Volume II - Maintenance and Training Manual-NEW.pdf

SEA FORCE® 490

SOLAS APPROVED

OPERATION, MAINTENANCE

AND TRAINING MANUAL

Volume II

1250 NORTH GROVE ST, ANAHEIM, CALIFORNIA 92806

Willard Marine, Inc. Sea Force® 490 SOLAS O/B i

FOREWORD

The Operation and Maintenance Manual for the Willard Marine, Inc. Sea Force® 490 SOLAS O/B provides information on the Operation, Maintenance, and Repair of the boat. The information is detailed enough to allow support and service of the Willard Marine Sea Force® 490 SOLAS O/B by shore and shipboard personnel. Safety notes have been included to allow safe operation, maintenance and repair of this vessel.

iii

Contents

PART 1 INTRODUCTION 1

1-1 SCOPE 1

1-2 SAFETY NOTES 2

PART 2 GENERAL INFORMATION AND DATA 3

2-1 RESCUE EQUIPMENT DESCRIPTION 3

Description of Rescue Equipment 3 2-1.1 Fluids and Lubricants Tables 4 2-1.2 Other 4

PART 3 OPERATION AND TRAINING 7

3-1 SAFETY AND OVERVIEW 7

3-1.1 General Precautions 7 3-1.2 Instructions 7 3-1.3 Onboard Equipment Preparation and Operation 7

3-2 LAUNCHING 9

3-2.1 Pre-Launch Checklist 9 3-2.2 Engine Start 10 3-2.3 Launch Procedure 12 3-2.4 Release from Mother Ship 14 3-2.5 Being Towed - Lanyard Use 15 3-2.6 Marshaling Life Rafts 15 3-2.7 Towing Life Rafts 16

3-3 RECOVERY 17

3-3.1 Approaching the Ship 17 3-3.2 Recovery Procedure 18

3-4 SHUTDOWN 19

3-4.1 Other Shutdown Procedures 19

3-5 TRAINING GUIDE 20

3-5.1 General 20 3-5.2 Training Procedure - Start-up 20 3-5.3 Training Procedure – Launching 20 3-5.4 Training Procedure - Being Towed 21 3-5.5 Training Procedure - Towing 21 3-5.6 Training Procedure - Man Overboard Recovery 21 3-5.7 Training Procedure - Recovering 22

PART 4 MAINTENANCE PROCEDURES AND LOG 23

4-1 GENERAL INFORMATION 23

iv

4-2 INSPECTIONS 23

4-2.1 Regularly Scheduled Inspections 23 4-2.2 Inspection Following Vessel Operation 23

4-3 MAINTENANCE PROCEDURES 31

4-3.1 Hull Maintenance 31 4-3.2 Tube Maintenance 31 4-3.3 Propulsion Engine 31 4-3.4 Electrical System Maintenance 31 4-3.5 Bilge Pump System and Hull Drain Maintenance 32

PART 5 REPAIR PROCEDURES 35

5-1 GENERAL INFORMATION 35

5-2 FRP COMPONENT INSPECTION AND REPAIR 35

5-2.1 Planning the Repair 35 5-2.2 Preparing the Damaged Area 35 5-2.3 Finishing 35 5-2.4 Inspection 36 5-2.5 General Procedures 36 5-2.6 General Techniques 37 5-2.7 Field Repair/Solvent Bonding Technique 39 5-2.8 Inspection 39 5-2.9 Emergency Repairs 40 5-2.10 General Conditions 40 5-2.11 Tubes - Air Retention Test 40 5-2.12 Preparing To Patch 41 5-2.13 Glue Mixing (Optional Part) 41 5-2.14 Gluing Techniques (both Glue Types) 42 5-2.15 Seam Leak Repair 43 5-2.16 Small Hole or Tear Repair 43 5-2.17 Large Hole or Tear Repair 43 5-2.18 Inflation Tube Removal and Reinstallation 44

PART 6 OPERATION LOG 45

6-1 OVERVIEW 45

Part 1 INTRODUCTION

1-1 SCOPE

This manual is intended to provide guidance for maintenance and operation of the Willard Marine’s Sea Force® 490 SOLAS O/B. It is not intended as a training manual for endusers or as a substitute for the instructions and recommendations of materials or equipment manufacturers concerning the use of their products. It is not intended to provide design and engineering information, nor is it intended to address all possible circumstances which may be encountered in maintence and operation of the craft. Where conflicts exist between this manual and other related documents (i.e. Ship’s launching and recovery Procedures, Guidance Drawings or other equipment specific technical manuals) the documents related to the equipment will normally take precedence.

1-2 SAFETY NOTES

This section and elsewhere in this manual Safety notes in the manual. They are reprinted for emphasis and quick reference.

• DANGER, WARNING AND CAUTION NOTES

The following is the “DANGER”, “WARNING” and “CAUTION” notes reprinted for quick reference and emphasis.

The definition of the terms is as follows:

DANGER

AN EXTREME VIOLENT AND CONTINUOUS HAZARD TO

LIFE.

CAUTION

An operating or maintenance procedure, practice, condition, statement, etc. which if not strictly observed, could result in damage to or destruction of equipment, loss of mission effectiveness or long-term health hazards to personnel.

WARNING

An operating or maintenance procedure, practice, condition, statement, etc which if not strictly observed could result in injury to or death of personnel.

Part 2 GENERAL INFORMATION AND DATA

2-1 RESCUE EQUIPMENT DESCRIPTION

The following section gives a functional description of the major components and primary systems of the Sea Force® 490 SOLAS O/B.

Description of Rescue Equipment

Bailer: The white plastic bailer is used to scoop water out of the boat. Bailer is stowed in the jockey style seat stowage.

Boat Hook: The telescopic aluminum boat hook measures from 4 to 7 ½ feet long and is 1 1/8 inches in diameter.

The single hook, ball-point boat hook is stowed using webbing straps along the inboard side of the starboard tube cradle. The webbing straps allow the boat hook to be immediately available for use and stowed easily.

Compass: The 4 ½” compass is flush mounted on the level portion of the central console immediately in front of the steering position. The console light is switched on and off with the navigation lights. Located on the instrument panel is the switch that operates both.

Fire Extinguishers: Two fire extinguishers are located in the jockey style seat stowage. The fire extinguishers are ready for immediate use. Remove the safety pin by pulling firmly. Aim the nozzle of the fire extinguisher at the base of the fire and squeeze the trigger to release the fire retardant.

CAUTION

Be careful to point the fire extinguisher at the base of the fire. Chemical fire retardant can cause serious eye injury and health risks.

First Aid Kit: The First Aid Kit is for use during a medical emergency. Contents of, and basic instructions for use are included within the kit. Kit is stowed in the jockey style seat stowage.

Flashlight: The waterproof flashlight has three battery cells and a replacement bulb. One spare battery set and 2 spare bulbs are found in the waterproof tube repair container. Flashlight and spares are stowed in the forward seat stowage.

Heaving Lines: Two heaving lines are provided. Each is one hundred feet of light 5/16” buoyant heaving line with a 6” diameter buoyant rubber rescue quoit attached to one end; line and quoit are stowed in the jockey style seat stowage

Knife: The knife is to be Coast Guard approved and is stowed in the forward seat stowage.

Ladder: The ladder, complete with wooden rungs/handholds is stowed in the forward seat stowage. The ladder may be positioned anywhere along either side of the boat by clipping and attaching it to the internal lifeline at the appropriate position.

Paddles: Two wooden paddles are provided strapped to the port inboard sides using webbing straps along the tube cradle of the inflatable tube.

Painter: The boat is supplied with a one hundred foot painter with loops in both ends. The looped end can be attached to the painter release pennant and is stowed in the forward seat stowage.

Painter Release Pennant: The painter release pennant is attached to the tow eye that is closest to the ship when the rescue boat is launched. The release pennant has a release snap shackle on the outboard end. A lanyard attached to the release snap shackle and the bow bitt is used to release the boat from the painter. This can be done under load when the rescue boat is being towed. The painter release pennant is stowed in the forward seat stowage.

Radar Reflector: A radar release is stowed in the forward seat stowage and is supplied with clips to allow attachment to the antenna/light mast.

Searchlight: The searchlight is stowed in the forward seat stowage.

Sponges: Two sponges, are stowed in the jockey seat stowage, are used to cleanup small amounts of water that cannot be bailed with the bilge pumps or bailer.

Tube Inflation Pump: The tube inflation pump and hose are stowed in the jockey seat stowage.

Tube Repair Kit: The tube repair kit is stowed in the forward seat stowage. For a list of items in the repair kit see Table and Figures (Table 2-3).

Thermal Protective Aids: Two thermal protective aids are stowed in the jockey seat stowage.

Towline: A 170 feet buoyant towline is stowed in the jockey seat stowage.

Whistle: A plastic whistle is stowed in the forward seat stowage.

Storage: The vessel is stored in the Davit when aboard ship. The deck drain is open, engine start battery selector switch in the OFF position.

Rescue Heaving line with Quoit: This is thrown to a person in the water.

2-1.1 Fluids and Lubricants Tables

The following table gives type, amount and specification for the fluids and lubricants used on this vessel:

Table 2-1. Fluids – Propulsion System Propulsion System Requirements

Engine oil Review engine manufacturers Owner’s Manual for type and quantities.

Gear case oil Review engine manufacturers Owner’s Manual for type and quantities.

Premium Gasoline 97 Octane 6 gallons

Lubrication Marine water resistant grease

2-1.2 Other

Other includes all moving components that are not listed on previous page. This includes console hinges, forward console seat hatch, shackle pins, adjustment cables etc. All components in the marine environment require-lubrication. All hinges and adjsutment cables require occasional lubrication with light grease, light oil or silicon spray. This will insure that these parts will not seize up during operation.

Table 2-2. SOLAS Equipment List SOLAS Equipment List

The following is a required equipment list for a SOLAS approved vessel:

Bailer 1

Boat Hook 1

Fire Extinguishers 2

First Aid Kit 1

Flashlight 1

Foot Pump 1

Heaving Line with quoit 2

Knife 1

Paddles 2

Painter Release Pennant / Device 1

Radar Reflector 1

Sea Anchor 1

Searchlight 1

Sponges 2

Thermal Protective Aids 2

Towline 1

Whistle 1

Ladder 1

Painter 1

Tube Inflation Pump 1

Tube Repair Kit 1

Note: All stowed on boat.

Table 2-3. Tube Repair Kit Contents Tube Repair Kit Contents

Adhesive w/catalyst, four airtight coantiners and MSDS sheet

1 set

Instructions for use of adhesive and catalyst 1 ea

Patch material, coated fabric, 50 mm Diameter 5 pcs

Patch coated fabric, 50 mm Long minimum 5 pcs

Roughing Tool, 50 mm wide X 100mm Long minimum (Willard Marine supplied item)

1 ea

Sealing Clamp size to suit 75mm cut (Willard Marine supplied item)

6 ea

Pressure Gage, 5PSI capacity 1

Watertight Case / Bag 1

Note: Repair Kit stowed on boat in fwd seat stowage.

Part 3 OPERATION AND TRAINING

3-1 SAFETY AND OVERVIEW

3-1.1 General Precautions

Safety is important in all phases of rescue boat use. This includes launching, operation, recovery and maintenance. All systems within the boat have been designed to be operational, functional and safe.

GOOD SEAMANSHIP, combined with the safety instructions and warnings in this manual, must be practiced at all times.

3-1.2 Instructions

Safety instructions have been included where possible throughout the text of the manual. These instructions must be observed. The Emergency Procedures and Reference Section at the front of the manual have all the safety instructions reprinted for easy reference and emphasis.

CAUTION

One life jacket is required for each person on the boat. It is strongly recommended that life jackets be worn, by all personnel, at all times.

3-1.3 Onboard Equipment Preparation and Operation

All equipment listed on the Equipment List Label Plate, Figure 2-6, must be on board to meet SOLAS requirements. Lash and secure properly any other equipment carried onboard.

Basic operation of the onboard equipment is as follows:

Bailer: Use to bail water out of the boat or as a liquid holding, retrieving vessel.

Boat Hook: Use as a reaching, retrieving or pushing aid.

Compass: Provides directional guidance information. The switch that operates the navigation lights also operates the compass light.

Fire Extinguisher (2): Located in the jockey style seat stowage. Remove pin by firmly pulling. Aim the nozzle of the fire extinguisher at the base of the fire and squeeze the trigger to release Fire Retardant.

CAUTION

Be careful to point the fire extinguisher at the base of the fire. Chemical Fire Retardant can cause serious eye injury and health risks.

Flashlight: No specific operating instructions. A spare battery set and bulbs are stored in a watertight tube container.

Heaving Lines (2): Lines can be thrown a considerable distance if used properly. The line has to be coiled carefully to ensure it does not tangle when thrown. To maximize this distance, divide the coil in half and throw the half with quoit. Care must be taken that the line does not foul the propeller.

Knife: Coast Guard Approved.

Care should be taken when using the knife near inflated tubes. Even though the knife is designed to reduce the possibility of damage, any sharp object can damage tube fabric.

Boarding Ladder: Use to assist people from the water into the rescue boat. The ladder may be positioned where required, using the clips on the internal lifeline.

Paddles (2): Use to move the boat a short distance. Straddle the tubes to paddle effectively.

Painter: See boat operation.

Painter Release Pennant: See boat operation.

Radar Reflector: Used as radar targets or markers.

Remove the pieces and assemble as per instructions. Attach the reflector to the highest and most convenient position. Use the Radar Reflector when the rescue boat is in low visibility conditions or is itself the object of a search.

Searchlight: Turn on the switch to operate. This is a powerful light that works very well under most conditions. If the engine is not operating the light should be used sparingly as it drains the battery quickly.

Tube Inflation Pump: See boat operation.

Tube Repair Kit: See repair instructions.

Thermal Protective Aids: Provide warmth and protection from the weather. These are intended for victims rescued from the water.

Towline: See boat operation section.

Whistle (1): Attached to the console, blow through it to attract attention.

3-1.4 LAUNCHING

3-1.5 Pre-Launch Checklist

The Pre-Launch Checklist provides important inspection points. The items in the checklist have been discussed in the Preparation for Use Section. The actual checklist (Table 4-1) follows the inspection of the boat from bow to stern.

Table 3-1. Pre-Launch Checklist

PRE-LAUNCH CHECKLIST

1. Bow Area

a. Inflatable tube at operating pressure

2. Fuel Level

a. Full fuel tank

b. Secure fuel cap

c. Open fuel supply valve

d. Priming bulbs are full

e. Fuel/Water Separator clear of water, mounted on motor well

3. Engine Inspection

a. Visual inspection of belts, fasteners hoses etc.

b. Engine lubricationg oil level, oil resevoir tank level mounted on motor well

c. Engine intake ports are clear

4. Aft Seat Control Panels

a. Battery switch to “ON”, mounted on the stowage seat

b. Engine switch to “RUN”

c. Voltmeter reads greater than 11 volts

d. Electric bilge pump, switch set to “MAN”

e. Electric bilge pump, switch set to “AUTO”

f. Navigation lights

g. Steering handle operated

5. FWD Console Stowage Area

a. Contents of forward seat stowage (see Equipment Stowage label plate)

b. FWD seat stowage Dry

c. Secure console FWD hatch

6. Aft Bilge Area

a. Float switch

b. Hull drain plug installed

7. Lifting Pennant Onboard for Recovery

3-1.6 Engine Start

Make sure the area behind and below the boat is free of personnel and/or obstacles.

Normal Start-up

To flush the engine after use or to periodically test the engine, a motor flush attachment which fits over the outboard engines cooling water intake port with a garden hose can be connected and the hose end connected to the ship’s water supply. You can then start the motor. It can be run on deck for extended periods of time. Be careful that water and exhaust escaping from the engine exhaust ports does not damage other equipment behind and beneath the Sea Force® 490 SOLAS O/B.

Table 3-2. Engine Starting Procedure

CAUTIONS FOR HANDLING THE ENGINE

CHECK PRIOR TO STARTING ENGINE; in addition to consulting the “Owner’s Manual”

a. Check fuel level, engine oil level and turn on the bilge blower for a minimum of 5 minutes prior to starting the engine.

b. Check propeller for damage and that the castle nut is secured.

c. Fuel supply valve is open.

d. Before starting the engine squeeze the priming bulb until it feels firm.

STARTING

a. Turn on the key switch. Check that the warning lamps on the instrument panel go on and the buzzer sounds, start the engine. The warning lamp configuration varies depending on the engine model. For details refer to the operation manual.

b. Do not turn the starting motor for more than 15 seconds. If the engine doesn’t start wait for 15 seconds before trying again.

POST STARTING

a. Check that the cooling system indicator water discharge port has a steady flow of water coming out of this port while the engine is running. If water stops flowing this indicates a cooling system problem such as clogged water intakes or even a clogged discharge port.

b. Operate the engine at low speed and check that the low oil pressure, charging and overheating lamps go out. The warning lamp configuration varies on the engine model, for details refer to the owner’s manual.

c. Warm the engine up for no more than 5 minutes

OPERATION, consult “Owner’s Manual” for Break-In Procedure

a. If “Torque Steering” occurs adjust the trim tab to compensate steering.

b. Check control head for proper operation.

c. Do not keep the engine running with abnormal black exhaust.

d. Check for any abnormal heating, noise or vibrations and water, lube oil and gas leakage.

e. Rev the engine from time to time when operating at low speeds for a long period of time.

STOPPING

a. Allow the engine to run in idle for 5 minutes before stopping the engine.

Engine Warm-up

The actual engine start is done just before the boat touches the water and is released from the mother ship. The boat may be driven away from the mother ship immediately. It is good practice, when possible to proceed slowly until all gauges are in the correct operating range. The following list indicates normal operating conditions for most outboard motors. Refer to the Owner’s Manual for specifics:

Water Temperature: The normal operating temperature is between 135 and 190° F.

Oil Pressure: The operating oil pressure is between 15 to 60 psi (700-2600 RPM).

Voltmeter: The operating range of the voltmeter is 13 to 15 volts.

Tachometer: The operating range of the tachometer is 600 to 3700 RPM. Depending on the loading of the boat the maximum cruising RPM is 200 less than the maximum RPM attainable under that particular loading condition.

Alarm Lights: There are two alarm lights: temperature (thermometer), oil (oil can), one or more of these alarm lights on signifies an abnormal condition of the engine. These lights work in combination with an audible alarm (buzzer).

CAUTION

In the event of an alarm sounding, if possible stop the engine immediately and investigate the cause.

After starting the oil pressure alarm may sound for a few seconds until operating oil pressure is reached.

Temperature and Ammeter lights on with no buzzer indicates a charging fault. Engine will operate normally.

Immediate shutdown is unnecessary. Shut down all non-essential electrical equipment to reduce battery drain. If battery condition is poor do not shut engine down until operation is complete, as electrical starting may be impossible.

Temperature or oil light and the buzzer on, signals temperature too high or oil pressure too low. Check fluid levels. Give the engine coolant time to cool down if possible before removing the cap from the radiator.

3-1.7 Launch Procedure

The launching procedure is explained on the Launching Label Plate. (See Figure 2-2) Additional information and safety precautions can be found in the Davit Manufacturer’s Operation and Maintenance Manual.

1. ENSURE THAT THE "DEADMAN BRAKE" IS

FULLY ON AND THAT THERE ARE NO

OBSTRUCTION ON THE TRACKWAY.

2. RELEASE THE BOAT GRIPES FORE AND AFT.

3. RELEASED THE CRADLE GRIPE.

4. RELEASED FOR AND AFT KEEL BLOCKS.

5. BOARD PERSONNEL AS FOLLOWS:

A: TWO CREW AT FORWARD

END OF CONTROL CONSOLE.

B: TWO CREW AT AFT STOWAGE

BOX SEATING.

C: COXSWAIN POSITION AT

ENGINE CONTROL.

D: FOUR CREW AT FOREDECK

SEATING POSITION.

6. MAN THE BOAT AND CRADLE SEA PAINTER.

7. RAISE THE WINCH BRAKE LANYARD,

GRADUALLY AND CONTROL THE LOWERING

SPEED UNTIL THE CRADLE HAS PASSED

OVER THE RADIUS OF THE LOWER

TRACKWAY.

WARNING:

WINCH OPERATORS MUST ENSURE THAT THE

SEA PAINTERS ARE TENDED THROUGHOUT

THE LAUNCH SEQUENCE.

8. WHEN THE CRADLE HAS PASSED OVER THE

RADIUS OF THE LOWER TRACKWAY, RAISE

THE WINCH BRAKE LEVER TO ITS

MAXIMUM POSITION AND CONTINUE

LOWERING UNTIL THE BOAT IS WATERBORNE

AND THE CRADLE HORN IS BELOW THE

WATERLINE. RELEASE THE WINCH BRAKE

LEVER TO STOP THE DESCENT.

NOTE:

SECURE CRADLE PAINTER PRIOR TO THE

CRADLE ENTERING THE WATER.

9. START THE RESCUE BOAT ENGINE.

10. RELEASE RESCUE BOAT LIFTING PENDANT

BY PULLING THE LATCH LANYARD.

11. RELEASE RESCUE BOAT SEA PAINTER.

12. MANEUVER THE RESCUE BOAT AWAY

FROM THE SHIP.

LAUNCHING PROCEDURE

3-1.8 Release from Mother Ship

The boat is in the water with the engine running, in neutral and idle speed, and being towed by the painter. The offset painter causes the boat to veer away from the ship when towed. Shift the control lever to “forward”, release painter using the release lanyard, increase engine throttle and steer away from the mother ship. Operation of the boat is covered in the follow section.

3-1.9 Being Towed - Lanyard Use

When the boat is launched it is towed using the Bow Eye and the inboard Painter Fitting (painter fittings are located on the port and stbd side of the hulls bow area). This is designed to make the boat veer away from the mother ship. To release the towline pull the lanyard. The release shackle will release under full load. It is advisable that the boat be driven forward to reduce the load on the towline just prior to pulling the towline lanyard.

If the boat must be towed at sea it can be towed along side by attaching the tow line to the towing pendant with the release lanyard.

If the Sea Force 4940 SOLAS O/B is towed behind a similar size boat, it can be towed by the fwd bow eye. It is important to tow from a position that does not cause the towline to chafe the tubes.

3-1.10 Marshaling Life Rafts

An important function of the Sea Force 490 SOLAS O/B is to marshal life rafts. The object is to group all the life rafts together in a safe position. This may in some cases involve towing some or all the life rafts. In addition to the life rafts the rescue boat must pick up any survivors that are in the water.

The first priority of the rescue boat is to provide a safe place for the survivors. This means the life rafts must be marshaled in a safe location. Following this, the rescue boat must rescue all personnel in the water.

R AF TS G R O U P ED IN

SA FE LO C A TIO N

TO W IN G LIFE R AFT FR O M

U N SAFE LO C A TIO N

W IN D AN D

S EA S TATE

Figure 3-1. Marshaling Life Rafts Diagram

3-1.11 Towing Life Rafts

When towing a life raft is required, care must be taken when approaching the life raft.

The rescue boat approaches the life raft from downwind maneuvering close enough to pickup the life raft’s towline and tie it off on the tow bitt mounted which is part of the self righting frame.

To reduce the strain on the life raft the tension should be taken on the towline slowly. With the rescue boat moving slowly a turn is taken the bollard allowing the line to pay out as the tension comes on the towline. This is important in rough sea conditions when the waves will cause the rescue boat to surge ahead.

DROGUE

RECOVERED

WIND AND

SEA STATE

WIND AND

SEA STATE 21

2 - 3 KNOTS

MAXIMUM TOWING SPEED

TOWLINE

RECEIVING

APPRO

ACHING

TOWING

Figure 3-2, Towing Diagram

Watch for survivors in the water when approaching life rafts.

Keep hands clear of bollard when tying off towline.

3-2 RECOVERY

Part of operating a rescue boat is returning to the mother ship andd being recovered. This process can be difficult if the conditions are severe. It requires coordination between the ship and the rescue boat. The radio onboard the rescue boat allows communication and coordination between the two vessels. As part of the training program a standard procedure should be developed in case there is a communication breakdown.

The recovery procedures are listed on the bottom half of the Launch and Recovery Plates.

3-2.1 Approaching the Ship

The side of the ship on which the davit is located determine the orientation of the ship with respect to the wind and seastate conditions. Figure 4-9 details the ship’s position for recovery with a davit located on the starboard side of the ship. The ship should be making headway and maintaining maneuverability at approximately 2 to 3 knots.

It is important that all personnel remain seated and as out of the way as possible during the lifting of the boat back onto the ship.

WIND AND

SEA STATE

SH

IP

M O

VI

NG

-3

K

NO

TS

S E

A A

N D

W I

N D

S

H A

D O

W

Figure 3-3. Approaching the Ship

3-2.2 Recovery Procedure

The method of recovery is outlined on the launch and recovery label plates with the ships position being very important to make the recovery as easy as possible. The method as outlined on the label plates is as follows:

Figure 3-4. Recovering Procedure

3-3 SHUTDOWN

3-3.1 Other Shutdown Procedures

Clean the boat and return it to good working order. Review the operation log for any problems or reported damage. Immediately schedule repair work found in the log or during the shutdown procedure. If any of the problems discovered would make it difficult or impossible to operate the rescue boat effectively it must immediately be reported to the ship’s safety officer.

3-4 TRAINING GUIDE

3-4.1 General

The training of personnel to effectively operate the rescue boat is an ongoing process requiring regularly scheduled training.

The initial training is intended to make the crew and backup crew proficient in basic operating techniques.

Further training sessions refresh skills and use the learned techniques under different conditions.

Each ship and crew is different with various levels of experience, making it difficult to give a rigid training guide.

The familiarization of the crew with the boat, its equipment and manual is of primary importance. This training program is a series of lessons repeating a few basic techniques. These techniques are repeated under increasingly difficult conditions. To measure crews performance the training officer keeps a log of the training activities.

Identified weaknesses are then corrected as skills are increased.

Training starts with the ship either at dock or at anchor. The procedures in the manual are practiced in an orderly fashion. The first phase includes preparation for the launch of the rescue boat, and the actual launch under calm conditions. Crew are instructed about their specific responsibilities and have their performance reviewed. The operation of the vessel in harbor conditions gives the crew experience in handling the rescue boat and learning its performance characteristics.

The second phase of training is with the ship operating under calm conditions. At the time specific boat handling procedures are practiced. Following this stage the crew will have the basic skills to operate the boat. When the crews demonstrate proficiency in handling the equipment and boat, the skills are practiced under more difficult conditions. This does not mean under extremely rough conditions that represent a danger to crew and equipment.

EXERCISE PROPER CARE AT ALL TIMES.

The remainder of the training guide outlines individual phases of the operation. The information lists the objectives to be learned, the areas where problems arise, and training aids to assist in the development of the training program.

3-4.2 Training Procedure - Start-up

The training in the start-up procedure involves following through the checklist and manual. The procedures are clearly laid out. By completing the preparation for use and the start-up procedure, the crew will have inspected most of the items of the boat, and familiarized themselves with the various onboard systems.

3-4.3 Training Procedure – Launching

Launch the rescue boat following the information included on the Launching and Recovering Label Plate in the manual and the information supplied by the davit manufacture. Practice the two different launching procedures.

The first procedure is launching for a rescue or a man overboard when the rest of the ship’s crew is available to assist the launch and recovery. The object is to get the boat and crew away from the ship as quickly as possible and direct them to the required location. The ship positions itself to best launch the boat and direct the rescue.

The second procedure is launching during an evacuation of the ship. In this case the crew launches the boat without assistance. The crew must get the rescue boat into the water as quickly as possible to render assistance to the life rafts and coordinate the rescue and safe evacuation of the ship’s crew.

3-4.4 Training Procedure - Being Towed

There are three ways of towing the rescue boat: alongside following launching, by the bow bollard and by the bow eye.

Practice towing alongside and releasing from the mother ship. This is the most important towing exercise.

Launch the boat with the ship moving very slowly. Release the boat from the tow line using the release lanyard.

Raise the cradle out of the way. Then the crew can practice coming alongside the ship with the ship moving at various speeds. The crew reattaches the tow line and practices reducing the tension on the tow line and also using the lanyard to release the boat.

Next practice being towed by the bow bollard. The crew receives a line and ties it off to the bollard. This is a part of the recovery procedure. Practice paying out the line and placing the boat in an approximate position where the cradle would be for recovery. Use the outboard engine as a rudder to keep the boat away from the side of the ship. With most ships it is difficult and dangerous to attempt to tow a stranded rescue boat using the mother ship as the recovery vessel. Use a smaller boat if available for practicing being towed by the bollard.

The last method is being towed by the bow eye. This is used when the boat is towed for a distance without crew aboard. Center the outdrive and raise it to the middle of its range approximately 30 degrees. Turn the engine off and put it in forward gear. The outdrive partially down in gear has some drag and helps keep the boat going straight when being towed. Close the seacock for the water intake on the outdrive to reduce the chance of water being driven into the engine.

3-4.5 Training Procedure - Towing

The object of this training procedure is to train the crew to safely approach the object to be towed and to handle the tow line safely.

Use any convenient floating object to practice approaching an object to be towed. If possible use an inflated lift raft. Circle the object and then approach upwind. A life raft will drift downwind quickly if its sea anchor is not deployed. Approach parallel to the object, coming as close as possible without hitting. Practice approaches under different sea conditions for the best training. Approaching anything when conditions are rough and the waves are high is very difficult. Practice gives the coxswain experience in timing the approach.

The next phase of the training is taking an object into tow. Again use any floating object of reasonable size to practice towing. It is necessary to come alongside, secure or receive a tow line and to start towing the object.

When towing a life raft the coxswain brings the rescue boat alongside. A crew takes the tow line from the raft and immediately takes a couple of wraps around the stern bollard on the closest side of the boat.

Meanwhile the coxswain steers upwind veering slightly away from the raft. Do not cross directly upwind of the life raft and foul the sea anchor. Instruct the occupants of the life raft to pull in the sea anchor immediately after the rescue boat takes the tow line. The crew handling the towline does not immediately tie off the tow line. As the tow line starts to tension the crew pays out the tow line slowly to reduce the initial force on the life raft or object being towed. Secure the tow line once the object in tow starts to move.

The maximum speed that at which a life raft can be towed is 2 to 3 knots. If this speed is exceeded the towing patch will pull off the life raft. Not only will the tow be lost, the life raft may be damaged.

3-4.6 Training Procedure - Man Overboard Recovery

The object of man overboard training is to recover an individual from the water as quickly as possible. The survivor is found and the rescue boat is going to make the recovery. The basic technique is described in the Man Overboard Section of the manual. Initially use a floating object to practice approaches and recoveries. Use a dummy in a life jacket for further training. In final training rescue a volunteer who is dressed in an immersion suit for protection from the environment.

When approaching an individual in the water extreme care must be used so not to injure them.

Only do this training when the crew has demonstrated proficiency in handling the rescue boat and approaching objects in the water. Carry out these exercises only in a protected location under calm conditions. Use dummies if training is in the open and/or under rough conditions. There is some degree risk associated with any activity when conditions are rough.

3-4.7 Training Procedure - Recovering

The recovery procedure is detailed on the Launch and Recovery Placards (Figure 2-2 and 2-3). Two phases of the recovery require specific training: approaching the ship and hooking on the recovery pendant; and, the actual lift to the disembark/stowage position.

The training to approach the ship to use the sea painter is described in the Being Towed Section.

Start the recovery training with the ship at dock or at anchor. The ship’s crew lowers the cradle beneath the surface of the water. The rescue boat’s crew attach the lanyard to the central lifting cable and position themselves properly in the rescue boat ready for recovery. The ship’s crew slowly lift the cradle, rescue boat and its crew to the boat’s stowage position.

Information in this manual, information from the Davit Manufacturer’s Manual, and good seamanship will help train the crew to find the correct positions during recovery.

Next practice the recovery when the ship is traveling dead slow in calm water. Repeat the recovery procedure until the crews of both the ship and the rescue boat can proficiently coordinate this operation. The maximum speed the ship and the rescue boat can be moving while the rescue boat’s recovery is underway is determined by the Davit Manufacturer and good safe practices.

This concludes the Operation and Training Part.

Part 4 MAINTENANCE PROCEDURES AND LOG

4-1 GENERAL INFORMATION

Regularly scheduled maintenance is very important to maintain the operational status of the rescue boat. This part is divided into two sections; maintenance inspections and maintenance procedures for the primary systems.

Regular inspections are an effective way of maintaining the operational status of the Sea Force® 490 SOLAS O/B.

Periodic servicing helps keep all the systems operating and wear problems detected early. This maintenance program will reduce (the chance of) breakdowns and increase the Sea Force® 490 SOLAS O/B reliability. The inspections and service are scheduled on a as used, semi annually, annual and hourly basis. The outboard engine and associated components are maintained at regular intervals related to the number of hours of operation.

Inspections and service of the outboard engine are carried out after each use for the cooling water passages, engine oil level, propeller and cotter pin or nut, anode and water separator and then 20 hours of operation (break-in period) or first month and then scheduled every 100 hrs or every 6 months, followed by 200 hrs or every year and 400 hrs or every two years whichever comes first. When operating the boat in saltwater lubricate more frequently. Also when ooperating in salt water, turbid or muddy water the engine should be flushed with clean water after every use. The servicing frequency is a typical period duration for outboard motors for exact duration times and inspecton items refer to the owners manual.

4-2 INSPECTIONS

4-2.1 Regularly Scheduled Inspections

This section includes the maintenance forms for the regular servicing of the Sea Force® 490 SOLAS O/B. The forms provide a step by step procedure for the scheduled maintenance of the rescue boat.

Use of the forms will help maintain the boat and it’s operational status. The forms are copied and punched as required. These, when used regularly, will form the maintenance history record for the boat.

Though the forms are complete, the maintenance should not be limited to items listed within the forms. Good marine maintenance practices should be used at all times.

4-2.2 Inspection Following Vessel Operation

Visually inspect the boat following operation. Complete the operational log (see Part 6) immediately after operation. Information from the visual inspection and operational log is used to schedule required maintenance.

Any condition reducing or stopping the operational capacity of the rescue boat must be immediately reported to the ship’s safety officer.

DAILY INSPECTION AND AFTER USE SERVICE CHECKLIST

Boat Serial No. Date:

Completed By: Time:

Number Area Description

1. Inflatable Tube Check air pressure in all chambers

2. Check engine oil level

3. Check fuel line

4. Check fuel filter

5. Inspect cooling water intake ports

6. Inspect for fuel or oil leaks

7.

Engine

Inspect engine belts and hoses

8. Check propeller and cotter pin or nut

9. Check anodes

10.

Propeller

Check propeller guard (if installed)

11. Fuel Tank Check fuel level and fuel lines

12. Fuel Priming Bulb Inspect for cracks and tight hose connections

13. Navigation Lights Check to assure operational

14. Batteries Check battery condition and cable connection tightness

15. Bilge Pump Check the manual and electric operation

Maintenance procedures for engine are found in the engine Owners / Operation Manual.

Maintenance procedures and schedules are found in the Owners manual in the Servicing section.

Number Problem Report Corrective Action

Signature:

DAILY INSPECTION AND AFTER USE SERVICE CHECKLIST

(Continued)

Boat Serial No. Date:

Completed By: Time:

ENGINE BREAK-IN FIRST MONTH or 20 HRS INSPECTION AND SERVICE CHECKLIST

Completed By: Time:

Number Area Description

1. Operate under varying loads for the first 20 hrs, see Owner’s Manual for specifics

2. Inspect for any fluid leaks

3. Change engine oil and filter

4. Change gear case oil

5. Check-Adjust throttle linkage

6. Check-Clean spark plugs

7. Check-Adjust Idle speed

8. Check coolant level

9.

Engine

Check bolts and nuts for tightness

10. Lubrication Grease moving parts.

Maintenance procedures for engine are found in owner’s Operation and Maintenance Manual.

ENGINE SEMI ANNUALLY (6-months) or 100 HRS INSPECTION AND SERVICE CHECKLIST

Completed By: Time:

Number Area Description

1. Change engine oil

2. Change gear case oil

3. Check-Adjust throttle linkage

4. Check-Adjust idle speed

5. Check fuel filter low pressure side

6. Check bolts and nuts for tightness

7.

Engine

Lubricate (more frequently if used in saltwater)

8. Propeller Lubricate (more frequently if used in saltwater)

Maintenance procedures are found in manual.

ENGINE YEARLY or 200 HRS INSPECTION AND SERVICE CHECKLIST

Completed By: Time:

Number Area Description

1. Change engine oil

2. Change gear case oil

3. Check-Adjust throttle linkage

4. Check-Adjust idle speed

5. Check fuel filter low pressure side

6. Check bolts and nuts for tightness

7. Inspect wiring

8.

Check Hoses and clamps for condition and tightness

9.

Engine

Lubricate (more frequently if used in saltwater)

10. Propeller Lubricate (more frequently if used in saltwater)

ENGINE EVERY TWO YEARS or 400 HRS INSPECTION AND SERVICE CHECKLIST

Completed By: Time:

Number Area Description

1. Change fuel filter low pressure side

2. Change fuel filter high pressure side

3.

Engine

Replace spark plugs

ANNUAL (every year) INSPECTION AND SERVICE CHECKLIST

Completed By: Time:

Number Area Description

1. Sling Lift Inspect for damage.

2. Fuel/Water Separator Change element

3.

On-Board Equipment

Remove all equipment on the equipment list and visually inspect or operate to prove required operation. Review expiration dates and replace as required.

4-3 MAINTENANCE PROCEDURES

4-3.1 Hull Maintenance

The hull is constructed of Fiberglass Reinforced Plastic (FRP) requiring very little maintenance. Regular damage inspection is the most important part of the maintenance procedures. Regular cleaning will maintain the appearance of the fiberglass and parts.

The colored gelcoat on the exterior of the FRP components oxidizes and turns whitish with time. The oxidation can be removed with a fine rubbing compound or fiberglass cleaner. Following cleaning, wax the fiberglass surfaces to protect and reduce future oxidation.

Wahing down the entire boat after each use with clean fresh water to remove salt and soot is a must.

4-3.2 Tube Maintenance

Constructed of neoprene/hypalon coated, ultraviolet damage resistant fabric the inflatable tube requires little regular maintenance. Inspect tubes regularly and maintain at correct pressure. Cleaning with mild soap and water is the only required regular maintenance. Patch any area showing wear to the core material.

If the inflatable tube has been damaged severely or requires a major overhaul, remove and the inflatable collar for service to an authorized service depot. Removal and installation procedures for the inflatable collar are in the Repair Part of the manual.

4-3.3 Propulsion Engine

Preventive maintenance is the key to keeping the propulsion system operating properly. Use the maintenance log to determine scheduling of the specific maintenance procedures. Use the Engine Owner’s Operation and Maintenance Manual to perform the engine maintenance procedures.

4-3.4 Electrical System Maintenance

General

Little regular maintenance is required for the electrical system. Preventive maintenance is primary inspections of all electrical systems. Inspect wiring for signs of damage or corrosion. Check the wiring at the console hinge.

Opening the console too far without care can damage the wiring and controls in this area. Include in the regular inspection an orderly procedure, checking through each electrically operated component. At this time replace any faulty breakers, switches and/or bulbs. Most of the individual electrical components cannot be serviced. Replace faulty components. The radio and some of the engine components can be rebuilt or serviced. Lift open by unlatching the fwd clamp on the console’s mid section to allow access to the wiring, connections and panel lighting.

Battery System Maintenance

1) Clean battery or batteries during maintenance.

2) Check that battery boxes are in good condition and the tie downs will keep batteries in correct position.

3) Check that the terminals are tight and free of corrosion. If necessary, scrape the terminals to remove any corrosion. Corrosion can interfere with the electrical connections and greatly affect electrical systems performance.

CAUTION

All work on batteries must be done with battery switch in the OFF position, to reduce the chance of a spark causing an explosion.

CAUTION

Ensure battery connections are made properly with correct battery polarity. Connections are negative (black) to negative and positive (red) to positive. Incorrect connections will damage the charging system.

CAUTION

Do not disconnect or switch charging circuits with engine running. This will damage the voltage regulator.

4-3.5 Bilge Pump System and Hull Drain Maintenance

Manual Bilge Pump

Check the bilge pump for correct operation before each launching. Place a hand over the pump exit on the transom and operate the pump at the same time. Pressure must be felt. If no pressure is felt or pump is known not to be working inspect the following points.

Strainer is located under coxswain’s removable flat.

Blockages or the pickup hose is collapsing.

Torn diaphragm.

Dirt under or distorted valves. Removing the pump cover and internally inspecting for debris.

Blockage of outlet hose.

Any of these problems are repairable. The rubber components of the pump are available as spare parts from the manufacturer.

Keep the bilges clean and free of debris, fasteners and materials that can be sucked up into the pump strainer.

WARNING

To reduce the chance of explosion never expose batteries to spark or open flame. Do not smoke near batteries. Batteries generate hydrogen gas which is explosive and flammable. Battery fluid contains sulfuric acid.

Electric Bilge Pump

The electric bilge pump has a sealed motor and almost no user serviceable parts. Inspect the outlet hose and inlet strainer for debris. Inspect the wiring for wear or damage. During the regular maintenance, inspect the pump and automatic float switch and replace if necessary.

Part 5 REPAIR PROCEDURES

5-1 GENERAL INFORMATION

This part is divided into sections by major components or systems. The divisions include: FRP components (hull, deck and console), inflatable collar, propulsion, electrical, steering and bilge pump systems. Damage inspection and repair techniques are part of each section.

5-2 FRP COMPONENT INSPECTION AND REPAIR

CAUTION

Do not make rectangular or sharp-cornered cuts; round, or oval-shaped repairs ensure a stronger repair.

5-2.1 Planning the Repair

(a) Using chalk, outline the area to be cut and/or scarfed.

(b)Based on the size of the repair, estimate the amount of resin and glass reinforcement necessary to repair the damage.

5-2.2 Preparing the Damaged Area

CAUTION

To prevent damage to equipment, check for interference that may be in the way of the saw, such as wiring, fuel lines, and or hull members.

1) If the damage extends through the hull, cut out the damaged area with a saw. Check for interferences. If, however, the damage is surface-type and extends only part way through the hull, the damaged area may be removed by grinding with a disc sander.

2) Coat entire sanded area with catalyzed resin.

3) Place and center lay-up over damaged area with smaller ply facing in.

4) Using a squeegee, work out all air bubbles by squeezing patch from center outward in all directions.

5) Work patch so it conforms to hull contour.

6) Secure a second backing or cover plate over separating film with tape or shoring so the patch remains in firm contact with the original backing plate.

7) Finishing

8) Place and center the smallest tailored ply over the damaged area.

9) Saturate the smallest ply with the resin mixture so the mixture squeezes through and pushes out entrapped air.

10) Continue procedure by centering and saturating successively larger tailored plies until all are laid up with largest ply on top.

11) Cut and place separating film over patch.

12) Using squeegee, work out all entrapped air and excess resin by squeezing patch from center outward in all directions.

13) Place cover plate over patch to maintain gentle pressure

14) Cure and finish.

5-2.3 Inspection

Inspect the fiberglass components for damage periodically. In an orderly manner, inspect the hull from bow to stern looking for evidence of damage. If damage to the exterior surface is found, where possible inspect the interior surface near the damaged area. Immediate repair is required if the damage extends to the interior.

Determine the extent of damage and chose the type of repair needed. General repair tech- niques are combined with the “TYPE” repairs. Divided into four categories the “TYPE” repairs represent different amounts of damage to the various boat structures.

Following are the definitions of the “TYPE” repairs:

TYPE 1 Repair procedure for minor damage that is limited to one side of the laminate.

TYPE 2 Repair procedure for damage that is severe enough to crack or break through the entire laminate. This repair is from one side and is limited to areas that are not heavily loaded or if the second side of the laminate is not accessible. TYPE 2 can also be used to repair one side of a cored laminate where the coring and second side have not been damaged.

TYPE 3 Repair procedure for damage to non-cored laminate that shows obvious internal damage or damage to nearby structural members. This is a two sided repair. TYPE 4 Two sided repair procedure for severe damage to a cored laminate in a structural area.

5-2.4 General Procedures

The general procedures discuss safety, construction details, repair materials, repair tools and general techniques.

Successful repair of FRP damage is made by using the general procedures combined with the specific details of the “TYPE” repairs.

Safety

The repair procedure involves grinding the glass during preparation of the damaged area and use of resins for the actual repair. It is very important to wear eye protection, avoid skin contact with chemicals and work in a properly ventilated area. “Warnings” and “Cautions” are listed throughout the text and must be followed. These safety notes have been reprinted in the Emergency Procedures and Reference Part of the manual for emphasis.

Read completely and understand the complete FRP repair section prior to starting and FRP repair.

FRP Construction Details

This vessel is constructed of fiberglass cloth, structural foam core, buoyant foam and fire retardant polyester resin.

The hull, deck and console lay-up details are provided in the drawings. The cavity outside of the longitudinal stringers is filled with buoyant foam. The foam extends from the transom forward to the sling lift points.

Repair Maintenance

Basic materials are required for a fiberglass repair. . Most of these materials are in the standard fiberglass repair kit.

Repair Tools

Many of the disposable tools required are in the FRP repair kit.

5-2.5 General Techniques

General techniques take a typical repair through its steps from start to finish.

1) Inspect damage and determine type of damage. This determines the working area to be prepared.

2) Prepare working area. Areas near the repair must be isolated from the work. All machinery must be covered and protected from the fiberglass dust and resin used in the repair.

Fiberglass dust…