R-556-2043.pdf

REVISION No. . CHANGE NO. .

SPECIFICATION FOR OVERHAUL OF HYDRAULIC

CYLINDERS USED ON VARIOUS USCG CUTTERS

R-556-2043

ORIGINATED BY: Arnold J. Abbas . DATE: 11/2019 .

UPDATED BY: . DATE: .

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

DEPARTMENT / DIVISION: Medium Endurance Cutter Product Line (MECPL) .

INTERNAL REVIEWER: Stephen R. Twomey . DATE:11/2019

SWORB APPROVAL: . DATE: .

1.0.SCOPE

1.1. This specification provides the requirements for the receipt, inspection & condition/test reports, overhaul, testing, preservation, and packaging, packing and marking (PPP&M) of hydraulic cylinders currently used on U. S. Coast Guard Medium Endurance Cutters nationwide.

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

1.2.1. a) Actuating Cylinder Assembly, NSN: 3040-01-103-6565, P/N: R433010583.

b) Hydraulic Cylinder, NSN: 3040-01-123-6695, P/N: P161934

c) Hydraulic Cylinder, NSN: 3040-01-518-4648, P/N: 75778

d) Hydraulic Cylinder Jib, NSN: 3040-01-581-1046, P/N: YMD-10376

e) Hydraulic Cylinder Luff, NSN: 3040-01-581-1539, P/N: YMD-10375

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 cylinders listed above constitute the GFP applicable to this specification. Individual hydraulic cylinders 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 (A) 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 cylinder 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 overhaul 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.

2.2.1. Military Specifications

a. DODD 4140.01-M-1, Dated 7 Sep 2007; Compliance for Defense Packaging:

Phytosanitary Requirements for Wood Packaging Material (WPM).

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

c. MIL-PRF-131K, Dated 08/2005, Barrier Materials, Water Vapor Proof, Grease Proof, Flexible, Heat-Sealable

d. MIL-STD-2073 1E Standard Practice for Military Packaging

2.3. 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.

2.3.1. Coast Guard Specifications.

a. USCG-SFLC Specification D-000-0100 Rev G, 02/2006; Bar Coding for USCG Surface Forces Logistics Center procured material.

b. USCG SFLC Technical Standard 556 Hydraulic Equipment.

c. USCG SFLC Standard Specification 6310 Requirements for Preservation of Ships Structures.

2.3.2. Coast Guard Technical Publications

a. TP 2719 Sec. A, Fin Stabilizer Machinery, 270 A Class

b. TP 2837 Sec. C, Fin Machinery and Hydraulic Subsystems 270 B Class

c. TP 9169 Sec. A, Electro-Hydraulic Steering System & Alarm System Upgrade

d. TP 3485C Sec. A, Single Point Boat Davit, Model D5700CT

e. TP 3943 Sec. A, Twin Pivot Arm Davit, Type TW.PIV 5.0B

f. TP 4924 Sec. A, Folding Boom Crane, Model FB0-21

2.3.3. Coast Guard Drawings

a. 901-WMEC-561-009 Steering Gear Hydraulic Assembly

2.4. Commercial Documents – The following specifications and standards form a part of this specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the current DLA ASSIST database for Military Specification.

a. International Standard ISO/EIC 17025 General Requirements for the competence of testing and calibration laboratories. Third Edition 2017-11

b. Society for Protective Coatings SSPC-SP 10/NACE No. 2, Near White Blast Cleaning, dated 09/2000

c. Society of Automotive Engineers AMS-STD-595A (R) Colors Used in Government Procurement.

d. American Society for Quality (ASQ) Q9001-2008, dated 2008, Quality Management Systems-Requirements.

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

2.6. Specification Order of Precedence – In the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence.

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

3.0. REQUIREMENTS

3.1. General – Inspections, overhaul and testing of each hydraulic cylinder shall be accomplished in accordance with the Original Equipment Manufacturer (OEM) procedures, specifications, references and standard practices. The Contractor shall complete these requirements in accordance with the contracted delivery date.

3.1.1. The Contractor is responsible for acquiring and maintaining current OEM procedures, specifications, references and standard practices.

3.1.2. The overhaul requirements described herein are considered the minimum necessary and are not intended to replace any procedures, controls, examinations, or tests normally employed by the Contractor to assure the quality of the product. The overhaul of the hydraulic cylinders is intended to return the cylinder performance and appearance to a like new condition.

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

3.3. Overhaul – The Contractor shall provide all labor and materials to perform the overhaul services as described below for each hydraulic cylinder.

3.3.1. Preliminary disassembly and inspection of the hydraulic cylinder shall be conducted in accordance with OEM procedures, specifications, references and standard practices to determine the condition of all components of the hydraulic cylinder. All external fittings and piping will be removed for inspection and replaced as needed.

3.3.2. A detailed cost estimate shall be submitted with an Open & Inspect Report (OIR) for each cylinder to the Coast Guard Contracting Officer within ten (10) days after receiving the cylinder for review. Contracting Officer’s approval is required prior to the start of any overhaul or order of material. The Contractor shall also provide the replacement cost of an identical new hydraulic cylinder for comparison to the overhaul cost.

a. The open and inspect Condition Found Report with a detailed cost estimate shall contain the following as a minimum:

1. Date of inspection.

2. Identification of cylinder by serial number, part number, and stock number. If no serial number appears on the hydraulic cylinder, the Contractor shall assign a serial number. The serial number shall be stamped on the hydraulic cylinder.

3. Condition of the shipping crate and any cost of repair.

4. Cost of overhaul labor as applicable.

5. Comments, if any, pertaining to unusual observations during disassembly and inspection.

6. A list of defective or worn parts recommended for repair/refurbishment (vice replacement) and the associated cost to accomplish these repairs.

7. List of required replacement parts. Identify any existing non-OEM parts that need replacement.

8. Provide digital photo documentation as per subsection 3.6. of this specification.

9. Cost of new cylinder for comparison to cost of overhaul.

b. Upon acceptance of the cost estimate and authorization to proceed by the Contracting Officer, the Contractor shall overhaul the hydraulic cylinder in accordance with the OEM procedures, specifications, references, standard practices and the cited references.

3.3.3. The Coast Guard Contracting Officer will determine the disposition of any hydraulic cylinder delivered for overhaul that is Beyond Economical Repair (BER) and notify the contractor in writing.

3.3.4. Each cylinder shall be overhauled to a condition which is equivalent to an identical new hydraulic cylinder, with the operating and performance characteristics restored to the original design and technical specifications.

3.3.5. All replacement parts used in the overhaul shall be new OEM parts. Reclaimed, recycled, or aftermarket parts are not acceptable and shall not be used.

3.3.6. Remove any label plates and replace at the conclusion of the painting. New label plates shall be used if the original plate is missing, not legible or in poor condition.

The label plate shall contain hydraulic cylinder; model and serial number and pertinent characteristic information as a minimum requirement. A separate label plate made of similar material, as the original label plate, shall be attached stating the Contractor’s name, contract number and date of overhaul.

3.3.7. Paint removal: Removal of existing paint shall be accomplished by abrasive blast to near white metal in accordance with SSPC SP-10/NACE No.2 where practicable.

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.

3.3.8. Paint application: Paint coating shall be in accordance with USCG SFLC Standard Specification 6310 Requirements for Preservation of Ships Structures.

a. For NSN’s: 3040-01-103-6565 Fin Cylinder, 3040-01-123-6695 Steering Cylinder are Ship’s INTERIOR Machinery Operating Temperatures under 200 degrees. All surfaces intended for paint shall be coated with a two part epoxy to MIL-DTL-24441C and applied 5-6 mils dry film thickness (DFT), any color. The finish coat shall be 2-3 mils dry (DFT) of silicone alkyd enamel type II or III class 1. The color of finish coat shall be gray in accordance with SAE AMS-STD-595A - (R) Colors Used in Government Procurement color number 16187. All surfaces not intended for paint shall be masked, capped or plugged. All masking shall be removed after the paint has cured. Total paint thickness shall be 7 to 9 mil minimum dry film.

b. For: NSN’s: 3040-01-518-4648 SPD Cylinder, 3040-01-581-1046 Jib Cylinder and 3040-01-581-1539 Luff Cylinder are ship’s EXTERIOR structure deck machinery items. All surfaces not intended for paint shall be masked, capped or plugged. All masking shall be removed after the paint has cured. Surfaces intended for paint shall be coated with one application of Zinc-Rich Primer- Polysiloxane System, 3.0 to 4.0 mils DFT. The top coat shall be applied with two (2) applications of (polysiloxane) Ameron PSX-700 or equal. The first application with a thin coat, at 1.0 to 2.0 mils DFT. Followed by a second full coat at 5.0 to 6.0 mils DFT. Authorized colors shall be in accordance with SAE-AMS-STD-595A (R) Colors Used in Government Procurement color number 10371 (SPAR). Prior to the application of paint, surface cleaning and preparation shall be accomplished in accordance with the paint manufacturer’s instructions. All painting shall result in a minimum of 9.0 to 12.0 mils DFT

3.3.9. Paint Data Sheet: Paint data sheets shall be prepared to certify the paint type and mil thickness used on each cylinder. The paint data sheet shall be packed with the overhauled hydraulic cylinder at time of packaging. A copy of the paint data sheet shall also be provided to the Coast Guard Quality Assurance Representative.

3.3.10. Reassembly: The hydraulic cylinder shall be reassembled using only new OEM authorized parts. All fasteners shall be torqued to the manufacturer’s requirements or by use of general torque values for the type and size of fastener.

3.4. Testing – After completion of overhaul, the Contractor shall conduct the following tests to ensure proper functionality and seal integrity. These tests shall be in conjunction with any standard contractor quality assurance procedures. All testing shall be conducted on Contractor-supplied test equipment.

3.4.1. The Contractor shall be required to maintain a test equipment calibration program in compliance with ANSI/NCSL Z540.3-2006. The program shall be documented and traceable to the National Institute of Standards (NIST). The calibration system records shall be maintained for inspection for the duration of any contract referencing this specification.

3.4.2. The contractor shall have installed a new 3 micron filter in the hydraulic test equipment.

3.4.3. Leak Test – The contractor shall conduct the following leak test. If any leakage occurs during the test, the hydraulic cylinder shall be repaired and re-tested until a successful test can be achieved. At the completion of testing, the cylinder shall be drained, rod end retracted, and cylinder hydraulic ports sealed with threaded plugs or caps.

a. Operate cylinder using contractor-supplied test equipment through several cycles of fully extended to fully retracted positions in order to test the general operation. No binding or chatter of the rod is acceptable.

b. Perform a static test of both sides of the piston at 150% of operating pressure as per cylinder data (refer to appendix B), for not less than 5 minutes. The hydraulic cylinder shall be tested with the rod fully extended, and the rod end of the hydraulic cylinder shall be tested with the rod fully retracted. Any external leakage shall be grounds for rejection.

c. Test for Internal Bypass leakage. The test shall be tested in both directions of rod travel. Test shall begin with the rod retracted and loaded with 2,000 lbs (the load will try to force the rod to retract) the rod will be extended half its length and stopped. Hold position for 5 minutes and inspect for creeping of the rod. The load can then be reversed (the load will try to force the rod to extend).

The rod will be retracted half its length and stopped. Hold position for 5 minutes and inspect for creeping of the rod. Pass/failure criteria for this test will be rod creep greater than one half inch in either direction is a FAILURE.

3.4.4. Test results shall be documented on a report. A copy of the test report shall be packed with the tested hydraulic cylinder in a sealed plastic bag (heat sealed or “zipper closure”) and a copy shall be turned over to the Coast Guard Quality Assurance Representative. The report shall contain the following information at a minimum:

a. Contractor name.

b. Contract number.

c. Delivery order number.

d. Cylinder model number.

e. Date of test.

f. Description of each test conducted, acceptable OEM tolerances as applicable, and actual results observed.

g. Name of the person conducting the testing.

h. Name of Coast Guard Quality Assurance Representative.

3.5. Delivery – Each overhauled and tested hydraulic cylinder shall be delivered to the Coast Guard completely assembled and ready for installation. The Contractor shall preserve, package, and mark each hydraulic cylinder assembly in accordance with section 5.0. of this specification.

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

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

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

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

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

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

f. When the hydraulic cylinder 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.

3.7. Notifications & Inspections – The Contractor shall be responsible for notifying the Contracting Officer at least ten (10) calendar days prior to the contractor being ready for any Quality Assurance (QA) 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 to conduct all required inspections. 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 or have performed any of the inspections or tests that 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 this specification. 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 the specification shall not relieve the Contractor of the responsibility of assuring that all products or supplies 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 2.4.3.) of this specification. The inspection system shall be documented and available for review by the Coast Guard.

4.4. Test Equipment Calibration Program – The Contractor shall be required to maintain a test equipment calibration program in compliance with ANSI/NCSL Z540.3-2006 (document 2.4.1.) of this specification. The program shall be documented and traceable to the National Institute of Standards (NIST). The calibration system records shall be maintained for inspection for the duration of any contract referencing this specification.

4.5. Tests & Inspections – The inspections/tests required here and in the appropriate subsections outlined in section 3.0. of this specification are the minimum required and are not intended to supplant any controls, examination, inspections or tests normally employed by the Contractor to assure the quality of the item in question.

4.5.1. The following Post Repair tests and inspections will be witnessed by an SFLC Quality Assurance Representative:

a. Verify paint requirement and paint thickness (subsection 3.3.9.)

b. Operational test (paragraph 3.4.2.a.)

c. External leakage test (paragraph 3.4.2.b)

d. Internal leakage test (paragraph 3.4.2.c)

e. Verify Preservation, Packaging, Packing, and Marking (section 5.0.)

4.6. Failure Responsibility – If the specified item fails to pass any inspection / test, the Contractor shall report the failure and the recommended corrective action to the Contracting Officer with a Condition Found Report (CFR). If approved, the corrective action on the materials or processes shall be accomplished in accordance with this section.

4.6.1. General Statements

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

b. After all corrective actions have been taken the inspection / test shall be repeated unless waived by the Contracting Officer.

c. Acceptance shall be withheld contingent upon satisfactory completion of all inspections / tests.

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

e. Each corrective action report shall include, but not be limited to the cause of each defect, corrective action suggested, and the 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, PACKING, & MARKING

5.1. Preservation – An overhauled hydraulic cylinder 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 cylinder undergo the following preservation requirements.

5.2. Seal all open ports with a threaded cap or plug to prevent the intrusion of moisture or dirt. Attach a tag to the rod end hydraulic port with the following printed on the tag:

This cylinder must be filled with fluid prior to operation. Ensure air is bled from the cylinder.

5.3. Each hydraulic cylinder shall be bagged in a Class 3 waterproof bag as per MIL-PRF- 131K, dated 08/2005, with one 80 unit desiccant pack for every four (3) LF of hydraulic cylinder inside bag. The bag opening shall be heat sealed closed. The contractor must use suitable blocking to securely hold the cylinder stationary inside the shipping container. The method of securing the cylinder shall be sufficient as to ensure the bags remain sealed.

5.4. Packaging – Each overhauled hydraulic cylinder 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 and corrosion resistant wood screws; the box covering shall be constructed from ½ inch plywood with a removable lid secured by corrosion resistant wood screws in the solid framing material. The cylinder shall be packaged with the rod fully retracted and have suitable blocking to securely hold the cylinder stationary inside the box. Box shall be constructed for safe containment of the cylinder and withstand multiple shipments and handling by commercial carriers.

5.5. Marking – Each preserved and packaged hydraulic cylinder shall be marked with stenciled in the upper left-hand side of the two longest sides of each box. The stenciling shall be 1 inch minimum height black characters on a white painted background. If the small size of crate makes 1 inch characters impractical, smaller characters may be used;

however, in no case may the characters be smaller than ½ inch height.

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

5.5.1. The marking shall consist of the Stock Number, Item Name, Part Number, Contract Number, Delivery Order Number, Gross Weight (in lbs.), Condition Code (Condition A), Unit of Issue (i.e. 1 EA), and the words COAST GUARD SFLC MATERIAL. For specific marking information, see the appropriate data sheet referenced in appendix (B) of this specification.

5.5.2. SAMPLE MARKING

STOCK NUMBER SEE CONTRACT

ITEM NAME SEE CONTRACT

PART NUMBER SEE CONTRACT

CONTRACT NUMBER SEE CONTRACT

DELIVERY ORDER NUMBER SEE CONTRACT

SHIPPING WEIGHT AS DETERMINED BY CONTRACTOR

CONDITION CODE CODITION “A”

QUANTITY & UNIT OF ISSUE 1 - EACH

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER

DO NOT DESTROY

5.6. Bar Coding – The Contractor shall affix bar code labels near each marking specified in section 5.5. of this specification.

5.6.1. All bar code labels shall be in accordance with SFLC Specification D-000-0100 (document 2.3.1.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.

6.0.NOTES

6.1. Government & Commercial Document Sources

6.1.1. Government Documents

a. Assist (Database for Military Specifications) (https://assist.dla.mil) Acquisition Streamlining and Standardization Information System

b. DOD & Navy Publications and Forms (Other Than DODSSP) Naval Publication and Forms Center 5801 Tabor Ave.

Philadelphia, PA 19120 215-697-2197

c. For additional information contact the Contracting Officer USCG Surface Forces Logistics Center 2401 Hawkins Point Road Baltimore, MD. 21226-5000

(410) 762-6487

6.1.2. Commercial Documents

a. Society of Automotive Engineers INC. (SAE) 400 Commonwealth Drive Warrendale, PA 15096-0001 Phone 1-724-766-4841

FAX 1-724-776-0790

www.sae.org

b. American Society for Testing & Materials (ASTM) 100 Barr Harbor Drive PO Box C700 West Conshohocken, PA 19428-2959 Phone 1-610-832-9500

FAX 610-832-9555

www.astm.org

c. American National Standards Institute (ANSI) 25 West 43rd Street http://www.sae.org/ http://www.astm.org/

(Between 5th and 6th Avenues) 4th Floor New York, NY 10036 Customer Service Phone 1-212-642-4900

FAX 1-212-398-0023

www.ansi.org http://www.ansi.org/

Appendix A Hydraulic Cylinder Information

NSN: 3040-01-103-6565, P/N R433010583, Hydraulic Cylinder Assembly, 270 WMEC Fin Stabilizing System. Rexroth, double acting hydraulic cylinder, Bore diameter: 4", Rod diameter:

2.50", Stroke: 13.62", Max Operating Pressure: 3,000 PSI

NSN: 3040-01-123-6695, P/N: P161934, Hydraulic Cylinder, 270 Hydraulic Steering System, Double acting hydraulic cylinder, bore diameter- 7", Rod diameter- 3.50", compressed length 63", stroke 36", approximate weight 650 lbs. Max operating pressure - 2,400 PSI, Minimum burst- 9,600 PSI. Used on 270' WMEC steering system. Special feature - Eye rod and cylinder ends are equipped with sealed spherical bearings and thrust washers.

NSN: 3040-01-518-4648, P/N: 47045, Hydraulic Cylinder, 210 WMEC Allied 5700 Single Point Davit, Single acting cylinder assembly, 6" bore diameter x 22" stroke. Rod diameter 3", Operating pressure 2,500 PSI, Approximate weight 200 lbs.

NSN: 3040-01-581-1046, P/N: YMD-10376, Hydraulic Cylinder Jib, 270 WMEC Appleton Marine FB20-21. Single acting cylinder assembly, 7" bore diameter x 35.75" stroke. Rod diameter 3.5", Operating pressure 3,500 PSI.

NSN: 3040-01-581-1539, P/N: YMD-10375, Hydraulic Cylinder Luff, 270 WMEC Appleton Marine FB20-21. Single acting cylinder assembly, 8" bore diameter x 34.5” stroke. Rod diameter 4", Operating pressure 3,200 PSI.