LifeBoats Phaethon Operation Manual HHI 1958

OPERATION / MAINTENANCE MANUAL JYN65 TOTALLY ENCLOSED LIFEBOAT TANKER AND DRY CARGO VERSION
Jiangyin Norsafe F.R.P. Co., Ltd.

Yuecheng Town, Jiangyin City, Jiangsu, China
Telephone: Telefax: E-mail address:
+ 86 510 8698 7718 + 86 510 8698 7371

jynorsafe@cnorsafe.com
Jiangyin Norsafe
IMPORTANT NOTICE: During the warranty period, all necessary spare parts must be supplied by Jiangyin Norsafe. The use of spare parts supplied by other suppliers violates and forfeits the warranty.
Rev. 0 1 2 Issued for construction Updated manual as per latest solas version Revised according to MSC 1205 Reason for issue Date 05.03.99 22.06.07 22.09.08 By ZH HL HL Chk JW JG TT
JYN65 TELB_Manual_Tor 3.36_rev02
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IMPORTANT: In this manual:
A WARNING!
Is an operation procedure, statement or practice which, if not strictly followed, could result in serious injuries or even death, not only to the operator, but also to all onboard.
A CAUTION!
Is an operation procedure, statement or practice which, if not strictly followed, could result in death or serous injury.
A NOTE!
Is an important note must be emphasized.
A NEVER!
Is a prohibited action which used could result in the death of occupants.
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Direct all inquiries regarding spare parts and service to:
Jiangyin Norsafe F.R.P. Co., Ltd.

Yuecheng Town, Jiangyin City, Jiangsu, China
Telephone: Telefax: E-mail address:
+ 86 510 8698 7718 + 86 510 8698 7371 jynorsafe@cnorsafe.com
Please quote the Jiangyin Norsafe boat build number when contacting Jiangyin Norsafe. Has been given on enclosed certificates, and is also shown on the nameplate on the lifeboat. During the warranty period, all necessary spare parts must be supplied by Jiangyin Norsafe. The use of spare parts supplied by other suppliers violates and forfeits the warranty.
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CALL FOR SERVICE FORM

Please use a copy of this form, and fill in as much as possible of the following information. Please fax this form to Int. + 86 510 86987371. All sales and service are acc. to Orgalime S92. All warranty claims must be accepted in writing by Jiangyin Norsafe prior to dispatch of parts or service personnel. Boat build no.: Boat type: Voltage / frequency onboard: Ship is build at (Yard): Date of receipt of equipment: Date of delivery of ship to owner: Name of vessel: Ship owner: Contact person: Shipping address for parts: Telephone number: Telefax number: Signature: Type of service (please tick): Spare parts only Quote price first Warranty claim Service only Spare parts and service
Send parts immediately without quoting Ordinary service call
Description of problem (please add more sheets if necessary):
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LIST OF CONTENTS
1. INTRODUCTION 7 1.1 General specification ........................................................................................................ 7 1.2 General description........................................................................................................... 7 2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 OPERATION PROCEDURES 10 Emergency abandonment of ship procedure ............................................................... 10 Hook release procedure............................................................................................... 15 Operation of emergency air system (tanker version only)............................................ 16 Operation of sprinkler system (tanker version only)..................................................... 17 Check before starting engine (Only if time allows during emergency) ......................... 17 To start engine - normal start....................................................................................... 18 To start engine - emergency start ................................................................................ 18 To stop engine ............................................................................................................. 18 Recovery after boat drill ............................................................................................... 18
3. SYSTEM DESCRIPTIONS 21 3.1 Steering console .......................................................................................................... 21 3.2 Electrical system.......................................................................................................... 21 3.3 Fuel tank ...................................................................................................................... 22 3.4 Water and provision tanks ........................................................................................... 22 3.5 Equipment tank............................................................................................................ 22 3.6 Emergency air supply system (tanker version only)..................................................... 22 3.7 Sprinkler system (tanker version only) ......................................................................... 23 3.8 Sea anchor .................................................................................................................. 23 3.9 Rain water collector ..................................................................................................... 23 3.10 Painter release operation............................................................................................. 23 3.11 Drain plug operation .................................................................................................... 25 3.12 Bilge pump operation .................................................................................................. 25 3.13 Normal steering .......................................................................................................... 25 3.14 Emergency steering operation .................................................................................... 25 3.15 Rowing the boat.......................................................................................................... 26 4. MAINTENANCE PROCEDURES 27 4.1 Steering system ........................................................................................................... 27 4.2 Bilge system ................................................................................................................ 29 4.3 Hatches........................................................................................................................ 29 4.4 Fuel system ................................................................................................................. 29 4.5 Electrical system.......................................................................................................... 29 4.6 Emergency air supply system (tanker version only)..................................................... 29 5. 6. 7. MAINTENANCE SCHEDULES APPENDIX A APPENDIX B 32 34 36
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1.
1.1 General specification JYN65 TOTALLY ENCLOSED LIFEBOAT
INTRODUCTION
Dimensions (LxBxD) Capacity Weight of boat with all equipment Total boat load Hook distance Speed Colour
6.50 X 2.30 X 1.20 m 36 persons (Maximum) 2923kg (Tanker Version) 5623kg (Tanker Version) 6.10 m 6 knots Safety Orange
Fig 1 Equipment arrangement 1.2 General description The lifeboat is laminated from fire-retardant polyester resin. The space between the seat and the hull, and the canopy liner and canopy is filled with polyurethane buoyancy foam, which provides the craft with enough buoyancy to remain afloat and upright even if holed below the waterline. The lifeboat is totally self-righting even fully loaded with persons and flooded. Therefore it is important that all passengers fasten their seat belt and remain in their seats at all times. The lifeboat is fitted with two lifting hooks, one forward, the other one aft. These lifting hooks are designed to be released simultaneously from inside the craft when it is fully waterborne. It is possible to release the lifting hooks when the boat is out of the water but this procedure is EXTREMELY DANGEROUS and must only be considered under very special circumstances. Therefore the crew of the craft should familiarise themselves with all the operations of the lifting hooks and the other functions of the boat before attempting to operate it.
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The boats main entrance door is situated aft . Additional hatches are provided at the helmsmans position, at the forward end and on both side of the canopy. The steering position has a steering console containing the normal steering, engine instrument panel, and engine control lever, sprinkler control lever (tank version and for USCG boat only) and emergency air supply controls(tank version only). An external water spray system is installed on the canopy of the boat which will provide the outside of the boat with a protective layer of water should the lifeboat encounter a fire on the water surface (tanker version only). Internal air cylinders will, when operated, provide the passengers and engine at full speed with air at a controlled rate for at least 10 minutes (tanker version only). Emergency steering tiller can be operated from within the lifeboat. The centre tank section contains water & provisions tanks, fuel tank and equipment tanks. There is also an access to the air cylinders (tanker version only) and drain plug. A fuel shut-off valve is located on the top of fuel tank. The engine compartment has a removable top cover for access to engine, shaft and sprinkler pump for tank version if thats not remotely controlled from the helmsman position. The main engine starting battery and emergency starting battery are contained in the watertight box in the inner liner at the aft of the engine compartment. A manual bilge pump is mounted on the right side of the pillar. Natural ventilation is achieved via one automatic valve located on the aft of the boat. This valve also prevents the cabin from becoming dangerously under pressure while the engine is running. An over pressure relief valve is mounted on the aft of the boat. This valve prevents the cabin from becoming dangerously over pressure when the emergency air system is in operation (tanker version only). The lifeboat may be rowed using provided oars through the side hatches. The lifeboat is fitted with shock absorbing skates/fenders to provide protection to the inboard side of the lifeboat during launching. The diesel engine is approved type, with water-cooling system. Full detailed specifications of the engine are contained in the engine manufacturers manual. Main engine starting is by 12 V battery with electric starter. Emergency engine starting is by a totally independent 12 V battery system. Battery switches are mounted on aft side of the pillar. A battery charger is installed inside the canopy on the pillar (42 V AC / 12 V DC). The charger is totally enclosed in a cabinet, with two channels capable of operating two
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circuits simultaneously and separately. The charger is connected to the ships power supply 42V AC via a plug on the side of the lifeboat near the hatches A fuel tank with a capacity sufficient for 24 hours running for the fully loaded lifeboat at 6 knots is mounted in the centre tank section.
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2. OPERATION PROCEDURES
All crew and personnel using this lifeboat should learn all operating procedures contained in this and reference manuals. Failure to follow any of these procedures correctly or in their intended mode can result in serious injuries or even death, not only to the operator, but also to all onboard.
The following procedures are to be rigidly adhered to for * Emergency embarkation, * Lowering, * Operation through fire and toxic gases (tanker version only). * Release of Hooks * Recovery of the lifeboat. These procedures should be adopted as part of the normal lifeboat drill. It can not be emphasised too strongly that frequent and conscientious practice for lifeboat drills should be maintained. 2.1 Emergency abandonment of ship procedure This applies to boat only, see davit manufacturers instruction manual for details about davit. 2.1.1 After being assigned a lifeboat, passengers await instructions from the lifeboat crew. 2.1.2 Prepare boat for launching by releasing the lashing arrangement and bringing the boat into boarding position. See davit manufacturer instruction manual. 2.1.3 Helmsman and crew enter lifeboat and check. No. Operation Guide
Schematic Diagram
Crew check the hooks to ensure they are in locked position.( The indicator on each hook is horizontal )
Open the boarding door and secure the door in open position
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No.
Operation Guide
Schematic Diagram
Helmsman disconnects external power plug enters and check release handle to ensure it is in locked position and safety pin is installed.
Helmsman ensure the bottom plug is fitted and tight.
Turn on the main battery switch.
Open the fuel oil valve. Crew board the boat and remove the painter from the equipment tank and secure to painter release hook on lifeboat and the other end to ship if a painter is to be used during launching and is not already connected,
Never enter lifeboat without ensuring complete closure of release hooks. Incomplete resetting of the release hooks can cause the lifeboat to drop and may result in death or serious injury.
2.1.4 When told to board, passengers should enter the lifeboat quickly and orderly wearing their life jackets. All passengers board lifeboat occupying the seats furthermost from the entrance first.
Seating positions of persons should be carefully selected to maintain a good trim of the lifeboat.
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If the seat belt is not fastened, serious injury or death may occur.
No.
Operation Guide
Schematic Diagram
Confirm that all passengers in the lifeboat are seated and their seat belts are fastened.
Close the door
Helmsman start the engine. Please see section 2.6 for additional detail.
OFF STOP
ON START
[Tanker version only] In case of burning liquid on sea surface, it is now the time to activate the emergency air system. Please see section 2.3 for additional detail.
OPEN
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[Tanker version only] In case of burning liquid on sea surface also need activate the sprinkler system. Please see section 2.4 for additional detail.
Helmsman pulls and maintains steady pull on the winch brake release wire until the boat is completely waterborne and no tension exists in the fall wires
When using remote control gear from within the boat never wind the cord or wire around fingers, hand or wrist as this may result in the cutting off of fingers / hand.
2.1.5
Helmsman operates the hook release handle Confirm the following before the operation: The lifeboat is fully waterborne; The engine is started; All crew are in their seats with seatbelts fastened.
No.
Operation Guide
Schematic Diagram
Confirm the lifeboat is waterborne
Remove the safety pin
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UP
(3)
Hydrostatic pressure will automatically push the safety pawl (2) up into the red area after the boat has been waterborne for about 20 seconds.
R el ea se
(2)
(1)
Lift the release lever up and pull in the arrow release direction. Lifting hooks now released. (Emergency release, please see section 2.2.2 for additional detail).
The safety pin should never be removed until the boat is completely waterborne. Failure to comply with any of the hook procedures may result in death or serious injury.
The release lever has an automatic safety pawl which is moved to red position when boat is waterborne.
2.1.6 No. 1 Operation Guide Helmsman now engages engine gear and instructs forward crewmember to pull the painter release handle (if painter has been used) Schematic Diagram
Helmsman push throttle control lever and steer away from danger on designated compass course.
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[Tanker version only]. After moving away the dangerous area, turning off the sprinkler/air system if used and the fresh air will be automatically supplied.
2.1.7
Crew member removes radar reflector from storage compartment and installs on top of the steering tower and at the same time fixes mast in the upright position. For information how occupants in the lifeboat should organise themselves see Survival Manual. (refer loose equipment)
2.1.8
2.2 Hook release procedure The boat is equipped with an ON/OFF load release hook forward and aft. These hooks are controlled from a release handle mounted on the starboard of the pillar. Please see hook manufacturers manual and instruction labels inside of lifeboat for details about release system. 2.2.1 Normal operation ( off-load procedure ) This operation is the normal method of launch and release and is conducted when the lifeboat is fully waterborne. ( Please refer to section 2.1.5 for detail) In case where the hook is not released by above operations, confirm condition of each hook and weather the boat is waterborne or not . Even though the hooks cannot be released by the off-load release operation described above, on-load release procedure, described in the below section is possible. 2.2.2 Emergency operation (on-load procedure ) This operation is conducted when the lifeboat is not fully waterborne or the hydrostatic interlock fails to work, the following procedure should be followed exactly:
Pay due precautions and conduct the on-load release in accordance with orders of the officer in charge. Operation of the release handle upon insufficient confirmation of safety may result in death or serious injury due to dropping the lifeboat in water form a height.
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Confirm the following before the operation: The lifeboat is as close as possible to the water surface; The engine is started; All crew are in their seats with seatbelts fastened.
No.
Operation Guide Confirm the lifeboat is as close as possible to the water surface, but the hydrostatic interlock is not triggered. Operation Guide Remove the safety pin
Schematic Diagram
No. 2
Schematic Diagram
UP ( 5)
el ea se
Break the plexiglass cover

R
( 3)
Manually lift the hydrostatic safety pawl to the red area and hold.
( 2)
( 4)
Lift the release lever up and pull in the arrow release direction. Lifting hooks will now be released.
2.3 Operation of emergency air system (tanker version only) The lifeboat is equipped with an emergency air supply system, which should be operated if fire or toxic gas conditions exist outside the boat. If the air system is to be used, carry out step 2.3.1 and 2.3.2 before passengers enter the boat and step 2.3.3 during launching.
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VALVE(A) LOW PRESSURE SUPPLY TO CABIN REGULATOR LOW PRESSURE ADJUSTMENT
CABIN SUPPLY GAUGE CYLINDER PRESSURE GAUGE TO AIR BOTTLES
CHARGING POINT (ONE INCH 14 THREAD) TURN VALVES COUNTER-CLOCKWISE TO OPEN CHARGINE VALVE
3 X 45 LTRS (20 MPa)

HIGH PRESSURE AIR HOSE
Fig 1
Emergency Air System
2.3.1 Helmsman is to inform crewmember to open valve on each air cylinder, fig.1 2.3.2 Ensure that all hatches are closed. 2.3.3 Open valve(A) on low-pressure side of regulator. Air is sufficient for 10 minutes operation, drive boat out of danger area at full speed.
Regulator was pre-set at factory. It should not be re-adjusted.
2.4 Operation of sprinkler system (tanker version only) The lifeboat is equipped with a sprinkler system to protect it from fire in case of burning liquid on the sea surface. Note that the visibility through windows is very poor when the sprinkler is operated. 2.4.1 Ensure that all hatches and openings are closed. 2.4.2 Once the boat is waterborne, turn the sprinkler valve to open position by remote handle which is located on the right side of the pillar (for USCG). Normally the sprinkler valve is located in the forward end of the engine compartment. 2.4.3 Increase engine R.P.M. to full speed and leave danger area. 2.5 Check before starting engine (Only if time allows during emergency)
Starting any engine can be dangerous in the hands of inexperienced people. Before attempting to start any engine, the operator should be familiar with the engine instructions mounted in the boat and the engine manufacturers instruction manual.
- Ensure that the batteries are in serviceable condition and correctly connected. - Check that the oil levels in the engine and the gearbox are correct. - Check that the fuel tank is full and that the system is primed. - Check that fuel valve on the top of the tank is open.
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- Check that the water level in the header tank is filled up with mixture of water/antifreeze. Under no circumstances must the engine be started without liquid in the cooling system. - Ensure that the gearbox is in neutral. 2.6 To start engine - normal start 2.6.1 Disconnect ships external power supply by pulling the plug near the embarkation access. (If fitted) 2.6.2 Turn main battery switch to "ON" position. The charging light and oil pressure lights will now be on and the buzzer will sound. 2.6.3 Please refer to the starting instruction posted close to the helmsmans position or to the engine instruction manual. 2.6.4 If the engine should fail to start due to poor battery condition, continue with the emergency starting procedure. If the engine fails to start within 15 seconds, despite good battery condition, release the switch and investigate the cause. The starter motor should be allowed to cool for at least 15 seconds before attempting to restart.
This engine can be run with the boat out of the water for a maximum of 5 minutes, but the propeller shaft should only be engaged for a few seconds at a time to check its operation.
While the lifeboat engine is running the alternator will charge all batteries. The battery charger mounted on the pillar only operates when the boat is stowed in the Davit and the ships power supply is connected. 2.7 To start engine - emergency start The procedure is same as the normal start, please refer to section 2.6, except need turn the emergency start switch clockwise to the ON position by using the same key as for main battery. 2.8 To stop engine Please refer to the stopping instruction posted close to the helmsmans position or to the engine instruction manual. Emergency stopping of the engine can be achieved by closing the fuel shut-off valve located on the injector pump on the engine. This valve is normally closed by a solenoid operated by the stop button, but it may be closed manually if the solenoid is defective. 2.9 Recovery after boat drill After disengaging and before bringing the boat back alongside for recovery, the lifeboat crew must ensure that the hooks are closed and the release lever is in the locked position with the safety pin inserted. Follow this procedure:
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No. Operation Guide Schematic Diagram
The Helmsman must ensure that the release handle is in the fully released position
The forward and aft hook men ensure that the hooks are manually held down in position for locking.
Helmsman lock the hooks moving release handle forward in track .The release handle can only be moved to locked position when hooks are in correct position for hoisting.
The forward and aft hook men should carefully pay attention to that the cam bolt mechanism is in locked position. Both hooks should now be pulled firmly upwards to ensure both hooks are firmly locked in the closed position Operation Guide The helmsman must now insert safety pin. When release handle is in locked position it indicates that release mechanism is properly and completely reset and ready for hoisting. But always check at the hooks. The forward and aft hook men place the end link of the fall wires into the hooks ensuring the safety guard drops down into the closed position. The boat should now be lifted until just clear of the water surface and stopped. Schematic Diagram
No.
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The Helmsman should check that the hydrostatic safety pawl has moved to the green area. The boat can now be safety hoisted to its stowed position.
Lash boat to davit and ensure boat is left ready for emergency use.
Both forward and aft hooks should be connected simultaneously to prevent damage due excessive load on one hook. If only one hook is connected, the lifeboat may be suspended by only that hook and may result in death or injury.
Do not connect the suspension link of the davit to the hooks until reset of the hooks has been fully completed. It is dangerous to connect the suspension link during the resetting operation of the hooks and result an incomplete reset. In case of using recovery strops, it is required to connect the bottom link of the strops instead of suspension link to hooks.
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3.
3.1 Steering console
SYSTEM DESCRIPTIONS
The helmsman position is equipped with a steering console which contains the engine instrument panel, engine throttle/gear control lever, steering, searchlight with plug, compass and switches for cabin lights and position light. The helmsman also operates hook release and lowering control, see davit manufacturers manual for details about the latter. 3.2 Electrical system The lifeboat electrical system is powered by 12 V DC maintenance free batteries. To activate the system, the main or emergency battery switches must be turned on. When the boat is stowed in the davit, power is supplied via the plug near the embarkation access at 42 V AC. (The incoming power supply is fed directly to a 42 V/300 W engine heater , (if fitted) . Additional power is supplied to the battery charger 42 V AC/12 V DC that charges the main and emergency starting batteries. These should not be applicable if solar power panel is installed. Battery switches Main engine starting is by 12 V battery with electric starter. Emergency engine starting is by totally independent 12 V battery system. Battery switches are mounted on the aft side of the pillar with a battery box in the aft engine compartment. The external power supply (if fitted) must be disconnected before engine is started. Before the engine can be started the main switch must be turned clockwise to the ON position. The engine starting procedures may now begin. Should the main starting battery fail to start the engine, use the emergency battery to start the engine. The emergency start switch should be turned clockwise to the ON position by using the same key as for main battery.
Radio battery if fitted, the radio battery switch must be turned clockwise to the ON position to supply power to the radio.
Battery charger A battery charger (42 V AC/12 V DC) is installed inside the canopy on the aft side of the pillar. The charger is a totally enclosed cabinet with two channels capable of operating two circuits simultaneously and separately. The battery charger has indicator lights for both batteries. The indicator lights signal the charging process and battery condition.
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Red: Charger is not connected, faulty battery or battery is not correctly connected. Yellow: Charging by 14.4 volt in progress Green: Fully charged batteries, voltage drops to 13.3 volt for maintenance charging. 3.3 Fuel tank A diesel fuel tank is located in the middle of the centre section. The tank capacity is sufficient for 24 hours operation at full speed. The tank is filled by removing the filler plug located on top of the tank. 3.4 Water and provision tanks Water and provision tanks are located in the centre section of the lifeboat. It is recommended to store water in sealed containers in the tank. Details of quantities can be found on loose equipment list. 3.5 Equipment tank A tank is provided to the front of the boat for the storage of loose equipment and provisions. Details of provisions and equipment can be found on the loose equipment list. 3.6 Emergency air supply system (tanker version only) The emergency air supply system is designed to supply the interior of the lifeboat with air for the passengers and engine. (fig. 1), The system consists of the following components: a) b) c) d) e) Air cylinders pressurised to 20MPa. High pressure air hoses Charging point with valve Air pressure-regulating valve Low pressure valve and air hose
This air system contains high-pressure air and it is dangerous if not properly maintained. Only qualified personnel or representatives of Jiangyin Norsafe should maintain this system.
The emergency air system should be kept fully charged at all times i.e. if the pressure drops below 18MPa the system should be recharged to 20MPa.
C H A R G IN G P O IN T (5/8" x 14 TPI)
C H A R G IN E V ALV E
Fig. 2 Detail of charging point
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3.7 Sprinkler system (tanker version only) The sprinkler system is designed to cover the entire surface of the lifeboat with a film of seawater when the boat is waterborne. This will protect the lifeboat and occupants should they have to encounter a fire on the sea. When the boat is waterborne, open the water inlet valve. This allows a self priming pump to pump seawater through the boat internal piping to the sprinkler heads mounted on the canopy, which are fitted with spray nozzles that disperse the water into a thin film, which covers the boat. 3.8 Sea anchor After removing sea anchor from the storage tank, deploy as follows: 1. Secure the end of hawser and tripping line to the painter release hook. 2. Throw sea anchor into the sea. For proper operation, ensure that tripping line is slack when hawser line is taut. 3. Recover sea anchor by pulling tripping line.
Fig. 3 Sea Anchor 3.9 Rain water collector The rain water collector consists of a rectangle section on top of the canopy with drain hole in the centre. Collect the water in the supplied 2 x 5 L plastic containers.
Drain hole Water pipe 5L plastic container
Fig. 4 Rain water collector system 3.10 Painter release operation At the forward end of the boat there is quick release hook to releasing the painter line. To disengage the painter under tension, pull sharply on the painter release handle in the front of the boat (fig. 5). To reset the hook, pull releases handle, return the hook to its
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original position and let go release handle. Make sure that the end of the hook is under the release lever (fig.5a, 5b).
Fig. 5
Painter release handle
Fig. 5a
Painter release hook (closed)
Fig. 5b Painter release hook (open)
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3.11 Drain plug operation The lifeboat is fitted with an automatic drain valve, which will close automatically when the boat is waterborne. However, it is recommended that the drain plug be closed when the boat is waterborne to prevent any leakage. The drain plug is fitted on the lower area of the boat. After recovery of the boat is completed always ensure that the drain plug is open.
The brass cover on the drain plug must not be removed when the drain plug is opened. If the cover is removed, the plastic ball will be lost and the plug will not close automatically when the boat is waterborne.
3.12 Bilge pump operation Operate the bilge pump handle to remove water from bilge.
Fig. 6 Bilge Pump 3.13 Normal steering The normal steering of the lifeboat is by mechanical arrangement as detailed in the maintenance section of the manual. 3.14 Emergency steering operation If main steering system fails to operate the rudder, use emergency steering as follows:
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PORT
CONNECTING PIN STARBOARD FORWARD
Fig. 7 Emergency steering system 3.14.1 Remove emergency steering tiller from it's stowed position and place the end of tiller over rudder stock. 3.14.2 It is now possible to steer the boat with this emergency tiller, but helmsman must give instructions on direction.
Before operating emergency steering, the connecting pin may need to be removed.
3.15 Rowing the boat Should it be necessary to row the lifeboat, proceed as follows: 3.15.1 Open side doors and secure in open position. 3.15.2 Fit rowlocks in holders below side door on both sides. 3.15.3 Remove oars from stowed position under the canopy and fit into the rowlocks, rowing the boat.
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4. MAINTENANCE PROCEDURES
4.1 Steering system Check the steering system every three (3) months.
1 2 3 4
Steering wheel Cable steering Emergency tiller Rudder stock
1. Steering wheel 2. No.1 (Main switch) located below control console 3. Start / Stop switch (Engine) 4. Fuel tank level meter 5. Oil lamp 6. Temp. lamp 7. Charge lamp 8. Battery lamp 9. Engine throttle/gear control lever 10. Light switches for searchlight, cabin light, flash light & compass. 11. No.2 (Emergency switch)-located below control console 12. Tachometer 13. Compass 14. Oil pressure gauge 15. Volt gauge 16. Water temperature gauge
Fig. 8 Control console (Different customer specifications results in various instrumentation)

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4.2 Bilge system If the pump fails to prime or chokes, check for: Air leaks or blockages in the inlet hose and it's connection to the pump. A torn diaphragm. Dirt under valves or distorted valves. Collapse of the inlet hose during suction stroke.
To change the rubber parts If the rubber parts are broken (Order spare part, See page 5), they can be replaced. 4.3 Hatches Rubber gaskets around hatches should be checked for deterioration. If any signs of cracking or brittleness exist, gasket should be replaced immediately. 4.4 Fuel system Only clean diesel fuel should be used. The fuel tank should be refilled after engine has been used. Before removing the filler cap, always clean around it to prevent dirt etc. from entering the system. Check all fuel lines for leaks and deterioration. Leaking couplings may be tightened; otherwise lines need to be replaced. 4.5 Electrical system The main engine start battery, emergency start battery and the lifeboat radio battery (if fitted) should be checked to ensure the terminals are tight and clean. Should the terminals show any signs of corrosion, disconnect and clean thoroughly and grease with a light silicone grease. No other maintenance is required to the batteries. If the batteries need to be replaced, use sealed batteries only. Other types may cause explosion due to hydrogen release.
The wiring diagram and the components are described in the manufacturers instructions and operation manual delivered with the lifeboat.
4.6 Emergency air supply system (tanker version only) be Should the air pressure in any of the air cylinder drop below 18MPa the system should recharged to 20MPa. To recharge the system proceed as follows: 4.6.1 Make sure charging valve is closed. 4.6.2 Open low-pressure valve to purge air from system. 4.6.3 Close low-pressure valve. 4.6.4 Connect charging line to charging point (fig. 2).
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4.6.5 Open charging valve. 4.6.6 Open valves on air cylinders. 4.6.7 Start compressor and charge to 20MPa. 4.6.8 Stop compressor when pressure is 20Mpa. 4.6.9 Close valves on air cylinders 4.6.10 Open low-pressure valve to check and relieve pressure at regulator.. 4.6.11 Close charging valve. 4.6.12 Close low-pressure valve. 4.6.13 Disconnect charging line. System is now ready for emergency use. Recharging air must be of breathable quality, dry, oil free, clean and with a water content of no more than 3-4PPM. Excessive moisture will cause misting, internal freezing of the regulator and jam in either open or closed position. This will temporarily (until ice melts) disables the system. Before leak testing the system, open the valves on all air cylinders. Mix up a strong soapy water solution and with a small brush liberally cover all joints and connections. Leakage can be detected by spotting air bubbles. 4.7 Sprinkler system (tanker version only) It is important that after using the sprinkler system, it is flushed with fresh water to remove salt deposits. To flush the system proceed as follows: 4.7.1 Close the intake valve. 4.7.2 Fit brass hose nipple connector to nozzle holder and tighten by hand only. Hose connector is stored in the equipment tank (fig. 9). 4.7.3 Install " hose on connector and flush for 10 minutes with fresh water at maximum 7 bar pressure. If any nozzles become blocked during flushing, they must be removed, cleaned and installed back in original position. It is very important that the nozzle face in the original direction. 4.7.4 If some parts of the spray system has not been flushed (very little or no water coming out of the nozzles) this part must be flushed by repeating step 2-4 using a nozzle in this area. 4.7.5 Removes hose connector and close the valve on the manifold on the canopy of the lifeboat.
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4.7.6 Open the intake valve to drain the water inside the pipes. 4.7.7 Open the drain valve on the bottom of the pump to drain the pump. 4.7.8 Close the drain valve and intake valve.(for no-controller type only) "Dead ends" in sprinkler system will automatically drain through drain holes.
Fig. 9 Hose connector 4.8 Lubrication and greasing points. Anticorrosion maintenance Following mechanisms must be maintained according to the maintenance list with waterresistant grease: Under pressure valve and Over pressure valve. Handles of hatches / door inside and outside.
NOTE! For maintenance of following items please refer to the manufacturers instruction manuals: Hooks Engine Gearbox
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5. MAINTENANCE SCHEDULES
This lifeboat should always be maintained to ensure that it is ready for immediate use. Therefore the following checks should be made: RECOMMENDED MAINTENANCE 1.ENGINE See separate instructions mounted in the boat and in the engine manual -Start engine using main start battery. -Start engine using emergency start battery. -Engage forward and aft gear for a few seconds each to check its operation. Also check that propeller and shaft can turn freely by hand with engine stopped and gear in neutral. -Inspect for leaks in fuel and cooling water systems. -Check stuffing box on propeller shaft for lubrication. -Grease stern tube gland. 2.ELECTRICAL INSTALLATION -Check battery leads - see lamp on battery charger. -Check that batteries are tight, clean and fully greased. -Check that dynamo charges (when charging while the engine is running the light is out) -Check that electrical plug is connected to boat and supply is turned "ON". -Check main battery switches are turned "OFF". -Check that engine heater, if fitted, and battery charger are turned "ON". -Check instrumentation and engine controls. Replace defective lamps and fuses if necessary. - Check all connections and the fuse to verify soundness with clean the Solar panel surface, if fitted. -Check lifeboat radio equipment, if fitted. 3.HATCHES -Check door and hatches for tightness and gasket condition. -Check that hatches/hatch dogs move and hatches operate freely. 4. BILGE -Drain the boat. -Take off pump covers and remove any foreign bodies. *
For boat drill Weekly Monthly When required
* *
* * *
* * *
* * * * * * *
* * * * * * * * * *
* * *
* * *
* *
* *
* *
* * *
* * *
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* * *
5.EMERGENCY AIR SUPPLY SYSTEM (tanker version only) Check air bottle pressure. Pressure within 18-20MPa. Refill if necessary. -Check low-pressure outlet side. Pre adjusted/sealed 5-7MPa. 6.SPRINKLER SYSTEM (tanker version only) -Move sea inlets valve and lubricate. Must be kept shut when sprinkler system is not in use. (no-controller type only) -Check V-belts -Flushing through of sprinkler system -Check nozzles for possible defects -Check hose connection for possible defects 7.MISCELLANEOUS -Check that gaskets and tank lids are intact. -Check and lubricate operating cables. -Grease rudder shaft. -Ensure steering system operates freely. -Check that equipment and provision is in order. -Carry out replacement in accordance with current regulations. -Check inside of boat to ensure free access throughout and all loose equipment stored in its correct location. -Visual inspection of the davit/boat to ensure that the system is ready to be used should an emergency arise. -Visual inspection of fibreglass. -Ensure embarkation area is free of obstructions. -Grease threads of slip hooks and turnbuckles of lashing. -Combat any signs of corrosion by scrubbing off with a wire brush and wiping with a non-fluffy oily rag. Alternatively a good quality aerosol spray inhibitor can be used. * * * * *
* *
* *
* * * * * * * * * * * * * * * * *
* *
* * *
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6. APPENDIX A
(NOTE: sign after completing all the items in the maintenance schedule)
INSPECTION LOG FOR LIFEBOAT INSPECTIONS.

Check. no: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Date: Sign. Condition: Actions taken:
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INSPECTION LOG FOR LIFEBOAT INSPECTIONS.

Check. no: 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 Date: Sign. Condition: Actions taken:
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7. APPENDIX B
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NORSAFE NLDE-3 Marine Diesel Engine Set
OPERATION MANUAL
NLDE-3 (380J-3)
BETTER
BY
DESIGN
NORSAFE AS
Rev. 1 2 Reason for issue ISSUED FOR INFORMATION PREHEATER STARTER INCLUDED Date 01.06.06 22.04.08 By Chk HENRY TT JOH TT
CONTENTS
1. General precautions 1 2. Introduction 2 2.1 Description of the engine set 6 3. General engine data 7 4. Engine sort 8 4.1 Sort based on lifeboat release method 8 4.2 Sort based on cold starting assistance method 8 5. Main structure of engine 9 5.1 Fuel system 9 5.2 Lubrication system 9 5.3 Cooling system 10 5.4 Electric system 11 5.5 Gearbox 12 5.6 Wiring diagram 13 5.6.1.1 General wiring diagram 13 5.6.1.2 Electrical system parts description 15 5.6.1.3 Instruments panel 15 5.6.2.1 Special wiring diagram 16 5.6.2.2 Electrical system parts description 18 5.6.2.3 Instruments panel 18 5.7 Starting precautions 19 6. Operation of engine 19 6.1 Starting 19 6.1.1 Starting by spring starter (if installed) 21 6.1.2 Hand starting (if installed) 22 6.2 Operation 23 6.3 Stopping 23 7. Routine maintenance 24 7.1 Initial attention 24 7.2 Routine maintenance periods 24 7.3 Lubrication oil specification 24
1
7.4 Gearbox oil specification 25 7.5 Main spanner torque setting 26 7.6 Tighten sequence for cylinder heads bolts 26 7.7 Check of lubrication oil level 26 7.8 Lubrication oil change 26 7.9 Alternator belt tension 26 7.10 Gearbox oil checks and change 27 7.11 Priming the fuel system 27 7.12 Drain the coolant 27 7.13 Changing fuel filter element 27 7.14 Valve clearance adjustment 27 7.15 Starting and running the engine while the lifeboat Is hooked in davits or free fall rig 27 7.16 General precaution about electrical system 28 7.17 Storage 28 8. Trouble shooting 30 8.1 Difficult in starting the engine 30 8.2 Insufficient output 30 8.3 Black smoking from exhaust 31 8.4 Low lube oil pressure 31 8.5 Engine knocking 31 8.6 Engine overheating 32 8.7 Engine over speed or override 32 Appendix 1NLDE-3 diesel engine set delivery list 33 Appendix 2Tools supplied with NLDE-3 marine diesel Engine set 33
1. GENERAL PRECAUTIONS
. Ensure that the engine is securely mounted. .Ensure that the ventilation and combustion air dusts are not obstructed. . Keep the engine and surrounding areas clean. . Never allow any part of the body to come into contact with high pressure fuel oil when testing injection equipment. . Avoid contact with exhaust pipe when the engine is, or has recently been running .These parts can be very hot and can cause severe burns. . Rectify all fuel water and oil leaks as soon as possible. . Isolate the battery when working on the engine. . All drive belts must receive regular attention. . Keep electrical contacts free from corrosion etc by smearing them with petroleum jelly. . Some batteries under charge release explosive gases, therefore these battery compartments must be well ventilated at all times. Never allow any smoking, sparks or flames near these batteries. . Wear protective goggles when handing liquids which is harmful to eyes, for example, battery acid. If any of these substances are splashed in the eyes, wash out thoroughly with clean water. .Many liquids used in engines are harmful if taken internally. In the event of accidentally swallowing oil, fuel, antifreeze or battery acid obtain medical assistance immediately.
2. INTRODUCTION
The NORSAFE marine diesel engine set, type NLDE-3 is based on 380J-3/380C diesel engine and adapted for lifeboat propulsion conforming to the latest requirements include SOLAS 1974, 1996 Amendments. It is essential that the operators read carefully the main points in this manual before the engine is put into service. Reference is made to: CHECKS BEFORE STARTING STARTING OPERATION and STOP . The engine must be able to start and operate under the most severe conditions. Therefore the engine set must be carefully maintained in accordance with this manual. The information, specification, illustrations, instructions and statements contained within this publication are given with our best intentions and are believed to be correct at the time going to press. As our continued technical development, we reserve the right to amend any technical information with or without prior notice. While every effort is made to ensure the accuracy of the particulars contained within this publication neither the manufacturer nor dealer shall in any circumstances be held liable for any inaccuracy or the consequences thereof. User of this manual are advised that the specification details apply to NLDE-3 engine set and not to any one particular engine. In case of difficulty, consult NORSAFE AS, NORWAY/CHINA or a local distributor for further advice and technical assistance. The information given is subject to the companys current condition and is for the assistance of users and is based upon results obtained from tests carried out at the place of manufacture. Our company doesnt guarantee that the same results will be obtained elsewhere under different conditions.
When purchasing parts, or giving instruction for the clients repairs, please refer to engine part catalogue and specify NORSAFE AS. Our company can not be responsible for any damage arising from the parts that have not been supplied by our company.
Note: The dimension in bracket is only for matching ZF12M gearbox.
Fig.1 NLDE-3 marine diesel engine set overall dimensions

4
Note: The dimension in bracket is only for matching ZF12M gearbox.
Fig.2 NLDE-3 marine diesel engine set starting manually overall dimensions
5
2.1 DESCRIPTION OF THE ENGINE SET

1. Fuel filter 2. Breather 3. Fuel injector 4. Injection pump 5. Inlet manifold 6. Outlet cock 7. Lube oil dipstick 8. Tachometer sensor 9. Gearbox dipstick 10. Expansion tanker cap 11. Fresh water pump 12. Lube oil filter 13. Gearbox 14. Gearbox oil screw 15. Alternator 16. Expansion tanker 17. Lube filling cap 18. Exhaust body 19. Lube cooler 20. Either pump 21. Starting liquid reservoir 22. Water inlet pipe 23. Water outlet pipe 24. Starting motor 25. Gearbox handles
3. GENERAL ENGINE DATA Engine set Model NLDE-3

Model Type Combustion chamber type Cylinder number BoreStroke (mm) Total displacement Fire order Compression ratio Rated power/Speed (kW/r/min) Rated fuel consumption(g/kWh) (l) 380C-3 In linewater coolingFour stroke Direct injection 3 8090 1.357 132 18:1 20.6/2800 255 Combination of forceSplash Force cooling through keel cooler Anticlockwise(view from flywheel ) Electric (option spring starter/Manual starting/Hydraulic motor starting) 550
Rated lube consumption(g/ kWh 2.72 Lubrication method Cooling method Rotation direction Diesel Engine Starting method Exhaust temperature at rating()
Air consumption in 10minutes (m3) 16.148 Model Ratio Rated output/Speed (kW/r/min) output shaft rotation ZF12M 2.63(Forward)/1. 95(Reverse) 19.7/1065 SCG025 2.74(Forward)/2. 67(Reverse) 19.7/1020
Gearbox
Clockwise(view from output end) Mechanical or soft cable remote

795.6560638 828560638
Engine set
Operation method Overall dimension Weight (kg)
195
200
4. ENGINE TYPES
4.1 VARIANTS BASED ON LIFEBOAT TYPE
NLDE-3 marine diesel engine set is sorted two different engine types. One is used for totally enclosed lifeboats that is lowered by davits the others is used for totally enclosed free fall lifeboats. The engine set all equipped crankshaft pulley to drive the sprinkle pump. There is a postfix letter "F" in serial number for free fall lifeboat engines to distinguish with normally totally enclosed lifeboat engines. The difference is shown as follows between two engines: A. The lube oil suction position and structure. B. The marks on engine oil dipstick. (Shown in figure 3) C. The marks on gearbox oil dipstick. (Shown in figure 3)
Fig. 3 The oil dipstick of diesel engine & gearbox for free fall lifeboat
4.2 TYPES BASED ON COLD STARTING ASSISTANCE METHOD

4.2.1 The engine is normally installed with a glow plug intake preheating device when the engine is started by electrical motor. 4.2.2 The engine is normally installed with a FJ-30-I cold starting injection device when the engine is started by manual, spring starter or by hydraulic motor.
8
5. MAIN STRUCTURE OF ENGINE

5.1 FUEL SYSTEM The fuel system is important controlling components of the diesel engine. They are composed of injectors, fuel filter, injection pump and high and low pressure pipes and various connections. The feed pump takes fuel from the fuel tank and send it to the filter. The fuel, after passing through the filter, passes into the injection pump. The fuel passes into the high pressure pipe then to the injector which atomizes the fuel to fine droplets for combustion. Small amount of fuel passes through the oil return pipe into the fuel tank. Fuel pump timing . 24~27TDC Injection pressure . New: 20.5Mpa/used: 20Mpa Diesel oil conforming GB252 light diesel fuel grades No.0 or No.-35 or to USA specification ASTM D-975-77 Grades NO.1-D and 2-D. If the engine has to work in areas with extremely low ambient temperatures, use fuel with good clog characteristic. Clog point(CFPP) -25 . 5.2 LUBRICATION SYSTEM The lubrication system is made up of an oil sump, a suction strainer, an oil pump, lube cooler, filter and various pipes. The oil pump draws the lube oil contained in the oil sump through oil suction strainer then the lube oil flow into lube cooler and lube filter. The lube oil in main oil passage is separated into three flows. One passes through main bearing and flow into connecting rod bearing; The second passes through the camshaft bearing and flow the sloping oil passage to lubricate the valve rocker arm shaft liner; the third one flow into timing idle gear bearing. Cylinder liner, piston, piston pin, connecting rod l shells etc are splash or atomized lubricated. The lubrication oil should be added properly. If it is added too much, it would be burning; if added to less, the bearing shells would be burnt. It is ideal to add the oil until its level reaches between the upper and low marks on the dipstick. When the oil level goes down to the low mark, lube oil
9
should be added. Before starting the diesel engine, the oil level should be checked. Lube oil pressure ...98kpa ~120kpa at idle. 250~390kpa at rated output. Oil sump capacity5.2liters. ZF12M Gearbox sump capacity.. 0.56 liters. 5.3 COOLING SYSTEM The cooling system of the engine set is of forced circulative water cooling close type, which consists of lube oil radiator, water tank, water pump, rubber hose, pipes etc. The cooling system of the engine is closed water cooling system. The cooling liquid comes from the keel cooler through the lube oil cooler and water pump to the engine block, cylinder head, water cooling exhaust pipe and outlet then feed back to keel cooler to make circulation cooling. Too high cooling temperature will cause the lamp in the control panel to light up and acoustic alarm to function. Water temperature ..65~85.Maximum temperature 95 Antifreeze liquid should be used as an all year round coolant. This liquid will give low temperature protection down to -25. Additionally, antifreeze liquid will protect the cooling system from corrosion. Warning: Antifreeze contains Glycol and other constituents which are toxic if taken internally, and can be absorbed in toxic amounts under prolonged skin contact. If antifreeze is swallowed accidentally, medical advice should be sought immediately.
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Fuel tank
Fig 4 Piping layout

1.Cooling water pump 2.Lube cooler 3. Keel cooler 4.Lube oil pump 5.Lube oil filter 6.Pressure control valve 7.Main bearing 8.Camshaft bearing 9.Rocker arm 10. Overflow pipe 11. Fuel oil filter 12.Fuel feed pump 13. Fuel injection pump 14. Fuel high pressure pipe 15. Fuel injection nozzle 16. Water exhaust pipe 17. Fuel oil supply pipe
5.4 ELECTRIC SYSTEM. 5.4.1 The electric system is composed of battery charging alternator, starting motor, relay regulator, switch, alarm buzzer, alarm lamps and instruments. You can select one of two electric diagram (shown diagram 1, diagram 2) Note: Voltage: 12V. Battery capacity 90Ah 5.4.2 ELECTRIC HEATER (IF INSTALLED) Automatic temperature electric heater is installed into the oil sump.
11
The Automatic temperature electric heater will heat the lube oil in oil sump. The temperature controlling parts will automatically shut off the power if the temperature is up to 35.If oil temperature is below about 25 ,automatic temperature electric heater will again heat the lube oil to make the lube oil temperature to normal working temperature. Automatic temperature electric heater main technical data: Input Voltage and power: 42V 300W If the ambient temperature is under -15,this heater is recommended. Note: Don not connecting the power before immerging the Automatic temperature electric heater into the oil. Otherwise the heating parts will be damage. 5.5 GEARBOX Gearbox model: Reduction ratio Forward Reverse ZF12M 2.63 1.95
Rotation direction of propeller .. Clockwise (view from output end)
12
5.6 WIRING DIAGRAM

5.6.1.1 General wiring diagrams (Suitable for glow plug intake preheating device)
Fig 5 Wiring diagram I-1

13
Fig 6 Wiring diagram I-2
14
5.6.1.2 ELECTRIC SYSTEM PARTS DESCRIPTION Following parts is installed either engine side or panel side Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Description Tachometer Starting switch Buzzer
Alarm lamp (water temp.) Alarm lamp (lube pressure) Alarm lamp (charging)
Tachometer sensor Temperature sensor Lube pressure sensor Starting motor Battery Battery switch Voltage regulator Generator Diode Charging diode
Glow plug preheating device
Electric diagram 1 Has Has Has Has Has Has Has Has Has Has
Electric diagram 2 Has Has Has Has Has Without Has Has Has Has
User provided by oneself Has Has Has Has Has Has Has Has Has Has
5.6.1.3 INSTRUMENTS PANEL

According the choice of the buyer, the engine set is normally fitted one of the two instruments panel.
Buzzer
Oil pres. temp. A T 0 Water S HE
PR EH STA EAT RT PR E TA RT
Oil pres. Buzzer

0
Tachometer Start
Tachometer
Charging light.
PR EH ST EAT AR T
Water temp.
PR
EH
EA
ST
AR
Start
Fig 7 Panel without charge alarm
Fig 8 Panel with charge alarm

15
5.6.2.1 Special wiring diagrams (suitable for the engine set started by manual, spring starter or hydraulic motor with FJ-30-I assistance)
Tachometer
6 4 5 1 3
Switch
3 2 1
Buzzer
High water temp. alarm
Diode Low oil pressure alarm Discharge alarm
CAP
1 1
2 2
3 3
4 4
5 5
Temp. sensor
6 6
Pressure sensor
7 7
8 8
9 9
10 10
11 12 11 12
Voltage regulator
G
Tachometer sensor
2 50mm
Double charge diode

2 50mm
Armature
B+ + -
Starter
Generator
Change over Battery switch
Battery 1 Battery 2 12 Volt 12 Volt Items with dotted line not included in normal delivery.
Fig 9 Wiring diagram II-1

16
Magnetic
Tachometer 6 4 5 1 3
Switch 3 2 1
Buzzer
High water temp. alarm
1 1
2 2
3 3
4 4
5 5
Temp. sensor
6 6
Pressure sensor
Low oil pressure alarm
7 7
8 8
Voltage regulator Magnetic B+ F Generator G
Tachometer sensor
50mm2 50mm2 Starter + G G
Battery 1 12 Volt
Battery 2 12 Volt
Change over Battery switch Items with dotted line not included in normal delivery.
Fig 10 Wiring diagram II-2

17
Armature
5.6.2.2 ELECTRIC SYSTEM PARTS DESCRIPTION Following parts is installed either engine side or panel side Electric diagram Electric diagram 2 1 1 Tachometer Has Has 2 Starting switch Has Has 3 Buzzer Has Has 4 Alarm lamp (water temp.) Has Has 5 Alarm lamp (lube pressure) Has Has 6 Alarm lamp (charging) Has Without 7 Tachometer sensor Has Has 8 Temperature sensor Has Has 9 Lube pressure sensor Has Has 10 Starting motor Has Has 11 Battery User provided by oneself 12 Battery switch 13 Voltage regulator Has Has 14 Generator Has Has 15 Diode Has Has 16 Charging diode Has Without 5.6.2.3 INSTRUMENTS PANEL According the choice of the buyer, the engine set is normally fitted one of the two instruments panel. Item Description
Buzzer
Oil pres. 0 Water temp. S
TA AR RT
Oil pres. Buzzer

0
T
Water temp.
ST AR
ST
AR
Tachometer Start
ST
Tachometer
Charging light.
Start
Fig 11 Panel without charge alarm
Fig 12 Panel with charge alarm
The alarm lamp and buzzer will work if the water temperature and lube pressure are abnormal. It is normal for lamp and buzzer alarm of oil pressure is on before the engine started. Once the engine is started, the
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lamp and buzzer alarm for oil pressure will be off automatically. 5.7 STARTING PRECAUTIONS Starting any engine can be dangerous in the hands of inexperienced people. Before attempting to start any engine, operator should be fully familiar with starting procedure and controls. .Ensure that the batteries are in serviceable condition and correctly connected. .Check that the oil levels in the engine and the gearbox are correct. .Check that the fuel tank is full and that the fuel system is primed. .Check that all water drain plugs and cocks are closed. Check that water inlet valves, if fitted, are opened. .Check that water level in the expansion tank is filled up with antifreeze liquid and oil level in oil sump and gearbox. .Turn battery main switch on. Oil pressure light and charging light will now be on and the buzzer will sound.
6 OPERATION OF ENGINE
6.1 STARTING Before attempting to start the engine ,the operator should be familiar with the safety precautions as described earlier. Move the speed/gearbox lever into the neutral position by means of the control lever. Turn the switch to energize the starting motor. Release immediately, if the engine start, and it will return to position 0.The alarm light as well as the buzzer should now be off. If the engine should fail to start ,due to poor battery condition ,turn the battery switch to the second start battery and repeat the starting procedure. If the engine fail to start within 15 seconds ,despite good battery condition ,release the switch and investigate the cause .The starting
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motor should be allowed to cool for at least 15 seconds before attempting to restart. At low temperature (below -5) it may be necessary to start the engine by means as follows: A.The engine is started by glow plug intake preheating device if installed Turn the starting switch anticlockwise to preheat position to preheat The engine 25 seconds then turn starting switch to start the engine. Once the engine is started, release the switch immediately, starting switch is automatically turn back to original position. If fail to start the engine, repeat above procedure again. Note: The preheating glow plug max. Preheat time shall be less than 90 second. B. The engine is started by manual, spring starter or hydraulic motor with FJ-30-I cold starting injection assistance. Procedure is shown as follows (1).Open the dust cover of the liquid storage. Insert the pouring liquid pressure can into the hole of the liquid storage. Squeeze the can to pour the liquid into liquid storage. (2).Set the gearbox at idle stably position and put the handle of fuel rack at mid-position. (3).Start the engine. At the same time, operate the hand Pump until the engine runs stably. (4).If knocking appears while the engine is starting; the operation of hand-pump must Be slowed or stopped, so as to Regulate the injecting liquid quantity for starting engine stably
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low tem p. starting liquid pouring system

1.A ir pipe 2.H and pum p 3.Liquid 4.Liquid pipe 5.Injector 6.A ir inlet pipe
CAUTION: Keep away from all heat sources (even sun light).The liquid is highly flammable. Notice: The customer shall select one of cold starting assistance option glow plug intake preheating device or FJ-30-I liquid pouring system. They can not be used on one engine at same time. 6.1.1 STARTING BY SPRING STARTER (IF INSTALLED) According to the buyer requests, we can install and supply the FQ engine starter (hand starting) for the engine starting. This starter makes use of man-power to press its spring to store the energy. The engine is rotated, as the energy relives at a moments and causes the engine running over the speed of starting revolution of the engine quickly, and then the engine is starting. Operation order and method: 1. Press the reset button. 2. Insert the handle, anticlockwise rotation, press the butterfly spring to fully pressing state.(The red mark is appearing). 3. The energy will relieve at a moment when the lever is pressed. At that time the engine speed rises over the starting revolution of the engine, and then the engine is starting. 4. If it is necessary to rotate the engine with the hands, press the reset button and draw-up the reliever lever and then the engine can be rotated with the handle.
21
reset button release handle cranking bar
78 APPROX
130 DIR
116 DIR
287.6
75 37.75 125.75
Fig. Spring starting motor

Note: 1. when use the FQ starter, never open the decompression. 2. If fail to start in clod winter, a FJ-30 cold starting device can be started the engine successfully. 6.1.2 HAND STARTING (IF INSTALLED) According to the buyer requests, we can install and supply hand starting system as the second engine starting. The hand starting is started the diesel engine by man power through cranking the starting shaft driving injecting pump gear through the chain transmission. The gear train drives the crankshaft rotation. Once the rotation is up to starting speed, push down decompression handle, the engine will be started successfully. The hand starting operating procedure is shown as following paragraph: 1. Make the handle of gearbox in neutral position, fuel adjusting handle in neutral speed position. 2. Loosen the locking screw in starting supporting bracket. 3. Pull the decompression lever at the side of the cylinder cover. Two crews turn the starting shaft by cranking bar one clockwise and the other anticlockwise. You will feel it easily and smoothly to turn the engine rotation. If feels difficult to turn, the release handle may do not work properly.
22
As fast enough as the engine rotate (About 200 rpm) by hand cranking, push the decompression handle immediately. At same time, the engine will be started successfully. 4. Once the engine is started and speed more than the hand cranking speed, the cranking bar will draw back from the starting shaft automatically. 5. In cold winter, one shall pull and push the FJ-30 hand pump to pour into intake pipe with starting gas while the engine speed turns over than 150 rpm. At this time crews turn the engine speed turns fast enough to reach starting speed, once push the decompression handle, the engine will be started successfully. Note: Any one must not adjust the screws installed decompression shaft in the cylinder cover before consultation. We will not be responsible for any damage arising from without the permission of Norsafe as. 6.2 OPERATION When all function are normal, engage the gearbox by pushing the controlling lever forward or backward. Increase the speed gradually if possible, allowing the engine to warm up, before going full speed. In case of emergency, the lever can be moved into full speed position immediately. If one or more alarm do not go out, or light up when the engine runs, the engine should be stopped at once to trace the reason. 6.3 STOPPING Move control lever into neutral position. Allow the engine to idle for approx. 2 minutes to cool. Stop the engine. Switch off the battery main switch. If fresh water is only used, all of cooling water must be drained out from the cooling system when the ambient temperature is below 5 (Except anti-freeze coolant is used)
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7. ROUTINE MAINTENANCE
The engine has passed the lifeboat engine test programmer before delivery. Still however the engine is not completely run in. It is recommended to operate the engine moderately during the first hours after it has been put into service. Full speed only for short periods During the first 15-20 hours. 7.1 INITIAL ATTENTION 1. Check and tighten all hose clamps and unions, paying particular attention to the fuel system. 2. Check and tighten all external nuts and bolts, particularly mounting bolts, shaft coupling bolts and exhaust manifold bolts and nuts. 3. Check belt tension, see ALTERNATOR BELT TENSION section. 4. Check lubrication oil and water coolant level. 7.2 ROUTINE MAINTENANCE PERIODES Period Attention
After the first 15 hours or after See INITIAL ATTENTION the first 3months Check engine oil level. Check coolant level. Before start or weekly Check fuel level in tank. Grease stern gland Check gearbox oil level Every 3 months or 25 hours Check battery condition Change gearbox oil and lube oil Change lube oil filter Every year or 200hours Check alternator belt tension Check electric connect
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7.3 LUBRICATION OIL SPECIFICATION Temperature in starting Below Between Between Above and and -15 -15 30 4 30 30 Mono-grade 5w 10w 20/20 w 30 Multi-grade 5w /30 10w/30 15w/30 10w/30 15w/40 20w/40
The temperatures mentioned in the table are the ambient temperatures at the time when the engine is started. However, if the running temperatures are much higher than the starting temperatures a compromise must be struck and a higher viscosity oil used, providing starting is satisfactory. Multi grade oils overcome the problem, provided they have a suitable specification. The engines must be run on heavy duty lubricating oils, meeting the requirements of API CC.DEF2101D, MIL-L-2104B or MILL-L-46152A/B Straight mineral oils are not suitable, neither are oils of less detergency than specified. API CD, Series 3, or MIL-L-2104C/D oils can inhibit the running in process in new or reconditioned engine but can be recommended for engines running at high load factor, particularly in conjunction with high ambient temperatures. Following or equivalent types of oil can be used: Mobile Delvac 1300 series BP energol DS3 Shell Rimula oil Gulfpride Seies 3 Esso lube XD3+ Elf Disal HD3 Chevon Delco Super 3 Texaco URSA S3 Fina Solna 3 Castrol Deusol RX super Norol Marine TMA 300 Amocol New Supper ACE3
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7.4 GEARBOX OIL SPECIFICATION Automatic Transmission Fluid -ATF FORD Specification M 2 C-33 G GM Specification ATF DEXRON D EXXON ATFD or ATF (or refer to gearbox operation manual ) 7.5 MAIN SPANNER TORQUE SETTINGS DESCRIPTION Flywheel bolt Cylinder head nut Connecting rod bolts Prop. shaft coupling bolts (acid proof) Crankshaft main bearing Nm 60 140 70 70 125
7.6 TIGHTENING SEQUENCES FOR CYLINDER HEAD BOLTS.

7 11 1 5 4 10 14
13
3 9 6
2 8
12
7.7 CHECK OF LUBRICATION OIL LEVEL The lubrication oil level should always be checked before starting. The level should never be allowed to fall below mark. 7.8 LUBRICATION OIL CHANGE The oil change should be down when the engine is warm. Run the engine after oil change and check for any leaks. Stop the engine, allow the oil to settle and top up if necessary. 7.9 ALTERNATOR BELT TENSION. It is important that the belt tension is checked after an overhaul or
26
when new belt is installed. New belt tension: A force of 3~3.5 kg to deflect belt 3.5 mm Checking and adjustment at service intervals: A force of 2~2.4 kg to deflect belt 3.5 mm 7.10 GEARBOX OIL CHECK Check the oil level. Fill up if the oil level is below the mark. ZF12M Gearbox sump capacity: 0.56 liters. 7.11 PRIMING THE FUEL SYSTEM The fuel system has to be primed before initial starting, after fuel filter change, if the fuel system has been disconnected, or if the engine has run out of fuel and stops. 1. Loosen the vent plug on top of the fuel pump. 2. Turn on the handle of the fuel feed pump 3. Start the handle up-and-down movement. 4. When no air is left, retighten the vent plug and turn off the handle of the fuel feed pump. 7.12 DRAIN THE COOLANT Remove the cap on the top of expansion tanker. Drain the coolant through the cock in front of engine. Close the cap and cock after draining. Refill the cooling system with correct water anti-freezing mixture. Let the engine run idle for 20~30 minutes. 7.13 CHANGING FUEL FILTER ELEMENT If the fuel oil tank is installed at a level above the engine, the cock must be closed before fuel filter change. Unscrew the filter container and discard the filter element. Ensure that the rubber gaskets and the spring are correctly fitted before the filter container is reinstalled after filter change. Priming the fuel system after filter element change, see section 7.11. 7.14VALVE CLEARANCE ADJUSTMENT The valve clearance is: Exhaust valve (cold): 0.25~0.30 mm
27
Intake valve (cold) : 0.20~0.25 mm 7.15 STARTING AND RUNNING THE ENGINE WHILE THE LIFEBOAT IS HOOKED IN DAVITS OR IN FREE FALL RIG The engine should be started and run once a week and after any kind of maintenance work. The running should be limited to 5 minutes at idle speed. The water temperature alarm should be watched. 7.16 GENERAL PRECAUTTIONS ABOUT ELECTRIC SYSTEM The following points must be strictly observed when working on the electric system, otherwise serious damage can occur. 1. Never remove any electrical cable without first disconnecting the batteries. 2. Never disconnect the alternator cables while the engine is running. 3. Only disconnect the batteries with engine stopped and all switches in the OFF position. 4. Always check that cables are connected to their correct terminals before reconnecting the batteries .A reversal of polarity or short circuit will destroy diodes and transistors in the alternator and regulator. 5. Never flash any connections to check the current flow. 6. Always keep the electrical connections properly tightened. 7.17STORAGE 1. If the engine is to be put out of service for a long period of time, it is necessary to drain out lubricating oil, cooling water and fuel when engine is still warm after stopping the engine. 2. Perform maintenances accordingly. 3. Dismantle both intake and exhaust manifolds and pear into the cylinder liners from the air passages about 0.2 kg of clean dehydrated oil (By heating the lubricating oil to 110~120, until all air bubble on surface of oil disappear). And rotate the crankshaft so that the valves, cylinder liners and pistons etc. are all covered with a layer of this oil. Then install the
28
intake manifold and exhaust body. 4. Remove sludge and dust from outer surface of the engine. Smear anti-rust oil on to exposed machined surfaces of parts of the engine. Rubber plastic components are prohibited to be smeared with oil. 5. Block the intake manifold and exhaust pipe flange with wooden plug, or wrap them up properly with plastic cloth in order to prevent any dust from getting in. 6. The engine so preserved should be stored in room of good ventilation and low humidity but without any dust. It is strictly forbidden to store the engine wherever there are chemical. The preservation according to above procedure may be good for three months. Over this period, repeat this procedure.
29
8 TROUBLE SHOOTING
This section is intended as a guide only. If you have any difficulty, please consult NORSAFE AS or Jiangyin Norsafe China. 8.1 DIFFICULT IN STARTING THE ENGINE Causes
(1).The fuel filter or pipes are obstructed. (2).Air is locked in the fuel
Remedial method
Clean the filter or pipes Drain the air and tighten all fuel pipe connectors (3).The fuel injection advance angle is Adjust the fuel injection advance angle as incorrect. specification. (4).The valve clearance is incorrect Adjust the valve clearance as required. (5).Battery not fully charged or poor wire Charge the battery fully or tighten the connections connections. (6). No fuel in tanker or poor spray from Fill up the fuel or adjust the injecting injector pressure as required. (7).Low cylinder compression pressure Check and change the piston ring or cylinder liner. Change the cylinder head gasket if damaged. (8)Electric system malfunction Check and fasten all electric connectors
8.2 INSUFFICIENT OUTPUT Causes
Remedial method
(1) Low cylinder compression pressure Refer to 8.1(7) (2) The fuel injection advance angle is Refer to 8.1(3) incorrect. (3) The valve clearance is incorrect Refer to 8.1(4) (4) Fuel supply for each cylinder is Adjust the fuel quantity of fuel injection unequal. pump. (5) Low engine speed Adjust the engine speed to specification. (6) Excessive wear of plunger couple of Renew new plunger couple. Injection pump (7) The inlet or exhaust system clogged. Clean.
30
8.3 BLACK SMOKING FROM EXHAUST Causes Remedial method
(1). The engine is overloaded Reduce the load properly. (2). Fuel injector defeats Renew one. (3).Poor fuel quality Change the fuel as specification (4)The fuel injection advance angle Refer to 8.1(3) is incorrect. (5)Combustion is incomplete Check the injector, fuel injection advance angle, cylinder gasket and cylinder compression pressure etc.
8.4 LOW LUBE OIL PRESSURE Causes

(1) (2) (3) (4) (5) (6) Lube oil in oil sumps too low. Lube oil pipe leaks Lube filter obstructed. The lube oil is too thickness Pressure sensor or lamp defeats Gear pump worn out and clearance is over (7) Pressure valve malfunction (8) Worn of main bearing, camshaft bearing, connecting rod bearing
Remedial method
Fill up to the right mark. Tighten all connectors. Replace lube filter. Replace the lube oil as specification Replace a new one. Replace gears pump and adjust the clearances Replace a new one. Check, repair or replace a new one
8.5 ENGINE KNOCKING Causes

(1).The fuel injection advance angle is incorrect. (2) Air or water is mixed in fuel system (3)Fuel supply for each cylinder is unequal. (4)Wear of the certain components exceeds specification limits (5)Valve clearance is too much or small
Remedial method
Refer to 8.1(3) Refer to 8.1(2) Refer to 8.2(4) Replace the worn parts. Readjust the valve clearance again.
31
8.6 ENGINE OVERHEATING Causes

(1) Temperature of coolant water too high a. Insufficient coolant or vapor lock in cooling system b. Cooling water pump defeats c. Water pump belt is loose (2) Lube oil temperature is too high. a. Low or high lube oil level. b. Low lube oil pressure with insufficient flow. (3) The engine is overloaded.
Remedial method
Add water coolant Repair or replace water pump Refer to section 7.9 Fill or drain the lube oil Refer to 8.4 Refer to 8.3(1)
8.7 ENGINE OVER SPEED OR OVERRIDE Causes

(1) Governor malfunction. (2) Control bar of fuel injection pump is stuck. (3) Fuel supplying of injection pump is too large. (4) Oil gets into cylinder too much
Remedial method
Stop engine and repair immediately. Ditto Stop the engine and readjust fuel pump delivery. Stop the engine and check and repair
32
Appendix 1NLDE-3 diesel engine set delivery list This list is a standard delivery list. No. Description 1 2 3 4 5 6 7 8 Marine diesel engine set Tools supplied with engine Unit Set Box Qty 1 1 Remarks
NLDE-3 marine diesel engine set Piece 1 operation manual Gearbox operation manual Piece 1 NLDE-3 marine engine set parts Piece 1 catalogue Instruction for wheel house NLDE-3 Class inspecting certificate Product inspecting certificate Piece 1 Piece 1 Piece 1
Appendix 2Tools supplied with NLDE-3 marine diesel engine set No. 1 2 3 4 5 6 7 Description Feeler gauge 8# screw driver Spanner810 Spanne1316 Spanne1821 Spanne1719 Cold starting liquid
33
Unit 1 1 1 1 1 1 1
Qty
Only provide when engine started by manual or spring starter
Contact with:
Norsafe A/S
Address:PO Box 115N-4852 Frvik, Norway Tel: (+47) 3705 8500 Fax: (+47) 3705 8501
Website: www.norsafe.no
Jiangyin Norsafe F.R.P Co., Ltd.

Address: Yuecheng Town, Jiangyin City, Jiangsu Province,China Tel: (+86) 510 86987718; 86986033 Fax: (+86) 510 86987371 Zip code: 214404 Website: www.norsafe.no
NORSAFE NLDE-3 Marine Diesel Engine Set
Parts Catalogue
NLDE-3(380J-3)
BETTER
BY
DESIGN
NORSAFE AS
Rev. 1 2 Reason for issue ISSUED FOR INFORMATION THERMOSTAT REMOVED Date 01.06.06 22.04.08 By Chk HENRY TT JOH TT
CONTENTS
Fig .1 Cylinder Head Cover Assembly1 Fig .2 Cylinder Head Assembly3 Fig .3 Engine Block Assembly 6 Fig .4 Oil Filling Assembly 10 Fig .5 Timing Gear Train Assembly 12 Fig .6 Piston and Connecting Rod Assembly 14 Fig .7 Crankshaft and Flywheel Assembly 16 Fig .8 Valve Timing Mechanism Assembly 18 Fig .9 Water Pump Assembly 21 Fig .10 Oil Sump Assembly 24 Fig .11 Lubricating Oil Pump Assembly 26 Fig .12 Fuel System 28 Fig .13 Exhaust Pipe and Expansion Tank Assembly 30 Fig .14 Lube Oil Filter/ Alternator/Starting Motor 32 Fig .15 Intake Pipe Assembly 34 Fig .16 Intake Pipe Assembly (Special) 36 Fig .17 End Cover Assembly 38
Fig. 1 Cylinder Head Cover Assembly
Fig. 1 Cylinder Head Cover Assembly Item No. 1 2 3 4 5 6 Parts No. Parts Description Or Specification CZ380Q-0100 Cylinder head cover 1 GB3452.1-82 O seal washer 33.52.65 GB308-89 Z380-01007 Steel ball15 Breath seat Quant ity 1 1 1 1 1 1
Remarks
Z380-01008 Breathing cap CZ380Q-0100 Cylinder head cover sealing ring 4
Fig. 2 Cylinder Head Assembly Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 20 Parts No. Or Specification CZ475Q-170004 CZ475Q-171001 GB308-89 N85Q-17105 GB97.1-85 N85Q-17102 CZ475Q-171004 N85Q-17103 WB9311 GB5783-86 GB97.1-85 Z380-17001 CZ475Q-170002 GB5782-86 GB93-87 CZ475Q-170007 CZ475Q-020012 GB41-86 CZ475Q-021004 Quant ity 1 1 1 1 6 1 1 1 1 4 4 1 1 4 28 1 1 12 3
Parts Description Thermostat body Switch body Steel ball 9.5 Washer Washer 8-140HV Tighten Bolt Valve rod Handle Water temperature alarm sensor Bolt M622 Washer 6 mm Thermostat cap Thermostat cap gasket Bolt M822 Washer 8 mm Soft pipe connector Thermostat body gasket Nut M8 Exhaust valve seat
Remarks
Fig . 2 Cylinder Head Assembly

Item No. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Parts No. Or Specification CZ475Q-021003 CZ380Q-021001 CZ475Q-020008 GB5783-86 CZ475Q-021002 CZ475Q-020009 CZ475Q-020010 CZ475Q-021010 CZ475Q-021011 CZ475Q-020011 GB93-87 CZ475Q-020001 CZ475Q-021005 GB900-88 N85-02109 CZ475Q-021008 CZ475Q-021009 CZ475Q-090008 CZ475Q-090007 Quant ity 3 1 1 4 6 6 1 14 1 1 6 6 6 3 6 6 5 3 3 3
Parts Description Intake valve seat Cylinder head Front hoisting ring Bolt M820 Valve stem guide Backing hoisting ring Cylinder head bolt Oil plug Bowl plug () Injector fasten nut Washer 6 mm Injector fasten stud Injector inlaying sleeve Stud M820 Bowl plug (I) Bowl plug (IV) Sealing water pipe Intake gasket Exhaust pipe gasket
Remarks
QB81313 (17) Valve sealing ring
Fig. 3 Engine Block Assembly

Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Parts No. Or Specification CZ380Q-031001 CZ475-031008 N85-03006 GB898-88 GB93-87 GB6170-86 CZ475Q-031015 CZ475Q-031016 CZ475Q-031011 CZ475Q-031010 CZ475Q-031009 CZ475Q-030013 CZ475Q-030012 CZ475Q-030015 CZ475Q-031014 N85-03110 CZ475Q-031006 GB5783-86 GB97.1-85 N85-03020 CZ475Q-033000 YB1011 N85C-03004A Quant ity 1 3 1 2 34 9 3 1 8 8 1 2 2 4 4 4 2 9 23 1 1 1 1
Parts Description Engine block Main bearing cap Camshaft middle bushing Stud M825 Washer 8 mm Nut M8 Bowl Plug 30 Plug Main bearing cap bolt Main bearing cap bolt washer Rear main bearing cap Crankshaft thrust piece (lower) Crankshaft thrust piece (upper) Main bearing shell (lower) Main bearing shell (upper) Z1/16 tape plug Main bearing cap locating sleeve Bolt M825 Washer 8 mm Lube oil filter gasket Water outlet cock Lube oil pressure sensor Lube oil pressure sensor pipe
7
Remarks

Item No. 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Parts No. Or Specification CZ475Q-031004 GB119-86 CZ475Q-031014 CZ475Q-031002 CZ380Q-030003 CZ480Q-031017 CZ475Q-031003 380C3-01017BH(I) GB898-88 GB898-88 GB898-88 CZ475Q-031012 GB119-86 CZ475Q-030008 CZ475Q-030009 GB5783-86 CZ475Q-120002 GB899-88 CZ475Q-120001 GB5782-86 JB119-86 CZ475Q-120003 CZ475Q-120004 Quant ity 2 2 1 1 1 3 2 2 1 1 2 1 1 1 1 2 1 3 1 3 1 1 1
Parts Description Main oil passage plug Pin B1010 Rear camshaft bushing Plug Cylinder head gasket Cylinder liner Cylinder head locating sleeve Engine foot Stud M890 Stud M865 Stud M860 Camshaft front bushing Pin B850 Idling gear shaft Idling gear plate Bolt M850 Gear case gasket Stud M825 Gear case Bolt M845 Pin B818 Gear case cover gasket Gear case cover
8
Remarks

Item No. 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 Parts No. Or Specification GB5782-86 GB5782-86 CZ475Q-120007 JB2600-86 CZ475Q-120006 CZ475Q-120005 GB5782-86 GB5782-86 CZ475Q-120008 CZ475Q-120009 GB93-87 GB6170-86 CZ475Q-030010 CZ475Q-030011 GB5783-86 JB2600-80 GB899-88 GB97.1-85 GB93-87 GB898-86 CZ480Q-030017 GB93-87 GB65-86 Z380-03401,2 (BH) Quant ity 5 1 1 1 2 1 5 1 1 1 9 1 1 1 8 1 2 2 2 2 1 2 2 Each
Parts Description Bolt M855 Bolt M865 TDC pointer Oil sealing DR557512 Front cover gasket Front cover Bolt M835 Bolt M1095 Alternator bracket Alternator bracket sleeve Washer 10 mm Nut M10 Flywheel case gasket Flywheel case Bolt M1030 Oil sealing DL8010012 Stud M1230 Washer 12 mm Washer 12 mm Nut M12 View window plate Washer 6 mm Screw M68 Engine foot
9
Remarks
Fig . 4 Oil Filling Assembly
10
Fig . 4 Oil Filling Assembly

Item No. 1 2 3 4 5 6 Parts No. Or Specification N85-19005 GB5783-86 GB859-87 Z380-10001 GB3452.1-82 Z380-10002 Parts Description Push rod case gasket Bolt M825 Washer 8 mm Oil filling pipe Sealing ring Oil filling cap Quant ity 1 2 1 1 1 1 Remarks
11
Fig . 5 Timing Gear Train Assembly
12
Fig . 5 Timing Gear Train Assembly

Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Parts No. Or Specification CZ475Q-040001 CZ475Q-041001 CZ475Q-040003 GB97.1-85 GB93-87 GB5783-86 CZ475Q-041002 GB5783-86 GB93-87 CZ475Q-070003 CZ475Q-040002 GB5783-86 GB93-87 CZ475Q-070002 Parts Description Camshaft timing gear Idle gear Injecting pump timing gear Washer 6 mm Washer 6 mm Bolt M616 Idle gear bushing Bolt M122.5 Washer Camshaft gear circlip Camshaft gear Bolt M820 Washer 8 mm Camshaft thrust plate Quant ity 1 1 1 6 6 6 1 1 1 1 1 2 2 1 Remarks
13
Fig . 6 Piston and Connecting Rod Assembly
14
Fig . 6 Piston and Connecting Rod Assembly

Item No. 1 2 3 4 5 6 7 8 9 10 11 Parts No. Or Specification CZ480Q-050001 CZ480Q-050002 CZ480Q-051000 GB893.1-86 CZ480Q-050005 CZ480Q-052002 CZ480Q-050006 CZ480Q-052003 CZ480Q-052004 CZ480Q-052001 CZ480Q-050004 Parts Description 1st piston ring 2nd piston ring Oil ring Piston pin Circlip Piston Connecting rod Connecting rod bearing shell Connecting rod cap Connecting rod bolt Connecting rod bushing Piston pin Quan Remarks tity 3 3 3 6 3 3 6 3 6 3 3
15
Fig . 7 Crankshaft and Flywheel Assembly
16
Fig .7 Crankshaft and Flywheel Assembly
Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Parts No. Or Specification CZ475Q-060006 CZ475Q-060005 CZ380Q-060004 CZ475Q-060007 GB1096-79 CZ475Q-060008 CZ380Q-060003 GB119-86 GB278-89 CZ475Q-061002 CZ475Q-061001 CZ475Q-060002 CZ475Q-060001 GB5783-86 CZ475Q-33001 GB93-87
Parts Description Crankshaft pulley bolt Crankshaft pulley washer Crankshaft pulley Oil thrower Flat key C106.3 Oil plug Crankshaft Pin B820 Bearing B60203 Flywheel gear ring Flywheel Flywheel bolt plate Flywheel bolt Bolt M825 Locating bolt Washer 8 mm
Quant ity 1 1 1 1 1 3 1 1 1 1 1 1 6 4 2 6
Remarks
17
Fig . 8 Valve Timing Mechanism Assembly
18

Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Parts No. Or Specification CZ380Q-070001 GB1096-79 CZ475Q-070004 CZ480Q-070005 CZ475Q-022002 CZ475Q-022007 GB859-87 GB41-86 GB5782-86 GB79-85 GB802-88 CZ475Q-022009 GB5783-86 CZ475Q-022008 CZ475Q-022001 CZ475Q-022101 CZ475Q-022003 CZ475Q-02102 CZ475Q-022201 CZ475Q-022005 CZ475Q-022006 CZ380Q-022004 Quant ity 1 1 6 6 1 2 8 3 4 3 3 3 4 6 6 3 3 6 3 2 1 1
Parts Description Camshaft Key C814 Valve tappet Valve push rod Front rocker arm support Plug Washer 8 mm Nut M8 Bolt M845 Bolt M840 Nut M8 Washer 8 mm Bolt M825 Valve clearance adjusting nut Valve clearance adjusting screw Exhaust valve rocker arm Rocker arm shaft spring Valve rocker arm bushing Intake valve rocker arm Middle rocker arm support Rear rocker arm support Rocker arm shaft
Remarks
19

Item No. 23 24 25 26 27 28 Parts No. Or Specification N85-020011 N85-02002 N85-020031 N85-020032 CZ475Q-020003 CZ475Q-020002 Quant ity 6 12 6 6 3 3
Parts Description Valve spring seat (upper) Valve collet Valve outer spring Valve inner spring Exhaust valve Intake valve
Remarks
20
Fig. 9 Water Pump Assembly
21

Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Parts No. Or Specification GB5873-86 GB93-87 GB6170-86 GB93-87 CZ475Q-080002 CZ475Q-080010 HG4-401-74 GB893.2-86 GB278-89 CZ475Q-080005 CZ475Q-080007 GB1099-79 GB5783-86 GB93-87 CZ475Q-080013 CZ475Q-080004 GB1153-89 CZ475Q-080009 CZ475Q-080001 ZBT320051-88 Quant ity 4 4 1 1 1 1 1 1 1 2 1 1 2 2 1 1 1 1 1 1
Parts Description Bolt M620 Spring washer 6 mm Nut M10 Spring washer 10 mm Washer Water pump pulley Fan belt Circlip 40 Bearing E60203 Bearing space sleeve Water pump shaft Key 46.51.6 Bolt M830 Washer 8 mm Adjusting bracket Water pump body Oil cup (M6) Rear cover of water pump Hose pipe Soft pipe clamp 24
Remarks
22

Item No. 21 22 23 24 25 26 27 Parts No. Or Specification CC4105Q-080009 ZBT320051-88 CZ475Q-080011 CZ475Q-080012 CZ475Q-080008 CZ475Q-080006 IIF-15 Plug Soft pipe clamp 28 Connecting pipe Water pump rear cover gasket Water pump gasket Water pump impeller Water seal Parts Description Quant ity 1 1 1 1 1 1 1 Remarks
23
Fig. 10 Oil Sump Assembly
24
Fig. 10 Oil Sump Assembly
Series No. 1 2 3 4 5 6 7 8 9 10 11 12
Parts No. Or Specification CZ380Q-110005A 2-08202 Z380-11002 2C3-F08501 GB308-89 GB893.1-86 Z380-11001 A-20402 A-10706 Z380-11003 Z380-11004 2C-34014
Parts Description Oil sump gasket Joint screw Oil sump partition Check valve housing Steel ball 32 Circlip 35 Oil sump Oil drain screw Washer 18 Dipstick pipe Dipstick Washer 14
Quantity 2 1 1 4 4 4 1 1 1 1 1 2
Remarks
25
Fig . 11 Lubricating Oil Pump Assembly
26
Fig . 11 Lubricating Oil Pump Assembly

Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Parts No. Or Specification GB6170-86 GB93-87 GB848-88 CZ475Q-130003 GB1099-79 CZ475Q-131001 CZ475Q-132001 CZ475Q-132002 GB119-86 CZ475Q-131002 CZ475Q-131006 CZ475Q-130007 CZ475Q-130008 CZ475Q-130009 CZ475Q-130010 GB5783-86 GB93-87 CZ475Q-130001 CZ475Q-134000 GB5783-86 GB899-88 Z380-13011 Parts Description Nut M10 Washer 10 mm Washer 10 mm Transfer gear Key 3513 Lube oil pump shaft Sleeve Lube oil pump block Pin A520 Inner rotor Outer rotor Gasket Lube oil pump cover Oil suction strainer Filter strainer Bolt M825 Washer 8 mm Flange gasket Drain oil pipe Bolt M810 Stud M830 Oil inlet flange
27
Quant ity 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 8 1 1 4 4 1
Remarks
Fig . 12 Fuel System
28
Fig . 12 Fuel System
Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13
Parts No. Or Specification CZ380Q-146000 CZ380Q-142000 CZ380Q-141000 N85-15500 (A) CZ475Q-140001 CZ380Q-145000 CZ475Q-144100 GB5783-86 GB93-87 GB97.5-85 CZ475Q-144200 CZ475Q-144800 CZ380Q-143000
Parts Description Fuel pipe from feed pump to filter High pressure oil pipe Injecting pump Connector of fuel inlet pipe Injecting pump gasket Fuel pipe from filter to feed pump Fuel filter Bolt M1020 Washer 10 mm Washer 10 mm Welder part for fuel filter Injector Injector fuel return pipe
Quanti Remarks ty 1 1 1 1 1 1 1 1 1 1 1 3 1
29
Fig . 13 Exhaust Pipe and Expansion Tank Assembly
30
Fig. 13 Exhaust Pipe and Expansion Tank Assembly Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Parts No. Or Specification GB5782-86 GB93-87 GB97.1-85 Quant ity 8 8 8 1 1 1 1 1 8 10 6 1 1 4 6 1
Parts Description Bolt M684 Washer 6 mm Washer 6 mm Complex radiator cap Complex radiator cover seat Expansion tank Inlet water pipe Exhaust pipe body Washer 8 mm Washer 8 mm Bolt M8112 Gasket Exhaust flange pipe Stud M820 Nut M8 Outlet pipe connector
Remarks
Z380-17008 Z380-17009 Z380-09006 GB97.1-85 GB93-87 GB5872-86 Z380-09007 Z380-09008 GB899-88 GB6780-86 Z380-17006
31
Fig . 14 Lube Oil Filter/ Alternator/Starting Motor
32
Fig . 14 Lube Oil Filter/ Alternator/Starting Motor
Item No. 1 2 3 4 5 6
Parts No. Or Specification JX0706P1 380C3-09301 JFW17C3 QD138 YZ90ZH6 Filter seat Alternator
Parts Description Lube oil filter
Quant ity 1 1 1 1 1 1
Remarks
Starting motor Lube oil cooler Pressure adjusting screw set
33
Fig. 15 Intake Pipe Assembly
34
Fig. 15 Intake Pipe AssemblyGeneral
Series No. 1 2 3 4 5 6 7 8 9 10 11
Parts No. Or Specification GB5782-86 GB93-87 GB97.1-85 GB5783-86 CZ475Q-090005 CZ475Q-090004 CZ380Q-090001 Z380-09003B GB5783-86 YRZ12V-51 Z380-09005
Parts Description Bolt M830 Washer 8 Washer 8-140HV Bolt M816 Cover plate Cover plate gasket Intake pipe Intake pipe mouth Bolt M825 Glow Plug Intake End plate
Quantity 2 6 2 2 3 4 1 1 2 1 1
Remarks
set
35

Only for the engine set started by spring starter or manual starting device or hydraulic starting device
36

Only for the engine set started by spring starter or manual starting device or hydraulic starting device
Series No. 1 2 3 4 5 6 7 8 9 10 11
Parts No. Or Specification GB5782-86 GB93-87 GB97.1-85 GB5783-86 CZ475Q-090005 CZ475Q-090004 CZ380Q-090001 Z380-09003 GB5783-86 FJ-30 Z380-09101
Parts Description Bolt M830 Washer 8 Washer 8-140HV Bolt M816 Cover plate Cover plate gasket Intake pipe Intake pipe mouth Bolt M825 Cold starting liquid filler Filler bracket
Quantity 2 6 2 2 3 4 1 1 2 1 1
Remarks
37
Fig. 17 End Cover Assembly
38
Fig. 17 End Cover Assembly
Item No. 1 2 3 4 5 6 7 8 9 10 11
Parts No. Or Specification Z380-03501 380C3-01804 GB899-88 GB93-76 GB6170-86 ZF12M Z380-01805 GB898-88 GB93-76 GB5782-86 Z380-01802
Parts Description End cover Cover plate Stud M1240 Washer 10 mm Nut M10 Gearbox Fuel adjusting bracket Stud M1075 Spring washer 10 Bolt M835 Bracket
Quant ity 1 1 2 12 12 1 1 10 6 6 1
Remarks
39
Contact with:
Norsafe A/S
Address:PO Box 115N-4852 Frvik,Norway Tel: (+47) 3705 8500 Fax: (+47) 3705 8501
Website: www.norsafe.no
Jiangyin Norsafe F.R.P Co.,Ltd.

Address: Yuecheng Town,Jiangyin City, Jiangsu Province,China Tel: (+86) 510 86987718; 86986033 Fax: (+86) 510 86987371 Zip code: 214404 Website: www.norsafe.no

LifeBoats Phaethon Operation Manual HHI 1958

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OPERATION / MAINTENANCE MANUAL JYN65 TOTALLY ENCLOSED LIFEBOAT TANKER AND DRY CARGO VERSION

Jiangyin Norsafe F.R.P. Co., Ltd.

Telephone: Telefax: E-mail address:

+ 86 510 8698 7718 + 86 510 8698 7371

JYN65 TELB_Manual_Tor 3.36_rev02

JYN65 TELB_Manual_Tor 3.36_rev02

Direct all inquiries regarding spare parts and service to:

Jiangyin Norsafe F.R.P. Co., Ltd.

Telephone: Telefax: E-mail address:

+ 86 510 8698 7718 + 86 510 8698 7371 jynorsafe@cnorsafe.com

JYN65 TELB_Manual_Tor 3.36_rev02

CALL FOR SERVICE FORM

Send parts immediately without quoting Ordinary service call

Description of problem (please add more sheets if necessary):

JYN65 TELB_Manual_Tor 3.36_rev02

JYN65 TELB_Manual_Tor 3.36_rev02

JYN65 TELB_Manual_Tor 3.36_rev02

JYN65 TELB_Manual_Tor 3.36_rev02

JYN65 TELB_Manual_Tor 3.36_rev02

JYN65 TELB_Manual_Tor 3.36_rev02

Helmsman ensure the bottom plug is fitted and tight.

Turn on the main battery switch.

JYN65 TELB_Manual_Tor 3.36_rev02

Close the door

JYN65 TELB_Manual_Tor 3.36_rev02

Confirm the lifeboat is waterborne

Remove the safety pin

JYN65 TELB_Manual_Tor 3.36_rev02

JYN65 TELB_Manual_Tor 3.36_rev02

JYN65 TELB_Manual_Tor 3.36_rev02

Break the plexiglass cover

JYN65 TELB_Manual_Tor 3.36_rev02

VALVE(A) LOW PRESSURE SUPPLY TO CABIN REGULATOR LOW PRESSURE ADJUSTMENT

CABIN SUPPLY GAUGE CYLINDER PRESSURE GAUGE TO AIR BOTTLES

3 X 45 LTRS (20 MPa)

Emergency Air System

Regulator was pre-set at factory. It should not be re-adjusted.

JYN65 TELB_Manual_Tor 3.36_rev02

JYN65 TELB_Manual_Tor 3.36_rev02

JYN65 TELB_Manual_Tor 3.36_rev02

JYN65 TELB_Manual_Tor 3.36_rev02

Fig. 2 Detail of charging point

JYN65 TELB_Manual_Tor 3.36_rev02

Drain hole Water pipe 5L plastic container

JYN65 TELB_Manual_Tor 3.36_rev02

Painter release handle

Painter release hook (closed)

Fig. 5b Painter release hook (open)

JYN65 TELB_Manual_Tor 3.36_rev02

JYN65 TELB_Manual_Tor 3.36_rev02

CONNECTING PIN STARBOARD FORWARD

JYN65 TELB_Manual_Tor 3.36_rev02

Steering wheel Cable steering Emergency tiller Rudder stock

Fig. 8 Control console (Different customer specifications results in various instrumentation)

JYN65 TELB_Manual_Tor 3.36_rev02

JYN65 TELB_Manual_Tor 3.36_rev02

JYN65 TELB_Manual_Tor 3.36_rev02

JYN65 TELB_Manual_Tor 3.36_rev02

JYN65 TELB_Manual_Tor 3.36_rev02

INSPECTION LOG FOR LIFEBOAT INSPECTIONS.

JYN65 TELB_Manual_Tor 3.36_rev02

INSPECTION LOG FOR LIFEBOAT INSPECTIONS.

JYN65 TELB_Manual_Tor 3.36_rev02