TECHNICAL SPECIFICATION

Transcription

1 MASSACHUSETTS BAY TRANSPORTATION AUTHORITY TECHNICAL SPECIFICATION EE&QA-879 Orange Line No. 12 Car WABCO GH-5½ Tread Brake Unit (P.N ) Overhaul ISSUED: July 06, 2017 REVISIONS: EQUIPMENT ENGINEERING & QUALITY ASSURANCE 1

2 Equipment Engineering and Quality Assurance Technical Specification Specification: EE&QA-879 SUBJECT: Orange Line No. 12 Cars WABCO GH-5½ Tread Brake Unit (P/N ) Overhaul Page: 2 Date: July 06, 2017 Revised: Revision: 1.0 PURPOSE SCOPE DELIVERABLES SPECIFICATIONS General Overhaul Final Testing CONTRACTOR REQUIREMENTS WARRANTY Fleet Defects DELIVERY PAYMENTS APPROVALS REVISIONS APPENDIX

3 Equipment Engineering and Quality Assurance Technical Specification Specification: EE&QA-879 SUBJECT: Orange Line No. 12 Cars WABCO GH-5½ Tread Brake Unit (P/N ) Overhaul Page: 3 Date: July 06, 2017 Revised: Revision: 1.0 PURPOSE The Massachusetts Bay Transportation Authority (MBTA), herein referred to as the Authority, seeks to completely overhaul WABCO GH-5½ Tread Brake Units used on the Orange Line No. 12 cars. 2.0 SCOPE A. This Technical Specification covers the requirements for the overhaul and testing of WABCO s GH-5½ Tread Brake Units (original P.N ) currently installed on the MBTA s Orange Line #12 Cars. The selected vendor, herein referred to as the Contractor, shall be recognized as being "technically responsible for the overhaul of the WABCO GH-5½ Tread Brake Units. In this document "technically responsible for" is defined as the overall responsibility for the proper design configuration, inspection, assembly and testing of the equipment defined in this specification. The overall cost to complete the rebuild must not exceed fifty-five percent (55%) of the cost of a new WABCO GH-5½ Tread Brake. The Contractor shall include the cost to purchase a new WABCO GH-5½ Tread Brake unit with their bid offer. The "technically responsible for" responsibilities include, but are not limited to, the following types of activities: 2.1 The specification of new components, anti-loosening hardware and sealants, protective coatings and lubricating materials. 2.2 Ensuring that the overhaul brake units meets all of the requirements outlined in this specification, including verifying that all required tests have been performed and satisfactory results were achieved. 2.3 Warranty responsibility (for hardware and workmanship). 2.4 Ensuring that the item s documentation is complete and accurate. 2.5 Ensuring that the original item reliability, maintainability and safety characteristics/requirements are achieved or exceeded. 2.6 Ensuring that replacement components for obsolete parts are completely compatible with the existing design arrangement. All none OEM parts must be verified as acceptable replacements in writing by the MBTA engineering. 3

4 Equipment Engineering and Quality Assurance Technical Specification Specification: EE&QA-879 SUBJECT: Orange Line No. 12 Cars WABCO GH-5½ Tread Brake Unit (P/N ) Overhaul Page: 4 Date: July 06, 2017 Revised: Revision: 2.7 The identification of official configuration of the overhaul item shall be properly secured and identified on its name plate. 2.8 The arrangement of, responsibility for, and payment of all shipping and delivery costs for all items associated with this specification. 3.0 DELIVERABLES The materials and services to be provided by the Contractor pursuant to this Technical Specification shall include the following deliverables: 3.1 Thirty (30) days after Notice To Proceed (NTP) and a written scope of work From the Contractor detailing: Service Bulletins from the OEM that may not have been incorporated into the item. Approval shall be obtained from the MBTA prior to incorporating a particular Service Bulletin. Additional tasks, if any, which are identified by the Contractor and approved by the MBTA. 3.2 WABCO GH-5½ Tread Brake Units will be completely overhauled. Thirty (30) days after NTP the contractor shall deliver the first units to the Authority. Cost and method of shipping the tread brake units to and from the Authority s facilities shall be the responsibility of the Contractor. Tread brake units will be delivered palletized. Each pallet will contain eight (8) total brake units; Six (6) GH-5½ Tread Brake Unit CP , one (1) GH-5½ - HL Tread Brake Unit CP and one (1) GH-5½ - HR Tread Brake Unit CP Combined overhaul, testing and return delivery time of brake packages shall not exceed thirty (30) calendar days from the notification date of units shipped from the Authority s facility. 3.3 Protective packaging for return shipment/delivery of the item(s) to the MBTA as stipulated in section 7.0. The packaging shall mitigate transport damage to the item(s) and to its (their) protective paint coating(s). Copies of the original Test Certifications for the specific items involved shall be shipped integral with the packaging by using a sealed envelope of appropriate size that clearly 4

5 Equipment Engineering and Quality Assurance Technical Specification Specification: EE&QA-879 SUBJECT: Orange Line No. 12 Cars WABCO GH-5½ Tread Brake Unit (P/N ) Overhaul Page: 5 Date: July 06, 2017 Revised: Revision: 4.0 SPECIFICATION identified as containing Copies of Test Certifications. 4.1 General Requirements The GH 5-½ Tread Brake Unit shall be overhauled in accordance with the procedures provided in the appendix of this Technical Specification as defined within this Technical Specification. The overhaul includes a thorough inspection of all components not slated for disposal. All reusable parts shall be thoroughly cleaned in accordance to OEM cleaning procedure prior to inspection and reuse. Thread locker, grease and all other appropriate consumables will be applied in accordance with OEM specification. All hardware is to be disposed of and replaced with new hardware. Painted parts are to be re-painted black. Any parts to be repainted will be fully stripped, appropriately masked, primed, and painted. Any surface rust is to be removed without causing damage to underlying surface. Where conflicts between documents may arise, this Technical Specification and MBTA generated processes shall take precedence over O.E.M. documentation unless a deviation is requested by the Contractor and Approved by the MBTA. If MBTA documentation does not exist for a specific overhaul task or specification then the O.E.M. spec; Appendix 1: WABCO Operation and Maintenance Information GH-5½ Tread Brake Unit, is to be referenced. 4.2 Overhaul: [See Appendix 1: WABCO Operation and Maintenance Information for the MBTA GH-51/2 Tread Brake Unit, (original part No )]: A. Completely clean and disassemble the GH-5½ Tread Brake Unit and all its reusable components. The Brake Package as a unit shall be steam cleaned upon initial reception. B. All rubber or composite components containing rubber shall be replaced. All fastening, adjusting hardware, springs and pins shall be replaced. C. Refer to table in Appendix 2: GH-5½ Tread Brake Unit Overhaul Parts List. Parts are labeled with one of 4 instructions: i. Components Off The Shelf (COTS) Hardware, Replace: Replace part. ii. Dispose and Replace: Replace part. 5

6 Equipment Engineering and Quality Assurance Technical Specification Specification: EE&QA-879 SUBJECT: Orange Line No. 12 Cars WABCO GH-5½ Tread Brake Unit (P/N ) Overhaul Page: 6 Date: July 06, 2017 Revised: Revision: iii. iv. Inspect, Contact MBTA Engineering for Authority to Replace or Reuse If Necessary: Inspect in accordance with Appendix 1: WABCO Operation and Maintenance Information GH-5½ Tread Brake Unit. Sections III.E Cleaning, Inspecting, and Repairing notes D and H. If inspection fails or is in question contact MBTA Engineering for permission to replace or reuse the specific part. A contact name, number and will be provided with the first shipment of overhaul brake units to the Contractor. Refer To Part Level Instructions For This Assembly: Disregard this line item and refer to the part level instructions for all parts within the assembly or subassembly. D. Clean all reusable parts with an aliphatic organic solution such as mineral spirits or naphtha. Refer to Appendix 1: WABCO Operation and Maintenance Information GH-5½ Tread Brake Unit. Sections III.E Cleaning, Inspecting, and Repairing notes A, C, D and H. E. All OEM painted parts will have their existing paint removed, surfaces prepared, and repainted. All surfaces to be painted are the surfaces that originally came painted from O.E.M. i. Sandblasting is an approved method of paint removal. Contact the MBTA for approval to use other methods of paint removal. The cost to remove paint by sandblasting or any other approved method shall be submitted by the Contractor in their bid package. ii. Prepare surface per O.E.M. instructions in Appendix 6: Variprime 615S Self Etching Primer Specification Sheet. iii. iv. Mask all mating faces, through holes and threads. Prime all surfaces to be painted per O.E.M. instructions in Appendix 6: Variprime 615S Self Etching Primer Specification Sheet. Let primer cure per Appendix 6: Variprime 615S Self Etching Primer Specification Sheet. v. Paint appropriate surfaces per instructions in Appendix 7: ALK-FP901 Black Enamel Paint Specification. Let part cure per ALK-FP901 Black Enamel Paint Specification. F. Assemble the overhaul GH-5½ assembly by ensuring that parts are appropriately lubricated and tightened per Appendix 1: WABCO Operation and Maintenance Information GH-5½ Tread Brake Unit section III.F Lubrication and Assembly. 6

7 Equipment Engineering and Quality Assurance Technical Specification Specification: EE&QA-879 SUBJECT: Orange Line No. 12 Cars WABCO GH-5½ Tread Brake Unit (P/N ) Overhaul Page: 7 Date: July 06, 2017 Revised: Revision: G. A new O.E.M. serialized number plate shall be installed into the same place and position as the original O.E.M. serial number plate. This shall be done in sequential order starting from the first rebuild. NOTE: During assembly step III.F.17 place an appropriate configuration of shims between items 16 and 104 in order to eliminate lateral play while ensuring O.E.M. functionality. Grease all mating faces with appropriate grease per III.F.1a. The shims shall be placed evenly on both sides of the mating hole on part 104. Shim specification can be found in Appendix 8: Precision Brand Shims. Shims shall be purchased from Precision Brand. MBTA must approve any substitute shims or sourcing deviation. 4.3 Final Testing Test each individual repaired brake package per Appendix 4: Wabtec Passenger Transit G Type Tread Brake Unit Test Specification. Print and complete test specification data sheet per Appendix 7: Wabtec Passenger Transit G Type Tread Brake Unit Data Sheet. All passing units will be shipped with their completed Wabtec Passenger Transit Test Specification; G Type Tread Brake Units Data Sheet attached. Contact MBTA for specific instructions regarding failing units. 5.0 CONTRACTOR REQUIREMENTS The selected Contractor shall have a minimum ten years of previous transit experience performing as the prime contractor, manufacture or remanufacture of overhauling Air Brakes for rail cars similar to those on the Authority s Orange Line No. 12 subway cars. The Contractor shall provide service-proven overhauled rail cars air brakes by using components that have functioned successful in revenue service since delivery. The Contractor shall meet the certifications of Quality Assurance from the Association of American Railroads (AAR) as specified in M-1003 or the certification of an equivalent ISO Quality Assurance program. Additionally all upgraded/modified components must be selected with the understanding and guarantee to insure reliable revenue operation. The selected Contractor shall have the capability to deliver up to forty-eight (48) overhauled brake packages every thirty (30) days. 6.0 WARRANTY Each overhauled item shall be warranted for a period of two (2) years on parts and labor. If overhauled unit failed before the two years warranty the Contractor is responsible for all the cost associated with repairing the failed brake unit, including shipping the failed 7

8 Equipment Engineering and Quality Assurance Technical Specification Specification: EE&QA-879 SUBJECT: Orange Line No. 12 Cars WABCO GH-5½ Tread Brake Unit (P/N ) Overhaul Page: 8 Date: July 06, 2017 Revised: Revision: units back the Contractor s repair facility. 6.1 Fleet Defects A Fleet defect is defined as cumulative failures of the same component in the same or similar application during the warranty period. The cumulative failures shall not exceed 15% of the overhauled units operating in revenue service. 7.0 DELIVERY Within thirty (30) days of being notified of a fleet defect the Contractor shall submit a proposed corrective action plan to address the defect on the MBTA s revenue fleet. Upon implementing the corrective action, all components shall be warranted for either one (1) year from the date of the corrective action, or for the remainder of the warranty period, whichever is greater. All materials shall be delivered to the MBTA s Wellington Carhouse located in Medford, MA or any other address designated by the MBTA s Project Manager. All components shipped to MBTA shall be packaged in Protect HD 100 Moisture Barrier Material, or approved equal, with the inclusion of a desiccant to sustain a state of dryness. Certain replaced components will be required to be returned back from the Contractor. Referring to Appendix 3: GH-5½ Tread Brake Units Parts Catalog part 48 (Body, Cylinder) and assembly 85 (Slack Adjuster Ratchet Nut, Parts 86-90) are to be packaged and returned along with the pallets. Parts 12 (Head, Brake), 16 (Hanger), and 92 (Cylinder Lever) are to be returned to the MBTA if replaced during the overhaul. For each incoming pallet to the MBTA there shall be a corresponding box of used parts delivered concurrently. The returned parts shall all be protectively wrapped for shipping and packaged in Protect HD 100 Moisture Barrier Material, or approved equal, with the inclusion of a desiccant to sustain a state of dryness. 8.0 PAYMENTS Payments will be made as the brake units are delivered. Overhauled tread brake units shall be delivered palletized. Each pallet will contain eight (8) total brake units; Six (6) GH-5½ Tread Brake Unit CP , one (1) GH-5½ - HL Tread Brake Unit CP and one (1) GH-5½ - HR Tread Brake Unit CP Such payments will include shipping cost per pallet. The total of all the per pallet payments is not to exceed the price bid for the contracted work and shipping. 8

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10 Equipment Engineering and Quality Assurance Technical Specification Specification: EE&QA-879 SUBJECT: Orange Line No. 12 Cars WABCO GH-5½ Tread Brake Unit (P/N ) Overhaul Page: 10 Date: July 06, 2017 Revised: Revision: 10.0 REVISIONS 10

11 Equipment Engineering and Quality Assurance Technical Specification Specification: EE&QA-879 SUBJECT: Orange Line No. 12 Cars WABCO GH-5½ Tread Brake Unit (P/N ) Overhaul Page: 11 Date: July 06, 2017 Revised: Revision: 11.0 APPENDIX Appendix 1 (pp12-19): Appendix 2 (pp20-23): Appendix 3 (pp24-29): Appendix 4 (pp30-53): Appendix 5 (pp54-56): Appendix 6 (pp57-59): Appendix 7 (pp60-61): Appendix 8 (pp62): WABCO Operation and Maintenance Information GH-5½ Tread Brake Unit. GH-5½ Tread Brake Unit Overhaul Parts List. GH-5½ Tread Brake Units Parts Catalog Wabtec Passenger Transit Test Specification; G Type Tread Brake Units. Wabtec Passenger Transit Test Specification; G Type Tread Brake Units Data Sheet Variprime 615S Self Etching Primer Specification Sheet ALK-FP901 Black Enamel Paint Specification Precision Brand Shims 11

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20 Equipment Engineering and Quality Assurance Appendix 2 WABCO Operation and Maintenance Information GH-5½ Tread Brake Unit. Page: 1 Fig No. Parts Name PC. No. Overhaul Instructions 1 ELASTIC STOP NUT COTS HARDWARE, REPLACE 2 WASHER COTS HARDWARE, REPLACE 3 SPRING DISC DISPOSE AND REPLACE 4 1/8"X1" COTTER PIN COTS HARDWARE, REPLACE 5 CLEVIS PIN DISPOSE AND REPLACE 6 POSITIONING SPRING DISPOSE AND REPLACE 7 BOLT, HANGER LEVER COTS HARDWARE, REPLACE 8 TEE HD, KEY (BRAKE SHOE) INSPECT, CONTACT MBTA FOR AUTHORITY TO REPLACE / REUSE IF NECESSARY 9 PIN, CYL. SPR., 3/8"X2-3/4" DISPOSE AND REPLACE 10 SPRING, TORSION DISPOSE AND REPLACE 11 RETAINER, BR. SHOE KEY DISPOSE AND REPLACE 12 HEAD, BRAKE INSPECT, CONTACT MBTA FOR AUTHORITY TO REPLACE / REUSE IF NECESSARY 13 ELASTIC STOP NUT COTS HARDWARE, REPLACE 14 WASHER COTS HARDWARE, REPLACE 15 HANGER LEVER BOLT COTS HARDWARE, REPLACE 16 HANGER INSPECT, CONTACT MBTA FOR AUTHORITY TO REPLACE / REUSE IF NECESSARY 17 CAP SCREW, 3/8"X3/4" COTS HARDWARE, REPLACE 18 LOCK WASHER, 3/8" COTS HARDWARE, REPLACE 19 RETAINING RING DISPOSE AND REPLACE 20 RETAINING RING COTS HARDWARE, REPLACE 21 PROTECTOR RING (DUST BOOT) DISPOSE AND REPLACE 22 DUST BOOT DISPOSE AND REPLACE 23 SLACK ADJUSTER SCREW DISPOSE AND REPLACE SOCKET HD CAP SCRW 1/2"X 24 1/1/4" COTS HARDWARE, REPLACE 25 WASHER, INT. TOOTH LOCK, 1/2" COTS HARDWARE, REPLACE 26 DUST BOOT RETAINER ASY DISPOSE AND REPLACE 27 PHL. HD. MACH SCR..190X5/8" COTS HARDWARE, REPLACE 28 SQUARE NUT, # COTS HARDWARE, REPLACE 29 DUST BOOT RETAINER DISPOSE AND REPLACE 30 DUST BOOT DISPOSE AND REPLACE 31 HAND BRAKE ASMBLY REFER TO PART LEVEL INSTRUCTION FOR THIS ASSEMBLY 32 PIN, CYL. SPR., 1/8"X 1-3/4" DISPOSE AND REPLACE 33 FULCRUM PIN DISPOSE AND REPLACE 34 HAND BRAKE LEVER INSPECT, CONTACT MBTA FOR AUTHORITY TO REPLACE / REUSE IF NECESSARY 20

21 35 FULCRUM HANDBRAKE INSPECT, CONTACT MBTA FOR AUTHORITY TO REPLACE / REUSE IF NECESSARY 36 GASKET DISPOSE AND REPLACE 37 PIPE PLUG 1-1/4" PIPE DISPOSE AND REPLACE 38 RETAINER, CYL. PIN DISPOSE AND REPLACE 39 PIN, CYL. LEVER DISPOSE AND REPLACE 40 CAP SCREW, 1/2 X 1-1/2" COTS HARDWARE, REPLACE 41 WASHER SPRING LOCK, 1/2" COTS HARDWARE, REPLACE 42 CYLINDER ASY REFER TO PART LEVEL INSTRUCTION FOR THIS ASSEMBLY 43 RETAINING RING DISPOSE AND REPLACE 44 SEAT, SPRING INSPECT, CONTACT MBTA FOR AUTHORITY TO REPLACE / REUSE IF NECESSARY 45 SPRING RELEASE DISPOSE AND REPLACE 46 CUP PACKING DISPOSE AND REPLACE 47 PISTON DISPOSE AND REPLACE 48 BODY CYLINDER DISPOSE AND REPLACE 49 GASKET, CYLINDER DISPOSE AND REPLACE 50 SCREW, 3/8 X 7/8"HX HD COTS HARDWARE, REPLACE 51 LOCK WASHER, 3/8" COTS HARDWARE, REPLACE 52 COVER, BACK INSPECT, CONTACT MBTA FOR AUTHORITY TO REPLACE / REUSE IF NECESSARY 53 GASKET, BACK COVER DISPOSE AND REPLACE 54 FITTING, ALEMITE, 1/8" X 90* DISPOSE AND REPLACE 55 SCREW FL HD 1/4X3/4" COTS HARDWARE, REPLACE 56 COVER, FULCRUM PIN (W 1/8 NPT) INSPECT, CONTACT MBTA FOR AUTHORITY TO REPLACE / REUSE IF NECESSARY 57 COVER, FULCRUM PIN INSPECT, CONTACT MBTA FOR AUTHORITY TO REPLACE / REUSE IF NECESSARY 58 GASKET, FULCRUM PIN COVER DISPOSE AND REPLACE 59 PIN, FULCRUM DISPOSE AND REPLACE 60 LOCK NUT INSPECT, CONTACT MBTA FOR AUTHORITY TO REPLACE / REUSE IF NECESSARY 61 LOCK WASHER COTS HARDWARE, REPLACE 62 BEARING, SL ADJ RING DISPOSE AND REPLACE 63 SLACK ADJ RING ASY REFER TO PART LEVEL INSTRUCTION FOR THIS ASSEMBLY 64 SPRING, PAWL DISPOSE AND REPLACE 65 RETAINING RING COTS HARDWARE, REPLACE 66 PIN, PAWL LINK DISPOSE AND REPLACE 67 PAWL DISPOSE AND REPLACE 68 RETAINING RING COTS HARDWARE, REPLACE 69 PIN, PAWL LINK DISPOSE AND REPLACE 70 STEM ASY REFER TO PART LEVEL INSTRUCTION FOR THIS ASSEMBLY 71 RING, RETAING, 1/4" COTS HARDWARE, REPLACE 72 PIN, ROLLER DISPOSE AND REPLACE 73 ROLLER DISPOSE AND REPLACE 74 WASHER COTS HARDWARE, REPLACE 75 STEM DISPOSE AND REPLACE 76 RING, RETAING COTS HARDWARE, REPLACE 77 PIN, PAWL LINK DISPOSE AND REPLACE 21

22 78 LINK, PAWL DISPOSE AND REPLACE 79 SPRING, SLACK ADJ DISPOSE AND REPLACE 80 SEAT, SPRING DISPOSE AND REPLACE 81 SPRING, DETENT DISPOSE AND REPLACE 82 RATCHET DISPOSE AND REPLACE 83 BODY, RING DISPOSE AND REPLACE 84 SPACER, SLACK ADJ INSPECT, CONTACT MBTA FOR AUTHORITY TO REPLACE / REUSE IF NECESSARY 85 SLACK ADJ RATCHET NUT ASY REFER TO PART LEVEL INSTRUCTION FOR THIS ASSEMBLY 86 LOCK NUT DISPOSE AND REPLACE 87 LOCK WASHER DISPOSE AND REPLACE 88 GEAR DISPOSE AND REPLACE 89 KEY DISPOSE AND REPLACE 90 NUT, RATCHET DISPOSE AND REPLACE 91 BEARING, FULCRUM PIN DISPOSE AND REPLACE 92 CYLINDER LEVER, ASY INSPECT, CONTACT MBTA FOR AUTHORITY TO REPLACE / REUSE IF NECESSARY 93 CAP HD SCREW, 1/4 X 1/2" COTS HARDWARE, REPLACE 94 WASHER, PLAIN, 1/4" COTS HARDWARE, REPLACE 95 WASHER, LOCK, 1/4" COTS HARDWARE, REPLACE 96 BEARING DISPOSE AND REPLACE 97 RING, RETAINER COTS HARDWARE, REPLACE 98 STRAINER DISPOSE AND REPLACE 99 NUT, ELASTIC STOP 5/16" COTS HARDWARE, REPLACE 100 GEAR, DRIVER DISPOSE AND REPLACE 101 SPRING, RETURN DISPOSE AND REPLACE 102 O-RING, 15/16" OD COTS HARDWARE, REPLACE 103 SHAFT, DRIVE GEAR DISPOSE AND REPLACE 104 BODY INSPECT, CONTACT MBTA FOR AUTHORITY TO REPLACE / REUSE IF NECESSARY 22

23 -Image Referenced from: GH-5½ Tread Break Units; Parts Catalog. Pg. 2 23

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57 VARIPRIME 615S SELF-ETCHING PRIMER GENERAL DESCRIPTION A two-component, self-etching primer designed for spot, panel and overall repairs. It is fastdrying and provides excellent corrosion resistance and direct-to-metal adhesion. The products referenced herein may not be sold in your market. Please consult your distributor for product availability. MIXING COMPONENTS Variprime 615S Self-Etching Primer Variprime 614S Slow Converter Variprime 616S Converter Variprime 620S Fast Converter Tips for Success Keep cans closed when not in use to prevent moisture absorption, which may lead to blistering, loss of adhesion or other product failure. MIX RATIO Combine the components either by volume or weight (cumulative). Mix thoroughly. Component Volume Weight (qt.) 615S Self-Etching Primer grams 616S Converter grams VISCOSITY seconds in a Zahn #2 cup. POT LIFE 72 hours ADDITIVES Accelerator: Fish Eye Eliminator: Flex Additive: Retarder: Not recommended Not recommended Not recommended Not recommended TINTING Not recommended PRIMER/SEALER Fill N Sand 131S Acrylic Primer Surfacer 4004S Ultra Productive 2K Primer Filler ChromaBase "4 to 1" 7701S / 7704S / 7707S 2K Urethane Primer Filler ChromaBase "4 to 1" 7710S / 7740S / 7770S 2K Urethane Sealer ChromaPremier Pro 33430S Productive Primer Filler ChromaPremier 42400S / 42410S / 42440S / 42470S / 2K Premier Sealer ChromaPremier Pro 44410S / 44440S / 44470S 2K Premier Sealer Tips for Success For optimum holdout and performance, VariPrime 615S Self-Etching Primer must always be primed or sealed prior to topcoat application. 57

58 APPLICATION SUBSTRATES Properly prepared/cleaned steel, aluminum and galvanized SURFACE PREPARATION Wipe surface with First Klean 3900S Surface Cleaner or Prep-Sol 3919S Cleaning Solvent. Sand and featheredge with P180 DA grit paper followed by P240 DA grit. Remove sanding residue with Final Klean 3901S Surface Cleaner, 3939S Lacquer and Enamel Cleaner or 3909S Low VOC Surface Cleaner. GUN SETUPS* Compliant Siphon Feed: Gravity Feed: HVLP Siphon Feed: Gravity Feed: AIR PRESSURE* Compliant Siphon Feed: Gravity Feed: HVLP Siphon Feed: Gravity Feed: 1.5 mm-1.8 mm 1.4 mm-1.6 mm 1.5 mm-1.8 mm 1.3 mm-1.6 mm psi at the gun psi at the gun 6-8 psi at the gun cap 6-8 psi at the gun cap *The listed setups cover the usual range for standard application equipment. APPLICATION Apply 2 medium coats. Flash between coats until dull (normally 5 minutes). CLEANUP Clean spray equipment as soon as possible with lacquer thinner. DRY TIMES AIR DRY Nib Sanding: recommended) Priming: Max Allowable Dry Time: 5-10 minutes after flash (wet sanding not minutes 24 hours; then sanding is required FORCE DRY Not recommended Note: Variprime 615S should be primed or sealed within 16 hours for best performance. 58

59 PHYSICAL PROPERTIES All Values Ready To Spray Max. VOC (LE): 721 g/l (6.0 lbs./gal) Max. VOC (AP): 700 g/l (5.8 lbs./gal) Avg. Gal. Wt.: 992 g/l (8.28 lbs./gal) Avg. Wt.% Volatiles: 72.0% Avg. Wt.% Exempt Solvent: 6.8% Avg. Wt.% Water: 1.0% Avg. Vol.% Exempt Solvent: 9.7% Avg. Vol.% Water: 1.0% Theoretical Coverage: 200 sq. feet per RTS gallon at 1 mil Recommended Dry Film Thickness: mils in 2 coats Flash Point: See MSDS/SDS VOC REGULATED AREAS These directions refer to the use of products which may be restricted or require special mixing instructions in VOC regulated areas. Follow mixing usage and recommendations in the VOC Compliant Products Chart for your area. SAFETY AND HANDLING For industrial use only by professional, trained painters. Not for sale to or use by the general public. Before using, read and follow all label and MSDS/SDS precautions. If mixed with other components, mixture will have hazards of all components. Ready to use paint materials containing isocyanates can cause irritation of the respiratory organs and hypersensitive reactions. Asthma sufferers, those with allergies and anyone with a history of respiratory complaints must not be asked to work with products containing isocyanates. Do not sand, flame cut, braze or weld dry coating without a NIOSH approved air purifying respirator with particulate filters or appropriate ventilation, and gloves. Revised: January

60 Alkyd Enamel Factory Pack ALK-FP CPC 106 ALK-FP101 ALK-FP301 ALK-FP401 ALK-FP601 ALK-FP701 ALK-FP801 ALK-FP827 ALK-FP901 ALK-FP951 Component A Alkyd Enamel - Ford Blue Alkyd Enamel - Ice Gray Alkyd Enamel - John Deere Green Alkyd Enamel - Kubota Orange Alkyd Enamel - Case IH Red Alkyd Enamel - Bright Yellow Alkyd Enamel - New Cat Yellow Alkyd Enamel - Black Alkyd Enamel - White RECOMMENDED USE Type: Alkyd Enamel The ALK-FP series of topcoats are fast drying alkyd enamels that produce a durable, chemical resistant finish. They are intended for industrial use on primed or un-primed surfaces. Suitable application include agricultural and construction equipment, metal fabrication, castings, cabinets and machinery. CHEMICAL RESISTANCE 10% Sulfuric Acid Good 10% Ammonia Very Good Xylene Fair Oil Very Good 500 hours salt spray Fair 10%Hydrochloric Acid Good 10%Sodium Hydroxide Good Isopropyl Alcohol Good Gasoline Fair SURFACE PREPARATION The surface to be coated must be sanded, free of all contamination, including dust, dirt, oil, grease and oxidation. Chemical treatment or the use of a conversion coating will improve the adhesion and performance properties of the finished coat. Metal PHYSICAL CONSTANTS (varies by color) Mixed VOC 4.68 lbs./gal. Cold Rolled Steel Percent Solids by Weight 48.0 ± 8% Percent Solids by Volume 35 ± 5% Hot Rolled Steel Weight Per U.S. Gallon lbs/gal Flash Points (Penskey Martins) 71ºF (22ºC) Galvanized Ready To Spray Viscosity #2 Zahn = N/A #3 Zahn = seconds Galvaneal PERFORMANCE FEATURES Pencil Hardness HB-H Aluminum Flexibility Excellent Fade Resistance Good 96 hour Humidity Good Sheen 60º angle Plastic/Fiberglass Adhesion Excellent Resistance to intermittent Water Resistance exposure. Not recommended for immersion service In Service Temperature 200ºF (93ºC) Limitations Note: As you approach 200 F, depending on the pigmentation, the color may change, but film integrity will be maintained until 200 F. Reccommended Primers EPX-900, HBA- 3035, HSP-900/902, PLC-900, VAP-9XX EPX-900, HBA- 3035, HSP-900/902, PLC-900, VAP-9XX EPX-900, HSP- 900/902, PLC-900 EPX-900, HSP- 900/902, PLC-900 EPX-900, HBA- 3035, HSP-900/902, PLC-900, VAP-9XX Direct To Properly Treated Substrate Very Good Very Good Not Recommended Not Recommended Fair Surface should be free of all contamination. Because of the variability of plastic/fiberglass substrates, coating performance should be confirmed on the actual plastic/fiberglass substrate being used. 60

61 APPLICATION DATA SAFETY Mixing Directions Ready-To-Spray. These materials are designed for application only by Stir thoroughly before and occasionally during use. professional, trained personnel, using proper equipment under controlled conditions and are not intended for sale to the Thinning general public. Safe application of paints and coatings Thinning is not normally required; however, under adverse requires knowledge of equipment materials and individual conditions, small amounts (10% or less) of xylene or aromatic 100 training. Directions and precautionary information on both may be added. equipment and products should be carefully read and strictly Pot Life N/A Application Equipment Conventional Spray: psi at the gun. observed for personal safety and property protection. Consideration must be given to eliminate conditions, which may generate hazardous atmospheres during spray application or subject operators or bystanders to injury or illness. Special precautions must be taken when utilizing Airless: psi. Tip = spray equipment, particularly airless equipment. Highpressure injection of coatings into the skin by airless Air Assisted: 850-psi min. at the tip, psi. Tip = equipment may cause serious injury requiring immediate medical attention at a hospital. Treatment advice may also be Note: As needed, 5% slow Aromatic solvent may be required to eliminate popping. obtained from Poison Centers. Air quality should be maintained with adequate ventilation; applicators can achieve additional protection by wearing respirators and other Drying Times* 77 F (25 C) and 50% relative humidity. protective garments such as gloves and overalls. In all cases, wear protective eye equipment. During the application of all To Touch: 10 to 20 minutes coatings materials, all flames, welding and smoking must be prohibited. Explosion proof equipment must be used when To Handle: 45 Minutes* coating these materials in confined areas. To Tape: To Dry: 4 hours** PRECAUTIONARY INFORMATION To Recoat: Before 4 hours or after 72 hours *** Force Dry: (Allow 10 minutes air dry) Bake: ºF * This condition does not mean that the paint film has reached full cure. It is a stage where handling can be achieved without loosening, wrinkling or otherwise marring the film under minimal pressure from fingers or hands. Drying time listed may vary, depending upon film build, color selection, temperature, humidity and degree of air movement. ** Paint film is not fully cured for 7 days. *** IMPORTANT! If this product is recoated between 4 hours and 72 hours, lifting of the previous finish will occur. Before 4 hours, the coating is adequately solubilized to prevent lifting, while after 72 hours, cure has progressed to a point where solvent resistance is achieved. Application of film thickness in excess of that recommended for this product will substantially extend dry time and lengthen the recoat window. Recommended Spreading Rate 561 sq. ft. at 1.0 mil dry film per U.S. gallon (varies by color). Coverage figures do not include losses due to mixing, transfer or application of coating or losses due to surface irregularities or porosity. Clean Up Toluene or Xylene Application Precautions and Limitations Apply only when air, product or surface temperature is above 60ºF (16ºC) and when surface temperature is at least 5ºf (3ºc) above the dew point. Brush and roller application is not recommended. Brush and roller application is not reccommended. Before using the products listed herein, carefully read each product label and follow directions for its use. Please read and observe all warnings and precautionary information on all product labels. Prevent all contact with skin and eyes and breathing of vapors and spray mist. Repeated inhalation of high vapor concentrations may cause a series of progressive effects including irritation of the respiratory system, permanent brain and nervous system damage and possible unconsciousness and death in poorly ventilated areas. Eye watering, headaches, nausea, dizziness and loss of coordination are indications that solvent levels are too high. Intentional misuse by deliberately concentrating and inhaling the contents can be harmful or fatal. KEEP OUT OF THE REACH OF CHILDREN MEDICAL RESPONSE Emergency Medical or Spill Control Information (412) ; CANADA (514) Have label information available. Recommended Wet Film Build (Unreduced): mils MATERIAL SAFETY DATA SHEET Recommended Dry Film Build: mils Material Safety Data Sheets for the PPG products mentioned Film in excess or below these recommended film builds may cause in this publication are available through your PPG Distributor. problems such as, adhesion failure, pigment floatation, solvent FOR ADDITIONAL INFORMATION REGARDING THIS PRODUCT, SEE popping, slow cure, and accelerated gloss and color failure. THE MSDS AND LABEL INFORMATION. To the best of our knowledge, the technical information in this bulletin is accurate; however, since PPG Industries, Inc. is constantly improving its coatings and paint formulas, the current technical data may vary somewhat from what was available when this bulletin was printed. Contact your PPG Distributor for the most up-to-date information. PPG Industries Progress Drive Strongsville, OH PPG Canada Inc Royal Windsor Drive Mississauga, Ontario L5J 1K PPG Industries Part No. CPC 106, 1/07

62 Precision Brand Products, Inc Curtiss Street Downers Grove, IL USA Phone: Fax: General 62