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DMG-39 NANNI

MANUAL FOR OPERATION, MAINTENANCE AND TRAINING FOR FREEFALL LIFEBOATS

"V"

ERNST

HATECKEr ^ Survival- & Deck equipment

Boatyard Ernst Hatecke GmbH Am Ruthenstrom 1 21706 Drochtersen Phone: 0049-(0)4143-9152-0 Fax: 0049-(0)4143-9152-40 E-mail: [email protected] www.hatecke.de Edition 12/06

mailto:[email protected]

http://www.hatecke.de

Index

1.1 Operation Manual 1.1.1 In the interest of safety 1.1.2 Yard and yardnumber 1.1.3 Handling and use of freefall-lifeboats 1.1.4 Description of GFF-boats 1.1.5 Stowageplan for equipment 1.1.6 Alarm 1.1.7 Alarm 1.1.8 Stretcher 1.1.9 Instruction for launching 1.1.10 Freefalliaunching 1.1.11 Start the engine 1.1.12 Emergency tiller/radar reflector 1.1.13 Air supply and sprikler system (only for tanker lifeboats) 1.1.14 Spr inkler sys tem (only for tanker lifeboats) 1.1.15 Air supp ly sys tem (only for tanker lifeboats)

1.2 Maintenance Manual 1.2.1 In the interest of safety 1.2.2 Charging the battery by solargenerator 1.2.3 Wiring diagram for battery charging by solargenerator 1.2.4 Charging the battery (from the ship) 1.2.5 Wiring diagram for battery charging from the ship (Standard) 1.2.6 Wiring diagram for battery charging from the ship (with engine heater, optional) 1.2.7.1 Weekly inspection 1.2.7.2 Monthly inspection 1.2.7.3 Annual thorough examination (ace. to IVISC.1/Circ.1206) 1.2.7.4 5-Years overhaul and testing (ace. to MSC.1/Circ.1206) 1.2.7.5 Log Scheme 1.2.7.6 Authorized service station 1.2.8 Maintenance of GRP-boats 1.2.9 Lubricant-and fuelplan

1.3 Trainings manual: 1.3.1 Trainings instructions 1.3.2 In the interest of safety 1.3.3 Handling and use of freefall-lifeboats 1.3.4 Launching and recovery instructions 1.3.5 Freefalliaunching 1.3.6 Simulated launching (from MSC.I/Circ. 1206) 1.3.7 Simulated launching

Additional: Engine manual Engine certificate Function description of the charging regulator

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: [email protected], www.hatecke.de



1.1 Operation Manual

ERNST

HATECKEf:: Survival- & Deck equipment

"~N

Boatyard Ernst Hatecke GmbH Am Ruthenstrom 1 21706 Drochtersen Phone: 0049-(0)4143-9152-0 Fax: 0049-{0)4143-9152-40 E-mail: [email protected] www.hatecke.de



1.1.1 In the interest of safety

A WARNING 1. Before launching close all hatches and the entrance door. 2. Secure all items and fasten seat belts (adjust to your size). 3. Don't wear lifejackets during freefall launching. Failure to observe this procedure may

lead to serious injury or death! 4. Keep out of the way of the propeller. 5. Always keep hands and feet clear when near moving and rotating machinery. 6. Before starting the engine, read it's instruction manual. 7. Pyrotechnics in the inventory case are EXPLOSIVES. 8. During operation of davit be cautious with long links, snap hooks and counter weights. 9. DO NOT open the engines cool water filler cap when hot. 10.Before releasing aft lashing to enter boat for maintenance or training fasten falls of davit

/ crane to the long links of hoisting slings from boat. After maintenance or training fasten lashing again and afterwards release hoisting slings from falls.

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-915240, E-mail: [email protected], www.hatecke.de



1.1.2 Yard and yardnumber

The information given in this manual is based on our long experience and "know-how" in the building of totally enclosed lifeboats.

In case of an emergency it is very important that the occupants know how to handle the lifeboat and it's equipment.

All personel should study this manual at lifeboat drills, to make themselves thorougly conversant with the system and to ensure a speedy and safe launching in an emergency.

The technical specifications are not binding and can be altered without prior notice.

In case of enquiries regarding existing boats please quote the details given below:

„„.>.,p. GFF6,5M

Building no. 10837

ERNST

HATECKEf: ^ Survival- & Deck equipment

Boatyard Ernst Hatecke GmbH Am Ruthenstrom 1 21706 Drochtersen Phone: 0049-(0)4143-9152-0 Fax: 0049-(0)4143-9152-40 E-mail: [email protected] www.hatecke.de



1.1.3 Handling and use of freefalMifeboats 9

At launching:

1. The occupants should always use the same seat.

2. In an emergency situation, the boat should be launched with the engine running. Where lifeboat drills are being carried out, start the engine and run it for a short time and then switch off before launching the boat. Start the motor again when the boat is afloat.

3. Lifejackets should not be worn during the launching of the boat, but should be taken on board and put on as soon as the boat is afloat. The wearing of a lifejacket during launching may lead to injury!

4. Check before launching that the impact area is free from floating objects.

5. During the launching period (release/water-borne) the boat occupants must ensure that their heads remain close to the head rests provided at each seat.

6. As soon as the boat is afloat, the hydraulic release piston should be brought back to its housed position.

Lifting the boat back on board:

1. Before leaving the seat, loosen the seat belt.

The boat lifting sling(s) should be put into the crane hook(s) from the aft platform. Do not stand on the cabin roof.

2. Before setting the boat back into the launching ramp, the securing hook on the ramp cross-strut should be put in the "open" position.

3. Once the boat is back in the launching ramp and secured in place, open vents, connect ^ the battery charger cable (if any) and start the charger.

•

•




1.1.4 Description of GFF-boats

Hull and canopy:

The complete boat is constructed of G.R.P. material using selfextinguishing resins. The hull is of round frame constructions, with a fine entry for high speed and good freefall immersion characteristics. The boat has a transom stern with a rescue platform at waterline level designed to assist in bringing on board those being rescued.

The canopy is of double skin construction designed to act as buoyancy to make the boat self-righting even when partly flooded.

The innerbottom has hatches to the storage and engine compartmen.

The external hull and canopy are orange coloured (RAL 2004), the internal surfaces are light green (RAL 6019)

Engine: The engine fitted is a water-cooled (closed system) diesel engine and is installed below the cabin sole and gives a boat speed in exess of 6 knots.

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: OÖ49-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: [email protected], www.hatecke.de



1.1.5 Stowageplan for equipment

( J P K ) ( 3 } ( ^ (1,2,4,5.7-11.15,18.22-25,28-34)(19)(J6) (27) ( 6 ) (17) (25)

1. 1 buoyant bailer 2. 2 buckets 3. 2 hatchets 4. 1 Container with distress signals as:

6 hand flares 4 rocket parachute flares 2 buoyant smoke signales, orange 1 daylight signal mirror 1 jackknife with tin opener and marling spike 1 electr. torch with 1 spare bulb and 2 spare batteries

5. 2 tin opener 6. 1 fire extinguisher 7. 1 fishing tackle 8. 1 whistle 9. 5 Itrs. containers with drink water (3 Itrs. for each person) 10. lifeboat food ration (one for each person) 11. 2 drink cups 12. 1 sea anchor towing and mooring line 13. 2 painters, 15m long, dia. 14mm 14. 2 buoyant lines, 30m long, dia. 8mm, with buoyant rescue quoits 15. 1 first aid kit for lifeboats with seathlckness rations (6 doses for each person) 16. 1 lifeboat compass 17. 1 manual bilge pump 18. 1 radar reflector 19. Diesel-fuel 20. 2 boat hooks 21. 1 search light 22. thermal protective aids (one for 10 persons/min. 2 per boatt) 23. 1 Survival-manual/life-saving signal card 24. 1 embarkation ladder

loose equipment: 25. 1 key for seats/fuel tank 26. 1 set lifting slings 27. 1 emergency tiller 28. 2 straps for stretcher

spare parts for the engine: 29. 1 vee-belt 30. 1 fuel filter 31. 1 pump impeller 32. 1 oil filter 33. 1 set of common tools 34. 1 oil drain pump

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-915240, E-mail: [email protected], ww.hatecke.de


http://ww.hatecke.de

1.1.6 ALARM

All personal proceed to boat station. Warm clothing to be worn. Lifejackets to be carried but not put on.

Note: Do not put on lifejacket before the lifeboat is afloat. Failure to observe tis procedure may lead to serious injury or death during the launching.

1. Disengage the the boat lashings.

2. Disconnect the battery charger (does not aplly to boats equiped with solargenerator).

3. Board the freefall lifeboat.

Boatyard Ernst Hateckc GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: [email protected], www.hatecke.de



1.1.7 ALARM

A DANGER CAUTION: Secure all items fasten seat

3.

hatch and vent

embarcation hatch

Close all hatches and openings.

4. Fasten seat belts as soon as seated!!!

Boatyard Emst Hatcckc GmbH, Am Ruthenstrom 1,21706 Drochtetsen, Phone; 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: [email protected], ww.hatake.de


http://ww.hatake.de

1.1.8 Stretcher

To SOLAS 74(83) chapter III, regulation 41 " The lifeboat shall be so arranged that helpless people can brought on board either from the sea or on stretchers."

Inside the boat the stretcher has to be secured. Four lashing points are on the floor of the boat, two lashing belts are in the equipment locker.

All handling and use of the stretcher will be done to the stretcher manufacturers instructions.

For missuse of stretchers in freefall lifeboats ERNST HATECKE GmbH will not be responsible.

1.1.9 The system instruction for launching

Freefall

The boat runs down the launching ramp and on hitting the water submerges briefly before emerging and moving away from the stern of the ship.

Instructions for free-fall launching look at next page.

Boatyard Emst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: [email protected], ww.hatecke.de


1.1.10 Freefall launching

Close all hatches and vents. Fasten seat belts.

Close the valve screw (pos.1), operate the hydraulic pump (pos.2). (After abt. 20 strokes the locking device will disengage - the boat is now free.)

CAUTION: Before replacing the boat in the launching ramp, the hydraulic piston should brought back into its housed position by opening the valve screw (pos.1)

EMERGENCY RELEASE:

Operate only when mainreiease system is damaged.

Close the valve screw (pos. 3). Operate the emergency release pump (pos. 4). (After abt. 30 strokes the locking device will disengage - the boat is now free.)

CAUTION: Before replacing the boat in the launching ramp, the hydraulic piston should be brought back into its housed position by opening the valve screw (pos. 3). After replacing the boat in the launching ramp the valve (pos. 3) should remain in the open position.

#




0 1.1,11 start the engine

searchlight masthead lantern

V-*Q interior light charging lamp

oil pressure engine temperatui

STOP START

NANNI ENGINE

To start the engine:

1. Switch on main power (main swith). 7 ON

2. With gear lever in NEUTRAL, press the grey button and move lever into Ahead / Start position.

O START

3. Press the START-button.

4. Bring the gear lever bacl< into the NEUTRAL position (the grey gear button springs back automatically).

* Speed and gear box control lever:

a) With the grey gear button pressed in, the lever controls only the engine speed.

b) With the button in the "out"-position, the lever first operates the gear change (either ahead or astern) and then by further movement of the lever away from the neutral position, the engine speed is increased.

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: [email protected], www.hateckc.de


http://www.hateckc.de

1.1.12 Emergency tiller / radar reflector

In case of malfunction of the steering gear it is possible to steer with an emergency tiller.

1. The emergency tiller is located near the seats below the steering tower.

2. Fit the emergency tiller through the floor (near the embarcation hatch) on to the rudder shaft.

The radar reflector is stored in the equipment locker. Assemble the radar reflector. Mount it in the socket on the aft end of the superstructure.

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtetsen, Phone: 0049-{0)4143-9152-0, Fax: 0049-(0)4143-915240, E-mail: [email protected], www.hateckc.de



^ 1,1.13 Air supply and sprinkler system

(only for tanker lifeboats)

Befor launching in case of fire: 1. Open the compressed air bottle valves. 2. Close all vents. 3. Open the sea valve at the sprinkler pump. 4. Open the valve of the air supply system.

After testing the sprinkler system with sea water, the system should be flushed through with fresh water.

Boatyard Ernst Hatecke GmbH, Am RuÉenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: [email protected], www.hatecke.de



1.1.14 sprinkler system (only for tanker lifeboats)

In case of passage through any fire, it is necessary to engage the sprinkler system.

The sprinkler system is designed to cool the surface of the boat.

The sprinkler system also fulfills the equally important purpose of keeping the temperature inside of the boat low enough for comfort and safety.

freshwater connection

The sprinkler system consists of sprinkler pump fitted at the fore end of the engine, operated by the engine via a flexible clutch. The sprinkler pump delivers the water to the sprinkler tubes and to the spraynozzles.

After testing the sprinkler system with sea water it should be flushed through with freshwater.

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: [email protected], wwv.hatecke.de


http://wwv.hatecke.de

0 1,1.15 air supply system (only for tanker lifeboats)

Air supply system:

To supply the boat with fresh air in case of passage through fire or a cloud of gas the boat is equipped with bottles of compressed air.

The quantity of compressed air is sufficient to supply passengers and engine with fresh air for 10 minutes.

The compressed air bottles (T) (50 Itrs.x200 bar) are connected to a joint pipe system (2). Through a valve(3) the compressed air passes into the pressure reducer (4). The pressure reducer is so adjusted, that it will supply the fresh air for 10 minutes into the inner of the boat.

Refilling of the compressed air bottles

Unscrew the protection cap from the filler piece © a n d connect the high pressure hose from the compressor. Make sure that the valve @ is closed. Charge the bottles (T) until the pressure gauge (7) shows a pressure of 200 bar (make sure that the bottles valves (6)are opened. Disconnect the high pressure hose of the compressor and fit the protection cap to the fillerpiece(5). The air supply system is now ready for use.

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: OÜ49-(0)4143-9152-40, E-mail: [email protected], www.hateckc.de



1.2 Maitenance Manual

ERNST

HATECK _ Survival- & Deck equipment




0 1,2,1 In the interest of safety







1-2,2 Charging the battery by solar generator

Nanni Diesel Engine

solar generator

ri CHARGING OF BATTERIES

1. ^ OFF

2. SWITCH BATTERY SELECTION WEEKLY

: \

v_ 1

/

Note:

The solar generator will supply constant charging current if the boat is on board.

If the engine is running the batteries will be supplied by engines dynamo.

Only sealed Battery type should be used!

A Caution: Do not open the batteries I Do not top up with water! Fasten batteries after installation!




((I 1,2,3 Wiring diagram for battery charging by solargenerator

Nanni Diesel Engine ø o Y? ® ® ^ n o o o o Q Q

^ _ . _

v-^-

83 30

STARTING RELAY IN SOX

86 87 3

HEATING RELAY INBOX

0 4 p 2 Ö5 Ö7Ö8Ö9

X X

ENGINE STOP RELAY

rt!

t -'-»- v Engine starter

V \l 6

Alternator

/77

32 14 15A\

S G I - - / \

31

04 Ö5 p i

Switch Battery (Stop Pos.)

13

86 87

85 30

SL

MAINS WITCH RELAY INBOX

^^-

Connecting

Searching light

^ ^ / •

p2 t)OX

'ôior aenerotor

8

7 rØ-

Overcharge protecüon

6

^ ^

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: [email protected], ww.hatecke.de



1.2,4 Charging the battery (from the ship) ^.

Nanni Diesel Engine

[connect the charger cable]

Connect the charger cable for 42 Volt AC.

CHARGING OF BATTERIES

^ OFF

2. SWITCH BATTERY SELECTION WEEKLY

Note: Check charging current of the battery charger which is fitted under the helmsman's seat.

On board the ship, the charging cable should be kept connected to the lifeboat battery charging socket and the batteries kept under constant charge.

Caution: Maximum charging current is 6 amps.

Only sealed Battery type should be used!

A Caution: Do not open the batteries ! Do not top up with water! Fasten batteries after installation!




H 1.2.5 Wiring diagram for battery charging from the ship (Standard)

Nanni Diesel Engine ø ø ø ø r:; :J o Q o o o o

ICE _ J

- V - - ^ - - -

I RI I \

STARTING RELAY INBOX

21

S P I - -

22 n} R2

8S 30

HEATING RELAY INBOX

0 4 0 2 05 Ö7Ö8Ö9 Êngine

XX

1 ENGINE STOP RELAY

t

|l V V. A

AltematOf

o'^ rh

32 14 15A\

M

04 Ö5 0 1 I 5.

Switch Battety (Slop Pos.)

^

86 87

I R3 \—


, 4 ^ X' 14 i Ix^

—(g l

dat ier ie cnarqer

1 2 V= i1 ^

^^^<hÄ

Slop control box

^ ^

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: [email protected], www.halecke.de


http://www.halecke.de

1.2,6 Wiring diagram for battery charging from the ship ø (with engine heater, optional)

Nanni Diesel Engine ø ® ø ø r:; n o o o o Q o

CE

-H-

83 30

STARTING RELAY INBOX

1 HEATING RELAY INBOX

Ö4 Ö2 Ö5 Ö7Ö8Ö9 _Epgine

X

t

ENGINE STOP RELAY

V W <!>

Alternator

o>-^ / TV

32 14 15A\

S G I - - / \

31

Switch Battery (Stop Pos.)

é * -

13

86 87

Ö4 ÖS Ö l


" V XI „ , . i XI

A 0 ^Â

—0-1 Searching light

Ö2 3 txjx

Eng i hea te r

< 2 & o t t e r y c h a r g e r 1 60X f 17oowi ; 5 5 V

10A 16A

4 2 ^

Stop control box

r i 01




1.2.7.1 Weekly inspection

A Qualification level. By supervision of a senior ships officer in accordance with the information provided by the manufacturer

Electrical installation:

1. Check battery charging system. 2. Check functioning of external and inside lights. 3. Switch the battery switch

done remark

Engine:

4. Test run the engine, demonstrate that the gearbox and gearbox train are engaging satisfactorily.

Miscellaneous:

5. Visual inspection of the boat to ensure that they are ready for use.

Only for Tanker Lifeboats:

Air supply system:

6. Check the pressure (200 bar) at the gauge. If necessary fill up the pressure to 200 bar.

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0M9-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: [email protected], www.hatecke.de



1.2.7.2 Monthly inspection


lai

Electrical Installation: 1. Check battery charging System. 2. Check function of external and internal lights. 3. Switch the battery switch

done remark

Engine: 4. Check fuel level in the tank (Fill up the fuel tank only on launching ramp). 5. Check lubricating oil level in the engine and gear box.'(Renew oil and oil filter at least once a year) 6. Check the cooling water level in the compensating tank. 7. Check functioning of the oil pressure lamp, the water temperature lamp and the

battery charching lamp. 8. Check the tension of the generators drive-belt. 9. Check the antifreeze In the cooling water.

10. Grease the sterntube bearings (5 turns with the grease gun which is fitted in the engine space).

11. Test run the engine, demonstrate that the gear box is engaging satisfactory. Hydraulic release gear: 12. Check the oil level in the pumps and the fittings for tightness. Miscellaneous: 13. Lubricate all hatch dogs and hinges. 14. Check inventory. 15. Lubricate the release and the lashing hook. 16. Lubricate the lifting sling. 17. Drain the bilge. 18. Visual inspection of the boat to ensure that it is ready to use.

#

* with boat on even keel

Only for tanker lifeboats:

Air supply system: 19. Check the pressure (200bar) at the pressure gauge. If necessary fill

up the pressure to 200 bar. Caution: Do not apply oil anywhere to the air supply system ! Oil under pressure explodes ! sprincler system: 20. Check operation of the sea water inlet valve and grease it. 21. Drive the boat and use sprincler system for one minute minimum. 22. After testing the sprincler system should be flushed with fresh water.

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtetsen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: [email protected], www.hatecke.de



1.2.7.3 Annual thorough examination (acc.toMSC.1/Circ.1206)

A Qualification level. By manufacturers representative or a person appropriately trained and certified by tine manufacturer. Lool< at page 1.2.7.6 Authorized service stations.

Items listed in checklists for the weekly/monthly inspections form the first part of the annual thorough examinatio. When carrying out this examination the inspection of these items should be performed by the ship's crew in the presence of the manufacturer's representative or a person appropriately trained and certified by the manufacturer for the work to be done.

Inspection and maintenance records of inspections and routine maintenance carried out by the ship's crew and the applicable certificates for the launching appliances and equipment should be available.

Lifeboat: Examination and check for satisfactoiy condition and operation

1. Condition of Lifeboat structure including fixed and loose equipment. 2. Engine and propulsion system. 3. sprincler system, where fitted. 4. Air supply system, where fitted. 5. Manoeuvring system. 6. Power supply. 7. Bailing system.

Release Gear: Examination and check for satisfactory condition and operation *

8. Operation devices for activation of release gear. 9. Hydraulics hoses annd fittings.

10. Holding device fastening.

Test:

11. Operation test of release function

according to manufacturers checklist (Doc.no. 0201)

Boatyard Emst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-915240, E-mail: [email protected], www.hatecke.de

http://Doc.no



1.2.7.4 5-Years Overhaul & Testing (acc.toMSC.1/Circ.1206)

A Qualification level. By manufacturers representative or a person appropriately trained and certified by the manufacturer. Look at page 1.2.7.6 Authorized service stations.

Items listed in checklists for the weekly/monthly inspections also form the first part of the annual through examination, when carrying out this examination the inspection of these items should be performed by the ship's crew in the presence of the manufacturer's representative or a person appropriately trained and certified by the manufacturer for the work to be done.


Lifeboat: Examination and check for satisfactory condition and operation *

1. Condition of Lifeboat structure including fixed and loose equipment. 2. Engine and propulsion system. 3. Sprincler system, where fitted. 4. Air supply system, where fitted. 5. Manoeuvring system. 6. Power supply. 7. Bailing system.

Release Gear : Examination and check for satisfactory condition and operation *

8. Operate devices for activation of release gear. 9. Hydraulic hoses and fittings.

10. Holding device fasteming.

Test:

11. Operation test of release function 12. Overload test Ace. to SOLAS Chapt.lll, reg. 20.11.2

according to manufacturers checklist (Doc. no 0202)

Boatyard Ernst Hatecke GmbH, Am Ruåenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: [email protected], ww.hatecke.de



1.2.7.5 Principal log scheme

No: Kind of service:

-

Note: Date:

-

Name:

Boatyard Ernst Hatecke GmbH, Am RuÉenstrora 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: [email protected], www.hatecke.de



1.2.7.6 Authorized service stations

Necessary larger repairs, as well as the "annual thorough examination" and the "5-years overhaul" should be conducted by the manufacturer's representative or a person appropriately trained and certified by the manufacturer.

ERNST

HATECKEr Survival- & Deck equipment

Please contact: HATECKE SERVICE GMBH Am Ruthenstrom 1 21706 Drochtersen / Germany Telefon: +49-4143-9152-60 Telefax: +49-4143-9152^4 e-mail: [email protected] Internet www.hatecke.de



1.2.8 Maintenance of GRP-boats

Even GRP-boats are subject to damage to greater or lesser extent. The most common damages are scratches in the gelcoat which may also penetrate the laminate.

The gelcoat colours are:

Outer surface: orange RAL 2004 Inner surface: light green RAL 6019

In case of extensive damage contact the builders at the following address.

Sometimes the gelcoat finish looks dull and the colour is faded.

Restore the original finish by sanding the surface with a fine grade water sandpaper of grade 400 or finer, or using a rubbing compound.

After sanding or rubbing the surface must be waxed. Rubbing should be done by hand or with a rotary polishing buff. Waxing should always done by hand.

ERNST ^'^•'•i-^

HATECKEr^Z 1 ^

Survival- & Deck equipment




1.2.9 Lubricant- and fuel plan

OIL LIST FOR FREEFALL-LIFEBOATS, TYPE GFF/GFF M Ambient temperature for -25 up to +50°C

No.

1

2

3

4 4a 4b 4c

5

APPLICATION POINT

Engine

Gearbox

fueltanl<

Grese points Sterntube Rudder-trunk Others

Hydr. release system

RECOMMENDATION

Multigrade oil SAE15W-40 API CD/SF

DEXRON ATF-oil API CD/SF

Marine Diesel with plogging point lower -25°C

Grease with EP additives NLGI-class 2

ISOVG15HLP

Est. qty. unit: Oil: LTRS. Grease: KGS.

QTY/SET

Look at engine manual

Look at engine manual

ca. 120

2,50

3,00

SET/SHIP

1

1

1

TOTAUSHIP

ca.120

2,50

3,00

Remarks: The boat has been delivered with oil filled and fuel partially filled. For further informations look at engine manufacturers instruction manual.




1.3 Trainings iVIanuai

ERNST

HATECKEI Survival- & Deck equipment




1.3.1 Trainings instructions

To SOLAS chapter III,part B, regulation 19,3.3.3 "...each lifeboat shall be launched, and manoeuvred in the water by its assigned operating crew, at least once every three month during an abandon ship drill."

To SOLAS chapter III,part B, regulation 19.3.3.4 "Lowering into the water, rather than launching of a lifeboat arranged for free-fall launching, is acceptable where free-fall launching is impracticable provided the lifeboat is freefall launched with ist assigned operating crew aboard and manoeuvred in the water at least once every six month"....

Furtheron to chapter III,part C, regulation 44, 6.5.1.5 "It should be possible to test the release mechanism without launching the lifeboat".

ToMSC.1/Circ.1206,Annex2, 2.4.1:

MSC.1/Circ.1206 "The monthly drills with free-fall lifeboats should be carried out according to the manufacturer's instructions, so that the persons who are to enter the boat in an emergency are trained to embark the boat, to take their seats in a correct way and to use the safety belts; and also are instructed on how to act during launching into the sea."

To MSC.1/Circ.1206, Annex 2, 2.4.2:

MSC.1/Circ.1206 "When the lifeboat is free-fall launched as part of a drill, this should be carried out with the minimum personnel required (max. 4 persons) to manoeuvre the boat in the water and to recover it. The recovery operation should be carried out with special attention, bearing in mind the high risk level of this operation. Where permitted by SOLAS, simulated launching should be carried out in accordance with the manufacturer's instructions, taking due note of MSC.1/Circ.1206 on Guidelines for simulated launching of free-fall lifeboats."

On the following pages you will find: 1.3.2 In the interest of safety 1.3.3 Handling and use of freefall-lifeboat 1.3.4 Launching instructions 1.3.5 Freefall launching 1.3.6 Recovery procedures 1.3.7 Sinnulated launching (from MSC.1/Giro. 1206) 1.3.8 Simulated launching








Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-915240, E-mail: [email protected], wwv.hatecke.de


http://wwv.hatecke.de

1.3.3 Handling and use of freefall-lifeboats

At launching:

1. The occupants should always use the same seat.

2. In an emergency situation, the boat should be launched with the engine running. Where lifeboat drills are being carried out, start the engine and run it for a short time and then switch off before launching the boat. Start the motor again when the boat is afloat.

3. Lifejackets should not be worn during the launching of the boat, but should be taken on board and put on as soon as the boat is afloat. The wearing of a lifejacket during iauncliing may lead to injury!

4. Check before launching that the impact area is free from floating objects.

5. During the launching period (release/water-borne) the boat occupants must ensure that their heads remain close to the head rests provided at each seat.

6. As soon as the boat is afloat, the hydraulic release piston should be brought back to ist housed position.

Lifting the boat back on board:

1. Before leaving the seat, loosen the seat belt.

2. The boat lifting sling(s) should be put into the crane hook(s) from the aft platform. Do not stand on the cabin roof.

3. Before setting the boat back into the launching ramp, the securing hook on the ramp cross-strut should be put in the "open" position.

4. Once the boat is back in the launching ramp and secured in place, open vents, connect the battery charger cable (if any) and start the charger.

Boatyard Emst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-915240, E-mail: [email protected], ww.hatecke.de



0 1.3.4 Launching and recovery instructions

Freefall: The boat runs down the launching ramp and on hitting the water submerges briefly before emerging and moving away from the stern of the ship.

Instructions for launching procedure on the following page.

Instruction for free-fall look also in the Operation Manual (in front of this).

Launching by davit: In some cases (shallow water, ice-drift, drifting parts of the cargo) it is necessary to launch the boat with max. number of persons by davit.

Instruction for launching procedure look at the davit manufacturers instruction.

Recovery by davit: Freefall lifeboat with crew of max. 4 persons must be sailed astern under the davit.

Instructions for recovery procedure look at the davit manufacturers instructions.




1.3.5 Freefall launching




EMERGENCY RELEASE:

HYDRAULIC PISTON ^ ^ ^

LOCKING DEVICE

Operate only when mainrelease system is damaged.



Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-915240, E-mail: [email protected], www'.hatecke.de


1.3.6 Simulated launching (from MSC.1/Circ.1206, Annex 2)

INTERNATIONAL MARITIME ORGANIZATION 4 ALBERT EMBANKMENT LONDON SEI 7SR ;li m^

IMO

IMO GUIDELINES FOR SIMULATED LAUNCHING OF FREE-FALL LIFEBOATS

1 Definition Simulated launching is a means of training the crew in the free-fall release procedure of free-fall lifeboats and in verifying the satisfactory function of the free-fall release system without allowing the lifeboat to fall into the sea.

2 Purpose and scope The purpose of these Guidelines is to provide a basic outline of essential steps to safely carry out simulated launching. These Guidelines are general; the lifeboat manufacturers instruction manual should always be consulted before conducting simulated launching. Simulated launching should only be carried out with lifeboats and launching appliances designed to accommodate it, and for which the manufacturer has provided instructions. Simulated launching should be carriedout under the supervision of a responsible person who should be an officer experienced in such procedures.

3 Typical simulated launching sequence 3.1 Check equipment and documentation to ensure that all components of the lifeboat and launching appliance are in good operational

condition. 3.2 Ensure that the restraining device(s) provided by the manufacturer for simulated launching are installed and secure and that the

free-fall release mechanism is fully and correctly engaged. 3.3 Establish and maintain good communication between the assigned operating crew and the responsible person. 3.4 Disengage lashings, gripes, etc. installed to secure the lifeboat for sea or for maintenance, except those required for simulated

free-fall. 3.5 Participating crew board the lifeboat and fasten their seatbelts under the supervision of the responsible person. 3.6 All crew, except the assigned operating crew, disembark the lifeboat. The assigned operating crew fully prepares the lifeboat for

free-fall launch and secures themselves in their seats for the release operation.

3.7 The assigned operating crew activates the release mechanism when instructed by the responsible person. Ensure that the release mechanism operates satisfactorily and the lifeboat travels down the ramp to the distance specified in the manufacturer's instructions.

3.8 Recover the lifeboat to its stowed position, using the means provided by the manufacturer and ensure that the free-fall release mechanism is fully and correctly engaged.

3.9 Repeat procedures from 3.7 above, using the back-up release mechanism when applicable. 3.10 The assigned operating crew disembarks the lifeboat. 3.11 Ensure that the lifeboat is returned to its normal stowed condition. Remove any restraining and/or recovery devices used only for

the simulated launch procedure.




1.3.7 Simulated launching

A The simulated launching operation should be carried out with special attention, bearing in mind the high risk level of this operation

Simulated launching of free-fall lifeboats without allowing the lifeboat to fall into the sea.

1. Connect the falls of the davit by their hooks to the long link of the hoisting slings. 2. Top up the davit until the falls, the counterweight, and the long link of the

hoisting slings are all vertical "in line" (hoisting slings also must be tight). Maybe you have to" winch up" the falls a little bit.

IMPORTANT: Do not allow slack on the falls, otherwise the running distance on the sliding ramp will be to long.

3. Disconnect the aft lashing of the boat. 4. Participating crew board the lifeboat and fasten their seatbelts under the supervision of

the responsible person. 5. All crew, except the assigned operating crew (max. 3 persons), disembark the lifeboat. The

assigned operating crew fully prepares the lifeboat for free-fall launch and secures themselves in their seats for the release operation.

6. The assigned operating crew activates the release mechanism when instructed by the responsible person.

7. Operate the release mechanism (instructions inside the boat or on page 1.3.4 of this manual).

8. Recover the lifeboat to its stowed position, using davit and winch (look at Launching ramp manual) and ensure that the free-fall release mechanism is fully and correctly engaged.

9. Repeat procedures from 6. above, using the back-up release mechanism when applicable.

IMPORTANT All information here given on this page depent on ERNST HATECKE GmbH manufactured davit systein type "FFA" ERNST HATECKE GmbH will not be responsible on any systems of other manufacturers. For handling and training look at the manuals of these manufacturers.




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KUBOTA BASIC ENGINES

TABLE OF CONTENTS

1. SAFETY INFORMATION

2. GENERAL INFORMATION

3. ENGINE IDENTIFICATION • Technical Characteristics

4. PREPARATION BEFORE STARTING

5. ENGINE OPERATION • Starting the engine • Stopping the engine • Running in/Guarantee visit • List of guarantee verification operations

MAINTENANCE Engine oil drain Replacing the oil filter Reducer reverser gear box Replacing the fiiel oil filter Replacing the complete injector nozzle fitting Cleaning the cooling system Cleaning the thermostat Electrical/Battery equipment Cylinder head Rocker arm adjustment Recommendations Periodic maintenance table

- J

Recommended on board repair kit

1 - SAFETY INFORMATION

These directions for use have been provided to help you to use your engine and its fittings. They include important instructions which should be observed while operating the engine.

These instructions must be read by the operator.

They should be permanently kept in the place where the engine is used.

SAFETY SYMBOLS These symbols are used to indicate danger. They are intended to attract your attention to those elements or operations which can endanger you or other users of this engine. Read the instructions highlighted by the safety symbols attentively. It is essential that you read the instructions and the safety regulations before starting the engine.

A A A

DANGER Signifies that a very serious danger exists which may result in the strong possibility of death or serious injury if the specific suitable safety measures are not observed.

WARNING Signifies that a danger exists which may cause injuries or death if specific suitable safety measures are not observed.

ATTENTION Reminds you of safety measures or directs your attention to dangerous practices which may cause injuries to persons or damage the boat or its components.

The user should take all necessary precautions as regards operation and protection and should seek the advice of a professional.

Disregard for these safety instructions may lead to: Bodily harm, environmental pollution dangers (leaks of dangerous substances), dangers to property with risks of failure of the essential functions of the engine.

OBSERVING THE SAFETY RECOMMENDATIONS Follow the warning and attention labels affixed to the engine Disengage the contact key and turn off the battery main switch before performing any work on the engine or its fittings Close the engine cover and replace the protection devices before starting the engine Always keep the area surrounding the engine clean and free of any debris Place any flammable liquids outside and away from the engine compartment Never use the engine when under the influence of alcohol or medication

WEAR PROTECTIVE CLOTHING To avoid bodily injury, remain clear of rotating parts and do not wear oversize garments close to a running engine Use safety equipment such as glasses, gloves, etc. according to circumstances and needs

FUELS AND LUBRICANTS Stop the engine before adding fuel or lubricant Do not smoke and do not draw near with an open flame whilst adding fuel Wear gloves when checking for any possible leaks Hot lubricating oil can bum you - allow the engine to cool before checking the motor oil level, changing the motor oil, or the oil filter cartridge Always use the fuels and lubricants recommended by NANNI DIESEL

ENGINE EXHAUST WARNING Run the engine in a well ventilated place, away from persons and animals-the accumulation of engine exhaust can be toxic

PRESSURE Do not open the engine coolant and motor oil reservoir caps when the engine is warm. Release all pressure in the line before loosening the caps Do not check for possible pressure leaks with bare hands - wear gloves - liquids ejected under pressure may cause serious injury - in case of contact with a spurt of fluid, immediately consult a physician

BATTERY ^ A mixture of highly explosive, inflammable and volatile gas, forms when recharging the battery. Never smoke and do not draw near to the battery with an open flame or spark Never short circuit the battery terminals The battery electrolyte is highly corrosive - Wear protective gloves and glasses.

ELECTRICAL WIRING Turn off engine electrical contact and battery main switch before any repair to the electrical equipment. Check the state of the cables and the electrical wiring - a short circuit may cause fire.

DISPOSAL OF FLUIDS The different fluids used for the operation of the engine may be toxic and hazardous to your health. Carefully read the instructions appearing on the labels of these products. Observe the environmental protection regulations relative to the disposal of motor oil, fuel, engine coolant fluid, filters and batteries

2 - GENERAL INFORMATION

Your NANNI DIESEL engine is a product of the research and quality manufacturing of NANNI fNDUSTRIES. It is constructed from the finest materials available, according to finite specifications, and in accordance with very strict production methods.

Your NANNI DIESEL engine is a dependable and long-lasting power source for your boat.

Proper installation of the engine on board your boat is of the greatest importance for safe navigation and also for respect of the environment.

The NANNI INDUSTRIES engineers are among the world's most highly skilled. Their experience, their knowledge of the seas, their mastering of techniques in association with the skills of the engineers of MAN and KUBOTA guarantee you the best available combination of performance/reliability/economy.

WARNING: The installation of your engine must be performed by a naval vessel mechanics professional, in compliance with the NANNI INDUSTRIES installation instructions.

These operating instructions contain information which are necessary for the proper operation of the engine.

Present in over 50 countries through its network of agents and authorised dealers, NANNI INDUSTRIES guarantees your safety world-wide.

Whether it be parts, labour, or simply advice, everything has been considered to properly serve your needs.

Do not hesitate to contact your authorised NANNI DIESEL dealer.

Read this manual attentively before proceeding with the installation of the engine. Follow the safety measures.

WARNING: The proper operation of a marine engine is linked to use suitable for the engine and its gear box's specifications (type of boat, hours and RPMofuse).

3 - ENGINE IDENTIFICATION

On all correspondence, requests for information and orders for parts, it is essential to indicate the references appearing on the engine and reversing gearbox identification plates.

® ® ® ® ® ® Ä Type B Serial number C NANNI Serial number D Specification

IMPORTANT: Note the serial number and the engine and transmission model designations. Keep a copy of this information in a safe place.

IDENTIFICATION OF PRINCIPAL PARTS ® ® ®

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Keel cooling Engine coolant filler hole A Not valid Fresh water pump Not valid Alternator Flexible suspension Electrical connector Starter Engine oil filler hole Engine oil change pump Air filter Dry exhaust Oil filter Oil pressure transmitter Reverse gear box Injection pump Fuel pump Fuel filter Stop control Speed-control Not valid Not valid Not valid

•

4 - PREPARATION B E F O R E STARTING

Once the engine has been installed on board, and before removing the protective covers from the various filler holes, clean the external surfaces of the engine.

GENERAL VERIFICATION ® ® Fill with motor oil and transmission fluid Fill with coolant fluid Check tension of belts Check that the different connectors and oil and water change plugs are properly tightened Check that the electrical cable terminal, battery terminals, battery switch, extension wiring connectors are properly tightened Check the electrolyte level of the batteries Check the acceleration and stop controls (by moving them several times) Check for proper synchronisation of the "gas and clutch" lever (essential in the case of a single lever control). Clutching must terminate when starting to accelerate. Perform a final check of the clamps as well as a visual check of the marine propulsion assembly. If necessary, retouch the paint on the assembly and the accessories.

DANGER: • Do not do not draw near to the battery with an open flame or spark. A mixture of extremely explosive gasforms when the battery is being recharged- Do not short circuit

• The battery electrolyte is highly corrosive: if the battery acid comes in contact with the skin, immediately wash with soapy water - in case of contact with the eyes, rinse abundantly with water and immediately consult a physician. - Start with the positive terminal when connecting cables to the battery. - Start with the negative terminal when disconnecting cables from the battery

WARNING: • Do not allow fuel or lubricant to spill on the engine. • The fluids used for the operation of the engine may be dangerous to your health. • The motor oil may damage your skin - wear gloves.

NOTE: Modem diesel engines are precision machines which require the use of high quality lubricants.

ENGINE A N D REVERSING G E A R B O X L U B R I C A T I O N Engine

Oil pump driven lubrication system, pressure regulated by a discharge valve. Disposable cartridge oil filter

Transmission Refer to separate specifications

Adding motor oil ® Through the filler hole located on the rocker arm cover, unscrew the cap. check the level with the aid of the dipstick. Do not exceed the maximum level.

NOTE: Qualities and quantities of oil are described in the table of technical characteristics

FUEL SYSTEM Composition ® Main disposable cartridge filter Fuel pump (A) Injection pump (B) High pressure injector pipe © Injectors

Fuel system purge Check the fiiel level in the reservoir Open the fiiel valve. Unscrew the thumbwheel A. Move the fiael pump hand lever; if necessary, turn the crankshaft ft)r resistance. Move the hand pump a certain number of times to expunge any air bubbles in the return system. Retighten the thumbwheel A Start

DANGER: - Do not smoke, or draw near with an open flame or spark - Always mop up any spilledfitel

KEELCOOLING SYSTEM ® It consists of one closed liquid coolant system.

Closed liquid coolant system It consists of a pump controlled by the crankshaft by means of a V-belt, a Keel cooling and a thermostat.

Coolant fluid ®®® Recommendations for the first use

Check that the Keel Cooling block fiuid drain plug and the carter motor are tightened. Prepare a permanent antifreeze mixture with 50% antifreeze and 50% fresh water. The necessary quantity is indicated in the technical specifications..

a) Engines with A cap and expansion tank: Fill the mixture into the A filler hole until the maximum fill level is reached; close cap A. Pour the mixture into the expansion tank filler hole until the maximum fill level is reached; close cap . Start the engine and verify the level after several minutes.. Subsequent checks are to be made only with the expension cap; do not again open the A cap.

Allow the engine to run for 2 to 3 minutes whilst gradually accelerating. Stop the motor and top off the expention tank fluid level. The additional fills will be only with fresh water when the engine is cold

DANGER: - Fill the engine with coolant liquid only when the engine is turned off and cold - Do not smoke or draw near with aflame. -Stay clear of rotating parts while the engine is operating.

ATTENTION: Never add undiluted antifreeze.

ELECTRICAL EQUIPMENT

Engine - ® a Battery

Alternator Starter Glow plug Stop solenoid

_ Oil pressure alarm g Water temperature alarm h Water temperature gauge (option) i Connector j Oil pressure gauge (option)

Instrument panel ® a Water temperature alarm indicator b Oil pressure alarm indicator c Glow plug indicator d Battery charge indicator e Audible alarm buzzer f Starter button g Stop button h Instrument lighting i Connector

Wire position Colour Function 1 2 3 4 5 6 7 8 9 10 11

Red Black Brown Brown 1 White

Violet Grey-1 Yellow-green

Positive Negative Starter Glow plug Stop

D + alternator Oil alarm Water alarm

5. ENGINE OPERATION

STARTING THE ENGINE

DANGER - Firmly close the engine cover and replace the protective elements before starting the engine

Check the diesel fuel level Open the diesel fuel feeder valve Check the engine and gear box motor oil levels Check the level of coolant fluid Close the battery valve Check that the gear box control lever is in the neutral position Desynchronise the clutch gas control by using the device on the box Position the gas control lever in the accelerate position Switch on the main power, the oil alarm indicator will illuminate and the buzzer will sound Then preheat by pushing the red botton in first position (for 5 to 10 seconds depending upon the outside temperature) Then push completely the same botton until the engine starts. Release it immediately after the motor has started Check the indicators and other fiinctions after the engine starts Immediately stop the engine if the buzzer sounds, if the temperature rises abnormally or if the other indicators illuminate

ATTENTION: Search for and eliminate the cause before starting the engine Allow the engine to run at approximately 1000 rpm

If the engine does not start on the first attempt, repeat the steps after waiting 30 to 60 seconds after each attempt

WARNING: Never cut the electrical circuit by using the battery main switch whilst the engine is running. This may cause damage to the alternator.

STOPPING THE ENGINE

Return the control lever to the idle/neutral position Allow the engine to idle for several minutes in order to stabilise the temperature Push the stop button

ATTENTION - Check the engine and the engine compartment for any possible leaks.

ENGINE RUN IN - GUARANTEE VISIT

Running in

During the first 20 hours of operation, it is recommended that you take precautions to properly Run in your engine and that you not attain maximum engine performance except during short periods. Never race your engine immediately after starting, without having allowed it to warm up. Guarantee visit

This mandatory visit with an authorised NANNI DIESEL representative will take place either after 20 hours of operation or 45 days after your engine is placed in service..

Every new engine is guaranteed against all parts defects according to the terms and conditions specified ^m 9

on the certificate of guarantee which is furnished to the buyer upon delivery of the engine (warranty card to be returned).

LIST OF GUARANTEE VERIFICATION OPERATIONS - (Customer's Responsibility)

DANGER: To avoid bodily injury, stop the engine and allow it to cool, turn off the battery main switch before any repair

Follow the safety and environmental protection instructions

Change the lubricant of the: - Engine

Reverser gear box

Clean: - The diesel fuel pre-filter

Check: - The level of the coolant fluid - Theadjustment of the valves

The tightness of the intake and exhaust manifold The tightness and the operation of the diesel fuel system The tightness of the cooling system The belt tensions

- The tightness of the screws and bolts - The tightness of the engine mounts - The alignment of the engine - The stuffing box - The lubrication of the stuffing box

Replace: - The oil filter cartridge - The diesel fuel filter cartridge.

Electrical equipment

Check: - The tightness of the contacts and cable terminals - The level and density of the battery electrolyte

The alternator charge - The correct operation of the instrument panel

Perform: - A check of the condition of the battery.

10

6. MAINTENANCE

DANGER: To avoid bodily harm, stop the engine and allow it to cool, turn of the battery main switch before making any repairs

Follow the safety and environmental protection instructions

The performance level of lubricants necessary for the proper operation of the engine and the recommended maintenance schedule are described on page X.

IMPORTANT - These recommendations are essential. Following these recommendations will prolong the life of your engine and will affect the applicability of the guarantee which is provided. - Do not make any unauthorised modifications to the engine.

Damage caused by the use of parts not bearing a manufacturer's reference number are not covered by the guarantee Repairs and maintenance must be performed by an authorised NANNI DIESEL engine repair facility

If the engine is used for a number of hours less than the number specified for maintenance intervals, then maintenance must be performed at least once per year. In this case, it is recommended that maintenance be performed before winter storage. The engine will therefore be protected by new, clean lubricants.

Valve adjustments ® ® - The valves are adjusted according to their injection order

Place the valves in a rocking motion on the cylinder before being adjusted Turn the crankshaft in the direction in which the engine rotates, so as to place the piston at upper dead centre

- Adjust the intake and exhaust valves (refer to the values in the table of technical characteristics)

Electrical equipment ® ® - Regularly check the tension of the alternator belt. Tighten the belt between the pulleys. It should have

10 mm give

DANGER -Stop the engine and turn off the battery main switch before making any repairs to the electrical system

11

Battery Check the battery charge once per season

- The density of the electrolyte should be between 1.270 and 1.285 - The electrolyte should be check periodically. The level should be maintained at 1 cm above the

accumulator plates. Add distilled water, if necessary.

DANGER - Never draw near with a flame, and never check the battery with "a spark", because the gases which may be released are inflammable and explosive - The battery electrolyte is highly corrosive. If battery acid come in contact with your skin, immediately wash with soapy water, eyes, rinse abundantly with water and immediately consult a physician

Do not short circuit.

R E C O M M E N D A T I O N S In order to ensure proper operation of the alternator and integrated regulator:

Never: - Turn off the battery main switch whilst the engine is running (risk of damage to the regulator)

Reverse the battery terminals. The terminals are respectively marked + (positive) and - (negative); the negative is earthen; the cable terminations and the cables must be correctly attached. Change the charge circuit while the engine is running.

For use of several batteries, install a charge distributor (consult with us). In case of starting the engine with a spare battery and jumper cables, proceed in the following manner:

Disengage the main battery circuit, connect the spare battery to the main battery by connecting the + to the + and the - to the -. Once the engine starts, disconnect the jumper cables and do not cut the main battery circuit.

You must disconnect the 2 battery cables when: you use a battery charger

- before any repair to the electrical system before doing any soldering work on a metal hull

Rinsing the cooling system Fresh water system ® ® - Remove the tank cap

Drain the water from the Keel cooling block and from the engine block Refill the system with fresh water and let the engine run for several minutes

- Drain the water and again replace it with a mixture of antifreeze and fresh water Fill the cooling system according to instructions.

NOTE: In the case where a hot water system is connected to the engine, also completely empty the latter and to refill it, note the quantity of the coolant mixture being added. Check to see that all air is purgedfi-om the system during the refilling

WARNING: Liquid under pressure. Do not open the cap when the engine is warm. Allow the engine to cool and open the cap with caution.

Cleaning the Keel Cooling Block ® ®

Remove the covers - Replace the O-rings and remount the tube and the covers

Do not forget the copper gaskets on the covers assembly screws..

WARNING: Corrosive products may hazardous to your health. Read the instructions on the product label carefully.

12

Replacement of the diesel fuel filter ® ® The diesel fuel filter is a disposable-type filter.

Close the fuel valve - Unscrew the cartridge at the head of the filter

Coat the gasket of the new cartridge with engine lubricant Screw the new cartridge onto the filter head, then tighten it by hand % of a turn (do not use tools) Open the fuel valve

- Purge the system Start the engine and check for sealing

ATTENTION: - Always mop up and spilled fuel - Follow the environmental protection instructions

Replacement of the injectors® ® Remove:

The injectors piping - The screw and the diesel fuel return piping - The complete injector

Dismantle the injector - Replace the injector gasket and nozzle

Remount the parts and check the injector calibration value

WARNING: Do not allow diesel fuel to spray onto your skin - wear gloves

IMPORTANT: This work must be performed by an authorised NANNI DIESEL engine repair facility. The injectors should be checked every 400 hours or every 2 years

Motor oil change ® ® The motor oil is removed by the oil change pump, preferably when the engine is slightly warm

Pump until the engine is completely drained Refill to full level with new motor oil

- Check the level with the use of the dipstick - Do not exceed the maximum level

WARNING: Hot oil can burn you — Avoid all contact with your skin Respect the environmental protection regulations

13

Replacement of the oil filter ® ® - The cartridge is of the disposable type

Unscrew the cartridge at the head of the filter - Coat the gasket of the new cartridge with engine lubricant

Screw the new cartridge onto the filter head, then tighten it by hand % of a turn (do not use tools) - Check that the filter does not leak when the engine is running

Stop the engine and add motor oil to the maximum fill level if necessary

WARNING: Hot oil can bum your - Avoid all contact with your skin Respect the environmental protection regulations

Reversing gear box Refer to detailed instructions in the reversing gear box manual attached to the operating manual Consult with us for specific reversing gear box information

Reversing gear box control system Verify the remote controls regularly. The cable stroke should be 35 mm on both sides of dead centre (O A = O - B). The lever must be able to move freely to its stroke limits.

Attention to the lever position (refer to fig. ® et ®)

Turbo ®® Engines equipped with a Turbo: Turbo compressor should be checked every 400 hour for proper operation

DANGER: To avoid bodily injury, do not start the motor without the air filter

IMPORTANT: Allow the engine to idle before stopping the engine

14

6 - MAINTENANCE Periodic Maintenance Table

CHECK Oil level (engine and gear box) Battery charge (indicator) Water temperature and operation General sealing

EVERY DAY

x X

x

Battery electrolyte level (every 15 days) Operation of the controls Belt tensioii Valve adjustment Starter and alternator mountings Tightness of screws and assemblies

Engine mounting and alignment Injector calibration

Thermostat, to be cleaned Level in the heat exchanger Keel cooling tube

REPLACE: Oil filter Fuel filter Motor oil Gear box lubricant Coolant fluid

X

AT 20 HRS

X

X

X

X

X

EVERY 100 HRS

X

X

X

EVERY 200 HRS OR EVERY YEAR

X

X

X

X

X

X

X

X

EVERY 400 HRS OR EVERY 2 YEARS

X

X

X

X

X

15

Technical specifications NANNI DIESEL ENGINE

Number of cylinders Maximum power * Maximum rated load * Idle speed (on gear) Maximum no load speed Cycles Stroke-Bore ratio Cubic cylinder capacity Rate of compression Rotation direction Injection order Injection pump Injection pressure Fuel consumption Advemce injection timing Weight (including, gear box) Alternator Battery capacity (minimum) Cooling system

Coolant fluid: (50% water + 50% antifreeze) Valve clearance (when cold) Motor oil Motor oil capacity 0°- 35° forward

HURTH gear box * HURTH gear box oil capacity HURTH gear box lubricant TECHNODRIVE gear box * TECHNODRIVE gear box oil capacity TECHNODRIVE gear box oil Anti-pollution certification Electromagnetic compatibility CEM 89/336/CE

3.100 KG 3 in line

21.3kW(29hp) 3 600 rpm 950 rpm

3 900 rpm 4

76 x 73.6 mm I 001cm3

23/1 Counter clock-wise

1-3-2 Nippon Denso (Bosch type)

140 bar 190g/kW/h

22°+1° before UDC 130 kg

1 2 V - 6 0 A llOA/h

4.150 KG 4 in line

27.6 kW (37.5 hp) 3 000 rpm 850 rpm

3 300 rpm 4

78 x 78.4 mm 1498 cm3

22/1 Counter clock-wise

1-3-4-2 Nippon Denso (Bosch type)

140 bar 190 g/kW/h

11° (static) 23° to 3 000 rpm 145 kg

12 V - 6 0 A llOA/h

By fresh water /sea water keel cooling

41 51 )

0.15 to 0.20 mm (intake and exhaust) API CD - SAE 15 W 40

4.5 1

ZFIOM 0.35 1

Automatic Transmi TMC40

0.21

4.5 1

ZF12M 0.55 1

ssion Fluid, Type A TMC60

0.8 1 API C D - S A E 15 W 40

BSO - Level 2 Certificate no. CE P98155T

BSO - Level 2 Certificate no. CE P98155T

ATTENTION: The specifications are defined only for use of pleasure craft. Consult with us for all other uses.

Recommended on board repair kit for motor types 3.100 K and 4.150 KG DESCRIPTION V-belt Oil filter Fuel oil filter

Rocker arm cover gasket Complete nozzle fitting Glow plug Thermostat Thermostat gasket O-ring tube Injector gasket

Quan

2 1

3.100 KG 970 637 399 970 302 742 970 310 302

970 302 833 970 302 816 970 302 821 970 301412 970 302 608 970 301 719 970 142 109

4.150KG 970 637 399 970 302 742 970 622 350

970 302 765 970 302 816 970 302 821 970 301412 970 302 608 970 301 719 970 142 109

16

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Le16avril2004

NAtiONAL blSTMlBUTORS

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KUBOTÅ BASED ENGINES

CRAMM INGENIEURS-EN Hadelsburo - Postbus 510 - NL-8901 BH LEEUWARDEN S 58.28.80.700. Fax : 58.28.80.643. E-MAIL: salesOcramm.nl

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MAN ROLLO B.V. Koraalrood 17 - P.O. BOX 595P - NL-2700 AN ZOETERMEER S 79.36.83.683. Fax : 79.36.14.902. E-MAIL: salesfömanrollo.nl - INTERNET : www.manrollo.com NEPTUNE ENTRETIEN SARL Bale de Numbo - 3 bis rue Carnot - 98846 NOUMEA a 687.28.53.60. Fax : 687.28.01.95. E-Mail: neptune(a»offratel.nc - INTERNET: www.neptune.nc LEES DELTA MARINE P.O. BOX 72 047, Papakura - AUCKLAND S 9.299.6019. Fax: 9.298.9986. E-MAIL: lees.deitaOJxtra.CO.nz - INTERNET : www.enqineer.net.nz NOGVA MOTORFABRIKK AS Postbox 55 - N-6280 SOVIK S 70.20.84.00. Fax : 70.20.84.10. E-MAIL : lidvar.fvlkesnestSnoqva.no M.E.S STR RACIBORSKIEGO 32 - 80-215 GDANSK S / Fax : 58 347 90 72 E-MAIL : mesOqIobtel.pl - INTERNET : www.mes.hq.pl

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maDmm:a_:(]&sce_^ 1

Spare parts catalogue

Catalogue de pieces détacfiées

(ErsatzteiC^taCog

CataCogo de piezas de repuesto

CataCogo parti di ricamSio

3.100KC-SOLAS HATECKE VERSION

We reserve the right to carry out at any time whatsoever, without notice and without the obligation to up-date this booklet

any modifications to parts or supplies of accessories as may be deemed necessary for technical or commercial reasons

Reproduction, multiplication or translation in full or in parts Is not permitted without written authorization.

Nous nous reservens le droit d'apporter, sans préavis ni obligation de mise å jour de ce catalogue, les modifications rendues necessaires pour des raisons techniques ou commerciales..

Les reproductions ou traductions, méme partielles, sont interdites sans autorisation écrite de notre part.

Wir behalten uns vor das Recht notwendige Aenderungen einzufuehren, ohne Voranzeige und ohne Verpflichtung diese Herausgabe auf den letzten Stand zu bringen.

Nachdruck, Vervielfaeltigung oder Uebersetzung, auch auszagsweise, ist ohne schriftliche Genehmigung nicht e laubt.

Nos reservamos el derecho de aportar, sin previo aviso ni obligaciön de puesta al dia de este catålogo, las modificaciones necesarias por razones técnicas o comerciales.

Las reproducciones o traducciones, incluso parciales, estan prohibidas sin autorizaciön escrita de nuestra parte.

Ci riserviamo il diritto di apportare, senza preaviso e senza l'obbligo di aggiornare questa pubblicazione, le modifiche eventualmente necessarie per qualunque necessitå tecnica o commerciale. Riproduzione, anche parziale, vietata senza nostra autorizzazione scritta.

NANNI INDUSTRIES S.A. Zone industrielle - avenue Mariotte - B.P.107 - 33260 LA TESTE - FRANCE

Tel.: (00.33) 05 56 22 30 60 - Fax. : (00.33) 05 56 22 30 79

1 - PREFACE 1,1 For technical reasons and for simplification, the illustrations in this catalogue are only by way of example. 2 - GUIDE FOR CONSULTATION OF THE CATALOGUE 2.1 Identify in the table 00,00 "table Index" the table to be consulted. 2.2 Every table is composed of two pages. An enlarged view of the articles is shown on the first page.

The tables giving part number, quantities relating to the engine and eventual obervations are shown on the second page. 3 - RULES FOR ORDERING 3.1 All orders must be written and sent to NANNIDIESEL. Spare Parts Dept. with the following references : - Quantities requested - Part no - Number of order, method of shipment, etc

3.2 for urgent orders or in case of doubt, it is necessary to indicate the serial number and the year of productiion of the engine and as much useful information possible to identify the part. 4-GENERAL 4.1 Any queries concerning your orders of spare parts must bear the number and date ot the order and/or the number of the sales invoice.

4.2 Any complaints regarding shipments must be presented within 8 days from receipt of the goods.

4.3 Any mistakes deriving from the transmission or incorrect interpretation of urgent orders taken by telephone, telegram or telex will be chargeable to the Distributor who passed the order.

1 - PREFACE

1,1 Pour des ralsons techniques et de simpllcité, les illustrations de ce catalogue sont seulement fournies å titre indicatif. 2 - METHODE DE CONSULTATION DU CATALOGUE 2.1 Rechercher sur la page 00,00 "index des planches" le numéro de la planche å consulter.

2.2 Chaque planche est composee de 2 pages. La premiere page montre la vue éclatée des pieces. La deuxieme page donne les symboles, les quantités pour moteur, ainsi que les observations eventuelles. 3 - INSTRUCTIONS POUR COMMANDES DE PIECES 3.1 Toutes les commandes doivent étre adressées å NANNIDIESEL avec les elements suivants : - Quantité demandée - Code de la piece

- Numéro de commande, mode d'expédition, etc 3.2 Pour des commandes urgentes ou en cas de doute, il est necessaire d'indiquer le numéro de serie et l'année de fabrication du moteur ainsi qu'un maximum d'informations permettant d'identifier la piece. 4 - GENERALITES 4.1 Tout renseignement concernant votre commande de pieces détachées doit comporter le numéro et la date de la commande et/ou le numéro et la date de la facture de vente.

4.2 Toute reclamation concernant l'expédition doit étre faite sous 8 jours å dater de la reception de la commande.

4.3 Toute erreur decoulant de l'expédition ou d'une mauvaise interpretation d'une commande urgente enregistree par telephone, télégramme ou telex sera å la charge du distributeur qui a passé la command

PAGE NUMBER REVISION EDITION DATE DESCRIPTION

• • •

ENGINE CATALOGUE

3 WOKC-SOLAS-HATECKE EOJ^DQCoD&iÖ©!/ SPÄHE PARIS CATALOGUE MODIFICATION

GROUP 00-00

PAGE 1

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DATE 02-03-04

DESCRIPTION CYLINDER HEAD COVER/ OIL BREATHER FUEL PIPE FUEL FILTER ASSY HEAT EXCHANGER EXH MANIFOLD'

ELECTRICS FLYWHEEL H O U S I N G ' REAVERSING GEAR ENGINE MOUNT SPARE PARTS LIST

GROUP N° 05-00 21-00 23-00 46:00 __

77-0Ö""-80-0Ö' ""' 82-00 91-00 95-00

DESCRIPTION - 3 100KC-SOLAS GROUP

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GROUP 21.C0

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Qty 1 r" 1

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Professional-Line solarnova

Solar module SOL 12 K For applications like sport- and commercial shipping, hobby and small units For the electrical provision of low power consuming equipment the solamova offers this heavy load module. 40 crystalline silicon cells of size 5 x 5 cnf are connected by a: specific high reliable welding process. This module has a nominal power of 12 watts and is designed for nominal battery voltages of 12 volts.

The established sandwich-technique protects the module excellent against environmental influences as for instance rain, dust, hail and seawater. The edges of the module are protected by a sealing of synthetic rubber and a frame made of stainless steel. The connection cables comply with the instructions of VDE and are led out UV-protected at the module rearside. In addition a plastic cap guarantees the complete sealing of the cable connections.

The specific regidity of this module is based on the usage of two chemically hardened glass plates in combination with the small module size. By this the module is well suitable for sailing and motor yachts.This type of module is also designed for a lifetime of more than 20 years and is proved since many years in similar construction for following applications:

Communication Systems: • Data recording and transmission • Emergency highway calling systems • Portable transceivers • Relay stations

Traffic Systems: • Railway communication systems • Warning lights • Obstruction lights • Navigation buoys • Life-boats

Measuring Technique • Remote measuring and data recording of me

teorological, climatological and environmental data

Recreation, Sport and Hobby Systems: • Recreation vehicles • Camping/Caravans • Sailing ships • Motor ships • Handheld radios • Amateur radios • CB-radios • Refrigerators • Lighting • Fans • Circulation pumps for swimming pools • Fountains • Power supply for expeditions

n Mechanical Data: Electrical Data:

Solar cell Base material: crystalline silicon

Cell size: 5x5 cm*

Embedding Glass/EVA/Glass

Frame Stainless steel

Solar cell temperature

Open circuit voltage

Short circuit current

Voltage at power max.

QOC

25.3 V

0.70 A

20.5 V

0.64 A

13.1 W

25 »C

23.1V

0.72 A

18.4 V

0.65 A

12.0 W

60 »C

20.2 V

0.73 A

15.6 V

0.66 A

10.3 W

The rnaxirnurn deviation of nominal power is less than 10 %. All values mentioned above are valid for an irradiation of AM 1.5-10ÖmW/cm^.

Weight approx. 1490 g

Cable Length: 150 cm (FFY11Y-2X 1.5mm*) (+) = brown; {-) = blue

Accessories Teakwood mounting brackets

Dimensions in mm

V*2 I;,. . '.iS*%-' ' 665

Hi.

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Energy Output per Module:

Nominal voltage: 12 V Solar cell temperature: 25 °C

irradiation 3.0 (kWh/rhM]

4.0 5.0 6.0

2.0 2.6 3.3 3.9

Qualification:

This module generation conresponds to the specification no. 503 of the Joint Research Centre ISPRAoftheCEC.

Operation Conditions:

Temperature T„,|„: -50''C; T ^ : +90''C

Humidity up to 100% rel.humidity at +90''G

Wind pressure stable up to wind speeds of von 160 km/h

CorrosiiDh corrosion-resistant to sea water and maritime climate

*" Boundary values for short term exposure only!

Remarks:

solamova Produktions- und Vertriebsgesellschafl mbH Industriestraße 23-33 D-22880 Wedel Telephone (O 41 03) 60-256 25 Telefax (O 41 03) 60-47 01

Installation of modules has to be perfbnmed such a way that the rearward connections (leads, junction box) are located above.

The technical data given merely serve for information purposes and - depending on the individual application concerned - can vary.

s o t 12K EA)12.96

Charge Regulator CDC 106, CDC 206 Operating Instructions

solarnova

The charge regulators BCR123 40-150 and BCR 243 80-240 have been specially designed for use in photovoltaic systems with smaller outputs. They can be used for 12 V or 24 V batteries. Due to the high protection class IP 65, they can also be installed outdoors. Modern circuitry ensiures an extremely low own electric energy consumption (at 12 V) of PV = 0.1W. The units can be used for solar generators with a charge output up to 150 W with the 12 V verslonand up to 240 W with the 24 V version. They protect the battery safely against overcharging and overdischarging, operating conditions which would othenvise drastically reduce the service life of the batteries. The built-in varistor protects the unit against voltage peaks which might develop from lightning striking near the solar generator.

1. Operating Description 1.1 Charging Operation During charging operation, the solar generator current flows into the battery at low loss via a high current relay. When the battery has reached gassing voltage, it is switched to trickle charge operation with reduced current, to avoid the battery being overcharged (electrolyte loss, damage to the electrodes). If the batteiy voltage drops below a certain voltage limit dueto self-discharging, to the load from the connected cdhsurher appliance or to the falling solar géheratbr current, the full charging operation is switched back. Thehigh current relay employed is designed for 1 million switching operations at a maximum current of 16 A. In operation conditions, the relay only switches 9 A for 12 V and 7.5 A for24 V, so that a high reliabii'rty is guaranteed.

1.2 Discharging Operation If the battery voltage drops below the overdischarge voltage during discharge operation, the load is disconnected from the battery by an overdischarge relay. The load is automatically reconnected when a minimum charge of the battery is ensured.

ATTENTION: For safety reasons, the overdischarge protection has priority. When connecting the unit for the first time, this could lead to pverdischarge being signalised although the battery is charged. However, with ah intact battery this reading will disappear shortly after charging current has flown from the solar generator. At charge Surges, e.g. when connecting large consumer appliances^ itis possible that the battery voltage drops momentarily below the bverdischarge threshold, without it being overdischarged. To avoid the överaischärge alarm responding in such cases, the charge release takes place after a delay.

1.3 Temperature Follow-up / Temperature Sensor The gassing voltage of the battery varies with the temperature at a rate of 5 mV per "G. based on a2 V cell. In most cases where the ambient temperature of the battery only alters slightly, the overcharge switch-off threshold can be adjusted adequately accurately with a fixed resistor Ro*{see table 1), which is conneaed to terminal 3 and 4. The units are equipped from works with a 12 kOhm resistor Rg;.this corresponds to a gassing voltage of 14.4 V forl2V batteries, or 28 8 V for 24 V lead batteries, at an electrolyte temperature of 25''G. If the temperatures are expected to deviate

§really, the the resistor should be adjusted according to table 1. hould there be strong ternperature fluctuations, it is recommen

ded to measure the electrolyte temperature diredly- In this case, an NTC resistor is required (temperature sensor TS1). which is attached directly to the battery pole and connected to the terminal instead of the resistor fl-. The temperature sensor can be used within the range of 5 to 60*0.

WARNING: The temperature sensor follows up the battery voltage accordingio the electrolyte temperature. When temperatures are below 25°C, this leads to a system voltage of > 14.4 V with 12 V units or >28.8 V with 28 V units (see table 1). which can cause damage to various consumer appliances. Therefore, please do not fail to check the max. allowed operating voltage. When attaching the sensor, make sure the bonding is perfect - high transition resistances or open contacts cause increased system voltage.

RQ resistor for different electrolyte temperature

Temperature in-C

-10 0

-(•10 -1-20 - 30

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...+10

... +20

... +30

... +50 >+50

in kOhm

27.0 18.0 15.0 12.0" 6.8 3.9

End Load Voltage [V] ±2% 12 V Battery 24 V Battery

15.64 14.95 14.67 14.40 13.95 13.37

31.28 29.90 29.33 28.80 27.90 26.75

' ' Setting at works

Table 1

1.4 Manual Charge Control In some cases it is desirable to deactivate the overdischarge protection momentarily, to be ableto draw current from the battery. For this purpose, a switch can be connected to terminals 13 and 14 which, when closed, will put back the overdischarge relay. This should only be used for short periods and while observing the battery voltage, to prevent the battery from being damaged. Another possibility is to switch off the load in normal operation at these terrhinals on purpose.

1.5 Overdischarge Warning Device Indicators for overdischarge warning can be connected at terminals 11 and 12. The indicators must not exceed a max. current consumption of 1 A.

1.6 Cut-off Connection When the cut-off connection (terminal 1 and 2) is used, the battery voltage can be covered in the error-compensated mode. This is always necessary when the chargé regulator is mounted at a distance from the battery and thus the charge and load current cause an unacceptably high voltage drop at the mains leads. If the cut-off connection is used, the bridges W1 and W2 on the left and right next to the terminal strip must be switched off beforehand.

2. Installation and Connection instructions 2.1 Order of Connection There is no particular order of connection to follow. However, it is advisable to first ensure the power supply and measuring of the unit, i.e. first connect the cut-off line or the battery so that the' consumer appliances are not endangered by unacceptably high voltages.

2.2 Reverse Current Diode In order for the solar system to be as efficient as possible, reverse cunent diodes are not installed in these charge regulators. Such diodes, which liein series to thesolar generator, produce on-state losses during the charging phase, which are higher than the reverse cui'rent losses during darkness. Nevertheless, in series diodes cannot be done without in certain cases, it is especially advisable with multiple module systems to decouple the single solar generator strings by means of reverse current diodes. These can be installed in the solar module connection boxes (see Module Data Sheet).

2.3 Design of Cable Cross-Section, Cable Lengths

Cable A: Four-core cable for battery voltage measurement and/or temperature sensor connection. Outer diameter max. 7.5 mm. If the integrated resistor R. is used and the four-conductor measurement of the battery is not required, then cable A can be left off.

Cable B. C. D: Two-core cable, 2 x 2.5 mm^ (flexible) or 2 x 4 mm* (solid) for solar generator, battery and consumer connection. Due to the cable entry used, the outer diameter of cable B. C. D is max. 13.5 mm. If the four-conductor measurement of the battery voltage is not present, attention must be paid to the max. allowable voltage drop

A*

Cable B for the solar generator - charge unit U^=10% Cable D for the charge unit - consumer appliance U^ = 4 % Cable C for the charge unit - battery U^ = 1 %

Electrical Data

max. permissible cable length

Assumption:

Cable

B C D

Max.

12 V Unit 2 x 2 . 5 mm^ 10.0 m

1.0 m 3.5 m

2 x 4 mm* 150 m

1.5 m 5.5 m

24 V Unit 2x2 .5 mm* 20.0 m

2 0 m 7.0 m

2 x 4 mm* 30.0 m

3.0 m 11.0m

permissible voltage flows throughout

Table 2

If longer cable is required for the installation, the battery voltage must be measured at the battery terminals (use cable A).

Cable E: Four-core cable for connecting an overdischarge warning device and/or a mechanical switch for switching off and on the consumer appliance; max. diameter 7.5 mm.

2.4 Suitable Cable Types (Selection)

Designation Underground cable Plastic-sheathed cable Rubber hose pipe Weak current cable

Type NYY-0 NYM-0 H07RN-F YR

n x A " 2x4 2 x 4 2 x 2 5 4x0.8

for cable B, C. D B, C. D B.C.D A.E

" n = core number!, A = cross seaion (mm*) *> not for underground laying, but permitted for laying outdoors

Tables

rFF^ Control electronics

Lightning protection

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2) 2)

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106 12 25

150 9

10 14.4 10,8

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240 7.5

10 28,8a:2% 21.5 ± 3 %

CDC Nominal voltage [V] max. voltage {v) max. solar generator capacity (W] max. solar generator current (A] max. load current JA] End load voltage {V] (25''C) Overdischarge voltage jV] Switch back threshold [v] after "Load off Power consumption, nominal operaion [mA] Power consumption after load release [mA] Lightning protection as per VDE 0432 Part 2/10.78. Impulse form and duration 8/20 s [V] Temperature compensation: Adjusted to 25°C. Adjustable to any other temperature by connecting defined resistors R (see table.1) or temperature sensor TBI

12.3 ± 3 % 24.6 + 3%

< 8

<60

1.000

< 8

<30

I.OOO

2)

3)

Charge reguiaor for lead batteries. Valid for E = 1000 mW/m*. T . = 25°C Voltage thresholds apply for commerciallyavailable leaj t-teries with their permissible charge and discharge curre. ,-

Mechanical Data

Connection cross-section (mm*) solid (flexible) 4 (2,5) Housing Terluran Dimensions LxWxH (mm) 160 x 80 x 55 Weight (kg) 0.4 Protection class IP 65 Operating temperature range ("C) -1Ö to + 55 Storage temperature ("C) -40 to •f-80

Fixirtg Méasuremérits

r I L.

1 2 3

1 1 1 I

PG7

4

1

S 6 7 • 1 -

e 9

_J Lpl L_

PG135

1 PC13,5

10

+ • • .

PG13,S

1

11

• p l 1 1

12 -1-

13 U

1

PC7

"1

Cable A for: Cut-off

Temp. sensor

B C Solar Battery Generator

Consurüer Appl.

E Alarm signal Load On/Off

s. 2.3 s. 2.4

Connectior) Plan

solamova Produktions- und Vertriebsgesellschaft mbH Industriestr. 23-33 D-22880 Wedel Tel.:04103-602625

SL

IDIN

G R

AM

P

DMF-20

Operating and maintenance manual for launching- and retrieval system of freefall lifeboat type: FFA

with under oil hydraulic power pack

ERNST

HATECKE Boatyard Ernst Hatecke GmbH Am Ruthenstrom 1 21706 Drochtersen Phone: 0049-(0)4143-9152-0 Fax: 0049-(0)4143-9152-40 E-mail: [email protected] www.hatecke.de Edition 09/06



Index

1 Operation Manual

1.1 Yard and yardnumber 1.2 In the interest of safety 1.3 Description of the launching-and retrieval system 1.4 Launching instruction 1.5 Freefall launching 1.6 Launching and recovery by davit (Under deck version) 1.7 Launching and recovery by davit (On deck version)

2 Maintenance Manual

2.1 In the interest of safety 2.2 Hydraulic equipment 2.3 Hydraulic oil & lub plan 2.4.1-3 Recommended oil chart 2.5.1 Weekly inspection 2.5.2 Monthly inspection 2.5.3 Annual thorough examination (ace. to MSC.1/Circ.1206) 2.5.4 5-Years overhaul & testing (ace. to MSC. 1 /Cire. 1206) 2.5.5 Testing according to SOLAS Chapt. Ill, Reg.20.11.1 2.5.6 Log Scheme 2.5.7 Authorized Service Stations

Additional:

General layout Wires / small parts Lashing (boat) Wiring diagram (optional) Hydraulic plan Documentation of winch

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fa.x: 0049-(0)4143-9152-40, E-mail: [email protected], www.hatecke.de


1,1 Yard and yardnumber

The information given in this manual is based on our long experience and "know-how" in the building of rescue boats, all kind of life boats their equipment and their launching and recovery systems.

In case of an emergency.also in normal practise it is very important that every body knows how to handle the boat, the launching system and it's equipment.

All personal should study this manual at lifeboat drills, to make them selves thorougly conversant with the system and to ensure a speedy and safe launching in an emergency.


In case of enquiries regarding existing boats please quote the details given below:

Type: FFA 6.5M

Building no.: 10838

ERNST

HATECKEI Boatyard Ernst Hatecke GmbH Am Ruthenstrom 1 21706 Drochtersen Phone: 0049-(0)4143-9152-0 Fax: 0049-(0)4143-9152-40 E-mail: [email protected] www.hatecke.de



1.2 In the interest of safety

A WARNING 1. During operation of the davit be cautions with long links, snap hooks and counterweights.

2. DO NOT put your hands on snap hooks, long links, counter weights and falls with tension on this parts.

3. Always keep hands and feet clear near moving and rotating mashinery.

4. Before launching close fronthatch and door.

5. Secure all items and fasten seat belts (adjust to your size).

6. Don't wear lifejackets during freefall launching. Failure to observe this procedure may lead to serious injury or dead!

7. Keep off in reach of propeller.

8. Before starting read engine instruction manual.

Boatyard Emst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: ü049-(0)4143-9152-40. E-mail: [email protected], www.hatecke.de



•

1.3 Description of the launching-and retrieval system

This launching and retrieval system is installed in the stern area of the ship to use freefall-lifeboat as follows:

1. freefall-launch of freefall-lifeboat up to 20° list and 10° trim of the ship from certificated height. 2. controlled launch of the freefall lifeboat up to max. number of persons it is certified by means

of davit arm and winch up to 5°list and 2° trim of the ship. 3. recovery of freefall-lifeboat with crew of max. 4persons at a speed of 5m/min (winch) up to

5°list and 2° trim of the ship.

Boat wil be turned out or swing in by A-fram. Hoisting and lowering by winch with two falls each for one hoisting sling of freefall lifeboat.

Sheaves for falls leading out of polyamide and all bolts from stainless steel.

Davit arm as well as winch are powered by hydraulic power pack. Max. working pressure is 200 bar. Overpressure of hydraulic power pack should be adjusted to max. 220 bar.

Boat is secured in stowage position by hooks and lashing system.

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-915240, E-mail: [email protected], w-w-w.hatecke.de


1.4 Launching instruction

Freefall The boat runs down the launching rannp and on hitting the water submerges briefly before emerging and moving away from the stern of the ship.

The boat will clear the vessel irrespective of weather conditions or angle of heel. Instructions for launching procedure on the following page.

Instruction of freefall procedure look at page 5, look also at the manual of the freefall-lifeboat.

Launching by davit In some cases (shallow water, drift-ice, drifting parts of the cargo) it is necessary to launch the boat with max. number of persons by davit.

Instructions for launching procedure on the following pages.

Recovery by davit Freefall-lifeboat with crew of max. 4 persons must be sailed astern under the davit.

Instructions for recovery procedure at page 6 and 7.

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(G)4143-915240, E-mail: [email protected], www.hatecke.de



1.5 Free fall lamiching




EMERGENCY RELEASE:

Operate only when mainrelease system is damaged.



Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone; 0049-(0)4143-9152-0, Fax: OÖ49-{0)4143-915240, E-mail: [email protected], www.hatecke.de



1.6 Launching and recovery by davit (Under deck version)

@(ii5)(jii2) Abb./fig.3

( A ) WINDE / WINCH

(5)DAVIT

Abb./flg.1

Abb./fig.2 ^

In \

:A

i

® I Free fall launching:

Disengage the boat lashing on the platform and enter the boat - further more information for launching inside the boat. (Look also page 1.5 of this manual.)

II Launching by davit: The main switch on the switch board box (fig. 1 ) is switched on. Push in the green button on the push button box (Fig. 2 ) - now the system is ready for work. 1. Disconnect the falls from the lashing eyes and hook them to the hoisting sling. 2. Disengage the boat lashing on the platform and to the keel. 3. Tighten up the boat falls by winch (lever A fig. 3). 4. Swing out the davit to if s max. outreach (lever B fig. 3). 5. Lower the boat (lever A fig.3 ). 6. Disconnect the falls after the boat is waterborne.

III Recover of the boat (max. 4 persons on board): The davit is max. swung out. The falls are in reach of the boat. Both lashings at the sliding ramp are disconnected. 1. Manoeuvre the boat astern below the falls and connect them to the hoisting sling. 2. Lift on the boat (lever A fig.3) until the distance of the falls counterweights to the stoppers

is about 1 meter. 3. Swing in (lever B fig.3) the davit to i fs resting position. 4. Pull the boat with the winch (lever Afig.3) into it's resting position. 5. Disconnect the hoisting slings from the falls, pick the falls into the lashing eyes at the

boat station and tighten up the falls by winch (lever Afig.3). 6. Attach the boat lashings. 7. Switch off the hydraulic unit - push in the red button at the push button box.

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0Q49-(0)4143-9152-40, E-mail: [email protected], www.hatecke.de



1.7 Launching and recovery by davit (On deck version)

I Free fall launching: Disengage the boat lashing on the platform and enter the boat - further more information for launching inside the boat. (Look also page 1.5 of this manual.)

II Launching by davit: The main switch on the switch board box is switched on (must be switched on all the time of course the heater inside). Push in the green button on the switchboard box - now the system is ready for work. 1. Disconnect the falls from the lashing eyes and hook them to the hoisting sling. 2. Disengage the boat lashing on the platform and to the keel. 3. Tighten up the boat falls by winch. 4. Swing out the davit to it's max. outreach. 5. Lower the boat. 6. Disconnect the falls after the boat is waterborne.

III Recover of the boat (max. 4 persons on board): The davit is max. swung out. The falls are in reach of the boat. Both lashings at the sliding ramp are disconnected. 1. Manoeuvre the boat astern below the falls and connect them to the hoisting sling. 2. Lift on the boat until the distance of the falls counter weights to the stopper is about 1 meter. 3. Swing in the davit to about it's resting position. 4. Pull the boat with the winch into it's resting position. 5. Disconnect the hoisting slings from the falls, pick the falls into the lashing eyes at the boat

station and tighten up the falls by winch. 6. Attach the boat lashings. 7. Switch off the hydraulic unit - push in the red button on the switchboard box.




2.2 Hydraulic equipment

UNDER-DECK POWER PACK: Power pack with service tank capacity of 90 Itr. is equipped with fixed mounted starter box (400V/50Hz or 440V/60Hz) for under deck mounting. All components are mounted to the tank. Starter box allways shall be in ON-position. To operate power pack push greenbutton of push button box on deck. Pressure to hydraulic cylinders and winch will be handeled by valve station on deck. Working pressure 200 bar, max. pressure 220 bar should be adjusted at valve station. Tank of power pack is filled with hydraulic oil after ventilation of cylinders, winch motor and piping system max. oil level should controlled monthly. The water content of the oil has to be controlled every month by opening the drain screw before starting operation.

mj

L

ON-DECK POWER PACK: Power pack with service tank capacity of 90 Itr. is equipped with fixed mounted starter box (400V/50Hz or 440V/60Hz, IP 56) for installation on free deck. Most of the components are mounted in the tank, under oil. Starter box allways shall be in ON-position. Hydraulic unit is protected against overheating. Pressure to hydraulic cylinders and winch will be handeled by valve station. Max. pressure 220 bar should be adjusted at power pack . The tank of the power pack is filled with hydraulic oil after ventilation of cylinders, winch motor and piping system max. oil level should controlled monthly. The water content of the oil has to be controlled every month by opening the drain screw before starting operation.

5

a

HYDRAULIC CYLINDERS: The working pressure of the cylinders are 200 bar. They are designed with a very high security with a test pressure of 400 bar. The rod material is stainless steel, chromium plated and super finished. Both cylinders are protected with overcenter valves, which are directly installed in the welded cylinder bottom.

HYDRAULIC WINCH-MOTOR: The motor is also protected by an overcenter valve for opening and closing the brake. d -

it=i^




2.3 Hydraulic oil and lub plan

No.

1

2

3

4

: Designation:

Hydraulic oil

Gearbox oil

Grease

Grease

Oil/grease type:

Look at next page

Look at next page

Look at next page

Look at next page

Quantity(ltrs.)

look at page 10a, b, c

look at winch manual

•I-

•1-

Service:

Make oil control at the hydraulic power pack monthly. Oil change after 200 -1000 - 2000 operation hours, but at least every 5 years.

Check outside visually to leakage before each operation. Oil change after 200 -1000 - 2000 operation hours, but at least every 5 years.

Grease after four weeks

Grease after four weeks

Greasing of grease points and chainging of gearbox oil of winch should be carried out during docktime with basket.

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: G049-(0)4143-9152-0, Fax: 0049-(0)4143-915240, E-mail: [email protected], www.hatecke.de



2.4.1 Recommended oil chart ( winch 07.02.08, and 10.01)

RECOMMENDED OIL CHART

OIL LIST FOR FREEFALL-LIFEBOAT DAVIT SYSTEMS, TYPE FFA

Ambient teperature for -25° up to +50° deg. C

No.:

1

2

5

6

APPLICATION POINT

hydraulic system

winch gear *)

wire fall

chain and falls hook

RECOMMENDATION

ISO VG 22 HLP or VG 32 HLP

OVG 150-200

wire fall grease ace. to lub-oil makers standarts

grease with EP additives NLGI - class 2

EST QTY UNIT; L.O/SYS. OIL: LTRS. GREASE: KGS.

QTY/SET

90

abL2 /3 ,5 *)

10

2,5

SET/SHIP

1

1

1

1

TOTAL/SHIP

90

abt. 2 /3 ,5 *)

10

2,5

*) = depends on winch type,look at winch manual.

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4i43-915240, E-mail: [email protected], www.hatecke.de



2 .4 .2 Recommendecl oil c h a r t (ZOLLERN winch 4 20)




No.:

1

2

3

4

APPLICATION POINT

hydraulic system

winch gear

wire fall


RECOMMENDATION

ISO VG 22 HLP or VG 32 HLP

ISO VG 220

wire fall grease ace. to lub-oil makers standarts



QTY/SET

90

abt. 2

10

2,5

SET/SHIP

1

1

1

1

TOTAL/SHIP

90

abt.2

10

2,5

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fa.x: 0049-(0)4143-9152-40, E-mail: [email protected], www.hatecke.de



2.4.3 Recommended oil chart (low temperature duty winch 07.02.08, and 10.01)




No.:

1

2

3

4

APPLICATION POINT

hydraulic system

winch gear *)

wire fall


RECOMMENDATION

PLANTOLUB POLAR POLAR 22S (CLP E 22 to DIN 51502)

ISO VG 629

wire fall grease ace. to lub-oil mal<ers standarts



QTY/SET

90

abt. 2 /3 ,5 *)

10

2,5

SET/SHIP

1

1

1

1

TOTAL/SHIP

90

abt. 2 / 3,5 *)

10

2,5

*) = depends on winch type,lool< at winch manual.

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-(0)4143-9152-40, E-mail: [email protected], ww-w.hatecke.de




1. Visual inspection to ensure the system is ready to use.

2. Check adjusted overpressure (220 bar) of hydraulic power pack. (Switch on power pack and hoist the davit arm against end position)

done remark




1.2.7.2 Monthly inspection


1. Check oil level of hydraulic power pack. 2. Make sure there is no condensed water inside the hydraulic power pack. 3. Make sure there is no water inside the electrical box of the power pack. 4. Check adjusted overpressure (220 bar) of hydraulic,

(switch on power pack and hoist the davit arm against end position)

5. Operate the winch in order to sprincier all inner parts by oil. 6. Check the Lashing aft & fore. 7. Grease wire rope falls and chain fore runner. 8. Visual inspection to ensure that the system is ready to use.

done remark

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen, Phone: 0049-(0)4143-9152-0, Fax: 0049-{0)4143-9152-40, E-mail: email@Hatecke,de, www.hatecke.de


1.2.7.3 Annual thorough examination (acc.toMsc.i/circ.i206)

A Qualification level. By manufacturers representative or a person appropriately trained and certified by the manufacturer Look at page 1.2.7.6 Authorized service stations.

Items listed in checklists for the weekly/monthly inspections also form the first part of the annual thorough examination, when carrying out this examination the inspection of these items should be performed by the ship's crew in the presence of the manufacturer's representative or a person appropriately trained and certified by the manufacturer for the work to be done.


Davit: Examination and check for satisfactory condition and operation

1. Davit structure, in particular with regard to corrosion, misalignments, deformations and excessive free play.

2. Wires and sheaves, possible damages such as kikns and corrosion. 3. Lubrication of wires and moving parts. 4. Hydraulic system. 5. Hydraulic winch and winch foundation. 6. Dynamic winch brake test with empty boat. 7. Re-inspection of stressed structural parts.

according to manufacturer's checklist (Doc. no. 3001)




1.2.7.4 5-Years Overhaul & Testing (ace toMsci/circi206)




Davit: Examination and check for satisfactory condition and operation *

1. Davit structure, in particular with regard to corrosion, misalignments, deformations and excessive free play.

2. Wires and sheaves, possible damages such as kikns and corrosion. 3. Lubrication of wires and moving parts. 4. Hydraulic system. 5. Hydraulic winch and winch foundation. 6. Dynamic winch brake test with 1,1 times the weight of the Lifeboat and ist full

complement of persons & equipment, or equivalent load. 7. Re-inspection of stressed structural parts.

according to manufacturer's checklist (Doc. no. 3002)




2.5.5 Overliauling and testing ace. to SOLAS Chapt.lll, Reg. 20.11.1

Ace. to SOLAS, Chapt.lll, Reg.20.11.1 following has to carried out with the davit system: "Operationally test under a load of 1.1 times the total mass of the life boat when loaded with its full complement of persons and equipment whenever the davit system is overhauled. Such overhauling and test shall be carried out at least once every 5 years" Overhauling of system has to be carried out ace. to requirements of class or national authority.

Testing with 1.1 times x GA: After overhauling the davit system has to be tested with 1.1 x GA. The winch brake of the davit system shall be of sufficient strength to withstand a dynamic test with a proof load of not less than 1.1 times the maximum working load at maximum lowering speed (5 meters/min.).

Testing has to be carried out under supervision of class or national authority.

A WARNING: During operation of davit be cautious with long links, snap hooks and counter weights.


No: Kind of service: Note: Date: Name:




1.2.7.6 Authorized service stations


HATECKEP:";/ Survival- & Deck equipment

Please contact: HATECKE SERVICE GMBH Am Ruthenstrom 1 21706 Drochtersen / Germany Telefon: +49 - 4143-9152-60 Telefax: +49-4143-9152-44 e-mail: [email protected] Internet www.hatecke.de



A P

Part A SCALE 1 : 2

SECTION C-C

T-'^

S.W.L lowering ( 22 persons) A640 kg S,Wi. hoisting ( 4 persons) 3290 kg

wiring schedule (in sea stored position)

Non rotating galvanized steel wire 16mm dia. Breaking load 150 KN

starboard side L =34100 mm port side L =32500 mm

1046

LATFORM. LADDER AND AILING BY YARD

®

C

3 4

-frame spacing=700-150

2. DECK

"T 8

1. DECK

o o vO

POOPDECK

9

O IXl i_n

-o^ Mk F, Fy Mx

®

iNote if not ottierwise stated, all weldings are Sbjnm

forces / momenfs

Fx (KN)

Fz (KN)

Fy (KN)

My (KNm)

Mx(KNm)

Mz (KNm)

® -91

122

15

25

60

17

® 136

-12

30

12

1

27

SECTION A - A

5496.5 PLATFORM BY YARD

SECTION E-E SCALE 1 : 10 SCALE 1 : 2

o CO N D I CSI

CM

8

It

300

oo,

SECTION B - B

1^

^ é x: c/i

E a t—

\s\ CD CSI

o CM

" 7

— ([ OF LAUNCHING RAMP

o LH 04

250

, _ _ - ,

. l- . vO

- JLZ03-0401-04 at JINLING S.Y - JLZ04-0401 25 at JINLING S.Y.

- JD1100TEU-5.10 af jangdong S.Y -313^315 of Aker Tulcea S.Y.

19

18

17

16

15

14

13

12

11

10

8

no.

bracket a 250x250x6

cover plate pl.6 245x245

longit. girder D 250x250x6

spring washer

hex. nut M20

hex. screw M 20x50

hex. screw M 20x70

connection plate connection plate

connection plate

connection plate

140

36

36

34

pieces

hydraulic power pack / instalation materials

lashings

wire plan

hydraulic winch

hydraulic cylinder

bearings

davit arm

sliding ramp

usual name of part

8

8

42

62

39

39

542

51

146

270

520

800,5

1312

1650

weight kg

ST 52.3

ST 37-2

ST 52-3

hot. galv. steel

hot. galv. steel

GL GRAD A

GL GRAD A

ST 52-3

ST 52-3

material

DIN 127 B

DIN 934

DIN931-8.8

QlN93T-ffH

D65MH-33

D65ML-33

DB65M-05

Type: 07.02.08

ZD/SGe 140/90, stroke 1178

DB65m-04

DB65M-03/DB65M-10

DB65M-02

note / draw. no.-.

total weight -. 5497 kg

14 13

12

11

10

8

REV.

hull no. XZ04-0420-25 added

hull na lZ-0415. JLZ04-04T7 * 19 added.

distance from d ship to d slidhg ramp dianged from 7155 to 7205

hull no. 1Z04-0416 added.

huU no. JD1100TEU-9/10 added.

Length from the steel wre corrected.

hull no. JLZ04-409-14 added.

hull no. KA 401-405 of Kouan S.Y. cancelled

Chain-links removes after JD1100TEU-6. Breaking load corrected.

hull no. JLZ04-0403*04 added

hull no. 1Z04-0401/02 and KA 401-05 added

hull no. JD1100TEU-5/6/7/8, XZ04-0403-0408 added,

Pos.3 altered. Weight ätered.

hull no. added. Weight fron Pos. 6 corrected.

ALTERATION

062/07

124/06

057/06

009/06

241/05

22V05

194/05

080/05

055/05

035/05

295/04

241/04

126/04

113/04

ALT. No.

14.0a07

23.06.06

13.0106

13.0106

17.10.05

07.09.05

13.07.05

Ot03.05

03.02.05

25.0105

nit04

30.08.04

OS05.04

23.04.04

DATE

U.M.

S.T.

U.M.

S.T.

S.T.

S.T.

S.T.

U.M.

S.T.

U.M.

U.M.

U.M.

S.T.

S.T. EXECUTED EXAWNED

NAME

DRAWH

EXAM»®}.

SCALE:

1:25/1:10/1:5 1:100

DATE;

17.03.04

/rjs'io^

NAME: ERNST

HATECKEI D-21703 Drochtersen . Gainany

041A3/9152-0 «143/9152-40 emaléHarecke.de wwwhMeckede

DOCUMENT TITLE: FFA 6.5 M

GENERAL LAYOUT FOR HULL JLZ01-0104-07 AT JINLING S.Y.

"T OOOJMthi (<0

D65MG-33 {D65MG-20)

Hydraulic winch O.VKNm Winch type; 07.02.08

6 hex. screws M20x55, DIN 933, galv. s t e e l 8.8

6 spring washers, B22 DIN 127, galv. steel

6 hex, nuts M20 DIN 934, galv. steel, 8

neu IX1.1 wi

Jz ^^:%M.

Washer PA 6G Weight: 0,31 kgs

Counter weight: lead Weight: 30,0 kgs R+V Draw, RV05039-0

Pressing clamp DIN 3093

Nan rotating galvanized steel wire 16 mm dia. Breaking load 150 KN Length starboard 34100

portside 32500 Total weight: 79,92 kgs

Pressing clamp DIN 3093

Lifeboat snaphook, size 13-8, Code WA32S WLL 5,3 to Weight: 1,5 kgs

?:;';'I,, ,'fh'f/'/>Thh^//,hh'zzzss: s

ØJ

r7>,U^,,rr.

••<^"'i'<'<"i'^-,hh'^'/,h>^ .1 1 >.U^^.U^^JJJ:gs^, ?Z/-^-^f-/^^-^f-z^->-^.^:,^,\.\. . .1.1.1,1, . .1. .1. .1,. iM-^,)j.j^,

UUmittHHI^WUHuu.LU.u,|.^^^l,^^;,^„„^^^^^^^,,^^

Schnitt section

''"" ,uux.„., .., n^

ai)

1

M

CO OD 04 O

LH O ON

, 1

SWL lowering (22 persons) 4725 kgs 2365 kgs each side SWL lowering (4 persons) 3375 kgs i690 kgs each side

REV.

length 792 mm changed to 710 mm

dimension between pressing clamps changed

Chain replaces by steel rope.

Counterweight corrects

fork shackle, chain and snaphook changed from size 10-8 to size 13-8

bearings

ALTERATION

010/06

086/05

049/05

011/05

213/03

ALT. No.

16.01.06

09.03.05

02.02.05

17.01.05

30.06.03

08.04.97

DATE

ü.M.

U.M.

S.T.

S.T.

U.M.

U.B. EXECUTED EXAMINED

^ -

NAME

Weight: 146 kgs

DRAWN:

EXAMINED;

SCALE

1:10/1:2.5

DATE:

02.12.96

y/P:^yf^(^ DOCUMENT TITLE:

NAME:

U.B. ^ % ^

ERNST

HATECKEI Postfach 11 07 . D-21703 Drochtersen . Germany

)g

0'H43/9152-0 04143/9152-40 emaR®Hatecke.de www.halecke,de

f A 6.5 M

WIRE PLAN

DOCUMENT NO.:

DBé5M-05

http://www.halecke,de

"m ai (T) Fore lashino :

One wire * 12 mm/1570 N/mm2 with thimble on both ends and a shactde 2.5t on one end and a turnbuckle with strap on the other end. ( adjustment ring 13/22/80 )

(D-(TlAft lashing :

One wire <t) 12 nim/1570 N/mm2 with thimble an both ends and one shackle 1.0t on one end One wire ø 12 mm/1570 N/mm2 with thimble on both ends ... on one end and a turnbuckle with strap. ( adjustment ring 13/22/80 )

m. -m. 11 W-11

«;1

ip

Æy Æ. ch ^

(foéé

_ 5 _ 4

2_ 1

no.

lashing eye lashings foundation lashing hQol<, aft

- JLZ03-0401-04 af JINLING S.Y.

- JLZ04-0401-25 af JINLING S.Y.

- JD1100TEU-5^10 al Jiangdong S.Y.

- 313^315 of Aker Tulcea S.Y.

17

GL Grad A GL Grad A GL Grad A

dwg na: DADLA-14 dwQ no.: DADLA-1A

10

REV.

fiull no. JLZ04-0420-25 added fiull no. JLZ-0415, JLZ04-0417 ^ 19 added.

hull no. JLZ04-0416 added.

hull no. JD1100TEU-9/10 added.

hull no. JLZ04-409-14 af Jingling SY


hull no. JLZ04-0403^04 added

hull no. JLZ04-0401/02 and KA 401-05 added

hull no. JD1100TEU-5 /6 /7 /8 , JLZ04-0403-0408 added.

hul l no. added. ALTERATION

062/07 124/06 009/06 241/05

194/05 080/05 035/05

295/04 241/04

113/04 ALT. No.

14.03.07 23.06.06 13,01.06

17.10,05

13,07,5

01,03,05 25,01,05

11.11,04

30,08.04

23,04,04 DATE

S.T.

S.T.

S.T.

S.T.

U.M.

U.M.

U.M.

U.M.

S.T. EXECUTED EXAMINED

NAME

Gewichf: weight: 51 kg

DRAWN:

EXAMINED:

DATE:

23.03.04

x-^.gf^. (py^

NAME: ERNST

H Ä T E C I C E ^ ^ ^ D-21703 Drochtersen . Gertnany

04143/9152-0 04143/9152-AO [email protected] www.hafecke.de

fairlead block stainless steel SCALE:

lashing step o/ /o stainless steel lashing hook, fore 11 steel hot galv dwg.no.: DADLH-14 1:25/2,5

piece usual name of part part ident. no. weights kgs material note

DOCUMENT TITLE: FFA 6,5M

Lashing far hul l JLZ 01-0104-07 at JINLING S,Y,

DOCUMENT NO.;

D65ML-33


http://www.hafecke.de

http://dwg.no

ANLAGEN - DECKBLATT / SUPPLEMENTARY SHEET

ANLAGE / PLANT :

KUNDE / CUSTOMER :

KOMM. NR. / SERIAL NUMBER :

AUFTRAGS NR. / ORDER NO. :

ZEICHN. NR. / DRAWING NUMBER

BAUJAHR / BUILDING YEAR :

SPANNUNG / VOLTAGE :

FREQUENZ / FREQUENCE :

STEUERSPG. / CONTR. VOLTAGE :

NENNLEISTUNG / POWER :

NENNSTROM / NOMINAL CURRENT :

POWER PACK FREIFALL-SYSTEM-OD-12450

HATTECKE

STANDARD UNTEROEL 12450

12450 El

2001

400/460V AC

50-60HZ

230VAC

10,5/13KW

22,7/23.4A

r n u D

: —SYSTEME[_J L J H Y D R A U L I K —

Hydrauliksysteme und Anlagenbau GnnbH Handelshof 24 28816 Stuhr

Tel. 0421 - 898989 Fox. 0421 - 89898-77

BEMERKUNG :

OHNE UNSERE VORHERIGE ZUSTIMMUNG D5RFEN DIESE SCHALTUNTERLAGEN WEDER V E R V I E L F Z L L T I G T ; NOCH DRIHEN Z U G 2 N G L I C H GEMACHT WERDEN UND SIE D5RFEN DURCH DEN EMPFÄNGER ODER DRITTE AUCH NICHT IN ANDERER WEISE VERWENDET WERDEN:

Art.Nr. 4292-2EL

^

^ C^DESC^® i^ H V D R A U L_IK — S Y S T E M E ' ^

DRAWN CHECK APPR.

DATE 12.02.01

NAME F.R

T I T L E

ANLAGEN - DECKBLATT / SUPPLEMENTARE SHEET

SH. '1

OF,

Fl

LI L2 L5 PE

SUPPLY 400V/50H2 460V/60HZ

Kl

717 PE

FiT

F2r

F3[

•Ix

"Ix

•Ix

o h-Q. X

HYDRAULIK UNIT EL-MOTOR 10,5kW

13,0KW

THERMISTERSCHUTZ MI

REV DATE NAME DESCR. OF REVISION ^ H V D R A U l _ I K - i « i r S T E M E CJ

DRAWN CHECK APPR.

DATE 12.02.01

NAME F.R

TITLE

HYDRAULIC UNIT MAIN (ÄCUIT _ ^

PROJ. JOB SH.2 OF 4

DRAW.-NO. 12450E2

REV.

L4

95

F2 r 96

S16 M

S17 E-\

L5

K1I Al

A2

-O-

rJL,X2

H1

MOTOR HYDRAULIK PUMP MAINS

o

E2

-o-

F2 A l

T°> Ti' T2 A2

XI 3

<>—Q

XI 4

F l

F2

F5

V i

1 i

I K

ANTI CONDENSAT HEATER

o I—

CL

X

ro

THERMISTER-SCHUTZ Ml

3 C- \ /I HA TC ncTC-OD r*cr D C \ / i c i r » k ' ^ H Y D R A U L I K — S Y S T E M E 1—^

DRAWN CHECK

DATE 12.02.01

NAME F.R

TITLE

HYDRAULIC UNIT CONTROL CIRCUIT

PROJ.

DRAW.-NO.

JOB SH.3 OF 4

1 94.SnF.^ REV.

Q1 2 4 6

'J-NAV^

Fl 35A

A

o o oö L I L2 L3PE

K1\

2 4

Ö Ö O O U V W PE

F3 2A

T1 100VA

115/230V

«OW-MV

F4 0.5A LU

L4 L5

SUPPLY 400V/50HZ 460V/60HZ

EL. MOTOR HYDRAULIC 10.5kW 13,0KW

CONTOL VOLTAGE 230V AC

REV DATE NAME DESCR. OF REVISION

C ^ i^ V—1H YDRAUI - IK -^ iK t -STEME LJ

DRAWN

CHECK APPR.

DATE 12.02.01

NAME

F.R

TITLE HYDRAULIC UNIT MAIM CIRCUIT

PROJ. JOB SH.4

OF 5 DRAW.-NO.

12450E4 REV.

hydraulic hose dimensions i [ hydraulic pipe dimemsions

IN ACCORDANCE TO CONTROL UNIT CHECK TURNING DIRECTION OF WINCH

mit Bedienrichtung abstimmer Drehrichtung der Winde

JLZ03-0401-04 at JINLING S.Y. JLZ04-0401 ^ 25 at JINLING SY. JD1100TEU-5 10 at Jiangdong SY. 313-315 of Aker Tulcea S.Y.

hüll no. JLZ04-0420-25 added hüll no. JLZ-0415, JLZ04-0417 - 19 added. hüll no. JLZ04-0416 added. hüll no. JD1100TEU-9/10 added. hüll no. JLZ04-409-14 added. hüll no. KA 401-405 of Kouan S.Y. cancelled hull no. JLZ04-0403+04 added length of Pas. 12a+12d changed hull no. JLZ04-0401/02 and KA 401-05 added hull no. JD1100TEU-5/6/7/8, JLZ04-0403-0408 added. hull no. added. ALTERATION

062/07 124/06 009/06 241/05 194/05 080/05 01.03.05

035/05 331/04 06.12.04

295/04 11.11.04 241/04

113/04 ALT. No.

14.03.07 23.06.06 13.01.06 17.10.05 13.07.05

25.01.05

30,08,04 23.04.04 s.T.

DATE

s.T. S.T. S.T.

S.T.

U.M.

U.M.

U.M.

U.M.

U.M.

EXECUTED EXAMINED

NAME

S t ü c k l i s t e Nr.: Bill of material no.: S 6 5 M H - 3 3 Gewicht: weight: 542

DRAWN:

EXAMINED:

SCALE:

1:25/1:10

22.03.04

/f5'.'^.^y

ERNST

HATECKEiP^ D-21703 Droctitersen . Germany

] 04143/9152-0 \M 04143/9152-40

j [email protected] ] www.hatecke.cte

DOCUMENT TITLE: p p y \ ^ ^ 5 ^

HYDRAULIC PLAN FOR HULL JLZ 01-0104-07 at JINLING S.Y.

DOCUMENT NO.:

D65MH-33


http://www.hatecke.cte

Nr.

no.

1

2 3 4 5

6 7a-r

8 9 10

11

12a-13

12 11 10 8 7 6 5 4 3 2 1

REV.

Anz.

piece

1

2

1

8 2 22

6

d 2

Benennung

usual name of part

power pack with switch board box 440V/60Hz

/

/

/

hydraulic cylinder

winch pipe dia. 16x2

screwed coupling T-screwed coupling pipe cleat with welding fitting and screw dia. 16

hose cleat with welding fitting and screw DN 12 hose dia. SN-12x

power pack foundation

Teilenr.

part ident. no.

Z27/200-110F -lO-GD-Ha

Werkstoff

material

3-

X5CrNi18 9 seamless

Continental AC/Uniroyal

F^ 70x15 ST 37

Bemerkung

note

Q=32 Itrs/min p=200 bar p=12,6kW tank capacity=90 Itrs

ZD/SGe 140/90-1178 Niro Cr 1/2" type: 07.02.08 look at chart on drawing G 16 PS T 16 PS RA 16

look at chart on d

Gewicht kc

weight

508 (oil incL)

(520)

(270) 10

/

3

2

vg. 10

(7) - JLZ03-0401-04 at JINLING S.Y. - JLZ04-0401-14 - 25 at JINLING S.Y. - JD1100TEU-5-10 at Jiangdong S.Y. - 313^315 of Aker Tulcea S.Y. ^ ^ . .

hvdr. cylinder changed to ZD/SGe 140/90-1178 hull no. JLZ04-0420-25 added hull no. JLZ-0415, JLZ04-0417 ^ 19 added. hull no. JLZ04-0416 added. hull no. JD1100TEU-9/10 added. hull no. JLZ04-409-14 added.


hull no. JLZ04-0403+04 added

hull no. JLZ04-0401/02 and KA 401-05 added hull no. JD1100TEU-5/6/7/8, JLZ04-0403-0408 added.

hull no. added. ALTERATION

071/07 062/07 124/06 009/06 241/05 194/05

080/05

035/05

295/04 241/04

113/04 ALT. No.

21.03.07 14.03.07 23.06.06 13.01.06 17.10,05 13.07.05

01.03.05

25.01.05

11.11.04 30.08.0^

23.04.0^ DATE

u.M. U.M.

S.T.

S.T.

S.T.

S.T.

U.M.

U.M.

U.M.

U.M.

S.T. EXECUTED EXAMWED

NAME

Gewicht: weighh 542 kg

DRAWN:

EXAMINED:

SCALE:

DATE:

22.03.04

2Z.<P7.^?-

NAME:

S.T

^ ^

ERNST

HATECKEiV"V FS

D-21703 Orachtersen . Germany

DOCUMENT TITLE: p p ^ 6 , 5 M 4 4 0 V / 6 0 H Z [

HYDRAULIC PLAN FOR HULL JLZ 01-0104-07 at JINLING S.Y.

04143/9152-0 04143/9152-40 email@Hateck£de wwwJiafecke.de

DCUMENT NO.:

S65MH-33

http://wwwJiafecke.de

DMF-07

OPERATION AND MAINTENANCE MANUAL FOR

WINCH TYPE: 07.02.08

ß b

ERNST i l

HATECKEI Survival- & Deck equipment

Boatyard Ernst Hatecke GmbH Am Ruthenstrom 1 21706 Drochtersen Phone: 0049-{0)4143-9152-0 Fax: 0049-(0)4143-9152-40 E-mail: [email protected] www.hatecke.de EDITION: 09/06



Index

1.1.1 In the interest of safety 1.1.2 Specification 1.1.3 Drawing 1.1.4 Part list 1.1.5.1 Weekly inspection 1.1.5.2 Monthly inspection 1.1.5.3 Annual thorough examination (ace. to MSC.1/Circ.1206) 1.1.5.4 5-Years overhaul & testing (ace. to MSC.1/Circ.1206) 1.1.6 Grease and service points 1.1.7 Oil chart 1.1.8 Orderform for spare parts

Additional: gearbox manual

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: [email protected]. www.hatecke.de




READ THIS MANUAL BEFORE USING THESE WINCH.. This manual contains important safety, operation and maintenance information. Make this manual available to all persons responsible for the operation, installation and maintenance of these winch.

A WARNUNG Do not use this winch for lifting, supporting, or transporting people or lifting or supporting loads over!

Always operate, inspect and maintain this winch in accordance with the Eropean Machine Derectives and any other applicable codes and regulations.

Make sure that their are minimum 3 layers wire rope on the winch drum before lifting!

Check the wire rope cleats on winch drum for tightness!

During operation of the davit be cautions with long links, snap hooks and counterweights!

DO NOT put your hands on snap hooks, long links, counterweights and falls with tension on this parts!

Always keep hands and feet clear near moving and rotating mashineryl

Boatyard Ernst Hatecke GmbH .Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-915240. E-mail: [email protected]. www.hatecke.de



1.1.2 Specifications winch type: 07.02.08

line pull second layer hoist lower

speed capacity hydraulic motor gearbox brake flow pressure

44 KN 48,5 KN 5 mtr/min dia. 16 in 2 layers MB 100 ED2065MN or RE 812TS 31.6 FL 635 or FL 75 22 l/nnin 170 bar

Boatyard Emst Hatecke GmbH. Am Ruthenstrom 1.21706 Orochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-915240. E-mail: [email protected]. www.hatecke.de



1.1.3 Drav\fing

CD •^—i

O

^ • 5 -

• < -

CD O) CD CL C O

_ c/) , . i _

m Z CL

Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-maii: [email protected]. www.hatecke.de



CD 3

> 3

®

Nr,

no

1 1A IB 1C ID 2 2A 2B 2C 2D 2E 2F 3 A

AA

5 5A 5B 5C SD 6 7 8 9 10 11

8

7

6 5

4

3

2

1

REV,

An2.

piece

1 1 1 1 1 1 1 2 6 6 6 6 1 i,

i,

1 1

2 1 2 1

'. /, 8 21,

12

Benenliuncj

usual name ut pari

wincti

winding drum

wincli sidelrame pl,20.0

winch sidetrame pl20.0 winch midtrame pl,150 bearing foundation bearina support pl,20,0

baseplate pi, 20,0

bracl<el pt,10,0 hex. screw, M20 x 60

hex nut M20 washer 20Fnm

bearing shall

rope clamp inner hexscrew M10x30

bearing-/drivefoi,indatiDn bearing/drivesupporf pl,20

baseplate pi, 20,0

holder f, hvdr,pipe pi, VO distance piece

bearing case

hex, screw M16 x 40 washer 16[nm

inner hex, screw, 1^12x40 hex screw, MIA x 55

hex, nut M14

Teielir,

pan (Tent no

DIN 933 - 88 DIN 934 - m8

DIN 125

DIN 912 - 8,8

DIN 933 - 88

DIN 125 DIN 912 - 88

Ü\H 933 - 8,8 DIN 934 - m8

WerkstDlt

material

SBST Grade A

SBST 523

SBST Grade A

SBST Grade A

SBST Grade A

SBST Grade A SBST Grade A SBST Grade A

SBST Grade A

ST, galv. ST, galv. ST, galv.

42CrMo4V

SBST Grade A

ST, galv. SBST Grade A SBST Grade A

SBST Grade A

XSCrNi 18 9 SBST Grade A

ST, galv.

ST, galv.

ST, galv. ST, galv.

ST, galv.

PDS.13 und 15 geändert.

Seilklemme auf Milleltlanscl'i versetzt

Pos. 3 (Passung g6) POS« SEr ON M u s 185; POSJA'SA SECTCNS COMPLETED Pos^ aut Radius 185 Desetzl.Pos2A*5A Schnitle erweiterl P0S,5 CHANGED.POSIÖ TAKEN Off Pas 9 qeanderl.PDS 10 tierausnenomf en MLASURL CHANCLO FROM 20 10 35 P0S.5D Maß von 20 aul 35 qeanderl P0S.5Ü HYDR0-M0TOP.GEAl?,BfiAKE,0vERCEN[ER TURNEO Hvdro-Motor.Gelrietje.Bremse und Overcenter aeöretit m. 1A LENGTH EHA(ÆEt),P(K,l8.Erø,!A Itv PLANES,P0S5A WJLDHG PPEPAR.SE. C-C POS lA Lance ueanderLPDSIBCÜiA.SA Flachen ar<iesn.PDS5A Kanlenvorher.SclYiill C-C

ALTERATION

Bemerl yng

nole

pipe 267,0 X 20,0

round 0200

D 15 X 15

INA PME60

153/05

62/99

135/98

ALT, No,

20,05,05

12,02,59

13,10,98

09,12,97

15,09,97

24,06,97

07,05,97

1612,96

DATE

U.B.

F.H.

D.t .

KKleine

IKleine

iKleine

KKleine

KKleine [XKUIED

Gewicht

weight

EXAMNED

nut

corresponding drawing : Vi66M-02

ÜRAWM

EXAM^Ü

SCAIE-

DAIEi

12,0996

fJAMC'

H. Kleine

ERNST

HATECKEBPV^

2a oû;)/9i5Z-o

ra ef?j(@H3'BCki? de

D-21703 Orothferseti. Germany

IXlEiUMENT TITLE: ^ r . r n , r ^,

FFA 5,/ •• 66M

STEEL PLAN WINCH TYPE 07,02,08

DXUMENT NÜ,:

s W66M-02

Nr.

no.

12 13

14 15

16 17 18 19 20

Anz.

piece

24

Benennung

usual name ol pari

washer M14

Teilenr,

pan ioeni, no

DIN 125 gear E02065MN

allemaltel, ^^^^ ^^ Q ^ 2 T S 31,6 F24 A25

hydro-drive ÜMSS10D or PARKER MB 100

hydraulic brake FL635 allemali.el, ^^^^ .^^^^ ^^^^^^ p, 75

adaptor tlanoe 1 overcenter 0MS-60L or PARKER MB 60L conneclion Hange FR065

shaft cover RDF065

hydraul ic lube PHD

Werksioll

malerial

ST, galv

Bemerkung

nole

BREVINl

Dynamic Dil

RANDER + CO BREVINl

Dynamic Dil

BREVINl RANDER * CD

RANDER * CO RANDER • CO

RANDER * CD

Gewictit kc

weigni

8 7

6 5

/, 3

2

1

REV.

Pos,13 und 15 geändert.

Seilklemme auf Mitlelflansch versetzt

Pos, 3 (Passung g6) POS,« SET ON PADllS 165 ; P0S2A.5A SECTIONS COMPLETED Pos,« aul Radius 185 aesel?I.Pos2A*SA Schnille erweiierl POS« CHANGEOPOS« TAKEN OFP Pns9 neandert,Pos10 herausoenommen MEASUISE CHAteO FROM 20 10 35 P0S5D MaB von 20 aul 35 neanoeri PDS,5D HYDRO-MOTOR.GEAR.BRAKE.OVEPCENTER TUONEO Hvdro-Molor Gelriet)e,Brefnse und Dvercenler qedrehl. Pas 1A LEIJGTH CIIANGB,P0S,«,C,0,2A.5A NEW PLANES,POSSA wElE« PfiEPAll,S£L E-C PDS 1A Lance qeSnderl,P0S,'B,ca2A,5A Flachen anqesD,P055A KanlenvorbecSchnill C-C

ALTERATION

153/05

62/99

135/98

ALT, No,

20,05,05

1202,99

1310,98

091297

15,0997

24,06,97

U.B.

F,H

U,M,

KKleine

iKleine

KKleine

07,05,97 HKleine

16,1296

DATE

KKleine cxEmiU) EXMMD

NMC

corresponding drawing : V^66M-02

DRAWN:

EXAMftU

SCALE:

DATE:

12,09,96

NAME

H. Kleine

ERNST

H A T E C K E M I V

W 0A1V3/91G2-0

FHM emM@HatBCXi?dp

0-21703 Dr-ocniersen , Germany

DOCUMENT TITLE: r - f * r - i ^ ^ K/

FFA 5,/ - 6,6M

STEEL PLAN WINCH TYPE 07,02,08

DOCUMENT NO:

S W66M-02

•Ü

(A

I (D

O ro b n


A Qualification level By supervision of a senior ships officer in accordance with the infonnation provided by the manufacturer.

1. Visual inspection of the winch

done remark

1.1.5.2 iVIonthiy inspection

A Qualification level By supervision of a senior ships officer in accordance with the information provided by the manufacturer.

m 1 .Visual inspection of the winch. 2. Operate the winch in order to sprincler all inner parts by oil.

done remark

Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: [email protected]. www.hatecke.de



•

1.1.5.3 Annual thorough examination (ace toMsci/circ 1206)




W i n c h : Examination and check for satisfactory condition and operation *

1. Hydraulic winch & winch foundation 2. Dynamic winch brake test with empty boat

' according to manufacturer's checklist (Doc. no.0301)

• Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: ÜÜ49-(0)4143-9152-40. E-mail: [email protected]. www.hatecke.de



1.1.5.4 5-Years overhaul & testing (ace toMsci/circi206)




W i n c h : Examination and check for satisfactory condition and operation *

1. Hydraulic winch & winch foundation 2. Dynamic winch brake test with 1,1 times the weight of the Lifeboat and ist full complemen(t

of persons & equipment, or equivalent Load.

#

* according to manufacturer's checklist (doc. no.0302)

Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-915240. E-mail: [email protected]. www.hatecke.de



mounting side SB. Side view view drive side SB.

3

> 3 30

(@

mounting side SB. Top view

¥.

S

c D

view drive side PS.

pressure port

Check oil level in the gear box of the winch Check foundation bolts of winch Change oil of gear box

yearly

• •

5 yearly

•

( j filling and breather plug

^ ^ oil level plug

^ ^ magnetic drain plug

1 1 Brake releasing plug

(r_j) brake breather plug

( U ) brake oil level plug

(W) brake drain plug

t 3 O 3"

•< (D O

b b 00

0>

o (S

0) (D <

5' (D •u O

(/)

1.1.7 Recomanded oil chart


OIL LIST FOR WINCH TYPE: 07.02.08

Ambient temperature -25° up to +50° C

No.:

01

02 03

04

05

APPLICATION POINT

hydraulic system

winch gear winch bral<e

grease points

RECOMMENDATION

ISO VG 22 HLP or VG 32 HLP ISO VG 150-200 ISO VG 22 HLP or VG 32 HLP grease with EP additives NLG! - class 2


QTY/SET

90

abt.2 abt.1

2,5

SET/SHIP

01

01 01

01

TOTAL/SHIP

90

abt.2 abt.1

2,5

Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-{0)4143-9152-40. E-mail: [email protected]. www.hatecke.de



1.1.8 Orderform for spareparts for winch type: 07.02.08

No.

1

2

3

4

5

6

7

8

9

10

Description of the part Page in manual: No.: Piece:

Building no. of boat:

Yard and hull no. of the ship:

Order address: r. Hatecke Service GmbH

Am Ruthenstrom 1

21706 Drochtersen

Phone: 0049-(0)4143-9152-60

Fax: 0049-(0)4143-9152-44

E-mail: [email protected]

vwww.hatecke.de

Invoice address:

Delivery address:

«

Requested time of delifery:

« Boatyard Ernst Hatecke GmbH .Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-915240. E-mail: [email protected]. www.hatecke.de


http://vwww.hatecke.de



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brewini power

irangiuifsåou D i v i s i o n o f B r e v i n i G r o u p

a wewtm PLANETARY PARTNER

Manuale di installazione e manutenzione Riduttori Gamma Base e serie "S"

Installation and maintenance manual - Standard series and "S" series gear units Notice d'installation et d'entretien - Réducteurs gamme standard et serie "S"

Installations - und Wartungshandbuch - Getriebe in Serienausführung und Serie "S" Manual de instalaciön y mantenimiento - Reductores gama base y Serie "S"

Manual de instala^äo e manuten^äo - Redutores Gamma Base e serie S.

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Lubrewana riduÉÉori PLANETARY PARTNER

1. INTRODUCTION: 1.1 How to consult the inanual 1.2 Scope of the manual 1..3 Warranty 1.4 General warnings 1.5 Reproduction and copyright restrictions 1.6 Revisions

2. TECHNICAL DATA: 2.1 Code description 2.2 Configurations 2.3 Versions of gear-coupling unit with active clutch safety systeni

3. SUPPLY CONDITION:

Page 32 Page 32 Page 32 Page 32 Page 32 Page 33 Page 33

Page 33 Page 34 Page 34 Page 36

Page 37

4. PACKING, HANDLING, RECEIVING, STORAGE: Page 37 4.1 Packing Page 37 4.2 Handling Page 37 4.3 Receiving Page 38 4.4 Handling the machine witliout packing Page 39 4.5 Storage Page 39

5. INSTALLATION: Page 40 5.1 General instructions Page 40 5.2 Installation instructions fortlange moimted gear unit Page 41 5.3 Installation instructions for foot mounted gear unit Page 41 5.4 Installation instructions for shaft moiuited gear unit Page 41

5.4.1 Mounting the reacdon arm on the gear unit Page 41 5.4.2 Installing the gear unit with an FS outpiu Page 41 5.4.3 Disassembling the torque coupling and gear unit Page 42 5.4.4 Installing the gear unit with an FP output Page 42 5.4.5 Disassembling the gear luiit with an FP output Page 43

5.5 Installing the gear luiit type "RPR" Page 43 5.6 Installation instructions for gear unit-coupler assembly with active clutch safety system Page 44 5.7 Accessory installation instructions Page 44

6. START-UP OF AUXILIARIES (BRAKES - CLUTCHES- ETC.): Page 44 6.1 Negative multi-disc brake Page 44 6.2 Disk brake Page 44 6.3 Installation instrucüons for gear unit-coupler assembly with active clutch safety system Page 45

7. LUBRICATION: 7.1 Gear unit lubrication

7.1.1 Viscosity

Page 45

Page 45

netmon

7.1.2 Additives Page 45 7.2 Expansion tank Page 46 7.3 Brake lubrication Page 47 7.4 Grease features Page 47 7.5 Lubricant table Page 48 7.6 Diagrams and oil checking with auxiliary cooling system Page 48

8. CHECKS: Page 49 8.1 First start-up checks Page 49 8.2 No-load tests Page 49

9. MAINTENANCE: Page 50 9.1 Routine maintenance Page 50 9.2 Oil Change Page 50 9.3 Unscheduled maintenance Page 50

10.MAINTENANCE OF AUXILIARIES (BRAKES - CLUTCHES- ETC.): Page 50 10.1 Procedure to replace disks or seals for muki disc brake Page 50 10.2 Proceduie to replace disc brake pads Page 51 10.3 Maint. proc. for hydr. power pack on gear unit-coupler assembly with active clutch safety

system Page 51

2.5.4 Installation instructions tor shafl mounted gear unit (see chapter 5.4) 2.5.4.1 Mounting the reaction arm on the gear unit (see chapter 5.4.1) 2.5.4.2 Installing the gear unit with an FS output 2.5.4.3 Disassembling tlie torque coupling and gear unit

2.5.7 Accessory installation instructions (see chapter 5.7)

2.6. START-UP OF AUXILIARIES (BRAKES - CLUTCHES- ETC.): (see chapter 6)

2.7. LUBRICATION: (see chapter 7.) 2.8. CHECKS: (see chapter 8.) 2.9. MAINTENANCE: (see chapter 9.) 2.10. MAINTENANCE OF AUXILIARIES

(BRAKES - CLUTCHES- ETC.): (see chapter 10.) 2.11. SCRAP DISPOSAL: (see chapter 11.) 2.12. PROBLEMSAND RELATIVE SOLUTIONS: (see chapter 12.) 2.13. LEGISLATIVE STATEMENTS: (see chapter 13.) 2.14. SERVICE NETWORK: (see chapter 14.)

Page 41 Page 41 Page 52 Page 53 Page 44

Page 44

Page 45

Page 49

Page 50

Page 50

Page 51

Page 51

Page 159

Page 161

11. SCRAP DISPOSAL: 11.1 Machine demolition 11.2 Fxology information

Page 51

Page 51

Page 51

12.PR0BLEMS AND RELATIVE SOLUTIONS: Page 51

13.LEGISLATIVE STATEMENTS:

14. SERVICE NETWORK:

Pagel59

Pagel61

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Installation and maintenance "S" series gear units 2.1. INTRODUCTION: (see chapter 1.) Page 32 2.2. TECHNICAL DATA: (see chapter 2.) Page 33 2.3. SUPPLY CONDITION: (see chapter 3.) Page 37 2.4. PACKING, HANDLING, RECEIVING, STORAGE: (see chapter 4.) Page 37 2.5. INSTALLATION: Page40

2.5.1 General instructions (see chapter 5.1) Page 40 2.5.2 Installation instnictions for flange mounted gear unit (see chapter 5.2) Page 41

ridiMoti rittutiori

1. INTRODUCTION: Brevini Riduttori S.p.A. would like thank you for choosing one of its products and is pleased to include you among its preferred Customers. Tlie company hopes you will be satisfied when using the gear unit.

1.1 How to consult the Manual It is easy to consult this manual by referring to the table of contents which can be used to find the subject of interest very quickly. The chapters are organized into a hierarchical structure that makes it easier to find the required intbrmation.

1.2 Scope of the IManual This manual provides the Gear unit user with all the information necessary to ensiue correct installation, use and maintenance in compliance with the safety restrictions set forth by current standards. To understand this manual even better, we would like to describe the following terms used in the document:

HAZARDOUS AREA: area within or in proximity to the machine in which the presence of an exposed person represents a risk to the safety and health ofthat person.

EXPOSED PERSON: any person who is inside all or part of a hazardous area.

OPERATOR: person assigned to install, operate, adjust, perform routine maintenance and clean the macliine.

SKILLED TECHNICIAN: a specialized person who performs unscheduled maintenance or pairs requiring special knowledge of the machine, its operation, safety devices and relative operating methods.

m ATTENTION: Operator accident-prevention standards

a I WARNING: The machine and/or its parts may be damaged

o. I PRECAUTION: Additional information regarding the operation being carried out NOTE: Provides useful mformation

For any doubts or if the manual has been damaged or lost, please do not hesitate to contact the BREVINI RIDUTTORI S.p.A. Technical Service Department.

1.3 Warranty Conditions BREVINI RIDUTTORI S.p.A. warrants that its products shall be free from defects for a period of 12 months from the date the product is shown to have been placed in operation by original user and/or in any case tor a period of maxunum 18 months from the date of shipment. The warranty shall not be valid if the defect or not conformity will prove to be depending on not correct on not suitable applications of the product, or if the product has been luicorrecdy placed in operation. Tlie warranty by BREVINI RIDUTTORI S.p.A. is expressly limited to the repair or replacement of the detected product, which is returned our factory after notification of failure, and thereafter if the product is found by BREVINI RIDUTTORI S.p.A. to be, in fact, defective. BREVINI RIDUTTORI S.p.A. shall not be liable for any damages, either material or economic, resulting from or caused by any defects. Brevini Riduttori S.p.A. will only be liable for repair or replacement of the product. The gearbox is intended to be used in suitable environment and for suitable applications in appliance widi what has been foreseen at the moment the project has been studied. Improper use of the gearbox is forbidden. Any change or replacement of machine parts, which has not been authorized by BREVINI RIDUTTORI S.p.A., may represent an accident risk and therefore releases the manufacturer from any civil or penal liabilities, and makes the warranty unvahd.

1.4 General warnings Personnel must be informed about the following subjects regarding macliine operating safety: - Accident risks. - D.P.I, devices designed to ensure operator safety (individual protection devices: goggles, gloves, hard-hat, etc.). - General accident-prevention rules or those set forth by international directives and by the laws of the country where the machine will be used. When dehvered, check that the Gear unit has not been

damaged during transport and that any accessories are complete. - Before standing to work, the operator must be familiar with machine features and must have read this entire manual.

1.5 Reproduction and copyright restrictions BREVINI RIDUTTORI S.p.A. reserves all rights. It is prohibited to reproduce all or a portion of the structure and contents of this manual, unless expressly authorized by BREVINI RIDUTTORI S.p.A.. Furthermore, it is prohibited to store such information on any type of support (magnetic, magnetic-optical, microfilm, photocopies, etc.).

1.6 Revisions Subsequent revisions of the manual will be issued as a result of machine fimctional changes or replacements.

2. TECHNICAL DATA: Each gear imit is supplied with an identification name-plate and a manutacmre's declaration (as per the enclosure II B) which have been prepared according to EEC dhective 392 and subsequent amendments. The identification nameplate contains the main technical data regarding tlie functional and construction features of the gear unit. Therefore, it must always be visible and undamaged.

1) Reduction ratio 2) Serial niunber 3) Type or gear unit/Gear tmit output 4) Year built 5} Gear imit input 6) Gear unit weight

(i> b =

bwewinL widfuÉÉon=

REGGIO EWUA-ltoly 42100 Vh U.Degcla,14 Tel.0522-9281

TYPE OUTPUT

S.N. mpi

DATE I r Ä: ^

lew* 'ml

::s2^^. ifåA.

IA Code description

Gear unit family I

2.2 Configurations

Hnii/onlalpoiilion

IU0-II90 ]^ll-8flll ScnVI'OL

\'i:rlical posiünn

om 1190 I'O-SOll hLfi.' I ' l l l ,

V

B3C

lUO Q O l LEVEL PLUG

B 3 A B 3 B V 6 B

O BREATHER END FILLING PLUG

• )

l lnM'i i i i l il piio|llii<i ^ l l ' K il pi f l ' l l i l l

8 3

B7

B3C

B7B

B3D

B7A

BSB

B6

B8

B7D

B8C

B3B

B6A

B7C

V5 V6

V5B

V5A

V5D

I I

B8D V5C

V6B

V6A

V6D

fl620 - fl635 BRAKES

V5 ^ V6

^ MAGNETIC DRAIN PLUG

Q OIL LEVEL PLUG

5" AND 9" BRAKES

k:ui B 3 ^ V5 ^ V6

O BREATHERAND FILLING PLUG

• BRAKE OPENING CONTROL COUPLING

il if I It „_i L !'ik. L_ 3. I.A.I J,

23 Versions of gear-coupling unit with active clutch safety system

( ~ ) BREATHERAND FILLING M ^-^ PLUG ^ ^ OIL LEVEL PLUG (o^

0 CIRCUIT PRESSURE GAUGE SOCKET (1/4 Gas plug)

I MAGNETIC DRAIN PLUG

SOLENOID VALVE CONTROL SOCKET

3. SUPPLY CONDITION: The exterior of the gear units are painted with a synthetic epoxy primer ("RAL 5010" blue), unless otherwise indicated in the contracts. Such protection can withstand normal industrial environments, including outdoor sites, while additional synthetic top coats can also be applied. If the machine will be used under particularly aggressive environmental conditions, special types of paints can also be applied. The machined external parts of the gear unit, such as the ends of the hollow and non-hollow shafts, support surfaces, spigots, etc. are protected with rust-inhibitor oil (tectyl). The internal parts of the gear unit casings and drives are also protected with rust-inhibitor oil. All the gear units, unless otherwise indicated in die contracts, are supplied without lubrication (as indicated by a special adhesive sticker attached to the gear unit to notify the user of such a supply condition).

4. PACKING, HANDLING, RECEIVING, STORAGE: 4.1 Pactdng

4.2 Handling Note: the weight shown on the nameplate does not include any accessories: such as brakes, motor flanges, wheel flanges, etc.; consequently, to obtain the gear unit + accessories total weight, please add, depending on the gear unit size, a max approximate extra weight of 40 kg. for input accessories; for output accessories, please calculate a max value equal to approx. the 8% of the gear unit weight depending on the unit size.

To move packages, use lifting equipment that is suitable for the type of packing and for which the capacity is indicated on such equipment.

I Brevini Riduttori S.p.A. products are packed and shipped in crates or on pallets, depending on the specific case. - All Brevini products, unless otherwise indicated in the contracts, are packed with wrapping that can withstand normal industrial environments.

Do not tilt or nun the package upside down while lifting or during transport.

•

WM

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•;*;; '•-f - X ^"'•-ÄilfiSlSS-'":'';

•

If the packages are unloaded from a fork-lift truck, make sure the weight is balanced on die forks.

I <S' si «rj'tpt'ffr I?:T j : t*:*;f if _

If necessary, place wooden wedges under the package to make lifting easier.

If die packages are unloaded with a hoist and, in any case, with a hook, make sure that die load is balanced and for slinging use lifting accessories that are legally certified. For packages shipped on pallets, make sure that the lifting accessories do not damage the machine.

While lifting and positioning the package, avoid any violent impacts or bumps.

4.3 Receiving

When the Machine is receiving, make sine the supply corresponds to what is specified in die order. Also check that the package and its contents have not been damaged during tiansport.

m-I The s&ap holding the product to the packmg is sharp. It may hit the operator while the product is being unloaded. The packing must be eliminated as follows: - use a pair of shears to cut the straps (warning: the ends may hit the operator) - cut or remove the external packing - cut the internal strap (warning: the ends may hit the operator) - remove the machine from the pallets. If die machine has been damaged or if tliere are any defects or missing parts, immediately notify the 13RE-VINI RIDUTTORI S.p.A. Service department; Tel. ++.19-522-9281, Fax ++39-522-928200/928300.

4.4 Handling the machine without packing

W

m, Before removing die machine from its packing make sure it is solidly attached to die liftmg accessories so that it cannot slide or flip over. Before handling the machine, remove die wood blocks inserted in the packing to keep it stable dmng shipment. Lift the machine making sure the load remains balanced during the various operations.

4.5 Storage

Us 111 \ 3*11. _ - - ,

If the product must be stored for more dian 2 months, do the following: - Protect the shafts and the spigots with a film or grease and/or nist-inhibitor liquids - Completely fill the gear unit and any muhi-disk brake with suitable oil (see tparagraph 7.4) -Store the machine in a cool place at a temperature ranging from -5°C to +30°C - Protect the packages against dirt, dust and moisture.

NOTE: For extended storage of more than 6 mondis. the rotating seals will no longer be efficienl. It is recommended to check them periodically by turning the internal gears by and rotating the input shaft. For a negative muhi-disk brake, release the brake by using a hydraulic pump or similar device (see paragraph 8.1 for the brake opening pressure). It is recommended to replace the gaskets when the machine is started.

. - _ P ^

^:!!.L!..l!..l!,.!b.,..*S.Ji. ' ' •• ' •• ^l N ' vm ii 11 'i 't F Ü i' !it"!l l(i II

• Do not stacks pieces on top of each other. • Do not walk on or place pieces on top of the package.

• Do not store any material mside the package.

• Deep the package away from any passage areas.

- If possible, insert wooden wedges between the package and the floor.

5. INSTALLATION:

5.1 General instructions Install the Product carefully following the steps listed below: - When installing the Gear unit, make sure the oil, breather, level and drain plugs are in the correct position. Their position will vary according to the assembly position (see paragraph 2.2 Configurations). _ If the gear unit is supplied in the multi-disk brake configuration, make sure that the brake oil, breather, level and drain plugs are in the correct position?. Their position will vary according to the assembly position (see paragraph 2.2 Configurations). - The brakes in general must be correctly comiected to their specific control circuits and, for hydraulically controlled brakes, they must be bled like the hydraulic circuit. - When installing RPR or MDU series gear units, be very carefiil not to damage any grease pipes or those used to empty the oil in the gear unit (located on the side of the gear unit suppon). They should be positioned so that it is easy to access the grease gun and any oil expansion tank (during installation protect the pipes and the tank). - The Gear unit is normally supplied with a flange for couphug die electric, hydraulic and air motors. - The customer is responsible for installing suitable guards for the input shafts, as well as coupHngs, pul

leys, belts, etc., according to the ciurent safety standards in force in die country where die machine is used. - For Gear units installed outdoors, use rust-inhibitor paint and protect the oil guard and relaUve sliding guides with water-repellent grease and provide protection against bad weadier. Note: BREVINl RIDUTTORI S.p.A. advises against filling its products with oil prior to installation

5.2 Installation instructions for flange mounted gear unit -They must be attached to a rigid structiu-e with a clean support surface that is perpendicular to die drive axis. - The spigots and die coupling surfaces of the gear unit must be clean without any dents. Tlie checks described above are particularly important ensure perfect alignment between die driven shaft and die output shaft of the gear imit. This is even more important tor gear units with a splined fermale output shaft which cannot bear any radial or axial loads. - Lubricate all die spigots of die gear unit and die housing seat with grease or oil. - After having inserted the gear tuiit mto its housing and having placed it in the correct position, fit the reference pins in their seats, then tighten die attachment bolts (recommended minimum class 8.8), applying torque as indicated in the table "torque setüng" paragraph 8.1, making sure that such torque settings are compatible with the other parts (nuts and/or strucUue).

NOTE: It is recommended to use class 10.9 or 12.9 bolts where the application involves severe impacts, frequent stops, starts, reversals or when it exceeds 70% of die maximum tolerated torque.

NOTE: Diuing installation, for right angle gear units with a male input shaft, the input axis may not be in the ideal position. To solve this problem, it is recommended to do the following: - for connections using couplings which can compensate for the misalignments, measure die existing misalignment, check the acceptable misalignment from the couphng and, if die value is greater, shim the motor to obtain the acceptable clearances - for a connection with mechanical devices that caimot be used to compensate for the clearances, align die mo

tor using .shims.

5 J Installation instructions for a foot mounted gear unit - Make sure diat die assembly feet rest on a flat siuface. If not, shim diem so that all are level. - An improper support for the feet may break die unit. - Attach the unit using bolts with a minimum class 8.8 tightened at the torque settings indicated in paragraph

5.4 Installation instructions for a sliaft mounted gear unit Particular attention is required when installing these gear units, therefore follow the mstructions described below.

5.4.1 Mounting the reaction arm on the gear unit - Check that spigots of the gear imit and die reacdon arm are clean, not dented and that there are no traces if paint. - Lubricate the couplings and insert die reacdon arm on the gear imit spigot, dien insert any dowels. - Attach the reaction arm using minimum class 8.8 bolts. - It is recommended to use class 10.9 or 12.9 bolts where the application involves severe impacts, frequent stops or starts, reversals or when it exceeds 70% of the maximum gear unit torque. - Check that the reaction arm anchor system does not lock the gear unit, but allows it to move fi-eely in space in order to absorb the movements imposed in it by the shaft. For torque settings refer to the table "torque setting" paragraph 8.1, making svu-e diat such settings are compatible widi die odier parts (nuts and/or attachment suiic-tures).

5.4.2 Installing the gear unit with an FS output

NOTE: the connection couplings are supplied ready for installation, dierefore they need not be disassembled prior to the initial installation.

- Slightly unscrew three bolts of die torque coupling located at 120° undl die mner ring can just be turned by and (excessive tightening might deform the inner ring). - Insert it above the shaft of the gear unit whose external surface was previously lubricated.

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L'> Is p. m " lU i j I Ei •' ^ » 'Sp.

i:dli£]:l;31.J:L!l. mtt. ' 1

wm - degrease the internal surface of the gear unit shaft and the machine shaft. - Insert the gear unit on the machine shaft or vice versa (excessive axial force should not be necessary). - Position the center line of the coupling on the center line of the useful section of the machine shaft (see fig. No. 1). During this operation refer to dimension "a" which will vary according to the size of the coupling, as indicated here in the table No. 1 - Use a torque wrench and gradually tighten all the bolts in the coupling in a circular direction (not diametrically opposed) until they are fiiUy tightened at a torque setting corresponding to the value reported in the table No. 1. - Check that the 2 rings remain concentric and parallel while tightening, keeping in mind that the maximum tolerated parallelism error is 0.25-()..35% of the external diameter of the couplings.

NOTE: Excessive tightening may permanently deform the inner ring, thus refer to the torque settings indicated in the table.

5.4.3 Disassembling the coupling and the gear unit - Gradually release the attachment bolts in a circular direction. Initially each bolt must be backed off only a quarter of a tum to prevent the attachment elements from seizing and to avoid tilting. - Remove the gear unit from the driven shaft. To do this a hole on the gear unit shaft can also be used to pump oil under low pressm-e so that it can be pulled oif gradually. - remove the coupling from the gear unit shaft.

Table No. I

Disk type

SD62M

SDIOOM

SÜ 125 M

SD140M

SD 165 M

SDI75M

SDI85M

SDI85H

SD220H

SD240H

SD280H

SD340H

SD 390 H

dsh.

50

75

90

100

120

130

140

140

165

180

220

260

300

)iraensiun!

dxD

62x110

100x170

125x215

140x230

165x290

I75X.300

185x330

185 X.330

220 X 370

240 X 405

280x460

340 X 570

390 X 660

112

29

43

52

58

68

68

85

112

134

144

172

200

212

11

10

12

12

10

8

8

10

15

20

15

20

20

24

BolB

Type

M6x25

M8x35

M10x40

M12x45

M16x55

M16x55

MI6x65

M16x80

MI6x90

M20xlOO

M20xl20

M24xl20

M24xl40

Ma

12

29

58

100

240

240

240

240

240

490

490

820

820

a

17

30

35

40

45

45

55

55

67

72

87

102

120

Ma = Torque setting Nm

5.4.4 Installing the gear unit with an FP output - Insert the stop ring, if provided, in its housing on the shat^pos.n"!. - Grease the seats of the o-rings pos. N°2 and 3 on the cover püs.n°4; tlien insert tlie respective o-rings in their seats; then insert the cover on the shafl. - Insert the other stop ring pos.n°5, then the tongue pos.n°6 in their respective seats on the shaft. - Assemble the torque arm pos. N°7 on the reduction gear. ^ - Suitably Iti-b r i c a t e both the shaft and its seat (re-d u c t i 0 n " gear fern a 1 e shaft); then carry out coupling of the shafl and the reduction gear (do not force). - Place the cover pos. n°4, clamping it wiüi die screws and the respective dowty wa.shers pos. u°8 (supplied with accessories), taking care to gradually screw the screws in

a circular direction (not in the diametrically opposite direction) imtil completely clamped using a torque given m the "tightening torque" table, paragraph 8.1 (screw classes 8.8), by means of medium loctyte. - Assemble all die other screws and relative dowty washers pos.n°9 (omitting one at the top),insert ftu'ther lubricant in the hole which has been left open; then assemble Ulis last screw as well to thus close the coupling in a lubricated hermetic chamber, by means of medium loctyte.

5.4.5 Disassembling the gear unit with an FP output - Whilst suitably supporting the reduction gear free the torque arm. - Remove the screws pos.n°9 replacing them with longer screws, suitable for the room available. - Remove the screws pos. N°8; then screw the screws pos. n°9 gradually in a ckcular direction (not in the diametrically opposite direction) until the reduction gear is unlocked.

WARNING: the dowty type washers in pos. N°8 and 9 cannot be reused when reassembling the reduction gear after repairs or any other type of operation; diey must always be replaced with new washers.

5.5 Installing the gear unit type "RPR" - The units must be fixed to a rigid structure and the supporting surface should be thoroughly clean, with no trace of soldering waste, at right angles to the driving axes. - The centring and coupling surfaces of the gear unit must be clean and dent free. The measures described above are essential for ensuring perfect meshing between the gear pinion and die fifth wheel. Fiflh wheel constructors usually mark diree teeth of the fifth wheel green; the point of major ovality of the pitch 0 used for positioning the gear unit.

ATTENTION It is advisable to contact die constructors of the fiflh wheel direct if there are no coloured (usually green) teeth on the fifth wheel, or other distinguishing marks.

If the gear unit is of the type with a rest and an eccentric to regulate die clearance between die pinion and the ring gear, then there should be a notch on die fiflh wheel (.see fig.) which indicates the pomt of major eccentricity, cor

Painted leetli I

responding to die maximum meshing reached between the pinion and the fifdi wheel; whether die gear unit is placed inside or outside the fiflh wheel, (see fig.) The value of clearance between the sides of die pinion teeth and the fifth wheel, is obtained by multiplying the value of the teethmg module by the two fixed values of 0.03 and 0.04.

Example: for teething of m=20, simply multiply 20 x 0.03 = 0.6 and 20 x 0.04 = 0.8, to obtain two values of 0.6 and 0.8; diis means that the clearance of tlie sides of the teetli for perfect meshing must have a value which falls between 0.6 and 0.8 mm., thus die gear unit is placed with die notch in correspondence with the three coloured teeth, (usually green), of the fifth wheel, tum die gear unit to move it clo.ser to the fifth wheel, inserting die shim value as resulting from the described calculation in the sides of die teedi which are meshed widi the fifth wheel or the pinion; dien clamp the gear unit.

Check the clearance between the sides at different points around die pitch circle of die fiflh wheel a second time.

After having positioned the gear unit and checked die situation, tighten the fixing screws (minimum recommended class 8.8) by applying a tightening torque as shown in the "tightening torque" table, paragraph 8.1, making sure dial they are compatible with their counterparts (nuts and;' or fixing structiue).

ATTENTION when positioning gear unit with eccentric, all the holes for oil level, load and discharge, engine controls, laminated brake etc .etc.- will be moved out of place with respect to the "BREVINl" drawings.

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5.6 Installation Instructions for gear unit-coupler assembly with active clutch safety system

When preparing to install this kind of assembly, die first thing to remember is that the whole internal drive is held in place by the clutch on the assembly. Consequently, if the output shaft doesn't rotate, it will be difficult to install the assembly in its housing if the gear unit fitting holes do not coincide with the holes in the interface on the vehicle itself To Ime up these holes, you have to release die clutch so that the output shaft can rotate freely. To do this, use a hand-operated hydrauhc pump, as the clutch can be opened with a minimum pressure of 3 to 5 bar, then proceed carefiilly with the steps listed below: (for the location of die symbols see chapter 2.2.1) - lift the assembly with suitable lifting equipment and fit the gear unit output shaft into its housing on the vehicle, keeping it supported all the ume and trying to mate the fitting holes in die assembly with those in the vehicle. - connect the hand-operated hydraulic pump to the assembly via the 1/4 gas hole - power up (12 Volt) the solenoid valve on the on the power pack so that the valve is excited. - Using the pump, increase the pressure on the assembly slowly and gradually it can be rotated by hand.

ATTENTION: if the solenoid valve is not excited, the hvdraulic pump simply pumps die oil into the assem-bly,

- at this point, the assembly can be rotated easily so as to align the fitting holes widi the interface on the vehicle; this done, insert the pins (if needed) and attachment bolts (recommended minimum class 8.8), applying torque as indicated in the "torque setting" table, paragraph 8.1, making sure that these settings are compatible with the nuts and/or structure. - if Ulis operation is performed with the gear unit output shatl not inserted in its housing, it will be very difficult to get the assembly fitting holes in phase widi die shaft spline, and die only way to set the timing will be by trial and error. - After fixing the assembly in position, cut ofl" the cui-rent to the solenoid valve, disconnect the hand-operated hydraulic pump and refit the 1/4 Gas plug.

5.7 Accessory installation instructions

Motor Assembly: While assembling the gear unit on the motor, the coupling must be lubricated with a thin layer of grease or with a no-grip lubricant. Carefully insert the motor shaft in to the coupling and make saie that die motor spigot perfectly matches the gear unit spigot. After checking Üiat the motor is properly centered, tighten all the attachment bolls applyng die torque indicated in the table "torque setting" paragraph 8.1. Accessory Assembly: To mount pinions, pulleys or couplings, use suitable equipment avoid seizing. As an alternative, heat the piece to80'=-100''C. Lubricate the grooves with a thin layer of grease or a no-grip lubricant and tighten attachment bolts applyng the torque indicated in the table "torque setting " paragraph 8.1.

6. START-UP OF AUXILIARIES (BRAKES - CLUTCHES- ETC.):

6.1 Negative multi-disk brake NOTE: The negative multi-disk brake is used only as a parking brake, or in special situation as an emergency brake. - Connect the fittings of the system hydraulic chstiit to the brake control hole (see paragraph 2.2 "configuration") of all the gear units with these features uistalled in the system. - Pressiu'ize the hydraulic circuit and then bleed all brakes. Slightly unscrew the brake control fitting, and maintain pressure until only oil is expeloled without any air. Then re-tghten die fitting.

6.2 Disk brake - Connect the fittings of the system bralce circuit to tlie brake control hole "A" (see fig. No. 2) of the brake clamp located on the gear unit for all the gear units with diese features installed in the system. Bleed The brakes after mjecting oil into the circuit (remove the air from the brake circuit). -At least two persons are needed to carry aout this operation. NOTE: For the bleeding operation it is recommended, after having removed the rubber guard of die bieder val

ve "B", to attach a piece of rubber hose with a lenght of about 20 cm to collect any oil into a can Cwich should not be doumped in the environment since such oil is a major pollut-tant).

- Slightly unscrew (1 turn) die bleeder valve "B" and keep activating the brake control until only oil without any oir is expelled from the vlave. Immediatelly close the valve and release the brake control. NOTE: if oil not expelled the first time the brake control is aetived close the bleeder valve and release the brake control. Then open the valve again and activate the brake control and continue in this manner until only oil is expelled. - Repeat this operation for all gear units with these features installed in die system, then top-up die oil in the brake circuit.

6.3 Gear unit-coupler assembly with active clutch safety system

- the hydraulic pump used by the power pack is reversible, thus guaranteeing the same constant pressure at all times, regardless of the direction of rotation

ATTENTION: the pressure relief valve on the power pack has been pre-set to the right pressure (25.S ± 2 barl It is absolutely forbidden to alter Üüs valve setting.

- power up die solenoid valve with direct ciurent (12 Volt) via die socket on the power pack (see chapter 2.2.1 for location of symbol)

- to prime the hydraulic pump (after filling the assembly with lubricating oil), simply start the coupler PTC rotating, as the pump is self-priming.

7. LUBRICATION:

7.1 Gear unit lubrication The Brevini gear units are supplied without oil, therefore the user must the lubricant according to what is indicated in the table shown in paragraph 7.4.

Basic oil specifications The basic parameters of the selected oil are: - viscosity at nommal operating conditions - additives The oil must lubricate the bearmgs and the gears and all these components work mside die same box, In different operating conditions. We will look at diese parameters one by one.

7.1.1 Viscosity Nominal viscosity is referred to a temperature of 40 °C, but rapidly decreases with an increase in die temperature of the gear unit. If the operating temperature is between 50 "C and 70 °C, a nominal viscosity can be chosen according to the following guide table, choosing the highest viscosity if the highest temperature is foreseen.

n,[rpm]

>20

<5

<5

50 °C

VG150

VG220

VG320

70 °C

VG220

VG320

VG460

7.1.2 Additives In addition to the normal antlfoaming and antioxidant additives, it is important to use lubricating oils with ad-dhlves tliat have EP (extreme-pressure) and antiwear properties, according to ISO 6743-6 L-CKC or DIN 51517-3 CLP Clearly, therefore, products with stronger EP characteristics will have to be found for slower gear unit speeds. It should be remembered diat die chemical compoimds replacing hydrodynamic lubrication are formed to die detriment of the original EP load. Therefore, with very low speeds and high loads it is irnpor-tant to keep to the maintenance intervals so as not to diminish the lubricating characteristics of die oil excessively

mm§ I t! t.1 ll !i I * ' .ia,.J..e.fe I -g^—ir^ ^-j ^-^T-J-

- 1 i ^ 3 - > f

h L i r. iiili a. a. 45

..1?l ll% •

Checking the oil with non-forced lubrication If the gear unit is fitted horizontally, the oil level should be at the centre if proper lubrication is to be guaranteed (see fig. 7).

Fig. 7

For applications with a very low output rotation speed (n, < 5 rpm) it is advisable to fix the level at a value higher than 50-100 mm (see fig. 8). To check the oil level, simply use a transparent tube, positioning it as shown in fig. 8. If the output speed is extremely low (n < 1 rpm), or if long gear unit downtimes are foreseen, it is advisable to fill the entire casing. In this case, a special "expansion tank" must be fitted.

Fig. 8

If a gauge is titled tor checking the level visually (or by means of an electrical signal), this must be fitted as shown in the diagram in tig. 9. Position die breather cap above the level mdicator, using a tube of the right length, connecting the upper (empty) part of the gear unit to just below the breather This will prevent oil from spilling out.

Fig. 9

Filing and level - The gear units are equipped widi oil level, breatlier, filer and drain plugs and their position changes according to the installation configuration. - Check the exact position of the plugs using the diagrams on paragraph 2.2 "configuration". - Unscrew the level-filler plugs, put oil into the Gear unit and when tliis oil flows out of the level hole, replace the plugs. - In the RPR or MDU series, one of the support bearings must be lubricated with grease, using the grease gun located above the gear unit attachment tlange, and using a generic type of grease with the features indicated in paragraph 7.3. - The lubricant oil used in the gear imit-coupler assembly with active clutch safety system is the same as the oil used in the clutch pump. - Turn the gear luiit a few times to eliminate any air pockets and then check the various levels.

7.2 Expansion tank

ATTENTION: make sure the expansion tank is installed higher than the top part of the gear unit.

For apphcations with an expansion tank, do the following: (see figure 3). - Remove the plug "A" - To enhance gear unit ventilation (only diu-ing the fill

ing phase) it is also possible to remove one of the lop of the gear unit. -As the oil rises to the top of the open plug in the top part of the gear unit, replace die plug. - Continue filling until the oil reaches the min. visual level plug on the tank which should not to be exceeded to provide space for the volume of the hoi oil to expand. - Replace the plug. - With the gear unit running under steady-state thermal conditions, and the oil at its maximum expansion temperature, never exceed the max. level. - Run tlie gear imit for a few minutes to eliminate any air pockets, then check the various levels.

Vertical in-line fitting and right-angled fittiii(! with expansion tank

X A.

H max

^ min

n"3

7.3 Brake lubrication

Multi-disk brake - The Brevini multi-disk brakes are supplied without oil. - The user must select die lubricant features. - To lubricate the multi-disk brake unit, Brevini Ridut-tori recommends using mineral oils with enhanced heat and aging resistance and viscosity ISO VG 32. with a viscositv index greater than or equal to 95. - Hydraulic oils are suitable, in general.

Multi-disk brake filling and level - The multi-disk brakes are equipped with oil level, filler and drain plugs and their position changes according to the installation configuration. - Check the exact position of the plugs using tlie diagrams on page 7. - Unscrew the level/filler plugs, put oil into die brake and when this oil flows out of the level hole, replace the plugs. - Turn the brake a few times to eliminate any air pockets and then check the various levels.

Disk brake - Disk brake do not require any lubrication.

7.4 Grease features

Type of soap:

Consistency: Base Oil:

Additives: Viscosity index: Pour point:

stearaie hydroxide lithium 12 or equivalent NLGl No. 2 Mineral oil widi viscosity from 100to320cSTat40°C Rust inhibitors 80 Minimum -10° C maximum

r,|j.-;f I -ipitii ~^: '~n m a i m v-' •'! h'ii li P' ' f'~ i'-'' I'^^r.'.ZT',..'. .HM' 1. iry.k,K...LL,.i.fc.-:,-, f'r^-".....!"...y^..li!!,.!M£[l 1.1.,}=. ;i.li...!liljil..i I j ix j . . .f.y...! I...?..:

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7.4 Lubricant table

Agip

Aral

Bf Caflrol

Cepsa

Dea Elf Lub.Marillt:

Esso

Fachs

Fachs Lubritcch

Klüher

Mobil

Nils

Omv üptanol

Q8 Repsol

Shell

Texaco

TotalfinaElf

Tribol

Labiicanl

Agip Aral

BP Castiol

Cepsa

Dea E!f LubMaiine

Esso

facLs

fuchs Lubritcch

KIQber

Mobil

Nils

Omv Optimol

Q8 Shell

Texaco

TülaltinalU

Tribol

Mineral

ISO VG 150

Blasia 150

DrgolBGlSO

Encrgol GR-XP 150

Alphaniax 150

EagrajiajesHPlSO

F a l c i m a P l J O '

Epoija 1 150

Spartan EP 150

Kcnep Compound l(J4

GcaimMcraPlSO

KlüheroilGEM 1-150

MobilgeaiXMPlSO

Ripa'ss EP 150

Gei'llSTISO

OpiigearBMISO

Goya NT 150

Siiper Taiiio 150

Omala 150

Meropa 150

CaiteiEf 150

1100-150

ISO VG 220

Blasia 220

Digol 6 0 2 2 0

EncrgolGR-Xf 150

Alplianiax220

£ngTanajesHP220

falcon Ci f 220

Epoiia Z 220

Spartan EP 220

Rcnqi CoinpouDiJ 1(J6

GeannastcrCLP220

Klüberoil OEM 1-220

Mohilgcar.KMP220

RipicssEP220

Gear HST 220

OpligearBM220

Goya NT 220

Saper Taaro 220

Ülllala220

Meropa 220

Carter EP 220

1100-220

ISO VG 320

Blasia 320

Drgol BG 320

Eneigol GR-XP 150

Alpharnax 320

£nsrjnajesllP320

falcon Cl.f 320

Eporia Z320

Spartan EP 320

Itencp Compountl lOÜ

GcannaslcrCLP320

Klüberoil GEM 1-320

Mobil(;carXMP320

Ripiess EP 320

Gear HST 320

üpligearßM320

Goya NT 320

Super Tauro 320

Omala 320

Meropa 320

Carter Ef 320

1100-320

Synthetic

ISO VG 150

Drgol PAS 150

Enenyn L \ P 15U

Alphasyn E U 50

EngranajesIlfXlSO

totorllCLP150

Spartan SEP 150

RHiohnmisjuCLPlia

OcannaslcrSVNISO

Üübersviilh EG 4-150

MobÜEtiiSHCXkil'liO

l ti ears)TitlieIicA15ü

El Grcco 150

Omala HD 150

Pinnacle EP 150

tar tciSHlSO

1510-150

ISO VG 220

Blasia SX 220

Dtgol PAS 220

Eiiersyn £XP 220

Alphasyn £P 220

EngianajesHfX230

Inloi IICIP 220

Epona SA 220

SpailauS£P220

Riiiolinanis)naP220

Gcann;isicrSyN220

Klübereynlh EG 4-228

MobilceirSHCXMPlJO

Atoil synth 220

Gear SllG 220

OptigearsmåeticA 150

E.IGKCÜ22Ü

Omala lU) 220

Pinnacle EP 220

Carter 5U 22Ö

1510-220

ISO VG 320

Blasia SX 320

Drgol PAS 320

Enersvn£XP320

Alphasyn EP 320

Engianajes HPX 320

Inlor HCLf 320

Epona SA 320

Spailan SEP 320

Rcnalin Ulis« CLP 32(1

Geamiastei SYN 320

Klübcrsynlli EG 4-320

MobilstatSllCXMflsü

Gear SHG 320

Optiieir siiÉttic A liO

El Greco 320

Omala HD 320

Pinnacle EP 320

Carter SH 320

1510-320

Table of lubricant oils suitable for alimentary use (Approved according to USDA-Hl and NSF-Hl specifications) Lubricant

Agip

Aral

Bel-Rav

BP Chevron

Esso

Kfnlonf

Klübtr

Mil Nib Optimo!

Palelo

RDJTII Purple

Shell

Texaco

Itibol

Lubricant

Agip

Aril

Btl-Rav

ChevroG

Esso

Kcvsloac

» t t Mobil

Nik Optunol

Piltlo

Ruval Purple

Sbtll

lexaco

Tribol

Hydnulic oils

1SOVG32

RDColFoodlubeHlpowa32

£uralHvii32

No-TojllDHYdOil32

Eaerpar M 32

L«br!cala¥OilfM32

NuloFCIl

NtV'istace SL 32

SuiimitHvs\TiFG33

l)ltfM32

Mizir]2

OplilebllYJ2

Ntn-liisOJHvljjlclSO);

Paly-0nanlfDAJ2

Cassia Fluid llf 32

Cygnus Hydnidic Oil 32

food Pmof 1840(32

ISOVG46

Eural IW 46

No-IoiHDllydOiH«

EneiiiarM4fi

Lubricating Oil FM 46

N u l o f O «

Nevastane SL 46

Sununit Hmil FG 46

D1LFM46

Mizar 46

OptiltbHy48

»j-riiiOilll)dnuliclS04i

Poly-Guard FDA 46

Cissida Fluid llf 46

Cj'gmLsHydnulicOiI46

IS0VG6S

Eural llvd 68

No-TMllDWOil68

EneiparM68

Lubricating Oil FM 68

NutofG68

Ne\'astane SL 68

Suirjnit Hysyii FG 68

DTLFM6S

Mizar6S

OptilcbHYSS

\ii-lojOilll,ffliiciS06l

Poly-Guard FDA 68

Cissida fluid HF 68

CjgnusHydKulicOil68

Food Proof 1M046 I Food Proof 1840/6!

Gear oils

ISO VG ISO

WfoidHitlllloiiiütlSti

tiaa! Gear 150

No-roxS\n Gear 150

Ne\'iftme EP ISO

Klüberoil 4 UHlNliO

DTE FM 150

Ripress Synt Food 150

OptilebGIlSO

Non-Iox Oil Gear ISO 150

My-GtianlFDAliO

Cissida Fluid CL 150

tVglUK Gear PAO 150

ISO VG 220

Lurdl Gear 220

No-Toj Syn Gear 220

Lubricaiii{OilFM220

Gear Oil FM 220

Nevastane tP 2211

Kliiberoa4UHlN220

DTE FM 220

Ripress Sjnt Food 220

OptilebOT220

Nün-To,iOilGcailSO220

Püly-GuaidFDA220

Cassida Fluid GL 220

tVgmis Gear PAO 220

Food Piool 1810)220

ISO VG 320

RocolIc«»HiltillTiti]it)20

No-Tox S™ Gear 330

Nevastane LP 320

KlüberoiU Ulli N 320

DTE FM 320

Ripress S\nt food 320

Opliieb 01J20

Non-Io.i Oil Gear ISO J29

Polv-GuaidfDA320

Cassia Fluid GL 320

Food Proof 1810/320

7.6 Diagrams and oil checking with auxiliary cooling system

Horizontal gear unit See paragraph 7.1 for levels.

Vertical gear unit See paragraph n° 7.2 for definition of levels, also for right angle gear units

8. CHECKS:

8.1 First start-up checks

Before starting the machine check the following:

- Check that all the oil plug are in the correct position (see paragraph 2.2 "configuration"). - Check that all oil levels are correct. - Check that all the grease guns are full of grease. - Check that the operating pressure (see table on the right) is sufficient to fully open the multi-disk brake to avoid overheating and any prematiu'e wear of brake disks.

Type of brake

FL620/12

FL635/12

FL250.4C FL250.6C FL350.6C

FL350.8C

FL45Ü.6C

FL450.8C

FL650.10C

FL650.12C FL650.14C

FL750.10C

FL750.I2C

FL750.14C

FL96Ü.I2C

FL960.I4C

FL960.I6C FL960.I8C

Openint (t

Max.

21

12

10,24

10,53 15,80

16,20

20,48

21,03

14,20

14,56

15,00 18,40

18,95

19,49

15,56

15,56

15,56

15,56

; pres.sure ar)

Mill.

26

15

13,28 13,28 19,92

19,90

25,59

25,59

19,92

19,92 19,92

25,59

25,59

25,59

21,98

21,98

21,98

21,98

Static torque

(Nm)

210 315

181 186 278

381

360

492

428

528 633

556

684

819

1019

1189

1359 1528

ATTENTION: Given the type of brake, the operating pressure should never drop below the minimum brake opening pressure to avoid the braking action.

ATTENTION: The gear units and any multi- disk brakes are shipped without oil. The customer is responsible for fiHing such devices (see lubrication chapter paragraph 71.

- Check that all the bolts with ISO metric threads are correctly tightened (see table "torque setting values").

Values Tabic

d t p mm

3x0,5

4x0.7

5x0.8

6x1

7x1

9x1.25

8x1

10x1.5

10x1.25

11x1.75

12x1.25

14x2

14x1.5

16x2

16x1.5

10x2.5

18x1.5

20x2.5

20x1.5

22x2.5

22x1.5

24x3

24x2

27x3

27x2

30x3.5

30x2

Torque •1.8

kN

1.2

2,1

3.5

4.')

7.3

9.3

9.9

14.5

15.8

21,3

23,8

29

32

40

43

49

57

63

72

78

88

90

101

119

131

144

165

Nm

0.9

1.6

3.2

5.5

9.3

13.6

14,5

26,6

28

46

50

73

79

113

121

157

178

222

248

305

337

383

420

568

615

772

850

Setting Bolts 5.8

kN

1.5

'2.7

4.4

6.1

9.0

11,5

12,2

18

19,5

26

29

36

40

50

54

60

70

77

89

97

109

112

125

147

162

178

204

Nm

I.I

2

4

6.8

11,5

16,8

18

33

35

56

62

90

96

141

150

194

220

275

307

376

416

474

519

703

760

955

1060

8.8

kN

2,3

4,1

6.7

9,4

13.7

17.2

18.9

27

30

40

45

55

61

76

82

95

110

122

140

152

172

175

196

230

225

280

321

Nm

1,8

3.1

6.1

104

17.2

25

27

50

53

86

95

137

150

214

229

306

345

432

482

502

654

744

814

1100

1200

1500

1670

10.9

kN

3,4

6,0

9,8

13.8

202

25

28

40

43

50

65

80

90

111

121

135

157

173

199

216

245

250

280

328

363

300

457

Nm

2.6

4.5

8,9

15,3

25

37

40

73

78

127

139

201

220

314

336

435

491

615

687

843

9.32

1080

1160

1570

1700

2130

2370

12.9

kN

4,0

7.0

11.5

16.1

23.6

30

32

47

51

69

77

94

105

130

141

158

184

203

133

253

266

292

327

384

425

467

535

Nm 3 5,3 10,4 17,9

30 44 47 86 91 148 163 235 257 369 393 509 575 719 804 987 1090

1240 1360

1840

1990

2500

2380 d= boll diameter kN = axial pre-loading

8.2 No-load tests

p= bolt pitch Nni= lorque setting bolts

- After a brief period of operation (5-10 minutes) check the oil levels under no-load conditions, topping up those levels which have gone down check that nuts and bolts

Tyir \ 'I ä

TJ i j 'I 1 1 — i ^

i I I I ] ^ I H r | M | j • 1, •! •! i l I I 1 1 ; |i ü fs I !• \ 1 M é • t l l

t ' l

I t l I

' I Ij

l l !

«

of the various attachments are properly tightened. - Check that the brakes lock and release at the right time and all operate correctly.

9. MAINTENANCE:

Introduction Maintenance can be "routine or unscheduled".

ATTENTION: All maintenance activities must be carried out under safety conditions.

9.1 Routine maintenance:

The operator is responsible for routine maintenance and must carry out the following activities. - After a brief operating period of about 100 hotirs (breaking-in), change die oil in the gear unit and the multi-disk brake (if installed) and wash the interior of the unit with cleaning liquid. - Check that there are no metallic parts with unusual dimension in the magnetic plug of the gear unit and in any multi-disk brake. - Change the oil in the gear unit while it is hot so that it is easier to drain. - Stibsequeut oil changes will be made every 200-2500 hours of operation or, in any case, each year. - Do not mix different types of oil. - Periodically check the levels (about once a month) ant top up if necessaiy.

ATTENTION: when checking the oil levels in gear units equipped with a mtilti-disk brake or hydraulic motor or both, if the levels have risen, this means that oil is penetrating either from the brake seals or from the motor rotary seal. Contract die "Brevini Service Department".

- For each unit it is recommended to keep a chart that will be duly filled out and updated each time maintenance in performed.

9.2 Oil Change

- Use die diagrams on paragraph 2.2 "configuration" to identify the oil plug according to die gear unit configuration and always paragraph 2.2 for the multi-disk brake configuration. Unscrew the drain plug and the filler plug to help drain the oil from die gear unit. Once die oil has been emp

tied, replace die drain plug. If the gear unit is equipped with a multi-disk brake, repeat the same operation with the multi-disk brake. - In the MDU series, starting with size "550", a pipe is supplied to empty the oil in die gear unit, therefore it must be empüed using a suction pump, removing the plug from the emptying pipe located on the flange attaching the gear unit and fitting to it. - Wash die interior of the gear unit with a suitable cleaning liquid that is recommended by the lubricant manu-facliuer. If die gear unit is equipped with a multi-disk brake, repeat the same operation with die multi-disk brake, as follows: Put liquid into the gear unit and the mtdd-disk brake (if any), hen replace the filter plugs; run the device for a few minutes at a high speed, dien remove the cleaning liquid again from die gear unit and the mulü-disk brake, (if any). - See paragraph 7 Lubrication for filling mstructions.

9.3 Unscheduled maintenance

Brevini Riduttori prohibits the gear unit to be opened to carry out any operation that is not included in routine maintenance procedures. Brevini Ridiutori do not im-dertake any Uability for all those operations out of rou-Une maintenance which may have caused damages to people or thhigs. When die need arises, contact the nearest Brevini Service Centres as listed on page 161.

10. MAINTENANCE OF AUXILIARIES (BRAKES - CLUTCHES- ETC.):

10.1 Procedure to replace disks or seals for mult! disk brakes

"Brevini Riduttori S.p.A." prohibits this operation to be performed on its units, dierefore if braking action becomes inefficient contact die nearest Brevini Service Centres as listedon page 161.

10.2 Procedure to replace pads for disk brakes

- Use a screwdriver or similar tool to pry between die disk and the pad to make die position of the brake clamp rettact up to the start of die stroke.'Carry out this operation first on one side and then on the odier for both pistons. - Use a pin remover and hammer to remove one of die two pins "A" from its seat (see fig. 4), remove die two springs "B", then remove the odier pin. - With a mechanical clamp pull oiu die two worn pads, use compressed air to clean away any dust from the pad seats in die brake clamp, then insert the new pads. - Mount one of the pins "A" in its seat, place the two springs "B" in dieir position, put them under tension, them moiuit the other pin hi its seat. - Activate the brake a few times to re-position die pistons of the brake clamp with the new pads. - Brake a few times to check if bleeding is required.

10.3 .Maint. proc. for hydr. power pack on gear unit-coupler assembly with active clutch safety system

- The power pack "B" has an inspectable 100 ft bronze filter, upstream of the pressiue relief valve. - With each routine maintenance job (oil change) on the gear unit-coupler assem- ( A ) bly you are advised either to change the power pack filter, by unscrewing die cap "A", or at least to regenerate it by washing thoroughly with solvent and blow-cleanmg inside die filter with air. - If die power pack "B" has to be replaced; empty the lubricant oil out of the assembly, cut off the current to the solenoid valve, disconnect the oil deliveiy tube, unscrew and remove the 4 bolts pos. "C" and then widi-draw the power pack for replacement. - To reassemble, go tlirougli die above steps in reverse order; see par. 6.3 for resetdng die power pack.

n . SCRAP DISPOSAL:

11.1 Machine demolition

If die machine must be scrapped, it, should become non-operational: - Disassemble the various parts. - Disconnect any motor unit. But fust after having completely emptied all die oil from gear imit.

11.2 Ecology information

The disposal of gear unit packagmg materials, replaced parts, components or the gear unit and lubricants must comply widi environmental restrictions, widiout polluting the soil, water or air. The party receivuig die materials is responsible for carrying out the operation m conformity with the current standards hi force m the eoim-try m which the machine is used. Instructions for suitable waste treatment - Iron, aluminium, copper materials: these are recyclable materials which must be sent a to a special authorized collection center. - Plastic and rubber materials: diese materials must be delivered to a dump or to special recycling centers. - Used oils: dehver to a special C.Di.R.A. (hi Italy the Consorzio Obbligatorio OUi Esausti).

12, PROBLEMS AND RELATIVE SOLUTIONS:

If maUuncüons occur, consult die followmg table. If die problems contmue, contact the nearest Brevini Service Center as listed on page 161.

.:,|1 ..' i:.:,,r.jiri'.'.y l,!il.JI„J.!il J' t' Ht!L.,..*H!^L.[ tidtaHon

PROBLEM

With motor ninning the output shaft

Oil leak üom breather during opcraliuj)

Oil leak from seals

Excessive noise

Disk brake does not release

Excessive vibrations

Excessive heating

Mu III-disk brake does

Multi-disk

not brake

Disk brake does not brake

POSSIBLE CAUSE

1) Incorrect motor assembly

2) Internal malfunction malfunction

3) Brake blocked

1) Level too high

2) Incorrect breather position

3) Possible wear of muhidisk brake seals or hydraulic motor

I) Clogged breather plug

2) Stiffening of seals due to prolonged storage

3) Damaged or worn seals

1) Internal malfunction

1) Residual pressure inhydraulic circuit

1) Gear unit incorrectly installed

2) Coupling structure weak


1) No ventilation

2) Iligli thennal power

1) No pressure to the brake


3) No pressure in the circuit

1) Pressure delivered to brake

2) Worn disks

1) No pressure to the brake

2) Worn brake pads

SOLUTION

1) Check coupling bem'cen gear unitfmotor

2) Contact a Service Center

3) Clieck hydraulic circuit

1) Lower oil level

2) Check breather position


1) Unscrew and thorougly clean the plug

21 Clean the area and clieck for leakage again after a few days



1) Check hydraulic Circuit

1) Check the connection and in-line configuration

2) Strengthen the structure


i) Remove fairing

2) Insert oil circulation

I) Check connection to hydraulic circuit

2) Contact a Ser\'ice Center

3) Check hydraulic circuit

1) Check hydraulic circuit Center

2)ConuiclaService Center

1) Check hydraulic circuit

2} Replace brake pads

2.5. INSTALLATION: 2.5.4.2 Installation of gear unit with FS output - Glean and degrease the internal surface of the gear imit shaft and machine shaft. - Lubricate the coupling housing (fig. 1 [X)int A). - If the coupling is new there is no need to disassemble it and grease it. - If die coupling is being overhauled, disassemble it and gi'ease die zones marked "C" (see fig. 1). - Remove cap "Z" (see fig. I) in order to bleed off the air when fitting die sliafl. - Fit the coiiphng on to the gear unit widiout tightening die bolts, leaving cap "2" loose (see fig. 1).

- If die gear unit is in a vertical working position widi die output shaft undemeadi, make sure die coupling can't come out and fall; in any event, never tighten die coupling bolts before fitting the shaft into its housing. - Fit the gear unit on to the machine shaft or vice versa (excessive axial force shouldn't benecessary); there should be no interference when assembling, so make sure die shaft and gear unit are properly aligned. - Refit cap "Z" (see fig. 2), dien position the coupling (see fig. 2 point A) - Using a torque wrench, tighten all die bolts gradually in a circular sequence (i.e. not in a diametrically opposite sequence) until

Fig. 2

diey are all tightened to torque value'T" in uible N° 1. - Set die torque wrench to 3 - 5% above die setting given in table N° 1, diea dghten the coupling bolts to the new setting.

Table 1

S3 00 S4oa S600 5860 S1200 S1800 53600

S3S00

IfpcafeMplliit

3Ü09-13SX3?0 ilCS-105X320 3A"i8.2!0'G7O

3208 •340> 405 J303-2(iOX4EM SJOfi JOO. S-j 320S-J40X570

•30.'1-360X5M

V

as l l i 114

U4 1T2 I;B 2pa

210

<=^ 0

WIS W2D M20 M2Ü M24 M24

M2J M27

T [Nml

290 490 490 490 S4Ü S40 12S0

1250

X(M»)fnr tji» rfireort

^ f f i 50 65 55 55 65 65

— —

£B 1Ü0

i i f i 115

115 120 1JÜ 125

125

^ 56 5S 53 58 7Ü 70

ti5

85

- Set the torque wrench again to setting "T" in tab. 1, dien recheck the torque on the couplmg bolts, taking care not to tighten die bolts fitfdier; if this happens, repeat the torqti-ing procediue. - When the fitting of the coupling has been completed correctly, check die assembly visibly to make sure diat the front surfaces of die internal and external rings are on die same plane (see fig. 2 point D).

2.5.4.3 Disassembling the coupling and gear unit - Gradually loosen die attachment bolts, proceeding in a circular direction. Initially, loosen each bolt by just a quarter of a turn to avoid bending and seizing.

ATTENTION: because of the high axial force, if die bolts are unscrewed totally in one or two turns diis could caase the two rings in the coupling to separate violendy, putting the operators in danger.

- If the cüiipling rings do not come apart spontaneously after misciewing die bohs, transfer some of the Isolls (two bolts at 180° - tbiu bolts at W) into die internal ring extracLon holes(see fig. 3). - Slide die coupling along its axis to release it and remove cap "Z" (see fig. 4), and inffoduce pressmised oil (max. 1000

b a r ) t h r o u g h the 1/8" G hole to fa-cditate die detachment of die gear tmit from the machine shaft. - If this mediod doesn't free die gear unit (because of die shaft coupling being unable to hold the pressure), flien, if diere is sufficient space, you can Uy die mediod illustrated in fig. 5, using hydraulic pushers, pressing against

Fig. 5

die 2 180° bosses on die gasket holder cover, being carefirl not to exceed the following axial loads:

S300 S400 S600 S850 S1200 S1800 S2500 S3500

Axial load fNl 30000 30000 45000 50000 70000 80000 100000 115000

.. ;•:!'. Ji l l ; •' i j I

I i : I! '

_|j^^^ll_,l; ', ,i r I' r ! M' I iémøa

^ ^ ^ • f ^ ' ' m - If the coupling is assembled a long time before it is start

ed up, then you will have to separate the coupling rings

(after removuig die gear unit) and clean the mating surfac

es thoroughly, removing any traces of dirt, rust, etc.

- Before reinstalling the overhauled coupling, top up with

lubricant in the zones marked "C" (see fig. 2).

i'-^hntSåU tiduttati

ATTESTATQ DI CONFQRMITA' - UNT EN 10204 - 2.1 CONFORMITY CERTIFICATE - UNI EN 10204 - 2.1

ATTESTATION DE CONFORMITE - ÜNT EN 10204 • 2.1 KONFORMITÄTSBESCHEINIGUNG - UNI EN 10204 - 2.1

CERTIFICADO DE CONFORMIDAD - UNI EN 10204 - 2.1 ATESTADO DE CONFORMIDADE - UNI EN 10204 - 2.1

La Brevini Spa dichiara sotto la propria responsabilita, sulla base del risultati ottenuti dai test standard di verifica effettuati sui prodotti costruiti con gli stessi materiali e con lo stesso metodo di produzione, che il prodotto, é conforme alle prescrizioni dell'ordine ed alle regole tecniche corrispondenti ai regolamenti ufliciali.

DIRETTORE DI PRODUZIONE

Brevini Spa under its own responsability, on the basis of the results of its standard tests aimed to verify products which are manufactured using the same materials and production method, declares that the products comply fully with the order requirements and with all technical norms corresponding to the official regulations.

MANUFACTURING DIRECTOR

La Sté Brevini Spa declare sous son entiere et seule responsabilité, sur la base des resultats obtenus suite aux tests standard de controle effectués sur les produits fabriqués ä partir des mémes matériaux et des mémes procédés de fabrication, que le produit est conforme aux prescriptions de la commande et aux standards techniques des réglementations officielles.

DIRECTEUR DE PRODUCTION

Die Brevini Spa erklärt vollverantwortlich, auf der Grundlage der erzielten Ergebnisse der Standard-Prüftests, die auf den mit gleichen Materialien und mit der selben Produktionsmethode konstruierten Produkten durchgeßhrt wurden, daß das in der vorigen Seite genannte Produkt mit den offiziellen Regelungen übereinstimmenden technischen Regeln entspricht

PRODUKTIONSLEITERS

Brevini Spa deciara bajo su propia responsabilidad, sobre la base de los resultados sacados de los ensayos estandares de verificacion efectuados en los productos fabricados con los mismos materiales y con el mismo método de producciön, que el producto cumple las prescripciones del pedido y las reglas técnicas correspon-dientes a los reglamcntos oficiales.

DIRECl'OR DE PRODUCCIÖN A Brevini Spa deciara sob sua responsabilidade, com base nos resultados obtidos em testes padronizados de veririca9äo efetuados nos produtos construidos com os mesmos materials e com o mesmo método de produ9äo, que 0 produto esta em conformidade com as prescri9öes do pedido e com as normas técnicas correspondentes aos regulamentos oficiais.

DIRETORDEPRODUgÄO

14. RETE DI ASSISTENZA - SERVICE NETWORK - ADRESSES DES CENTRES DE SERVICES APRES-VENTE-KUNDENDIENST -REDES DE ASISTENCIA -REDE DE ASSISTÉNCIA

Europi • Europe • Europe • Europa • Europa • Europa

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Lubrevini piemonte Brevini Plemontes.r.l. Corso Franda 94 10143 TORiNO Tel.:+39-011-7492045 Fax:+39-011-7493407

iSn.it

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Brevini Nederland B.V. Röntgenvêg 24 - BP 429 2408 AB ALPHEN AAN DEN RUN HOLLAND Tei.:+31 -172-476464 Fax:+31 -172-425388 [email protected]

Brevini Belgio S A 42-43, Rue Theodore Baron B-5000 NAMUR - BELGIQUE Tel.:+32-81-229194 Fax:+32-81-230862 [email protected]

vewtm ewaha

Brevini EspaAa S.A. Pol. Ind. "Los Huerteciiios", C/Abedul, s/n 28350-CIEMPOZUELOS (MADRID) ESPAIÂ Tei . :+34-91-8015165 Fax:+34-91-8015170 [email protected]

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Brevini Finland Oy. Louteisrinne, 5 02270 ESPOO - FINLAND Tei:+358-20-743 1828 Fax:+358-20-7431829 [email protected]

vewMu tränte

Brevini Power Transmission France 198, avenue Franidin Roosevelt 69516 VAULX EN VELiN Cedex tei.: +33-04-72-81-25-55 fax: +33-04-72-81-2545 [email protected]

LUbrewini geiråebe

Brevini Getriebe PiV Drives GmbH industriestraße, 3 61352 Bad Homburg Tel.:+49(0)6172 102-0 Fax:+49(0)6172 102-152 [email protected]

Lubrewtni iwând

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-^-^mmysÂ ' t ^ ' • J 1 ! • s • B • j l • ' • * ! » : . J j ' ~:

iisü. ; . « ' ^^MÛ-^:

;?-?= •'."..w.

•W.r- ^














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RE

SC

UE

BO

AT

DMR-31

MANUAL FOR OPERATION, MAINTENANCE AND TRAINING

FOR RESCUE BOAT TYPE: RB 400

ERNST

HATECKEI Boatyard Ernst Hatecke GmbH Am Ruthenstrom 1 21706 Drochtersen Phone: 0049-(0)4143-9152-0 Fax: 0049-{0)4143-9152-40 E-mail: [email protected] www.hatecke.de EDITION: 09/06



Index

1.1 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8 1.1.9 1.1.10 1.1.11 1.1.12 1.1.13

Operation Manual: In the interest of safety Yard and yard number Description of the boat Stowage plan for equipment Alarm Preperation for lowering Lower the boat - start engine Disengage hoisting hook and painter Turn the capsized boat Release lifting hook Pick in lifting hook Radar reflector Flash light

1.1.14 Search light (optionally)

1.2 Maintenance Manual: 1.2.1 In the interest of safety 1.2.2 Recomended maintenance and checks 1.2.2.1 Weekly inspection 1.2.2.2 Monthly inspection 1.2.2.3 Annual thorough examination (ace. to MSC.1/Circ.1206) 1.2.2.4 5-Years Overhaul & Testing (ace. to MSC.1/Cire.1206) 1.2.2.5 Principal log scheme 1.2.2.6 Authorized service stations 1.2.3.1 IVIaintenanee of GRP-boats 1.2.3.2 IVIaintenanee of GRP-boats

1.3 Trainings Manual: 1.3.1 Trainings instructions 1.3.2 In the interest of safety 1.3.3 Launching and recovery instructions 1.3.4 Launching and recovery instructions

1.4 Additional: Engine manual Lifting hook manual

Boatyard Ernst Hatecke GmbH, Am Ruthenstrom 1,21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: [email protected]. www.hatecke.de



1.1 OPERATION MANUAL

ERNST





A WARNING

1. During operation of the davit be cautions with long links, snap hooks and counterweights! 2. DO NOT put your hands on snap hooks, long links, counter weights and falls with tension

on this parts! 3. Always keep hands and feet clear near moving and rotating mashinery! 4. Keep off in reach of propeller! 5. Before starting read engine instruction nnanual!

6. DO NOT run engine in an enclosed area. Exhaust gases contain carbon monoxide, an odourless and dradly poison!

7. DO NOT store, spill, or use gasoline near an open flame! 8. DO NOT refuel indoors where area is not well ventilated! 9. Avoid skin contact to battery acid (corrosive)!

10. Misuse of the release gear can injure or kill!




#

•

1.1.2 Yard and yardnumber

The information given in this manual is based on our long experience and "l<now-how" in the building of all kinds of boats.

In case of an engagement it is very important, that every one knows how to handle the boat.

All personal should study this manual at boat drill, to make themselve thoroughly conversant with the system to ensure a speedy and safe engagement.


In case of enquiries reguarding existing boats please quote the details given below.

RB400 Boat type:

Hull no.: _ 10839




1.1.3 Description of boat

Construction: The hull is built in round-frame-construction. Square stern providet to install a outbord engine. All parts are built of GRP. Polyurethan foam filled buoancy tanks. Outside with rubber stripes and grab line. One twart fore with hatch and equipment locker for the inventory.

Fittings: At the fore end one painter releaser. Aft two bollards. Fittings for hoisting slings.

Engine: One hand-steered outboard engine, long shaft. 20 Itrs. fuel tank.

Loose equipment: Look at page 1.1.4

Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Orochtersen. Phone: 0049-(Ü)4143-9152-0. Fax: 0049-(0)4143-9152-4ü. E-mail: [email protected]. www.hatecke.de



1.1.4 Stowage plan for equipment

® ® ® @ @ 0-15, 18,23-28

1 2 3

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

1 1 1

1 1 1 2 1 1 1 1 1 1 2 1 2 1 1 1 1 1

bailer bucket, 5 Itrs. with lanyard Container with distress signals 1 jack knife with tin-opener 1 el. torch with spare bulb and 2 spare batteries 1 whistle fire extinguisher sea anchor with lanyards painter with long link buoyant line with ring buoyant towing line first aid kit radar reflector boat hook search light rope ladder thermal protective aids towing line for liferaft paddles compass (fixed installed) securing wire for outboard engine fuel tank bilge pump hoisting sling

Spare parts for engine: 22 1 spare fuel tank 23 1 cool water pump impeller 24 1 set of sealings 25 2 spark plugs 26 1 starter rope 27 1 flush connection 28 1 bag with tools

Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drachtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: [email protected]. www.hatecke.de



1.1.5 ALARM

®*® ALARM

®

1 <^ ^ ^

At alarm all boat personal went, equiped with

their personal equipment, to their meating

place.

Boatyard Emst Hatecke GmbH .Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: [email protected]. wvwv.hatecke.de


http://wvwv.hatecke.de

1.1.6 Preparation for lowering

© Abonding the ship: CHECK THAT EVERY BODY IS PRESENT! 1. Fasten painter. 2. Davit clear for lowering (study the davit /

crane manufacturers instructions). 3. Remove lashings. 4. Lower the outer end of the boat stowage rest

if necessary.

© Board the boat (wait until order is given), swing out the davit.

1. The occupants tal<e place on the marl<ed areas. Take care for the propper trim of the boat hanging in the hoisting sling.

2. Swing out the davit (study the instructions of the davit manufacturer).




1.1.7 Lov\fer the boat - start engine

© Lowering. With the remote control wire it is possible to operate the boat winch from inside the boat. (Study the also the winch manufacturers instructions).

\FJstart the engine : For starting instruction look at the engine manufacturers handbook in the appendix of this manual.

A CAUTION: | x j ^ Keep off of reach of propeller

A WARNING: Always keep hand and feet clear

riSi near moving and rotating mashinery.

Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: [email protected]. vww.hatecke.de


http://vww.hatecke.de

1.1.8 Disengage hoisting hook and painter

© Release the hoisting hook If the boat Is waterborn.

1.) Hold the hoisting sling (otherwise it falls down). Furter instructions depend on type of hook in use. Look for instructions inside the boat or at the davit, (look also manual in the additional)

Q~n Release painter.

Pull up forceful (arrow direction) the painter releaser lever.

f I j The boat is now free. ^ - ^ Engage the motorgear to foreward, run

the outboard engine with high speed and steer away from the vessel.

Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: Ü049-{0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: [email protected]. www.hatecke.de



1.1.9 Turn the capsized boat

In case of capsizing the boat will not right it self. The swimming boat crew (1) has to enter the boats bottom at the outboard engines side (2) and to take the grablines. Than they have to swing (3) the boat up and down until it rotates.

4.) After turning the boat drain it with the bilge pump. CAUTION: The boat crew must leave the boat during turning, to prevent accidental contact with the boat.

Boatyard Ernst Hatecke GmbH .Am Ruthenstrom 1.21705 Drochtersen. Phone: 0049-{0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: [email protected]. www.hatecke.de



# 1.1.10 Release lifting hook (only to lifting hook "SIMPLEX 1.1", manufacturer: ERNST HATECKE GmbH)

Lowering "OFF-LOAD"

After the boat is waterborn:

1.) Normal release of the release hook OFF LOAD

Pull down "white" handle to release sling from hook.

Releasing "ON-LOAD I I

"ON-LOAD" release should only be done whilst the boat is in the water Misuse of the release gear can injure or kill.

1.) Emergency release use only when boat is waterborne.

a) Remove safety pin. b) Pull down "red" handle.

A WARNING: Hook can be ACCIDETAL released ON LOAD in any position !!! Be carefull when releasing hoisting hool<s "ON-LOAD" long links and falls leave the hooks with high speed.

s-y.-

A WARNING:

Misuse of the release gear can injure or kill!!!

Boatyard Ernst Hatecke GmbH .Am Ruthenstrom 1.21706 Drochtersen. Phone; 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: [email protected]. www.hatecke.de



1.1.11 Pick in lifting iiooic (only to lifting hook "SIMPLEX 1.1", manufacturer: ERNST HATECKE GMBH)

Make lifting hook ready for use:

After releasing "ON LOAD" make the lifting hook ready for use again.

1.) Pull down the "white" handle and hold it.

2.) Push back the "red" handle into it's original position let off the "white" handle.

3.) Push in the safety pin.

4.) Push back the hook into it's original position.

Pick in the long link for hoisting:

1.) Check that the hook and release lever are In the correct position (safety pin In place).

2.) Push the long link Into the hook (the stop pawl is moveable).

ik WARNUNG: Keep hands clear when you pick in the long link In the lifting hook.

Boatyard Ernst Hatecke GmbH. Am Ruttienstrom 1.21706 Oractitersen. Plione: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: email§Hatecke.de. www.fiatecke.de

http://www.fiatecke.de

1.1.12 Radar reflector

•

/

X

In the equipment of this boat is also a radar reflctor, it is stored in the inventory locker. Assemble it to the enclosed instruction, erect it on the socket at the forward bulkhead.

Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1,21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-915240. E-mail: [email protected]. www.hatecke.de



1.1.13 Flash light

•

The boat is equiped with a flash light. Swith on the flash light in bad weather condition and in the night. 1. The flash light fix mounted on the fore deck. 2. The battery of the flash light is fix installed in the inventory locker. 3. To switch on the flash light pull out the wire pin. 4. To switch off the flash light push in the wire pin.




1-1.14 Search light (optionally)

In the equipment of this boat is also a search light.

1. The search light is stored in the inventory locker. 2. For function put the plug into the socket of the outboard engine.

Caution: Search light works only with running outboard engine. Their is no battery the current comes direct from the ignition coil.

Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Orochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-915240. E-mail: [email protected]. www.hatecke.de



1.2 MAINTENANCE MANUAL

ERNST

HATECKE I Boatyard Ernst Hatecke GmbH Am Ruthenstrom 1 21706 Drochtersen Phone: 0049-(0)4143-9152-0 Fax: 0049-(0)4143-9152-40 E-mail: [email protected] www.hatecke.de




WARNING

1. During operation of the davit be cautions with long links, snap hooks and counter weights! 2. DO NOT put your hands on snap hooks, long links, counter weights and falls with tension

on this parts! 3. Always keep hands and feet clear near moving and rotating mashinery! 4. Keep off in reach of propeller! 5. Before starting read engine instruction manual!




Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-{0)4143-9152-0. Fax: OÜ49-(0)4143-9152-40. E-maii: [email protected]. www.hatecke.de




A Qualification level. By supervision of a senior sliips officer in accordance witti ttie information provided by tlie manufacturer.

Outboard engine: (look also manufacturers manual)

1. Test run the engine, demonstrat that the gear box and gearbox train are engaging satisfactorily.

Miscellaneous:

2. Visual inspection to ensure that the boat is ready to use.

done remark




1.2.2.2 MonthBy inspection

A Qualification level. By supervision of a senior ships officer in accordance with the infornnation provided by the manufacturer.

^^^^^^^^^^^^^^^^^3^^^^

Outboard engine: (look also manufacturers manual)

1. Check fuel level in the tank. 2. Check gear oil level (Change gear oil at least after one year) 3. Grease the moveable parts. 4. Testrun the engine with the boat in the water, demonstate that the

gear box and gear box train are engaging satisfactory.

Painter releaser:

5. Clean the painter releaser (remove salt deposites) 6. Lubricate and oil moveable part of the painter releaser. 7. Check function.

Miscellaneous:

8. Check the the f lash l ights battery vo l tage (if necessary change the battery) 9. Lubricate all hinges.

10. Clean the boat with water and soap, flush with fresh water. 11. Check equipment. 12. Visual inspection to ensure that the boat is ready to use.

done remark

Boatyard Ernst Hatecke GmbH .Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: [email protected]. www.hatecke.de



1.2.2.3 Annual thorough examination (acc.toMSC.1/Circ.1206)

A Qualification level. By manufacturers representative or a person appropriately trained and certified by the manufacturer. Lool< at page 1.2.2.6 Autliorized service stations.

Items listed in checl<lists for the weel<ly/monthly inspections also form the first part of the annual thorough examination, when carrying out this examination the inspection of these items should be performed by the ship's crew in the presence of the manufacturer's representative or a person appropriately trained and certified by the manufacturer for the work to be done.


Rescue boat : Examination and check for satisfactory condition and operation *

1. Condition of Rescue boat structure including fixed and loose equipment. 2. Engine and propulsion system. 3. Manoeuvring system. 4. Power supply. 5. bailing system.

Release Gear : Examination and check for satisfactory condition and operation '

6. Operation devices for activation of release gear. 7. Excessive free play (tolerances). 8. Hook fastening. 9. Operational test of on-load release function.

10. Operation test of off-load release function.

* a c c o r d i n g t o m a n u f a c t u r e r ' s check l i s t (Doc . n o . 0 5 0 2 )

Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-915240. E-mail: [email protected]. www.hatecke.de ^ ^



1.2.2.4 5-Years Overhaul & Testing (acc.toMSC.1/Circ.1206)

^

Qualification level. By manufacturers representative or a person appropriately trained and certified by the manufacturer Look at page 1.2.2.6 Autliorized service stations.



Lifeboat: Examination and check for satisfactory condition and operation '

1. Condition of Rescue boat structure including fixed and loose equipment. 2. Engine and propulsion system. 3. IVIanoeuvring system. 4. Power supply. 5. bailing system.

Release Gear: Overhaul

6. Dismatling of hook release units. 7. Examination with regard to tolerances and design requirements. 8. Adjustment of release gear system after assembly. g.Operational test with a load according to SOLAS Reg.111/20.11.2.3.

10. Examination of vital parts with regard to defects and cracks.

replace hoisting

hook by an overhauled

one.

* according to manufacturer's checklist (Doc. no. 0502)

Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Droditersen. Ptione: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-915240. E-mail: [email protected]. www.liatecke.de


http://www.liatecke.de


No: Kind of service: Note: Date: Name:

Boatyard Ernst Hatecke GmbH. Am Ruttienstrom 1.21706 Droctitersen. Ptione; 0049-(0)4143-9152-0. Fax; 0049-{0)4143-9152-40. E-mail; [email protected]. www.tiatecke.de


http://www.tiatecke.de

A

1.2.2.6 Autiiorized service stations


ERNST

HATECKEr ~-./ Survival- & Deck equipment

Please contact: HATECKE SERVICE GMBH Am Ruthenstrom 1 21706 Drochtersen / Germany Telefon: +49-4143-9152-60 Telefax: +49 - 4143-9152-44 e-mail: [email protected] Internet www.hatecke.de



1.2.3.1 Maintenance of GRP-boats (GRP- repair)

Even GRP-boats are subject to damage to greater or lesser extent. The most common damages are scratches in the gelcoat which may also penetrate the laminate.

The gelcoat colours are: Outer surface: orange RAL 2004 Inner surface: light green RAL 6019

In case of extensive damage contact the manufacturer.

Sometimes the gelcoat finish looks dull and the colour is faded.

Restore the original finish by sanding the surface with a fine grade water sandpaper of grade 400 or finer, or using a rubbing compound.

After sanding or rubbing the surface must be waxed. Rubbing should be done by hand or with a rotary polishing buff. Waxing should always done by hand.

DAMAGES OF GRP SHOULD BE REPAIRED AS SOON AS POSSIBLE, WATER WILL BREAK IN THE LAMINATE AND DESTROY LARGER PARTS!

LOOK AT SKETCH BELOW 1.1 Small not through going damages. 1.2 Grind the damage with sandpaper or a rasp until you reach unbroken laminate. Repair

procedure as under no. 2.1. 2.1 Through going damages. 2.2 Cut away the broken material with a jig saw and a rasp. 3.1 Sharp the edges with sandpaper. 3.2 Take a piece of wood as a rabbet behind the laminate. Clean the surface with a thinning

agent. 3.3 Start to laminate with resin and glassfibre until the hole is filled up. 3.4 After starching take the wood away (abt. 30-40 min.) and grind the surface before painting.

GREATER DAMAGES, DAMAGES OF HIGHLY STRAINED OR STRESSED PIECES AND BULKHEADS SHOULD BE REPAIRED BY THE YARD!

Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-{0)4143-9152-0. Fax: 0049-{0)4143-915240. E-mail; [email protected]. www.hatecke.de



1.2.3.2 Maintenance of GRP-boats (GRP- repair)

THE MANUFACTURING FOR REPARATURES WITH GLASSFIBRE STARCHED POLYESTER RESIN (Not oblygatory terms of reference)

FUNDAMENTAL: For the starching of polyester resin the addition of starching substances and dispatching substance is necessary. All three substances are highly inflammable. The starching substance is poisonous and eye corrosive (CAUTION !) Please be careful, when putting these substances together. Spots, witch should be repaired, must be dry.

When working with these materials, take care, that you work in a temperature from abt.20°C. Storing capacity: 9 months.

IMPORTANT:

Preparing:

Manufacturing:

Starching substance and dispatching substance in no case should meet together (EXPLOSION)!!!!!

On the spot of reparature the loose fabrics should be put away, the brinks should be bevelled and roughed. From the glassfibre mat are to be cut out great enough pieces. For to get a good effect at the brinks the mat is to be pitch out at the ends (1 quire glassfibre mat will give abt. 1mm material thickness). The polyester resin could be thinned with monostyrol (abt. 10%) for a better working. The mixing with starching substance and dispatching substance should be done in the following proportion: 1000 polyester: 20 starching substance : 5 dispatching substance. First the polyester resin is to be mixed with the starching substancexactly. Then the dispatcher is be mixed with the other both substances. Pay attention, that you don't prepare more materials than you need.

The cuted glassfibre mats should be put on the spots of reparature. With a brush you touch lightly the mixed polyester resin, until the mat is wet. With the following pieces you do this in the same way, until you have the necessary material thickness.

After starching (starching time abt.30-40 minutes) you may polish the spot. if you like painting, please use DD-lacs. For cleaning the tools, use monostyrol (50%) or aceton (chemically clean).

Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(Ü)4143-9152-0. Fax: 0049-(0)4143-915240. E-mail: [email protected]. www.hatecke.de



1.3 TRAININGS MANUAL

ERNST




1.3.1 Tainings instructions To the:

"Consolidated text of the International Convention for the Safety of Life at Sea, 1974, Chapter III, Reg.19:"

4 On-board training and instructions

4.1 On-board training andin the use of the ship's life saving appliances, including survival craft equipment, and in the use of the ship's fire-extinguishing appliances shall be given as soon as possible but not later than two weeks after a crew member joins the ship. However, if the crew member Is on a regularly scheduled rotating assignment to the ship, such training shall be given not later than two weeks after the time of first joining theship. Instruction in the use of the ship's fire-extinguishing appliances, life-saving appliances, and in survival at sea shall be given at the same interval as the drills. Individual instruction may coverdifferent parts of the ship's life-saving and fire-extinguishing appliances, but all the ship's life-saving and fire-extinguishing appliances shall be covered within any period of two months.

4.2 Every crew member shall be given instructions which shall include but not necessaily be limited to:

4.2.3 special instructions necessary for use of the ship's life-safing appliances in severe weather and severe sea conditions; and

*) for more detailed information to all points look the original IMO papers.





A WARNING

1. During operation of the davit be cautions with long links, snap hooks and counter weights! 2. DO NOT put your hands on snap hooks, long links, counter weights and falls with tension

on this parts! 3. Always keep hands and feet clear near moving and rotating mashinery! 4. Keep off in reach of propeller! 5. Before starting read engine instruction manual!




Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1,21706 Orochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-9152-40. E-mail: [email protected]. www.hatecke.de



1.3.3 Launching and recovery instructions

® Abonding the ship: CHECK THAT EVERY BODY IS PRESENT! 1. Fasten painter. 2. Davit clear for lowering (study the davit /crane

manufacturers instructions). 3. Remove lashings. 4. Lower the outer end of the boat stowage rest if necessary.

I n Board the boat (wait until order is given), swing out the davit.

1. The occupants take place on the marked areas. Take care for the propper trim of the boat hanging in the hoisting sling.

2. Swing out the davit (study the instructions of the davit manufacturer).

(I I h Lowering. ^ ~ - - ^ \A/ith *hQ ram With the remote control wire it is possible to operate the boat

winch from inside the boat. (Study the also the winch manufacturers instructions).

V[V/ start the engine : For starting instruction look at the engine manufacturers hanilhnnk in thp appsnfliv nf thi.t; manual

A CAUTION: Keep off of reach of propeller

A WARNING: A lways keep hand and feet clear near mov ing and rotat ing mashinery.

Boatyard Ernst Hatecke GmbH. Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: Ü049-(0)4143-915240. E-mail: [email protected]. www.hatecke.de



1.3.4 Launching and recovery instructions

© Release the hoisting hook if the boat is waterborn.

1.) Hold the hoisting sling (otherwise it falls down). Furter instructions depend on type of hook in use. Look for instructions inside the boat or at the davit, (look also manual in the additional)

( y j ) Release painter.

Pull up forceful (arrow direction) the painter releaser lever.

ID The boat is now free. Engage the motorgear to foreward, run the outboard engine with high speed and steer away from the vessel.

Recovery will be done by reverse step VII to I.

Boatyard Ernst Hatecke GmbH .Am Ruthenstrom 1.21706 Drochtersen. Phone: 0049-(0)4143-9152-0. Fax: 0049-(0)4143-915240. E-mail: [email protected]. www.hatecke.de



1.4 ADDITIONAL

ERNST




mm miMli^

OWN

LIT-18626-05-47

ccinlaitlis LheniicBls known \o the

d»t«qts or Kttn^r mprodüccive harni.

''>.'.*vriP Ur-CAUF:?*-«!

ci:> EMU01449

TO THE OWNER Thank you for choosing a Yamaha outboard motor. This Owner's manual contains information needed for proper operation, maintenance and care. A thorough understanding of these simple instructions will help you obtain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer.

In this Owner's Manual particularly important information is distinguished In thefoHpwing ways.

The Safety Alert Symbol means G i , ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!

A GAUTiON indicates special precautions that rriust be taken to avoid damage to the outboard motor.

Hßm A NÖTE provides key information to make procedure seäsier or clearer.

* Yiämaha continually seeks advancements- in product design and quality. Thel'efore, while this manual contains ithé most current product information available at the time of printing, there may be minor discrepandes between your machine and this manual. If there is any question corieerning this manual, please; consult your Yamaha dealer.

Failure to follow WARNING instmctions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor.

NÖTE:

The F15MH, FISPR and their standard aeeeæpflési are used as a base for the explanations and illustrations in this manual. Therefore, some items may not apply to every model.

EMU01446

Fi5e OWNER'S MANUAL

©2003 by Yamaha Motor Corporation, USA 1st Edition, April 2003

A|l rights reserved. Any reprinting or unauthorized use without the written pemnission of Yamaha Motor Corporation, USA

is expressly prohibited. Printed in Japan

P/N UT-18626-05^7

EMA2D010

CONTENTS cx>

o m

•.CD

M

9

AtoZ

/• ' "

GENERAL INFORMATION

^-

/

BASIC COMPONENTS

^

y

OPERATION

'^-

/

MAINTENANCE

v_

y-

TROUBLE RECOVERY

N -

/

INDEX

>-

1

J

1

J "I

J

1

J \

J

1

J

READ THIS OWNER'S MANUAL CAREFULLY BEFORE OPERATING YOUR OUTBOARD MOTOR.

cx> EMB00010

Chapterl

GENERAL INFORMATION

IDENTIFICATION NUMBERS RECORD. 1-1 Outboard motor serial number 1-1

EM ISSION CONTROL INFORMATION .1-2 Star labels....... .A- 3

SAFETY INFORMATION .1-4

IMPORTAN T LABELS .1.6

BASIC BOATING RULES .1-7

FUBJNG INSTRUCTIONS ...1-11 Gasoline .........,v....1 -12

ENGINE OIL....... 1 -13

BATTERY REQUIREMENT 1 -14

PROPELLER SB_ECTION 1-15

STARTÎN-GEARPROTECTION ... ......:1 -16

vö CE> IDENTIFICATION NUMBERS

RECORD

401012

PUTBOARD MOTOR SERIAL NUMBER

YAMAHA MOTOR CO., LTD.« MADE IN JAPAN • PAYS D'ORIGINE JAPON

The ioutboard motor serial number is äämped on the label attached to the port side of the damp-bracket. Record your outboard motor serial number inthe spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is stolen.

i 'Outbcörd motor sma\ number

1-1

vD CE> EMUCn385

EMISSION CONTROL INFORMATION

EMU01387

NORTH AMERIGAN MODELS This engine conforms to U.S. Environme ntal Protection Agency (EPA) regulations for marine SI engines. Seethe label affixed to your engine for details.

Approval label of Bfnissipn oontrd certificate This label is attached to the bottom cowling.

1 Emission contrölinformation label

"5? BVISaON CONTRÖLINFORMATION ENGIhEFÄMLY.: C~IIIIZ3 JiS3«3N^^raRKeDI~iySS?FEGULA]!CE«3?M\Rirei ENai^S-THSB«NEatoî\Eia'~rKurcRN/Buissio^ luRwæNaNES FEfeTO^ÊCIIAÊraUrt^l»IR3RI*N^BWJCEPEOTCA^lC^^ reb:r— ICiKPEBJ äPAFteuua'

qj<whr: 5PAMaiJ(KÄPH):^_'';

gTlINNEUlRAl

ggfucfflii w • t -KE HJbLU/ UUJÆ ACWERniSEBCWER 1" VALVaASIinrt : INT 1 EXr 1

New Technology ;(4-istroke) EM

Manufactured date label This label is attached to the damp bracket.

2 Manufactured date label

1-2

^:^ CI>

000851

EMU01389

STAR LABELS Your outboard motor is labeled with a California Air Resouræs Board (GARB) star label. See below for a description of your particular label.

1 Star label

One Star - Low Emisapn The one-star label icléntifiés éhgihés that meet the Air Resouræs Board's 2001 exhaust emission istandaras. Engines meeting these standards have ' ^ % lower emissions than corivéhtidriål carbureted two-stroke engines. These engines are equivalent to the US. EBA-s 2 0 0 6 ^ a n -dards for marine engines..

Two Stars -\ireiry Low Britssion The two-star label identifies engines that meet thie Air Resources Board's 2004 exhaust emission standards. Engines meeting these standards have 20% lower emissions than One Star-Low-Ehfiissio n engines.

Three Stars - Ultra Low BtiissiOh The three-star label identifies engines that meet the Air Resources Board's 2008 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star-Low-Emissio n engines.

1-3

^^ cx^ EMU00917.

Q SAFETY

INFORMATION

8 Before mounting or operating the outboard motor, read this entire manual. Reading it should give you an under-standin g of the motor and its operation.

8 Before operating the boat, read any owner's or operator 's manuals supplied with it and all labels. Be sure you understand each item before operating.

8 Do not overpower the boat with this outboard motor. Overpowering the boat could result in loss of control. The rated power of the outboard should be equal to or less than the rated horsepower capacity of the boat, If the rated horsepower capadty of the boat is unknown, consult the dealer or boat mänufäctu rer.

8 Do not modify the outboard. Modifications could make the motor unfit or unsafe to use.

8 Never operate after drinking alcohol or taking drugs. About 50% of all boating fatalitie s involve intoxication.

8 Mave an approved personal flotation device (PFD) on board for every occupant. It is a good idea to wear a PFD whenever boating. At a minimum, children and non-swimmers should always wear PFDs, and everyone should wear PFDs when there are potentially hazardous boating Conditions.

8 Gasoline is highly flammable, and its vapors are flammable and explosive. Handle and störe gasoline carefully. Make sure there are no gas fumes or leaking fuel before starting the engine.

8 This product emits exhaust gases which contain carbon monoxide, a colorjéss, odorless gas which may cause brain damage or death when inhaled. Symptoms include nausea, dizziness, and drowsiness. Keep cockpit and cabiri areas well ventilated. Avoid blocking exhaust outlets.

8 Check throttle, shift, and steering for proper operation befpre starting the engine.

8 Attach the engine stop switch lanyard to a secure place oh your pipthingv or your arm or leg while operating. If you accidental ly leave the helm, the lanyard will pull from the switch, stopping the engine.

8 Know the rhariné laWs and regulations where you will be boating - and obey them. Refer to "RULES OF THE ROAD" section for basic boating rules.

8 Stay informed about the weather. Check weather forecasts before boating. Avoid boating in hazardous weather.

8 Tell someone where you are going: leave a Float Han with a responsible person. Be sure to cancel the? Float Ran when you return.

8 Use common sense and good jüdgmeht when boating. Know your abilities, and be sure you underhand how your boat handles under the different boating condition s you may:encounter; Operate within your limits, and the limits of your boat. Always operate at safe speeds, and keep a careful watch for obstacles and other traffic.

8 Always watch carefully for swimmers during the engine pperatipn.

8 Stay away from swimming areas.

1-4

vö '^ cx> 8 When a si/vimmer is in the water near

you shift into neutral arid shut off the engine.

8 Be informed about boating safety. Additiona I publications and information can be obtained from many organizations, including the following:

United States Coast Guard

Consumer Äffairs Staff (G-BG) Office of Boating, Rublic, and Consumer Affairs U.S. (3oast Guard Headquarters Washington, D.C. 20593-0001 Boating Safety Hotline: 1-800-368-5647

National iyiarihe Manufacturers

Association (NMMA)

401 N.Michigan Ave. Chicago, 1160611

Marine Retailers Association of America

155 N.Michigan Ave. Chicago, 1160601

1-5

va ^d^ CD EMB30011

IMPORTANT LABELS

WARNING LABELS 1

WARNING This engine is equipped with a neutral starting device. The engiie will not start unless the shift control is in neutral position. - • • 6E0.836 27.41

WARNING * Be sure shift control is in neutral

before starting engine, (exæpt 2HP) * [Do not touch or remove electrical parts

when starting or during operation. * Keep hands,hair.and dothes away from flywheel

arid other rDtating:parts whi leengine ismrining. „ ^ i SA1.83625-41

CAUTION LABELS 3

CAUTION Transpoatid storetheengine only as shown

O.therwise^nginedamagecould resultfrom leaking oö.

1

1-6

CO EMB40010

BASIC BOATING RULES (Rules of the road)

Just as there are rules whieh apply when you are driving on streets and high ways, there are waterway rules which apply when you are driving your boat. These rules are used internationally, and are also enforced by the United States Coast Guard and local agendes. You should be aware of these rules, and follow them whenever you encounter another vessel oh the water.

Several sets of rules prevail according to geographic location, but are all basically the same asthe International Rules of the Road. The rules presentejd here in your Owner's Manual are cGsndensed, and have been provided for your convenience only. Consult your local U.S. Coast Guard Auxiliary or Department of Motor Vehicles for a complete set of rules governing the waters in which you will be using your boat,

STEERING AND SAILING RULES AND SOUND SIGNALS Whenever two vessels on the water meet one another, one vessel has the right-of-way; it is called the "stand-on" vessel. The vessel which does not have the right-of-way is called the "give-way" or "burdened" vessel. These rules determine which vessel has the right-of-way, and what each vessel should do.

CX) Stand-on vessel The vessel with the right-of-way has the duty tP continue its course and speed, except to avoid ah immediate collision. When you maintain your direction and speed, the other vessel will be able to determine how best to avoid you.

Give-way veifflel The veosél which does not have the right-of-way has the duty to take positive and timely adipn tostay out Ofthe v/ay pfthe Stand-On vessel. Normally, you should not cross in front of the vessel with the right-of-way. You should slow down Or change directions briefly and paæ behind the other vessel. You should always move in such a way that the operator of the Other vessel can see what you are doihjg.

"The géheral pirtidentläl alle " This rule lis called Rule 2 in the Ihtemätignal Rules arid says,

'In obeying and construing these rules due regard shall 'be had to all dangers of navigation and epilision, and to any special di cumstänces, which may render a departure from the above rules necessary in order to avoid immediäte dandér.'

In other Words, follow the standard rules except when a collision will occur unless both veæels try to avoid each other. If that is the case, both vessels become "Give-Way" veæe|s.

1-7

\ ^^ CX>

RULES WHEN ENCOUNTERING VESSELS There are three main situations which you may encounter with other vessels which could lead to a collision unless the Steering Rules are followed:

Meeting (you are approaching another vessel head-on) Crossing (you are travelling across the other vessel's path) Overtaking (you are passing or being passed by another veæel)

In the following illustratioh, your boat is in the center. You should give the right-of-way to any vessels shown in white area (you are the Give-Way vessel). Any vessels in the shaded area must yield to you (they are the Give-Way vessels). Both you and the meeting vessel must alter course to avoid each other.

Meeting If you are meeting another power vessel head oh, and are close enough to run the risk of collision, neither of you has the right-of-way! Both of you should alter course to avoid an accident. You should keep the other vessel on your port (left) side. This rule doesn't apply if both of you

will dear one another if you cohtihue on your set course and speed.

Crossing When two power driven vessels are CTOssing each other's path close enough to run the risk of collision, the vessel which has the other on the starboard (right) side müä keep out of the way of the other. If the other vessel is on your right, you niust keep out of its way; you are the Give-Way vessel. If the other vessel is on your port (left) side, remember that you should maintain course and direction, provided the other vessel gives you the right-of-way as it should.

Overtaking If you are passihg another vessel, you are the "Give-Way" vessel. This means that the other vesisel is expected to maintain

1-8

%s> its course and speed. You rnüst stay out of its way until you are dear of it. Likewise, ifanother vessel ispaæing you, you should maintain your speed and direction so that the other vessel can steer itself around you.

OTHER SPECIAL SITUATIONS There are three other rules you should be aware of when driving your boat around other vessels.

Narrow channels a lid bends When navigiating innarrovtf channels, you should keep to the right when it is; safe and practical to do soi If the ofJ^rator of a power-driven vessel is preparing to go around abend that may obstruct the view of other water vessels, the operator should sound a pirolonged blaä on the whistle (4 to 6 seconds). Ifanother vessel is around the bend, it too should sound the whistle. Even if no reply is heard, however, the véséél should still proceed around the bend with caution. If you navigate such waters with your boat, you will need to carry a portable air horn, available from local marine supply ätores:

Fishing vessel right-of-way All vessels which are fiehihg; with nets, lines or trawls are considered to be "fishing vessels" Under the Ihtéfnational Rules. Vessels with trolling lines are not considered fishing vessels. Fishing vessels have the right-of-way regardless of position. Fishing vessels, cannot, however, impede the passage of other vessels in narrow channels.

CI> Sailing vessel righf-of-rway Sailing vessels should normally be given the right-of-way. The exceptions to this are: 1. When the sailing vessel is overtaking

the power-driven vessel, the power-driven vessel has the right-of-way.

2. Sailing vessels should keep clear of any fishing vessel.

3. In a narrow channel, a sailing vessel should not hamper the safe passage of a povêr-drivén vessel whidi can navigate only in such a channel.

Reading buoys and other markers The waters of the United states are rharked for safe navigation by the lateral system of buoyage. Simply put, bupys and markers have ah arrangement of shapes, colors, nurnbers and lights to show which side of the buo y a boater should pass on when navigating in a par-tieulaf direction. The markings oh these buoys are oriented from the perspective of being entered from seaward (the boater is going towards the port). This means that red buoys are passed on the starboard (right) side when proceeding from open v/ater into port, and black buoys are to port (left) side. When havi-gating out of port, your position with respect to the buoys should be reversed; red buoys should be to port and black buoys to starboard.

Many bodies of water used by boaters are entirely within the boundaries of a particular state. The uniform State Watenway Marking System has been devised fpr these waters. This system uses buoys and signs with distinctive shapes and colors to show regulatory or advisory information. These markers are white with black

1-9

\S^ letters and orange boarders. They signify speed zones, restricted areas, danger areas, and general information. Remember, markings may vary by geographic location. Alv\/ays consult local boating authorities before driving your boat in unfamiliar waters.

cr>

P roc ééci ng - tcwartl. hé ad of navigation, from seavarl .

SECONDARY CHANNEL BUOYS STARTS NEWNUMBERINC, SYSTEM,

0" CAN .BUOY

Odd nuTter. Leave tpport

i OR

0" NUN BUOY

Even nuntier. .Leave to startioail

ffl No change

MAIN CHANNEL BUOVS

0 9 •UGHTED BUOY (Port Hand)'

Odd runter, increasing ODwanj head ofnaviga-tion.lieave topdrt Øéft) proceeding upstream.

JVwhite Light

L [ J UGHTED BUOY (Starboad Hard)"

Even nurrter.inciEastn gtavaiti head cafna/ig'a-üon. Leave to slartnanj (righQ pnxeedng upstream

SWhce Uglt

I OR

Red Ught

M t UGHTED SAFE WATER BUOY

No itrrtér.' Martfs rridchannel, pass, on ät\a side, Letter has no lateral sigrificance, used for idertificab on and location purposes-

i | Top Mark

VVtite ügrt [ vvtite ti^t«

OR

Ca 0 9

RB • L- RG

UGHTED PREFERRED CHANNELTO PORT BUOY • t

No mrrter. Topmost band .red - prefeired charinel istoleft ofbuoy. Leiter has nolateral

signif icance, used for idmbficstion arid locatiDh purposes .

Red or I wr i te Ljght

^ • i L ^ ^ ^ ' i r '

[XJnev.

Red Li git

1-10

vSJ EMB01010

i=UEL)NG INSTRUCTIONS

#

GASOUNE AND FTS VAPORS ARE HIGHLY FLAMMABLE AND EXPLOSIVE 8 Do not smoke when refueling, and

keep away from sparks, flames, or other soürgeö of ignition.

8 Stop engine before refueling. 8 Refuelin a well-ventilated area. Refuel

portable fuel tanks olf the boat. 8 Take care not to spill gasoline. If gaso

line spills, wipe it up imnriediatély with dry rags

8 Do not overfill the fuel tank. 8 Tighten the filler cap securely after

refueiihg. 8 If you should swallow some gasoline

inhale ä kit of gasoline vapor; or get gasoline in your eyes, get immediate medical attention.

8 If any gasoline spills onto your skin, immediately wash wtth soap and Water. Charige ctothing if gasoline spills on it.

8 Touch the fuel nozzle tothe filler opening or funnel to help prevent electrosta-tk: sparks.

Use only new clean ^gasoline which has been stored in dean containers and is not Gontaminat ed with water or foreign matter.

1-11

\S^ CX) EMU01804

GASOLINE

Recommended gasoline: Regular unleaded gasoline with a minimum octane rating of 86 (Pump Odane Number) =(R+M)/2

If knocking or pinging occurs, use a different brand pfgasplihe or premium unleaded fuel.

EMBS0610

Gasohol There are two types of gasohol: gasohol epntainin g ethähöl and that isontaining methanol. Gasohol containing ethanol eari be used if ethanol content does not exceed 10% and the fuel meets minimum octane ratings. Gasohol containing methanol is not recommended by Yamaha because it can cause fuel system damage or engine performance problems.

1-1S

^:^ C£> ENGINE OIL

Recommended engine oil:

4-stroke motor oil with a combination of

corresponding SAE and API as shown in

the chart.

SAE API

- 1 It U-lT

- i r tr 4 r r

10W-30 ^

1Gfi/V-40 >

SE

SP

S<3

SH

SJ

Engine oil quantity:

See Chapter 4 , " Specificatio hs."

*=e r i K m l i ^ M I

Arinkjr.<i;rllk'U." w-A» '> • • • ' j r M-n (*•• nv . lv

r^k« h rh h <^M.II^ IK h Jr

001162

All 4-stroke engines are shipped from the

factory without engine oil.

1-13

vø i ^ CI^ BATTERY REQUIREMENT

Do rrøt use a battery that does not meet the specified capacity. If a battery which does n<A meet specifications is used, the electric system could perform poorly or be overloaded, causing electric system damage.

For electric start models, choose a battery which meets the following specifications.

Minimum cold (CCA/SAE):

245 amps at

cranking amps

-18°C(-0.4°F) Minimum marine cranking amps (MCA/ABYC):

323ampsatO°C(32°F) Minimum reserve éapadty (RG/SAE):

52 minutes

A battery cannot be connected to models that do not have a rectifier or Rectifier Regulator. Models without a rectifier or Rectifier

Regulator F15MH

8 If you w ish to use a battery w ith the above modelsi, install an optional Rectifier Regulator.

1-14

vö '^ CJ:> EMU01395

PROPELLER SELECTION

The performance of your outboard motor will be critically affected by your choice of propeller, as an incorred choice could iadversely affect performance and could also seriously damage the motor. Engine speed depends oh the propeller size and boat load. If engine speed is too high or too low for good engine performance, this will have an adverse effed on the fengine.

Yamaha outboard moitprs are fitted With propellei's chosen to perform well over a range of applications, but there may be uses where a propeller with a different pitch would be more appropriate. For a greater operating load, a smaller-pitch propeller is more suitable as it enables the corred engine speed to be maintained. Conversely, a larger-pitch propeller is more suitable fora smaller operating load.

Yamaha dealers stocl< a range of propellers, and can advise you and install a propeller on yûr outboard that is best suited to your application.

1-15

m VÖ I s ^ cr> NOTE: At füll throttle and under a maximum boat load, the engine's rpm should be within the upper half of the full throttle operatin g range, as listed in "SPECIFICATIONS" on page 4-1. Select a propeller which fulfills this requirement. If operating under conditions which allow the engine's rpm to rise above the maximum recommended range (such as light boat loads), reduce the throttle setting to maintain the rpm in the proper operating range.

1 Propeller diameter (in inches) 2 Ropeiler pitch (in inches) 3 Type of propeller (propeller mark)

Refer to the section "CHECKING PROPELLER" for instructions on propeller removal and installation.

EMU01209

START-IN-GEAR PROTECTION

Yamaha outboard motors or Yamaha approved remote control units are equipped with start-in-gear protection device(s). This feature permits the engine to be started only when it is Neutral. Always select NeutraT before starting the engine.

• 1-16

' ^

-MEMO-CD

(j^.

CX:>

/Q EMC00010

i R Chapter 2

BASIC COMPONENTS

MAIN COMPONENTS . 2 - 1

OPERATIONS OF CONTROLS AND OTHER FUNCTIONS

Fuel tank Gear shift lever Choke knob Recoil starterhandle Starter button Tille r handle Remote control Steering frietion adjusting Trim angle adjusting rod... Warning Indicator(s) Tilt lock mechanism Tilt support knob Tilt support bar Power tilt unit Top Gowlihq lock lever..... Flush ihg device

WARNING SYSTEM Overheat warning Low oil Dressure warnina

lever....

.2-2 2-2 .2-3 2-3

. ...2-3 2-3

.2-4 2-7

...2-1 1 2-11

...2-11 2-12

....2-12 . ...2-12 ....2-12 ...2-13 ...2-13

...2-14 2 -14 .2-14

CD MAIN COMPONENTS

/

Ö00944

101121 701061

1 Top cowling 2 Tppcowling locklever 3 Oil drain bolt 4 Anti-cavitdion plate 5 Propeller 6 Cooling water inlet 7 Trim angle adjusting rod 8 Qamp bracket 9 Recoil starter handle O Choke knob q Warning indicator w Gear shift lever

* & Tillei'handle i - Steering friction adjusting lever t Transom clamp handle y Rope attachment

* u Tilt lock lever i Rushing device

* o Starter button * p Rower tilt switch * a Tilt support knob * s Remote control

* May not be exactly as shown; also may not be included as standard equipment on all models.

2-1

Q CT)

EMC20010

OPERAnONS OF CONTROLS AND

OTHER FUNCTIONS

u 902051

EMC21012

FUEL TANK If your model was equipped with a portabi? fuel tank, its fundion is as follows.

1 Fuel hose joint 2 Fuel meter(lf equipped) 3 Fuel tank cap 4 Airventscrew(lf equipped)

Fuel hose joint This connector is provided for connecting or disconnecting fuel hose.

Fuel meter This meter is on the fuel tank cap. It shows current fuel quantity in the fuel tank approximaitely.

EMC51010

Fuel tank cap This cap is for filling fuel. To remove it, turn it Gounterclockw ise.

EMC610,10

Air vent screw This screw is on the fuel tank cap. To loosen it, turn it cxjunterclockw ise.

2-2

n CD GEAR SHIFT LEVER (for Til ler control model) Turning the gear-shift lever towards you engages the clutch with the forward gear so that the boat moves ahead. Turning the lever away from you engages the reverse gear so that the boat moves astern.

1 Neutral 2 Forward 3 Reverse

EMC42210

GHOKE KNOB Pulling out this knob (setting it to ON) supplies a rich mixture required to start the engine.

aiic*4oio

RECOIL STARTER HANDLE (If equipped) PuN the handle gently until resistance is felt. Then vigorously pull! the handle äraight out to aank the engine to start it.

STARTER BUTTON (for Tiller control model) When you push the starter button, the electric starter motor cranks the engine to start it.

2-3

I Q ! %

TILLER HANDLE (for tiller control models) Moving the tiller handle from side to side changes the steering diredion. In addition, this handle has the following functions.

1 Throttlecontrol grip 2 Throttleindieator 3 Throttle friction adjusting knob/screw 4 Engine stop button/Enginestop lanyard

switch 5 Power tilt switch (if equipped)

EMC40011

Throttle control grip The throttle control grip is on the tiller handle. Turn the grip counterclockwise to increase speed and clockwise to deaease speed.

EMC40210

Throttle indicator The fuel consumption curve on the throttle indicator shows the relative amount of fuel consumed for each throttle position. Choose the setting that offers the best performance and fuel economy for the desired operation.

1 Throttleindieator

2-4

11 CD EMU01294

Throttle Friction Adjusting Knob A fridion device in the tiller handle provides resiäance to movement of the throttle grip. This is adjustable for operator preference.

Resistance

Increase

Decrease

Knob

Turn clockwise

Turn countercloc*n«jse

When constant speed is desired, tighten the adjusting knob to maintain the desired throttle setting.

Do not overtighten the friction adjusting knob. If there is too much resistance, it may be difficult to move the throttle grip, which could result in an accident.

EMC27110'

Engine stop button Pushing this button opens the ignition circuit and ôps the engine.

EMC28210

Engine stop lanyard switch The lock-plate on the end of the lanyard must be attached to the engine äop switch for the engine to run. The lanyard should be attached to a secure place on the operator's clothing, or arm or leg. Should the operator fall oyerbbard or leave the helm, the lanyard will pull out the lock plate, stopping ignition to the engine. This will prevent the boat from running away under power.

2-5

t ci:> 8 Attach the engine stop switch lanyard

to a secure place on your dothing, your ami or leg while operating.

8 Do not attach the lanyard to dothing that could tear loose. Do not route the lanyard in such a way that it could become entangled, preventing It from function! ng.

8 Avoid accidentally pulling the lanyard during nomial operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the lx)at tol)e thrown forward.

NOTE: .

The engine cannot be started with the loek-plate removed.

1 Lock-plate 2 Lanyard

EMU01323

Power Tilt Switch The power tilt adjusts the motor angle in relation to the transom. The power tilt switch is located on the tiller handle. Pushing the switch "UP ' tilts the motor up, Pressing the switch "DN" tilts the motor down. When the switch button is released, the motor will stop in its current position. NOTE:

Refer to the section "TILTING UP/DOWN" for ipstrudions on usage.

2-6

5 ci:> REMOTE CONTROL Both the shifter and the throttle are actuated by the remote control lever. In addition, this remote control also has the electrical switches.

1 Remotecontrol lever 2 Neutral interlock trigger 3 Neutral throttle lever 4 Main switch/Ghoke switch 5 Engine stop lanyard switch 6 Power tilt switch 7 Throttlefrietioii adjusting screw

Remote Control Lever Moving the lever forward from the Neutral position engages Forward gear. Pulling the lever back from Neutral engages Reverse. The engine will continue to run at idle until the lever is moved about 35° (a detent can be felt). Moving the lever farther opens the throttle, and the engine will begin to accelerate.

1 2 3 4 5 6 7

Neutral Forward Reverse Shift Fully closed Throtle Fully open

2-7

=•9 cr> N eut ral Interfpck Trigger To shift out bf Neutral, the neutral Interlock trigger of the remote control lever must first be pulled up.

EMU00100

Neutral Throttle Lever To open the throttle without shifting into either Forward or Reverse, place the remote control lever in the Neutral position and lift the neutral throttle lever. NOTE: ^

The neutral throttle, lever will operate only when the remote control lever is in Neutral. The remote control lever will operate only when the neutral throttle lever is in the dosed position.

1 Fully open 2 Fully closed

EMU00101

Main switch The main switch controls the ignition system; its operation isdescribed below. 8 OFF Bectrical circuits switched off. (The key can be removed^) 8 ON Bectrical circuits switched on. (The key cannot be removed.) 8 START Starter-motor will turn and start engine. (When the key is released, it returns automatically to "ON".)

2-8

© ' % •

Hl

CX> Choke Switch While the hiain switch is being pressed in at "ON" or "START", the choke system will switch on, to supply a rich mixture required to start the engine. (When the key is released, it Will switch off automatically.)

w 1 ,

1 t *

000569

Engine Stop Lanyard Switch The lock-plate 1 must be attached to the engine stop lanyard switch for the engine to run. The lanyard 2 should be attached to a secure place on the operator's clothing, or arm or leg. Should the operator fall overboard or leave the helm, the lanyard will pull out the lock plate, stopping ignir tion to the engine. This will prevent the boat from running away under power.

8 Attach the lanyard to a secure place on your clothing, your ami or leg while operating.

8 Do not attach the lanyard to dothing that could tear loose. Do not route the lanyard in such a way that it could become entangled, preventing it from functioni ng.

8 Avoid acddentially pulling the lanyard during normal operation. Loss of engine power rneans the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat tobe thrown fonA/ard.

NOTE:

The engine cannot be started with lock-plate removed.

the

2-9

CX) EMU01316

Power Tilt Switch The power tilt adjusts the motor angle in relation to the transom. The power tilt switch is located on the remote control lever grip. Pushing the switch "UP' tilts the motor up. Pressing the switch "DN" tilts the motor down. When the switch button is released, the motor will stop in its current position. NOTE: Refer to the section "TILTING UP/DOWN" for instructions on usage.

Throttle Friction Adjusting Screw A friction device in the remote control box provides adjustable resistance to movement of the remote control lever, and can be set according to operator preference. An adjusting saew is located onthe front of the remote control box.

Resista nee

Increase

Decrease

Saew

Turn clockwise

Turn counterclockwise

Do not overtighten the friction adjusting screw. If there is too much resistance, it may be difficult to move the lever, which could result in an accident.

€ 2-10

<x>

i"» 'I l . - ' " . r

408033

EMU 01295

STEE RING FRICTION ADJUSTING LEVER A friction device provides resistance to steering movement. This is adjustable according to operator preference.

Resistance

Increase

Decrease

Lever

Turn to port

Turn to starboard

Do not overtighten the friction adjusting lever. If there is too much resistance, it may be difficult to steer, which could result in an acddent.

EMU01297

TRIM ANGLE ADJUSTING ROD The position of the trim angle adjusting rod determines the minimum trim angle of the outboard motor in relation to the transom.

EMU01128

WARN IN G INDICATC>R(S) If the engine develops a condition monitored by the warning system, an indicator will come on. Refer to the "WARNING SYSTEM" section for details.

1 Warning indiGator(s)

2-11 •

It CX) TILT LOCK MEGHANISM (for Manual tilt model) The tilt-lock mechanism Is used to prevent reverse thrust from the propeller lifting the outboard motor when reversing. To lock it, set the tilt-lock lever in the Lock position. To release it, place the tilt-lock lever in the Tilt position.

1 Tilt-lock lever

EMU00155'

TILT SUPPORT KNOB To keep the outboard motor in the tiltéd-up position, push the tilt support knob under the swivel bracket.

EM D4801P'

TILT SUPPORT BAR The tilt support bar 1 keeps the outboard motor in the tilted up position.

EMU01348

POWER TILT UNIT This unit tilts the motor up and down and is controlled via the power tilt switch.

1 Power tilt unit 2 Power tilt motor

Do not step on or exert pressure on the power tilt motor. The power tilt unit qouid be damaged as a result.

2-12

CD EMD62011

TOP COWLING LOCK LEVER To remove the engine top cowling, turn the lock lever. Then lift off the cowling. When replacing the cowling, check to be sure it fits properly in the rubber seal. Then lock the cowling again by moving the lever upward.

1 Top cowling locklever

FLUSH IN G DEVICE This device 1 is used to dean the cooling water passages of the motor using ä garden hose and tap water. NOTE: . ^ _

Refer to "Cleaning Cooling-water Passages" in Chapter 4 for instrudions on usage.

2-13

% CD WARNING SYSTEM

Do not continue to operate the engine if the warning device has activated. Consult your Yamaha dealer If the problem cannot be located and corrected.

EMU00T70

OVERHEAT WARNING This engine has an overheat warning device. If the engine temperature rises too high, the warning device will activate.

(1 ); Included (—)i N/A

Activation of warning device

The engine speed v\/iil automatically decrease to about 2,000 r/min.

The overheat warning indicator will come on.

Thebuser will sound.

Tiller control model

1

—

—

Remote control model

1

—

1

If the warning system has been activated, stop the engine and check the water inlet for clogging.

2-14

Q

<x> EMD86112

LOW OIL PRESSURE WARNING If oil pressure drops too low, the warning device will adivate.

(1 ):lncluded (—):N/A

Activation of warning device

Enginespeed will automatically decrease to about2,(CKX)r/min.

The low oil pressure warning indicator will corne on.

Th e b u ^ r wil 1 so u n d.

Tiller control model

1

1

—


1

1

1

If the warning system has been activated, stop the engine as soon as it is safe to do so. Check oil level and add oil as needed. If the oil level Is correct, consult your Yamaha dealer.

Do not continue to run the engine If the low oil presisure lamp is "ON". Serious engine damage may occur.

2-15

CE>

--^

EMF00010

Chapter 3

OPERATION

INSTALLATION . ...„ .3- 1 Mounting the outboard motor 3-2 Clamping the outboard motor...... .3-4

BREAKING IN (RUNNING IN) ENGINE .3-5

PRE-OPBRATION CHECKS 3-6 Checking the engine oil level 3-7

FILUNGFUEL .3 -8

STARTING ENGINE ,3-9

WARMING UP BSIGINE .......3 -16

SHIFTING Forward Reverse ..

STOPPING ENGINE.

.3-17

..3-17 . 3-18 ...3-19

TRIM MIN G OUTBOARD MOTOR ...3- 20 Adjusting trim angle 3-21

TILTING UP/DOWN 3-24

CRUISING IN SHALLOW WATH?. .3- 28

CRUISING IN OTHER CONDmONS 3 -31 Cruising in salt water 3 -31 Cruising in turbid water 3-31

fcÄ CD EMF10010

INSTALLATION

Incorre et engine height or ot>structions to smooth water flow (such as the design or condition of the boat or accessories such as transom ladders/depth Ander transducers) can create airborne water spray while the boat is cruising. Severe engine damage may result if the mc or is operated continuously in the presence of airborne water spray.

NOTE:

During water testing check the buoyancy of the boat, at rest, with its maximum load. Check that the static water level on the exhaust housing isilow enough to prevent water entry into the powerhead, when water rises due to waves when the outboard is not running.

3-1

CT:> EMF12012

MOUNTING THE OUTBOARD MOTOR

- ^

I J

1 / 1 / 1 1 1 / 1 /

iT

1 P 104011

Improper mounting of the outboard motor could result In hazardous oondi-tjons such as poor handling, loss of control, or fire hazards Observe the following: 8 The infomiation presented in this æc-

tion is intended as reference only. It is not possible to provide complete instruct ions for every possible boat/m(4 or combination. Proper mounting depends in part on experience and the specific boat/motor com-binatbn.

8 Your dealer or other person experienced in proper rigging should mount the motor. If you are mounting the motor yourself, you should be trained by an experienced person, [pennanent mounte d type]

8 Your dealer or other person experienced in proper outboard motor mounting should show you how to mount your motor, [portable type]

Mount the outboard motor on the ænter line (keel line) of the boat, and ensure that the boat Itself iswell balanced. Othen/vise, the boat will be hard to steer. For boats without a keel orwhich are asymmetrical, consult your dealer.

1 Center line (keel line)

3-2

•ir

CX>

Overpowering a boat may cause severe instabil'it y. Do not install an outboard motor with more horsepower than the maximum rating on the capacity plate of the boat. If the boat does rrat have a capacity plate, consult the boat manufacturer.

Mount ing Height To run your boat at opt im urn éffideney, the water-resistance (drag) of the boat and outboard motor muä be made as little as possible. The mounting-height of the outboard motor greatly affeds the water-resiäa nee. If the mounting-height istpo high, cavitation tends to occur, thus reducing the propulsion; and if the propeller tips cut the air, the engine speed will rise abnormally and cause the engine to overheat. If the mounting-height is too low, the water-resistance will ihaease and thereby reduce engine efficiency. IVIount the engine so that the anti-eayita-tion plate is between the bottom of the boat and a level 25 mm (1 in.) below it.

NOTE: 8 The optimum mounting height of the

outboard motor is affected by the boat/motor combination and the desired use. Test runs at different heights can help determine the optimum mounting height.

8 Refer to the section "TRIMMING OUTBOARD MOTOR" for instructions on setting the trim angle of the outboard.

3-3

.-fc^ CT) CLAMPINGTHE OUTBOARD MOTOR 1) Haee the outboard on the transom so

that it is positioned as dose to the ænter as possible. Tighten the transom damp SCTews evenly and securely. Check the damp-screws for tightness occasionally during operation of the motor asthey can work loose due to engiiie vibration.

L(X)se damp screws could allow the motor to move on the transom or fall off the transom. This could cause loss of control and serious injury. Make sure the transom screws are tightened securely. Occasionally check the screws for tightness during operatrøn.

2) An engine restraint cable or chain should be used. Attach one end to the engine restraint cable attachment point and the other to a secure mounting point on the boat. Otherwise, the engine could be completely lost if it accidentally falls off the transom.

Secure the damp bracket to the transom with the bolts provided with the outboard. For details, consult your dealer.

Avoid uising bolts, huts or washers other than those contained in the engine packaging. If used, they must be of at least the same quality of material and strength and must be tightened securely. After tightening, test mn the engine and check their tightness.

1 Motor mounting parts

3-4

cr> BREAKING IN (RUNNING IN)

ENGINE

Your new engine requires a period of break-in (running-in) to allow mating sur-faæs of moving parts to wear-in evenly. Correct break-in (running-in) will help ensure proper performance and longer engine life.

Failure tofollow the break-in (running-in) procedure rnay result in reduced engine life Greven severe engine damage.

Break-in (running-in), time: lOhours

EMF53711

Run the engine under load (in gear with a propeller installed) asfoHöws. 1) For the first hour of operation:

Run the engine at 2,000 r/min or at approximate iy half throttle.

2) For the second hour of operation: Run the engine at '3,000 r/min or at approximate Iy three-quarter throttle, and during this period run it at full throttle for approximately one minute every ten minutes.

3) For the next eight hours of operation: Avoid continuous operation at full throttle for more than five minutes at a time.

4) After these first 10 hours: Operate the engine normally.

3-5

cx> PRE-OPERATION GHECKS

If any item in the pre- peratiön check is not working properly, have it inspected and repaired before operating the outboard motor. Otherwise, an accident could occur.

Do not start the engine out of water. Overheating and serious engine damage can occur.

EMF41liO

Fuel 8 Check to be sure you have plenty of fuel

for your trip. 8 Make sure there are no fuel leaks or

gasoline fumes. 8 Check fuel line connéGtions to be sure

they are tight, 8 Be sure the fuel tank iö positioned on ä

secure, flat surface, and that the fuel hose isnot twisted or flattened, orlikely to contact sharp objects.

EMF42210

Oil 8 Check the level of the oil in the sump

with the dipîck. If necessary, add oil to bring the level up to the upper mark.

3-6

/^

cr> Controls 8 Check throttle, äiift, and steering for

proper operation before starting the engine.

8 The controls should work smoothly, without binding or unusual free play.

8 Look for loose or damaged connec

tions. 8 Check operation of the barter and stop

switches when the outboard motor is in the water.

EMF43511

Engine 8 Check the engine andengine mounting. 8 Look for loose or damaged fasteners. 8 Cheek the propeller for damage.

/" }

• » c ^ 4 / J.

201012

CHECKING THE ENGINE OIL LEVEL 1) Put the outboard motor in an upright

position (not tilted). 2) Pull out the oil dipstiek and wipe it

clean. 3) Completely re-insert the dipstick and

pull out it again. 4) Check the oil level using the dipstiek

to be sure the level falls between the upper and lower marks. Fill with oil if it is below the lower mark, or drain to the specified level if it is above the upper rnark

1 Oil dipstick 2 Lower level mark 3 Upper level mark

3-7

CX) FILLING FUEL

1) Remove the fuel tank cap. 2) Fill the fuel tank carefully. 3) Close the cap securely after refueling.

Wipe up any spilled fuel.

Fuel tank capacity: Referto SPEGIFIGATION S, page 4-1.

EM F21110

Ring Free Fuel Additive Gasoline is a predse blend of many different substances, eajc^ chosen to give certain characteristics. Gasoline blends have been changing in recent years in respi3nse to concerns about pollution and resulting emissions regulations. One of the most obvious changes has been the elimination of lead from most fuels.

As gasoline has changed, the amount of additives such as aromatics and oxygenates has Increased. These additives iare irnportant for the engines in passenger ears, but they can have detrimental effects in marine engines, because of increased deposits in the combustion chamber. When enough deposits colled, pision rings begin sticking. Performance drops and engine wear increases draniati-cally.

While many additives available may reduce deposits, Yamaha recommends the use of Ring Free Fuel Additive, available from your Yamaha dealer. Ring Free has repeatedly proven its ability to clean combusti on deposits from inside the engine, notably the critical piston-ring-land area, and fuel system components. Follow product labeling for use instructions.

3-8

902053

I: ' * 11

14. ^

304044

cr> « /

EMU 01147

STARTING ENGINE

8 Before starting the engine, make sure that the lx>at istightly moored and that you dan steer dear of any obstructidhs. Be sure there are no swimmers in the water near you

8 When the air verit screw is loosened, gasoline (petrol) vapor will be released. Gasoline (petrol) is highly flamrhable, and its vapors are f|amnnab|e and explosive. Refresh from smoking, arid keep away from open flames and sparks while loosening the air vent screw.

8 This product emits exhaust gases which contain carix>n monoxide, a coU prjess odorless gas which may cause birain damage or death when inhaled. Symptoms include nausea, dizzinesi and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blodking exhaust outlets.

1) If there isan air vent screw on the fuel tank cap, loosen it 2 or3 turns

2) If there is ä fuel joint on the niötör, fjrmly connect the fuel line to the joint. Then firmly connect the other end of the fuel line to the joint on the fuel tank.

NOTE:

During engine operation place the tank horizontally , or fuel cannot be drawn into the engine.

3) Squeeze the primer bulb with the outlet end up until you feel it become firm.

3-9

s- cr>

mØSi

PROCEDURE FØR TILLER CONTROL

MODEL 4) Hace the gear-shift lever in the neu

tral position. N011E:

The start-in-gear protedion device prevents the engine from starting except when in Neutral.

5) Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg. Then, install the lock plate oh the other end of the lanyard in the engine stop switch.

8 Attach the engine stop switch lanyard to a secure place on your dpthing, your ami orleg while operating.

8 Do not attach the lanyard to dothing that could tear loose^ Do not route the lanyard where it could become entangled, preventing it from functioning.

8 Avoid acddentally pulling the lanyard during normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the tx>at could slow rapidly. This could cause people and objects in the boat tobe thrown forward.

6) Race the throttle control grip in the "START" position.

3-10

ci:> Manual start model 7) Pull out theehoke knob completely.

After the engine starts, return the knob to the original position.

NOTE:

8 It is not necessary to use the choke when restarting a warm engine.

8 If the choke knob is left pulled out after the engine starts, the engine will stall.

8) Pull the starter handle slowly until you feel resi ânce. Then, give a strong pull straight out to crank: and start the engine. Repeat it, if necessary.

9) After the engine starts, return the starter handle slowly to the original position befoi'é releasing it.

10) Return the throttle to the fully closed position.

3-11

Æ a EMF63511'

Bectric start model 7) Pull out the ehoke knob completely.

After the engine starts, return the choke knob to the original position.

NOTE:

8 It is not necessary to use the choke when restarting a warm engine.

8 If the choke knob Is left pulled out, the engine will stall.

8)

9)

Push the stärter-bütton to start the starting motor. Immediately the engine starts, release the starter-button to return it to the original position.

10) Return the throttle control grip slowly to the fully closed position so that the engine does not stall.

8 Never push the starter-switch while the engine is running.

8 Do not keep the starter motor tuming for more than 5 seconds. If the starter-motor is turned continuously for more than 5 seconds, the t>attery will be quickly discharged, thus making it impossible to start the engine, If the engine will nol start after 5 seconds of cranking, release your hand from the starter-switc h, and crank the engine again after an interval of 10 seconds

3-12

N ' ^

p '^^^"pv Jn 701015

CD EMU00247

PROCEDURE FOR REMOTE CONTROL MODEL 4) Race the remote control lever in the

Neutral position. NOTE:

The start-in-gear protection device prevents the engine from starting except when in Neutral.

5) Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg. Then, install the lock plate on the other end of the lanyard in the engine äop switch.

8 Attach the engine stop switch lanyard to a secure place on your dcthing, your ami or leg vvhile operating.

8 Do not attach the lanyard to dothing that could tear loose. Do not route the lanyard v\ here it oould become entangled, preventing from functioning.

8 Avoid acädentally pullihg the lanyard during normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be throw n forward.

6) Turn the main switch to "ON",

3-13

æ>

701042

701041

BectriG Start Model 7) Open the throttle slightly lifting the

neutral throttle lever upwards partially. You may need to change the throttle opening slightly depending on engine temperature. After the engine starts, return the throttle to the original position.

NOTE:

8 As a starting point, lift the lever just until you feel resistance, then lift slightly more.

8 The operation of the neutral throttle lever is possible only when the remote control lever is in " N " .

8) Resînand hold themain switch to opei'afe the remote choke syêm. (The remote choke switch returns to its home position when you release your hand. Therefore, keep the switch pressed in.)

NOTE: 8 It is not necessary to use the choke

when the engine is wärm. 8 Set the choke knob to the home posi

tion, or the remote choke system will not operate.

9) Turn the main switch to "START", and hold it for a maximum of 5 seconds.

10) Immediately after the engine starts, release the main switch to return it to "ON".

3-14

cjy 8 Do not tum the main switch; to

"START' when the engine is running. 8 Do not keep the starter-motor tuming

for more than 5 seconds. The battery will rapidly become exhausted and it will be irppossible for it to start the engine. If the engine does not start within 5 seconds, retum the rnäin switch to "ON", wait 10 seconds;, and then crank the engine again.

3-15 ^

Æ CT> EMG0041;1

WARMING UP ENGINE

1) Before beginning operation, allow the engine to warm up at idling speed for 3 minutes. (Failure to do this will shorten engine life.)

2) Be sure the low oil pressure warning indicator goes off after starting the engine.

3) Check for a steady flow of water from the coQiing-water pilot hole.

8 If the low oil pressure indicator does not go off after the engine starts, stop the engine. Othen/vise, serious engine damage oould occur. Check the oil level and add oil if necessary. If the cause for the low oil pressure warning indicator canned be found, consult your Yamaha dealer.

8 A continuous flow of water from the pilot hole shows that the water pump is pumping water through the cooling passages. If water is not flowing out of the pilot hole at all times while the engine is running, do not continue to run the engine. Overheating and serious damage could occur. Stop the engine and check to see if the water inlet on the lower caang is blocked- If the problem cannot be found and corrected, ccMisult your Yamaha dealer.

3-16

Jr CX) EMU00261

SHIFTING

Before shifting, make sure there are no swnnmers orobstades in the water near you.

^ 1 ^ \ > \ N

To diange the shifting position from forward to reverse or yioe-versa, dose the throttle firät so that the ertgirte idles (or runs at bw speeds).

EMU00265

FORWARD Til ler control rhodél

1) Habe the throttle control grip In the fully dosed position.

2) Turn the gear-shift lever quickly and firmly from Neutral to Forward,


Pull up the neutral interlock trigger if equipped and move the remote control leVer quickly and firmly from Neutral to Fonward.

3-17

.-fc^ cx> EMU01326

REVERSE

When operating in Reverse, go slow ly. Do not open the throttle more than half. Otherwise, the boat may become unstable, w hich could result in loss of control and an accident.

402013*

1) Rape the throttle control grip in the fully dosed position (for filler control model).

2) Check that the tilt-lock lever (for Manual tilt/lHydro-tilt model) is in the locked position.

N

U 'f .

,.406025

Tiller control rriodel

3) Turn the gear-shift lever quickly and firmly from Neutral to Reverse.


3) Pull up the neutral ihterlock trigger if equipped and move the remote control levér quickly and firmly from Neutral to Reverse.

3-18

cx> EMU00273

STOPPING ENGINE

Let it cool off for a few minutes at idle or low speed first. Stopping the engine immediately after operating at high speed is not recommended.

EMUOOZ77

1) Rjsh and hold the engine ôp button or turn the rriäin switch to "OFF".

••~-:*\—n

- - ' ^ J'U

^^='*~ "vSîift.' I 304045 ''^\u [ >

2) If the fuel joints are provided, djlcoh-nect the fuel line from the motor after stopping the engine.

3) Tighten the air vent screw oh the fuel tank cap after stopping the engine, if it is equipped.

4) Remove the key if the boat will be left unattende d.

NOTE: The engine can also be stopped by pulling the lanyard and removing the lock plate from the engine; stop lanyard switch (then turning the main switch to "OFF").

3-19

J: a> EMU01412

TRIMMING OUTBOARD MOTOR

The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. The correct trim angle will help improve performance and fuel economy while reducing ärain on the engine. The correct trim angle dependis upon the combination of boat, engine, and propeller. Correct trim is also affected by variables such as the load in the boat, sea conditions, and running speed.

Excessive trim for the operating conditions (either trim up or trim down) can cause tx>at instability and can make steering the boat more difficult. This increases the possibility of an accidents If the boat begins to feel unstable oris hard to steer, slow down and/or readjust the trim angle.

NOTE: ,

Refer to the section "ADJUSTING TRIM ANGLE' for instructions on usage.

1 Trim operating angle

3-20

CF> ADJUSTING TRIM ANGLE EMU 00951

Manual tilt model There are 4 or 5 holes provided in the damp bracket to adjust the outboard motor trim angle. 1) Stop the engine.

Remove the trim angle adjusting rod 1 from the clamp bracket vyhile tilting the motor up slightly. Reposition the rod in the desired hole.

To raise the bow ("trim-out"), move the rod away from the transom. To lower the bow ("trim-in "), move the rod toward the transom. Make test runs with the trim set to different (angles to find the position that works best for your boat and operating conditions.

2)

3)

8 Stop the engine before adjusting the trim angle.

8 Use care to avoid being pinched when removing or installing the rod

8 Use (äutipn when trying a trim position for the first time. Increase speed gradually and watch for any signs of instability or Control problems. Improper trim angle can cause loss of control.

NOTE: .

The outboard motor trim angle can be changed approximately 4 degrees by shifting the trim adjusting-rod one hole.

3-21

cx> EMU014U

PcÄwerTilt Model

8 Be sure all people are dear of the outboard motor when adjusting the tilt angle, also be careful not to pinch any body parts between the drive unit and damp bracket.

8 Use caution when trying a trim position for the first time. Increase speed gradually and watch for any signs of instability or control problems Improper trim angle carl cause loss of control.

8 Use the power tilt switch located on the bottorh engine cowling (if equipped) only when the boat is at a comptete stop with the engine off.

1) Häee the geiar-shift lever in the neutral position.

2) Tilt the engine to the desired angle using the power tilt switch.

NOTE: ^__ Stay within the trim operating angle when trimming the outboard motor using the power tilt system.

To raise the bow ("trim-out"), tilt the engine up.

To lower the bow C'trim-in"), tilt the engine down.

Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions.

3-22

CX> EMU19160

Tri mangle settings and boat handling When the boat ison plane, a bow-up attitude results in less drag, greater stability and efficiency. Tliis Is generally when the keel line of the boat is up about 3 to 5 degrees. With the bow up, the boat may have a greater tendency to steer to one side or the other. Gqmp^ for this as you steer. The trim tab can also be adjusted to help offset this effect.

1 Optimum angle (leyel keel line) 2 Bow up 3 Bow down

Bow Up Too much trim-out puts the bow of the boat too high in the water. Performance and economy are decreased because the hüll of the boat ispushlng the water and there is more air drag. EKcessive trim-out can also cause the propeller to vehtiläte, which reduces performance further, and the boat may "ppfpoise" (hop in the water), which could throw the operator and passengers pyerboard.

Bow Down When the bow of the boat is down, it is easier to accelerate from a standing start onto plane. Too much trimîh causes the boat to "plow" through the water, decreasing fuel economy and making it hard to increase speed. Operating with excessive trim-in at higher speeds also makes the boiat unstable. Resistance at the bow is greatly increased, heightening the danger of "bow steering" and making operation difficult and dangerous.

3-23

Æ cx> NOTE:

Depending on the type of boat, the outboard motor trim angle may have little effect on the trim of the boat when operating.

EMH10111

TILTING UP/DOWN

If the engine will be stopped for some time, or if the boat Is moored in shallows, the engine should be tilted up to protect the propeller arid casing from damage by collision with obstructions, and also to reduce salt corrosion.

8 Before tilting the mcôr; follow the procedures under "STOPPING ENGINE". Never tilt the motor while the engine is running. Severe damage from overheating can result.

8 Do not tilt up the engine by pushing the steering handle as this could break the handle.

Be sure ail people are dear of the outboard motor When adjusting the ti|t angle, also be careful not to pinch any body parts between the drive unit and engine bracket.

Leaking fuel is ä fire hazard. Disconnect the fuel line if the engine will befitted for more than a few minutes. Otherwiise, fuel may leak, (if the fuel connector is provided on the motor.)

3-24

3z

^ U--—'=-^

l _ ^406023*

CT) EMU00290

PROCEDURE FOR TILTING UP Mariual tilt model

1) Race the gear shift lever in Neutral. 2) Remove the fuel line connection from

the motor. 3) Hace the tilt lock lever in the release

position. 4) Hold the rear of the top cowling with

one hand and fully tilt the engine up. 5) The tilt support bar tui-ns to the

locked position automatically.

403**3

BUIU00300

PROCEDU RE FOR TILTING DOWN Manual tilt moctel

1) Race the tilt lock lever in the lock position.

2) Slightly tilt up the engine until the tilt support bar is released automatically.

3) Tilt down the engine.

3-25

cx> >^

\ !•'

^ 5 ^ ^ ^ ^ - ^ 5 ^ " ^ -

- — ' \ * ' . I '

. \

304045

EMU01312

PROCEDURE FOR TILTING UP Power tilt model

1) Remove the fuel-line connection from the motor.

r t M & i DN ^m

m^

/ '

• . » -

p 701034;

2) Push the power tilt switch "UP' until the outboard has tilted up completely.

3) Push the tilt support knob into the clamp bracket tosupport the engine.

After tilting the engine, be sure to support it with the tilt support knob. Otherwise, the erigine could fall back down suddenly if oil in the power tilt unit should lose pressure.

3-26

fc^ a> EMU01313

PRO CE DU RE FOR TILTI N G DOWN Power titt model

1) Push the power tilt switch "UP' until the engine is supported by the tilt rod.

2) Pull out the tilt support knob. 3) push the power tilt switch "DN"

(Down) to lower the engine to the desired position.

3-27

CI> CRUISING IN SHALLOW

WATER

Manual tilt model

The outboard motor can be tilted up partially to allow operation in shallow water.

8 Raæ the gear îft in the Neutral position before using the shallow Water cruising system.

8 Run the boat at the lowest possible speed when using the shallow water cruising system. The tilt-lock mechanism does not work while the shallow water cruising system is being used. Hitting an underwater obstade coukJ cause the engine to lift out of the water, resulting in loss of control.

8 Use extra care when operating in reverse. Too much reverse thmst can cause the engine to lift out of the water, inoeasing the chance of acd-dent and personal injury.

8 Retum the engine to its normal position as soon ais the boat is back in deeper water.

Place the gear-shift in the Neutral posi tion before uäng the shallow water cruising system.

3-28

\

3-

.406023*

cx> PROCEDURE Manual tilt model

1) Race the gear shift lever in the neutral position.

2) Haee the tilt lock lever in the release position.

:403056

3) Slightly tilt up the engine. The tilt- support bar will lock automatically, supporting the engine in, a partially raised position.

NOTE: ; : ; ,

This motor has 2 positions for shallow water auising.

RETURNING TO ORIGINAL POSITION 1) Race the tilt lock lever in the lock

position. 2) Slightly tilt up the engine until the tilt-

support bar automatically returns to the free position.

3) Then, slowly lower the engine to the normal position.

3-29

Ir

000922

nM~"ij DN gN

m^

/ ,

w^

^

p 701034

C£> CRUISING IN SHALLOW

WATER

Power tilt model

The engine can bé tilted up partially to allow operation in shallow water.

8 Race the gear shift in the Neutral post tion before setting for shallow water cruising.

8 Return the engine to its normal position as soon äs the boat is t}ack in deeper water.

Do not tilt up the outboard motor so that the cooling water inlet of the lower unit IS above the surface of the water when setting for and cruising in shallow water. OthenA ise severe damage from overheating can result.

PROCEDURE 1) Hape the gear shift lever in the neu

tral position. 2) Slightly tilt up the engine using the

power tilt switch.

3-30

fc^ CD GRUISINX3 IM OTHER

CÖNÖITIONS

CRUISING IN SALT WATER After operating in salt water, wash out the æoling-water passages ,with fresh water to prevent them from b eeoming dpgged-up with salt deposits.

NOTE: ^ — —

Refer to cooling syäem flushing in^ruo-tions in "TRANSPORTING AN© STORINlG OUTBOARD MOTOR".

CRUISING IN TURBID WATER It is strongly recommended that the optional chromium-plated water-pump kit be installed if the outboard is to be used in turbid (muddy) water conditions.

3-31

cr> EMK00010

Chapter 4

AINTENANCE

SPECIFICATIONS .4 -1

TRANSPORTING AND STORING OUTBOARD MOTOR........... 4-3

Trallefin g outboard motor 4-3 Storing outboard motor. 4-5

PBRIODIG MAINTENANCE .4-9 Replacement parts 4-9 Maintenance chart ....4- 10 Greasing...... .;,;.......; . .......4-12 Cleaning and adjusting spark plug ...4-13 Checking top cowling ................ .i.......4-14 Checkirig fuel system ...4-15 Inspecting fuel filter 4-16 Inspecting idling speed .:4-17 Changing engine oil... 4 -18 Replacing fuse .........4-20 Checking wiring and connectors...... ,4-21 Exhaust leakage................ .,4-21 Water leakage 4-2 1 Checking power tilt system.v;; ..,.. .....;4-22 Checking propeller... ....4-23 Changing gear oil............ ...4-25 Cleaning fuel tank 4 -26 Inspecting and replacing anode(s)....4-27 Chedkihg battery ;4-28 Checking bolts and nuts 4-30 Cleaning cooling-^watef passages .....4-31 Motor exterior 4-32 Coating the boat bottom .........,..;.„ ...4-32

ay SPECIFICATIONS

^""'•~~"~^~—-.,,__^^ Model Item ^"~'"~~~~—~^.^^^^

DIMENSIONS

Overall Length Overall Width OverallHeight S/L Transom height S/L Weight S/L

PERFORMANCE

Fullthrottle operating range Mäximuna: output Idling speed (Neutral)

ENGINE

Type Displaæment Bore X stroke Ignition system Sparkplug Sparkplug, gap Gphtrpis/äem Staftihgsystem,

A/alveciearance (cold engine) IN EX

Battery lyiin. cold CT an king amps (CCA/SAE) Min.marihécrarikingamps(MG'VABYQ Min. reserve capacity (RG/SAE)

AiternatoF output Startingcarburetion system

DRIVEÜNIT

Geänpösitiohs Gearratio Trim and tilt system Propellermark

FUa.ÄNDOIL

Recomménde d fuel

Füeltank capaeity Recommended engine oil

Engine pil'capacity (withput oil filter) (with oil filter)

Recorrimended gear oil Gearoil capacity

TIGHTENING TORQUE

Sparkplug Propeilernut Engine oil drain bolt Engine oil filter

Unit

mm,(in.) mm (in ) mm (in.) mm (in.) kgOb.;)

r/min kW (HP):@:r/min

r/miri

cnri (cu.i n.) mm (in.)

NGK: mm (in.)

mm (in.) mmj(in.;)

ampsat-18°C(<).4°F) amps at;p°C(32°F)

minutes V-A :(W)

P.O.N. L (US gal, Irnpgal)

API SAE

L (US qt, Imp qt) L(USqt, Impqt)

CTn^(USpz, Imp oz)

N-m (kgf'm, Ib-ft) N-m (kgf-m, Ib-ft) N-m (kgf-m, Ib-ft) N-m (kgf-m, Ib-ft)

F15IVIHC

1,001(39.4) 427(16.8) 1,080 (42.5)/1,207 (47.5) 440 (17.3)/567 (22.3) 45(99)/47(104)

4,500 5.500 11.0 (15.0) @5,000 900 -1000

4-ströke, OHC, L2 323(19.71) 59.0x59.0(2.32x2.32) GDI system DPR6EA-9 0.8 0.9(0.031 0.035) Til ler control Manual start 0.15 0.25(0:006 0.010) 0.20 0.30(0.008 0.012)

— — — 12-(80) Choi« valve

Forward-Neutral-Reverse 2.08(27/13) Manual tilt J

Regular unleaded gasoline (Minimum 86) 25(6.60,5.50) 4-strokB motor oil SESF,SG, SH.SJ 10W-30,10W-40 1.0(1.06,0.88) 1.2(1.27,1.06) Hypoid gear oil (SAE90) 250(8.45,8.80)

18(1.8,13) 35(3.5,25) 28(2.8,20) 18(1.8,13)

4-1

ci:>

F15EHC

1,001(39.4) 427(16.8) 1,080 (42.5yi,207 (47.5) 440 (17.3)/567 (22.3) 48 (106)/50(110)

4,500 5,500 11.0(15.0)@5,000 900 -1000

4-Etrofe, 0HG,L2 323(19.71) 59.0x59.0(2.32x2.32) CDI system DPR6EA-9 0.8 0.9(0.031 0.035) Tillerebntrbl Bedricäaft 0.15 0.25(0.006 0.010) 0.20 0.30(0:008 0.012)

245 323 52 12-10 Chote valve

Forward-Neutral-Réyerse 2.08(27/13) Manual tilt J

Regular unleaded gasoline (Minimum 86)' 25 (6.60,5.50) 4-stroke motor oil SE, SF,SG,SH, SJ 10W-30,10W^0 1.0(1.06,0.88) 1.2(1.27, 1.06) Hypoid gear oil (SABO) 250(8.45,8.80)

18(1.8,13) 35 (3.5,25) 28 (2:8,20) 18(1.8,13)

F15PRC

643(25.3) 369(14.5) —/1,207(47.5) —/567(22.3) —/54(119)

4,500 5,500 11.0:(15.0)@5,000 900 r1000

4-äroke, OHC, L2 323(19.71) 59.0x59.0(2.32x2:32) CDI syäem DPR6EA-9 OS 0.9 (0,031 0.035) Remote control Bectric start 0.15 0.25(0;006Ö.Ö10): 0.20 0.30(0:008 0.012)

245 323 52 •12-10 Choke valve

Forwärd-Neutral^Reverse 2.08(27/13) Ftowertilt J

Regular unleaded gasoNnei (Minimum 86) 25(6.60,5.50) 4-ströke motor oil SE,SF,SG, SH.SJ 10W-30,10W-40 1.0(1.06,0.88) 1.2(1.27,1.06) Hypoid.gear oil (SAE90) 250(8.45,8.80)

18.(1.8, 13) 16(1.6, 11) 27(2.7, 20) 18(1.8,13)

F15PHC

1,001 (39.4) 427(16.8) ^1,207(47.5) —/567 (22.3) —/55(121)

4,500 5,500 11.0(15.0) @5,000 900 -1000

4-.strote, OHC, L2 323(19.71) 59.0x59.0(2.32x2.32) CDI system DPR6B\-9 0.8 0.9(0.031 0.035) Tiller control Bedricstart 0.15 0;25(0.006 0.010) 0.20 0.30(0.008 0.012)

245 323 52 12-10 Choke valve

Forward-Neutral-Reyerse 2.08(27/13) Fbwer tilt J

Regular unleaded gasoline (Minimum 86) 25 (6.60,5.50) 4-stroke motor oil SE,SF,SG,SH,SJ 10W-30, lOWÔ 1.0(1.06,0.88) 1.2(1.27, 1.06) Hypoid gear oil (SAE90) 250(8.45,8.80)

18(1.8,13) 16(1.6,11) 27(2.7,20) 18(1.8,13)

4-2

CI> EMU 01369-

TRANSPORTING AND STORING OUTBOARD MOTOR

Leaking fuel Is a fire hazard. When transporting and storing the outboard motor, dose the air vent screw and fuel cock to prevent fuel from leaking.

EMK20210-

TRÄILERING OUTBOARD MOTOR The ^mötor should be trailered and stored In the normal runhlng positlon. If there is insuffldent: road dearanee in this position, then trailer the rnotor in the tilt position using a motor support device such as a transom saver bar. For further details, consult your Yamaha dealer.

8 Never get under the lower unit while it is tiKed, even if a motor support bar is used. Severe injury could occur if the outboard äcädentally faljSL

8 USE CARE when transporting fuel tank, w hefher in a boat or car. DO NOT fill fuel container to maximum capadty. Gasoline will expand conad-erably äs it wantis up and can build up pressure in the fuel container. This can cause fuel leakage and a potential fire hazards

Do not use the tilt support lever/knob when trailering the boat. The outboard m(ôr could shake loose froni the tilt support and fall. If the motor can not be trailered in the down position, use an additk>nal support device to secure it in the uppositkHi.

4-3

cX> Clamp handle mounting model

When transporting or storing the outboard motor while removed from a boat, fold the tiller handle and lean the motor on the tiller handle tokeep ina horizontal posit i on.

Keep the power unit higher than the propeller at all times Othen/vise, cooling water can mn into the cylinder, which could result in damage.

NOTE:

Place a towel or the like under the outboard motor to proted it from damage.

4-4

cx>

1 f^^\

jwn^ m \

000923

EMK16210'

STORING OUTBOARD MOTOR When storing your Yamaha outboard for prolonged periods of time, (2 months or longer), several important proædures must be performed to prevent expensive damage. It is advisable to have your outboard serviced by an authorized Yamahia dealer prior to storage. :Howéyer; the follovving procedu res can be performed by you,, the ov/ner, witli a minimum of tools,

2

MsUtaBLîCiriiMi^^Ê&i«^ / hr==?^^âp^^^^

10206 5

8 To prevent problems whieh can 'be caused by oil entering the cylinder from the sump, keep the engine in the attitude shown w;hen transporting and storing it.

8 Do not place the engine on its skle before the coolirtg Water has drained from it completely, or water may enter the cylinder through the exhaust port and cause problema

8 Store the engine in a dry, well-ventilated place, not indirect sunlighti

1 Vertical position 2 HoriaDntal ppsitipn (onthe pprt side)

EMK21010

Filling Fuel Tank Fill the fuel tank with fresh fuel and add one ounce of "Yamaha Fuel Conditioner and Stabilizer" (Part No. LUB-FUELC-12-00) to each gallon of fuel. NOTE:

The use of "Yamaha Fuel Gonditioner and Stabilizer" eliminates the need to drain the fuel system. Consult your Yamaha dealer or other qualified mechanic if the fuel system isto be drained instead.

4-5

CX) EMU 00338

Flushing Cooling System and Fogging Engine Cooling system flushing is essential to prevent the æoling system from clogging up with salt, sand, ordirt. Inaddition, fogging of the engine is mandatory to prevent expensive engine damage due to rust. Perform the flushirig and fogging at the same time.

8 Do not toLK:h or remove electrical parts when starting or during operation.

8 Keep hands, hair and clothes avvay from flywheel and other rotating parts while engine is running.

EMK25610

8 Flushing in a Water Tank

If the fresh water level is below the level of the anti-cavitation plate, or if the w ater supply is insufficient, engine seizure may occur.

1) Remove the engine top cowling. 2) Install the outboard motor on the

water tank. 3) Fill the tank with fresh water to above

the level of the anti-cavitation plate. 4) Run the engine at a fast idle for 10-^15

minutes. 5) Just prior to turning off the engine,

quickly spray "Yamaha Stof-Rite Engine Fogging Oil" (Part No. LUB-STRRT-12-00) into the silencer cover. When properly done, the engine will smoke excessively and almost stall.

4-6

CX)

- • n W

^^"^ ^ i —w

605Ö24

6) Remove the motor from the water tank.

7) Install the silencer cover and top cowling.

1 Water surface 2 Lx»west water level

EM K26011

Lubiicat ion 1) Remove the spark plüg(s). Spray a

Yamaha "Stor-Rite Engine Fogging Oil" into each cylinder for 10 seconds. Grease the spark plug threads and reihstall the spark plug(s) and torque to proper specification. (Refer to the "GLEANING AND ADJUSTING

SPARKPLUG"). 2) Turn the engine over with the stop

lanyard disconneded to work the fogging oil into the piston rings.

3) Change the gear-case oil. (Refer to "CHANGING GEAR OIL"). Inspect the oil for the presence of water which indicates a leaky seal. Seal replacement should be perforrned by an authorized Yamaha dealership prior to use.

4) urease all grease fittings. (Refer to the "GREASING")

EMK27011

Cleaning and Anti-con'osion Measui« 1) Wash down the exterior of the out

board with fresh water and dry off completely.

2) Spray the engine's exterior with ''Yamaha Silicone Protectant" (Part No. LUB-SILCNE-13-00).

3) Wax the cowling with a non-abrasive wax such as "Yamaha Silicone Wax" (Part No. ACC-11000-15-02).

4-7

CX) EMK290T1

Battery Care

Battery electrolyte is poisonous and dangerous, äiusing severe bums, etc It oori-tains sulfuric add. Avoid contact with skin, eyes, or clothing. Antidote: EXTERNAL; Flush with water. INTBÂL; Drink large quantities of water or milk. Foltow with milk of magnesia, beaten egg, or vegetabte oil. Call physician immediately. EYES; Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosivø gases: Keep sparkle flame, cigarettes, etc aWay. Ventilate when charging or using in a ck>sed space. Always wear eye protection when working near batteries. KEB> OUT OF REACH OF CHILDREN.

Batteries Vary among manufacturers. Therefore the following procedures may not always apply. Consult your battery manufacAu rer-s instructions.

1) Disconnect and remove the battery from the boat. Always disconnect the black negative lead fir^ to prevent the risk Of shoriing.

2) Clean the battery easing and terminals. Fill each cell to the upper level with distilled water.

3) Store the battery on a level surface in ia cool, dry, well-ventilated place out of direct sunlight.

4) Qnee a month, check the specific gravity oTthe electrolyte and recharge as required to prolong battery life.

4-8

PERIODIC MAINTENANCE

Be sure to turn off the engine when you perfonn maintenance unless otherwise specified. If the owner is not färniliär wJith machine servicing, this work should be done by a Yamaha dealer or other qualified mechanic.

Maintenance, replacement, or repair of the emission opntrc devices and systems may be perfonned by any marine éhgirie repair establishmerit or individual. All warranty repairs however, including those to the emission control system, must be perfonrhed by an authorized Yamaha marine dealership. A service manual is available for purchase through a Yamaha dealer for owners who have the mechanical skills, tools, and other equipment necessary to perform mainte nance not covered by this owner's manual.

EM K33p11

REPLACEMENT PARTS If replacement parts are necessary, use only genuine Yamaha parts or equivalents of the same type and of equivalent strength and materials. Any part of inferior quality may malfunction, and Vné resulting loss of control could endanger the operator and passenger's. Yamaha genuine parts and accessories are available from a Yamaha dealer.

4-9

CX) EMU193B1

MAINTENANCE CHART Frequency of maintenance operations may be adjusted according to the operating conditions, but the following table gives general guidelineis. Refer to the sections in this chapter for explanations of each owner-specific action. The mark (* ) indicates the check-ups which you may carry out yourself. The mark(1 ) indicates work tobe carried out by your Yamaha dealer.

Item

Spark plug(s)

Greasing poirits Gear oil Fuel-system Fuel filter (disposable) Fuel tank (Yamaha portableitank) Idling speed (earburetor models) Anode(s) Cooling water passages Propel ler and cotter pi n Tirhingbelt Battery Throttle link/throttle cable /throttle pick-up timing Shiftlink/shift cable Themiostat Powertri mand tilt unit Water pump Engine oil Oil ,fi Iter (cartridge) Valve clearance (OHC, ÖHV> Cowlingdamp

Actions

Gleaning/ adjustment / replacement Greasing

Change Inspection Inspectibh / replacement

Gleaning

Inspection / adjustment

Inspection / replacement Cleaning Inspection /replacement Inspection / replacement Inspection / charging


Inspection / adjustment Inspection 1 nspection Inspection Inspedion / change Change


Inspection

Initial 10 hours (1 month)

*

* *

* /1

* /1

* /1

*

1

50 hours (3 months)

*

* /1

* /1 * *

E\«ry 100 hours (6 months)

* .*

*

* /1

* 71

* 71 * * 1

*

1

200 hours (1 year)

*

•

1

1

1

*

N Q T F :

When operating in salt water, turbid or muddy water, the ehgine shpuld be flushed with clean water after each use.

4-10

o^ Ifem

Timing belt

Actions

Replacement

Every 500 hours (2.5 years)

1000: hours (5 years)

1

m

4-11

ci:> EML00011

GREASING Yamaha marine grease (Water resistant grease)

I f.- --îÅh f K

r' r = ^ < Ä

4-12 103192

CX) CLEANING AND ADJUSTING s PARK PLUG

When removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator oxjld allow external sparks, which could lead toexpkision or fire.

The spark plug Js ari important engine component and is easy to ihspeeä. The condition of the spark plug can indicate something about the condition of the engine. For example, if the eenter electrode porcelain is very white, this could indicate an intake air leak or carburetion problem in that Cylinder. Do hot atterhpt to diagnose any problems yourself. Inäiead, take the outboard motor Xo a Yamaha dealer. You should periodically remove and inspect the spark iplug because heat and deposits will cause the spark plug to slowly break dpvyn and erode. If electrode erosion becomes exceæive,or if carbon and other deposits are excessive, you should replace the spark plug with another of the correct type.

Standard spark plug: Refer to "SPECIFIGATIO NS", page 4-1.

Before fitting the spark plug, measure the electrode gap with a wire thickness gauge; adjust the gap to spedfication if necessary.

Spark plug gap: Refer to "SPECIFICATIO NS", page 4 - i .

4-13

•

CT) When fitting the plug, alyyays deari the gasket surface and use a new gasl<et. Wipe off any dirt from the threads and screw in the sparl< plug to the correct torque.

Sparkplug torque: Refer to " SPECIFICATIÖ NS", page 4-1.

NOTE:

If a torque-wrench is not available when you are fitting a spark plug, a good egti^ mate of the correct torque is 1/4 to 1J^ a turn past finger-tight. Have the spark plug adjusted to the correct torque as soon as possible with a torque-Wrench.

Initial of spark plug I.D. mark

B

C/BK

D

Rug wrench size

21 mm (13/16 in.)

16 mm (5/8 in.)

18:3 mm (23/32 In.)

1 Spark pluggap 2 Spark plug I.D. mark (NGK)

CHECKING TOP COWLING Check the fitting of the top cowling by pushing it with both hands. If the fitting is loose have it repaired by a Yamaha dealer.

4-14

cr>

^^c£ •^.

106064

EMK38010

CHECKING FUEL SYSTEM

Gasoline (petrol) and Its vapors are highly flammable and explosive. Keep away from sparks, dgarettes^ flames or other sources of ignition.

Check the fuel line for leaks, craete, or malfunctions. If any problem is found, it should be repaired immediately by Yamaha dealer or other qualified mechanic.

Checking points 8 Fuel system parts leakage. 8 Fuel hose joint leakage. 8 Fuel hose cracks or other damage. 8 Fuel cpnnedor leakage.

Leaking fuel can result in fire or explosion. 8 Check for fuel leakage regularly. 8 If any fuel leakage is found, the fuel

system must be repaired by a qualified mechanic Improper repairs can make the outboard unsafe to operate.

4-15

ci:> EMK50001'

INSPECTING FUEL FILTER

Gasoline (petrol) is highly flammable, and its vapors are flammable and explosive. 8 If you have any question about properly

doing this procedure, consult your Yamaha dealer.

8 Do not perform this procedure on a hot or running engine. Allow the engine to cool.

8 There will be fuel in the fuel filter. Keep away from ^»rt^s, dgarettesi, flames or other sources of ignition.

8 Thi s procedure Will allow some fuel to spill. Catch fuel in a rag. Wipe up any spilled fuel irnmediately.

8 The fuel jfilter must be reassembled carefully with O-ring, filter cup, and hoses in place. Irnproper assembly or replacement can result in a fuel leak, which could result in a fire or explosion hazard.

EMK5P310

Check the fuel filter periodically. The fuel filter is,a one-piece, disposable type. If foreign rftatter is found in the filter, replace it. For replacement of the fuel filter, consult a Yamaha dealer.

4-16

ci:> INSPECTING IDLINCBSPEED

8 Do not touch or remove electrical parts when starting or during operation.

8 Keep hands, hair and dpthes away from flywheel and other rotating parts w hile engine Is running.

Thi s procedure must be perfomied while the outtioard motor Is in the water. A flushirKi ättadirrieint ortest tank can also be used.

A diagnostic tadiometer shpulcl be used for this proæduré. Results may vary depending on whether testing isconduct-ed with the flushing attachment, in a test tank, or with the outboard motor in the water. 1) $tart the engine and allow it to warm

up fully iri neutral until it is running smoothly. If the outboard motor is rnounted on a boat, be sure the boat is tightly moored.

2) Verify whether the idle speed isset to specification. For idle speed spedfiea-tions, see "Specifications" in this chapter.

NOTC: Correct idling speed inspection is only possible if the engine is fully warmed up. If not warmed up fully, the idle speed will measure higher than normal. If you have difficulty verifying the idle speed, or the idle speed requires adju^ment, consult a Yamaha dealer orother qualified mechanic.

4-17

cx> EMU01415

CHANGING EN GINE OIL

8 Avoid draining the engine oil immediately after stopping the engine. The oil is hot and should be hap'^'^^ ^^^ ^^^^ to avoid bums.

8 Be sure the outboard is securely fastened to the transom or a stable stand.

- A

—^V J

ooæ23

' / I 60103 2

8 Change the engine oil after the first 10 hours of operation, and every 100 hours or at 6-month intervals thereafter. Otherv\/ise, the engine will wear quickly.

8 Do not overfill the oil, and be sure the engine isin an upright posftion (n(4 tilted) when checking and changing the engine oil.

8 If the oil level is above the upper level mark, drain, until the level meets the specified capacity. Overfilling the oil may cause leakage or damage.

1) Put the outboard motor in an upright position (not tilted).

2) Prepare a suitable container which can hold a larger amount than the engine oil capacity. Loosen and remove the drain bolt i while holding the container under the drain hole. Let the oil drain completely. Wipe up any spilled oil immediately.

3) Rjt a new gasket on the drain bolt. Apply a light coat of oi! to the gasket and reinstall thedrain bolt.

Tightening torque: Referto"SPEGIFICATIO NS", page 4-1

4-18

cx> NOTE:

If a torque wrench is not available when you are installing the drain plug, finger tighten the bolt just until the gasket comes into contact with the surface of the drain hole. Then tighten 1/4 - 1/2 turn. Have the drain plug torqued to the correct value with a torque wrench as soon as possible.

4) Remove the oil filler cap 2 . Add the correct amount of oil through the filler hole. Reinstall the filler cap.

Engl ne oil grade/capacity: Refer to "SPECIFICATIO NS", page 4.1.

5) Start the engine and watch to make sure the low oil pressure warning lamp turns off. Make sure that there are no oil leaks.

If the oil lamp does not turn off, or If there are oil leaks, stop tte engine and find the cause. Continued operation with a problem could cause severe engine damage. If the problem cannot be found and corrected, consult your Yamaha dealer.

6) Turn off the engine and wait 3 minutes. Recheck the oil level using the dipstick to be sure the level falls between the upper and lower marks. Fill with oil if it is below the lower mark, or drain to the specified level if it is above the upper mark.

7) Dispose of used oil according to local regulations.

4-19

CT) NOTE:

your 8 For disposal of used oil consult Yamaha dealer.

8 The oil should be changed more often when the engine is operated under adverse conditions such as extended trolling.

EMU01463

REPLACING FUSE If the fuse has blown on an Bedric start model, open the fuse holder and replace the fuse with a new one of proper amperage.

Be sure to use the specified fuse. An Incorrect fuse or a piece of wire may allow excessive current flow. This could cause electrical system damage and a fire hazard.

NOTE: If the new fuse blows again immediately, consult a Yamaha dealer.

1 Fuse holder 2 Fuse(2Qft) 3 Spare fuse (2QA)

4-20

cx> CHECKING WIRING AND CONNECTORS 1) Check that each grpunding wire is

prpperly secured. 2) Cheek that each ccnnectcr is engaged

secure ly.

EXHAUST LEAKAGE Start the engine and check that no exhaust lea I« from the jpints between the exhaust oover, cylinder head and crank case.

EMK78210

WATER LEAKAGE Start the engine and check that no water leate frpm the jpints between the exhaust cOvef, cylinder head and crank case.

4-21

CD CHEGKING POWER TILT SYSTEM

8 Never get under the lower unit while it is tilted, even when the tilt-support knob is locked. Severe injury couM occur if the outboard accidentally falls

8 Make sure no one is under the outboard before performing this test.

1) Check the power tilt unit for any sign of oil leaks.

2) Operate each of the power tilt switches on remote control and engine bottom æwling (if equipped) to check that all 9A/itches work.

3) Tilt up the motor and cheek that the tilt rod 1 is pushed out completely.

4) Check that the tilt rod isfi-ee of corrosion or other flaws.

5) Operate the motor to tilt down. Check that the tilt rod operates smoothly.

NOTE:

If any operation is abnormal, consult a Yamaha dealer.

Recommend ed fluid; Yamaha power trim & tilt fluid or ATF (DEXRON-E)

4-22

cr> T^..f^

K;^ t3.

Ä0>^r I 210014* i s ' '

EML0d013

CHEGKI NG PROPELLER

You could be seriously injured if the engine accidentally starts while you are near the propeller. 8 Before inspecting, removing or

installing the propeller, remove the spark plug caps from the spark plugs. Also, put the shift control in Neutral, put the main switch in the "OFF" poa-tk)n and remove the key, and remove the lanyard from the éiiginé stop switch. Turn off the battery cut-off switch if your boat has orie.

8 Do not use your hand to hold the propeller when bosening ortighteniing the propeller nut. Rjt a wood bk)ck t)etween the cavitation plate and the propeller to preverit the propéliér from tuming.

Propeller ched<ing Point 8 Check each of the propeller blades for

wear, erosion from cavitation or ventilation, or other damage.

8 Check the splines for wear and damage. 8 Check for fish line winding around the

propeller shaft. 8 Check the propeller shaft oil seal for

damage.

EMU0æ77

Removing the Propeller 1) Straighten the Gptter-pin 1 and pull It

out using a pair of pliers. 2) Remove the propeller nut 2 and

washer 3 . 3) Remove the propeller 4 and thruä

washer 5 .

4-23

cx>

i (C^

^ ^ - ^ ^

602053

Installing the Propeller

8 Be sure to Install the thrust washer before Installing propeller, otherwise, lower case and propeller boss may be damaged.

8 Be sure to use a new (xAter pin and bend the ends over securely. Otherwise, the propeller could come off during operation and be lost.

1) Apply Yamaha Marine grease or a corrosion resistant grease to the propeller-shaft .

2) Install the thrust washer and propeller on the propeller-shaft.

3) Install the washer and tighten the propeller nut to the specified torque.

Tightening torque: Refer to "SPECIFICATIO NS" page 4-1.

4) Align the propeller nut with the propeller shaft hole. Insert a new cotter pin in the hole and bend the cotter pin ends.

NOTE: ^ ^ ^ _ When the propeller nut does not align with the propeller shaft hole after tightening to the specified torque, then tighten the nut further to align it with the hole.

4-24

CD CHAN GIN G GEAR OIL

8 Be sure the outboard motor Is securely fastened to the transom or a stable stand, You could be severely injured if the outboard motor falls on you.

8 Never get under the lower unit while it is tilted, even when the tilt support lever or knob is locked. Severe injury could occur if the outboard motor accidentally falls.

1)

2)

3) 4)

Jilt the outboard rnptor so that the gear oil drain screw is at the lowest point possible. Race a suitable eohtaiher under the gear case. Remove the gear oil drain screw 1 . Remove the oil level plug 2 to allow the oil to drain completely.

Inspect the used oil after it has been drained. |f the oil is milky, water is getting into the gear case which can cause gear damage. Consult a Yamaha dealer for repair of the lower unit seals

NOTE:

For disposal of used oil consult your Yamaha dealer.

4-25

cr> 5) With the outboard rnotor ih a vertical

position , and using a flexible or pres-surized filling device, Inject the gear oil into the gear oil drain screw hole.

Gear oil grade and capacity: See "Spedfieations " in this chapter.

6) When the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug.

7) Insert and tighten the -gear oil drain screw.

EM L22012

GLEANING FUEL TANK

Gasoline (petrol) Ishighly flammable, and its vapors are flammable and expbsive. 8 If you have jany question about properly

doing this procedure, consult your Yamaha dealer.

8 Keep away from sparks digarettes flames or other sources of ignition when cleaning the fuel tank.

8 Remove the fuel tank from the boat before cleaning it. Work only outdoors in ah area with good ventilation.

8 Wipe up any spilled fuel bnmediately. 8 Reassemble the fuel tank carefully.

Improp er assembly can result in a fuel leak, \A/hiGh could result in a fire or explosion hazard.

8 Dispose of old gasoline (petrol)accprd-ingto local regulations.

1) Empty the fuel tank into an approved gasoline (petrol) container.

2) Pour a small amount of suitable solvent in the tank. Reinstall the rap and shake the tank. Drain the solvent completely.

4-26

cx>

V /r^ ' '7

1 ir' ->_!>• /

;'-'^v' V \

\ \ ' "»— X t

\ " \ • ' • • 604011

EML22110

Cleaning the Fuel Filter 1) Remove the screws holding the fuel

hose joint assembly .Pull the assembly out of the tank.

2) Clean the filter (located on the end of the suction pipe) in a suitable cleaning solvent. Allow the filter to dry.

3) Replace the gasket with ä hevy One. Reinstall the fuel hose joint assembly and tighten the screws firmly.

EMUT4622

INSPECTING ANE^REPLACING ANODE(S) Yamaha outboard motors are protected from corrosion by sacrificial anodes. Inspect the external anodes periodieally. Rem ove scales from the surface's of the anodes. Consult a Yamaha dealer for replacement of external anödes.

Do not paint anodes, as this would render them ineffective.

NOTE: Inspect ground leads attached to external anodes on equipped models. Consult a Yamaha dealer for inspection and replacement of internal anodes attached to the power unit.

4-27

CD EMU 04041

CHECKING BATTERY (for Electric start models)

Battery electrolytic fluid is dangerous; it contains sulfuric add and therefore is poisonous and highly caustic. Always follow these preventive measures: 8 Avoid bodily contact with electrolytic

fluid as it can cause severe bums or permanent eye injury.

8 Wear protective eye gear when handling or working near batteries.

Antidote (EXTe?ISIAL): 8 SKIN -Flush with water. 8 EYES - Flush w ith water for 15 minutes

and get imniediate medical attention. Antidote (INTERNAL): 8 Prink large quantities of water or milk

folk>wed by nriilk of magnesia, beaten egg, or vegetable oil. Get immediate medical attentk>n.

Batteris also generate explosive hydrogen gä^ therefore, you should always: follow these preventive measures: 8 Charge batteries in a well-ventilated

area. 8 Keep batteries av\ ay from fire, sparks,

or open flames (é^g., welding equipment, lighted cigarettes, etc).

8 DO NOT SMOKE when charging or handling batteries.

8 Kæp BATTBRIES AND B-ECTROLYTIC FLU ID OU T OF REACH OF CHILDRBM.

4-28

CX)

8 A poorly maintained battery will quickly deteriorate.

8 Ordinary tap-water contains minerals harmful to a battery, and should not be used for topping-up.

1) Check the electrolyte level at leaä once a.month; Fill to the manufacturer's reGommehded level when necessary. Top up only with distilled water (or pure de-iohized water suitable to use in batteries).

2) Always keep the battery in a good state of charge. Installing a voltmeter will help you monitor your battery. If you will not use the boat for a month bi'more, remove the battery from the boat and store it in a cool, dark place; Completely recharge the battery before using it.

3) If the battery will be stored for longer than a month, check the specific gravity of the fluid at least once a month and recharge the battery when it is low.

NOTE: . Consult a Yamaha dealer when charging or re-charging batteries.

EMU01279

Connecting the Battery

Mount the battery holder securely in a dry, well-ventilated, vibration-free location in the boat. Install a fully charged battery in the holder.

4-29

CD

8 Make sure the main switch (on applicable models) is "OFF" before working on the battery.

8 Reversal of the battery leads will damage the rectifier.

8 Connect the RED lead first when installing the battery and disconnect the RED lead last when removing it. OthenA lse, the electrical system can be damaged.

8 The electrKal contacts of the battery and cables must tie dean arxl properly connede d, or the battery will not start the engine.

Connect the RED lead to the POSITIVE (+) terminal first. Then connect the BLACK lead to the NEGATIVE (-) terminal.

1 Red lead 2 Black lead 3 Battery

EMU01280

Disconneding the Battery Disco nnec t the BLACK lead from the NEGATIVE (-) terminal first. Then disconnect the RED lead from the POSITIVE (+) terminal.

EM L40011

CHECKING BOLTS AND NUTS 1) Check that bolts securing the cylinder

head and engine and the nut securing the flywheel are tightened with their specified tightening torque.

2) Cheek the tightening torque of other bolts and nuts.

4-30

a:>

000936

CLEAN IN e GOOLIN G-WATER PASSAGES Flushing device equipped model

Perform this procedure right after operation for the most thorough flushing. 1) After shutting off the engine, unscrew

the garden-hose eonnedor 2 from the fitting 1 on the bottom cowling.

2) Screw the garden-hose connector 2 onto a garden hose 3 which is eonr nected to a frésh-watér supply.

3) With the engine off, turn on the water tap and let the watei' flush thro'ugh the cooling passages for about 15 minutes. Turn off the water and disconnect the garden hose 3 .

4) When flushing is complete, reinstall the garden-hose connector 2 on the fitting 1 on the bottom eoyvling. Tighten the connector securely^

Do not leave the garden-hose connector loose on the bottom cowlirig fitting or let the hose hang free during nomnal operation. Water will leak but of the connector instead of cooling the ertgine^ which can cause serious overheating. Be sure the connector is tightened securely on the fitting after flushing the engine.

NOTE: 8 When flushing the engine with the boat

in the water, tilting up the engine until it is completely out of the vyater will achieve better results.

8 Refer to cooling system flushing instructions in "TRANSPORTING AND STORING OUTBOARD MOTORS'.

4-31

CX) . . . < - " •

Æc # 001187

MOTOR EXTERIOR EM L4251i

Cleaning the Outboard Motor After use, wash the exterior of the outboard with fresh water. Flush the cooling system with fresh water. NOTE: ^ ^ ^ _

Refer to Flushing Cooling System instruo-tionsin "TRANSPORTING AND STORING OUTBOARD MOTOR".

Checking Painted Surface of Motor Cheek the motor for scratches;, nicks, or flaking paint. Areas with damaged paint are more likely to corrode. If necessary, dean and paint the areas. A touch-up paint isavailable from ä Yamaha dealer.

COATING THE BOAT BOTTOM A clean hull improves boat performance. The boat bottom should be kept as clean of marine growths as possible. If necessary, the boat bottom can be coated with an anti-fouling paint approved for your area to inhibit marine growth. Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion.

4-32

cx> -MEMO-

cr> EMN00010

Chapters

TROUBLE RECOVERY

TROUBLESHOOTING ..5-1

TEM PORÄR Y ACTION IN EMERGENCY 5-5

Impact damage; 5-5 Power tilt will hot operate 5-5 Starter will not operate 5-6 Treatment of submerged motbr..........5 -9

9 cx> EM U01204

TROUBLESHOOTING

A problem in the fuel, compression, or ignition syäems can cause poor starting, loss of power, or other problems. The troubleshooting chart describes basic checks and possible remedies. (This chart covers all Yamaha outboard motors. Therefore, some items may not apply to your model.) If your outboard motor requires repair, bring it to a Yamaha dealer.

Trouble

A. iStartervi/.illnot operate.

B: Bigine will not start (Starter operates).

Possible Cause

1. Battery capacity weakorlow.

2. Battery connections loose or corroded.

3. Fuse for electric start circuit bipvyn.

4. Starter components faulty.

5. Shift lever in gear.

1. Fuel tank empty. 2. Fuel contaminated or stale. 3. Fuel filter clogged. 4. Starting procedure incorrect.

5. Fuel pump malfunctions.

6. Spark plug(s) fouled or incorrect type.

7. Sparkplug cap(s) fitted incorredly. 8. Ftopr connections or damaged

igriition wiring.

9. Ignition partsfaulty.

10. Engine stop switch lanyard not attached.

11. Engine innerpartsdamaged.

Remedy

1. Check battery condition. Use battery of Tecpnriméndéd capacity.

2. tighten batterycables and dean battery terminals

3. Gh'eckfbr cause, of electric overbad and repair.Replace fuse withohebfcorrect amperage.

4. Hayeserviced by a Yamaha dealer.

5. Shiftto neutral.

1. Fiirtarik'with dean, fresh fuel. 2., Fill tank with dean, fresh fuel. 3. Clearibr replace.filter. 4. Reäd"STARJING ENGINE"

section. 5 Have serviced by a Yamaha

dealer.-6. Ihspeet'spark pi ug(s); Clean or

répiaée with recommended type. 7. Gheckand re-fit cap(s). 8. Ghéd<Wires:fpr wearbr breaks.

Tighten all loose connections. Replaceworn or broken wires.

9. Haveséryibed by a Yamaha dealer.

10. Attach lanyard.

11. Haveserviced by a Yamaha dealer.

5-1

9 CD Trouble

C. Bigine Idles irregu|ar|ypr stalls.

1,

2.

3. 4. 5.

6. 7. 8.

9. 10.

11.

12.

13.

14. 15.

16.

17. 18.

19.

Possible Cause

Sparkpjug(s) fouled or incorrect type. Fuel system obstructed.

Fuel contaminated or stale. Fuel filter dogged. Failed ignition parts.

Warning system activated.

Sparkplug gap incorrect. Poor opnnections or damaged ignition wiring.

Specified engine oil not used. Thermostat faulty or clogged.

Carburetor adjustments incorrect.

Fuel pump damaged.

Air vent screw on the fuel tank dosed. Chote knob pulled out. Motor angletoo high.

Carburetor dogged.

Fueljoint connection incorrect. Throttle valve adjustment incorrect.

Battery lead disconnected.

1.

2.

3. 4. 5.

6. 7. 8.

9. 10.

11.

12.

13.

14. 15.

1.6.

17. 18.

19.

Remedy

Inspect ,spärkplug(s), Clean or replacewith recommended type. Checkfor pinched or kinted fuel lineor other obstructions in fuel system. Fill tank with dean, fresh fuel. Clean or replace filter. Haveserviced by aYamaha dealer. Find and correct.cause of warning.

Inspect and adjust as spedfied. Check wiresfor wear 0r breaks. Tighten all loose connections. Replace worn pr broken wires. Check and replace oil as spedfied. Haveserviced by a Yamaha dealer. Haveserviced by a Yamaha dealer. Haveserviced by a Yamaha dealer. Open the airverit screw.

Return to home position. Return to normal operating position. Haveserviced by aYamaha dealer. Connect correctly. Haveserviced by a Yamaha dealer. Connect securely.

5-2

9 CP Troüb le

D. Warning buzzer sounds or indicator lamp lights.

E Engine powerloss.

Possible Cause

1. Cooling system clogged.

2. Engine oillevellow.

3: Heat range of sparkplug incorrect.

4. Specified engine oil not used.

5. Engine oil contaminated or deteriorated.

iS; Ql filter clogged.

7. Ql feed/injection pump mälfijhctions .

8. Load on^boat improperlydistributed.

9. Water jaümp/thermdstat faulty.

1. Propel ler damaged:

2. Propel ler pitch or diameter incorrect.

3. Trim angle incorrect.

4. Motor mounted at incorrect height on transom.

5. Warning system activated. 6. Boat bottom fouled with marine

growth. 7. Spark plug(s) fouled or incorrect

type. 8. Weeds or öther^foreigh matter

tangled onrgearhousing. 9. Fuel system obstructed.

10: Fuel filterdögged. 11. Fuel contaminated or stale. 12. Spark plug gap incorrect.

Remedy

1. Check water intate for restriction. 2. Fill oil tank with specified engine

oil. 3. Inspect sparkplug and replace it

with recommended type. 4. Check and replace oil with

specified type. 5. Replace oil with fresh, spedfied

type. 6. Have serviced by a Yamaha

dealer, 7. Have serviced by a Yamaha

dealer. 8. Distribute load to place; boat on an

even plane. 9. Have serviced by a Yamaha

dealer.

1. Havepropellerrepairedor replaced.

2. Install corred propel ler to operate outboa rd at its recommended speed (r/min) range.

3. Adjust trim angle to achieve most effident operation.

4. Have motor adjusted to-proper transom height.

5. Find and corred cause of warning. 6. Clean boat bottom.

7. Insped spark plug(s). Clean or replace with recommended type.

8- Remove foreign matter and dean lower unit.

9. Check for pinched or kinked fuel line or otherpbstrudions in fuel system.

1Q Clean or replace filter. 11, Fill tank with dean, fresh fuel. 12. Insped and adjust as spedfied.

5-3

• 9 CE) Trouble

E Engine power loss.

F. Bigine vibrates excessively:

Possible Cause

13; Poor connections or damaged ignition wiring.

14. Failed ignition parts.

15. Specified engine oil not used.

16. thermostat faulty or dogged.

17. Air vent screw dosed.

18. Fuel pump damaged.

19. Fuel joint connection incorrect. 20. Heat rangeof spark plug incorrect.

1. Propeller damaged,

2. Propellershaft damaged.

3. Weedsor other-foreign matter tangled on prpiDeller.

4. Motor mounting bolt loose. 5. Steeringpivot loose oi" damaged.

Remedy

13. Checkwiresfor wear or breaks. Tighten all loose connections. Replace worn or broken wires.

14. Have serviced by a Yamaha dealer.

15. Check and replace oil with spedfied type.

16. Haveservieed by aYamaha dealer.

17. Open the airvent screw. 18. Haveservieed by a Yamaha

dealer. 19. Conned corredly. 20. Insped sparkplug and replace it

with recommended type.

1. Havepropeller repairedor replaced.

2. Haveservieed by a Yamaha dealer.

3. Removeand dean propeller.

4. Tighten bolt. 5. Tighten or haveservieed by a

Yamahadealer.

5-4

9 CD EMN20010

TEMPORARY ACTION IN EMERGENCY

EMU01432

IMPACT DAMAGE

607011

The outboard motor can be seriously damaged by a collision while operating or trailering. Damage could make the out-boand motior unsafe to operate.

If the outboard motor hits any pbjed in the water, follow the procedure below. 1) Stop the engine immediately. 2) Inspect the control system and all

components for damage. Also, inspect the boat for damage.

3) Whether damage is found or not, return to the nearest harbor slowly and carefully.

4) Have a Yamaha dealer inject the outboard motor before operating it asaih.

EMU01321

POWER TILT WILL NOTOPERATE If the engine cannot be tilted up or down with the power tilt because of a discharged battery or a failure with the power tilt unit, the engine can be tilted manually.

1 Manual valve screw

EMU00421

1) Loosen the manual valve screw coun-terejockwis e until it stops.

2) Put the engine in the desired position, then tighten the manual valve screw clockwise.

5-5

9 cx> STARTER WILL NOT OPERATE If the starter mechanism does not operate (engine cannot be cranked with the starter), the engine can be started with an emergency starter rope.

8 Use this procedure only in an emer-genty and only to return to port for repairs.

8 When the emergency starter rope is used to start the engine, the start-in-geäf pj'dfection device does not operate. Make sure the gear shift lever/ remote control lever is in neutral. Otherwise, the boat could unexpectedly start to rriove, which could result in an accident.

8 Be sure no one is standing behind you when pulling the starter rope. It could whjp behind you and Iryure someone.

8 An unguarded rotating flywheel is very dangerous. Keep loose dothing and other objects away when starting the engine. Use the emergency starter rope only asinstructed. Do not touch the flywheel or other moving parts when the engine is running. Do fvA install the starter mechanism or top cowling after the engine is running.

8 Do not touch the ignition coil, high voltage wire, spark plug cap or other electric äI components when starting of operating the motor. You could be shocked.

5-6

9

, •^^^^^~>i ^ ' "^ / / j / 208065*

a> Bnerg enqr Starting Engine 1) Remove the top cowling. 2) Remove the cable 1 by pulling out it

from the starter if equipped.

^ fe

^ ^ ^ . . - . .

208066

3) Remove both ends of the choke rink rod 2 .

4) Remove the starter/ flywhleei cover after removing 3 bolts. Disconne ct the wire leads connected the starter/ flywheel cover.

5) Prepare the engine for starting. See "STARTING ENGINE" for procedures. Be sure the engine is in Neutral and that the lianyard lock plate is attached to the engine stop lanyard switch.

6) RJII up the lever 3 on the carburetor to operate the choke systern when the engine iscold. After the engine starts, return the lever to the original position.

5-7

9

f. Mifff^^

#v'W\ W :^^^

'208072

cr> 7) Insert the knotted end of the emer

gency starter rope into the notch in the flywheel rotor and wind the rope several turns clockwise.

8) Pull the rope slowly until resistance is felt.

9) Give a strong pull straight out to crank and start the engine. Repeat if necessary.

5-8

o cr> EMNS0012

TREATMENT OF SUBMERGED MOTOR If the outboard motor is submerged, Imm ediately take it a Yamaha dealer. Otherwise, some corrosion may begin almost immediately. If you cannot immediately take the outboard motor to a Yamaha dealer, follow the procedure bellow for taking care to rriinimize engine darnagé.

EMN50611

1:) Thoroughly wash away mud, salt, seaweed, eta with fresh water.

2) Remove the spark plug(s), then face the spark plug holes downward to callow any water, mud or contami-hantsto drain.

3) brain the fuel from the carburetor, fuel filter and fuel Nne. Drain the engine oil completely.

A% Fill the sump with the fresh engine oil as the same quantity asthe engine oil capacity.

Engine oil capacity: Refer to SPECIFICATION S, Page 4-1.

5) Feed engine fogging oil or engine oil through the carburetör(s) and spark plug hole(s) while cranking the engine with the manual starter or emergency starter rope.

6) Take the outboard motor to a Yamaha dealer as soon as possible.

Do not attempt to run the motor until it has been completely inspected.

5-9

CX)

AtoZ Chaptere

INDEX

INDEX .6-1

AfoZ CD INDEX

Adjusting trim angle ...3-21 Air vent screw 2-2 B Basic boating rules 1-7 Battery care .4-8 Battery requirement .1 - 14 Breaking in (running in) engine .3-5

Changing engine oil 4- 18 Changing gear oil............. .:4-25 Checking battery 4-28 Checking bolts and nuts .,., :4-30 Cheeking fuel syêm ................ 4-15 Cheeking painted surface;of motpr...,..4- 32 Cheeking power'tilt system ............... ..4-22 Cheeking propeller..... ...4-23 iGheckihg the engine oil level.. .......3-7 Checki ng top cowling .4-14 Checking wiring and cohnedors ....4-21 Choke knob 2 -3 Choke switch ....,,...:...;.. 2-9 Clamping the outboard motor 3-4 Cleaning and adjusting spark plug ......4-13 Cleaning and ähti^cörrösiön measure ...4-7 Cleaning cooling;-water passages 4-31 Cleaning fuel tank ..4-26 Gleaning the fuel filter 4-27 Cleaning the outboard motor .......4 -32 Coating the boat bottom 4-32 Connecting the battery......... 4-29 Cruising in other conditions 3-31 Cruising |n salt water........... ..3-31 Cruising in shiallow water .3-28 Cruisin g in turbid water 3-31 D Disconnecting the battery 4-30

Emergency starting engine.... .....;5-7 Emission control information..;.. ............1--2 Engine oil 1-13 Engine äop button .....,..;....... .2-5 Engine stop lanyard switch .2^5 ,2-9 Exhaust leakage 4-21 F Filling fuel .3-8 Filling fuel tank............. .........4-5 Flushing cooling system and fogging engine.......... ................ ................ ..............4- 6 Flushing device 2-13 Forward............... ..w,.,,..,,.... ...3-17 Fuel hose joint .2-2 Fuel meter...., ........2-2 Fuel tank..... ........2-2 Fuel tank cap............. 2-2 Fueling instructions ...............1 -11 G Gasohol .. 1- 12 Gasoline 1-12 Gear shift leVer :....v. -2-3 Greasing 4-12 I Identification numbers record 1-1 Impact damage 5-5 Important labels .......1-6 Inspecting and replacing anode(s).,..,..4 -27 Inspecting fuel filter................ ..............A -16 Inspecting idling speed 4-17 Installation ................ 3^^ Installing the propeller 4-24 L Low oil pressure warning 2-15 Lubrication.......... .............: .;..........;... .,..4-7 M Main components..... 2- 1 Main switch 2- 8 Maintenance chart 4-10 Motor exterior .4-32

6-1

AtoZ ci:> Mounting heigtif ...3-3 Mountin g the outboard motor 3 -1

N Neutral interlock trigger 2-8 Neutral throttle lever 2 -8 O Operations of controls and other fundions .2-2 Outboard motor serial number 1- 1 Overheat warning ................ 2-14 P Periodic maintenance...., .........4-9 RDwer tilt switch 2-6 ,2-10 Power tilt: unit :............. .........2-12 Fbwertilt will not operate. 5- 5 Pre-operation checks ,....3 -6 Propeller cheeking point 4-23 Propeller selection 1-15 R Recoil starter handle !2-3 Remote control.. 2-7 Remote control lever 2 -7 Removing the propeller 4-23 Replacement parts 4-9 Replacing fuse...... ...;............ .4-20 Reverse; 3-18 Ring free fuel additive 3-8

Throttle control grip............ ...2-4 Throttle friction adjusting knob .....2- 5 Throttle friction adjusting screw .....V..2-10 Throttle indicator .2 -4 Tiller handle ...:2-4 Tilt lock mechanism 2-12 Tilt support bar .,..2-12 Tilt support knob .2-12 Tilting up/down ......3^24 Top cowling lock lever .........2-13 Trailering outboard motor 4-3 Transpo rting and storing outboard motor .4- 3 Treatment of submerged motor........... ,.5-9 Trim angle adjusting rod 2-11 Trim angle settings and boat handling .:3-23 Trimming outboard motor ...3-20 Troubleshooting.... 5-1 W Warming up engine..... .3-16 Warning indicator(s) .2- 11 Warning system ,....2-14 Water leakage 4-21

Safety information Shifting.. Specifications Star labels Start-in-gearprotection.... Starter button ..,...,, Starter wil lnot operate .5-6 Starting engine..... 3 -9 Steering friction adjusting lever 2-11 Stopping engine.. 3-19 Storing outboard motor 4-5

...1-4 ..3-17

....4-1

.. .1-3

...1-16

...2-3

Temporary action in emergency 5-5

6-2

IMPORTANT WARRANTY INFORMATION FOR U.S.A. AND CANADA

Welcome to the Yamaha Family!

Congratulations on the purchase of your new Yamaha marine power. Yamaha Is committed to exceptional customer satisfaction, and we want your ownership experience to be a satisfying one. Please read the following warranty infonmation to help ensure satisfaction with your Yamaha.

Yamaha is ready to stand behind your purchase with strong warranty öDVerage. Tb be sure you reeeiveîrthebenéfitsof warranty, pleasetalæ the fpllowinig St

1. Be sure your new Yamaha is registered for warranty. Your boat dealer should do this at the time of sale. Make sure your dealer gives you a copy of the completed Yamaharegis-trationcard for your records. If you are unsure whether or not your Yamaha is registered, complete the Warranty Registration card found inside the cover of the Owner's Manual. Mail it to the diäributor for the country in which you live (see siep 6 for the correct address). If your Yamaha is not properly registered, a warranty repair could be unnecessarily delayed while registration records are checked.

2. Read the Limited Warranty statement which follows these instructions. This warranty applies to Yam aha outboardi motors sold in the United States.whetherpurdiased separately or when supplied asbitjiginal equipment by a boat builder. The term s also apply to original equipment packages sold in Canada, with coverage provided by Yamaha Motor Canada (see "Warranty Guide" for Canadian models). This warranty explains the conditions of the warranty, including the obligations that your dealer and you as the owner have under the warranty. For example, your Yamaha outboard must receive a proper pre-delivery inspection (PDI) by the selling dealer. Failure to take [this important step COu Id jeo pa rd ize wa rra nty coverage!

3. If you need warranty repairs, you must take your Yamaha outboard to an authorized Yamaha outboard dealer. Be aware that not all selling boat dealers are authorized Yamaha dealers. Only authorized dealers have the factory training, special tools, and Yamaha support needed to perform warranty repairs.

4. If you are away from horne, pr your selling dealer is not an authorized Yamaha dealer, use the following toll-free numbers to find the nearest Yamaha dealer.

U nited States Dealer Lpcatioris: 1 -800-692-6242 Canada Dealer Locations: 1-800-267-8577

5. Your warranty applies spedfically to repairs niade in the country of purdiase. If your U .S.-purchased Yamaha needs warranty service while in Canada, or your Canadian purchased Yamaha needs service while in the United States, Yamaha will assist the local dealer wheneverpossible. However, some products available in one country may not be sold or serviced in the other.

6. If you need any additional information about your Yamaha or warranty coverage which your dealer cannot provide, please contad usdiredly.

Yamaha Motor Corporation, U .S A P.O. Box 6555 Cypress, CA 90630 Attentip n: Customer Relations Department

Telephone No. (714)761-7439 Fax No. (714)761-7559

Yamaha Motor Canada Ltd. 480 Gordon Baker Road Toronto, Ontario M2H 3B4 Attention: Customer Relations Department

Telephone No. (416)498-1911 Fax No. (416)491-3122

YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARDMOTOR THREE-YEAR LIMITED WARRANTY

YamahaMotorCorporationM.S.A.hereby warrantsthat new Yamaha1999ôr-later modelfOürrstrol<eoutböardmdtorsoriginallyJis tributedby YamahalVlotorCorporationlJ:S.A.willbefreefromdefectsin materialand workm anshlpforthe peri odof tim est ated herein, subjectto certainstated limitatibnsWarranty coverage forputboardsdistributedjy non-LISyamäHaaffiliatedcompanieanay be different.

PERIÖDOF WARRÄNTYAny new Yamaha1999-or-later model four-strolceoutboardmotorpurchased'and registered with Yamaha M otorCorp oration p.S.A. for pleasu reuse in theUnitedStates.willbe warrantedagaihstdeföifsin materiabr workm anshiplbr a period of three(3) years fripmthedätebf purchasejubjectto exclusionaotedherdn.Any Yamatiaputboardmbtprpurchasédåndutilized for commercialapplicationwiUbe warranted fpra periodof on^1) year from thedateof purchase,subjectto exclusipnspted herein. Yam ahaperlp h era! equi pm en ilncludedwithtti emptor, such as gauges.fuel tanks.andhPses.remptecontrplboxes.and wiringexterr; nal fromfhemotorunit,willbe warrantedfprpne(l) year frpmthedate of purchaseof eitherpleasuredr conimercialjse: Replacement parts usedih warrantyrepairswillbéwaifarifedforthebalåhceof theapplicåbrewarrantypOTPd.

Thesecondandthirdyear of warranty (if applicabi erhall be limitedo coveringthecostof partsand laborform aipr com poientsonly. Themajorcomponehtsovered are:

'PowerUhltSection. 8 Power Head 8 Intakeivianifold 8 CartiuretorAssemblyand itsRelatedComponents 8 Ri el Injecti onSystem an dit s Related Com ponents 8 Fuel andOiJPumpAssemblies 8 IgnitonSystem(Standardand Microcomputer) Lower UnItSectloh 8 B<h åu stSystem 8 UpperiSasing :8 Lower-Unit Assembly Bracket Section i8 Bracket System 8 Ppwer tr i mandTi It Assembly

WARRANTY REG I ST RATI ONTO beeligiblefor warranty coverage, the outboardmotor mustbe registeredwith Yamaha Motor eorporatiör) U.S.A.Wan-anty i'egistratiohcan be accorriplishedliy anyauthorizedYamahaOütbpardMptpr[>aler::Up,Prirecapt of the reg i strät ion, an Ow n er' äi/Vairan ty Gård wi II b e sen tb y Yåm ah at o th ereg i stered p u rch aser.

OBTAINNGREPAIRSUNDÉWVARRANTY.To receiverepairsunderthiswan-anty, a validOwner'sWarrantyGardmustbe'presentecto an authbrizedYarriahäOutboardMbtörDealer.

Durin gthe periodof warranty, any au thorizedYam ah aputbparddeal er wil I,free Pf charge,i;eipai ror, replace, at Yamaha'sppticn, any partsadjudgeddefectiveby Yamahedueto faultyj/orkmanshipor maten alf rom thefactory.'Al ireplaced parts willbecometheproperty bfYamahaMotbrCorporationlJiSrA.

CUSTOM ÉR'SRESPONSIBIlJTVUnder theterms of thiswarranty, the customerwiM be resppnsitJiépr ensunngthat the putboard: motoris properivoperated,maintained3nd storedas specifiedn theapplicabltf)wner'sManual!

TheVownerbf theoutboardnfiotorshallgivenoticeto anauthprizedYamahåOutboardMptojDéala- pf any and all apparent defects with inten (10) d ays of disco veryand makethemotoiavailableat thatti m efor i nspectiorandrepairs at thedeal er'splacepf business.

GÉNHtALEXCLUSIONSFROM WARRANTY.Th i swarranty wil I not cover the repair of damage f thedamageis aresultof abuseor neglectof theproduct.Examplesof abuseandneglectinclucle,t3ütare nbtlimitedto; 1. Racingbr compîtipnise.mpdificatibrof priginat)arts,abnofma]strain. ;2. Lack of propeimaintenanceand off season storageas describedn thaOwner'sManualjnstallationof partsor accessoriesthatare

notequivalentn designand qualitigenuinéf'amahaparts. 3. Operatibnbf thenotbrat an rpm otherthan specifiedgseof lubricantor öirähatarenotsuitableforbutbbardmotpuse. 4. Damageas a resultof accidentspollisions5ontactwithforeignmaterials,or submersibn. 5. Growthof marineorganismon mptPisurfaces. 6. Nonnalcteteripratipn.

SPEanGPARTSEXCLUDEDFROIVl WARRANTY.Parts réplacéddueto nomnaWear or routinanaintéhancesuch as oil,spark plugs, shearplns,propeliers)iubs,fuel and olifilters, brushesforthestarter mptorand po\Ä(ertiltrnotor,water pufripirTipéllers,and anodes, are n otcovered by warranty.

Chargésforrenrioval of themötorfromä boatand trahsportinöhembtbrto andfronn ah authorlzedt'äm'ahäOutboafdMbtbrDearer åre excludedfronn warranty coverage. Specifb partsexcludedfromthesecondandthlrdyear of warranty(ifappllcable>ire: 8 Topand BottomCowling 8 Ej'ectrl cCom p on en t$oth er th an i g n I ti oreystem) 8 RubberComppnentûchas tiosestubes,rubberseals,

fitting sandel amp s)

TRANSFERDFWARRANTY.Transferof thewarrantyfromthe origlnatiurchaserto anysubsequentpurchaseris possibity havihgthe mptorlhspectedby an authorizedYamahaOutboardMotorDealer and requestingthe dealer to siitimila chångepf registratlohto Yam ah aMotorCorporation |J.S.A.Withinten (10)days of thetransfer.

YAMAHA MOTORCORPORATIONJJ.S.A.MAKESNO OTHERWARRANTYOF ANY KIND,EXPRESSEDOR IMPUEDALL IMPUED WARRANTIES OFMERCHANTABIUTY AND FITNESS FOR A PARTICULARPURPOSEWHICH EXCEED Tl^ OmJGATIONSAND TIME UM ITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION,U^S:A. ÅND EXCÜJDEDFROM THISWARRANTY.

SOMESTATESDO NOTAU.OW UMITATIONSON HOW LONG AN IM PUEDWARRANTY LASTS SO THEABOVE UM ITATIONS MAY NÖTAPPLYTO YOU.ALSO EXCLUDED FROM THIS WARRANTYARE ANY INaDENTMJOR CONSEQUENTIAIDAMAGES INCLÜDIN3:LOSSOFUSE.SOMESfATESDO NOTALLOW THEEXCUJSIONOR UMITATIONOFINCICENTALOR CONSEQUENTIAL DAMAGES, SO THEABOVEEXCUJSiONMAY NOffiPPLYTO YOU.

THISWARRANTY GIVES YOU SPECIHCLEGALRIGHrS.AND YOU MAY ALSO HAVE OThSRRIGHTSWItCHVARY FROM STATE TO STATE.

YAIM AHAM OTOICORPORATIONg.S.A. PostOfficeBox6555

Cyp ress, Cal I f o m I £80630

WARRAN TVQU ESTIONSftN DAN SWERS

Q. What cpstsare nny responsibilytduringthewarrantypéripd? A. Thecustomersresponsibilityncludeall costsof normalmaintenanceservlces, non-warrantyepairs, accidentand collisioÉlam-

ages.

Q. What are spmeexanriplesof " abnprmaråtrain,neglect,6r abuse? A. Thesetermsare general and overlapeach otherin areas.Specifioexamplesinclude:

Runninähemachineoutof ollpperatingthemachinovitha brokenor damage4)aftwhichcausesanotherpartto fail,damageor failurédue to irnpropeor carejessti'ansportation.and/ortledown.lf you have any specificquestipnspn operatiorDr maintenance, pleasecontactyourYamahäoutboarddealerforadvice.

Q. Doesthewarrantycover incidentabostssuchas towingor transportatio dueto afailure? A. No.Thewarrantyis limitedo repairof themachinatself.

Q. May I perfprmanyor allof thffecommendedmaintenanceshownin theOwner'sManualinsteadof havingthedealerdo them? A. Yes, if youare a qualifiedmechanicandfoHowtheproceduresspecifiedin theOwner'sand Service Manuals.We dorecommend,

höwevff, thatitenisrequiringspecialtoolsor equipmenbe dianeby aYamahaoutboarddealer.

Q. Willthewarrantybe voidor cancelédif Ido nobperateor maintairmy newoutboardexactly as specifiedn theOwner'sManual? A. iMo.thewarranty on anew outboardcannotbe "voidedlbr "canceled'However, if aparticularfaiiureis causedby operaton or

maintenanceotherthanas shownin theOwner'sManual,thatfailuremaynotbe coveredunderwarranty.

Q, WhatresRonsibilitijioesa Yamahaoütboarddealerhaveunderthiswan-anty? A. EachYamahaoutboarddealeris expectedto:

1, Completeiyö up eachoutboariJie sellspriorto delivery. 2. Explaihth eoperation/naintenance,and warranty requirementäo yoursatjsfactionat thetimeof sale, an dupbnyour'request

atanylater date. In additionpach Yam ah aoutboarddealeris hel dresponsiblrforhissetup,service and warrantyrepairwork.

Q. Is thewarrantytransferableto seconcbwners? A. Yes. Th e rem ai n derof an yexi sting warranty can betransferred uponrequest.Theunithasto beinspectedandre-régisteredby an

authorizedYamahaoutboarddealerforthepolicyto remaineffective.

CUSTOM EIBERVICE

If you rm ach ine requires warranty service, you must take it toanyauthorizedVannahaoutboarddealerwithinthe continentalUnted States. Be sureto bringyourwarranty registrationidentificationtsr othervalidproofof theoriginaldateof purchaseJf aquéstibnor problenriärisesregärdingwarranty, first cöhtactthebwneröf thedealershipSinceäll warrahtynfiattei'sare håndledet thedeälä" level, this person i s inthebest positlorto helpypu.lfyouare still not satisfiedandrequireadditionalassistancepi ease write

YAMAHAMOTOfCORPORATIOMI.S.A. CUSTOM EBSELATIOIMSDEPARTMENT

P.O.Ba 6555 Cypress,.Cal iforn i 00630

When contactingYamaha Motor Corporation,U.S:A:!don'tforget to includeany importantinformationsuch as names, addresses, model,éngin€serial number .dates, andreceipts.

CHAN GEOF ADDRESS

The federal govern nientrequiresæcti mmüfactu^r^^^ amotörvehicie.to maintaina cömpletejup-tp-datellstpf allfirst purchasers, against theppssibilit;iDf a saféiy-raatéddeféctand-fécå^^^ Thi si ist i s compliecfrom thepurchaseregisträtiönssent to YanahaMotop Corporation U.S.Aby thesellingdealerat thetimeof yourpurchase.

If you shouicfrnoveafter you have purchasedyburiiewputboarclpleaseadviseus ofyoürnew addressby sendinga postcardlistihg youroutboardmpdelname.enginæeriai/numbep/Jeawnum^b^ youiwarranty identificatib/ypur-nameandnewmallingaddresS:Mailto:

YAMAHAMOTOFGORPORATIONUS.A. WÄRRAN TYDEPARTM ENT

P.Ö.Bqce^. Cypress, Cai if o rn i EB0630

ThiswillensuréthatYariiahaMotorCorporatiphlJ.S.Ahasan up-tp-datéegistratipnrecprdin accordancewithfederal law.

EMU01178

IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE U.S.A. OR CANADA

Welcome to the Yamaha Family!

Congratulations on the purchaæ of ypur new Yamaha marine power. Yamaha iscom-mltted toexceptional customer satisfaction, and we want your ownership experience to bea satisfying one. Please read the following warranty infonmation to help ensure satisfaction with your Yamaha.

This model was manufactured ais a Ü.SA. spedfication model, and the warranty âte-ment shown in this manual is for market. To receive the benefits of the warranty that applies to the country inwhich you use ;your Yamaha, please note the following information.

1. The warranty on this model i s the^me as equivalent models sold in the country where you will receive service. If you need more information about your warranty coverage or your Yamaha outside the U.S.A. or Canada, please contact an authorized Yamaha dealer in your country.

2. Keep a copy of your sales; contract fbrinvoice for the purchase ofyour Yamaha and present it if you need warranty repairs. This document should show the date of purchase, which is important evidence the repairing dealer will need tobe sure your Yamaha is covered by warranty.

3. If your Yamaha needs warranty repairs, contact an authorized Yamaha dealer in the country where you are. He will explain how to get warranty service in that country.

4. This Yamaha model may not bespld in some countries. Therefore, in some cases your local dealer may not have all the parts or service information he may need, which may unavoidably delay repairs. If this happens, we thank you for your understandin g and assure you wewill attempt to resolve the situation asquickly as possible.

SYAMAHA YAMAHA MOTOR CORPORATION, USA

Printed in Japan April 2003-0.5 X 1 I 66M-28199-17 (F15AMH, F15AEH. F15AEP, FiSAEHP)

m Printed on recycled paper

YAMAHA OUTBOARDMOTOR WARRANTY REGISTRATION ENREGISTREMENT DE LA GARANTI E DU MOTEUR HORS-BORD

Please complete and maM t his card. This information is necessary t o accurately register your unit for warranty. Vaiillez sigier d-desscus pour attest«' que|emontage et I'inspection ont étéfaits.dans le respect des directi\Ae5d'inspectiGn et

quelamarche åsuivre pour l a ^ ä n t i e et I'entretien aété expliquéeål'acheteur au detal.

OUTBOARD MOTORM ODEL AND SERIAL NU M BER(From LD. label on clam pbracket) (For D e a l e r U æ Only) MODELE ETNO. DE SERIE DUMOTEUR HORS-BORD (sur l'étiquetted'identificatioMe lapresse de fixation) (A l'USagsdU OCnæSSicnna^

YAMAHADEALERNUMBER NO. DU CONCESSiÖNNAlE YAMAHA YAMAHA

YAMAHA MOTOR CO., LTD. • MADE IN JAPAN • PAYS D'ORIGINE JAPON

I I I I I I I DEALERNAME NOM bu CONCESSIONNARE

DATESGLD DATE DE LIVRAISÖN

OWNER'S NAME NOMDU PROPRIÉTAKE

MONTH MOIS

DAV JOUR

YEAR ANNÉE

USACE T-] PLEASURE (ChéckOne) I—' X^QISIR

UTILISM1ÖN r-|. GOMMERGIAL (Éncocher un.) •—' COMMERCIAL

ADDRESS ADR RS SF.

FIRST PRENOM

LAST NOM DE FAMILLE

STREET RUE.

PHONE NUMBER( ) NUMÉRODE TELEPHONE

CITY VILLE

STATBPROVINGE PROVINCE

ZIP GODE POSTAL

PLAGE PG)éJI;É3E HERE

ATTN: WARRANTY DEPARTMENT

WEST'MARINEJ

Fiskerihavnsgade 30 - 6700 Esbjerg - Denmark - Tel. +45 75 45 70 44 - Fax +45 75 13 21 48 - [email protected]

Please be aware of the following:

Never start the engine without sufficient water. It will cause serious problems and damage the engine and there is no warranty.

Always remember oil in the gasoline.


Date post:	17-Jul-2016
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