(143)6.15m RHIB Rescue Boat.pdf

FRV40-226-143-010

DESCRIPTION, OPERATION, INSTALLATION AND

MAINTENANCE INSTRUCTIONS

6.15m RHIB Rescue Boat Waterjet Version

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

50-SPNA-1-00031

PUBLISHED BY DIRECTION OF NOAA

FRV40-226-143-010

DESCRIPTION, OPERATION, INSTALLATION AND

MAINTENANCE INSTRUCTIONS

6.15m RHIB Rescue Boat Waterjet Version

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

PUBLISHED BY DIRECTION OF NOAA

19 NOV 2008

RECORD OF CHANGES

Change No.

Date Title and/or Brief Description Signature of Validating Officer

APPROVAL AND PROCUREMENT RECORD PAGE

APPROVAL DATA FOR: FRV40-226-143-010

TITLE OF MANUAL: 6.15m RHIB Rescue Boat, Waterjet Version

APPROVAL AUTHORITY: NOAA

Contract Ship Qty Of Building Number Applicability Manuals Yard

50-SPNA-1-00031 FRV40-226 2 EA Halter Marine Inc.

REMARKS:

CERTIFICATION: It is hereby certified that FRV40-226-143-010 to be provided under contract 50-SPNA- 1-00031 has been approved by the approval data shown above.

Date:________________

CHAND, LLC

Mathews, LA 70375

CAGE CODE: 0D5X4

VALIDATION PERFORMANCE

Title of Publication

6.15m RHIB Rescue Boat, Waterjet Version

Contractor Sub-Contractor(If Performing Validation)

Halter Marine Inc.

Contract No. (s) and Purchase Orders, If Applicable

Chapter Section Paragraph Date Check here if Validation Not validated Completed

Contents of this manual have been validated and certified to be applicable to the equipment furnished under the above procurement as specified for Validation.

Name & Authority of Validating Officer: Signature of Validating Officer:

FOREWORD

This manual is intended to clearly and accurately reflect the actual configuration of the installed equipment described for the FRV40-226-143-010. 6.15m RHIB Rescue Boat. Users are urged to report instances noted wherein the manual does not achieve this objective.

This technical manual provides the instructions necessary to operate, to perform maintenance on and troubleshooting of the 6.15m RHIB Rescue Boa.t The text is broken down as follows:

Section 1- OPERATION AND MAINTENANCE MANUAL FOR 6,15 MERLIN FAST RESCUE BOAT WATER JET VERSION. Page 11

Section 2- STEYR MARINE ENGINES. OPERATION, MAINTENANCE AND WARRANTY MANUAL. Page 37

OPERATION AND MAINTENANCE MANUAL

FOR 6,15 MERLIN FAST RESCUE BOAT

WATER JET VERSION

Norsafe AS Postbox 115

N-4852 FÆRVIK

NORWAY

Revision Table

Rev No: Description By Chk. by Date

0 Issued PSJ/PP PP 05.feb.2001

Norsafe as

2 waterjet versjon

Waterjet versjon 3

IMPORTANT:

In this manual A WARNING! is an operation procedure, statement or practice which, if not strictly followed, could result in injury or death to personnel.

A CAUTION! is an operation procedure, statement or practice which, if not strictly followed, could result in damage to equipment or loss of mission effectiveness.

Direct all inquiries regarding spare parts and service to:

Norsafe AS Postbox 115

N-4852 FÆRVIK

NORWAY

Telephone: Int. + 47 37 05 85 00 Telefax: Adm: Int. + 47 37 05 85 01 Tech: Int. + 47 37 08 65 40 Service Int. + 47 37 05 85 11

Please quote the Norsafe boat build number when contacting Norsafe. The number is given on enclosed certificates, and is also shown on the name plate on the boat.

During the warranty period, all necessary spare parts must be supplied by Norsafe AS.

The use of spare parts supplied by other suppliers violates and forfeits the warranty.

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LIST OF CONTENTS

1 INTRODUCTION

1.1 Certification

1.2 General description

2 LAUNCHING AND RECOVERY PROCEDURES

2.1 Launching the boat

2.2 Recovery of the boat

2.3 In case the boat is capzised

3 OPERATING PROCEDURES

3.1 Starting the engine

3.2 Engine operation

3.3 Flow deflector

3.4 Throttle / gear control

3.5 Stopping the engine (normal)

3.6 Stopping the engine (emergency)

3.7 Engine cooling

3.8 Dead man switch

3.9 Rescue of persons in the water

3.10 Towing

3.11 Rowing

3.12 Loose equipment

3.13 Fuel tank

3.14 Fuel shut off valve

3.15 Radar reflector and marker light

3.16 Battery charger

4 GENERAL ARRANGEMENT

5 MAINTENANCE PROCEDURES

5.1 Loose equipment

5.2 Hatches

5.3 Lifting hook

5.4 Self-righting bag

5.5 Engine

5.6 Sea water cooling circuit

5.7 Gearbox

5.8 Waterjet

5.9 Drive shaft universals

5.10 Electrical system

5.11 General

6 Maintenance schedules

7 LOOSE EQUIPMENT LIST FOR FAST RESCUE CRAFT

8 APPENDIX A

8.1 Inspection log

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1 INTRODUCTION

TECHNICAL SPECIFICATION 6.15 MERLIN FAST RESCUE BOAT0

Length overall = 6,25 m Length on fender = 6,15 m Breadth overall = 2,40 m Height overall = 2,40 m Height of lifting hook = 1,95 m Weight (incl. fuel) = 1450 kg Davit load w/6 persons = 1900 kg Fuel capacity = 115 litres Speed with 3 persons, (Approx.) = 29 knots Speed with 15 persons, (Approx.) = 8+ knots Engine = 144 HP

With other engines, some particulars may vary

1.1 Certification

Approved under the latest Solas regulations.

1.2 General description

The craft has been designed and constructed for offshore use in rough water. It will provide high sustained speed in rough offshore environments. The boat is moulded from fire retardant polyester resin. The space between the hull and liner is filled with polyurethane buoyancy foam, which provide the craft with enough buoyancy to remain afloat even if holed below the waterline.

Carrying capacity is up to 15 persons including space for a stretcher. The boat is self-bailing and protected by a closed cell foam fender covered with two layers of heavy duty PVC skin. This design gives excellent shock absorbing characteristics with low re-bound. Lifelines and handgrips are fitted around the gunwale.

An approved Off Load single point lifting hook for attaching the fall from a davit or crane is mounted on the centre console. The hook can only be opened when there is no load on the fall and must be used together with the painter release hook on the bow for safe launching of the boat.

In the event that the boat capsizes, it will automatically turn back to the upright position.

Fuel is filled at the bow of the boat. Access to the fuel tank is via a hatch on the deck in front of the console. Draining of the tank is made here.

Loose equipment is placed in a storage locker under deck forward or mounted in the boat. A bilge pump and a fire extinguisher is mounted under the sprayhood. Two batteries are installed under the seat, and a battery charger is mounted inside the console. When running, the engine will charge the batteries.

When the boat is in the stowed position, the charger will take over. The charger is supplied with 42V AC from the ship via a plug on the front side of the console.

Stephen.Spindler Highlight

Stephen.Spindler Highlight

6 waterjet versjon

2 LAUNCHING AND RECOVERY PROCEDURES

2.1 Launching the boat

The boat is attached to the davit or deck crane fall wire by a single point lifting hook mounted on the top of the console. The lifting hook is released manually by pulling on the release cable at the aft end of the console when the boat is fully waterborne.

This applies to the boat only, for davit/crane, see the davit manual.

To launch the boat, proceed as follows:

1 Prepare the boat for launching by removing any lashing, disconnecting external power supply plug, and open the fuel shut-off valve . see fig. 1.

2 Secure painter to painter release hook on bow with the other end secured to the ship. The position on the ship must be well forward of boat position. The length of the painter is to be such that when the boat is on the water with a taut painter line, the boat is directly under the davit/crane. See fig. 2

Figure 1: Fuel shut off valve below deck in front of console

Figure 2

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WARNING!

If the ship is making headway and the painter is not used, this may result in injury or death to the crew of the rescue boat, and damage to equipment. The main suspension hook must be released before the painter is released.

3 Crew to start engine.

4 Lower boat with its crew until fully water borne and with a slack fall wire. The boat is now hanging by the painter.

5 Remove safety pin on lifting hook. See fig.4

6 Release lifting hook by pulling on the release cable at the aft end of the console (near the knee of the driver). It is not possible to release the hook if there is any tension on the fall wire.

Figure 4.

Safety-pin and 4-tonn single point lifting hook.

8 waterjet versjon

7 Engage gear and then release the painter by pulling sharply on the painter release handle mounted on the forward spray hood. See fig.6

WARNING!

If the ship is making headway and the painter is released before the lifting cable, this may result in injury or death to the crew of the rescue boat, and damage to equipment.

8 Ensure that the marker light on top of the righting bag is in the proper position.

2.2 Recovery of the boat

To recover the boat, proceed as follows:

1 Ensure that the safety pin on the main hook is in place.

2 Manoeuvre the boat toward the loose painter end hanging from the ship.

3 Attach the painter to the painter release hook. See fig. 6 above 4 Let the boat drift slowly until the painter is taut. The rescue craft should now be situated directly under the davit or lifting crane.

WARNING!

If the ship is making headway and the painter is not fastened to the boat before the fall wire, this may result in injury or death to the crew of the rescue boat, and damage to equipment.

5 Place the end link of the fall wire into the single point hook on top of the console. See fig. 4 above. Make certain the hook is in closed position.

6 Hoist the boat just clear of water. Check the lifting hook to make sure it is fully locked and that the safety pin is in place. Please see the instruction plate mounted near the hook.

7 Stop the engine, (see chap. 3.5). It is wise to “race” the engine for 1-2 seconds one or two times to blow out water from the exhaust system before stopping the engine.

8 Hoist boat aboard and secure it on the cradle, connect the external power supply and refill fuel.

RELEASE

HANDLE

Figure 6.

Painter release handle on bow

Waterjet versjon 9

9 Check loose equipment and perform maintenance procedure as described in chap. 5. In cold weather the water filter between water jet and engine must be drained to avoid ice damage. Also engine heat exchangers must be drained, refer to engine manual.

NB! The boat can be recovered with its full complement of crew and passengers, subject to the capacity of the davit.

2.3 In case the boat is capzised

The boat is self-righting and will turn back to its normal upright position by itself.

1. After the boat has returned to the upright position, climb back into the boat, either over the side or the transom, where the water jet protection bar can be used to step on. Let the boat drain and check compartments for water. Also verify that no oil leaks have occured.

2. Run the starter motor on the engine in short bursts of one second a couple of times with the cord on the dead man switch removed. If the engine turns over normally, it is confirmed that no water has entered the cylinders.

3. Replace cord on dead man switch and start engine.

10 waterjet versjon

3 OPERATING PROCEDURES

3.1 Starting the engine

As the boat may be fitted with different engines, please refer to engine manual for details about engine operation and maintenance. Only a few general points are covered here.

For steering console description see fig.7

1 Turn main battery switch to “ON” position by turning clockwise.

2 Fix the dead man switch on the engine control panel in the run position by pressing a special clip onto the switch. This clip has a lanyard that is to be attached to the driver’s clothing. This ensures that the engine will stop if the driver is removed from his position.

3 Check that the throttle / gearshift control is in neutral position.

4 Push the red ON/OFF button to activate engine.

5 Push the green start button until engine start, but no longer than 15 seconds at a time to avoid overheating. When the engine start, release button.

6 If main battery is not able to supply enough power to turn the engine over, transfer battery switch key to emergency battery and turn on. Starting may now continue from step 3 with the emergency start battery.

7 If the engine does not start after 2-3 attempts, investigate and rectify the problem before starting is continued. Repeated starting attempts will only deplete batteries and damage the engine.

3.2 Engine operation

When the engine has started, leave the engine running at idle or fast idle for a few seconds to ensure that oil will reach all necessary parts before racing the engine.

Figure 7.

Steering console

Waterjet versjon 11

When the engine is running and forward gear is engaged, make sure that water is coming out of the exhaust pipe. This indicates the cooling water system is in order.

Check immediately after starting that the red warning lights at the lower left hand corner of the instrument panel, and that all alarms are quiet. If any alarm sounds during operation, reduce power immediately and the cause investigated. The Steyr engine is electronically controlled and will reduce power automatically to protect the engine in case of faults. See engine manual for details.

The warning lights are for:

Charging (picture of battery), Oil pressure (picture of oil can), and engine fault registered (picture of spark).

If the last one is on, consult engine manual.

3.3 Flow deflector

The flow deflector mounted to the stator is, when lowered into the jet stream, designed to force the water-trust forward. This enables the boat to reverse and a skilled helmsman can with partly-engaged deflector accurately manoeuvre and position the boat even in rough water or currents. Note that engine RPM must be fairly high during manoeuvring, 1000 to 2000 RPM depending on the response required.

DANGER!

At idling, the water jet gives very poor directional control. A consequence of this is a loss of steering if engine speed is suddenly reduced to idling when the boat is running at speed. When approaching ship or shore, speed must be reduced gradually.

Forward Push control lever forward, away from you. In topmost position the flow deflector will be out of the jet stream and the boat may accelerate forward.

Reverse Push control lever backward, towards you. In down-most position the flow deflector will be inn the jet stream and the boat may accelerate backward.

3.4 Throttle / gear control

To select forward gear move lever out of neutral position by pushing it forwards.

To increase speed, continue to push the lever away from you. When it stops, the engine is running at maximum forward speed.

To select reverse gear, move lever out of neutral position by pushing it backwards. This will turn the rotation of the impeller and the direction of the flow into a direction for witch this unit was not designed. This results in a very weak reverse thrust with no practical use other than to clear minor blockage at the jet intake.

12 waterjet versjon

3.5 Stopping the engine (normal)

After high speed running, leave engine to cool down at low RPM (around 1000) for 1 to 2 minutes with forward gear engaged. Idle engine and shift to neutral.

Push the red ON/OFF button until engine stops.

CAUTION!

(May not apply to all boats) Cooling water to the engine comes from the jet. Therefore the engine will have no cooling when the jet is not running, ie gearbox in neutral or reverse. Engine may run for a substantial time at idling from cold, but after high speed running it must cool down as explained above to avoid overheating.

3.6 Stopping the engine (emergency)

In an emergency the engine can be stopped at any speed, in or out of gear.

Push the stop button until engine stops.

Engine will also stop if the dead man switch lanyard is removed.

WARNING!

Activation of the dead man switch at high speed will cause an immediate deceleration of the craft, therefor all passengers should remain seated at all times especially when the boat is proceeding at speed.

3.7 Engine cooling

A mix of fresh water and antifreeze, which is circulated by a water pump, cools the engine. This mix is again cooled by seawater in a heat exchanger.

The seawater comes from the water jet, through a filter to the heat exchanger, and is expelled through the exhaust pipe. Taking water from the water jet eliminates the seawater pump on the engine and its dry run problems when the boat is stowed. It will also ensure a more continuos water flow through the engine, especially in choppy seas.

3.8 Dead man switch

The purpose of the dead man switch is to stop the engine when the operator leaves his control station either accidentally by falling into the boat or by falling or being ejected overboard.

The dead man switch consists of a lanyard with clip at both ends. One end is secured to the operator of the boat and the other end is fastened to the dead man switch on the engine instrument panel. If the operator is removed from his position the lanyard automatically turns the switch to the off position thus stopping the engine.

It is possible to manually hold the dead man switch out in the run position, thus operating the boat temporarily without the dead man switch clip.

3.9 Rescue of persons in the water

A person in the water will be drifting due to the effects of wind and sea, therefor it is important for the helmsman to plan any rescue and inform the crew of the plan.

To effectuate a safe and successful rescue bear in mind the following:

Waterjet versjon 13

Set a course that puts the boat in a position where the person in the water is drifting towards the boat.

Reduce speed when close to the person in the water. It is better to stop short than to overshoot and have to go around again.

When very close to the person, hold the boat in position with short engagements of the gear and let him drift into the side of the boat.

Two crew members should position themselves on the side of the boat on which the rescue is to be effected.

When contact is made the crew should grab the person under the arms and together pull him up into the boat. If the person is injured he should be placed on the stretcher keeping his head elevated.

CAUTION!

The helmsman should pay careful attention to the position of the person in the water.

Make sure he is always clear of the jet drive. If in doubt, put engine in neutral position.

Never attempt to bring someone into the boat over the stern. Always use the side of the boat.

3.10 Towing

A principal function of a rescue boat is to tow and marshal liferafts. Two towing points are located on the self-righting frame.

CAUTION!

During towing, care should be taken not to foul the jet intake with the towing line.

3.11 Rowing

Should it be required to row the boat, a set of paddles is supplied. These are secured to the port inside of the boat.

3.12 Loose equipment

Loose equipment according to regulation is supplied. A list of this is enclosed at the end of this manual. The equipment is stowed inside the equipment locker under the forward part of the deck or mounted in the boat. This equipment must be periodically checked to verify that it is in serviceable condition, and that it is complete.

3.13 Fuel tank

A 115 litres fuel tank is installed below deck level in front of the console. Only clean fuel of a grade specified by the engine supplier must be used.

WARNING!

Fire and explosion hazard. Fuel leakage from any part of the fuel system can be a fire and explosion hazard, which can cause serious bodily injury or death.

Careful periodic inspection of the entire fuel system is mandatory, particularly after storage. All fuel components including fuel tank, fuel lines, fittings, and fuel

14 waterjet versjon filters should be inspected for leakage, deterioration or corrosion. Any sign of leakage or deterioration necessitates replacement before further engine operation.

3.14 Fuel shut off valve

A fuel shut off valve is situated at aft. side of the fuel tank. Turn handle clockwise to close all fuel delivery in situation with fire and explosion hazard or while docked. See fig. 1

3.15 Radar reflector and marker light

A radar reflector is mounted aft on the frame for the righting bag. Take care not to damage it.

A position indicating light (white) is mounted on top of the capsize reversal arch. It is possible to remove the light and stow it in a more protected position in front/underneath of the righting bag. This is recommended if the boat installation gives high risk of damage during launch and recovery.

3.16 Battery charger

Inside the centre console is a battery charger for charging the batteries when the rescue boat is docked onboard the ship. Power is supplied to the charger via the quick disconnect plug located on the front of the console. Power to the boat must be supplied at 42 V AC. This is converted to 12 V DC by the battery charger for charging the batteries. Before starting the engine, disconnect the 42 V AC supply.

The batteries are charged independently, and the charger has indicator lights showing battery status.

CAUTION!

If engines are started without disconnecting the power supply, the charger may be damaged.

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4 GENERAL ARRANGEMENT

16 waterjet versjon

5 MAINTENANCE PROCEDURES

Foreword Maintenance to this craft is extremely important, as the duties it fulfils require the boat to be in a state of continuous readiness. In order to keep a record of continuous maintenance, sign the attached log sheet in chapter 8 after each inspection. Continue on additional sheet when the enclosed log is full.

5.1 Loose equipment

Loose equipment should be periodically checked to ensure equipment is properly stowed and is in serviceable condition.

See list at the end of the document

5.2 Hatches

Rubber gaskets around hatches should be checked for deterioration. If any sign of cracking or brittleness exist, gasket should be replaced immediately.

5.3 Lifting hook

Lifting hook should be checked for any visual damage or deterioration. Check if safety pin and hook is free to move. Occasionally grease the hook lightly using a grease gun.

5.4 Self-righting bag

A large air filled bag is installed to right the boat in case it has capsized. It is to be kept at a “firm” hardness by air pressure. The pressure is not critical, but if too low, it must be re-filled through the plug near one end.

Also check that the lashing has not deteriorated. Replace rope if worn or degraded. It is easiest to deflate the bag before replacing rope.

5.5 Engine

The engine maintenance and checks must be performed in accordance with engine manufacturer instruction manual, although some basic engine checks will be covered here.

The engine should be started using both main and emergency batteries during the periodic checks.

NOTE :Maximum 20 minutes idle speed running in sea when gearbox is disengaged.

Maximum 5 minutes idle speed running in davit.

5.5.1 Fuel / Diesel

Use only diesel of a quality equal to or higher than prescribed in manufactures manual. If refilling from a drum, allow drum to stand 3 to 4 days to precipitate the water and dirt to the bottom. Then use the fuel at the top.

A fuel filter and water-separator is installed in the engine compartment. This must be drained and filter cleared or changed as required

Waterjet versjon 17

5.5.2 Engine oil level

Check the engine oil level before starting. Ensure that the oil level is within the marked field on the dipstick. Refill if necessary on top of the crankcase, make sure not to exceed the maximum mark on the dipstick.

5.5.3 Cooling system

When the engine has cooled down, the cap on the fresh water expansion tank on top of the engine may be opened by ¼ turn.

Check the cooling water level against the lower edge of filler socket in the expansion tank.Refill tank from the top cap up till the lower edge of filler socket

(B) in the expansion tank. For refilling, use fluid specified in the engine manual.

5.6 Sea water cooling circuit

It should be checked that the filter next to the drive shaft is not clogged with debris. Open and clean as required.

Operate the intake valve so that it does not stick.

5.7 Gearbox

Gearbox oil level Check the gearbox oil level before starting. Ensure that the oil level is within the marked field on the dipstick. Refill if necessary through the dipstick hole, make sure not to exceed the maximum mark on the dipstick.

When the engine is started, engage gearbox in both forward and aft direction for a few seconds to verify its operation.

5.8 Waterjet

This unit has been designed to require the absolute minimum of maintenance.

However, it is recommended that the unit be dismantled and inspected for wear on bearings, seals etc, and corrosion annually as a minimum requirement. Note that for best performance, clearance between impeller and the housing must be minimum.

Furthermore, to comply with the recommended maintenance, both the log in the end of this manual and the provided manual from the manufacturer, will ensure maximum utilisation of the boat.

Grease the jet according to the manufacturers manual. Note that in addition to the two grease nipples near the drive shaft flange, there is one situated at the rear end of the Alamarin jet. It can be seen when looking into the steering

18 waterjet versjon nozzle from the aft. It ensures lubrication to the aft bearing so that the jet may be run out of the water for a short period.

5.8.1 Water seal

Any leakage through the water seal is detected by water flowing directly into the hull from under the bearing housing.

Inspect this area periodically to ensure that the main seal is sound. To inspect seal, see dismantling procedure in manufacturer handbook.

5.8.2 Sacrificial anodes

The unit is fitted with zinc anodes for cathodic protection. They will waste away in sea or contaminated water. (See manufacturers manual for exact anode locations).

Regulary inspect these anodes and replace if eroded by more than 50%. If allowed to disappear, corrosion will start on the aluminium parts, which will eventually damage the unit.

NOTE!

The rate at which anodes erode away will vary considerably depending on the nature of the water. Check anodes monthly initially until a safe longer check interval can be established from experience.

5.9 Drive shaft universals

Every 30 hours sparingly grease the universal joints and sliding splines. Do not over grease. Excess grease will be thrown out of the joints at high speed. It will then cover the fibreglass structure and require cleaning.

5.10 Electrical system

The start battery and radio battery, if fitted, should be checked to ensure the terminals are tight and clean. Should the terminals show any sign of corrosion, disconnect and clean thoroughly and smear with some vaseline grease.

Check searchlight and marker light. If failing to work inspect wires, contact and bulb. Clean or replace as necessary.

Check instrumentation and engine controls. Replace defective lamps and fuses as necessary.

5.11 General

Keep the boat clean and tidy. Minor damage to the gelcoat orange surface should be repaired from time to time. Larger damage needs more immediate attention.

Combat any signs of corrosion, particularly on steel parts, by brushing with a steel wire brush and painting. Alternatively, a good quality aerosol inhibitor, or even wiping with an oily rag, may be used.

Waterjet versjon 19

6 Maintenance schedules

RECOMMENDED MAINTENANCE

Sign the inspection log in appendix A after each inspection.

Fo r b oa t dr ill

W ee kl y

M on th ly

W he n re qu ire d

Boat and Davit system:

-Check system is ready for immediate use. See davit handbook for details.

Boat interior:

-Check loose equipment is correctly stored and in serviceable condition.

(see loose equipment list) -Inspect lifting hook and safety pin.

Engine:

-Check fuel system for leaks -Check fuel tank is full -Check oil level on engine and gear box -Check coolant level on engine -Lubricate engine (see engine manual) -Start engine using main battery -Start engine using emergency battery -Verify operation of gearbox -Check cooling water filter for debris -Service fuel filter -Check anode wear -Lubricate waterjet -Lubricate drive shaft

20 waterjet versjon

RECOMMENDED MAINTENANCE

Fo r b oa t dr ill

W ee kl y

M on th ly

W he n re qu ire d

Electrical installation -Check battery conditions -Check battery is recharging. (see lamp on battery charger) -Check main battery switch is turned off -Check instrumentation and engine controls.

-Check external power supply is connected to the boat and that it is turned "ON" -Check that all lights are working

Miscellaneous -Check that hatch dogs move and hatches operate freely.

-Check hatches for tightness and gasket condition.

-Drain the boat and check that the bilge pump is functional.

-Check the steering system operates freely.

-Check that the righting bag is properly inflated and lashing in good condition.

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7 LOOSE EQUIPMENT LIST FOR FAST RESCUE CRAFT

Item found in this list is supplied with each 6,55 MAKO, fast rescue craft.

ITEM No. DESCRIPTION SKETCH QTY. CHK'D REMARKS

1. Buoyant paddles.

Secured in the boat.

SOLAS '83 reg. 47.

2. Boathook.

1 Secured in the boat.

3. Buoyant bailer.

Placed in the equipment tank in boat.

4. Bucket with Line equipment tank in the boat.

SOLAS '83 reg. 47.

5. Compass.

Approved type.

Mounted in the boat at the steering position.

SOLAS '83 reg. 47.

6.

Sea anchor complete with tripping line equipment tank in the boat.

SOLAS '83 reg. 47.

7. Painter ø14 length = 18m

Secured in the boat.

SOLAS '83 reg. 47.

8.

Buoyant tow line ø16mm, 50m long.

Placed in the equipment tank in the boat.

SOLAS '83 reg. 47.

9.

Waterproof electric signalling torch.

Placed in the equipment tank in the boat.

SOLAS '83 reg. 47.

10.

Spare batteries and bulb in a watertight box.

equipment tank in the boat.

11. Whistle.

equipment tank in the boat SOLAS '83 reg. 47..

12. First aid kit in a waterproof case.

equipment tank in the boat.

SOLAS '83 reg. 47.

NOTE ! Only included if ordered.

22 waterjet versjon

ITEM No. DESCRIPTION SKETCH QTY. CHK'D REMARKS

13.

Buoyant rescue quoit with 30m buoyant line.

equipment tank in the boat.

14. Engine tool kit.

equipment tank in the boat or inside engine cover.

SOLAS '83 reg. 47

15. Portable fire extinguisher.

or placed in the equipment tank in the boat

16. Searchlight.

or placed in the equipment tank in the boat.

SOLAS '83 reg. 47.

17. Jack knife with lanyard.

equipment tank in the boat.

18. Radar reflector.

Placed on top of central console.

19. Rope ladder equipment tank in the boat.

20. Thermal protective aids.

10% of person s.

Min. 2

Placed in the equipment tank in the boat.

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8 APPENDIX A

8.1 Inspection log

(Note: Sign after completing all the items in the maintenance schedule)

INSPECTION LOG FOR RESCUEBOAT INSPECTIONS.

Check. on: Date: Sign.: Condition: Actions taken:

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INSPECTION LOG FOR RESCUEBOAT INSPECTIONS.

Check. on: Date: Sign.: Condition: Actions taken:

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INSPECTION LOG FOR RESCUEBOAT INSPECTIONS.

Check. on: Date: Sign.: Condition: Actions taken:

26 waterjet versjon

INSPECTION LOG FOR RESCUEBOAT INSPECTIONS.

Check. on: Date: Sign.: Condition: Actions taken:

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+ 6 CYLINDERS

WELCOME ABOARD

Congratulations on your decision of choosing a STEYR marine engine for your boat, and we hope you will enjoy it.

STEYR MOTORS GmbH has developed a high-speed diesel engine with modulated high-pressure fuel injection specifically for the marine environment. STEYR’s marine engines are designed to be adapted to various propulsion systems.

To come up to your expectations, please study thoroughly this manual for your new STEYR marine engine to get sufficient information on its operation and handling and to permit an optimal use of the various built-in functions.

With kind regards, STEYR MOTORS GmbH

STEYR MOTORS GmbH After Sales Service

Im Stadtgut B1 4407 Steyr, Austria www.steyr-motors.com 7th Edition, June 2007 P/N Z001022/0

YOUR STEYR MARINE DEALER

How to use this manual Table of Contents

PAGE 13 - 38START-UP AND FUNCTIONS

This section contains brief instruction, function description and normal operation, as well as correct start-up and handling of STEYR marine engines.

PAGE 5 - 12GENERAL PART

This section contains user instructions and general notes on safety for STEYR marine engines.

PAGE 39 - 42FUEL AND LUBRICANTS

This section defines the requirements as to fuel and lubricants for STEYR marine engines.

PAGE 43 - 54TECHNICAL DATA

This section contains technical data and product description of STEYR marine engines.

PAGE 55 - 82MAINTENANCE, TROUBLE SHOOTING

This section contains instructions for required maintenance and notes on the elimination of possible troubles on your STEYR marine engine.

PAGE 83 - 98DEALER´S ACTIVITIES

This section contains instructions for installation acceptance tests, propeller selection, removal from service, start-up after storage, adequate disposal and dealer´s test list.

PAGE 99 - 108WARRANTY, GENERAL DISTRIBUTORS

This section contains warranty conditions (services and obligations) for owners and manufacturers of STEYR marine engines.

full load speedrange

100%

90%

80%

70%

60%

50%

40%

30%

B

C D

RPM

A

O U

T P

U T

P O

W E

R

GENERAL PART

General

Product References, Illustrations and Specifications

Insurance

Stolen Unit

Owner Identification Card

Installation Acceptance Records

Dealer Service

Illustration Symbols

Repair Service

Replacement Parts

Before Casting Off

Engine Submersion

Bottom Painting

Boat Bottom

Boating Responsibilities

Safety

Symbols

This MANUAL is published by STEYR MOTORS GmbH with the main intention -to provide information in form of technical data and know-how based on our experience in the marine diesel engine business, which will enable you, after thorough study to operate and service the engines on your boat, ensuring their operating safety, reliability and long service life.

CE conformity:

Under regular maintenance, as described in the chapter "Maintenance and Trouble Shooting", the exhaust gas emission levels adhere to the limits stipulated, for pleasure boat operation, throughout the life time of the engine.

All warranty claims to be addressed to your local STEYR Marine Dealer.

(We have to rely on your assistance however) For continuous improvement with regard to form and contents of the information required.

Your comments on the following questions would be much appreciated -

- Which descriptions or terms are not understandable?

- Which enlargements or complements do you suggest ?

- Where did content-related mistakes slip in ?

Please address your comments and ideas to your STEYR - Marine Dealer.

< 3700 rpm.

< 2600 rpm.

< 4000 rpm.

Since this manual covers the whole family of STEYR marine engines, differing sections are marked as follows:

1.)

whole page applies to all engines

2.)

whole page applies to specified engine types only

3.)

whole page applies in principle for all engine types, but different data, e.g. technical data, is marked.

M0144K33

M0144K33

M0166K28

M0236K42

GENERAL

Product References, Illustrations and Specifications When reference is made in this manual to a brand name, number, product or specific tool, an equivalent product may be used in place of the product referred to unless specifically stated otherwise. Equivalent products which are used must meet all current US Coast Guard Safety Regulations and ABYC standards to avoid hazards.

Other countries may apply additional internal regulation. Please follow their advices appropriately.

Austria: Bundesamt für Schiffahrt Sweden: Navigation Office Finland: Navigation Office Norway: DNV = Det Norske Veritas USA: USCG = United States Coast Guard USA: ABYC = American Boat Yacht Council USA: NMMA = National Marine Manufacturers Association England: LR = Lloyds Register of Shipping France: BV = Bureau Veritas Germany: GL = GERMANISER Lloyd Italy: RINA = Registro Italiano Navale

All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of printing. STEYR MOTORS GmbH reserves the right to make changes at any time, without notice, to specifications and models and also to discontinue models, as well as the right to change specifications or parts at any time without incurring any obligation to equip same on models manufactured prior to date of such change.

Continual accuracy of this manual cannot be guaranteed.

All illustrations used in this manual may not depict actual models or equipment and are intended as representative views for reference only.

Insurance

Insurance on your STEYR Marine Engine and boat should be obtained as soon as practical for protection against loss by fire, theft, etc. Consult your local insurance agent.

Stolen Unit

The model and serial numbers on your engine are important for you. As to the location of these important numbers, refer to Model and Serial Numbers in this section.

Record each of these numbers in the spaces provided at the end of this manual and on a separate sheet. Store the separate sheet in a safe place other than your boat.

In case of theft, report the model and serial numbers to your local authorities and your insurance agent.

Owner Identification Card

When you purchases your boat, your dealer was obliged to issue an owner identification card for your STEYR Marine Engine.

This owner identification card gives proof and is to be submitted in case of warranty claims.

Refer to the photograph or drawing described in that paragraph.

Refer to specific items or features described in the text and illustrated on the photograph.

Refer to the general subject of the text.

Refer to an item or feature not clearly visible on the photograph.

Installation and pre-delivery inspection log

Your STEYR Marine dealer is also obliged to complete the Installation Acceptance Records (Chapter "DEALER´S ACTIVITIES"). Required tests and measurements are to be carried out accordingly.

A copy of the Installation Acceptance Records is to be forwarded to STEYR MOTORS GmbH.

Dealer Service - Maintenance

NOTE: Please do not forget to have confirmed in your manual that the installation acceptance test and the service have been carried out in accordance with the installation acceptance records.

This is also an opportunity to clarify with your STEYR marine dealer possible questions arisen during the first running hours on your boat, and to establish a service- and maintenance routine.

Services will be performed by STEYR Marine Dealers at local rates.

Costs for service material to be born by the owner.

Illustration Symbols

Repair Service

All repair works on your STEYR marine engine should be carried out by a licensed STEYR Marine Dealer with his professional knowledge, trained staff and special-purpose tools to solve all occuring problems. Preferably, all works on your STEYR marine engine should be carried out by the STEYR Marine Dealer that sold the equipment to you - he knows you and the equipment.

If problems occur during a trip, bring your STEYR marine engine to the next STEYR Marine Dealer. As to information on dealer addresses see page 3 with phone- and fax numbers of your STEYR Marine Dealer.

Replacement Parts

Your STEYR Marine Engine was designed to operate in a marine environment.

* For long periods at high RPM only use STEYR Marine matched replacement parts.

Before Casting Off

Check the weather report, wind and water conditions. Tell someone where you are going to and when you expect to arrive or return.

Recommended Minimum On-Board Tools large screwdriver wrench set small screwdriver 12-volt pilot lamp cross-point screwdriver flashlight tongs insulating tape long nose pliers wrench for socket head cap screws

Recommended Minimum On-Board Spare Parts propeller and small parts for propeller mounting fuses fuel filter bulbs impeller for raw water pump leakage screws

These lists represent a suggested MINIMUM, and are not intended to cover all boats or possible boating conditions.

Engine Submersion

Save engine from water as quickly as possible and contact your local STEYR Marine dealer for service.

It is imperative that your dealer removes all water from the engine and immediately relubricates all internal parts.

Electrical devices must be replaced. Delay in completing these actions may allow extensive engine damage.

Frequently check engine compartment for excessive water accumulation; water depth in bilge should be kept well below flywheel housing.

Bottom Painting

If your boat is in water where marine growth is a problem, the use of an antifouling paint will reduce the growth rate.

*Tin base antifouling paint (TBTA or TBTF) is recommended where its use is permitted.

*Copper base antifouling paint may be used, but will require more frequent inspection and replacement of sacrificial anodes. DO NOT PAINT any part of the vertical drive with copper base antifouling paint.

NOTE: Painting the vertical drive with copper base paint will accelerate galvanic corrosion.

* Vinyl-butyl base antifouling paint is a recommended alternative.

* DO NOT USE any graphite base antifouling paint.

NOTE: Never paint anti-corrosion anodes, or their effectiveness will be lost.

See your STEYR Marine contract partner for an antifouling paint that is suitable for your area.

Boat Bottom

The condition of the boat bottom can affect your boat's performance. Marine growth, present in fresh water as well as salt water, will reduce boat speed. A boat bottom with evidence of marine growth causes a reduction in top speed of 20 percent or more. Periodically clean the bottom of your boat following the manufacturer's recommendations.

Boating Responsibilities

As a boat owner, you have certain responsibilities to others. Be sure that all operators read this manual.

You are legally responsible for all occupants of your boat. Instruct at least one of your passengers in the basic fundamentals of handling your boat in case of an emergency. Show all hands the location of emergency equipment and how to use it. You are required by law to have one US Coast Guard approved life jacket for each person aboard, plus one approved throwable device for man overboard protection.

Learn the waterway rules of the locality in which you are going to operate your boat. Navigable waterways are controlled by Federal regulations while inland lakes are controlled by local jurisdictions. Obey these regulations to protect yourself, your passengers and fellow boating enthusiasts.

Thoroughly familiarize yourself with weather station warning system signals and waterway traffic signs.

Contact your local Coast Guard station and take advantage of their seasonal boat inspections and training courses.

Safety

This manual contains certain information related to the personal safety of you the operator, your passengers and bystanders.

The Safety symbol ATTENTION: appears next to important information to prevent you and others from being hurt.

The Note symbol NOTE: appears next to important information to keep machinery from being damaged.

Observe all notes and safety warnings contained in this manual.

WARNING

CALIFORNIA: PROPOSITION 65 WARNING

Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm.

Symbols

Certain symbols or combinations of symbols may appear on your STEYR Marine Engine or on its accessories. It is very important that you understand their meaning or purpose. If any symbol is not clearly understood, see your DEALER.

"Safety Warning" Symbols

"Position Indicator" Symbols

"Condition" Symbols

"Functional Description" Symbols

"Instructional" Symbols

Means risk of SERIOUS injury is present.

Follow instructions in the Operation, Maintenance & Warranty Manual before using motor or accsessory.

Indicates that contents are under pressure.

Indicates upward movement.

Example: While boat is at planing speed, activating trim switch to raise the bow of the boat.

Means place shift control in NEUTRAL before starting motor. Follow instructions in Operation, Maintenance & Warranty Manual before starting motor.

Identifies poisonous material.

Indicates that ELECTRICITY of more than 50 volts is present.

Indicates a potential fire hazard.

Indicates gear shift control positions:

FORWARD, NEUTRAL and

REVERSE

Indentifies the meter which indicates accumulative running hours of engine.

Identifies battery or a meter wich indicates status of battery-generator charging system.

Identifies the meter which indicates engine coolant temperature.

Identifies the meter which indicates battery voltage or amperage.

Indicates the amount of liquid in tank.

FILTER: Identifies a device which removes contaminants from engine´s oil system.

Identifies the meter which indicates engine speed expressed in revolutions per minute.

Indentifies the meter which indicates engine coolant pressure.

Identifies the meter which indicates the pressure of engine´s lubricating system.

FILTER: Identifies a device which removes contaminants from fuel.

Identifies the negative ground or negative voltage connection.

Identifies the STOP SWITCH.

It may also identify STOP position of the throttle control.

Identifies the EMERGENCY IGNITION

CUT-OFF SWITCH.

Emergency engine stop.

Identifies engine drain plugs and fittings.

FUSE: Identifies a device which protects the electrical system from overload.

Identifies the operating device for starting the motor.

Indicates FUEL is to be used or FUEL is present.

Indicates OIL is to be used or OIL is present.

Means read your Operation, Maintenance & Warranty Manual before operating the product. It contains information or instructions vital for operation of product.

ENGINE OIL FILL: Location for introduction of oil into the engine.

Indicates areas to be lubricated.

Indicates lubricating oil used in transmissions.

Indicates downward movement.

Example: While boat is at planing speed, activating trim switch to lower the bow of the boat.

or

START-UP AND FUNCTIONS

Before starting

Starting the engine

Stopping the engine

Starting the engine (for SOLAS only)

Stopping the engine (for SOLAS only)

Engine Break-In procedure

Operation after Break-In

Shifting

Remote control operating instructions

How to shift and control speed

Fuel economy

Gear box

High altitude operation

Instrument panel

Instrument indication during normal operation

Instrument panel (for SOLAS only)

Instrument indication during normal operation (only for SOLAS)

Emergency stop switch

Emergency stop switch (for SOLAS only)

Warning lights and audible alarm

START-UP AND FUNCTIONS

Electronic Engine Control Unit (ECU)

Diagnostic system

Counter-rotation models

Optional propellers

Propeller torque

Propeller care

Water jet

Operating procedure for freezing temperatures

Operation in salt water

Fuel pump

Fuel system checks

Fuel contamination

Cooling system (Function description)

Electrical equipment

Alternator

Battery

Circuit breakers

Inversion switch (for Solas only)

Interrupt crankshaft housing ventilation (for Solas only)

Instrument panel (for Solas only)

Dry operation (for Solas only)

Before Starting

Familiarize yourself with the handling of the boat, in particular how to use transmission, and then proceed as follows:

1. Check the bilge for excessive water accumulation. Always keep the bilge clean and dry. Never allow the water level in the engine compartment to exceed the bottom of the oil pan. If water accumulation is unavoidable, install a bilge pump with an automatic control switch.

NOTE: The water level in the boat's engine compartment will increase when the boat is operated at a high incline before planing speed is reached. Excessive water accumulation in the engine compartment/ bilge may cause engine failures.

2. Open the raw water intake valve.

NOTE: Operate the engine only while the raw water supply is assured or the cooling system is equipped with a flushing device. The raw water pump will be damaged and/or the engine will overheat if operated without cooling water.

3. Open the fuel stop valve.

NOTE: Only start the engine when a bubble-free fuel supply is guaranteed. Prior to first start-up of the engine (after installation, after storage etc.), purge the fuel system by "ignition ON" for 6 x 10 sec.

4. Check the operating resources

* coolant

* oil

* hydraulic oil

* transmission oil

* fuel

5. Control of electric

* Charge and charge state of battery.

Starting the Engine

Starting procedure for the STEYR marine engine is the same for both cold and warm engines. The electronic engine management system automatically regulates the fuel supply and the preheating period, for any given temperature. Therefore, the throttle lever should remain in neutral position.

1. To start the engine, move throttle lever into idle position and gear into neutral position.

2. Turn ignition key into position ignition "ON".An audible alarm will sound and the check are illumiated (temporary), indicating the correct function of the audible warning system.

NOTE:

In case of a low temperature start wait until the combined oil pressure/glow plug pre-warming indication light is turned off, before you continue with the start procedure.

3. Turn ignition key into position "START" and hold in this position until "starting" of engine, but under no circumstances hold in this position for more than ten seconds.

If engine does not start, release ignition key momentarily and repeat starting procedure.

4. As soon as engine starts, release ignition key. The audible alarm will stop when normal oil pressure has been reached.

ATTENTION: If engine fails to start within one minute and/or repeated attempts, contact your STEYR Marine dealer.

Never turn ignition key to position "START" when engine is running.

Stopping the Engine

1. Move throttle lever into idle position and gear in neutral position.

2. Cool down the engine.

3. Turn ignition key to OFF position.

ATTENTION: Do not stop engine at speeds above idle or “accelerate” engine while turning off ignition.

This may result in engine failures.

OFF ON

(VOID)

START

OPTIONAL

INSTRUMENT

Starting the Engine (for SOLAS only)

Starting procedure for the STEYR marine engine is the same for cold or warm operating condition. The electronic engine management system automatically regulates the fuel supply and the preheating period, for any given temperature. Therefore, the throttle lever should remain in neutral position.

1. To start the engine, move throttle lever into idle position and gear into neutral position.

2. Press the push button for ignition (ill.F; red) (push button lock in place); An audible alarm will sound and the check lights are illumiated (temporary),…