PDAG020.pdf

OVERHAUL DESCRIPTION

FOR OFFICIAL USE ONLY

ITEM NAME CYLINDER ASSEMBLY,ACTUATING, LINEAR

STOCK NUMBER 3040-99-239-4845

PART NUMBER SK7961

USED ON 270 DUAL POINT BOAT DAVIT

Items as received by the contractor must be complete and of the proper cited part number. Discrepancies shall be reported to the Coast Guard Contracting Officer.

OVERHAUL REQUIREMENTS:

1. Scope. This description initiates the inspection and overhaul of the item described below for SFLC stock replenishment.

NSN: 3040-99-239-4845

Item Name: Hydraulic Cylinder Welin Lambie: P/N 5727-1501 Bore Diameter 4.921" (125 MM), Rod Diameter 2.756" (70 MM), Compressed Length C-C 62.40" (1585 MM), Stroke Length 40.27"(1023 MM).

Note: Port sizes are 1/2" BSP (British Standard Pipe).

Max Operating Pressure 3000 PSI (207 BAR).

Seal Kit P/N 892-01013, NSN: 5330-99-615-9393, Hydraulic Cylinder, Seal Kit

1.1 Government Furnished Property (GFP): The following boat davit cylinder assembly will be provided to the contractor for inspection and refurbishment services required by this statement of work.

a) Cylinder Assembly, Actuating, Linear, P/N: 5727-1501, OEM: Welin Lambie, NSN: 3040-99-239-4845.

b) Hydaulic Cylinder, Seal Kit, P/N: 892-1013, NSN: 5330-99-615-9393,

1.2 Cylinder received by the contractor shall be of the manufacture shown above. If the cylinder has any other markings or manufacture, it shall be documented and immediately reported to the Coast Guard Contracting Officer.

1.3 The overhaul requirements described herein are not intended to replace any procedures, controls, examinations or tests normally employed by the contractor to assure the quality of the product.

2. Applicable Documents:

a) Federal Color Standard 595C Change 1 Colors Used In Government Procurement.

b) Z540.3 Requirements for the Calibration of Measuring and Test Equipment, dated 8/3/2006.

c) SSPC-SP10/NACE NO. 2 Near White Blast Cleaning, The Society for Protective Coatings.

d) U.S. Coast Guard Surface Forces Logistics Center Specification, D-000- 0100: Bar Coding for U.S. Coast Guard Engineering Logistics Center material, Rev G, Change 1, Dated February 2006.

e) SFLC Standard Specification 6310 Requirements for the Preservation of Ship Structures, Appendix A5 Deck Machinery.

f) MIL-PRK-131K Barrier Materials, Water Vaper Proof, Grease Proof, Flexible, Heat-Sealable.

3. Requirements:

3.1 Preliminary disassembly and inspection shall be conducted to determine the estimated cost of overhaul including replacement parts/material, labor, testing, paint preservation, packaging and marking cost. No other work shall be performed beyond the inspection phase until an inspection report has been submitted and authorization has been given by the Contracting Officer to proceed.

3.1.1 The inspection report shall include an estimate that shows a breakdown of all necessary labor and material addressed in 3.1.

3.1.2 Replacement Parts: Only new OEM equipment parts shall be used in overhaul work performed on the cylinder assembly. Reclaimed or recycled parts not normally used in new cylinder manufacture are not acceptable.

3.2 Inspection/ Overhaul:

3.2.1 The cylinder shall be completely disassembled.

3.2.2 Each item shall be cleaned to remove all residual oil, paint, rust and corrosion. The means by which used to clean the parts shall not compromise the part for possible re-use. Critical surfaces shall be protected during the cleaning process.

3.2.3 The rod and cylinder shall be measured and compared to the original manufactures design measurements/tolerances and straightness. The piston rod and cylinder surfaces shall be inspected for signs of scoring and pitting.

3.2.4 Mandatory replacement parts shall include: All seals, over centering valve, self aligning bearings, grease fittings with plastic protective caps.

Any parts that require chrome re-surfacing shall be hard chrome plated.

3.2.5 Cylinders that are determined suitable for overhaul shall be reassembled only upon authorization to proceed only after inspection report review and determinations by the contracting officer. The contracting officer will provide disposition instruction for any non-repairable cylinder.

3.3 Testing: Contractor shall test each overhauled cylinder in the presence of a Coast Guard Quality Assurance representative as follows:

3.3.1 Calibration: All test equipment and attached gauges shall be calibrated and have a current calibration sticker. Calibration shall be traceable to National Institute of Standards (NIST).

3.3.2 The cylinder shall be cycled its full stroke length a minimum of five times. The cylinder shall not have any erratic behavior or chatter during the test.

3.3.3 Inspect for external leakage by static test at the designed working pressure rating of 207 bars plus or minus 3 bars. The test duration shall be for a minimum of five minutes in both the extended and retracted position.

The cylinder shall be rejected if there are any signs of leakage.

3.3.4 Test for internal bypass leakage. The test shall be both in the directions of rod travel. The test shall begin with the rod retracted and loaded with 6850 lbs. to be lifted vertically (the load will try to force the rod to retract) the rod will be extended half its length and stopped. The cylinder is to hold the position for 15 minutes with less than 1" of creep on the rod. The load is than to be reversed (the load will try to force the

SHELF LIFE CD 0

1. Scope. This description initiates the inspection and overhaul of the item described below for SFLC stock replenishment.

NSN: 3040-99-239-4845

Item Name: Hydraulic Cylinder Welin Lambie: P/N 5727-1501 Bore Diameter 4.921" (125 MM), Rod Diameter 2.756" (70 MM), Compressed Length C-C 62.40" (1585 MM), Stroke Length 40.27"(1023 MM).

Note: Port sizes are 1/2" BSP (British Standard Pipe).

Max Operating Pressure 3000 PSI (207 BAR).

Seal Kit P/N 892-01013, NSN: 5330-99-615-9393, Hydraulic Cylinder, Seal Kit

1.1 Government Furnished Property (GFP): The following boat davit cylinder assembly will be provided to the contractor for inspection and refurbishment services required by this statement of work.

a) Cylinder Assembly, Actuating, Linear, P/N: 5727-1501, OEM: Welin Lambie, NSN: 3040-99-239-4845.

b) Hydaulic Cylinder, Seal Kit, P/N: 892-1013, NSN: 5330-99-615-9393,

1.2 Cylinder received by the contractor shall be of the manufacture shown above. If the cylinder has any other markings or manufacture, it shall be documented and immediately reported to the Coast Guard Contracting Officer.

1.3 The overhaul requirements described herein are not intended to replace any procedures, controls, examinations or tests normally employed by the contractor to assure the quality of the product.

2. Applicable Documents:

a) Federal Color Standard 595C Change 1 Colors Used In Government Procurement.

b) Z540.3 Requirements for the Calibration of Measuring and Test Equipment, dated 8/3/2006.

c) SSPC-SP10/NACE NO. 2 Near White Blast Cleaning, The Society for Protective Coatings.

d) U.S. Coast Guard Surface Forces Logistics Center Specification, D-000- 0100: Bar Coding for U.S. Coast Guard Engineering Logistics Center material, Rev G, Change 1, Dated February 2006.

e) SFLC Standard Specification 6310 Requirements for the Preservation of Ship Structures, Appendix A5 Deck Machinery.

f) MIL-PRK-131K Barrier Materials, Water Vaper Proof, Grease Proof, Flexible, Heat-Sealable.

3. Requirements:

3.1 Preliminary disassembly and inspection shall be conducted to determine the estimated cost of overhaul including replacement parts/material, labor, testing, paint preservation, packaging and marking cost. No other work shall be performed beyond the inspection phase until an inspection report has been submitted and authorization has been given by the Contracting Officer to proceed.

3.1.1 The inspection report shall include an estimate that shows a breakdown of all necessary labor and material addressed in 3.1.

3.1.2 Replacement Parts: Only new OEM equipment parts shall be used in overhaul work performed on the cylinder assembly. Reclaimed or recycled parts not normally used in new cylinder manufacture are not acceptable.

3.2 Inspection/ Overhaul:

3.2.1 The cylinder shall be completely disassembled.

3.2.2 Each item shall be cleaned to remove all residual oil, paint, rust and corrosion. The means by which used to clean the parts shall not compromise the part for possible re-use. Critical surfaces shall be protected during the cleaning process.

3.2.3 The rod and cylinder shall be measured and compared to the original manufactures design measurements/tolerances and straightness. The piston rod and cylinder surfaces shall be inspected for signs of scoring and pitting.

3.2.4 Mandatory replacement parts shall include: All seals, over centering valve, self aligning bearings, grease fittings with plastic protective caps.

Any parts that require chrome re-surfacing shall be hard chrome plated.

3.2.5 Cylinders that are determined suitable for overhaul shall be reassembled only upon authorization to proceed only after inspection report review and determinations by the contracting officer. The contracting officer will provide disposition instruction for any non-repairable cylinder.

3.3 Testing: Contractor shall test each overhauled cylinder in the presence of a Coast Guard Quality Assurance representative as follows:

3.3.1 Calibration: All test equipment and attached gauges shall be calibrated and have a current calibration sticker. Calibration shall be traceable to National Institute of Standards (NIST).

3.3.2 The cylinder shall be cycled its full stroke length a minimum of five times. The cylinder shall not have any erratic behavior or chatter during the test.

3.3.3 Inspect for external leakage by static test at the designed working pressure rating of 207 bars plus or minus 3 bars. The test duration shall be for a minimum of five minutes in both the extended and retracted position.

The cylinder shall be rejected if there are any signs of leakage.

3.3.4 Test for internal bypass leakage. The test shall be both in the directions of rod travel. The test shall begin with the rod retracted and loaded with 6850 lbs. to be lifted vertically (the load will try to force the rod to retract) the rod will be extended half its length and stopped. The cylinder is to hold the position for 15 minutes with less than 1" of creep on the rod. The load is than to be reversed (the load will try to force the rod to extend). The rod is to start from the fully extended position and load lifted to vertically until the rod has retracted half its length and stopped. The cylinder is to hold this position for 15 minutes with less than 1" of creep on the rod. Pass/failure criteria for this test is rod creep more than 1" in either direction it is a failure.

3.3.5 Upon completion of a successful test, the cylinder shall be drained of all residual hydraulic oil and the port openings shall be capped or plugged.

3.3.6 Any cylinder that fails any of the above tests shall be investigated to determine the cause of failure. The cylinder shall be investigated and the test shall be conducted again.

3.3.7 Test Certificate: Contractor shall provide a test certificate for each cylinder that has successfully passes the load test. Certificate shall be signed by the test official and contain the following information:

a) Contractors Name

b) Contract number

c) Date of test

d) A brief description of each test i.e. extended/contracted with time period for each position and test pressure.

e) Leakage observed: if Yes, list the amount, otherwise No.

f) Identify cylinder by serial or job number that passed.

3.4 Painting: Surfaces intended for paint shall be commercially blast to near white metal per reference 2c. Other types of surface cleaning are acceptable that will achieve a near white finish. Paint coating shall include a primer \ tie and finish top coat. Prime with one coat of "Zinc-Rich Primer- Polysiloxane System", at 3.0 to 4.0 mils DFT. Next apply a thin tie coat of "Polysiloxane" top coating, at 1.0 to 2.0 mils DFT. Finish with a full top coat of "Polysiloxane" top coating, at 5.0 to 6.0 mils Dry Film Thickness (DFT) each. Color of finish coat shall be "Spar" in accordance with Federal Standard 595C color number 10371.

4. Quality Assurance:

4.1 Notifications & Inspections: The contractor is 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.

4.2 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 contractors facility prior to the Coast Guards acceptance of the contracted items. The Coast Guard reserves the right to verify and have performed any of the inspections set forth herein where such inspections are deemed necessary to assure that supplies and services conform to prescribed requirements.

4.3 Inspections and Tests: The inspections and 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) Test requirements and calibration described in part 3.3.

b) Paint type, color and thickness inspection described in part 3.4.

c) Inspection of packaging, preservation and marking described in part 5.

4.4 Test and Inspection Reports: A copy of any standard contractor test or inspection report shall be turned over to the Coast Guard Quality Assurance inspector upon his arrival at the contractor's facility.

5. Preservation, Packaging and Marking

5.1 Preliminary. Overhauled cylinder shall be delivered to the Coast Guard Supply Center completely assembled and ready for installation.

5.2 Preservation. Each overhauled cylinder shall be placed in a MIL-PRF-131 Foil Bag after successful completion of testing.

5.3 Packaging. Each cylinder shall be individually packaged in its own wooden container. Container shall be constructed in such a manner as to prevent the cylinder from shifting within. Container shall be capable of protecting the cylinder from damage during multiple shipments by common carrier.

5.4 Marking. Each box shall be marked in legible waterproof print with the following information:

3040-99-239-4845

CYLINDER, HYDRAULIC

SK7961

Shipping Weight: As determined Government Contract NO. __________________________ Coast Guard SFLC Material Condition "A", 1 ea.

6. Notes:

6.1 Acceptance - Acceptance will be made at destination by a government representative. Acceptance will be contingent upon representative's verification of no damage in transit, correctness and completeness of order and contractors conformance to preservation, packing and marking requirements.

6.2 Source for Federal Color Standard 595B:

Standardization Document Order Desk 700 Robbins Ave.

Building #4, Section D Philadelphia, PA 19111-5094

(215) 697-1187 rod to extend). The rod is to start from the fully extended position and load lifted to vertically until the rod has retracted half its length and stopped. The cylinder is to hold this position for 15 minutes with less than 1" of creep on the rod. Pass/failure criteria for this test is rod creep more than 1" in either direction it is a failure.

3.3.5 Upon completion of a successful test, the cylinder shall be drained of all residual hydraulic oil and the port openings shall be capped or plugged.

3.3.6 Any cylinder that fails any of the above tests shall be investigated to determine the cause of failure. The cylinder shall be investigated and the test shall be conducted again.

3.3.7 Test Certificate: Contractor shall provide a test certificate for each cylinder that has successfully passes the load test. Certificate shall be signed by the test official and contain the following information:

a) Contractors Name

b) Contract number

c) Date of test

d) A brief description of each test i.e. extended/contracted with time period for each position and test pressure.

e) Leakage observed: if Yes, list the amount, otherwise No.

f) Identify cylinder by serial or job number that passed.

3.4 Painting: Surfaces intended for paint shall be commercially blast to near white metal per reference 2c. Other types of surface cleaning are acceptable that will achieve a near white finish. Paint coating shall include a primer \ tie and finish top coat. Prime with one coat of "Zinc-Rich Primer- Polysiloxane System", at 3.0 to 4.0 mils DFT. Next apply a thin tie coat of "Polysiloxane" top coating, at 1.0 to 2.0 mils DFT. Finish with a full top coat of "Polysiloxane" top coating, at 5.0 to 6.0 mils Dry Film Thickness (DFT) each. Color of finish coat shall be "Spar" in accordance with Federal Standard 595C color number 10371.

4. Quality Assurance:

4.1 Notifications & Inspections: The contractor is 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.

4.2 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 contractors facility prior to the Coast Guards acceptance of the contracted items. The Coast Guard reserves the right to verify and have performed any of the inspections set forth herein where such inspections are deemed necessary to assure that supplies and services conform to prescribed requirements.

4.3 Inspections and Tests: The inspections and 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) Test requirements and calibration described in part 3.3.

b) Paint type, color and thickness inspection described in part 3.4.

c) Inspection of packaging, preservation and marking described in part 5.

4.4 Test and Inspection Reports: A copy of any standard contractor test or inspection report shall be turned over to the Coast Guard Quality Assurance inspector upon his arrival at the contractor's facility.

5. Preservation, Packaging and Marking

5.1 Preliminary. Overhauled cylinder shall be delivered to the Coast Guard Supply Center completely assembled and ready for installation.

5.2 Preservation. Each overhauled cylinder shall be placed in a MIL-PRF-131 Foil Bag after successful completion of testing.

5.3 Packaging. Each cylinder shall be individually packaged in its own wooden container. Container shall be constructed in such a manner as to prevent the cylinder from shifting within. Container shall be capable of protecting the cylinder from damage during multiple shipments by common carrier.

5.4 Marking. Each box shall be marked in legible waterproof print with the following information:

3040-99-239-4845

CYLINDER, HYDRAULIC

SK7961

Shipping Weight: As determined Government Contract NO. __________________________ Coast Guard SFLC Material Condition "A", 1 ea.

6. Notes:

6.1 Acceptance - Acceptance will be made at destination by a government representative. Acceptance will be contingent upon representative's verification of no damage in transit, correctness and completeness of order and contractors conformance to preservation, packing and marking requirements.

6.2 Source for Federal Color Standard 595B:

Standardization Document Order Desk 700 Robbins Ave.

Building #4, Section D Philadelphia, PA 19111-5094

(215) 697-1187

6.3 National conference of standards laboratories (NCSL)

1800 30th Street, Suite 305B Boulder, CO 80301 Phone: (303)440-3339

6.4 SSPC - The Society for Protective Coatings

40 24th Street, 6th Floor, Pittsburgh PA 15222-4656 USA Phone: 1.412.281.2331, Toll-Free: 1.877.281.7772, Fax: 1.412.281.9992

WARRANTY:

A. Standard Manufacturer's Warranty

X B. Item being repaired as an "onboard repair" or a "system stock" item and will be put into inventory. NOT FOR IMMEDIATE INSTALLATION.

Contractor must guarantee item against defects that lead to failure for

90 days after installation for a period of up to two (2) years after delivery to Coast Guard.

GOVERNMENT ACCEPTANCE:

Acceptance will be made at destination by a Government representative.

Acceptance will be contingent upon the representative's verification of no damage in transit, correctness and completeness of order and contractor's conformance to preservation/packaging, packing and marking requirements.

PACKAGING AND MARKING FOR SHIPMENT:

X

A. Each unit shall be packed individually in it's own wooden box which shall be capable of providing adequate protection to the item during multiple shipments. Mark each box in legible black print lettering with the following information:

NATIONAL STOCK NUMBER

ITEM NAME

PART NUMBER

GOVERNMENT ORDER NUMBER

3040-99-239-4845

CYLINDER ASSEMBLY,ACTUATING, LINEAR

SK7961

PRESERVATION / PACKAGING:

A. Each unit shall be individually preserved and wrapped for protection against deterioration for a period of two (2) years minimum.

X B. See Attachments

B. See Attachments

And the words: "Coast Guard SFLC Material, Condition "A"

RECOMMENDED SOURCES:

BALTIMORE HYDRAULICS INC

708 E 25TH ST

BALTIMORE, MD 21218-5436

SERVICE@BALHYD.COM (REPAIRS)

CK1200@BALHYD.COM

410-467-8088

HYDRO AIR DEES

1809 FASHION CT.,SUITE 110

JOPPA,MD 21085-3237

EMAIL: FJOSEPHSON@HYDROAIR.NET 410-935-8747

BDORAN@HYDROAIR.NET (GOVT CUSTOMER SERVICE)

1-800-787-3337

A-TECH HYDRAULICS INC.

2713 NORTH POINT BLVD

BALTIMORE, MD. 21222

RFORSTER@ATECHHYDRAULICS.COM

WRITTEN BY:

DATE :

STEPHEN TWOMEY

06 DEC 21

Cost Estimate for Overhaul NOT TO EXCEED: $11,000