USCGC Polar Star Steering control troubleshoot

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TECHNICAL SERVICES

USCGC POLAR STAR (WAGB-10) – Z14501

SYSTEM ERRORS ON NAVIPILOT 4000

1. Objective. The objective of this requirement is to restore full capabilities to the ship’s Sperry Marine Navipilot 4000.

1. References.
   
   
   
   
   1. United States Coast Guard Technical Publication: 7359-561-A, NAVIPILOT 4000 HEADING CONTROL SYSTEM - INSTALLATION & OPERATION MANUAL
   
   
   2. United States Coast Guard Technical Publication: 4411-561-G, ROTARY HYDRAULIC POWER UNIT
   
   
   
   

1. Background. This requirement is for the contractor to perform field troubleshooting on a Sperry Marine Navipilot 4000. Reported on 29-Aug-2025, the ship’s crew noted a 5-degree starboard misalignment on the helm console throughout its range. The ship’s crew attempted to perform calibration of the system in accordance with the manufacturer’s manual but were unable to store the calibration due to receiving system errors. Additionally, reported on 10-Oct-2025, ship’s crew conducted maintenance procedure IAW ref 2.2 to zero potentiometers for control feedback on steering gear. After completion of procedure, ship’s crew noted a 3-degree starboard misalignment and a 15-degree port misalignment. Ship’s crew rechecked all measurements IAW applicable references. Unable to continue diagnosis without Sperry Marine technician. Lastly, previous relevant work conducted with Sperry Marine are WO # 38400 and # 44017.
   
   
   
   
   1. WO # 38400, Honolulu HI, 03-Dec-2024: Ship experienced helm calibration issues. Sperry Marine technician attempted hard restart and rewrite of system; errors returned after some time. Technician replaced the CDU and on SCU, all with firmware version L. Technician inputted parameters into SCU, calibrated helm and feedback input. Steering system and autopilot deemed corrected with no errors.
   
   
   2. WO # 44017, Vallejo, CA, 08-Aug-2025: Ship’s crew identified inability to operate the mini-wheel from the Aloft Conn Sky Bridge station when on the starboard steering pump. Sperry Marine technician verified mini-wheel functions with port steering system but is inoperable with the starboard steering system. The autopilot, helm steering, and NFU levers functioned on both port and starboard steering systems. Sperry Marine technicians departed without resolution and contacted their Germany office for additional guidance.
   
   
   
   

1. Tasks. The contractor shall provide services and technical expertise for a Sperry Marine NAVIPILOT 4000, which includes but may not limited to:
   
   
   
   
   1. Coordinate field visit and base access with provided points of contact for an Original Equipment Manufacturer (OEM) certified technical representative. Services must be conducted in the presence of designated USCG technician(s)/representative(s).
   
   
   2. Conduct an initial and final operational test of steering system locally and remotely at each helm console station. USCG personnel will operate all shipboard machinery and equipment. USCG personnel will secure and tag applicable equipment prior to start of any work.
   
   
   3. Complete and submit a “Navipilot 4000 Settings Verification Document”, or equivalent, with trip report. Skip any requirements unable to perform due to ship at the pier.
   
   
   4. Check configuration settings. Complete and submit forms outlining configuration settings; refer to Appendix A of reference 2.1.
   
   
   5. Check communications of mini wheel in each location. Perform corrections IAW applicable references ensuring mini wheel functions and all steering control modes for both steering pumps.
   
   
   6. Conduct helm unit calibration procedure based on software version. Verify calibration corrected any misalignments. Verify installation of compatible firmware in each Steering Control Unit (SCU). If determined by diagnosis, replace and configure SCU IAW applicable references.
   
   
   7. Perform troubleshooting and correction of noted errors, in addition to any others that may arise with the system. Any additional material and labor (and associated costs) outside the scope of the field visit must be approved by a warranted Contracting Officer (KO) prior to proceeding.
   
   
   8. Provide an invoice and trip report including at least the following: service dates and location, issue description with any errors/symptoms, troubleshooting steps, findings, resolution, and recommendations (if any). If parts are needed for additional work, the contractor must provide part number, the quantity needed, price per unit, lead time, and potential source(s) with contact information.
   
   
   
   

1. Government Furnished Property. None

1. Security Requirement. Base access is required. The contractor shall have a valid government issued ID (or driver’s license) and show proper identification at the security gate. The contractor must provide information at least 48 hours in advance for security to process access requests. A USCG representative from the ship or SFLC Product Line can sponsor and escort vendor to the ship.

1. Place of Performance. USCGC POLAR STAR at USCG Base Seattle, Berth F. Address: 1519 Alaskan Way S, Seattle, WA 98134

1. Period of Performance. 03-Nov to 14-Nov-2025

1. USCG Technical Points of Contact.
   
   
   
   
   1. USCG-SFLC-LREPL, Asset Manager: LT Mikael Axelsson, Mikael.J.Axelsson@uscg.mil, (571) 607-1134
   
   
   2. USCGC POLAR STAR, Engineer Officer: LCDR Josh Herring, Joshua.C.Herring@uscg.mil
   
   
   3. USCGC POLAR STAR, Main Propulsion Assistant: CWO Matthew Tuten, Matthew.R.Tuten@uscg.mil
   
   
   
   

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