N6817119Q6029_30WB1601_BOAT_OPERATOR_MANUAL_FINAL.docx

BOAT OPERATOR’S MANUAL FOR

30’ WORK BOAT – MEDIUM (WB-M)

HIN # MXDWB301K116

N00024–16–2211

HULL #30WB1601

MODUTECH MARINE, INC. - Builders of World Class Commercial Boats

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TABLE OF CONTENTS

TABLE OF CONTENTS CONTINUED

TABLE OF CONTENTS CONTINUED

LIST OF FIGURES

CHAPTER 1 – INTRODUCTION

This Boat Operator’s Manual is intended as a reference guide available to the crew of the Work Boat-Medium (WB-M) for safe and efficient operation of the vessel. Contained within this Boat Operator’s Manual (BOM) are explanations and descriptions that outline the care and maintenance requirements, procedures, operational capabilities and limitations, and emergency procedures. The WB-M Boat Operator’s Manual also contains detailed descriptions of the physical characteristics, fittings, and outfit lists of the vessel.

Notes, Cautions, Warnings, and Danger The following definitions apply to Warnings, Cautions, and Notes found throughout the text of this operator’s manual. These special passages call attention to special operating procedures or techniques that are essential to emphasize, and must be carefully followed to avoid equipment damage, personal injury or loss of life.

CHAPTER 2 – BOAT CHARACTERISTICS

This chapter contains the WB-M general description, hull and deck construction, location of interior and exterior fittings, and locations of major hull systems and components.

This chapter contains the following sections:

A. General Description B. Basic Hull and Deck Construction C. Main Deck Equipment D. Engine Room E. Pilothouse F. Mast

Section A. General Description

1. Design The WB-M is an all steel hull with a closed/removable aluminum cabin.

2. Description The WB-M has twin marine diesel engines and nozzled propellers.

a. The superstructure of the WB-M includes:

1) Pilothouse (PH) equipped with permanent seating with arm rests, and foot rests, seat belts for Coxswain, deckhand, and folding jump seat for two additional passengers.

b. Hull components include:

1) Raised walk around cabin amidships and self-bailing/quick draining exterior decks

2) Forward pusher knees and fendering all around vessel.

3) Forward and aft tow bitts to accommodate towing operations.

4) Two (2) side Bloom 16K-6.2M-S145C marine deck winches Port and Starboard. Winch capacity is 9,000 pounds of pull.

5) Heavy duty 200 pound capacity aluminum davit with steel hand winch suitable for retrieving equipment from the water.

3. Construction Heavy duty welded steel is used for hull construction with anti-corrosion treatment/coatings used throughout. Aluminum alloy 5086 is used for the removable pilothouse. Both, Metal Inert Gas (MIG) and Tungsten Inert Gas (TIG) welding techniques are used to assemble the WB-M.

4. Walking Surfaces Exterior MSG440 American Safety non-skid texture is applied to all exterior walking surfaces and cabin top to ensure slip and skid resistant working areas.

5. Manufacturer The WB-M is manufactured by:

Modutech Marine, Inc.

2218 Marine View Drive Tacoma, WA 98422

6. Mission The primary mission of the WB-M is to support Naval Installations and in forward operating areas in support of Commander, Naval Installations Command (CNIC) Port operations, including movement of waterfront equipment, craft and security barriers and assisting in ship and submarine movement.

7. Boat Specifications – Following are the physical characteristics of the WB-M:

Freeboard:

Safe Operating Conditions:

Fully Operational Sea State 2, Wind Speed 15 Knots

Section B. Basic Hull, Deck, and Pilothouse Construction

1. Hull Construction The WB-M structural Material is steel. Heavy Duty welded steel hull construction with anti-corrosion treatment/coatings used throughout.

a. Hull - The WB-M hull is constructed of various thicknesses ASTM A36 steel alloy plates.

b. Replaceable fendering - is non-marking D-rubber to protect sheer, hull sides, pusher knees, and underwater appendages.

2. Deck Construction The WB-M has three (3) primary working deck areas. The weather deck forward, the weather deck aft, and the pilothouse walk around. The deck plates are constructed of A36 steel alloy plate.

a. Weather Deck Forward – This deck can be utilized by the WB-M crew for mooring, towing, anchoring operations, winch operations and retrieving equipment from the water. Located on this deck are two (2) Bloom 16K-6.2M-S145C marine deck winches (Port and Starboard) for barge make-up to forward pusher knees

b. Weather Deck Aft – This deck can be used for mooring, towing, and retrieving equipment from the water.

3. Pilothouse Construction the WB-M pilothouse is a raised/removable 3 – person cabin. Structural material is 5086 aluminum alloy.

Section C. Main Deck Equipment/Hull Fittings

1. Mooring Stations The WB-M is equipped with two (2) Closed Chocks, two (2) Hawse Pipes

a. H-Bitts – Two (2) stern, located Port and Starboard and two (2) forward, located Port and Starboard welded to the main deck. The engineering design load is 18,000 pounds.

2. Towing Fittings

a. Towing Bitts – The WB-M is equipped with two (2) towing bitts, located forward and aft main deck. (SEE FIGURE 1) Rated design load (per contract requirement) is The engineering design load is 18,000 pounds.

3. Lifting Eyes Two (2) stern, located Port and Starboard inserted to main deck and two (2) forward, located Port and Starboard also inserted to main deck. (SEE FIGURE 2)

(FIGURE 2) STARBOARD BOW LIFTING EYE

4. Davit with Hand Winch The Davit is constructed of heavy duty aluminum with a steel Jeamar hand winch (model CMS1450) and has 600 lbs. workload limit suitable for retrieving equipment from the water. Located aft pilothouse. (SEE FIGURE 3)

(FIGURE 3) DAVIT

5. Anode Location The Anode provides cathode protection for the WB-M. Refer to Drawing Number 1128-005-10, Docking Plan & Anodes Arrangement for locations of anodes. Check routinely and replace as needed. (SEE FIGURE 4 - ANODES ARRANGEMENT LOCATION DRAWING #1128-005-10)

6. Grab Rails Aluminum handrails and railings are installed throughout as needed for safety, convenience, and while operating in rough water conditions.

7. Winches Located forward, Port and Starboard are two (2) Bloom hydraulic winches, model 16K-6.2M-S145C. These winches are rated up to 9,000 pounds. (SEE FIGURE 7)

(FIGURE 7) STARBOARD DECK WINCH

Section D. Engine Room

1. Engines The WB-M is equipped with two (2) Cummins QSL9-285 Marine diesel engines attached to ZF W325 marine reduction gears. Located between frames 5 and 8. For more information on engines refer to Cummins COTS manuals located in Pilothouse.

2. FLOCS

The WB-M is equipped with a Reverso GP-3024-24 Fast Lube Oil Changing System (FLOCS). It allows you to quickly change oil in both MDE and reduction gears (ZF W325).

3. Manual/Emergency Steering System The WB-M is equipped with a Jastram Hydraulic Steering System B/M 12619. Integrated for emergency steering operation under systems failure is a Jastram H110 Manually operated Steering Pump. (Located center aft in Engine Room). (SEE FIGURE 20)

4. Clean Agent Extinguisher and Portable Extinguisher The Main Clean Agent Fire Suppression System is located in Engine Room. (Sea-Fire FD-1300M) The Portable Extinguishers is located at the base of Engine Room ladder. (KIDDE 466204, Class ABC)

5. Engine Room Ventilation Provided by natural air vent and Delta T forced air in and out of Pilothouse; located port and starboard aft sides of Pilothouse.

6. Batteries The WB-M’s DC electrical system is 24 volt using six (6) 12 VDC batteries in series broken into three (3) banks: (SEE FIGURE 8)

· Port Engine Starting Bank – Two 12 VDC batteries in series = 24 VDC.

· Starboard Engine Starting Bank - Two 12 VDC batteries in series.

· House Bank - Two 12 VDC batteries in series.

All batteries are Optima 12V, Model D34M.

(FIGURE 8) PORT AND STARBOARD BATTERY BANKS

7. Fuel Tanks The WB-M is equipped with two (2) 200-gallon fuel tanks. (400 gallon total capacity) Fuel tanks are accessible for inspection and repair. Fills and vents are capable of fueling rapidly.

Sounding rod is stowed in tank fill. Fuel sounding is the manual method of sounding (determining fuel level). (SEE FIGURE 9)

STBD FUEL TANK AND RACOR

(FIGURE 9) STARBOARD FUEL TANK

8. Seawater Seacocks (sea valves) and Seawater Strainers (sea filters).

Located in the bilge inboard of the main engines for the WB-M are two (2) seawater seacocks valves and two (2) seawater strainers. These components provide seawater that is used for the cooling of the main engines.

9. Bilge Pumps

a. The WB-M is equipped with two (2) Rule 16A, 24V 3700 Bilge Pumps that are located under each engine. (SEE FIGURE 10) The RULE 42 Switch Panel has three (3) positions. First position; (MANUAL) forces pump to run wet or dry. Second position; (OFF) and will not allow pump to run. Third position; (AUTO) and allows pump to be switched ON and OFF via Ultra UPS-01 High Water Alarm Switch. When the bilge pump is operating, water is being removed from the bilge of the vessel and discharged overboard.

b. The WB-M is also equipped with a manually operated Whale Gusher Titan BP4410 Bilge Pump. It is located under hatch in tread plate at base of ladder. It is operated by moving the handle (stowed on clips on port stringer) in an back and forth motion and will quickly evacuate any water located in bilge, overboard.

c. The two (2) Flooding Alarms consist of one (1) ULTRA Bilge Pump Switch and Siren (UPS-01) and one (1) ULTRA Bilge Alarm (A-201) per flooding alarm. The Ultra Bilge Alarm (A-201) requires two (2) 9V batteries. This unit should be tested monthly and batteries changed yearly to ensure proper operation of Bilge Alarm.

(FIGURE 10) STARBOARD BILGE PUMP

SEA STRAINER

SEA VALVE

(FIGURE 11) PORT SEA STRAINER

10. D/C and A/C Circuit Breaker Panels location The WB-M has AC/DC panels as follows: (SEE FIGURE 12)

· AC Panel is P100, located on Portside, forward bulkhead of the Engine Room.

· DC Panel is 24DC1, located on the Starboard side, forward bulkhead of the Engine Room.

· DC Panel is 24DC2, located on the Starboard side, forward bulkhead of the Engine Room.

· DC Panel is 24DC3, located in the Pilothouse console on the Portside.

· DC Panel 12DC1, located in the Pilothouse console on the Starboard side.

12DC1

24DC3

P100

24DC2

24DC1

(FIGURE 12) AC, DC PANELS

11. Anchor and Rode Located in the aft portion of the engine room. One (1) Fortress Anchor FX-23 with non-ferrous stowage. 5/8” diameter anchor rode, 3/8” chain, and 3/8” shackle. Stowage provides easy accessibility for use.

(FIGURE 5) ANCHOR, CHAIN,

AND ROPE

(FIGURE 6) RODE STOWAGE

Section E. Pilothouse

1. Coxswain/Navigator Console The WB-M is equipped with a 3-person cabin with one main (coxswain) console that provides the essential equipment to operate and navigate the vessel in daytime, nighttime, and up to Sea State 3 conditions.

The WB-M Coxswain Main Console is located at the Starboard center position inside the pilothouse. At this console are all of the essential controls and equipment to maintain command and control of the vessel. Located at this station on forward main console are:

· Winch Control Switch

· Winch Control Levers

· Compass

· (2) Standard Horizon GX2200 VHF Radio System, located above main console

2. Storage Located in main console, overhead consoles Port and Starboard.

3. Steering System The WB-M uses Electrical solenoids to control the Hydraulic Steering system. The emergency steering system is manual hydraulic and located in Engine Room.

4. Pilothouse Crew Seating Located inside the pilothouse are three (3) crew member seats. The Coxswain’s seat is permanently installed, fully adjustable, seat with arm rests, and foot rest for Coxswain and deckhand. Two (2) fold down seats.

5. Pilothouses Windows and Door All windows are fixed watertight windows installed to provide 360-degree field of vision from operator’s station; with the exception of the two side sliding windows, located on port/Starboard side of pilothouse. The three (3) forward windshields are equipped with window wipers and defrost ducts. Aft of the cabin is the sliding door with detents in full and half open positions.

6. Integrated Electronic Navigation Located on the WB-M, on the main console are the electronic navigation equipment. The radio communication is located in the overhead.

The WB-M is equipped with the following integrated electronic navigation system to provide complete and comprehensive daytime, nighttime, and all-weather navigation. The system is a Furuno -TZT12 Display System consisting of:

· Furuno TZT12 12” LCD Radar, GPS, and depth sounder with built in US charting located on main console.

· 24” 4kw Radome, located on top of the Pilothouse

· Transducer, located in Engine Room, centerline through the hull

· Furuno GP320B GPS receiver antenna, located on top of Pilothouse

7. Radio Communication The WB-M is equipped with the following radio communication systems to provide complete and comprehensive ship to ship, ship to shore, ship to aircraft, and internal crew communications.

a. VHF radios is a Standard Horizon GX2200. VHF radio system consists of:

· (2) Standard Horizon Matrix, GX2200 (black) with mount kit

· Antenna (Shakespeare 5250-R), located on top of Pilothouse

· Stainless steel antenna 4-way ratchet-mount (Shakespeare 4187-HD surface mount)

· External speaker

8. VHF Radio DSC and AIS capabilities interfaced to TZT12 display

9. Hand-Held Spotlight The WB-M is equipped with a handheld Hella Model 998-502-011 located starboard side of the main console.

10. Outlets Four (4) Outlets throughout the WB-M. Three (3) are 120 VAC Duplex Receptacles locations; 1- Starboard side internal Pilothouse, 1- Port side external Pilothouse, and 1- Forward bulkhead of Engine Room. There is one (1) 30 AMP Shore Power Receptacle located, Starboard side exterior of the Pilothouse.

11. Emergency Equipment Stowage Locations There are three (2) Portable Fire Extinguishers (Kidde 466240, Class ABC) and one (1) First Aid Medical Kit (Orion OLN-811) located in Pilothouse.

· One (1) Portable fire extinguisher is located starboard aft Pilothouse

· One (1) Portable fire extinguisher at the base of the access ladder.

· One (1) First Aid Medical Kit is located inside stbd Main Console access door.

Section F. Pilothouse Top The WB-M is equipped with a forward and aft Mast located on top of the pilothouse; mounted on the mast are the Safety and Navigation Lights.

1. Mast WB-M is equipped with multiple antennas located on top of the pilothouse roof structure are the radar, GPS, communication, and navigation antennas. (SEE FIGURE 13)

a. Furuno GP330B GPS antenna

b. Shakespeare 5250-R radio communications antenna

c. Furuno 24” 4kW Radome radar antenna

2. Folding/Removal of Mast All Masts is secured with standard Type 316 Stainless Steel Hardware, Allowing for easy folding stowage and or removal. Quick disconnects are provided for all electrical component wiring. (REFER TO MODUTECH MARINE, INC. 30’ WORK BOAT MEDIUM ASSEMBLY INSTRUCTIONS provided with COTS Manuals in Pilothouse).

(FIGURE 13) MAIN MAST AND ANTENNA

Chapter 3 - VESSEL SYSTEMS This chapter will describe in detail, the WB-M systems including propulsion, fuel system, electrical system and communication and navigation. This chapter contains the following sections:

A. Propulsion System B. Fuel System C. Hydraulic System D. Electrical System E. Integrated Navigation and Radio Communication Systems F. Fire Suppression Systems G. HVAC System H. Ventilation System Section A. Propulsion Systems – Engines

1. Overview The propulsion system consists of two (2) Cummins -QSL9 engines coupled to two (2) ZF W325 Marine Reduction Gears. Propulsion system is conventional shaft/nozzle-propeller/rudder configuration.

2. Controls and Features

a. Engine Controls – Electronic combined engine and gearbox controls are available in pilothouse main console to provide enhanced maneuverability and stationary control. (SEE FIGURE 14)

b. Engine Starting Switches

c. Engine Display Module (EDM)

d. Gearshift and Throttle Control Lever Jog Lever Display Module Ignition Switches Rudder Angle Indicator Gearshift and Throttle Steering FFU Start/Stop Switches

(FIGURE 14) CONTROLS AND FEATURES

3. Engine Gauges OEM dimmable instrument package for each engine located in main console. Keyless start switch. Instrument package consist of; tachometer, engine water temperature, engine oil pressure, engine hour meter, voltmeter, gear pressure, gear temperature, intake temperature, gallons per hour, fuel consumption per hour, estimated range, speed, and load percentage. (SEE FIGURE 15)

(FIGURE 15) ENGINE CONTROL MODULE

4. Operation To ensure the operators of the WB-M get the full benefit of the installed Cummins QSL9 engines, this section will detail safe efficient operation of the engines.

a. Safe Operating Precautions – Before operating the Cummins QSL9 engines, the operators and maintenance personnel of the WB-M should read and familiarize themselves with the IMPORTANT SAFETY INFORMATION located in the Cummins COTS Owner’s Manual provided with the WB-M.

b. Prior to getting underway, the engines need to be warmed up to ensure proper performance. For ambient temperatures above 41° F (5°C), the engine should be warmed up for two (2) to three (3) minutes at idle. For temperatures below 41° F (5°C), the engine should be warmed up for no less than fifteen (15) minutes.

During the warm up period, observe the engine oil pressure indicator, engine overheat indicator, and engine cooling system indicator. If any abnormalities are observed, stop.

5. Starting the WB-M from a cold start

a. Unplug 110V shore power.

b. Switch ON 24 Volt Starting Battery Circuit

c. Switch ON 24 Volt ships Service Battery Circuit, verify 24DC-POS1 and 24DC1 (3 single pole) breakers are closed.

d. De-energize block heaters P100-3 and P100-4 (SEE FIGURE 12)

e. Visual inspection of all equipment

f. Check engine oil level

g. Check engine coolant level

h. Check gear oil level

i. Check hydraulic oil level and ensure valves are OPEN (steering/winches) (SEE FIGURES 22 & 23)

j. Verify seawater intake valve open (SEE FIGURE 11)

k. Check seawater strainer for leakage or debris (SEE FIGURE 11)

l. Check bilge area for excess water and oil

m. Check fuel level

n. Verify main engine fuel supply valve open (SEE FIGURE 9)

o. Check and turn ON fuel water separators (RACORS). (SEE FIGURE 9)

p. Verify clutch in neutral. Throttle at idle at control station. (SEE FIGURE 14)

q. Energize Fire Suppression System at 24DC3, breaker 12. (SEE FIGURE 12)

r. Energize both Engine Ignition Switches located on main console.

(SEE FIGURE 14)

s. Turn shaft/throttle/clutch breaker ON at power panel 24DC2, breaker 8. (SEE FIGURE 12)

t. Depress Active Station button located on Throttle Control Head. (SEE FIGURE 14)

u. Turn steering system control breaker ON at 24DC3, breaker 10 (SEE FIGURE 12)

v. Depress Engine Stop/Start Button for desired engine located on Mercury Marine Control Panel at main console. (SEE FIGURE 14)

w. Verify water flow within 10 seconds of starting at Overboard Discharge Port located outboard, midship port and starboard sides.

x. Verify oil pressure within 15 seconds of starting

y. Allow engine to idle for 15 minutes which exceeds engine manufactures recommendations.

z. Select steering control at main console.

6. Shutdown Procedures

a. Verify clutch in neutral. Throttle at idle at control station.

b. Depress Engine Stop/Start Button for desired engine located on Mercury Marine Control Panel at main console.

c. Ensure desired engine has come to a complete stop.

d. Turn steering system control breaker OFF at 24DC3-10

e. Turn shaft/throttle/clutch breaker OFF at power panel 24DC2, breaker 8.

f. De-energize both Engine Ignition Switches located on main console.

g. De-energize Fire Suppression System at 24DC3, breaker 12.

h. Turn OFF main engine fuel supply valve and fuel water separator (RACORS)

i. Close sea valves

j. Check bilge for excess water and oil.

k. Energize block heaters P100-3 and P100-4.

l. Switch OFF 24 Volt ships Service Battery Circuit

m. Switch OFF 24 Volt Starting Battery Circuit

n. Plug into shore power; turn on P100-SS located in the P100 power panel.

7. Seawater Cooling (Flush Procedure) With engines shutdown close raw water inlet ball valve at through hull. Install attached (lanyard) garden hose adapter to inlet of sea strainers. Attach fresh water hose and open fresh water supply valve (dockside). Allow engines to idle at operating temperature for 15 minutes.

(FIGURE 16) SEAWATER COOLING SYSTEM PROCEDURES

8. Maintenance and Safety It is essential that all the following safety procedures should be followed. However, it is impossible to warn against every conceivable hazard that may arise while performing engine maintenance. Read all maintenance procedures carefully and use caution and good judgment prior to performing any maintenance tasks.

a. Safety

· Make sure the engine is off prior to performing any maintenance or repair procedures. This will eliminate the following potential safety hazards:

· Engine exhaust contains carbon monoxide and is poisonous. Do not run the engine in a confined or partially enclosed space!

· Burns from hot parts – Do not operate the engine unless instructed to do so.

· Read all instructions associated with the maintenance or repair manuals and verify that the required tools are available and that you have the skills to perform the repair or maintenance item.

· Reduce the possibility of fire of explosion while working near fuel. Use only nonflammable solvents. Keep sparks, flames, and other sources of ignition away from fuel-related parts.

· Wear all applicable PPE such as safety glasses or face shield, gloves, ear protection, safety aprons, and shoes when necessary or recommended.

b. Maintenance Schedule

1) Engine Oil Level Check – The engine oil level should be checked prior to every voyage or mission. The engine oil level should be checked when the engine is not running. To check the engine oil level:

a) Remove the engine oil dipstick and wipe it clean.

b) Insert the dipstick back into the tube, wait 2-3 seconds and remove the dipstick. Observe the oil level on the dipstick.

c) If the oil level is low, remove the oil filler cap and add oil until the oil level is at the upper limit mark on the dipstick.

d) Install the oil fill cap and tighten securely.

2) Recommended Engine Oil, Engine Oil Changes, and Oil Filter Changes – consult Cummins QSL9 Manual for oil change parameters.

a) Winterization Procedures – The WB-M has a closed circuit cooling system. To winterize close ALL sea valves, drain all raw water from sea valves, and remove pencil zincs from heat exchanger to drain raw water.

WORK BOAT – MEDIUM

WORK BOAT – MEDIUM

45 | Page

Maintenance Interval Schedule Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, fluids, filters, and the installation of new components due to normal wear and aging. The performance of this product may be diminished if proper maintenance intervals and procedures are not followed. Components may experience accelerated wear if proper maintenance intervals and procedures are not followed.

Note: Use whichever of the following that occurs first in order to determine the maintenance intervals: fuel consumption, service hours, and calendar time. Before each consecutive interval is performed, all maintenance from the previous intervals must be performed.

Products that operate in severe operating conditions may require more frequent maintenance.

Daily Cooling System Coolant Level – Check Engine Air Cleaner Service Indicator – Inspect Engine Oil Level – Check Fuel System Primary Filter/Water Separator – Drain Walk-Around Inspection

Initial 10 Service Hours Belts - Inspect/Adjust/Replace Every 50 Service Hours or Weekly Zinc Rods - Inspect/Replace Every 250 Service Hours or 1 Year After cooler Condensate Drain Valve - Inspect/Clean Auxiliary Water Pump (Rubber Impeller) - Inspect/Replace Battery Electrolyte Level – Check Belts - Inspect/Adjust/Replace Cooling System Coolant Sample (Level 1) – Obtain Cooling System Supplemental Coolant Additive (SCA) - Test/Add Engine – Clean Engine Air Cleaner Element - Clean/Replace Engine Crankcase Breather – Clean Engine Oil Sample – Obtain Engine Oil and Filter – Change Fuel System Primary Filter (Water Separator) Element – Replace Fuel System Secondary Filter - Replace Fuel Tank Water and Sediment - Drain Hoses and Clamps - Inspect/Replace Initial 500 Hours (for New Systems, Refilled Systems, and Converted Systems) Cooling System Coolant Sample (Level 2) – Obtain Engine Valve Lash - Inspect/Adjust Fuel Injector - Inspect/Adjust Every 1000 Service Hours After cooler Core - Clean/Test Closed Crankcase Ventilation (CCV) Fumes Disposal Filter – Replace Turbocharger – Inspect Every Year Cooling System Coolant Sample (Level 2) - Obtain Every 3000 Service Hours Auxiliary Water Pump (Bronze Impeller) - Inspect/Replace Cooling System Water Temperature Regulator – Replace Crankshaft Vibration Damper – Inspect Engine Mounts – Inspect Engine Speed/Timing Sensors - Check/Clean/ Calibrate Engine Valve Lash - Inspect/Adjust Engine Valve Rotators - Inspect Fuel Injector - Inspect/Adjust Heat Exchanger – Inspect Starting Motor – Inspect Every 3000 Service Hours or 3 Years Cooling System Coolant (DEAC) - Change Every 5000 Service Hours Alternator – Inspect Water Pump - Inspect Every 6000 Service Hours or 3 Year Cooling System Coolant Extender (ELC) - Add Every 12 000 Service Hours or 6 Years Cooling System Coolant (ELC) – Change

c. Maintenance Information

2.5” X 3.5” X 12”

ZSS-24

d. Petroleum Oil Lube Chart

6 Gal in pan

e. Spare Parts List

f. Troubleshooting Guide

Fuel filter or fuel filter/water separator clogged.

Bad fuel; or boat stored without fuel.

Refuel.

Replace fuel filters.

Drain fuel tanks.

Battery discharged.

Clean and tighten battery -connections.

Recharge battery.

separator clogged.

Replace fuel filters.

Drain fuel tank and fuel vapor separator.

contaminated.

Fuel system malfunction, fuel pump failure, ignition malfunction.

Replace or repair faulty components as necessary.

2. Consult an authorized Cummins Service Center.

9. Technical and Consumer Information

a. Serial Number Locations:

STBD QSL9 CUMMINS ENGINE - 74059704

PORTQSL9 CUMMINS ENGINE - 74059703

STBD ZF 325 REDUCTION GEARS - 20276094

PORT ZF 325 REDUCTION GEARS – 20276093

b. Battery Requirements: 12V-214Ah, CCA1300 @ 0°F

c. Consumer Service Information Cummins – visit website: www.cmdmarine.com The following publications will provide the operators and maintenance personnel with additional information for the maintaining and repairing the Cummins engine.

Shop Manual – This manual covers complete maintenance and overhaul procedures. The manual is intended to be used by certified technicians. This manual is available through your local authorized Cummins dealer or visit www.cmdmarine.com.

Parts Manual – This manual provides a complete parts list. This manual is available through your local authorized Cummins Dealer or visit www.cmdmarine.com.

d. Warranty Statements Cummins engines are covered by the following warranties:

· Limited Warranty

· Engine Warranty

· Emissions Control System Warranty

Warranty CMD Quantum Commercial

QSB5.9/QSC8.3/QSL9/QSM11

Marine Propulsion

Coverage

Engines Included in this Coverage

Marine Propulsion

QSB5.9

QSC8.3

QSL9

QSM11

Products Warranted This warranty applies to new QSB5.9, QSC8.3, QSL9 and QSM11 Engines sold by Cummins MerCruiser Diesel, herein after “CMD”, that are branded as Cummins MerCruiser Diesel products and used in Marine propulsion applications anywhere in the world where CMD approved service is available* and delivered to the first user on or after January 1, 2004. This warranty excludes all engines branded and sold as Cummins Marine Diesel products. The ’Product’ consists of a new CMD Engine, as well as accessories, which are approved and supplied by CMD and which are either installed by CMD or a CMD authorized distributor. These Products have the following designation:

MARINE PROPULSION

Government

Service (GS) Rating Intended for use in variable load applications where full Power is limited to one hour out of every eight hours of operation.

Reduced power operation must be at or below cruise speed (rpm). Cruise speed (rpm) is dependent on the engine rated speed (rpm):

Rated

Speed

(rpm) Cruise

Speed (Reduction f r om r ated speed, rpm) L ess than

2,800 rpm rpm 2,8 t o

3,500 rpm rpm 3,5 t o

4,500 rpm rpm 4,5 t o

5,000 rpm rpm

This power rating is only for use in National, State or Local government non-revenue producing applications.

Intermittent Rating This power rating is intended for intermittent use in variable load applications where full power is limited to two hours out of every eight hours of operation. Also, reduced power operations must be at or below 200 rpm of the maximum rated rpm. This rating is an ISO3046 Fuel Stop Power Rating and is for applications that operate less than 1,500 hours per year.

Medium Continuous Rating This power rating is intended for continuous use in variable load applications where full power is limited to six hours out of every twelve hours of operation. Also, reduced power operations must be at or below 200 rpm of the maximum rated rpm. This rating is an ISO3046 Fuel Stop Power Rating and is for applications that operate less than 3,000 hours per year.

Cummins

Heavy Duty Rating This power rating is intended for continuous use in variable load applications where full power is limited to eight hours out of every ten hours of operation. Also, reduced power must be at least 200 rpm below the maximum rated rpm. This rating is an ISO3046 Fuel Stop Power Rating and is for applications that operate less than 5,000 hours per year.

Continuous Rating This power rating is intended for continuous use in applications requiring uninterrupted service at full power. This rating is an ISO3046 Standard Power Rating.

Base Engine Warranty This warranty covers any failures of the Product, under normal use and service, which result from a defect in CMD material or factory workmanship (Warrantable Failure). Coverage begins with the sale of the Engine by CMD and continues for the Duration stated in the following table. The Duration commences on either the date of delivery of the Product to the first end-user, or the date the unit is first leased, rented or loaned, or when the Product has been operated for 50 hours, whichever occurs first.

W ar r anty C ov e r age

P eriods Rating

QSB,

QSC,

QSL

QSM

Note:

C o v e r age ends at which e ve r occu r s fi r st, months or hou r s of usag e Note:

C o v e r age ends at whiche v e r occu r s fi r st, months or hou r s of usag e Months Hou r s Months Hou r s

GS

1,000 1,000 I n termitte n t 3,000 3,000 Medium Co n tinuous

Duty 5,000 6,000 He a vy

Duty 5,500 8,000 Co n tinuous 6,500 9,000

MerCruiser Diesel Responsibilities During Engine Warranty CMD will pay for all parts and labor needed to repair the damage to the Product resulting from a Warrantable Failure when performed during normal business hours. All labor costs will be paid in accordance with Cummins published Standard Repair Time guidelines.

When it is necessary for mechanics to make on-site warranty repairs CMD will pay reasonable travel expenses, including meals, mileage and lodging, for mechanics to travel to and from the repair dock.

CMD will pay for the lubricating oil, antifreeze, and filter Elements and other maintenance items that are not reusable due to the Warrantable Failure.

CMD will pay for reasonable labor costs for Engine removal and reinstallation when necessary to repair a Warrantable Failure.

Owner Responsibilities During the Engine Warranty Owner is responsible for the operation and maintenance of the Product as specified in the applicable CMD Operation and Maintenance Manual. Owner is also responsible for providing proof that all recommended maintenance has been performed. This warranty does not cover normal wear and tear of covered parts.

Before the expiration of the applicable warranty, Owner must notify a CMD service provider, distributor, authorized dealer, or other repair location approved by CMD of any Warrantable Failure and make the Engine available for repair by such facility. Locations in the United States and Canada are listed in the Cummins U.S. and Canada Sales and Service Directory; other locations are listed in the CMD International Sales and Service Directory.

Owner is responsible for the cost of lubricating oil, antifreeze, filter elements, and other maintenance items replaced during warranty repairs unless such items are not reusable due to the Warrantable Failure.

Owner is responsible for communication expenses, meals, lodging, and similar costs incurred as a result of a Warrantable Failure.

Owner is responsible for non-Engine repairs, “downtime” expenses, cargo damage, fines, all applicable taxes, all business costs, and other losses resulting from a Warrantable Failure.

In the event of any Product failure, Owner is responsible for the cost of towing the boat to the repair dock and for all associated docking and harbor charges.

Owner is responsible for maintaining the Engine hour meter in good working order at all times and to ensure that the hour meter accurately reflects the total hours of operation of the Product.

Owner is responsible for the costs to investigate complaints, unless the problem is caused by a defect in CMD material or factory workmanship.

Limitations

1. Maintenance Component Limitations CMD will replace certain maintenance components if they fail within 90 days or less after the base coverage starts. Maintenance components include but are not limited to: sea water pump impellers, zinc plugs, oil filters, fuel filters, air filters, water filters, fuel/water separator filters, expansion tank pressure caps, belts, and hoses.

2. Other Component Limitations CMD does not warrant components that are not supplied by CMD factory.

3. CMD supplied alternators and starters limitation Warranty coverage is limited to 2 years or 2,000 hours, whichever expires first for rating other than Government Service.

Warranty coverage is limited to 2 years or 1,000 hours, whichever expires first for the Government Service rating.

Consumer Products The warranty on Consumer Products in the United States is a limited warranty. CMD IS NOT ESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. Any implied warranties applicable to Consumer Products terminate concurrently with the expiration of the express warranties applicable to the Product. In the United States, some states do not allow the exclusion of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above limitations or exclusions may not apply to you.

CMD is not responsible for failures or damage resulting from what CMD determines to be abuse or neglect, including, but not limited to: operation without adequate coolants or lubricants; over fueling; over speeding; lack of maintenance of cooling, lubricating or intake systems; improper storage, starting, warm-up, run-in or shutdown practices; Unauthorized modifications to the engine. CMD is also not responsible for failures caused by incorrect oil or fuel or by water, dirt or other contaminants in the fuel or oil.

CMD is not responsible for failures resulting from:

1. Use or application of the Product inconsistent with its rating designation set forth above.

2. Incorrect installation.

Before a claim for excessive oil consumption will be considered, Owner must submit adequate documentation to show that oil consumption exceeds CMD published standards.

CMD is not responsible for failures of maintenance components supplied by CMD beyond 90 days after the coverage duration start date. Maintenance components include, but are not limited to: sea water pump impellers; zinc plugs; oil filters; fuel filters; air filters; water filters; fuel/water separator filters.

Parts used in warranty repairs may be new CMD parts; CMD approved rebuilt parts, or repaired parts. CMD is not responsible for failures resulting from the use of parts not supplied by CMD.

A new CMD or CMD approved rebuilt part used to replace a Warranted Part assumes the identity of the Warranted Part it replaced and is entitled to the remaining coverage hereunder.

CMD DOES NOT COVER WEAR OR WEAROUT OF COVERED PARTS.

CMD IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

THESE WARRANTIES SET FORTH HEREIN ARE THE SOLE WARRANTIES MADE BY CMD IN REGARD TO THESE ENGINES. CMD MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

Emission Warranty Products Warranted This Emission Warranty applies to new Engines certified to United States EPA 40 CFR 94 sold by CMD that are installed in vessels flagged or registered in the United States**.

Coverage CMD warrants to the first user and each subsequent purchaser that the Engine is designed, built, and equipped so as to conform at the time of sale by CMD with all U.S. Federal emission regulations applicable at the time of manufacture and that it is free from defects in workmanship or material which would cause it not to meet these Regulations within the longer of the following periods: (A) Five years or 5,000 hours of operation, whichever occurs first. The Emissions Warranty starts from the date of delivery of the Engine to the first user, or the date the unit is first leased, rented, or loaned, or when the Engine has been operated for 50 hours, whichever occurs first, or (B) The Base Engine Warranty.

Limitations The owner may elect to have maintenance, replacement, or repair of the emission control parts performed by a facility other than a CMD distributor, an authorized dealer or a repair location approved by CMD, and may elect to use parts other than new genuine CMD or CMD approved rebuilt parts and assemblies for such maintenance, replacement or repair; however, the cost of such service or parts and subsequent failures resulting from such service or parts will not be covered under this emission control system warranty.

Failures, except those resulting from a defect in materials, or factory workmanship, are not covered by this WARRANTY.

CMD IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

In the United States** and Canada, this warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Outside the United States** and Canada, in case of consumer sales, in some countries the Owner has statutory rights which cannot be affected or limited by the terms of this warranty.

Nothing in this warranty excludes or restricts any contractual rights the Owner may have against third parties.

* Locations in the United States and Canada are listed in the Cummins United States and Canada Sales and Service Directory; other locations are listed in the Cummins International Sales and Service Directory.

** United States includes American Samoa, the Commonwealth of Northern Mariana Islands, Guam, Puerto Rico, and the U.S. Virgin Islands.

Cummins MerCruiser Diesel 4500 Leeds Avenue - Suite 301 Charleston, South Carolina 29405 U.S.A.

Bulletin 4081921Printed in U.S.A. Rev. 5/08 2003 Cummins Inc.

Section B. Fuel Systems

1. Principles of Operation The WB-M diesel fuel system is comprised of two (2) of the following items: 200 gallon…