Preventative Maintenance for Rigid Hull Inflatables 2.3.2 Fuel
Contents
1. aa a IE EE a ER ae Preventative Maintenance for Rigid Hull Inflatables Cylinder Slider Cleaning and Greasing Clean slider assembly of any dirt Wipe off old grease Inspect all fasteners see illustration for tightness and good working order Grease all fasteners using Quicksilver 2 4 c OMC Triple Guard or equivalent Thoroughly grease the slider assembly see illustration Turn helm hard to Port and Starboard several times to work in the grease Inspect sliders Grease further if required VVVVVV Fasteners Greasing Points BOLT 1S THROUGH TILLER ARM WARNING Slider assembly must always be greased Do not operate the boat if the slider assembly is dry and free of grease aa a IE EE a ER ae Preventative Maintenance for Rigid Hull Inflatables 2 3 7 Kill Switches 2 3 7 1 Overview The purpose of the Kill Switch is to turn off kill the engine when the operator falls off the deck or moves far enough away from the operator s position to activate the switch accidental ejection 2 3 7 2 Inspection Requirements For both Mercury and OMC Kill Switches gt Inspect lanyard clasp for good Mercury Kill Switch working condition gt Ensure lanyard rope is not frayed SENNA or damaged in any way gt DO NOT add any length to the factory supplied lanyard gt Pull on lanyard to check that it is free to pull OMC Kill off Kill Switch gt Ensure that lanyard is not too long It Swit2. Optimax 1 Gal 92 877694k 1 2 5 Gal 92 881108K 1 4 5 Gal 92 881109K 1 i a msn amma Preventative Maintenance for Rigid Hull Inflatables Parts Supplied by the Inflatable Craft Maintenance Shop Part Number Spark Plugs 150 hp DFI engines only NGK PZFR5F 11 150 hp EFI engines only NGK BUZ8H 90 hp engines only NGK BUZHW 70 hp OMC engines only NGK BR9HS 10 EFI DFI On Engine Water Separator Fuel Filter 35 18458A 4 EFI DFI Inline Fuel Filter 35 816296 Spares only for remote stations and ships Spark Plugs Control Head and Cables Right and Left Hand Bottom End Starter A i a TE TI ER TI Preventative Maintenance for Rigid Hull Inflatables If your RHI IS DAMAGED IN ANY WAY DURING ROC HOURS of operation 0700 1900 7 days week contact Operation Officer Regional Operational Centre ROC 250 413 2800 If your RHI is OUT OF SERVICE contact Marine Controller Rescue Coordination Centre RCC 250 363 2994 If your RHI is DAMAGED IN ANY WAY contact Kevin Tomsett Supervisor of Small Craft 250 480 2651 250 812 1739 cellular If you are looking for RHI PARTS OR TECHNICAL INFORMATION contact Wayne Ingalls Officer in Charge Inflatable Craft Maintenance ICM 250 353 6656 Shop at Institute of Ocean Sciences 250 812 7942 cellular 250 474 2863 home 250 413 5995 pager If you are looking for RHI PARTS OR TECHNICAL INFORMATION contact Gordie Caird or Tom C
3. 121 Horns Warning p 96 99 Hoses p 71 Hull p 43 Hull Repairs p 48 53 Inflatable Collar p 22 23 Installing Tube p 30 34 Inventory Management Form p 11 12 Kill Switch Testing p 95 Kill Switches p 94 Lubricating an Engine p 59 68 Maintaining the Propeller p 86 90 Outboard Motor Controls p 81 Outboard Motor Repair p 100 107 Outboard Motor Troubleshooting p 100 107 Patching Tube p 34 41 Propeller p 80 Propeller Maintenance p 86 90 Propulsion System p 59 Radar p 129 Removing Tube p 30 34 Repairing Bilge Pump p 57 Repairing Hull p 48 53 Repairing Outboard Motors p 100 107 Repairing Self Righting Bag p 119 120 Repairing the Engine p 100 107 Repairing Tube p 34 41 i a msn amma Preventative Maintenance for Rigid Hull Inflatables Self Righting Bag Inspection p 111 112 Self Righting Bag Repair p 119 120 Self Righting Bag Cleaning p 118 119 Self Righting System p 109 110 Spares List p 132 Sponson p 22 23 Steering Gear Cylinder Shafts p 83 84 Steering Gear Fasteners p 82 Steering Gear Tilt Tube p 85 Steering System Bleeding p 91 93 Steering System Oil p 82 Testing Kill Switches p 95 Tie Bar System p 83 Tow Reel p 117 Tow Reel Attachments p 117 Transfer Form p 11 12 Troubleshooting Radios p 129 Tube p 22 23 Tube Attachments p 25 Tube Pressure p 26 Tube Repair p 34 41 Tube Valves p 27 30 Tube attachments
4. The normal geodetic datum used by the Raystar 112 sensor is WGS 84 aa a IE EE a ER ae Preventative Maintenance for Rigid Hull Inflatables 2 6 3 Radar 2 6 3 1 Overview Calibration The Raytheon Heading Sensor must be calibrated to ensure that the transmitted compass heading information is accurate Carry out this procedure before the unit is used as a navigational aid Calibration would have normally been done while the RHI was in the shop Calibration consists of two parts gt Compass Linearization Detects heading errors caused by iron objects engines and gas bottles Once such errors have been detected the heading sensor corrects them automatically gt Heading Alignment Required to match the displayed heading to a known heading or transit You can align the heading sensor with your ship s compass providing it is accurate Continuous Deviation Correction The Raytheon Heading Sensor normally monitors magnetic deviation continuously Every time your vessel completes a 360 turn within the time constraints of the system the compass checks the new deviation data and updates its correction data if required Deviation data is only used if gt The vessel has completed a 360 turn in 3 minutes or more gt There have been no sudden increases in speed gt It provides more accurate data than that already stored i a msn amma Preventative Maintenance for Rigid Hull Inflatables 2 6 3 2 Inspection Requi
5. and Mercury Mariner 90 HP Typical failures on these engines do not involve the electric control module ECM but connections set up and mechanical wear Batteries must have a cranking voltage of 9 5 volts or higher at the starter Low battery voltage can cause the oil and fuel pumps to malfunction Check all fuses Make sure all spark plug leads are pushed in all the way Check to see that the fuel pump filter is clean Ensure that the water separating fuel filter is full Check to see that the racor filters are on full is there water present If you suspect an onboard fuel problem run the engine on a day tank to see how it runs This can rule out many components Consult the EFI or DFI Service Manual for more trouble shooting details Check that control handles are in the Neutral position and that the kill switches haven t been thrown VVVVV Vv p N aa a IE EE a ER ae Preventative Maintenance for Rigid Hull Inflatables 2 3 9 3 Digital Diagnostic Tool DDT Most stations and ships have access to the Quicksilver Digital Diagnostic Tool DDT With a DDT you are able to monitor sensors and electronic control module ECM data values including status switches The ECM program can help diagnose intermittent engine problems It records the state of engine switches and sensors over a period of time and can be played back for review later When used correctly the DDT can be a valuable trouble shooting tool If use
6. Control Anodes 2 3 4 1 Overview Anodes help to protect your engine against corrosion They allow their metal to be slowly eroded instead of the metal of the outboard itself Each outboard has three corrosion anodes located as follows gt Two atthe sides just above the trim tab a and b one on OMC engines gt One at the bottom of the transom bracket c Hulls also have anodes located on the transom 2 3 4 2 Inspection Requirements gt Inspect the anodes for erosion and replace if less than 3 4 75 of original size gt If you replace the trim tab anode be sure to install the new unit in the exact same position gt Check that all anodes are securely fastened MERC Outboard gt Ensure that none of the anodes are painted or covered with a protective coating If an anode is coated over remove the paint or coating immediately 2 3 4 3 Preventative Maintenance Requirements gt Replace anodes at 50 gt Never paint over anodes gt Clean area before replacing zincs and anodes OMC Outboard a Preventative Maintenance for Rigid Hull Inflatables 2 3 5 Propeller 2 3 5 1 Overview WARNING Propellers don t require much care but you do need to check them daily to maintain vessel rf Never repair propellers in performance the field as you can cause more damage 2 3 5 2 Inspection Requirements Visually inspect the propellers for damage If the damaged
7. Rigid Hull Inflatables Steering System Oil Loss If you find oil loss during inspection investigate the cause and repair gt Check bilges for oil and clean up any oil found gt Ensure engines free to turn no restrictions on deck etc gt If any major repairs required i e hose replacement seals etc immediately bleed the system of air and top up 1 Turn helm hard to port applying enough force to exceed relief valve pressure 2 While one person maintains helm pressure the second person should carry out the inspection 3 Inspect the following for leaks or seepage gt Helm pump unit around shaft casing and filler tube ae Hose connections and fittings at helm pump Fi Hoses for seepage hose feels like it is saturated in oil Hose fittings and connections at steering cylinder Check cylinder end seal of ram in the out position VV VY 4 Helm hard to port Ensure bleed screws completely closed Repeat with the helm held hard to starboard Repair all leaks immediately wiping up any spilled oil Keep a close eye on all repairs to ensure that they are carried out properly Inform the Mate Coxswain of any major problems i e leaks at seals or worn holed hoses a mmm nn mae Preventative Maintenance for Rigid Hull Inflatables I ea TR EE a a Preventative Maintenance for Rigid Hull Inflatables 2 4 Self Righting System 2 4 1 Overview Although RHls are inherently very stabl
8. Steering System Oils Texaco H015 Shell Aero 4 Esso Univis N15 Chevron Aviation Fluid A Fluids Meeting Mil H5606c Specifications Teleflex Steering Fluid or Power Steering Fluid Sea Star Fluid HA5430 Preventative Maintenance for Rigid Hull Inflatables Step 2 gt Turn helm to starboard until the cylinder rod is fully extended on the right side of the cylinder gt Open the right hand bleeder Step 3 gt Hold onto the cylinder rod with your hand preventing it from moving back into the cylinder gt Turn the helm to port until a steady stream of air free oil comes out of the bleeder This may require bottle or more of oil gt While still turning the helm to port close the right hand bleeder screw gt Release the cylinder rod Step 4 gt Top up or replace oil bottle gt Continue turning the helm to port until the cylinder rod is fully extended on the left side of the cylinder gt Open the left hand bleeder screw Step 5 gt Hold onto the cylinder rod with your hand preventing it from moving back into the cylinder gt Turn the helm to starboard until a steady stream of air free oil comes out of the bleeder This may require 1 2 bottle or more of oil gt While still turning the helm to starboard close the left hand bleeder screw gt Release the cylinder rod Remove the oil bottle filling tube and reinstall reservoir cap gt Clean up any spilled oil
9. a propeller b continuity washer c thrust hub d propeller nut retainer e and propeller nut f onto shaft Before you torque the nut down ensure that the propeller spins freely It should not rub against the bottom end housing Place a block of wood between the gear case and propeller Secure propeller nut by bending three of the securely tightened propeller nut tabs into the thrust hub grooves Torque the propeller nut to factory specs 55 ft Ibs for EFI and DFI Optimax Mariner Preventative Maintenance for Rigid Hull Inflatables Propeller Replacement OMC Shift outboard to Neutral N position Pull Kill Switch to prevent engine s from starting Straighten cotter pin D and remove Remove index keeper E then loosen and remove propeller nut C and spacer B Place a block of wood between the gear case and propeller Hold the propeller and remove the propeller nut Pull propeller straight off shaft If propeller is seized to the shaft and cannot be removed have the propeller removed by an authorized dealer Preventative Maintenance for Rigid Hull Inflatables i 6 Coat the shaft with spline grease 7 Install thrust bushing A propeller spacer B engaging propeller shaft splines Finally install the propeller nut C 8 Torque to recommended factory specifications 9 Use stainless cotter pins to secure a a a TE E I a ER se Preventative Maintenance for
10. be able to tighten them properly Inspect deck area bolts for hairline cracks around the insert area If you find any notify the Mate Coxswain as this may indicate failure of fiberglass around bolt holes Preventative Maintenance for Rigid Hull Inflatables Tow Reel and Attachments Tow Reel Attachment Points gt Physically inspect all tow reel attachments for tightness and tighten as required gt Spin tow reel by hand to make sure the unit moves freely and is unobstructed gt If tow reel is hard to turn check for any foreign objects that might be jamming it Remove any obstructions gt If no objects are found to be jamming the reel or if the reel is still hard to turn after removal of obstruction remove reel assembly from frame and inspect clean and grease bushings gt Once the bushings have been cleaned and greased reinstall the tow reel assembly and re test gt Inspect tow reel handle for damage and proper storage in its own hangar gt Inspect condition of towline It must be in good condition no rub marks broken strands damaged eye A Tow Reel to Frame Attachment Points etc B Tow Reel to Vessel Attachment Points gt Sunlight can damage polypropylene line Use tow line cover when not in use Tow Reel Bushings Remove towline from reel and coil line neatly on deck Unbolt tow reel drum from tow reel frame Degrease bushings Inspect nylon bushings for uneven
11. cannot be stressed enough A gas drum has a 3 month life span or less in shipboard environments due to rust and condensation The fuel octane rating also has a 3 month life span without any gas stabilizer added to it It is imperative to rotate fuel and gas drums as a part of your preventative maintenance program Preventative measures at the source will help cut down on later fuel problems Fuel Line Visually inspect the fuel line for cracks swelling leaks hardness or other signs of deterioration or damage If any of these conditions is found it must be replaced Never use gas line antifreeze in any outboard engine Use Quicksilver Fuel Treatment and Stabilizer 92 12253 Fuel Oil System P SAFETY Compartment J Do not use electric gt Open Fueltank void space A or pumps They can gt Inspect top of fuel tank for fuel and clean up any moisture you ogi see ignite gas fumes gt Check void space bilge for fuel or water If only water present pump out bilge using a hand pump and wipe dry If fuel oil is present pump the bilge water into a waste barrel using a hand pump Wipe dry produce sparks that can Fuel Oil Tank gt Inspect tank for cracks leaks damage or bulging of sides gt Notify the Mate Coxswain if you find problems a SR a A ETT EEE eT EES a Preventative Maintenance for Rigid Hull Inflatables Hoses gt Inspect all fuel oil hoses for signs of chafing cracking ni
12. ps d completion Then repeat the procedure again with the helm turned to starboard WARNING Using a steering system with leaking seals or badly damaged shafts may result in the complete loss of oil This can cause steering failure resulting in property damage and or personal injury m I a TO EI Preventative Maintenance for Rigid Hull Inflatables Steering Gear Tilt Tube gt Inspect outboard motor tilt tube for salt deposits and or corrosion see illustration for areas vulnerable to corrosion Clean as required gt Grease through nipples as required see illustration for grease points gt If salt deposits or corrosion is extreme unbolt steering system arms and clean tube and carrier Reassemble steering system as outlined in the product manual Steering Gear Tilt Tube ee here a corrosion NX c ya W i S Grease through Check here nipples as required for corrosion Preventative Maintenance for Rigid Hull Inflatables 2 3 6 2 Preventative Maintenance Requirements Check Shift Cable Adjustments A ogy Shift Cable Retainer Cable End Guide A Remove Propeller 1 With remote control in Forward 2 The propshaft should lock solidly in gear 3 If the propshaft does not lock adjust cable barrel closer to cable end guide B Increase Gap 1 Shift remote control into Neutral 2 The propeller shaft should turn freely in either direction without any drag 3 If any d
13. rough handling gt Keep the terminals clean No corrosion should be present between the terminals and the terminal clamps When there is a build up of corrosion resistance will occur that hampers starting charging and current flow to all onboard electronics All new engines use an ECU module to control all of the engine functions Incorrect battery voltage will severely alter the ECU values resulting in a very rough running engine gt Nylock nuts should be used on all battery terminals gt Keep the terminal clamps tight and clean Coat with Vaseline or dielectric grease 2 6 1 4 Trouble Shooting and Repair Damaged batteries should be replaced Keep batteries secure at all times ensuring that securing straps work Preventative maintenance will prolong the life of the battery aa a IE EE a ER ae Preventative Maintenance for Rigid Hull Inflatables 2 6 2 GPS 2 6 2 1 Inspection Requirements Refer to the product manual that came with the equipment 2 6 2 2 Regular Maintenance Requirements Refer to the product manual that came with the equipment 2 6 2 3 Trouble Shooting and Repair Not much can go wrong with the GPS Here are a couple of simple faults to look for with the Raystar 112 GPS system No data output after 30 minutes No DC power Check power is switched of operation on Check fuse and breaker No satellites Path blocked Verify antenna is not No fix obstructed and is vertically mounted Note
14. the damaged area exceeds 25 of the Indicates leakage of the fabric due to panel area bag must be replaced excessive abrasion or porosity Hole or Tear Mark with grease pencil and repair area s as outlined in Section 2 1 4 3 of this guide After testing and repairs are complete and prior to the system returning to service 1 Remove Maintenance Safety Pin 2 Unplug Relief Valve 3 Re connect the Bag Fill Hose Da E a a A ER a OEE ED a DE EE ae Preventative Maintenance for Rigid Hull Inflatables Trouble Shooting and Repair DO NOT remove the firing head Call the Officer in Charge of Inflatable Craft Maintenance immediately regarding problems relating to the firing system Close up of ring Gerore OPeRAlics Preventative Maintenance for Rigid Hull Inflatables 2 5 Hoisting System 2 5 1 Overview SAFETY The hoisting systems The RHI may be hoisted with either a on the RHI are sling or rigid lift system Use only the appropriate lifting lugs on the deck designed to a minimum Follow the safe lifting practices outlined six times safety factor in Coast Guard Fleet Orders based on the ultimate strength of The RHI has four lift fittings Two are materials used mounted on the foredeck and two on the transom The foredeck lift fittings are through bolted into underdeck aluminum angles which in turn are through bolted to a transverse bulkhead The aft lift fittings are bolted through the transom
15. up any spillage and safely dispose of filter rags and liquid VV VV V WV Remote Tank Topping Up gt Place rags around the filling area to catch any spilled or dripped oil gt Remove oil filling cap from each reservoir and add oil to the required level gt Use only Optimax 1 gal 92 877694K 1 2 5 gal 92 881108K 1 or 45 gal 92 881109K 1 gt Reinstall cap and tighten securely gt Clean up any spilled oil and dispose of waste Remote Tank Legend material as required 1 Caps 2 Hose 3 Cl Always double check that se as remote oil tank caps are installed tightly as any air leak will prevent oil moving up to the engine reservoir tank causing severe engine damage Oil can also be forced into the bilge if remote tank lids are not secure Preventative Maintenance for Rigid Hull Inflatables Engine Reservoir Tank Topping Up gt Remove cover of each engine gt Visually check oil level in reservoir gt Add oil as required use the same oil as in the remote reservoir Topping can be done by just cracking cap loose as engine is running allowing air to escape as oil is pumped in by engine system gt Tighten fill cap gt Note New engines might not have a full tank as they are shipped from the factory half full The oil alarm will soun the engine is started for the first time a gt D 5 SAFETY Always double check that the engine oil tank cap is installed
16. wear cracks bad gouges and or missing pieces If you see severe damage replace bushing as soon as possible If you see minor damage clean up damaged area s using file or emery paper Grease bushing areas liberally and re install tow reel Clean up excess grease Inspect all bolt holes and fasteners for good condition Renew or replace as required gt Re install tow line and spin unit to ensure free rotation VVVV Vv a aa a IE EE a ER ae Preventative Maintenance for Rigid Hull Inflatables 2 4 3 Preventative Maintenance Requirements Cleaning and Lubrication Daily gt Wash down the entire self righting system with fresh water Weekly gt Clean the self righting bag with soap and water and the necessary fittings with fresh water and soap Dry and re coat with corrosion guard Refer to re packing procedure outlined in section 2 4 2 Annually gt Carry out annual maintenance routine as follows Bag gt Unbolt the attachment flanges from WARNING the self righting frame try and remove the bag Do not use a carbon gt Inflate the bag with air until the dioxide inflation relief valve begins to purge You can use any air source that can utilize a hand held hose and system to inflate the self righting bag for compatible adapter The source of inspection and testing air can be a foot pump a Repeated exposure to compressed air cylinder or an air carbon dioxide may compressor gt Visual
17. 0 hours Do not rely on a visual water fuel separation line being obvious on inspection There may be mostly water in the inspection bowl fooling you into believing that it s fuel gt Drain the bowl into a can and note whether there is water present gt Drain the filter until there is only fuel being discharged Change the filter element annually or as required depending on local fuel quality The newer model fuel injected engines require the use of fuel conditioners and de carbonizing agents gt Add the fuel conditioner to the fuel after re fuelling ensuring that the correct amount is added for the amount of fuel taken gt Spray the de carbonizing agent into the air box at a Fuel conditioner extends the shelf given r p m once the life of the fuel and reduces the o has been warmed amount of carbon build up in the gt Read the instructions on re a the de carbonizing agent The de carbonizing agent as each manufacturer removes most of the carbon requires a different method of product application build up I a TO EI Preventative Maintenance for Rigid Hull Inflatables Fuel Water Separator Draining gt In summer drain plastic bowls as required In winter drain daily Safely dispose of rags and drained liquid To drain place save all pan under Racor plastic bowl Plug both compartment drains to contain accidental fuel spillage Loosen self venting drain and remove water Once bowl is drained close s
18. An abused or poorly maintained hoisting system reduces this safety factor When hoisting the RHI using a four point polyester lift sling four load rated shackles attach the sling legs to the deck lifting fittings A spreader bar arrangement may be required with certain console configurations A variety of solid lift frames can also be used to hoist the RHI The base plates for these lift frames are mounted to the deck amidships in four locations They are through bolted into underdeck aluminum angles which in turn are through bolted to transverse bulkheads 2 5 2 Inspection Requirements Lift Sling Spreader Bar Optional Every time you hoist gt Inspect the lift sling spreader bar gt Inspect the polyester webbing for wear particularly at the attachment points to the yoke and the shackles gt Inspect the yoke for corrosion Annually gt Perform a certified load test to verify lift sling spreader bar integrity The load for this test should be two times the Safe Working Load SWL A SWL rating label is sewn to the polyester webbing This should be done in compliance with the CSA and Tackle Regulations and ISM procedures gt lt aa a IE EE a ER ae Preventative Maintenance for Rigid Hull Inflatables 2 5 3 Trouble Shooting and Repair Trouble Shooting If the RHI lifts at extreme angles or a bow down angle then 1 Check correct fore and aft orientation of slings 2 Check weight distribution 3 Ch
19. aa aE IE EEE Te a ER Preventative Maintenance for Rigid Hull Inflatables 2 3 2 Fuel System 2 3 2 1 Overview The facing page shows the fuel systems of the 733 630 OB and 590 OB vessels For other fuel system configurations please consult your Hurricane Technical Manual 2 3 2 2 Inspection Requirements Follow these general tips to keep your fuel system working well gt Always keep fuel storage tank full Fuel level is shown on the console mounted fuel gauge Note that electric fuel gauges are prone to inaccurate readings Determine fuel consumption through trials and by monitoring operating time to accurately determine fuel reserve capacity gt Use the correct fuel gasoline With gasoline make sure to use the correct octane and gasoline oil mixture when refueling check the engine manufacturer s technical manual for the right mix gt If your vessel has two fuel tanks always use the aft tank first This maintains your vessel s optimum center of gravity A gasoline fire or explosion can cause serious injury or death Carefully follow all service instructions Always stop the engine and disconnect the battery DO NOT smoke or allow open flames or sparks in the area Isolate the batteries and pull the kill switches Turn off bilge switch Preventative Maintenance for Rigid Hull Inflatables Gas begins to deteriorate after 5 weeks Checking for water in shipboard or shore based fuel storage containers
20. al low speed idle running time before the engine overheats again Do this only in an emergency as engine damage may result OMC Reference 2 Horn Sounds Rapid Short Tones That Vary With Engine Speed gt This is an indication that there is no oil flow from the pump gt Problem may be no oil in reservoir or failure of the injection oil pump gt Inform the Mate Coxswain and carry out any repairs required before running the engine OMC Reference 3 Ue N SAFETY Horn Sounds One Short Tone Every s Severe engine 40 Seconds damage will result if gt Oil reservoir level is at the engine is run approximately 1 4 tank above 1500 RPM gt Refill as soon as possible without a 50 1 fuel oil gt Reserve gives you approximately 30 minutes at maximum RPM but tank should be filled as soon as possible gt If tank is run dry system must be purged of air before being put back into service mixture OMC Reference 4 Horn Sounds Continuously At Or Near Full Throttle gt Ifthe alarm horn stops when RPM is reduced a fuel restriction is present If alarm continues see OMC Reference 1 gt The engine should be operated at reduced speed and the vessel should return to base gt Inform the Mate Coxswain gt Inspect F O filters and clean as required If problem continues contact Inflatable Craft Maintenance WARNING Don t run on your reserve oil Completely running out of oil can result in severe engine dama
21. and disconnect the battery Drain the fuel system completely Use an approved container to collect and store fuel Wipe up any spillage immediately Material used to contain spillage must be disposed of in an approved receptacle Any fuel system service must be performed in a well ventilated area Inspect any completed service work for sign of fuel leakage SAFETY A gasoline fire or explosion can cause serious injury or death Carefully follow all service instructions Always stop the engine and disconnect the battery DO NOT smoke or allow open flames or sparks in the area Isolate the batteries and pull the kill switches i a msn amma Preventative Maintenance for Rigid Hull Inflatables Filters vary in construction Consult the manufacturer s technical manual for instructions on fuel filter element replacement Use the following general procedure 1 Unscrew the old element from the filter bracket 2 Coat the sealing ring on the new fuel filter element with engine oil Thread new filter element onto the bracket tightening securely by hand 3 Run engine and check for leaks Fuel Filters gt Drain the transom mounted fuel water separator filter daily gt Drain the water separator filter located on the engine on a weekly basis When filter maintenance is done regularly the engine s filter should show little or no water because the transom filter will have captured it first gt Replace the filter cartridge every 10
22. area is larger than a dime replace the propeller Inspect the propeller shaft to ensure that it is straight If using flow torque hubs re torque the hubs after a good run 55 ft Ibs of torque VVVV 1 This propeller has thrown a blade because a 2 This propeller has hit a very hard object and very small nick has not been repaired and it may be out of balance even after extensive has gradually cracked and blown off repairs It should be replaced Note Cavitation is damage caused by air bubbles as the propellers race through the water SR a a ETT EEE TT EI Preventative Maintenance for Rigid Hull Inflatables 2 3 6 Outboard Motor Controls 2 3 6 1 Inspection Requirements Controls gt Check 2 control base securing screws for tightness see diagram below a gt Check 2 control handle mounting brackets see diagram below b gt Check 2 nylon locknuts see diagram below c gt Ensure all electrical connections are tight and the harness is properly secured and out of the bilge gt Check controls for ease of operation If controls require increase in effort to move investigate the cause Do not force controls check control and engine end for binding gt Repair and lubricate the unit using Quicksilver 2 4 C Marine Lubricant a Screw 10 32X4 00 2 b Mounting Bracket 2 c Nylon Locking Nut 10 32 2 a a a I a TE ET a ER re Preventative Maintenance for Rigid Hull Infla
23. caping Repair leaks as per the chart in the Trouble Shooting and Repair Section 2 4 4 After you ve repaired the leaks rinse dry and re coat with Protectant 303 Once all leaks have been repaired remove all air from the bag Remove plug and reinstall relief valve Calculate compensation pressures using 03 psi per degree and 49 psi per inch of mercury Deflate and re fold back over front to ensure proper inflation Centralize bag in cradle fold front over first then fold the back over top of the front fold This ensure that bag inflates toward the stern If the bag inflates forward it may not have enough lift to take the vessel over its center of gravity VV VVVVVVV VVV V VY VY VY V VV VV WV i a msn amma Preventative Maintenance for Rigid Hull Inflatables Cylinder and Firing Head Visually inspect the cylinder for corrosion nicks and dents Ensure cylinder is securely fastened Inspect cylinder for up to date hydrostatic inspection stamp If test is due tell the Mate Coxswain Check tightness of discharge hose Tighten as required using correct sized wrench Check tightness of the three locking bolts that hold the firing head to cylinder head Check tightness of hose clamps that hold the cylinder in place Visually inspect all hose fittings for corrosion and or damage Ensure that the Maintenance Safety Pin has been removed Visually inspect firing head Ensure that all fasteners are present and the unit is corrosio
24. ch should pull out if you fall to the deck 5 Ea AAAA AAAA SAFETY DO NOT run an engine with a faulty kill switch Preventative Maintenance for Rigid Hull Inflatables 2 3 7 3 Preventative Maintenance Requirements Testing For both Mercury and OMC Kill Switches k RUN Mercury Kill Switch gt While the engine is running pull the OFF Kill Switch for that engine gt Engine should come to an immediate stop gt Reinstall lanyard and re start engine to verify that lanyard is properly re installed gt Shut down motor via ignition key gt Start second motor and follow the above procedure again Sa Tell the Mate Coxswain if engine does not shut down OMC Kill when the lanyard is pulled Kill Switch released Switch Further investigation should be done immediately Check to ensure that the switch is free and not seized Toggle several times or Ts ro PER P a i mh E te tte Pad Bak Pe ee po DLR AM Ne ALN yn sly Warning If starting engines while RHI is onboard ship check the following Engine muffs properly installed and water supply on All personnel informed that engines will be started Area around propellers blocked off or access denied Propeller areas clear of objects or personnel Control in Neutral position aa a TE EE a ER re Preventative Maintenance for Rigid Hull Inflatables 2 3 8 Warning Horns 2 3 8 1 Overview Ca
25. cks sharp bends leaks and or holes If you find any damage replace or repair the hose gt Inspect hose path for any areas where chafing rubbing may occur If you find such an area protect the hose by re routing it or by putting a protective wrapping over the area gt Feel the hose for firmness If a hose feels mushy replace it as soon as possible Hose Clamps and Fittings gt Visually inspect all hose clamps Do not over tighten and fittings to ensure they are in fittings as they are being good condition gt Check all hose clamps for gt tightness gt Inspect areas around fittings for signs of leakage If leakage found remove hose and undo the fitting Re install the fitting using new thread sealant threaded into plastic Racor Filters gt Visually inspect filter bowls and drain as required gt Check filter bowls for cracks and or leaks Repair as required gt Inspect inlet and outlet fittings for tightness Adjust as required Priming Bulbs gt Inspect for visible signs of cracking and or leaks gt Test bulbs by pumping ensuring that they become and stay firm gt Inspect inlet and outlet fittings for tightness and condition Fuel Oil Gauge gt Inspect sending unit cover for tightness gt Visually assess the level of the fuel oil tank and compare it to the reading provided by the gauge If the gauge is not working check that it has power supply batteries on breaker panel in good conditi
26. d incorrectly it can add to the problem Remember the basics and keep it simple Refer to the Quicksilver Technician Reference Manual for further testing and operational procedures DDT Basics The DDT allows you to gt Record and view real time system data gt Perform static tests on some engines DFI 150 EFI 150 gt Read past history of failures or faults and passes which are retained by the ECM gt See details broken down to separate components Ignition Injector Pump Sensors Switches Misc RPM limit Break in time and system info gt Compare data values to the manufacturer recommended specs outlined in the Service Manual to hone in on engine problems BAe oe aN 2 3 9 4 The Onboard Fuel System This section covers only a few of the most common problems If any one of the basics fails fix that problem first then continue Contaminated fuel is a problem The EFI and DFI engines do not like water or other foreign objects i e rust from old gas drums mixed with the fuel Any of these can cause trouble for the engines Proper filtration checking for water and age of fuel are all very important Always consult your engine manufacturer s technical manual for details when trouble shooting the engine P N i a msn amma Preventative Maintenance for Rigid Hull Inflatables If fuel delivery to the engines is being restricted then the primer bulbs located in the aft machinery space will be soft or co
27. e many have an optional self righting system In a capsize situation the self righting system enables the operator to right the boat Detailed operating instructions are contained in the Hurricane Technical Manual and RHIOT Manual The system has four main parts gt An inflatable self righting bag gt A compressed air cylinder gt A firing head fill assembly gt Aself righting aluminum frame The inflatable self righting bag is made of an external layer of Hypalon a core of either nylon or polyester fabric and an internal layer of neoprene rubber It is bolted with aluminum flanges to a tray at the top of the self righting frame A fabric valise covers and contains the folded self righting bag The valise closure is velcro that automatically releases as the bag inflates The compressed air cylinder is attached to the self righting frame The firing head threads into the cylinder The self righting system is designed to operate manually not automatically A handle located on the transom activates the system This handle is attached to a firing head via a release cable enabling the operator to activate the system from the water When the release cable exits the firing head a spring loaded bayonet pierces the puncture disc located in the cylinder head The high pressure gas fills the self righting bag The self righting frame houses the entire system and provides the height necessary for the inflated self righting bag to ri
28. e engine Throttle adjustments must be re checked once the vessel is afloat Readjust as necessary i a msn amma Preventative Maintenance for Rigid Hull Inflatables Controls Repair and lubricate the unit using Quicksilver 2 4 C Marine Lubricant Lubricating Points on Control Cable This illustration depicts an OMC type control cable Adjusting Barrel or Knurl Si nT ie Engine End SAFETY If you don t tighten set screws handles may disengage causing a loss of throttle shift control To prevent shorts make sure that all connections are secure and have been lubricated with dielectric grease Preventative Maintenance for Rigid Hull Inflatables Steering System Bleeding This operation requires two people One at the helm and one at the cylinder Step 1 gt Remove steering reservoir cap gt Install threaded end of filler tube into reservoir filler hole helm gt Remove lid from oil bottle Use only recommended oils see below gt Holding bottle upright screw it into the filler tube bottle cap gt Turn bottle upside down and punch a small hole into the bottom of bottle gt Fill reservoir full of oil make sure oil is always visible in the filler tube gt If the level falls off stop immediately and install a new oil bottle WARNING If the oil level gets too low more air will be sucked into the system and you must start the bleeding process again Recommended
29. e n a a Preventative Maintenance for Rigid Hull Inflatables CHAPTER 3 Appendices 3 1 Spare Equipment List and Sourcing Information To obtain access to any of the spare equipment listed below contact Officer in Charge of Inflatable Craft Maintenance 250 363 6656 Shop lInstitute of Ocean Sciences 250 812 7942 cellular 250 474 2863 home 250 413 5995 pager Prince Rupert 2 engines 2 propellers Miscellaneous small parts Boat complete Port Hardy 2 propellers left and right 2 bottom ends 2 motors 2 propellers left and right Bottom end Bamfield 2 propellers left and right Bottom end Motor 1 EFI engine and 1 propeller e e S Campbell River 1 DFI engine Bottom end rey A i a TE TI ER TI Preventative Maintenance for Rigid Hull Inflatables 3 2 Consumables Mercury Parts Station Supplied Consumables Bulb Replacement OPT BB 4000 Western Marine Company 1 800 663 6790 Quicksilver TC W3 Premium 1 Gal 92 831229A 6 Mercury Marine Parts Plus 2 Cycle Outboard Oil 2 5 Gal 92 831232A 2 1 800 452 6668 MUST BE USED OR 55 Gal 98 831234A 1 WARRANTY IS VOID 1 Litre 92 831226 A12 case of 12 4 Litre 92 831229 A6 case of 6 Gear Oil High Performance 2 5 Gal 92 816026 A2 16 Gal 92 816026 A16 24C Marine Lube 14 0z 92 825407 A4 case of 4 Ll Spline Grease 92 816391 A4 a Racor Fuel Filter Depending on type S3227 Cl Quicksilver Fuel Treatment amp Stabilizer 92 12253
30. eck water in bilge Preparation for Shipment If you must send your hoisting system away for repair fold down or remove the lift frame to avoid damage to the RHI aE a a IE EI a ETE IRE Preventative Maintenance for Rigid Hull Inflatables 2 6 Electrical and Electronics 2 6 1 Batteries 2 6 1 1 Overview Requirements for engines EFI 650 850 max Cold Cranking amps DFI 800 1000 max Cold Cranking amps 2 6 1 2 Inspection Requirements On a weekly basis or after a long rough run 1 Make sure all terminals have nylock nuts on them and self right caps securely installed and the battery levels are topped up 2 Inspect all connections on battery post for cleanliness and tightness 3 If terminals are heavily coated with deposits isolate batteries and clean terminal posts and connections 4 Inspect top of battery for dryness If the top is wet the current can leak between terminals causing discharge Use baking soda to neutralize acid and wipe clean 5 Inspect battery case for bulging caused by overcharging and or freezing of battery 6 Inspect electrolyte level If level below 5 mm from top add distilled water Do not check specific gravity right after adding water Put battery on charge for at least 1 hour before checking specific gravity 7 Measure the specific gravity of the battery electrolyte to determine the battery s state of charge Observe the following points when using a hydrometer gt Hold hydrometer
31. eering system resulting in property damage and or personal injury Steering Gear Cylinder Shafts A Visually inspect the cylinder shafts for damage Cylinder Shaft Damage gt Look for large nicks scouring flaking of metal gouges loose connections or bends in the unit gt Inspect shaft for salt water corrosion A Nicks rough or damaged shaft will cause seal a damage and oil loss Tell the Mate sip Coxswain about damage Flaking Gouges aa a IE EE a ER ae Preventative Maintenance for Rigid Hull Inflatables B Visually inspect the seals gt Inspect seals in place for damage small tears pieces missing gt Inspect the seal area for oil leakage gt Have one person turn the helm to port Apply enough force to exceed relief valve pressure Maintain pressure gt Second person should fully inspect Leak in Way of Seal extended cylinder shaft If minor damage is found polish area using Brasso Clean polished area thoroughly with solvent after completion Wipe with steering fluid gt Atthe same time the second person should inspect the shaft for leaks and or damage gt Tell the Mate Coxswain if a seal is leaking Replace the seal or unit as Leak in Way of Seal soon as possible gt Check oil reservoir for correct fluid level Add as required If a seal is replaced or reservoir empty low bleed wry eA g the steering system Wipe up any oil Ae around the steering cylinder upon
32. elf venting drain Wipe up any spillage VVV WV Changing the Fuel Water Separator Filter Racor Filter Removing the Old Filter Place save all pan under filter being changed Plug compartment drain holes Loosen self venting drain and drain filter unit Remove Racor filter and plastic bowl as one assembly Remove reusable plastic bowl from filter assembly Remove O ring from plastic bowl gland Clean bowl and inspect for damage If bowl in good condition clean O ring gland 1 VVV V VVV WV Racor Filter Legend 1 Mounting Head 2 Filter Top Seal 3 Filter Element 4 O Ring 5 Reusable Plastic Bowl 6 Self Venting Drain Preventative Maintenance for Rigid Hull Inflatables Installing a New Filter gt Lubrciate new O ring with motor oil or light grease and place in plastic bowl gland gt Close self venting drain plug gt Spin plastic bowl onto new Racor SAFETY filter and tighten by hand Do not l 3 Improper installation use tools to tighten plastic bowl m 0 may cause explosion or filter element or fire resulting in Fill filter bowl assembly with clean serious injury or fuel oil death Lubrciate top of Racor filter using motor oil or light grease Carefully spin unit only mounting head After the filter seal makes complete contact with the mounting head tighten the unit an additional 1 3 to 1 2 turn by hand Complete priming fuel system and check for leaks Wipe
33. ge aa a TE EE a ER re Preventative Maintenance for Rigid Hull Inflatables 2 3 9 Trouble Shooting and Repairing Your Outboard Motor 2 3 9 1 Overview Consistency and attention to detail are essential elements of outboard motor maintenance You must have the User and or Service Manual to do proper repairs gt Step 1 Get the right manuals gt Step 2 Do the maintenance The horsepower and types of outboard engines used by the Department of Fisheries and Oceans vary greatly Instead of looking at specific engine models this section covers the similarities in all of the engines As engine technology advances so does the equipment required to diagnose the engine s operation There are very few components used in the construction of new user friendly adjustable repairable outboard engines Most engine components are go no go components requiring replacement rather than repair You can fix most common problems in the field with a little common sense and a service manual A technician is needed to repair or trouble shoot more complex problems It is embarrassing to take an outboard to a shop and say it doesn t start only to find out that the kill switch was activated or it was running rough and a spark plug wire was loose or completely off Basic problems like these have happened and they cost the Coast Guard time and money 2 3 9 2 What To Do If Your Engine Won t Start Mercury Mariner EFI and Opti Max DFI Engines 2 5L
34. ght the boat The frame is mechanically attached to the deck and or transom There is a small platform for navigation lights Variations to the frame model include gt Larger platform for radar antenna mounting optional gt Folding frame for air transport or storage optional gt Integral tow bollard gt Tow reel and attachments The structural strength of the self righting frame is very critical as any weakness may cause it to tear away from the deck when the vessel overturns or once the self righting system is deployed If this happens it will prevent the vessel from righting itself possibly causing further damage to the vessel and injury to the operator and or crew i I ea a TO ETT EEE Ia Preventative Maintenance for Rigid Hull Inflatables Self Righting System INFLATABLE SELF RIGHTING BAG VALISE SELF RIGHTING FRAME 2 4 2 Inspection Requirements General Inspect the self righting system weekly 1 Inspect exposed areas of the self righting bag for signs of wear and tear chafing visible rips or puncture holes and signs of wear around the mounting flange 2 Inspect the clamps that secure the compressed gas cylinder for tightness 3 Check the firing head fill assembly for gt Valve tightness gt Banjo tightness gt Fill hose tightness both ends and kinking or chafing gt Firing head tightness gt Firing cable handle attachment snap corrosion 4 Inspect the self ri
35. ghting frame for gt Attachment bolt tightness gt Fatigue cracks in aluminum particularly near welds gt Hinge and latch mechanisms if applicable a l i a msn amma Preventative Maintenance for Rigid Hull Inflatables Conduct a Bag Inspection and Air Retention Test monthly as follows Step 1 Inspection Install cylinder maintenance safety pin Undo the velcro to open the valise Remove debris and clean Visually inspect the bag for large tears or obvious damage Inspect corners of the bag where it is folded one side at a time Make sure there is no loose fabric or areas lifting on the bag Inspect all exposed areas of the bag for chafing or extreme wear or damage check this weekly Repair any damaged areas as outlined in the manual Proceed to Air Retention Test see next page VV VVVVVV WV Air Retention Test Sheet for Self Righting Bag af me au am aw oe ee me ee am am eR oe ee ae oe em a wee am OD Oe Oo ow oe On ee os a oe SELF RIGHTING BAG AIR RETENTION TEST SHEET BOAT DATE tenn 722 poe nooo ene penne Pres Temp Barometer Time to mmn nme nnn enn tromnn r feeron o 4 Start tea panosu patee see HeGecuectene fenn End fonnannnen Jeseni fewnnwonnne Difference tome n meee nen ne 4 4 2 2 Compensate o seria aca ai a
36. ida 22 4 partscenk al Corrected Pressure 2 75psi min meme Se rer we ey a A in So Ok a p N I a TO EI Preventative Maintenance for Rigid Hull Inflatables Step 2 Air Retention Test While the bag is installed on the frame Replace the relief valve with a plug Remove the cylinder outlet hose Inflate the bag with bellows until the pressure relief valve activates Ensure pressure relief re seals Replace the fill valve cap securely Allow the bag to sit for about 1 hour giving the pressure time to stabilize to the surrounding temperature After the bag has acclimatized adjust the air pressure back to 3 psi remove or add air as required Measure the air pressure and enter it next to Start on the test sheet see previous page Take the ambient air temperature and the barometric pressure and note them on the same line of the test sheet Wait an additional hour Re test the bag s air pressure and enter next to End on the test sheet Take a second reading of the ambient air temperature and barometric pressure and enter these next to End on the test sheet If there is a pressure difference you have a leak and you must find it With the bag still inflated mix up a water soap solution Using a paintbrush paint the solution over the bag including all seams and valves The leaks will be seen as a growing chain of bubbles If the hole is large you may even hear the air es
37. keep an exact circle If you turn too quickly the deviation data will be ignored 3 Turn the vessel continuously through two full circles 720 at a slow and steady speed Keep the vessel level You can go either clockwise or counterclockwise 4 Continue to turn through a further two full circles to ensure that you have obtained accurate data 5 The Heading Sensor will now correct all heading readings using the variation data obtained p N Sag a a I IE EE a ER ae Preventative Maintenance for Rigid Hull Inflatables 2 6 3 4 Trouble Shooting and Repair Refer to the product manual that came with the equipment 2 6 4 VHF Radios 2 6 4 1 Inspection Requirements Refer to the product manual that came with the equipment 2 6 4 2 Preventative Maintenance Requirements Refer to the product manual that came with the equipment 2 6 4 3 Trouble Shooting and Repair Here are some basic trouble shooting tips fort the ICON IC M59 VHF radio See product instruction manual for detailed programming and setting information gt Check inline fuse and dash breaker No sound from speaker gt Check squelch If the volume control is rotating too far clockwise check external speaker connection gt Turn up volume control Received signal cannot be understood gt Turn ON voice scrambler correctly gt Set voice scrambler code correctly a mmm nn mae Preventative Maintenance for Rigid Hull Inflatables a ra a LS ITT T
38. ll Replace the battery Check battery vent caps Clean any plugged or dirty holes with a toothpick This prevents a dangerous build up of acid fumes in the battery SAFETY Wear all required safety gear gloves glasses coveralls Do not smoke around battery Do not mix battery acid with salt water it makes chlorine gas Secure all batteries Make sure there is plenty of air circulation when batteries are charging Do not drop or leave tools on or near the battery Do not wear metal rings or watchstraps when working on or near batteries Do not spill any acid on yourself If you do flush with water immediately i a msn amma Preventative Maintenance for Rigid Hull Inflatables 2 6 1 3 Preventative Maintenance Requirements gt Check to ensure that the fluid level is at the base of the cell port gt Ensure that the top of the battery is clean Dirt and electrolyte on the top of the battery will allow an electron flow from the positive terminal to the negative terminal that can drain the battery overnight gt Check the specific gravity of each cell using the hydrometer This will enable you to determine the condition of each cell individually or the condition of the battery as a whole All cells should show similar reachings If one or two cells are significantly lower than the rest battery failure is imminent gt Ensure that your batteries have been retrofitted with caps designed to prevent spillage during inversion or
39. ll Kill Switch on engine being checked Remove top cowl Check oil level in engine mounted reservoir If the oil level is below the top of the tank the problem is low oil A Check the remote reservoir to verify that it is empty If the remote tank is full check filler caps for tightness and hoses to ensure no air leaks Bleed system before operating again If the engine mounted reservoir tank is full the problem may be the oil injection pump gt Do not run the engine unless it can be run using a remote tank with a 50 1 gasoline oil mix If engine is run without oil severe damage will result Y VVV WV v ZA y If alarm sounded because oil is low you can still operate the vessel for approx 30 min Keep close track of the oil level Vel If the engine oil runs out severe motor damage will result Preventative Maintenance for Rigid Hull Inflatables OMC Warning Horn Signals Horn sounds Engine overheating gt Reduce engine RPM See OMC Reference 1 continuously and engine to idle will not exceed 2500 RPM This is caused by a built in safety featured gt Return control handle to Neutral called S L O W gt Wait until engine cools down and warning horn stops before shutting down Horn sounds rapid short No oil flow from the oil gt Stop engine best See OMC Reference 2 tones that vary with pump solution engine REM gt If not possible to stop do not exceed 1500 RPM Horn so
40. llapsed It is more difficult to diagnose restricted fuel delivery Follow these steps 1 Check fuel level in both tanks 2 Ensure that fuel selector valves are correctly aligned with the fuel tank selection indicator Check fuel tank vents for kinks or blocking Remove deck fill caps If this corrects the problem fuel storage tank vents are suspect For fuel storage tank vent trouble shooting contact the Inflatable Craft Maintenance shop in Victoria Check fuel supply hoses for kinks Check fuel return hose for kinks inboard engine only Replace water separating fuel filter element Check fuel tank supply fittings for blockage Pick up screens may be blocked 0 Or ON ON Preventative Maintenance for Rigid Hull Inflatables Propeller Replacement Mariner 1 Shift outboard to Neutral N position 2 Pull Kill Switch s to prevent waj engine s from starting 2 4 j ee eeeNININININI NINN mead 3 Straighten the bent tabs on the propeller nut retainer 4 Place a block of wood between the gear case and the propeller to hold the propeller Remove propeller 5 Pull propeller straight off shaft If propeller is seized to the shaft and cannot be removed have the propeller removed by an authorized dealer Preventative Maintenance for Rigid Hull Inflatables See 6 6 7 8 9 ss Coat propeller shaft with Quicksilver Anti Corrosion Grease Install thrust washer
41. ly inspect the self righting degrade the fabric ot bag for chafing damage and the bag attachment flange damage Conduct Air Retention Test as per Section 2 4 2 Repair as required Check relief valve Repair or replace as required Check inflation deflation valve Repair or replace as required Check inflation valve Repair or replace as required VV V 303 Protectant can be used on the self righting bag to reduce friction when it s being folded a a TEE a ET Preventative Maintenance for Rigid Hull Inflatables Self Righting Frame gt Check for cracks around weld areas gt Tighten all mounting bolts and nuts gt Check overall condition of frame and supports DO NOT drill any holes in the support frames use only tie wraps Tow Reel gt Ensure tow reel spins freely gt Tighten all nuts and bolts gt Keep tow line cover on when not in use this protects the tow line from sunlight 2 4 4 Trouble Shooting and Repair The only repair you should do on the self righting system is to leaks in the bag Use the following chart Repairing Leaks to Self Righting Bags Location of Leak Repair Required gt Clean and tighten valve gt See product manual for removal and replacement of valve See tube repair section of this guide Section 2 1 4 Widespread Leakage gt Patch the area as outlined in Section Leakage appears widespread when many 2 1 4 3 small bubbles are in the middle of the panel gt If
42. n free Ensure the unit is ready for operation pin removed and all hoses secured Y VVVV V V VV WV WARNING Only a qualified person should take the firing head off as premature discharge of the bottle can occur a aT TE a EE Preventative Maintenance for Rigid Hull Inflatables Self righting system Check inspection date and pressure DO NOT change anything I ea a TO ETT EEE Ia Preventative Maintenance for Rigid Hull Inflatables Hose gt Check hoses for signs of wear or chafing Handle gt Ensure handle of firing cable is in good condition gt Check link between pull cables and handle crimp Cylinder and Firing Head Pull Handle Ne Locations of Frame Welds Frame Welds gt Visually inspect the aft frame for cracks in the tubing gt Inspect all welded areas for indications of cracking Look for lifting paint which may indicate a problem area gt If paint is lifting at a weld strip paint in surrounding area and closely inspect for cracks Re paint area when you are done gt If you find any cracks tell the Mate Coxswain gt Repair cracks as soon as possible i a msn amma Preventative Maintenance for Rigid Hull Inflatables Fasteners gt gt a Locations of Frame Physically inspect all frame fasteners Fasteners Carefully try to tighten the fasteners that secure the frame to the deck do not over tighten as the inserts will start to spin and you won t
43. nadian Coast Guard Department of Fisheries and Oceans rigid hull inflatables are equipped with propulsion systems that use a system of warning horns When a problem is detected the warning horn sounds Your system may also be equipped with a visual display The horn will sound continuously if the problem can cause immediate engine damage The horn will sound intermittently if the problem will not cause immediate engine damage 2 3 8 2 Inspection Requirements For both Mariner and OMC test the warning horns regularly as follows Turn on battery isolation switch Turn ignition key from OFF to ON test The warning horn will beep once as a self NOTE The alarm on the MERC model year 1999 2000 side mount controller will NOT sound when the key is in the ON position prior to starting Repeat steps for the other outboard motor If the alarm fails to beep tell the Mate Coxswain VV VVWV Each type of engine has its own signals If you hear the warning horn check these charts to see what it means and follow the steps Mariner Warning Horn Signals Horn sounds continuously Engine overheating gt gt gt Horn sounds intermittent short beeps Low level in the injection system Oil injection pump failure Stop engine Reduce engine RPM to See Marine Reference 1 idle Return control handle to Neutral Wait until engine cools down and warning horn stops before shutting down See Mariner Refere
44. nce 2 aa a IE EE a ER ae Preventative Maintenance for Rigid Hull Inflatables Mariner Reference 1 Horn Sounds Continuously Engine Overheating gt Check water discharge from water pump indicator hole A gt If no water discharge or discharge is intermittent stop the engine s Pull Kill Switch on engine being checked Tilt up engine Check cooling water intake holes for obstruction Remove any obstruction found Lower engine and re start Monitor engine water discharge If no obstructions are found the blockage may be in the cooling system or the water pump impeller may be damaged gt Do not run engine until the problem is corrected gt Ifa steady stream of water is present from pump indicator hole but the horn continues to sound there may be insufficient cooling water or an engine problem Notify the Mate Coxswain VV Vv If you are stranded you can stop the engine and allow it to cool back down This will give you some additional low speed idle running time before the engine overheats again Do this procedure only in an emergency as engine damage may result Mariner Reference 2 Horn Sounds Intermittent Short Beeps Low Oil gt On EFI DFI Outboards intermittent beeps can indicate water in the engine s fuel water separator A red light in front of the engine will also indicate that water is present in the fuel separators If this occurs drain the fuel water separators Stop engine Pu
45. on gt If the gauge still doesn t work check that the wire isn t broken gt If wiring is in good condition and the power supply is working the problem may be in the sending unit If this is the case notify the Mate Coxswain before proceeding any further Engine Connection gt Inspect fitting for tightness and condition gt Inspect engine fuel system for leaks and repair as required aL aE a I CE a ETSI Preventative Maintenance for Rigid Hull Inflatables Fuel Water Separator gt Visually inspect both Racor NOTE filters on the outboard s fuel If Racor filters are full of water the vapor separator for water and outboard water separators should or sediment on a daily basis also be drained If you find a lot of water drain other components as well e g fuel pump and fuel rail on a DFI engine See outboard service manual for details Remote Tank gt Check all connections and clamps for tightness gt Inspect all cap seals for good condition Replace if not in good condition gt Inspect remote hose for good condition Ensure that there are no chafing marks gt Check that the tank is well secured Remote Oil Reservoir Tank gt While the engine is running inspect engine reservoir hoses fittings and cap for leaks gt If you find leaks repair them and wipe up any spillage 2 3 2 3 Preventative Maintenance Requirements Before servicing any part of the fuel system stop the engine
46. ove Technicians Inflatable Craft Maintenance ICM 250 353 6656 Shop at Institute of Ocean Sciences 250 920 5052 cellular G Caird a a EE I EI I a ER se Preventative Maintenance for Rigid Hull Inflatables Air Retention Test p 111 112 Anodes p 79 Bag Inspection p 111 112 Batteries p 123 124 Battery Inspection p 123 124 Bilge Pump p 55 56 Bilge Pump Repairs p 57 Bleeding Steering System p 91 93 Checklist Daily Inspection and Maintenance p 17 18 Checklist Engine Inspection p 19 Checklist Vessel Specifications p 13 14 Checklist Weekly Inspection and Maintenance p 17 18 Cleaning the Self Righting Bag p 118 119 Cleaning Tubes p 27 Console p 54 Consumables p 133 134 Controls p 81 Corrosion Control Anodes p 79 Daily Vessel Inspection Checklist p 15 16 Daily Vessel Maintenance Log p 15 16 Deck p 43 Electrical System p 123 125 Electronics p 123 125 Engine Inspection p 60 Engine Inspection and Maintenance Schedule p 60 Engine Inspection Checklist p 19 Engine Lubrication p 59 68 Engine Maintenance p 60 68 Engine Repair p 100 107 Engine Troubleshooting p 100 107 Equipment Transfer Form p 11 12 Fiberglass Reinforced Plastic FRP Repairs p 48 53 Fuel Filters p 73 Fuel Line p 70 Fuel System p 69 72 Fuel Water Separator p 74 Gauges p 77 GPS p 127 128 Greasing an Outboard p 62 68 Help List p 135 Hoisting System p
47. p 25 Tube cleaning p 27 Tube installing p 30 34 Tube pressure p 26 Tube removing p 30 34 Tube repairing p 34 41 Tube valves p 27 30 Valves Tube p 27 30 Vessel Specifications Checklist p 13 14 VHF Radios p 129 Warning Horns p 96 99 Weekly Vessel Inspection Checklist p 17 18 Weekly Vessel Maintenance Log p 17 18 Wiring p 77 78 p s a mmm nn mae Preventative Maintenance for Rigid Hull Inflatables a mmm nn mae Preventative Maintenance for Rigid Hull Inflatables
48. rag is present adjust cable barrel away from cable end guide 4 Repeat Steps A and B Pull emergency Kill Switches Remove ignition keys Ensure propeller area clear of personnel a a a A ETE EEE Ia Preventative Maintenance for Rigid Hull Inflatables C Decrease Gap 1 Shift remote control into Reverse turn shaft while checking propeller shaft for movement 2 The propshaft should lock solidly in gear 3 If shaft does not lock adjust barrel away from cable end guide 4 Repeat steps A through C D Increase Gap 1 Shift remote control into Neutral 2 The propeller shaft should turn freely in either direction without any drag 3 If any drag is present adjust the barrel closer to cable end guide 4 Repeat steps A through D Pull emergency Kill Switches Remove ignition keys Ensure propeller area clear of personnel Preventative Maintenance for Rigid Hull Inflatables A e a mee OANOSA p Throttle Cable Adjustment Step A Set up NA Pull emergency Carry out this procedure before starting the Kill Switches engines 1 Secure RHI properly in its cradle Remove 2 Install water muff ignition keys 3 Block off area around propeller Ensure 4 Remove throttle cable from lever propeller area anchor pin B 5 Remove cable retainers D clear of 6 Remove throttle cable barrel from personnel receptacle 7 Turn on water supply 8 Check to make sure the propeller a
49. rea is clear of people or foreign objects a a I a TE ET a ER re Preventative Maintenance for Rigid Hull Inflatables Step B Testing 1 2 3 Adjust engine RPM to 600 700 RPM in forward gear Never increase RPM D Or Start engine being tested Ensure good water discharge Warm up engine above 750 or you will damage the engine Shift control lever into Neutral Reattach cable end to throttle lever anchor pin and secure with latch B With the throttle cable attached to the throttle lever hold throttle lever against idle stop C Adjust throttle cable barrel It should slip into the barrel receptacle A with a very light pre load of throttle lever against the idle stop C A piece of paper should drag through but not tear Lock barrel back into place using cable retainer Block off area around propellers Visually inspect area around propellers for foreign objects Have one crew member stand by to ensure nothing goes near the propellers Step C Pre Load Check 1 2 Place a thin piece of paper C between the idle stop screws and idle stop If the pre load is correct the paper can be removed without tearing only feeling a slight drag If the paper tears or if there s drag present readjust the barrel Do not try to synchronize Too much pre load control head shift handles creates an unnecessary by adjusting the throttle strain on the and shift cables or any control cable screws at th
50. rements Heading Alignment After checking calibration and deviation it s time to check the heading alignment Use one or both of the following techniques 1 Compare the heading information on your display instrument XX Radar or Ray data with the ship s magnetic compass for several headings 2 Choose reference points from a chart and navigate between them Then compare the readings from your heading sensor with the actual chart courses If the Heading Sensor s reading is different from the actual readings by a constant amount you need to correct the Heading Alignment Do this by adjusting the position of the compass as follows 1 You will be able to turn the Heading Sensor slightly 10 either way without having to loosen any bolts 2 If the Heading Sensor s readings are less than the actual readings rotate the sensor clockwise If the Heading Sensor s readings are less than the actual readings rotate the sensor counterclockwise 3 Check the headings again and repeat Step 2 if required 2 6 3 3 Preventative Maintenance Requirements To ensure that the compass has received accurate data perform the following procedure 1 Choose a calm day if possible Select an open area of water ideally with little or no current or tide 2 Roughly guess the size of the circle in order to keep your turn rate down to not less than 45 seconds for each 90 of turn You can turn more slowly than this and you do not need to
51. t green and or abandoned wires that weren t taken out properly the first time gt Inspect all wiring components thoroughly When in doubt change the component to ensure that all contacts are free of corrosion gt Make sure that 1 All contacts are tight and have proper nuts brass not steel 2 There is no excessive moisture in the contacts 3 Proper gauge of wire is used for the right application to reduce the possibility of chafing 4 All breaks have waterproof boots on them and the proper Amp rating for the application gt Use Ship to Shore and dielectric grease or Merc corrosion guard 92 827933 55 on all exposed wiring and electrical components gt Keep all wires neatly tie wrapped together gt Become familiar with the electrical system and know all the related components and their functions Knowing the system will help you trouble shoot future problems If you do these basic procedures on a regular basis there is less chance of something failing It will also help you find a problem and fix it before it becomes something major short circuit chance of a fire SAFETY It is known that some people have replaced breakers with a larger amp rating than required This could cause a short and a fire Contact the Officer in Charge of Inflatable Craft Maintenance before replacing a breaker with one of a larger amp rating rr am am nn mae Preventative Maintenance for Rigid Hull Inflatables 2 3 4 Corrosion
52. tables Steering System Oil gt Remove helm pump filler plug gt Helm units are mounted at 20 degrees The oil level should be 12 7 mm from the hole gt If oil level is below required level top up Use same oil as presently in the system See Recommended Steering box for recommended oils System Oils Texaco H015 Shell Aero 4 Esso Univis N15 Chevron Aviation Fluid A Fluids Meeting Mil H5606c Specifications Teleflex Steering Fluid Power Steering Fluid Sea Star Fluid HA5430 WARNING Never use brake fluid It may cause irreparable damage and loss of steering Steering Gear Fasteners On a weekly basis Physically inspect all steering gear fasteners and linkages for tightness Tighten all loose fasteners and replace any damaged or missing parts Wiggle all ball joints to check for excessive wear Replace as required Inspect 4 nuts securing the help pump Check for tightness Inspect helm securing nut for tightness Inspect all hydraulic lines and fittings for tightness VVVVVV Steering System Fasteners a a a TE E I a ER se Preventative Maintenance for Rigid Hull Inflatables Tie Bar System Check for overall condition of steering system and components Tie Bar System SAFETY The threaded rod must always fully cover Inspection Hole 1 but NEVER Inspection Hole 2 see right Failing to observe this warning may result in one engine being separated from the st
53. tightly as any leak will cause oil spillage Oil spillage may cause an engine fire SAFETY Always clean up any fuel spills immediately Dispose of liquid and rags safely Wait until fumes dissipate before starting the engine aa a TE EE a ER re Preventative Maintenance for Rigid Hull Inflatables 2 3 3 Gauges and Wiring 2 3 3 1 Inspection Requirements Inspect all gauges and wiring for broken wires loose connections and or faulty gauges every day 2 3 3 2 Preventative Maintenance Requirements Gauges gt Itis common for some 733s to have a bit of moisture in their gauges The moisture usually goes away once they get warm gt A few inaccurate tachometers have been noticed in the fleet The maximum r p m for an EFI 150 is 5600 and 5750 for DFI Optimax engine gt To check the accuracy of your tachometer you will need the Digital Diagnostic Terminal DDT hooked up to your engine Compare the true r p m from the DDT with what your tachometer gauge indicates at various r p m ranges gt If there is a discrepancy go with the DDT as the true r p m reading gt Check the true r p m against the recommended r p m for your propeller If necessary change the propeller to one with a lower pitch a a a TE E I a ER se Preventative Maintenance for Rigid Hull Inflatables Wiring Salt water is wiring s worst enemy The most common problems include corrosion on terminals loose connections rotten wires i e burn
54. unds one short Low oil level in oil tank gt Refill oil tank tank See OMC Reference 3 tone every 40 seconds level at reserve Horn sounds Fuel restriction gt Reduce engine speed See OMC Reference 4 continuously at or neat to idle full throttle but engine speed not effected OMC Reference 1 Horn Sounds Continuously and Engine Slows Down gt If overheating engine will automatically SLOW down to 2500 RPM gt Check water discharge from water pump indicator hole A If no water discharge or discharge is intermittent y A stop engine s Pull Kill Switch on engine being checked Tilt up engine Check cooling water intake holes for obstruction Remove any obstruction found Lower engine and re start Engine must be shut down ignition key OFF to re set SLOW function Monitor engine water discharge If no obstructions are found the blockage may be in the cooling system or the water pump impeller may be damaged Do not run engine until problem is corrected If a steady stream of water is present from pump indicator hole but horn continues to sound there may be insufficient cooling water and or an engine problem Notify the Mate Coxswain VV VV VV Frm Preventative Maintenance for Rigid Hull Inflatables In an emergency you can stop the engine after allowing it to cool down Once the alarm stops shut off the ignition switch and re start the engine This re set SLOW function will give some addition
55. vertically and draw in just enough liquid from the battery cell so that the float is vertical and free of the outer tube Take a reading at surface of liquid Disregard curvature where liquid rises against float stem due to capillary The specific gravity of electrolyte varies not only with percentage of acid in liquid but also with temperature A fully charged battery will read 1 270 at 27 C VV V Battery roll over cap Preventative Maintenance for Rigid Hull Inflatables 8 Test the batteries as follows gt gt Vv Vv V WV Shut down the engines and WARNING isolate the batteries Remove vent caps and Do not isolate check fluid level Add water batteries or change as needed and charge battery positions Test each cell of the battery z while the engines are using the hydrometer Squeeze the hydrometer running This will bulb and release it to suck cause various enough battery fluid up into onboard electronic the hydrometer to float the fail indicator inside the tube and Componenta te Ta take the reading On a bulb float type tester you will get a false reading if the indicator touches the sides or top of the instrument A reading from 1 260 to 1 300 in each cell means that the battery is healthy A consistent reading of approximately 1 225 probably means the battery is satisfactory but low on charge Any cell that varies more than 50 points from the others indicates a defective ce
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