Overhaul Description

This document is a detailed overhaul specification for a Cylinder Assembly (AActuating, Linear) with National Stock Number 3040-20-007-9327 and Part Number 3923-5100, used on 154' WPC Stern Launch Door vessels. The item has a 9-year shelf life and requires complete restoration to serviceable "A" Condition per Original Equipment Manufacturer (OEM) specifications and standards.

The contractor must disassemble, clean, and inspect the cylinder to determine estimated overhaul costs, then submit a detailed repair plan including material, labor rates, labor hours, testing, coating, preservation, packaging, marking, and bar-coding costs for Coast Guard Contracting Officer approval before proceeding. The inspection report must document contractor name, inspection date, cylinder identification, shipping crate condition, parts and materials for replacement with individual pricing, labor costs broken down by hours and hourly rate, and any unusual observations. Overhaul requires restoring the cylinder to meet all OEM design specifications and dimensions while functioning identically to new units, though appearance may differ. All replacement parts must be new OEM parts; reclaimed, recycled, or aftermarket parts are prohibited without written Contracting Officer permission. The cylinder boot must be replaced with new for each repair.

Testing requirements include standard production tests and inspections per OEM drawings and specifications. The contractor must perform leak tests using ISO VG 32 hydraulic oil, operate the cylinder through three complete full extension/retraction cycles, conduct static pressure tests at 3000 psi on both piston sides for minimum five minutes with no external leakage, test internal bypass leakage in both directions, and verify stroke length at 16 inches. Coating must use IAW coating manufacturer requirements with suitable primer compatible with final coating; color must match the original coating. All measuring devices and test equipment must be calibrated per IAW ANSI/NCSL Z540.3-2006 with current calibration stickers traceable to NIST. The contractor must provide certifications of successful standard production tests and inspections, with one certification placed in each unit box and copies forwarded to the Coast Guard Contracting Officer.

Preservation and packaging requirements specify individual preservation and wrapping for two years minimum protection against deterioration using Class 3 waterproof bags per MIL-PRF-131K with desiccant packs (one 8-unit pack per four linear feet of cylinder). Each cylinder must be packed individually in a wooden crate capable of protecting against damage during long-term warehouse storage and worldwide commercial shipments, using ring-type nails or wood screws with corrosion-resistant wood screws securing the lid. Cylinders must be secured with blocking to prevent movement over 50 lbs and accommodate forklift use. Markings on opposite box ends must display the National Stock Number, Item Name, Part Number, Government Order Number, and "Coast Guard SFLC Material, Condition 'A'" in machine-made stencils with permanent black print on white background, minimum 1/2 inch high lettering. All previous markings and quality assurance decals must be completely removed from reusable shipping containers prior to applying new markings. Standard manufacturer warranty applies, and items placed in inventory receive a two-year defect guarantee against failures occurring after installation. Government acceptance occurs at destination upon verification of no damage in transit, correctness, completeness, and contractor conformance to preservation, packaging, packing, and marking requirements.

The estimated cost for this overhaul is $12,000.57 with recommended sources including Jastram Engineering Ltd. (North Vancouver, BC), Baltimore Hydraulics Inc. (Baltimore, MD), and A-Tech Hydraulics Inc. (Baltimore, MD). The estimated cost to open and inspect is $500.00 each, with estimated repair costs of $12,000.57 and a new unit cost estimate of $24,000.00.