Zodiac Hurricane H638 SOLAS Manual MB10247 Rev 11-8-2016.pdf

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H638 DJ FRB NOAA

© 2016 Zodiac Hurricane Technologies Inc., All Rights Reserved

Revision Schedule

Date Title Revision Revision Description

22-MAR-2010 MB10247 0.90 Created from MB10246

21-APR-2010 MB10247 1.00 Initial publication

14-JUL-2010 MB10247 1.01 Minor text corrections

04-SEP-2014 MB10247 1.10 Removed part number hyphens and updated logo

08-NOV-2016 MB10247 2.00 Updated manual to current standards

Revision Schedule

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Revision Schedule

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Table of Contents Revision Schedule Table of Contents List of Figures List of Tables Introduction

Scope SOLAS Rescue Boat Certification Health and Safety

Safety Notes Seating and Restraints

General Arrangement Operation

Pre-Operational Checklist Engine Startup Engine Control Engine Shutdown

Emergency Engine Shutdown Steering

Forward Steering Reverse Steering

Stern Drive Water Jet

Collar Inflation / Deflation

Shipment / Transport Storage

Systems FRP Hull and Deck Structure

FRP Preventative Maintenance FRP Cleaning and Lubrication FRP Inspection

FRP Corrective Maintenance

FRP REPAIR TYPES

FRP Repair Materials and Tools General FRP Repair Procedure TYPE Specific FRP Repair Procedures

Collar Collar Preventative Maintenance

Collar Cleaning and Lubrication Collar Removal and Reinstallation Collar Inspection Collar Valve Inspection

Collar Air Retention Test Collar Corrective Maintenance

Temporary Collar Repairs Permanent Collar Repairs Collar Repair Preparation Glue Preparation Glue Application and Patching Ungluing Seam Leak Repair Small Hole/Tear Repair Large Hole/Tear Repair Collar Accessory Replacement Standard Inflation Valve Leak Repair Pressure Relief Valve Leak Repair

Fuel and Propulsion Fuel Storage and Delivery

Fueling Propulsion Fuel and Propulsion Preventative Maintenance

Fuel and Propulsion Cleaning and Lubrication Fuel and Propulsion Inspection Fuel Filter Replacement

Fuel and Propulsion Corrective Maintenance Fuel and Propulsion Troubleshooting

Steering and Control Steering

Engine Control Man Overboard Switch

Trim Tabs Steering and Control Preventative Maintenance

Steering and Control Cleaning and Lubrication Steering and Control Inspection

Steering and Control Corrective Maintenance Steering and Control Troubleshooting

Electrical DC Electrical

Batteries and Battery Switches DC Breaker Panel DC Switches

AC Electrical AC Breaker Panel

DC Electrical Preventative Maintenance DC Electrical Inspection

DC Electrical Corrective Maintenance DC Electrical Troubleshooting

AC Electrical Corrective Maintenance AC Electrical Troubleshooting

Drainage Electric Bilge Pump Drainage Preventative Maintenance

Drainage Cleaning and Lubrication Electric Bilge Pump Inspection

Drainage Corrective Maintenance Hoisting

Hoisting Preventative Maintenance Hoisting Cleaning and Lubrication Hoisting Inspection

Hoisting Corrective Maintenance Hoisting Troubleshooting

Above Deck Equipment Console Seating Antenna Arch Righting System

Arming the Righting System Activating the Righting System Righting System Preventative Maintenance

Righting System Cleaning and Lubrication Inflatable Bag Inspection Valve Inspection Righting Frame Inspection Pull Cable Inspection Compressed Gas Cylinder Inspection Firing Head/Inflation Assembly Inspection

Righting System Corrective Maintenance Inflatable Bag Righting Frame Compressed Gas Cylinder Firing Head/Inflation Assembly Righting System Troubleshooting

SOLAS Equipment SOLAS Cover

SOLAS Collar Cover SOLAS Ancillary Kit

Appendices Appendix A: Limited Warranty

Request for Warranty Service Customer Input Report Limited Warranty Registration Transfer Form Limited Warranty Deferral Agreement & Notification Notice of Intent to Place a Vessel in Service

Appendix B: Maintenance Specifications Lubrication Schedule Torque Specifications

Table of Contents

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Table of Contents

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List of Figures Figure 1: General Arrangement (Profile View) Figure 2: General Arrangement (Plan View) Figure 3: Hull and Deck Structure Figure 4: FRP TYPE 1 Repair Figure 5: FRP TYPE 2 Repair Figure 6: FRP TYPE 3 Repair Figure 7: FRP TYPE 4 Repair Figure 8: Inflatable Collar Figure 9: Air Retention Soap Test Figure 10: Patch Alignment Figure 11: Interior and Exterior Patches Figure 12: Fuel Storage and Delivery System Figure 13: Propulsion System Figure 14: Steering and Engine Control System Figure 15: DC Electrical Schematic Figure 16: Switch/Breaker Panel Electrical Schematic Figure 17: Shore Power Electrical Schematic Figure 18: Electric Bilge Pump Figure 19: Hoisting Configuration Options Figure 20: Lift Frame Figure 21: Console Arrangement Figure 22: Dash Layout Figure 23: Seating Arrangement Figure 24: Antenna Frame Figure 25: Removing the Safety Pin Figure 26: Inserting the Breakaway Pin Figure 27: Righting System Arrangement Figure 28: Righting System Activation Positioning Figure 29: Manual Fill Valve Detail Figure 30: Removing the Lanyard Grommet Figure 31: Pull Cable Tension Figure 32: Firing Head Alignment

List of Figures

List of Tables Table 1: FRP Repair Materials Table 2: FRP Repair Tools Table 3: Collar Air Retention Test Sheet Table 4: Lubrication Schedule Table 5: Torque Specifications

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List of Tables

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DANGER

WARNING

CAUTION

CAUTION

CAUTION

Read and understand this manual before operating the boat.

Improper operation can result in injury or property damage.

Introduction

Scope

Introduction The Zodiac Hurricane H638 DJ FRB NOAA Rigid Hull Inflatable Boat (RHIB) (hereafter referred to as the ‘H638 DJ’) are light-weight watercraft featuring a composite hull combined with an inflatable collar at the gunwale. The collar provides added buoyancy and increased stability in most sea conditions. The H638 DJ is designed for fast rescue and patrol missions and can be deployed via trailer or shipboard davit system.

Scope

This manual provides technical information specific to the Zodiac Hurricane H638 DJ FRB NOAA.

SOLAS Rescue Boat Certification

Lloyds Register has approved the H638 DJ Zodiac Hurricane RHIB models as Fast Rescue Boats in accordance with the International Convention for the Safety of Life at Sea (SOLAS).

Health and Safety

The H638 DJ is a high-performance watercraft and therefore carries inherent risks of serious injury or death if handled improperly. Boat operators, crew, and passengers must exercise proper judgment, care, and attention at all times while operating, riding, or handling the H638 DJ.

Safety Notes

This manual uses safety notes to indicate hazards that could result in injury, death, or property damage. Each safety note includes the following information:

Safety notes are categorized by the severity of the hazard. The safety note categories used in this manual are as follows:

The Danger note indicates an imminent hazard that will cause death or serious injury if not avoided.

The Warning note indicates a potential hazard that could cause death or serious injury if not avoided.

The Caution note with the general hazard symbol (!) indicates a potential hazard that could cause minor or moderate injury if not avoided.

The Caution note without the general hazard symbol (!)

indicates a potential hazard that could result in damage to equipment or property if not avoided.

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Introduction

Health and Safety

Seating and Restraints

The H638 DJ may be fitted with shock mitigation seating.

Shock mitigation seating systems reduce the impact loads experienced by passengers and crew during boat operation.

Boat operators must properly gauge the severity of impact loads imposed by boat maneuvers and sea conditions to prevent injury, death, or loss of vessel control.

Seat restraints reduce the potential for injury caused by involuntary ejection or contact with surroundings; however, these restraints can also impede escape if rapid egress is required. All crew and passengers must be instructed in the proper use of any installed seat restraints to ensure maximum potential for escape in the event of emergency.

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Figure 1: General Arrangement (Profile View)

Figure 2: General Arrangement (Plan View)

Introduction

General Arrangement

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Introduction

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Step # Checklist Item

1. Register float plan.

2. Verify safe weather for intended operations.

3. Verify all required documents are on board.

4. Verify navigation charts/equipment are on board.

5. Inspect hull for leaks/damage.

6. Inspect collar for damage/excessive wear.

7. Verify collar attachments are secure.

8. Verify collar is inflated to proper working pressure.

9. Verify scupper trunks are up and hull drain is closed.

10. Verify bilge pump(s) function properly and strainer(s) are free of debris.

11. Verify sufficient fuel on board for intended operations.

12. Inspect fuel lines/filters for leaks.

13. Verify engine oil is filled to correct level.

14. Verify engine coolant is filled to correct level.

15. Verify batteries are fully charged.

16. Verify navigation lights function properly.

17. Verify the horn functions properly.

18. Verify paddles are on board and stowed properly.

19. Verify mooring lines are on board.

20. Verify fire extinguishers are on board and stowed properly.

21. Verify inflation pump is on board and stowed properly.

22. Verify collar repair kit is on board and stowed properly.

23. Verify flares are on board and stowed properly.

24. Verify sufficient number of life jackets are on board (one (1) per crew member/passenger)

25. Verify mandatory SOLAS ancillary equipment on board and stowed properly (if applicable)

26. Verify drain plugs are installed.

27. Verify all loose equipment is stowed properly and all hatches are secured.

28. Inspect steering system for leaks and verify steering controls operate smoothly and freely.

29. Verify throttle/shift controls operate smoothly and freely.

Operation

Pre-Operational Checklist

Operation This chapter contains general instructions and procedures for operating the H638 DJ, including engine startup and shutdown, collar inflation, and preparation for transport or storage. Refer to the manufacturer manuals in the OEM Publications binder for detailed equipment operation and maintenance procedures.

Note: This chapter is not intended to address all aspects of boat operation. Boat operators and crew members must be trained in proper boat handling and navigation techniques prior to assuming command of the H638 DJ.

Pre-Operational Checklist

Pre-operational checks must be performed prior to startup to ensure the H638 DJ is seaworthy. Use the following Pre-operational Checklist to confirm that all boat systems and equipment are ready for operation.

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CAUTION

Stop engine immediately if an engine alarm sounds or engine fault is indicated.

Continued operation can damage engine.

WARNING

Warn passengers before performing an emergency engine shutdown.

Sudden stops can cause loss of footing resulting in serious injury or death.

DANGER

Do not disconnect engine wiring harness to stop engine.

The main engine and man overboard switches cannot stop the engine if the engine wiring harness is disconnected.

Operation

Engine Startup

Engine Startup

Refer to the manufacturer manuals in the OEM Publications binder for detailed engine startup and operating instructions.

Engine Control

Refer to the manufacturer manuals in the OEM Publications binder for detailed engine control instructions.

Engine Shutdown

Refer to the manufacturer manuals in the OEM Publications binder for detailed engine shutdown instructions.

Emergency Engine Shutdown

To perform an emergency engine shutdown:

Switch the main engine switch to the OFF position;

-OR-

Remove the man overboard actuator from the man overboard switch.

Note: The engine cannot be restarted until the man overboard actuator is reinserted into the man overboard switch.

Steering

The H638 DJ is steered by turning the stern drive unit or water jet nozzle via a mechanical or hydraulic steering system. Refer to the Steering and Control section of the Systems chapter of this manual for detailed steering system information.

Refer to the drive unit manufacturer’s manual located in the OEM Publications binder for detailed steering instructions.

Forward Steering

The steering controls when travelling forward are identical for both stern drive and water jet propulsion systems: turning the steering wheel clockwise will turn the boat to starboard; turning the steering wheel counter-clockwise will turn the boat to port.

Reverse Steering

The steering controls when travelling in reverse differ between stern drive and water jet propulsion systems as follows:

Stern Drive

When a H638 DJ with a stern drive is travelling in reverse, turning the steering wheel clockwise will turn the boat to starboard;

turning the steering wheel counter-clockwise will turn the boat to port.

Water Jet

When a H638 DJ with a water jet is travelling in reverse, turning the steering wheel clockwise will turn the boat to port; turning the steering wheel counter-clockwise will turn the boat to starboard.

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Operation

Collar

Collar

The H638 DJ inflatable collar consists of multiple airtight chambers separated by internal fabric baffles. This structure distributes impact pressure evenly and minimizes chamber baffle stress.

Refer to the Collar section of the Systems chapter of this manual for inflatable collar technical illustrations, maintenance procedures, and repair instructions.

Inflation / Deflation

The inflatable collar must be inflated to working pressure (3.0 - 3.5 psi (207 - 241 mb)) to ensure optimal boat handling and performance. An air pressure gauge is included in the collar repair kit supplied with the H638 DJ. The collar is inflated by connecting an external air source featuring a handheld hose and compatible adapter to each collar chamber inflation valve.

CAUTION

Always maintain proper collar working pressure.

Under-inflation can increase fabric wear and affect boat handling.

Over-inflation can damage the collar.

To inflate the collar:

Step 1. Remove the inflation valve caps from the port and starboard aft collar chambers.

Step 2. Connect the air hose to each inflation valve and inflate the port and starboard aft collar chambers until the chambers hold shape (approximately 1.0 psi (69 mb)).

Step 3. Repeat steps 1 and 2 on the remaining collar chambers, moving from aft to forward and alternating port and starboard.

Step 4. Return to the port and starboard aft collar chambers and inflate to working pressure (3.0 - 3.5 psi (207 - 241 mb)).

Step 5. Repeat step 4 on the remaining collar chambers, moving from aft to forward and alternating port and starboard.

Step 6. Reinstall the inflation valve caps on all collar chambers.

To deflate the collar:

Step 1. Remove the inflation valve caps from all collar chambers.

Step 2. Press the spring-loaded spindle within each inflation valve body and rotate the spindle one-quarter turn clockwise to lock open.

Step 3. Apply manual pressure to the collar exterior to remove air from the collar.

Note: A foot pump or vacuum may be used to remove air from the collar.

Step 4. Press the spring-loaded spindle within each inflation valve body and rotate the spindle one-quarter turn counter-clockwise to lock closed.

Step 5. Reinstall the inflation valve caps on all collar chambers.

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Operation

Shipment / Transport

CAUTION

Do not exceed maximum collar pressure (3.5 psi (241 mb)).

Ambient temperature and pressure changes can rupture collar and injure nearby personnel.

CAUTION

Do not allow water to collect on deck or in hull.

Water weight and freezing can damage hull and deck structure.

CAUTION

Do not run ropes/straps over the collar during transport.

Ropes/straps can chafe collar fabric or damage collar accessories.

Shipment / Transport

Observe the following precautions to prevent damage to the H638 DJ during shipment or transport:

Secure Load: Secure the H638 DJ to a cradle or trailer using the bow eye and transom tie down eye bolts.

Trailer/Cradle Load Capacity: Maximize hull contact with support bunks or rollers. Bunk cradles/trailers should support a maximum load of 200 lb/ft2 (100 g/cm2). Roller cradles/trailers should support a maximum load of 150 lb (68 kg) per roller.

Altitude/Temperature: Deflate the collar if extreme altitude and/ or temperature changes are expected to avoid collar rupture.

Environmental Standards: Comply with all applicable environmental and safety regulations if transporting the H638 DJ with fuel or other hazardous materials on board.

Note: Drain all fuel from the H638 DJ if transporting by air.

Consult the aircraft loadmaster for specific requirements.

Load Weight: Ensure the transport vehicle trailering capacity meets or exceeds the trailer load. If the boat will be towed on a trailer, ensure the tongue weight is 5 - 10% of the total weight of the boat, trailer, and ancillary equipment.

Drainage: Transport the H638 DJ in a bow high attitude.

Ensure electric bilge pumps are operational and set to AUTO.

Antennae: Fold the antenna frame and all antennae down.

Cover: Cover the H638 DJ during transport. Secure the cover properly to avoid collar damage.

Storage

Store the H638 DJ in an area with adequate ventilation to prevent mildew growth and accumulation of fuel vapors and condensation. Protect the H638 DJ from sunlight and air pollutants.

Note: Refer to the manufacturer manuals in the OEM Publications binder for additional long term storage preparation instructions if the H638 DJ will be stored for longer than six (6) months.

To prepare the H638 DJ for storage:

Step 1. Wash the H638 DJ with soap and fresh water.

Step 2. Flush the engine coolant system (refer to the manufacturer manuals in the OEM Publications binder for coolant draining instructions).

Step 3. Stabilize and treat remaining onboard fuel as per the manufacturer manuals in the OEM Publications binder.

Step 4. Lubricate all recommended points as per the Lubrication Schedule section of this manual and the manufacturer manuals in the OEM Publications binder.

Step 5. Connect the H638 DJ to shore power and switch all battery switches to the OFF position.

Note: Disconnect and store batteries in a cool, dry, well-ventilated location if the H638 DJ will be stored for longer than six (6) months; keep batteries fully charged during storage.

Step 6. Ensure electric bilge pumps are operational and set to AUTO mode.

Step 7. Remove the hull drain plug, clear the scupper trunks, and store the H638 DJ in a bow up attitude to prevent water accumulation.

Step 8. Deflate the collar if extreme temperatures are expected during storage to avoid collar rupture.

Step 9. Lower all antennae.

Step 10. Cover the H638 DJ during storage; secure the cover properly to prevent water from pooling.

Step 11. Secure the H638 DJ to a bunk or roller style cradle or trailer. Refer to the Shipment / Transport section of this manual for cradle/trailer load requirements.

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Systems

FRP Hull and Deck Structure

Systems This chapter contains inspection criteria, preventative and corrective maintenance procedures, schematics, and diagrams for the H638 DJ systems.

Refer to the manufacturer manuals in the OEM Publications binder for equipment-specific information, maintenance procedures, and technical illustrations.

FRP Hull and Deck Structure

The H638 DJ hull and deck structures are constructed of fiber-reinforced plastic (FRP). Structures are laminated in a female mold with fire-resistant vinylester resin and alternating layers of woven roving and chopped strand mat. Foam core inside the laminate augments the rigidity of select areas of the hull and deck structures.

The inflatable collar attaches to the hull via an integral collar cradle. Slotted extrusions at the top of the cradle and the sheer secure the collar to the collar cradle.

The self-bailing deck drains through one-way scuppers that can be hoisted above the waterline and secured with jam cleats.

Limber holes in the scantlings ensure water accumulates aft at the lowest point of the bilge. Deck hatches provide access to the bilge and machinery spaces for inspection, maintenance, and storage. A removable hull plug allows bilge water to drain when the H638 DJ is out of the water.

FRP Preventative Maintenance

The FRP hull and deck structures require minimal preventative maintenance aside from regular inspections for damage.

FRP Cleaning and Lubrication

Rinse the hull, deck, console, and seats with fresh water after every use. Fresh water and marine soap with wax will maintain the boat’s appearance, and significantly reduce corrosion. The paint applied to the laminate may oxidize and change color over time; however, this oxidation can be removed with a fine marine polish or cleaner. Remove surface corrosion of metallic fittings immediately with marine polish and protect with wax, paint or other sealant.

Note: Wash and wax all exposed hull and deck surfaces frequently. High quality wax virtually eliminates corrosion, oxidation, and color fading.

FRP Inspection

Weekly

Inspect the H638 DJ hull and deck structure from bow to stern for evidence of damage. Where exterior damage is discovered, inspect the interior surface near the damaged area (if possible).

Immediately repair any damage that extends to the interior surface (refer to the FRP Corrective Maintenance section of this manual for detailed repair instructions).

Note: Minor hairline cracks in the gel coat finish may be evident at sharp corners of the FRP hull and deck structures. These cracks are cosmetic and do not require immediate repair; however, monitor these cracks monitored regularly and repair if they become wider.

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Systems

FRP Hull and Deck Structure

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Figure 3: Hull and Deck Structure

Systems

FRP Hull and Deck Structure

L O

O S

E N

T O

O P

E N

S C

U P

P E

R S

E C

U R

E T

O C

L O

S E

S C

U P

P E

R P

A R

T N

O . P

-N -3

L -N

S C

U P

P E

R T

R U

N K

L A

N Y

A R

D L

O O

S E

N T

O O

P E

N S

C U

P P

E R

S E

C U

R E

T O

C L

O S

E S

C U

P P

E R

P A

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. P -N

-3

L

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P E

R T

R U

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L A

N Y

A R

D

1 2 3 4 5 6 7 9 10 11 1312 14 15

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Item Part Number Description Qty Unit

1 HC10203 Clam cleat (not illustrated) 2 Ea

2 HE20180 Eyestrap (not illustrated) 2 Ea

3 TC10156 Transom cap 1 Ea

4 LP10020-1 Lift point 2 Ea

5 HH12310 Hatch, 9.75 in x 26.75 in 1 Ea

6 GG6399998-O Aft deck cover 1 Ea

7 HH15148 Deck plate, 8 inch 1 Ea

8 GH6380016-O Hull and deck structure 1 Ea

9 MP00067-4 Fuel inspection hatch 1 Ea

10 HH15149 Hatch, 6 inch 2 Ea

11 GD5900190-O Fuel tank cover 1 Ea

12 HC10233 Folding cleat 2 Ea

13 LP63098 Flush lift point assembly 2 Ea

14 MP63800 Inboard tube attachment assembly 1 Set

15 GG6300195-O Fuel fill pod 1 Ea

16 MP63007-2 Bow post base 1 Ea

17 MP63807-2 Bow post top 1 Ea

Legend: Hull and Deck Structure

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Material Description

Epoxy Resin High quality marine epoxy only

Gelcoat Pigmented polyester resin

Glass Cloth E-Glass or carbon material only *

Mat 1 oz per square foot

Structural Glue Plexus MA590 or equivalent

Woven Roving 18 or 24 oz per square yard

* Refer to the structure drawings located in the technical manual supplement for weight and weave specifications.

Table 1: FRP Repair Materials

Item Tool Use

1 Coveralls, eye protection, respirator, gloves

Personal protection

2 Grease pencil / Chalk Marking the repair area

Power jig or saber saw with metal cutting blades, fine tooth and/or keyhole saw

Removal of damaged area

Grinder or disc sander with coarse and medium grit sanding discs, file

Final removal of damaged area, beveling edge of cutaway area

5 Measuring tape Measuring repair area

6 Scissors, shears Cutting templates, mat, and woven roving

7 Cardboard, craft paper Templates

8 Disposable containers, mixing implements

Resin mixing

9 Disposable brushes, putty knife Resin application

10 Polyethylene sheet, cellophane Separating film

11 Heavy cardboard, thin plywood, sheet metal

Cover or backing plate

12 Acetone Surface preparation and cleanup

Table 2: FRP Repair Tools

Systems

FRP Hull and Deck Structure

FRP Corrective Maintenance

When FRP hull and deck structure damage is discovered, the damage should be identified and corrected in accordance with the practices and procedures detailed in the following sections.

FRP REPAIR TYPES

FRP hull and deck structure damage is identified and categorized by repair ‘TYPE’ as per the following definitions:

TYPE 1: Minor damage limited to one side of the laminate.

TYPE 2: Damage that extends through the entire laminate.

TYPE 2 repairs are limited to areas that are not heavily loaded or where the opposite laminate side is not accessible. TYPE 2 repairs include repairs to one side of a cored laminate where the coring and opposite side are not damaged.

TYPE 3: Significant damage to non-cored laminate that includes apparent internal damage or damage to nearby structures. TYPE 3 repairs are two-sided repairs.

TYPE 4: Severe damage to cored laminate in structural areas.

TYPE 4 repairs are two-sided repairs.

FRP Repair Materials and Tools

The following tables list the typical materials and recommended tools used to repair the FRP hull and deck structure. Most of the materials and disposable tools are included in standard FRP repair kits.

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WARNING

Fiberglass dust is hazardous.

Do not inhale fiberglass dust.

Wear proper protective equipment when sanding fiberglass.

CAUTION

Protect machinery from fiberglass dust contamination.

Fiberglass dust is abrasive and can damage machinery.

WARNING

Do not smoke or allow open flame or heat sources in the area when using solvents.

Solvents are highly flammable and solvent vapors are explosive.

WARNING

Solvents are hazardous.

Avoid contact/prolonged exposure to solvents or solvent vapors.

Wear proper protective equipment when using solvents.

Continued on next page

Systems

FRP Hull and Deck Structure

General FRP Repair Procedure

The following procedure details a typical FRP repair. TYPE specific repairs are illustrated in the TYPE Specific FRP Repair Procedures section of this manual.

To repair typical FRP damage:

Step 1. Inspect the damaged area and identify the repair TYPE.

Step 2. Prepare the working area by isolating nearby surfaces from the working area and covering/protecting machinery against fiberglass dust and resins.

Note: Environmental conditions must be controlled when repairing FRP components. Maintain ambient temperature between 50° and 70° F (8° and 20° C).

Avoid temperatures in excess of 80° F (23° C) if possible.

A temporary shelter and space heater may be required for adequate environmental control.

Step 3. Prepare the damaged area by removing the damaged fiberglass and beveling the cutout edges to the correct angle (refer to the TYPE Specific FRP Repair Procedures section of this manual for detailed removal and edge beveling illustrations for the repair TYPE).

Note: Ensure the corners of the damaged area are rounded after removing the damaged fiberglass to reduce loading on the completed repair.

Step 4. Create a template using craft paper that is the size and shape of the outside edge of the prepared area.

Continue creating progressively smaller templates until the number of templates equals the number of layers in the undamaged laminate.

Step 5. Cut fiberglass cloth pieces to match the templates created in the previous step.

Step 6. Clean the prepared area with acetone and a clean cloth.

Step 7. Mix the resin and hardener as per the manufacturer’s instructions.

Note: The mixed resin remains workable for 20 - 30 minutes after mixing.

Step 8. Lay out a piece of separating film larger than the largest piece of fiberglass cloth on a flat surface; then lay the largest piece of fiberglass cloth on top of the separating film.

Step 9. Apply the mixed resin to the fiberglass cloth using the spreader and then center the next largest piece of fiberglass cloth on top of the first piece. Work the mixed resin into the fiberglass cloth until cloth appears clear (white patches indicate areas with insufficient resin to saturate the cloth).

Note: Use as little mixed resin as possible to saturate the fiberglass cloth.

Step 10. Repeat the previous step until all pieces of fiberglass cloth have been laid on the separating film and saturated with resin. The resulting patch will be cone shaped.

Step 11. Apply a thin layer of mixed resin to the prepared area using the brush.

Step 12. Using the separating film to handle the patch, position the patch over the prepared area. Ensure the patch is centered and aligned properly.

Step 13. Work the patch into place using finger pressure and smooth using the spreader. While holding the patch in place, slide the backing plate over the patch and block the backing plate securely.

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Continued from previous page

Systems

FRP Hull and Deck Structure

Step 14. Allow the repair to cure for a period of time dependent on ambient temperature. The cure time for ambient temperatures above 60° F (13° C) is three (3) to four (4) hours. Lower temperatures require longer cure times of up to 24 hours.

Step 15. After 24 hours, remove the backing plate and verify that the repair is fully cured by gently prodding the repair area with a sharp object. If the repair area is hard, the repair is fully cured; however, if the repair area is pliant or rubbery, increase the ambient temperature (do not increase the ambient temperature above 80° F (23° C)) while leaving the backing plate off to allow the repair to cure completely.

Step 16. Inspect the cured repair for correct alignment and a solid bond between the patch edge and the FRP component, as well as any raised or cloudy areas, voids, or other evidence of improper bonding. If multiple defects are discovered, remove the affected areas and repeat the repair procedure for those areas.

Step 17. Sand the patch and FRP component until smooth. Use caution to avoid excessive sanding of the patch edges.

Step 18. Paint the sanded area with similarly colored epoxy paint.

Note: Zodiac Hurricane recommends painting all FRP component repairs; however, painting is a cosmetic measure and is not required to complete the repair.

TYPE Specific FRP Repair Procedures

The following diagrams illustrate TYPE specific FRP repairs as per the FRP Repair TYPEs section of this manual. These diagrams should be used in conjunction with the General FRP Repair Procedure section of this manual to complete FRP TYPE repairs successfully.

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Figure 4: FRP TYPE 1 Repair Figure 5: FRP TYPE 2 Repair

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Figure 6: FRP TYPE 3 Repair Figure 7: FRP TYPE 4 Repair

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Collar

The H638 DJ inflatable collar construction consists of an external Hypalon® fabric layer, a core polyester fabric layer, and an internal neoprene rubber layer.

The collar is divided into multiple airtight chambers by internal fabric baffles. A standard inflation valve (ICV) is installed on each chamber to allow chamber inflation/deflation. A pressure relief valve is installed on each chamber to purge excess air if chamber pressure exceeds 3.5 psi (241 mb).

Lifelines secured with stainless steel D-rings run the length of the collar. Neoprene rubber rubstrakes protect the outboard surface of the collar. Step treads protect the top surface of the collar at high traffic areas commonly used to embark or disembark the H638 DJ.

The bow area of the collar is protected by a removable bow skirt attached to the collar lacing cuff and secured to the hull via aluminum attachment flatbars. An orange collar cover is provided to comply with SOLAS requirements when the H638 DJ is operating in a fast rescue/SAR role.

Collar

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Figure 8: Inflatable Collar

Systems

Collar

Plan View

Profile View

1 2 3 4 5 6

7 8 9 10 12 13

16 17 18 20

19 21

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© 2016 Zodiac Hurricane Technologies Inc., All Rights Reserved

Item Part Number Description Qty Unit

1 TA630HP052B-O Airholding tube 1 Ea

2 - Transom retaining strap 2 Ea

3 TP92047 Logo 3 Ea

4 TS11005-B Step tread 4 Ea

5 TP10050-BC-B D-ring patch 14 Ea

6 RN20030 Lifeline 42 Ft

7 TP20016-O-B Transom patch 2 Ea

8 HR20130 Tri-ring with slide (not illustrated) 2 Ea

9 TP10030-B-B Paddle blade patch 2 Ea

10 TP10033-B-F Paddle shaft patch 4 Ea

11 TP20010-O-B No rope flange 12.2 M

12 SB55000 Storage bag 4 Ea

13 TP10025-O-B Tube ID patch 1 Ea

14 TV50030B Inflation/deflation valve 3 Ea

15 TV10065 Pressure relief valve 3 Ea

16 TC20102 Cone end 1 Pr

17 TP20019-O-B Arrowhead tuck flange 1 Pr

18 TR82070P Rubstrake 44.2 M

19 TP20011-O-B Rope flange 11.9 M

20 TP20012-O-B Bow flange 1 Ea

21 LC10000-B-B Lace cuff 9 Ft

22 TP630001 Bow skirt (not illustrated) 1 Ea

Legend: Inflatable Collar

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CAUTION

Use additional personnel as necessary to assist in removing or reinstalling the collar.

Collar weight can cause injuries and rough handling can result in collar damage.

CAUTION

Do not clean/wax collar fabric with products containing silicone.

Silicone will permeate collar fabric and impede subsequent repairs.

CAUTION

Do not over-tighten collar attachment fasteners.

Over-tightening can strip fastener threads and damage collar attachment hardware.

Collar Preventative Maintenance

The collar assembly requires minimal preventative maintenance aside from regular washing and application of an approved marine spray wax/cleaner. During cleaning, inspection of the collar and installed components should be performed.

The inflation and pressure relief valves require occasional preventative maintenance.

Collar Cleaning and Lubrication

Rinse the H638 DJ collar with fresh water after every use.

Fresh water and marine soap (with wax) will maintain collar appearance and significantly reduce fabric and glue wear due to sand, salt, and other contaminants. Use an approved marine spray wax/cleaner such as 303 Protectant or Meguiar’s Marine Vinyl & Rubber Cleaner to reduce UV and salt damage and prolong collar life.

Collar Removal and Reinstallation

To remove the H638 DJ inflatable collar:

Step 1. Secure the H638 DJ to prevent movement.

Step 2. Deflate the collar.

Step 3. Detach the aft attachment straps, fuel vent hose, and inflation system hoses (if installed) from the collar.

Step 4. Detach the flange retaining plates.

Note: Record the location and orientation of the flange retaining plates prior to detachment.

Step 5. Unlace and remove the bow skirt (if installed).

Step 6. Pull the collar forward to remove it from the H638 DJ.

To reinstall the inflatable collar on the H638 DJ:

Note: Ensure the area in front of the H638 DJ is clean and free of any items that could damage the collar.

Step 1. Lay out the collar in front of the boat.

Step 2. Lubricate the tube flange and hull slot with soapy water.

Step 3. Slide the collar onto the hull as far aft as possible.

Step 4. Inflate the collar to working pressure.

Step 5. Attach the bow skirt (if installed).

Step 6. Attach and apply tension to the aft attachment straps.

Step 7. Attach the flange retaining plates starting at the bow and working aft.

Note: Attach and tighten the port and starboard flange retaining plates simultaneously by alternating between the port and starboard plates as each bolt is installed.

Adjust the collar (if necessary) as the flange retaining plates are attached to ensure correct collar positioning.

Systems

Step 8. Attach fuel vent and inflation system hoses (if installed).

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Collar Inspection

Inspect the inflatable collar if the external fabric layer or attached accessories are damaged or if the collar does not maintain working pressure for at least 24 hours.

To inspect the inflatable collar:

Step 1. Examine each collar section from bow to stern for excess wear or damage. Note the location and extent of any damage discovered during examination.

Step 2. Test collar air retention as per the Collar Air Retention Test section of this manual if no damage is evident during inspection.

Step 3. If the collar damage is minor (hole/tear less than 3 inches (75 mm) long), repair the damage as per the Small Hole/Tear Repair section of this manual; if the collar damage is more extensive (hole/tear between 3 inches (75 mm) and 15 inches (375 mm) long), repair the damage as per the Large Hole/Tear Repair section of this manual.

Note: Extensive collar damage (hole/tear longer than 15 inches (375 mm)) must be repaired by an authorized service center. Remove the collar as per the Collar Removal and Reinstallation section of this manual and send the collar to the service center for repair and replacement.

A spare collar, if available, can be installed to return the H638 DJ to active service.

Collar Valve Inspection

Inspect inflation valves and pressure relief valves with each usage for contaminants in the valve assembly. Contaminants can be blown out with compressed air. Inspect valve caps for damaged gaskets.

Collar Air Retention Test

The collar air retention test should be conducted annually, as well as when the collar does not maintain pressure for at least 24 hours, to verify the airtight integrity of the collar.

To perform the collar air retention test:

Step 1. Inflate each collar chamber to 3.5 psi (241 mb); verify the collar chamber pressure using a pressure gauge.

Step 2. Reinstall the valve caps securely and allow 30 minutes for the collar pressure to stabilize.

Step 3. Measure the pressure in each collar chamber, the ambient air temperature, and the barometric pressure;

record these measurements on the Collar Air Retention Test Sheet located in this manual.

Step 4. After 60 minutes, measure the pressure in each collar chamber, as well as the ambient air temperature and barometric pressure. Record these measurements on the Collar Air Retention Test Sheet located in this manual, adjusting the collar chamber pressure measurements to allow for temperature and barometric changes as follows:

-0.03 psi (-2 mb) for 1° F (0.5° C) temperature increase +0.03 psi (+2 mb) for 1° F (0.5° C) temperature decrease +0.49 psi (+34 mb) for 1” barometric pressure increase -0.49 psi (-34 mb) for 1” barometric pressure decrease

A pressure decrease of 0.3 psi (20 mb) indicates leakage in the collar chamber. To identify the specific leakage points, inflate the chamber to working pressure and brush the chamber exterior with a soap and water solution. Leaks are identified by growing chains of bubbles and categorized as valve leakage, cover patch leakage, seam leakage, widespread leakage, or hole/tear.

Figure 9: Air Retention Soap Test

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© 2016 Zodiac Hurricane Technologies Inc., All Rights Reserved

Ambient Temperature (°C or °F) Barometric Pressure Time Notes

Start

End

Change

Corrections psi psi mb mb

Total Correction = (Temperature Correction) + (Barometric Correction)

Total Correction psi mb

Chamber Number Start Pressure End Pressure Corrected End Pressure Difference* (Start minus Corrected End Pressure)

* Pressure difference equal to or greater than 0.3 psi (20 mb) for 24 hours indicates chamber failure.

Table 3: Collar Air Retention Test Sheet

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Collar Corrective Maintenance

Temporary Collar Repairs

The collar repair kit supplied with the H638 DJ includes rigid tapered rubber plugs or ‘leak stoppers’ designed to temporarily repair small collar holes/tears.

To temporarily repair a small collar hole/tear using a leak stopper:

Step 1. Insert an appropriately sized leak stopper into the collar hole/tear. Screw the leak stopper into the collar hole/tear in a clockwise direction until air passage around the leak stopper ceases.

Step 2. Immediately inflate the collar to working pressure using the foot pump supplied with the H638 DJ.

Note: Avoid over-inflating the collar as over-inflation may cause the leak stopper repair to fail.

Step 3. Record the collar damage in the operational log, noting the cause and location of the damage so permanent repairs can be scheduled.

Permanent Collar Repairs

Permanent collar repairs require a draft free, well ventilated, temperature controlled environment. The ambient temperature of the repair area must be maintained between 60° F (13° C) and 80° F (23° C) to ensure proper glue mixing and application.

Note: A temporary shelter and space heater may be necessary to control the repair area environment and temperature.

The procedures for permanent collar repairs vary depending on the nature of the collar damage; however, the overall repair sequence is the same regardless of damage specifics.

The sequence of events for permanent collar repairs is as follows:

Step 1. Identify the specific damage to be repaired as per the Collar Inspection, Collar Valve Inspection, and Collar Air Retention Test sections of this manual.

Step 2. Prepare the collar area to be repaired in accordance with the Collar Repair Preparation section of this manual.

Step 3. Prepare the glue used in collar repairs in accordance with the Glue Preparation section of this manual.

Step 4. Perform the repair procedure appropriate to the specific damage identified in step 1. Refer to the specific repair procedure sections of this manual as per the following list:

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CAUTION

Use light pressure when buffing collar fabric with an electric sander.

Excessive pressure can damage collar fabric.

Collar Repair Preparation

To prepare the collar for repair:

Step 1. Using grease pencil, draw an outline 2 inches (50 mm) in all directions from the collar damage to mark the repair area.

Step 2. Briskly wipe the repair area with a clean cloth soaked with methyl ethyl ketone (MEK) to remove grease, petroleum, or oxidized material. If the outline marked in step 1 is removed, re-draw the outline with a grease pencil. Allow MEK to evaporate before proceeding.

WARNING

Do not smoke or allow open flame or heat sources in the area when using solvents.

Solvents are highly flammable and solvent vapors are explosive.

WARNING

Solvents are hazardous.

Avoid contact/prolonged exposure to solvents or solvent vapors.

Wear proper protective equipment when using solvents.

Step 3. Buff the repair area with the buffing tool included in the collar repair kit, a pumice stone, or an electric disc sander with a 120 grit sanding disc, using gentle strokes to avoid exposing or damaging the internal webbing. Continue buffing until dust is produced and the collar surface dulls to a matte finish.

Step 4. Brush or wipe the repair area to remove dust/debris.

Glue Preparation

Zodiac Hurricane recommends Bostik 2402AP glue with Bostik 2402SX catalyst (hereafter referred to as “Bostik glue”) for collar repairs. Bostik glue is designed for the Hypalon® fabric used in the manufacture of the H638 DJ inflatable collar.

The mixing ratio for Bostik glue is 5 parts catalyst to 100 parts glue (by volume). The optimal environmental conditions for mixing and applying Bostik glue are as follows:

80° F (23° C)

Note: If Bostik glue is not available, Zodiac Milpro Hypalon®/ CSM Boat Glue (Zodiac Milpro part number Z7098) may be substituted; however, the environmental requirements for this glue are even more critical than for Bostik glue. Mixing/application of Zodiac Milpro Hypalon®/CSM Boat Glue should not be attempted if ambient temperature or humidity are outside the ranges listed previously in this section. Instructions for mixing and applying this glue are listed on the container label.

To mix Bostik glue properly:

Step 1. Combine five (5) parts catalyst and 100 parts glue (by volume) in a disposable container.

Step 2. Mix the catalyst and glue together with a spatula or similar implement for approximately two (2) minutes.

Step 3. Allow the mixture to sit for five (5) minutes to remove bubbles.

Note: Mixed Bostik glue has an active life of one (1) hour.

Always cover the container when not in use.

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Glue Application and Patching

The following procedure provides general instructions for using Bostik glue to repair collar damage by applying a patch. Refer to the repair procedures listed in the Permanent Collar Repairs section of this document for damage-specific repair instructions.

To apply a collar patch using Bostik glue:

Step 1. Prepare the repair area as per the Collar Repair Preparation section of this manual.

Step 2. Select a pre-cut patch from the collar repair kit and trim (if necessary) to match the repair area outline. If the repair area is larger than the pre-cut patches, cut a patch from material included in the collar repair kit.

Note: Patches should be circular or rectangular with rounded corners.

Step 3. Position the patch over the repair area and trace around the outside of the patch with grease pencil.

Mark lines on opposing sides of the patch that cross from the patch onto the collar. Lift the patch and verify positioning in relation to the collar damage to ensure proper patch coverage.

Note: If multiple repairs are performed at the same time, number each repair area and corresponding patch to ensure the proper patch is used for each repair.

Step 4. Buff the reverse side of the patch with the buffing tool included in the collar repair kit, a pumice stone, or an electric disc sander with a 120 grit sanding disc, using gentle strokes to avoid exposing or damaging the internal webbing.

Figure 10: Patch Alignment

CAUTION

Use light pressure when buffing collar fabric with an electric sander.

Excessive pressure can damage collar fabric.

Step 5. Brush or wipe the prepared side of the patch to remove dust and other debris.

Step 6. Briskly wipe the repair area and prepared side of the patch with a clean cloth soaked with toluene to remove grease, petroleum, or oxidized material. If any outlines or alignment marks are removed, re-draw them with a grease pencil. Allow toluene to evaporate before proceeding.

Continued on next page

Step 7. Apply a thin even coat of Bostik glue to the repair area and prepared side of the patch without brushing repeatedly over the same area. Allow glue to dry until tacky to touch (approximately five (5) minutes).

Step 8. Apply a second thin even coat of Bostik glue to the repair area and prepared side of the patch. Allow to dry until tacky to touch (approximately five (5) minutes).

Step 9. Apply a third thin even coat of Bostik glue to the repair area and prepared side of the patch. Allow to dry for 10 - 15 minutes or until the glue no longer adheres when touched.

Note: Ambient temperature will affect glue drying time;

higher ambient temperature will result in shorter drying time while lower ambient temperature will result in longer drying time.

Step 10. If possible, inflate the collar to approximately 2.0 psi (137 mb).

Step 11. Position the patch over the repair area using the grease pencil outline and alignment marks as guides.

Starting at the center of the patch, apply manual pressure to the patch and smooth towards the patch edges. Avoid touching glued surfaces with fingers.

Systems

Collar

WARNING

Do not smoke or allow open flame or heat sources in the area when using solvents.

Solvents are highly flammable and solvent vapors are explosive.

WARNING

Solvents are hazardous.

Avoid contact/prolonged exposure to solvents or solvent vapors.

Wear proper protective equipment when using solvents.

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Continued from previous page

CAUTION

Do not overheat collar fabric.

Excessive heat can weaken fabric structure. Heat damaged fabric must be replaced.

CAUTION

Do not force glued surfaces apart.

Excessive force can delaminate and/or damage collar fabric.

Step 12. Using a flat hard object such as a spatula, apply firm pressure to the patch center and smooth towards the patch edges to force out trapped air pockets.

Step 13. Remove excess glue from around the…