EAGLE SOW of NO. 2 SSDG OVHL (1).doc

OVERHAUL OF SHIP SERVICE DIESEL GENERATOR (ENGINE) ONBOARD CGC EAGLE

Intent: The NO. 2 Ship Service Diesel Generator engine onboard Coast Guard Cutter EAGLE requires an overhaul. This engine is a 3406C series CATERPILLAR powering an 1800 RPM, 320 KW generator. The engine is currently in use and operating without any known issues. This overhaul is required to meet a 12,000-hour maintenance requirement.

References:

a. CATERPILLAR technical publications for the 3406C series engine. Engine serial number is 1SS00792. Engine arrangement number is 177-8878.

b. Coast Guard drawings: None

c. Other references: See the attached parts list and photos. The parts list may not include all parts necessary to perform an overhaul. It is highly recommended that the vendor review and validate this information against a CATERPILLAR parts manual. Prospective vendors should also review the photographs showing the engine as mounted within CGC EAGLE’s generator room to get an idea of the working space available.

Location: This work will be completed within the ships generator room. The ship will be located at the following address;

COMMANDING OFFCIER

USCGC EAGLE (WIX 327)

2401 HAWKINS POINT RD

BALTIMORE, MD 21226

The unit POC is CWO Anthony Sayward at 860-442-1016 or via email at Anthony.E.Sayward@uscg.mil Performance period: The performance period is 15 Oct – 09 Dec 2025 Requirements:

a. The equipment will be operated with the vendor and contracting officer’s representative present to demonstrate that it is fully functional without abnormal noise, temperatures, or pressures. The vendor will generate a Condition Found Report (CFR) to document their observation of the equipment operating condition. The ships electrician will secure all power to the engine, record generator air gap readings, unwire the generator, and assist with relocating the generator away from the engine work area. Ship’s crew will drain and dispose of the jacket water, oil, and fuel within the engine.

b. Vendor will provide a CATERPILLAR certified tech rep to complete this task. (A copy of this certification must be provided prior to contract award.) The tech rep is responsible for disassembly, cleaning, inspecting, and reassembly of the engine as per the OEM technical publications.

c. The vessel will provide a minimum of two engineering personnel E-4 or higher to assist with this project at all times. The CG personnel will be under the supervision of the tech rep. They have no authority to deviate from the OEM published procedures or the direction/guidance provided by the tech rep. They will be serving solely as apprentices to increase their knowledge and skills levels on this series engine.

d. All work will be performed Monday – Friday from 0730 -1700. No work will be allowed afterhours or on weekends without approval from the ships engineering officer.

e. Vendor will provide all parts to conduct a complete overhaul of the engine as per the OEM technical publications renewing all seals, bearings, bushings, O-rings, gaskets, retaining clips etc. Vendor will also renew; the fuel transfer pump, fuel injection pump, fuel priming pump, governor drive assembly, fuel nozzles/injectors, cylinder head assembly, turbocharger, cylinder liners, pistons, connecting rods, wrist pins, piston rings, camshaft, jacket water pump, raw/sea water pump, lube oil pump, after cooler cores, lube oil cooler, vibration dampener, thermostats, non-metallic hoses, breather assembly, fuel and air filters, service/hour meter, etc. Note this is not an exclusive list, additional parts may be required to place the engine in a ready for full operation status for another 12,000 hours.

f. The vendor will clean and inspect the following items for reuse IAW the OEM technical publications: engine block, crankshaft, oil pan, jacket water expansion tank, after cooler housing, valve covers, intake and exhaust manifolds, accessory drive, auto timing device, timing gears, fly wheel, starter, and all hard lines for jacket water, raw water, fuel, etc. A CFR will be generated to document the inspection results of the above components. Should any component require replacement, another CFR shall be generated to document the inspection results and state why the part is condemned. The CG will purchase replacements as needed.

g. The vendor will provide all special tools, reference materials, cleaning equipment, crane services, etc. as necessary to complete this task. Cleaning of used parts or removal of any preservatives from new parts must be completed at an outside facility arranged by the vendor.

h. Vendor will also provide any sealants, assembly lube, thread locking compounds, anti-seize compounds, gasket material, gasket sealants/cements, lint free rags, cleaning chemicals/supplies, or CATERPILLAR specific materials as required by the technical publication. Ship’s crew will provide oil and jacket water to refill engine.

i. Under the direction/guidance of the tech rep, the ships electrician’s will relocate the generator and assemble on the engine. Once completed they will take and record the air gap readings. A CFR is required to document air gap results. If within the OEM specifications, ships force will rewire the generator and restore all power to the engine. If air gap readings are outside OEM specifications the tech rep and ships force will investigate, identify the cause, and take corrective action before reassembly can be continued. A CFR will be generated stating the discrepancy found and action taken to resolve it. Air gap readings must be confirmed again prior to continuing work. The finial air gap readings must be documented via a CFR.

j. The vendor and ships force will ensure all fluid levels have been replenished, all filters are clean and any heaters for oil/jacket water systems are in the “on” position. Once temperatures have stabilized and no leaks have been identified, the vendor will inform the engineer officer via CFR that they are ready to start the engine.

k. The engine will be started with contracting officer’s representative and tech rep present and ran in an unloaded condition for a minimum of 30 minutes. During this period the equipment will be checked for any leaks and to ensure all pressures and temperatures are within the normal range without any abnormal noise. If there are any leaks, unusual noises, or abnormal temps/pressures the engine must be stopped and corrective action taken before restarting. A CFR must be generated to document any issues discovered and action taken to resolve them. A CFR is also required to document a successful uninterrupted no-load test. On this same CFR, Vendor will request to complete an 8 hour loaded engine test. During this test vendor and ships force will complete recorded rounds of all engine parameters (fuel and oil pressures, jacket water temps, oil temps, generator KW, etc.) as per ships round sheets every half hour. Ships force will pull oil samples and conduct falling ball test hourly. All results will be recorded. Should any abnormal conditions develop during testing the engine will be secured and the test time reset to zero hours. A CFR must be generated to document the reason for stopping the test and what corrective action was taken. Once the engine completes an 8 hour uninterrupted load test without leaks, unusual noise, abnormal temps/pressures, or an indication of oil dilution this would be considered a satisfactory test and a CFR generated to document the test results. All round sheets and falling ball test documents will be included as attachments.

l. The vendor is responsible for transporting, and returning all cores to the facility where the parts were purchased. The items to be returned are: fuel transfer pump, fuel injection pump, governor drive assembly, fuel nozzles/injectors, cylinder head, turbocharger, cylinder liners, pistons, connecting rods, camshaft, jacket water pump, raw/sea water pumps, lube oil pump, after cooler cores, lube oil cooler, and vibration dampener. The CG will receive credit for return of these cores.

Warranty: Vendor to provide parts and labor warranty for a period of one year or 1,000 engine hours to cover parts and labor as needed because of a mechanical failure directly related to the overhaul.