:

a. PPG polysiloxane system: Dimetcote 302H / PSX-700 b. Sherwin-Williams polysiloxane system: Fast Clad Zinc HS / XLE-80. Color: SPAR (10371) per SAE AMS-STD595.

3.10. Winch Data Plates: Contractor shall apply two (2) plastic engraved data plates on the winch. Plates shall have a black face with minimum 3/16-inch high white engraved characters. Plates shall be applied to the winch using whether proof adhesive. Plates shall be located on opposite sides of the winch in areas that offer reasonable protection to the plate. Each plate shall contain the following information:

a. Winch NSN

b. Winch Model Number

c. Winch Serial Number

d. Load Rating

e. Rope Size

f. Rope Speed in feet per minute

g. Date of overhaul and contractors company name

3.11. Photo Documentation – The Contractor shall provide digital photo documentation to the Contracting Officer as follows:

a. During initial opening of the hydraulic winch after receipt.

b. When hydraulic winch is completely disassembly for open and inspection report.

c. When significant findings that will affect cost of repair/overhaul or time are discovered.

d. When other significant or unusual findings such as failed parts or damages are discovered.

e. When the hydraulic winch is tested to document configuration.

f. When the hydraulic winch is prepared for shipment to document “as shipped” configuration to include images of the PPP&M.

g. The photo documentation shall be color digital and shall be sent to the Contracting Officer and the Contracting Officer’s Representative via email.

3.12. Warranty- Standard manufactures warranty.

Notifications and Inspections - The contractor shall be responsible for notifying the Contracting Officer no less than seven (7) calendar days prior to the contractor being ready for any Quality Assurance (Q.A.) inspections or testing required herein.

4.0. QUALITY ASSURANCE:

4.1. Responsibility for Inspection - The contractor shall be responsible for the performance of all inspection requirements specified herein. The contractor shall provide space, personnel and test equipment for the conduct of all inspection requirements. All inspection and testing shall be performed at the contractor’s plant or at other facilities acceptable to the Coast Guard. The Coast Guard reserves the right to verify any of the inspections set forth in this specification where such inspections are deemed necessary to assure that supplies and services conform to the prescribed requirements.

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

4.3. Quality Program – The Contractor shall maintain an inspection system which shall insure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements in accordance with (ASQ) Q90001-2008, dated 2008, (document 2.5.1b) of this specification. The inspection system shall be documented and available for review by the Coast Guard.

4.4. Calibration System - The Contractor, as well as any subcontractors, shall be required to maintain a test equipment calibration program in compliance with reference 2.5.1a during the existence of this contract. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.4.1. The calibration system records shall be maintained for inspection for the duration of any contract referencing this specification. These records shall be available for review by any Coast Guard government representative.

4.5. Inspections & Tests - The inspections & tests required herein are the minimum necessary and are not intended to replace any controls, examinations, or tests normally employed by the contractor to assure the quality of the product. The following are required:

a. All testing as required by section 3.7.

b. Paint thickness

c. Data plate requirements in section 3.10.

d. Preservation, packaging and marking requirements.

4.6. Failure Responsibility - If a winch fails to pass any inspection or test, the Contractor shall report the failure and their recommended corrective action to the Contracting Officer. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

a. The Contracting Officer reserves the right to totally reject any failed winch without considering any suggested corrective action.

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

c. After all corrective action has been taken; the inspection/test shall be continued or repeated, at the option of the Contracting Officer.

d. Acceptance shall be withheld until re-inspection/testing has shown that the corrective action was successful and the item satisfactorily passes all inspections and tests.

e. All corrective actions shall be documented as part of the Contractor’s inspection system, and submitted for approval of the Contracting Officer.

f. Each corrective action report shall include, but not be limited to, the cause of each defect, corrective action suggested, and steps taken to prevent a recurrence of each defect.

4.6.2. A copy of any test, inspection or tolerance report shall be turned over to the Quality Assurance Representative upon arrival at the Contractors’ plant.

5.0. PRESERVATION, PACKAGING AND MARKING:

5.1. Preservation - An overhauled hydraulic winch is typically intended for long term warehouse storage and not for immediate installation. Therefore, it is critical that the Contractor ensure that the overhauled hydraulic winches undergo the following preservation requirements.

a. After final test acceptance, each winch shall be completely drained of all oil and fill and drain plugs reinstalled. All openings not previously plugged, shall be sealed with shipping plugs or caps.

b. A red warning tag shall be attached to the winch stating that the winch has been drained of lubricants.

c. Each hydraulic winch shall be bagged in an 8 mil minimum thickness translucent polyurethane bag, with a 40 unit desiccant pack. The bag opening shall be sealed closed with a plastic tie wrap. If the unit is skid mounted using hold down bolts, small holes will need to be cut in the bags to allow for bolting the hydraulic winch down. These holes shall be sealed around each skid stud with silicon sealant and rubber gaskets to ensure the bag is sealed.

5.2. Packaging - Each repaired/overhauled winch shall be individually packaged in its own wooden crate, mounted on 4x4 solid wood skids. The crate shall be framed using solid wood as framing material; the boxed cover shall be constructed from 1/2 inch plywood with a removable lid secured by CRES Phillip’s head wood decking screws in the solid framing material. The winch shall be bolted to the inside of the box with suitable blocking to securely hold and prevent the winch from shifting inside the box. Box shall be constructed for safe containment of the winch and withstand multiple shipments and handling by commercial carriers.

a. A copy of the manufactures start up procedures shall be placed in the shipping container of each winch.

5.3. Marking - The marking described herein shall be placed and/or verified to be on the longest two sides of each box on opposite ends.

a. Each container shall be marked in legible ¾-inch high black waterproof print and, 1/2” lettering is acceptable where ¾” lettering will not suitably fit marked as shown in bold text:

Stock Number:

SEE CONTRACT

Item Name:

SEE CONTRACT

Part Number:

SEE CONTRACT

Winch Serial No:

SEE CONTRACT

Contract Number:

SEE CONTRACT

Shipping Weight:

AS DETERMINED BY CONTRACTOR

Condition Code:

CONDITION “A”

Quantity & Unit of Issue:

1each

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER

DO NOT DESTROY

Note: All previous markings and quality assurance decals shall be removed from a reusable shipping container prior to the application of any new markings.

5.4. Bar Coding - Bar coding shall be supplied on all CLIN’s except for those that require data submissions only.

5.4.1. All bar coded labels shall be in accordance with reference 2.5.4.a.

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

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

c. The marking required in 5.3 of this specification can be applied separately or as part of the bar code label.

5.5. Preservation/Packaging Inspection - The Coast Guard reserves the right to witness the units prior to and after packaging. The Contracting Officer shall be notified in accordance with section 3.13 of this specification and prior to the final packaging of the completed units.

6.0. DOCUMENTS:

6.1. Government documents:

a. Department of Defense Single Stock Point (DoDSSP) Building 4, Section D 700 Robbins Ave.

Philadelphia, PA 19111-5094 215-697-2667/2179

215-697-1462 FAX

b. DOD & navy Publications and Forms (other then DODISS) Naval Publication and Forms Center 5801 Tabor Avenue

Philadelphia, PA 19120

215-697-2000

6.2. Commercial documents:

a. Steel Structures Painting Council 40 24th Street

Pittsburgh, PA 15222

(412) 281-2331

b. American Society of Mechanical Engineers United Engineering Center

345 East 47th Street

New York, New York 10017

(212) 705-7739

c. IEC Regional Centre for North America

446 Main Street

16th Floor

Worcester, MA 01608

(508) 755- 5663

NOMINAL DIMENSION DATA

DRUM DIA: 17 IN ESTIMATED.

DRUM LENGTH: 16 IN ESTIMATED.

WEIGHT: 1700 LBS ESTIMATED.

COLOR: SPAR (10371)

PULL TEST WEIGHT: 13,175 LBS is 125%

BRAKE TEST: 16,000 LBS

LIVE LOAD: 10,500 LBS

TEST PRESSURE: 2500 PSI @ 40GPM

DRUM CAP: 310 FT @ 7/8 IN

TECH PUB: TP 3630 APPENDIX W, BUOY CRANE – MODEL SB230-42

APPLICATION: WLM 175

SUPPLIER: APPLETON MARINE

MARKING DATA

COAST GUARD SFLC MATERIAL

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