SOW - RG Nozzle Blockage and Seal Replacement.docx

05 JAN 2026

SOW Reduction Gear Tech Rep Visit

Reduction Gear Tech Services

USCGC ELM (WLB 204)

Inadequate Generator Pinion Flow from Spray Nozzle Repair

1. Background, Problem Statement:

1.1 Main Reduction Gear (MRG) Info:

MFR ID 96-DHCMGH-CP

B Class Model Gear Unit Reduction: NSN 3020-XF-C11-6019 Input RPM 900 Output RPM 254 Gear ration 3.541:1

1.2 Background:

CGC Elm, completed an inspection of the LO System Flow from visible spray nozzles. After recent MRG failures the USCG is trying to identify any LO flow problems that can exacerbate the MRG aging issue prior to each Cutter’s scheduled future “Major Overhauls”. ELM, reported after their inspection:

A. Poor flow and excessive aeration from spray nozzles.

1.3 Problem Statement:

1. Clear any blockage and restore normal spray patterns at/from spray nozzles.

2 Tasking:

2.1 All Tasking is Performance Based. USCG realizes that it does not make sense to instruct the OEM on how to perform work and repairs on their equipment. Rather it is better to identify the problem/deficiency and identify the required end result desired to correct.

2.1 Inspect all other teeth. Blue check contact.

2.1.1 Set up a cleanliness boundary, to prevent any generated debris from entering the Internal gear box.

2.1.2 Inspect all other teeth for damage or abnormal condition. Report and document any additional damage. Similar repairs are to be performed but if additional time is required USCG/Contractor will negotiate prior to that additional repair commencing.

2.1.3 Perform tooth contact inspection (blue checks).

2.2 Restore Generator Pinion spray nozzles to normal spray pattern/flow with acceptable amounts of aeration.

2.2.1 Restore normal nozzle flow by any combination of escalating level of effort OEM methods. It is contemplated that any/all may be required:

2.2.1.1 Attempt to blow out with air.

2.2.1.2 Attempt to inject pressurized oil into spray bar external fitting.

2.2.1.3 Force more LO pump flow (GPM) into subject nozzles, by capping off (temporarily) other flows/hosses)

2.2.1.4 Ensure flow is balanced and nozzles are indeed blocked and not being starved of their required GPM by an unbalanced LO flow distribution.

2.2.1.5 Remove Gen Pinion Upper Housing Cover to directly access nozzles. Then either clean/unblock directly the existing or renew. Contactor shall travel to work cite, with contingency replacement nozzles in the event they are required.

2.2.1.6 Contractor shall have onsite a minimum of 03 replacement spray nozzles Part: 35000-0608 in the event nozzles need to be replaced.

2.2.1.7 Ensure oil level dipstick is proper length with proper markings.

2.2.1.8 Below is procedure used previously to remove cover. USCG Cutter crew will assist OEM Tech Rep as required in this evolution.

2.2.1.9 PROCEDURE TO REMOVE UPPER COVER

Remove Upper Generator Pinion Housing Cover Half to Access and clean Spray Nozzles Inside.

1. See Tech Pub Para 6.7.13 Turning Gear/Generator PTO Pinion Cover. (pages attached)

2. Following 6.7.13 as augmented by this SOW remove the Generator PTO Pinion Cover.

2.1. Disconnect Lube Oil Hoses. Cap/bag disconnected hose ends to prevent contamination.

2.2. Remove Breather Cap.

2.3. Remove Magnetic Pick-up Assemblies. Preserve/safeguard for reassembly.

2.4. Remove thru-cap (#108) at PTO end.

2.5. Disassemble the turning gear end as required to free cover and lift. Although TP says “Remove turning gear assembly and generator coupling” it may not be necessary just to remove upper cover of this SOW.

2.6. Remove all hold down fasteners.

2.7. Prepare cover for rigging.

2.8. As Soon as possible cover/close with suitable CLEAN heavy duty covering the Reduction Gear opening to prevent any debris or foreign object entry. Maintain boundary protection until cover is reinstalled.

2.9. Rig to landing area where cover internals can be hand cleaned, and spray nozzles removed/cleaned/and inspected.

2.10. In concurrence with Cutter’s EO that work is completed, rig the cover back into position.

2.11. Reconnect and torque all fasteners and remove items.

2.12. Torque values can be found in MPC WLB-225 M-A-16012 “MAIN REDUCTION GEAR (MRG) EXTERNAL HOUSING AND HOLD DOWN BOLTS INSP/CHK”.

2.13. Retorque the disturbed MRG pinion cover hold-down bolts after 50 hours of operation.

2.3 Inspect all other teeth. Blue check contact.

3 Provide written final report of the Tech Rep Visit

3.1 Provide final report of the Tech Rep visit. Include noteworthy findings and discussion on events, documentation of final results, and any lesson learned for similar repairs to other WLBs.

4 Delivery

The CTR will travel to and perform work on board

CGC ELM (WLB-204)

Base Tongue Point, 37573 Hwy 30. Astoria, Or. 97103

PERIOD OF PERFORMANCE

The period of performance for this contract will be up to 7 days on site 8-hour days period during an agreed upon time between 23 Mar 2026 – 30 Mar 26

5 PLACE OF PERFORMANCE & POC’S

The primary place of performance will be onboard:

CGC ELM (WLB-204)

Base Tongue Point, 37573 Hwy 30. Astoria, Or. 97103

5.1 GOVERNMENT FURNISHED RESOURCES

Technicians to support chain falling, lifting, interference removal and assistance with L/O analysis.

5.2 Security Requirement

Provide name of technician to crew prior to arrival and good contact information.

5.3 Point of Contact:

Any cutter site visits will be coordinated through the cutter POC.

Steven J. Reyes, CWO2 (EO)

CGC ELM (WLB-204)

Base Tongue Point, 37573 Hwy 30. Astoria, Or. 97103

POC: (808) 397-0851

6.2 Off site coordination: CWO Nathan Kirchner

Work Cell: (216) 577-1230 Email: Nathan.P.Kirchner@uscg.mil

LAST UPDATED: 01/05/2026 PAGE 4/5