Manual - Samsung 2021 PDF

INSTRUCTION MANUALS
Norsafe Order No. 5292

Client / Yard Samsung Heavy Ind Co.,Ltd.
Yard Hull No. 2021
Yard Order No.
Equipment type Serial number Description
GES40 MKII T 23782 Free Fall Lifeboat
Midget 530 MKII 50364 Waterjet Rescue Boat
HD-40 3708 Free Fall Lifeboat Davit
NDSC-25 3709 Rescue Boat Davit
Issue date and place 10.05.2013 Jiangyin, China
Rev. Issue date Prepared by Checked by Approved by

Contents:
1. MANUALS FOR GES40MKII FREE FALL LIFEBOAT

1.1 Operation & Maintenance manual for GES40MKII Lifeboat
1.2 Operation & Maintenance manual for NLDE-4 engine
1.3 Operation manual for ZF Marine gear, cod.310.01.0006e
1.4 Instruction manual for WJME battery charger
1.5 Instruction manual for Hydraulic steering gear
1.6 Survival manual
2. OPERATION & MAINTENANCE MANUALS FOR HD40 DAVIT

3. MANUALS FOR MIDGET530MKII RESCUE BOAT
3.1 Operation & Maintenance manual for Midget 530 MKII Rescue boat
1.1 Operation & Maintenance manual for Bukh Steyr 114HP engine
1.3 Operation & Maintenance manual for Alamarin 185j
1.5 Operation manual for K4 hook
4. OPERATION & MAINTENANCE MANUALS FOR NDSC-25

DAVIT
1. MANUALS FOR GES40MKII FREE FALL LIFEBOAT
1.1 Operation & Maintenance manual for GES40MKII Lifeboat
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OPERATION AND MAINTENANCE

MANUAL
GES 40 / GES 40 ULS / GES 40 MB ULS

FREE FALL LIFEBOAT
NORSAFE AS
P.O. Box 115
N-4852 Færvik
Telephone: + 47 37 05 85 00
Telefax: + 47 37 05 85 01
E-mail: mail@norsafe.com
Website: www.norsafe.com
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Rev.02/10 Operation and Maintenance Manual GES 40 and GES 40 MB Free Fall Lifeboat Page 1
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IMPORTANT NOTICE!
During the warranty period, all necessary spare parts must be supplied by
NORSAFE AS.
The use of spare parts supplied by other suppliers violates and forfeits the warranty.
Rev. Reason for issue Date By Chk
1 ISSUED FOR CONSTRUCTION 21.07.07 TT POP
2 UPDATED WITH GES 40 MB ULS 29.01.10 KGR BS
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LIST OF CONTENTS
1 GENERAL SPECIFICATION ............................................................................. 10
1.1 CERTIFICATION ............................................................................................... 10
2 OPERATING INSTRUCTIONS LIFEBOAT ....................................................... 11
2.1 RESTRICTIONS IN USE ..................................................................................... 11
2.2 BOARDING THE LIFEBOAT ................................................................................. 11
2.3 FREE FALL LAUNCHING MODE (NORMAL) ........................................................... 12
2.4 FREE-FALL LAUNCHING MODE (EMERGENCY) ..................................................... 14
2.5 RECOVERY OF LIFEBOAT .................................................................................. 15
2.6 TO ENSURE BOAT IS SECURELY ENGAGED WITH BOLT ON DAVIT. .......................... 16
2.7 SECURING OF LIFTING SLINGS .......................................................................... 16
2.8 BOAT STOWAGE .............................................................................................. 17
2.9 PROCEDURE FOR TRAINING FREE FALL OPERATION ............................................ 17
3 SYSTEM DESCRIPTION ................................................................................... 19
3.1 GENERAL ....................................................................................................... 19
3.2 STEERING CONSOLE ........................................................................................ 19
3.3 STEERING SYSTEM .......................................................................................... 19
3.4 CHECKS BEFORE STARTING ............................................................................. 20
3.5 ENGINE STARTING (NORMAL)............................................................................ 20
3.6 ENGINE STARTING (EMERGENCY) ..................................................................... 21
3.7 OPERATION .................................................................................................... 22
3.8 STOPPING ENGINE .......................................................................................... 22
3.9 FREE FALL HOOK RELEASE SYSTEM .................................................................. 22
3.10 SPRINKLER SYSTEM (TANKER VERSION ONLY) ................................................. 23
3.11 EMERGENCY AIR SUPPLY SYSTEM (TANKER VERSION ONLY) ............................. 23
3.12 OPERATING THE EMERGENCY AIR SYSTEM (TANKER VERSION ONLY) ................. 25
3.13 UNDER- AND OVERPRESSURE RELIEF VALVES ................................................. 25
3.14 HATCHES .................................................................................................... 25
3.15 BILGE SYSTEM ............................................................................................. 26
3.16 EMERGENCY STEERING TILLER ...................................................................... 26
3.17 FUEL TANK .................................................................................................. 26
3.18 WATER AND PROVISION TANK ........................................................................ 27
3.19 SEA ANCHOR ............................................................................................... 27
3.20 ELECTRICAL SYSTEM .................................................................................... 27
4 DRAWING .......................................................................................................... 28
5 MAINTENANCE INSTRUCTIONS LIFEBOAT. ................................................. 29

5.1 LOOSE EQUIPMENT ......................................................................................... 29
5.2 ENGINE .......................................................................................................... 29
5.3 PROPULSION .................................................................................................. 30
5.4 FREE FALL RELEASE SYSTEM .......................................................................... 30
5.5 HATCHES ....................................................................................................... 31
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5.6 ELECTRICAL SYSTEM ....................................................................................... 31

5.7 EMERGENCY AIR SUPPLY SYSTEM (TANKER VERSION ONLY) ................................ 32
5.8 SPRINKLER SYSTEM (TANKER VERSION ONLY) .................................................... 33
5.9 BILGE SYSTEM ................................................................................................ 34
5.10 LUBRICATION AND GREASING POINTS. ANTICORROSION MAINTENANCE.............. 34
5.11 HYDRAULIC STEERING SYSTEM ...................................................................... 35
5.12 SEAT HARNESS ............................................................................................ 35
6 MAINTENANCE SCHEDULES .......................................................................... 36
6.1 WEEKLY MAINTENANCE ................................................................................... 36
6.2 MONTHLY MAINTENANCE ................................................................................. 37
6.3 ABANDON SHIP TRAINING AND DRILLS ................................................................ 39
7 INSPECTION LOG FOR MONTHLY MAINTENANCE INSPECTIONS ............. 40
8 LOOSE EQUIPMENT LIST ................................................................................ 45
VALIDITY
This manual is valid for Norsafe Free Fall lifeboat GES 40, GES 40 ULS, GES 40
MB and GES 40 MB ULS max. 64 persons.
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INTRODUCTION
The lifeboat is moulded from fire-retardant polyester resin. The space between the
floor liner and the hull, and the canopy liner and canopy is filled with polyurethane
buoyancy foam, which provides the lifeboat with enough buoyancy to remain afloat
and upright even if holed below the water line. The lifeboat is totally self-righting
even fully loaded with persons and flooded. Therefore it is important that all
passengers fasten their safety harness and remain in their seats at all times. The
lifeboat is released from the fixed hooks on the davit by a hydraulic pump mounted at
the helmsman seat. Should this system fail to operate an identical and totally
separate system is installed at the aft bulkhead.
Steering is via a steering nozzle which provides excellent thrust and manoeuvrability.
The boat's main entrance door is situated on the aft bulkhead, additional hatches are
provided aft of the helmsman's position and on the forward end of the canopy. The
steering position has a steering console containing the normal hydraulic steering,
engine instrument panel and engine control lever.
The main engine starting battery and emergency engine start battery are contained
in a box aft of the engine compartment. A manual bilge pump is provided on the aft
bulkhead. There is also a manual bilge pump in front of the boat. Natural ventilation
is achieved via an automatic valve located on the aft bulkhead. This valve also
prevents the cabin becoming dangerously under pressured while the engine is
running. An overpressure relief valve is also mounted on the aft bulkhead. This valve
prevents the cabin becoming dangerously over pressured when the emergency air
system is in operation.
The boat is fitted with an type approved diesel fuelled water cooled engine. Full
detailed specification of the engine is contained in the engine manufacturers manual.
The lifeboat engine has got one main- and one emergency start system. The
systems are totally independent and separate. The battery switches are mounted on
the aft bulkhead port side. Battery charger for the starting batteries is located next to
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the battery switches. The charger is connected to the ship/platforms electric power
supply via a plug located on the outside of the aft bulkhead. Supply power from the
ship to the charger is normally 42 V AC. The charger converts this power to 12 V DC
to charge the lifeboat batteries when it is on the davit. The craft is fitted with
independent hydraulic cylinders (mounted aft). These cylinders are designed as the
principal free fall release and the emergency free fall release. Pumping either of the
hydraulic pumps (one mounted at the helmsman’s position and one mounted stb
side on the aft bulkhead) will lift the boat's stern clear of the fixed bolts welded to the
davit allowing the boat to free fall.
WARNING!
Before attempting this procedure the operator should be fully trained in all
operational modes of both this boat and it's launching appliance. Failure to follow
the procedures detailed in this manual may result in death or serious injury. In
addition to the free fall launch mode the craft can be lowered and recovered from
the sea by using the davit fall wire and attaching the boats lifting slings to the
lowering/recovery hooks on the davit traverse.
The seating arrangement in the boat allows for easy and quick boarding of all
personnel. The seats are arranged to face aft (except the helmsman).
The backrest of the seat is angled forward which will position the occupant in a
favourable angle when the boat enters the water during free fall. Thus minimising the
gravitational effect on the body during free fall accelerations and decelerations.
Each seat is fitted with a safety harness.
The free fall escape is the main means of evacuation. Always use this
concept whenever possible.
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Tanker version only:

An external water spray system is installed on the canopy of the boat which, when
operated, will provide the outside of the boat with a protective layer of water should
the boat encounter a fire on the surface of the water. The sprinkler control lever is
located under the deck. Internal air cylinders will, when operated, provide the
passengers and engine with air at a controlled rate for at least 10 min.
Emergency steering via a tiller can be operated from within the lifeboat. The centre
tank section contains the water tank and equipment tank, there is also access to the
air cylinders. The fuel tank is located aft of the engine room. A fuel shut-off valve is
located on the top of the fuel tank. There is access from the engine compartment to
the propeller shaft and sprinkler pump.
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Supplier information
Norsafe AS was established in 1903 as Jørgensen & Vik in Grimstad. At first they
manufactured wooden lifeboats and during the 1. world war the first partially
enclosed lifeboats were delivered. Aluminium was used from 1952 to 1958. Since
1958 fibreglass has been used as building material.
Norsafe AS moved from Grimstad to Arendal in 1990, and delivers today a wide
range of different lifeboats; from small rescue boats, through free-fall boats to
lifeboats.
Our market is ship owners and shipbuilders, and offshore oil field installations world-
wide.
Postal address: Norsafe AS

P.O.Box 115
N-4852 FÆRVIK
Norway
Visiting address: Tybakken, Tromøy, Arendal, Norway

Phone: +47 37 05 85 00
Telefax: Adm: +47 37 05 85 01
Service: +47 37 05 85 11
E-mail: mail@norsafe.com
Internet: www.norsafe.com
Due to continuous development, we reserve the right to change our product

specifications and manuals without notice.
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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 injury or death to personnel.
A CAUTION!
is an operation procedure, statement or practice which, if not strictly
followed, could result in damage to equipment or loss of mission
effectiveness.
How to order spare parts

Direct all inquiries regarding spare parts and service to the address on previous side.
Please quote the Norsafe boat build number when contacting Norsafe. The number
is given on enclosed certificates, and is also shown on the name plate on the boat.
During the warranty period, all necessary spare parts must be supplied by Norsafe
AS.
Please quote the Norsafe davit build number and the boat build number when
contacting Norsafe. The numbers are given on enclosed certificates, and are also
shown at the name plate close to the lifeboats aft door.
Regarding warranty claims:

Please note that all claims will be fully invoiced until accepted as a warranty claim by
Norsafe a.s. Please also enclose a copy of the relevant boat/davit certificate.
The warranty periode is normally limited to max. 18 months from delivery of
equipment or 12 months from delivery of vessel to owner, whichever comes first.
All claims are handled according to "Orgalime S 92" which is enclosed in this manual
under section 12, Appendix B. Please fill in a copy of the "call for service form" under
section 13, Appendix C.
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1 GENERAL SPECIFICATION
GENERAL TECHNICAL SPECIFICATION GES 40 / GES 40 ULS / GES 40 MB ULS FREE FALL
LIFEBOATS
Principal dimensions/data: GES 40 and GES 40 ULS ver1, ver2 and ver2a
Length over all 12,0 [m], (For GES 40 MB ULS 12,5 [m])
Breadth overall 2,75 [m]
Height overall 3,42 [m]
Capacity, maximum 64 persons
Construction Fire-retardant Glassfibre Reinforced Polyester (GRP)
Colour Orange (RAL 2004)
Speed (minimum) 6 [knots]
Max. installation height 30 [m], (For GES 40 MB ULS 32 [m])
TECHNICAL SPECIFICATION GES 40 / GES 40 ULS / GES 40 MB ULS FREE FALL LIFEBOATS
Principal GES 40 GES 40 GES 40 GES 40

GES 40
dimensions/data: ULS ver1a ULS ver2 ULS ver2a MB ULS
Weight boat with
8200 [kg] 10000 [kg] 9675 [kg] 8850 [kg] 9450 [kg]
equipment
Davit load w/64
persons 13000 [kg] 14800 [kg] 14475 [kg] 13650 [kg] 14250 [kg]
(75kg/person)
Davit load w/64
persons - 15760 [kg] 15425 [kg] 14610 [kg] 15210 [kg]
(90kg/person)
1.1 Certification
Totally Enclosed Free Fall Lifeboat designed and manufactured according to latest
SOLAS, Classification Society and National Authority requirements.
The boats with notation ULS are according to the “OLF Lifeboat Project, General
Overview and Structural Methodology, document nr. 07D9400263689.”
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2 OPERATING INSTRUCTIONS LIFEBOAT
WARNING!
Before operating any system onboard this lifeboat or it's launching appliance,
personnel must be fully trained in all modes of equipment operation.
Personnel who are unfamiliar with this lifeboat and launching appliance should not
attempt to perform any operation or maintenance procedure. If any doubt, contact
Norsafe A/S.
2.1 Restrictions in use

- Norsafe davit is only to be used in lowering/hoisting operation with boat
connected to hook.
- Norsafe davit is not to be used as a crane, meaning replacement of boat with
e.g. cargo net is not allowed.
- Norsafe davit is only to be used with boat weight not exceeding S.W.L. for the
davit arrangement.
CAUTION!
Any violation to these restrictions will invalidate the guarantee conditions.
2.2 Boarding the lifeboat

Personnel should, after being assigned a lifeboat, stop outside the
lifeboat and await instructions from the lifeboat crew. When told to
board, personnel should enter the lifeboat quickly and orderly
dressed in survival suits or carrying their lifejackets and properly
attached footwear. DO NOT wear the lifejackets until after the
drop.
Lifeboat crew prepares the lifeboat by:

1. Open aft entrance door and secure door in opened position.
2. Helmsman enters the boat, turns main battery switch to “ON”
and turns on the cabin light.
3. Check for loose items inside the boat.
4. Make sure that forward hatch and hatch above drivers seat
are closed.
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5. If there is danger of toxic gases. Prepare the air system by opening valves on
all air cylinders. Control that the air bottles are open by checking the pressure
in the bottles which is given on the air regulator.
6. Check VHF radio.
7. Helmsman verifies that rudder is in straight forward direction.
8. Helmsman take position in the free fall seat behind driving position and fasten
seat belts
9. Personnel enter the lifeboat. The forward seats should be occupied first,
except if only a small number of personnel are to use the lifeboat, when it is
recommended that personnel are concentrated in the middle of the lifeboat.
N.B. Board the lifeboat evenly both sides. The last seat by the emergency
hydraulic pump should be reserved for lifeboat crew member who should
board last after doing pre-launch checks.
10. Once seated, secure the safety harness and tighten adjustable lap strap.
Place foot on the floor against the seat in front and push body and head firmly
against the backrest of your own seat, keep head facing aft, do not turn to
side. Cross arms and grasp shoulder straps. Remain seated after launch
unless instructed otherwise.
DANGER!
Do not press knees against the seat in front as this may cause injury to the knees
when the seats flex during launch.
2.3 Free Fall launching mode (normal)

Before attempting any free fall launch it is vital that the crew of the lifeboat ensures
that the boat will achieve a clean unrestricted path down the skidway and that the
launch zone is clear of obstructions. The following checks should be made before
commencing free fall launch.
1. Lowering/retrieval hooks have been disconnected from the lifeboat lifting
slings and the slings are securely stowed on top of the boat. The boat shall
always have the lifting slings disconnected, leaving boat ready for immediate
use in an emergency.
2. All ropes etc. are clear of the lifeboat and launching ramp.
3. All personnel are seated and even distributed in the lifeboat and have
fastened safety harness.
4. Electrical plug on outside of lifeboat has been disconnected.
5. Steering nozzle is in mid/straight forward position.
6. Lashing arrangement has been disconnected.
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7. All hatches and openings are securely closed and locked.

8. Helmsman confirms that all hatches, doors and openings are closed.
9. Sit down in aft seat behind emergency release pump and fasten safety
harness.
10. Verify that all personnel are seated and have fastened safety harness.
11. Helmsman asks for confirmation that all hatches, doors and openings are
closed.
12. Helmsman confirms that landing area is clear.
13. Helmsman checks valve on pump is turned fully to “free fall” position and
removes safety pin.
14. Helmsman checks that gear lever is in “neutral” and start engine.
15. Helmsman informs personnel that boat is about to be released and starts
pumping.
Note: after a few strokes, pressure should be felt in the pump handle and the
boat will start to lift. Within a short period the boat will be released. Should no
pressure be felt on the pump within a few seconds or the boat is not released,
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check that the valve on the pump is turned fully to “free fall” position. If the
system still does not work, commence the emergency launching procedure.
16. After launch helmsman moves to the driver’s seat as quickly as possible.
17. If the air system is to be used, helmsman opens the valve according to
instructions in the boat.
18. After launch, helmsman engages the propeller and steers the lifeboat away
from danger.
19. Turn the valve of the pump to “recovery” position to allow hydraulic cylinder
below boat to retract.
20. Close down air and sprinkler system when it is no longer needed.
21. All personnel shall remain in their seats unless instructed otherwise by the
crew of the lifeboat.
2.4 Free-Fall launching mode (emergency)

If a free-fall launch has been unsuccessfully
attempted using the free-fall pump handle (normal)
and the lifeboat remains on the fixed bolt on the
davit, the emergency free-fall launch mode should
be followed. This procedure is identical to the free-
fall launch mode (normal) except that the other
hydraulic pump should be used. This pump is
operated by crew member sitting in the aft seat.
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Helmsman instructs crew member to operate pump. All other points remain
unchanged.
NOTE: It is possible to use both pumps at the same time.
2.5 Recovery of lifeboat

Before recovery of the boat, it must be ensured that both hydraulic release jacks
are fully retracted. Turn valves on both pumps to “recovery” position and insert
safety pin. The picture shows that the left jack is not retracted.
CAUTION!
If the jacks are not retracted, it is not possible to hang the boat on the davit bolt,
and the jacks will be damaged.
See davit and winch instruction manuals for details of their operation. The lifeboat
is recovered by lowering the traverse down to the lifeboat. The lifting slings are
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then, one at a time, removed from its securing point and the ring hooked onto the
hooks at the ends of the traverse. Take care to hang the slings without twisting.
WARNING!
This operation is very difficult and dangerous in all but the best of weather
conditions.
2.6 To ensure boat is securely engaged with bolt on davit.

Recover the boat following the instructions in the davit and winch manuals.
1. Visually check that securing bracket on boat has passed over the bolt on davit.
2. Carefully release the winch brake to allow the boat to lower on to the bolt on
davit. It may be necessary to pull the lifeboat backwards onto the davit bolt by
means of chain block or similar secured between securing bracket on the
lifeboat and a suitable point on the davit/rig/ship.
3. From below the boat check that the brackets on the boat have settled down on
the bolt on the davit. The correct position will leave a gap of approx. 1 - 5 mm
from underside of bracket to the bolt.
4. Secure the boat with lashing across the aft deck.
2.7 Securing of lifting slings

It is extremely important that if the lifting slings are attached to the boat, even during
free fall launch, they must be properly secured. If the slings are removed from the boat,
this chapter may be disregarded. It is not possible to lower the lifeboat by crane or davit
then.
Proper storage and securing of the lifting

slings is essential to a safe and successful
free fall launch. Therefore it must be stressed
that the lifting slings be stowed as shown on
the figure. Care must be taken to ensure that
the lifting slings are clear of the skidway and
cannot be fouled on any part of the launching
appliance or platform structure.
Before attempting any free fall launch, always

ensure that the lifting slings are properly
stowed and secured as shown on the figure.
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2.8 Boat stowage

The craft should always be left in a state of continuous readiness for any of the
described launching modes. The following check list should be followed as a minimum.
In addition the detailed maintenance schedules and procedures should always be
maintained:
1. Ensure boat is securely locked in the bolt on the davit.
2. Secure lashing arrangement.
3. Lower the davit traverse and disconnect the lifeboat lifting slings securing the
slings to the lifeboat
4. Turn of battery switches and connect lifeboat power supply
5. Fill lifeboat diesel tank.
6. Check all lifeboat equipment is securely stored.
7. Bilge any water from lifeboat.
8. Re-set both hydraulic free-fall pumps.
9. For tanker version only: open the sprinkler water inlet valve to drain any trapped
water. Then close the valve. Flush with fresh water. Open, and then close the
valve again.
10. Close all doors and hatches.
CAUTION!
If the hydraulic pumps have been used for free-fall or during lowering by wire, the
hydraulic pressure must be relieved to allow the hydraulic cylinders below the boat
to retract. Never attempt to recover the boat with the hydraulic cylinder extended
as they will be damaged by the bolt on davit.
2.9 Procedure for training free fall operation

1. Connect chains, turnbuckle and shackles as shown below.
2. Tighten turnbuckle until the chain is very tight.
3. Connect lifeboat slings to the boat and davit lifting transverse beam.
4. Operate davit so that the wire suspension is slightly aft of the boat COG.
5. Tighten wire, but do not lift the lifeboat (forward sling will be tight, aft sling will be
loose).
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6. Release aft lashing arrangement.

7. One person to board the lifeboat, close all hatches and take a seat and secure
seat belt.
8. Operate the free fall release mechanism from inside the boat until the boat is
free from the bolt on the davit
9. On signal from person outside that test is acceptable, person inside lifeboat
release pressure from release mechanism.
10. If lifeboat does not engage with the bolt on davit, person on outside operate
crane to lift lifeboat into stowed position.
11. Make sure boat is securely engaged with bolt on davit.
12. When lifeboat is safely stowed, person inside boat may exit.
13. Secure aft lashing and disconnect lifeboat slings from crane.
14. Disconnect chains, turnbuckle and shackles.
WARNING!
Chains, wires, turnbuckles and shackles to be controlled every year and changed
if needed. Check pad eyes and brackets for cracks at the same control.
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3 SYSTEM DESCRIPTION
3.1 General
3.2 Steering console

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 marker light.
Compressed air regulator is mounted between the front windows.
3.3 Steering system

On the helmsman's steering console is the steering wheel connected to a hydraulic
helm pump. From the back of the pump two hydraulic hoses are connected. These
hoses are connected to a by-pass valve located on top of the steering cylinder which
is linked to the rudderstock via a tiller arm. Externally there is a rudder nozzle which
is supported by a conventional solepiece arrangement. Turning the steering wheel
port or starboard will turn the rudder nozzle in the desired direction.
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1. Hand pump
2. Charge plug for hydraulic oil
3. Oil lock
4. High pressure hose
5. By pass valve
6. Hydraulic rudder machine
3.4 Checks before starting

Starting any engine can be dangerous in the hands of inexperienced people. Before
attempting to start any engine, the operator should be fully conversant 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 system is primed.
- Check that all water drain plugs and cocks are closed.
- Check that the water level in the header tank is filled up with mixture of water/anti-
freeze.
CAUTION!
Under no circumstances must the engine be started without liquid in the cooling
system
- Ensure that the gearbox is in neutral.
3.5 Engine starting (normal)
The normal engine starting is 12 V electric controlled by the helmsman. The main
battery switch is located on the aft
bulkhead port side and must be turned
to the "ON" position to activate the
system. To start the engine, proceed as
follows:
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1. Before attempting to start the engine, the operator should be familiar

with the safety precautions as described earlier.
2. Turn main battery switch to "ON" position.
3. Switch off and disconnect external power supply.
4. Check that fuel valve is open.
5. Push in the button on the throttle/gear control lever and push lever
forward.
6. Dependent on temperature, turn the starter switch into the preheat
position (position 1) and hold it for 10-20 seconds. Then turn the switch
further into position 2 to energise the starter. Release immediately
when the engine starts, and it will return to position 0. The alarm light
as well as the charging light 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 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.
In very cold weather (below approx. -10°C), it could be necessary to
increase the glowing time to approx. 30 seconds and run the starter
motor for up to 1 minute.
7. Pull throttle control back to idling position (button on side of control
handle will pop-out when lever is in neutral position).
3.6 Engine starting (emergency)

The emergency starting system is 12 V electric controlled by the helmsman. The
emergency battery switch must be turned to the "ON" position to activate the system.
To start the engine using the emergency starter, proceed as follows:
1. Turn the main battery switch to the "OFF" position.
2. Turn the emergency battery switch to the "ON" position.
3. Switch off and disconnect the external power supply.
4. Check that the fuel valve is open.
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5. Push in the button on the throttle/gear control lever and push lever
forward.
6. Hold starter switch to glow position for 20-30 seconds and release.
7. Press the emergency start button on steering console until engine
starts.
8. Pull throttle/gear control lever back to neutral position (button on side of
control handle will pop-out at neutral position).
3.7 Operation
When the engine has started, leave the engine running at idle or fast idle for a few
seconds to ensure that oil will reach all necessary parts before racing the engine.
Check immediately after starting that the oil pressure gauge and the voltmeter show
normal values and that all alarms are quiet. If abnormal values are shown, or any
alarm sounds during operation, the engine should be stopped immediately and the
cause investigated. To select forward gear move lever out of neutral position by
pushing it forwards. To increase speed, continue to push the lever away from you.
When it stops the engine is running at maximum forward speed.
3.8 Stopping engine

Move control lever into neutral position. Allow the engine to idle for approx. 2
minutes to cool. Stop the engine by pressing the stop button. Switch off the main
battery switch.
Should the engine stop button fail to stop the engine, close the fuel shut-off valve
located on top of fuel tank.
3.9 Free Fall hook release system

This consists of a manual hydraulic pump connected to a hydraulic cylinder mounted
on the release hook on the transom. By pumping, the cylinder will extend and lift the
boat hook over the bolt on the davit and thereby releasing it. For redundancy
reasons, two completely separate systems are installed. These systems are
assembled, filed with oil, and checked for leaks and operation before leaving our
factory. Very little maintenance is required, but should any problem occur, Norsafe
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as should be contacted as this system is of vital importance to the operation of the

lifeboat.
3.10 Sprinkler system (tanker version only)

The sprinkler system is designed to cover the entire surface of the boat with a film of
sea water when the boat is waterborne. This will protect the boat and occupants
should they have to encounter a fire on the sea. When the boat is waterborne, open
the water inlet valve located in front in the engine compartment. This allows a belt
driven self priming sprinkler pump to circulate sea water through the boat internal
piping to a manifold mounted externally on the canopy. The water is then distributed
through port and starboard sprinkler rails which are fitted with spray nozzles that
disperse the water into a thin film which covers the boat.
It is important that after using the sprinkler system, it must be flushed with fresh
water to remove salt deposits. To flush the system, remove a sprinkler nozzle from
the after spray pipes and connect a fresh water supply. Flush the system for 15 min.
Furthermore the sprinkler pump drain valve should be opened and the pump
drained, closing the drain valve afterwards.
CAUTION!
As water is also dispersed on the windows, visibility is severly restricted when the
sprinkler system is in operation.
3.11 Emergency air supply 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.
This system is designed to supply the interior of the craft with air for the passengers
and engine for 10 minutes of operation. The system consists of the following
components:
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1. 4 x 50 Lt. air cylinders pressurised to 200 BAR.

2. High pressure air hoses.
3. Air regulator.
4. Re-charging point with valve. Threads: 5/8" BSP.
5. Low pressure air hoses.
WARNING!
High pressure air can be extremely dangerous and therefore this system should
only be operated and maintained by trained personnel.
CAUTION!
The system contains air for approx. 10 min. running at max. R.P.M. to provide
maximum protection for the occupants it should be operated as follows:
The emergency air system should be kept fully charged at all times i.e. if the
pressure drops below 180 bar the system should be recharged to 200 Bar, see
maintenance section.
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3.12 Operating the emergency air system (tanker version only)
1. Decide on launching mode to be used and follow the detailed

instructions for that launch mode up to closing all hatches.
2. Check that all air cylinders are fully open by turning the valves installed
on their necks anticlockwise.
3. Start engine in neutral and reduce throttle to idle.
4. Launch boat by chosen method.
5. When waterborne, open valve "A" on high pressure side of regulators.
6. Open valve “B” on low pressure side of regulators until satisfactory flow
is achieved.
7. Select gear, increase speed and steer away from danger.
3.13 Under- and overpressure relief valves

Since the engine uses air for running, an underpressure relief valve is fitted to let air
into the boat and prevent discomfort to the passengers. For a tanker version, when
the air system is in use, an overpressure relief valve is fitted to let excessive air out
of the boat. It is designed to give a small overpressure to prevent toxic gases from
entering the boat and at the same time prevent too high pressure inside the boat.
It is important that these valves move freely. This can be verified by pulling the bolt in
the centre of the valve and on release, it should move back. The valves are situated
on the embarkation door aft.
3.14 Hatches
This lifeboat has 3 hatches, a forward hatch on the canopy, a steering tower hatch at
the helmsman position and an aft boarding hatch/door. It is possible to open and
close all hatches from inside and outside the craft.
WARNING!
It is vital to the safety of all passengers and crew that all hatches, doors and
opening for radio antenna (if fitted) are securely closed before any free-fall launch.
Failure to comply with this warning may result in death or serious injury.
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3.15 Bilge system
The lifeboat has two bilge pumps installed. One is located to starboard on the aft
bulkhead. The suction hose is placed in the engine compartment. The other bilge
pump is mounted in the front on the port side of the lifeboat. It’s suction hose is
coiled up next to the pump. To use, uncoil hose and place end in the compartment to
be emptied. To operate bilge pump: Remove bilge pump handle from it's stowed
position next to pump and install on pump. Pump bilge pump handle to remove
water.
3.16 Emergency steering tiller
Should the primary hydraulic steering fail, the craft can still be steered by the
emergency tiller. To operate this system proceed as follows:
1. Remove emergency tiller from it's stowed position and place over top of
rudderstock.
2. Turn the by-pass valve located on the top of the steering cylinder 90
degrees.
3. Steering may now be operated from the aft of the boat under guidance
of the helmsman.
3.17 Fuel tank

A diesel fuel tank is located under the step just inside the entrance door. The tank
capacity is sufficient for 24 hours operation at full speed. The tank is filled from the
filler plug located on the outside aft next to the entrance door. Before removing the
filler cap, always clean around it to prevent dirt etc. from entering the tank.
DANGER!
If any fuel is spilled on the GRP surfaces, always thoroughly remove all traces as
diesel fuel will make these surfaces extremely slippery.
There is a fuel shut-off valve on top of the fuel tank. When servicing the engine or
changing the fuel filter, this valve must be closed. Also close in case of fire to the
engine.
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3.18 Water and provision tank

The water and provision tank is located on the centre tank section around midships.
It is recommended that the water being in sealed containers. Quantities of these
items can be found below.
3.19 Sea anchor

After removing sea anchor from the storage tank, deploy as follows:
Secure the end of hawser and tripping line to the attachment point forward of
the front hatch.
Throw sea anchor into the sea. For proper operation, ensure that tripping line
is slack when hawser line is taut.
Recover sea anchor by pulling tripping line.
3.20 Electrical system

The boats electrical system is powered by 12 V batteries. To activate either the
main or the emergency electrical system, turn on the main battery switch or the
emergency battery switch.
When the boat is stored in the davit, 42 V AC power supply is connected. Power is
supplied to a dual standby battery charger which convert this 42 V AC supply to 12 V
DC for charging the lifeboat batteries.
The lifeboat should always be left with the main and emergency switches turned off
and the battery chargers turned on to maintain the lifeboat batteries in a fully
charged condition ready for immediate use.
WARNING!
When opening the battery compartments make sure that potentially explosive
gases are ventilated. Also never use any naked lights.
Do not attempt to start the engine until the external power supply has been
disconnected.
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4 DRAWING
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5 MAINTENANCE INSTRUCTIONS LIFEBOAT.

Foreword
Maintenance to this lifeboat is extremely important, as the duties it fulfils require the
boat to be in a state of continuous readiness. In order to keep a record of continuous
maintenance, sign the attached log sheet in chapter 8 after each inspection.
Continue on additional sheet when the enclosed log is full.
5.1 Loose equipment

Loose equipment should be periodically checked to ensure equipment is properly
stowed and is in serviceable condition.
See list at the end of the document
5.2 Engine
The engine maintenance and checks should be performed in accordance with
engine manufacturer instruction manual, although some basic engine checks will be
covered here.
5.2.1 Fuel / Diesel system

Use only diesel of a quality equal to or higher than prescribed in manufactures
manual. There is a fuel filter on the engine. See engine manuals for maintenance
procedure of this. Remember to close the fuel valve on top of the fuel tank before
working on the fuel system to avoid siphoning of fuel into the boat. The fuel tank
should be filled 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.
5.2.2 Engine oil level

Check the lube oil level before starting. Ensure that the oil level is within the marked
field on the dipstick. Refill if necessary on top of the crankcase, make sure not to
exceed the maximum mark on the dipstick. Note that the mark on the dipstick applies
both when the boat is hanging in the davit and when it is on the water.
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5.2.3 Cooling system

Check the cooling water level against the "Full" and "Low" marks on the subtank.
Refill subtank from the top cap on the heat exchanger.
5.3 Propulsion
NOTE Since a free fall lifeboat is almost never driven on the water, maintenance to
the propulsion system is mainly limited to verification of operation, visual inspection
for corrosion and greasing VERY sparingly.
5.3.1 Drive shaft

The coupling between engine and propeller must be inspect for corrosion, cracking
and loosening of bolts.
5.4 Free Fall Release system
5.4.1 Inspection
Check pump and cylinder for oil leaks. Remember both main and emergency
systems. Hose connections may be tightened slightly if leaks are found. Other leaks
or damaged or cracked hoses need attention from Norsafe service personnel.
If any leaks are found, check oil level at top of pump by opening centre bolt that has
a dipstick attached. Oil level should be on the blue end of the dipstick with the piston
retracted. Refill with hydraulic oil as required. Do not overfill; an airspace is required
for correct operation.
5.4.2 Testing
Use ONE of the testing methods below, depending on installed equipment. Normally
this test is performed once a year.
5.4.3 Testing WITH equipment for simulated free fall

Install turnbuckles between pad-eye on davit and bracket on aft end of boat, one
each side. Tighten with spanner. One person takes up position in the free fall seat
and fasten safety belt. This person must have radio contact with one person outside.
Close entrance door and remove aft lashing. Person inside operates release pump
to lift the boat clear of the davit bolt. Person outside informs when the boat is lifted
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high enough. Open valve on pump and let boat be lowered back on the bolt, person
outside verifies. Repeat using emergency pump. Replace aft lashing and open door.
Remove turnbuckles. To check that the jacking system is in good order, proceed as
follows:
5.4.4 Testing WITHOUT equipment for simulated free fall

Verify that the lashing across the aft deck is secure and has a slight slack. The aft
lashing should be tight enough to prevent any more than a few mm lift of the boat. It
will then act as a safety against release of the boat. One person enters the boat,
close the door and take up position in the free fall seat behind the helmsman
position. Another person stands outside the boat with a wooden stick or similar to
knock on the boat to signal to the person inside. The person inside starts pumping
the handle slowly. Once resistance is felt, only a couple of strokes should be
necessary. The outside person watches the boat carefully and signals the person
inside once the back of the boat lifts up a few millimetres. Inside person stops
pumping and relieves the pressure to retract the piston. Outside person confirms that
the boat goes back down to original position. If, due to friction, it does not, a suitable
jacking system must be used to bring the boat down before continuing. Repeat for
emergency release pump. Inside person the takes up position in seat behind the
emergency release pump.
WARNING!
The boat must only be lifted a few mm to verify that the system gives sufficient
force to lift the boat. The boat may be released if it is lifted more than 20mm.
5.5 Hatches
Rubber gaskets around hatches should be checked for deterioration. If any signs of
cracking or brittleness exist, gasket should be replaced immediately.

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
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batteries need to be replaced, use sealed batteries only. Other types may cause
explosion due to hydrogen release.
NOTE
The wiring diagram and the components are described in the manufacturers
engine instructions and operation manual delivered with the lifeboat.
5.7 Emergency air supply system (tanker version only)

Should the air pressure in any of the air cylinders drop below 180 Bar the system
should be recharged to 200 Bar. To recharge the system proceed as follows:
1. Make sure valve "A" is closed.
2. Close valve «B».
3. Connect charging line to charging point (see details below)
4. Open valve «A»
5. Open valves on all air cylinders.
6. Start compressor and charge to 200 Bar.
7. Stop compressor when pressure is 200 Bar.
8. Close valve «A» and lock with cable tie.
9. Close valves on air cylinders.
10. Open valve «B» to relieve pressure at regulator.
11. Disconnect charging line.
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Recharging air must be of breathable quality, dry, oil free, clean and with water
content of no more than 3-4PPM. Excessive moisture will cause misting, internal
freezing of the regulator, which may then jam in either open or closed position. This
will temporarily (until ice melts) disable 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.
5.8 Sprinkler system (tanker version only)

It is important that after using the sprinkler system in sea water, it is flushed with
fresh water to remove salt deposits. To flush the system proceed as follows:
1. Close intake valve.
2. Remove aluminium nozzle from a holder near the entrance door of the
lifeboat.
3. Fit brass hose connector to nozzle holder and tighten by hand only. Hose
connector is stored in the equipment tank.
4. Install ¾" hose on connector and flush for 15 minutes with fresh water at
maximum 10 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.
5. If some parts of the spray system have 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.
6. Remove hose connector and replace nozzle in original position.
7. Open inlet valve to drain inlet piping.
8. Open drain valve on bottom of pump to drain pump.
9. Close drain valve and inlet valve.
"Dead ends" in sprinkler system will automatically drain through drain holes.
If any of the spray nozzles become clogged, they should be removed and cleaned
immediately and replaced in their original position. The tension of the sprinkler pump
V-belts should be checked. Correct tension is approx. 12 mm depression of the belt
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at mid-span. In general the V-belts should be neither too tight nor too loose.
Overtightness results in added bearing pressure.
The sprinkler control lever should move freely from the open to closed position. If
sticking occurs, lubricate with water repellent grease at control lever intake valve.
5.9 Bilge system

If the pump chokes or fails to prime, 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.
5.10 Lubrication and greasing points. Anticorrosion maintenance

Following mechanisms must be maintained according to the maintenance list with
water resistant grease, remove old and hard grease as required:
Under and over pressure release valves (on aft door). Grease very sparingly.
Handles of hatches inside and outside.
Hydraulic jacks for boat release.
For protection against corrosion, brush with wire brush and spray surfaces with
TECTYL, alternatively vipe with oily rag.
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5.11 Hydraulic steering system

The hydraulic steering system should be free of leaks and contain no air within the
system. Check that no hydraulic fluid is present at any of the hose connections. If
leaks are found, tighten the connection. The system must be free of air to operate
properly, if it is suspected that air is in the system. Proceed as follows:
1. Remove the filler cap on top of the helm pump at the steering position.
2. Attach a suitable clear hose to the bleed nipple located on the top of
the hydraulic cylinder attached to the rudderstock. Place end of clear
hose in a container of suitable hydraulic fluid and open bleed nipple,
while adding hydraulic fluid to the helmpump. Turn the steering wheel
slowly to one side to extend the cylinder fully. When air-free, only
hydraulic fluid is seen, repeat the process on the other nipple.
5.12 Seat harness

Harnesses should be checked to ensure that they are securely mounted and no
tears, rips or loose stitching are present. If signs of deterioration exist, replace
complete harness.
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6 MAINTENANCE SCHEDULES
described launching modes. The following check list should be followed as a
minimum. In addition the detailed maintenance schedules and procedures should
always be maintained. It is recommended that in connection with the foregoing
checks, any signs of corrosion should be combated by scrubbing off with a wire
brush and wiping with a non-fluffy and oily rag. Alternatively a good quality aerosol
spray inhibitor can be used. Chains, turnbuckles and shackles should be controlled
for crack formations, corrosion and deformation each year and changed when
needed. Also check the padeyes and brackets at the same annual control.
6.1 Weekly Maintenance

This craft should always be maintained to ensure that it is ready for immediate use.
Therefore the following weekly checks should be made:
1. Visual inspection of the davit/boat system to ensure that the system is ready
to be used should an emergency arise.
2. Ensure embarkation area is free of obstructions.
3. Ensure that aft door and all hatches are closed and boat is ready to be used
in an emergency.
4. Check electrical supply plug is connected to boat and supply is turned "ON".
5. The free fall release system should be inspected for leakage of hydraulic fluid.
6. Steering system has no leaks.
7. Start engine using main start battery. N.B. The engine can be started while
the boat is in the davit but do not engage propeller shaft as this results in
permanent damage to the shaft bearings. Furthermore the engine should not
be run for more than 5 minutes at idling speed as overheating will result in
permanent damage to the engine.
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8. Start engine using emergency start battery. Therefore after starting the
engine using the normal starting system in step 7, the engine should be shut
down and re-started using the emergency start.
9. Check that dynamo charges (when charging while the engine is running, the
light is out).
10. Check that main battery switches are turned “OFF”.
11. Check battery chargers are “ON” and indicate “charging” or “fully charged”.
12. Ensure that aft door and all hatches are closed and boat is ready to be used
in an emergency.
13. It is recommended that in connection with the foregoing checks, any signs of
corrosion should be combated by scrubbing off with a wire brush and wiping
with a non-fluffy or oily rag. Alternatively a good quality aerosol spray inhibitor
can be used.
6.2 Monthly maintenance

1. Perform checks described in the weekly check lists.
2. The inside of the boat should be checked to ensure free access throughout
and all loose equipment is stored in its correct location.
3. Check air system pressure min. 180 Bar. Refill if necessary.
4. Check over- and underpressure valves move freely.
5. Check pressure air outlet side. Pre-adjusted / sealed 5-7 Bar. Check air
system for possible leakages if necessary.
6. Move sea inlet valve and lubricate. Must be kept shut when sprinkler system
is not in use.
7. Sprinkler pump V-belts: check for damage and correct tension.
8. Flush sprinkler system.
9. Check sprinkler pipes and nozzles for possible defects. Check hose
connection for possible leaks.
10. The free fall release system should be inspected and verified that both
systems are operating properly. This is done by lifting the boat with the
suspension sling, and pumping the hydraulic cylinder to lift the boat off the
fixed hook.
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11. Fuel tank filled.

12. Check that batteries are tight, clean and fully charged.
13. Check battery leads.
14. Check main battery switches are turned "OFF".
15. Check battery chargers are turned "ON".
16. Check control console instrumentation and engine controls. Replace
defective lamps and fuses if necessary.
17. Check tension of dynamo belt.
18. Check door and hatches for tightness and gasket condition.
19. Check that all hatches/hatch dogs and doors operate freely.
20. Check bilge pump system, take off pump cover and remove any foreign
bodies.
21. Drain the boat if necessary.
22. Seat belts: check to ensure they are not tangled or damaged.
23. Check food, water and equipment tank to ensure their contents are in
serviceable condition.
24. Check lifeboat radio equipment.
25. Grease stern tube gland. Before delivery Norsafe uses Swepco type Barium
Grease 105. This type of grease is used on all greasing points. An alternative
to this grease is STATOIL's UNIWAY C2N.
26. Grease rudderstock gland.
27. Grease steering cylinder.
28. Check that steering system operates freely.
29. Grease threads of sliphooks and turn-buckles where applicable. Grease davit
and winch in accordance with the Operation and Maintenance Manual for the
davit and winch.
30. Check that gaskets and tank lids are intact.
31. Check and lubricate operating cables.
32. Grease rudder shaft.
33. Check stuffing box on propeller shaft for lubrication.
The craft should now be checked externally at the following points:
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34. Fibreglass structure shows no signs of damage.

35. Propeller and shaft can turn freely by hand with engine stopped and gear in
neutral.
36. Turn steering system to ensure rudder nozzle moves freely and leave at
straight ahead position when check is complete.
6.3 Abandon ship training and drills

Please see SOLAS Chapter III, Regulation 18 "Abandon ship training and drills" for the
correct procedures. In general, free fall lifeboats shall be launched with its assigned
operating crew aboard and manoeuvred in the water at least once every three months during
an abandon ship drill.
Lowering rather than free fall launching is acceptable, where such launching is impracticable,
provided the lifeboat is free fall launched at least once every six months.
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7 Inspection log for monthly maintenance inspections

INSPECTION LOG FOR MONTHLY INSPECTIONS.
Check. no: Date: Sign.: Condition: Actions taken:
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
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26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
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53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
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80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
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107
108
109
110
111
112
113
114
115
116
117
118
119
120
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8 Loose equipment list
Free fall lifeboat equipment (Solas `83 reg. 41).
Norsafe build no:_________
Yard build no:__________
ITEM DESCRIPTION SKETCH QTY. CHK REMARKS

N 'D
o.
1. Boathook. 2 Secured in the boat.
2. Buoyant bailer. 1 Placed in the

equipment tank in
boat.
3. Bucket. 2 Placed in the

equipment tank in
the boat.
4. Survival manual. 1 Placed in the

equipment tank in
the boat.
5. Compass. 1 Mounted in the boat

Approved type. at the steering
position.
Sea anchor Placed in the

6. complete with 1 equipment tank in
tripping line of 10 the boat.
m length.
Painter ø20mm
7. 27m 2 Secured in the boat.
long
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8. Hatchet. 2 Placed in the

equipment tank in
the boat.
9. Rustproof/plastics 1 Placed in the

dipper with equipment tank in
lanyard. the boat.
Stored in a GRP
10. Water in plastic 192ltrs water tank in the
bags. Ration 3 . boat.
ltrs. per person. .
11. Rustproof/plastics 1 Placed in the

graduated drinking equipment tank in
vessel. the boat.
12. Food ration 64pack Placed in a

10.000 kJ per ets watertight tank in
person. the boat..
13. Rocket parachute 4 In screw top

flares. watertight box in the
equipment tank in
the boat.
14. Hand flares. 6 In screw top

watertight box in the
equipment tank in
the boat.
15. Buoyant smoke 2 In screw top

signals. watertight box in the
equipment tank in
the boat.
16. Waterproof 1 Placed in the

electric signalling equipment tank in
torch. the boat.
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17. Spare batteries and 1 Placed in the

bulb in a equipment tank in
watertight box. the boat.
18. Daylight 1 Placed in the

signalling mirror equipment tank in
with instructions. the boat.
19. Copy of lifesaving 1 Placed in the

signals on equipment tank in
waterproof card. the boat.
20. Whistle. 1 Placed in the

equipment tank in
the boat.
First aid kit in a

21. waterproof case. 1 Placed in the
equipment tank in
(See content list the boat.
on box)
22. Six doses of anti- 3 Placed in the first

seasickness 84 aid kit.
medicine per doses
person.
23. Seasickness bag. 6 Placed in the

4 no. equipment tank in
the boat.
24. Jack knife with 1 Placed in the

lanyard. equipment tank in
the boat.
25. Can opener. 3 Placed in the

equipment tank in
the boat.
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26. Buoyant rescue 2 Placed in the

quoit with 30m equipment tank in
buoyant line. the boat.
27. Manual pump. 2 Mounted in the

boat.
28. Set of fishing 1 Placed in the

tackle. equipment tank in
the boat.
29. Engine tool set. 1 Placed in the

equipment tank in
the boat
30. Portable fire 1 Mounted in the boat

extinguisher.
Nipple for
31. flushing of 2 Placed in the
sprinkler system equipment tank in
(tanker version the boat.
only)
32. Searchlight. 1 Mounted in the boat

at the steering
position.
33. Radar reflector. 1 Placed in the

equipment tank in
the boat.
N.M.D/ M.O.B.U.
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34. Thermal 7 no. Placed in the

protective aids. equipment tank in
the boat.
35. Blankets. 5 Placed in the

equipment tank in
the boat
36 VHF 1 To be installed near
radiotelephone the helmsman`s
with head- seat.
phones.
37 VHF emergency 1 The holder shall be
position indicating permanently
beacon for installed.
aeromoble
frequencies.
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1.2 Operation & Maintenance manual for NLDE-4 engine
1.3 Operation manual for ZF Marine gear, cod.310.01.0006e
1.4 Instruction manual for WJME battery charger
1.5 Instruction manual for Hydraulic steering gear
1.6 Survival manual
SPECIFICATION NO. WS 0133
REVISION NO. 03
DATE 07.09.06
SHEET 1 OF 10
SURVIVAL INSTRUCTIONS
SURVIVAL Prior to Abandonment

....................................
(1) Put on extra clothing.
(2) Put on life jacket.
(3) Take extra clothing or blankets if possible
MANUAL (4)
(5)
Drink water if possible.
Take screw-top plastic bottle if possible full of water.
In addition to the statutory lifeboat equipment e.g. emergency radio, water,

rations, first aid kit etc., the following extra items would be useful:
(1) Extra life jackets.
(2) Extra survival bags.
(3) Small plastic bags.
(4) Extra medical supplies.
(5) Extra electric torches.

NORSAFE AS
P.O.BOX 115
(6) Paper and pencil.
N-4818 FÆRVIK
TELEPHONE : +47 37 05 85 00
(7) Portable radio receivers, books, playing cards etc..
TELEFAX : +47 37 05 85 01
SPECIFICATION NO. WS 0133 SPECIFICATION NO. WS 0133
REVISION NO. 03 REVISION NO. 03
DATE 07.09.06 DATE 07.09.06
SHEET 2 OF 10 SHEET 3 OF 10
Abandoning Vessel Aboard the Lifeboat
(1) First Actions

All personnel should be able to board lifeboat without
getting wet. (1) ORDERS
(2) Obey orders at once. (An officer will normally be in charge but in his absence
a leader will need to be appointed or elected as soon as possible).
If for some reason this is not possible and a jump into the
water has to be made, remember: (2) STAY IN AREA
(a) Make sure it is clear to jump. Take the lifeboat to a safe distance away from the ship or platform as quickly
as possible. Having done this, remain in the area because this is where the
(b) Hold your nose. rescue craft or services will search first. Only if the ship or platform is close
either to land or to another ship should the lifeboat leave the area. If several
(c) Hold down your life jacket. lifeboats and life rafts have been launched, try to keep in a group. If possible
by using painter lines to tie the survival craft together. Stream the sea
(d) Put your feet together. anchor.
(e) Look ahead when you jump. (3) SEA-SICKNESS
Take seasickness medicine. It is essential to prevent seasickness if possible

as it is a great physical handicap and causes the loss of body fluids.
(4) TREATING INJURED
Maintain a clear airway to injured survivors and control any bleeding.
(5) WARMTH
If cold, get survivors to huddle together. Use all available spare clothing,
blankets and thermal protective aids.
DATE 07.09.06 DATE 07.09.06
(6) RADIO (5) WATCHES & LOOK-OUTS
If a portable radio is carried, send out emergency distress signals as soon as Watches should be set in pairs for about one hour at a time with one person
possible and keep sending them. on outside lookout and the other on watch inside the lifeboat.
(7) ROLL DOWN CANOPIES The outside lookout should be suitably dressed and protected from the
elements as well as being secured to the craft. This person is responsible for
If in a partially enclosed lifeboat, roll down the canopy/canopies to preserve keeping a lookout for ships, survivors, aircraft, land and any possible
heat or protect from hot sun. dangers, as well as collecting useful debris.
The person on the inside is responsible for supervising the boat

Subsequent Actions management whilst others rest. This includes attending the injured,
collecting rainwater and looking after equipment and valuable items.
(1) LEADER Depending upon the size of the lifeboat and the number of survivors, an
engineer’s and a helmsman's rotation should be arranged in addition to the
If no officer is present, a leader should be appointed or elected. inside and outside watches.
(2) SHARP OBJECTS (6) SEARCH FOR SURVIVORS, POST LOOKOUTS.
Collect sharp objects or potential weapons. Listen for whistles and look for survivors, signalling lights and lights of other
rafts, ships or aircraft. The look-outs should be properly briefed in their
(3) ROLL CALL duties, regarding the collection of useful debris, how to keep a look-out,
sector searches and the use of pyrotechnics, including when to use them.
A roll call must be made to establish the likelihood of further survivors being
found, the numbers available for watches, the numbers injured and the (7) SURVIVAL INSTRUCTIONS
expertise available in the boat.
As many survivors as possible should read the survival instructions in order
(4) ROUTINE that as much guidance as possible concerning the situation can be made
known.
Establish a routine and allocate duties to survivors, e.g. ration keeper,
lookouts, and balers.
DATE 07.09.06 DATE 07.09.06
(8) PASSING WATER (4) MORAL
Within two hours of boarding the lifeboat, all survivors should be encouraged Keep survivors occupied by playing cards or reading books if these are
to pass water in order to avoid later problems due to urine retention. available, or by any other means that can be devised.
Fishing should be carried out only if sufficient excess water is available to

Lifeboat Management drink, at least one litre per person per day. Fish fats and proteins accelerate
dehydration unless extra water is taken.
(1) LOOK-OUTS (5) LOG
Keep a sharp lookout at all times. Keep an accurate log of all main events with date and time.
(2) DISTRESS SIGNALS

Medical Aspects
Keep the distress signals dry but readily available.
(3) WARMTH (1) DROWNING
Keep as warm as possible in cold weather. Use all available clothing, Wear a life jacket. Although everyone should leave the ship or platform 'dry
blankets and thermal protective aids and place injured, or persons shod', this may not necessarily be the case and everyone should wear a
particularly at risk from hypothermia nearer the engine, which will run for 24 regulation life jacket.
hours at full power and much longer if kept on lights loads. The engine can
be a very valuable source of warmth in cold weather, but fuel should be (2) HYPOTHERMIA
conserved as much as possible, dependent upon sea conditions, by running
at light loads or using the engine for certain periods only. There is a risk of hypothermia in water below about 25 degrees C. Extra
clothing will delay the onset of hypothermia even though immersed, and of
course will provide extra warmth for the survivor in the lifeboat even though
immersion takes place. Totally enclosed or partially enclosed lifeboats
provide far better protection from the elements than the older open type, but
extra clothing is still essential for warmth in nearly all climates.
If survivor has been immersed in water and has hypothermia, strip off wet
outer clothing and replace with dry garments if available. Warm the patient
with extra layers of clothing and use lifejackets as extra insulation. Use a
thermal protective aid (plastic survival bag) if available.
(SPECIFICATION NO. WS 0133 (SPECIFICATION NO. WS 0133
DATE 07.09.06 DATE 07.09.06
(3) DEHYDRATION & STARVATION Injuries, Ailments & Treatment

(a) Take seasickness pills to prevent vomiting and loss of body fluids.
Use disposable bags if available (1) INJURIES
(b) In hot weather, ventilate the lifeboat by opening hatches, and in the A first aid kit is supplied with every lifeboat and a leaflet describing simple
case of a partially enclosed lifeboat, the canopies can be rolled up to provide first aid is enclosed with each kit.
an air-flow yet protect from the sun.
(2) FROST-BITE
(c) Keep in the shade to prevent sunstroke.
Usually occurs in extremities i.e. fingers, toes, ears. Wear protective clothing
(d) Do no be tempted to swim when the weather is hot. This uses if possible. Reduce lookout periods in very cold weather; watch each other’s
energy, and although sharks do not usually attack human beings, the conditions. Wriggle nose and cheeks and exercise hands and feet to keep
risk should not be taken. circulation going.
(e) Rest as much as possible to conserve energy Do not massage affected area once signs of frostbite have appeared. Warm
the area by holding hands against it.
(4) RATIONING
(3) URINE RETENTION
(a) No water for the first 24 hours, except to the injured and others who
have lost a lot of body fluid. This can be dangerous, so overcome 'mental blockage' early, before
rationing reduces urine production.
(b) 1/2 litre of water per day thereafter. Never take less than this unless
down to the last can, or its equivalent, per person. Make this remaining Drink plenty of water before leaving the vessel. If retention occurs, dangling
ration last two days. your hands in the water may help. After a period in a dark survival craft,
urine will appear dark and smoky. This is normal and no action is necessary.
Take water three times a day and swill it around the mouth before drinking it.
(4) SUNBURN
(c) Do no not drink seawater or urine, even if mixed with fresh water.
The results could eventually prove fatal. Avoid excessive exposure to the sun by keeping under cover. Keep head,
neck and other exposed areas covered. A very gradually acquired suntan
(d) No rations should be issued during the first 24 hours except to may be beneficial.
conscious injured persons, or possibly children. Rainwater should be
collected at every opportunity. Absolute fairness in ration distribution is vital,
and it is important that everyone can see that this is fair.
(SPECIFICATION NO. WS 0133
REVISION NO. 03
DATE 07.09.06
SHEET 10 OF 10
(5) SALT WATER BOILS
These are due to the skin becoming sodden with seawater. Do not squeeze
or prick boils. Keep them clean and cover with a dry dressing. Keep the area
as dry as possible to avoid chafing.
(6) DRY MOUTH & CRACKED LIPS
Swill water around your mouth prior to swallowing. Suck a button. Smear lips
with cream or soft petroleum jelly.
(7) SWOLLEN LEGS
This is common and due to long periods spent in a sitting position. It will
subside without treatment after rescue.
Acknowledgements are due to the Warsash College of Maritime Studies for

much of the information in these instructions.
2. OPERATION & MAINTENANCE MANUALS FOR HD40 DAVIT
Norsafe as
P.O. Box 115
N-4852 Færvik
Norway
Telephone : + 47 37 05 85 00
IMPORTANT NOTICE:
NORSAFE AS. The use of spare parts supplied by other suppliers violates and
forfeits the warranty.
1 ISSUED FOR INFORMATION 06.09.11 SKO GNI
2
3
4
5
6
Norsafe as
LIST OF CONTENTS
1 DAVIT OPERATION.......................................................................6
1.1 FREE FALL LAUNCHING MODE (NORMAL) ....................................................... 6
1.2 LAUNCHING USING THE WINCH AND FALL WIRE ............................................... 6
1.3 RECOVERY OF LIFEBOAT ............................................................................ 10
1.4 TO ENSURE BOAT IS SECURELY ENGAGED WITH BOLT ON DAVIT. .................... 14
1.5 BOAT STOWAGE ........................................................................................ 15
2 MAINTENANCE ...........................................................................17
2.1 MAINTENANCE INSTRUCTIONS FOR DAVIT / WINCH. ....................................... 21
2.2 PRESERVATION / HOT OIL FLUSHING OF HYDRAULIC POWER SYSTEM FOR
NORSAFE DAVIT SYSTEMS .......................................................................... 26
2.3 MAINTENANCE OF FALLS. ........................................................................... 27
2.4 MONTHLY MAINTENANCE INSPECTION REPORT. ............................................ 28
2.5 INSPECTION LOG FOR MONTHLY MAINTENANCE INSPECTIONS. ....................... 29
2.6 LUBRICATION CHARTS. ............................................................................... 34
3 APPENDIX A ................................................................................38
3.1 INSTALLATION / FIRST TIME START UP: ......................................................... 38
4 APPENDIX B ................................................................................40
4.1 WARRANTY CONDITIONS ............................................................................ 40
5 APPENDIX C ................................................................................48
5.1 CALL FOR SERVICE FORM ........................................................................... 48
H-160 and HD40 Operation and Maintenance Manual.doc Page 2

Norsafe as
VALIDITY
This manual is valid for Norsafe Davit HD40 used with Norsafe Free Fall Life boat
GES40 max SWL 13 500 kg, and H-160 used with Norsafe Free Fall lifeboat
GES40 ULS, max. SWL 16 000 kg.
WARNING!!!
Before attempting this procedure the operator should be fully trained in all
operational modes of both this boat and its launching appliance. Failure to follow
the procedures detailed in this manual may result in death or serious injury. In
addition to the free fall launch mode the craft can be lowered and recovered from
the sea by using the davit fall wire and attaching the boats lifting slings to the
lowering/recovery hooks on the davit traverse.
H-160 and HD40 is a davit system for the GES40 and GES40 ULS free fall
lifeboats. This system will allow free fall escape for the fully manned lifeboat,
completely independent of external power, also when the mother ship has a heel
up to 20° and a trim up to 10° or 17° in any direction if delivered according to NMD
rules. The system consists of launch ramp with polyethylene (PEHD 1000) strips
on skid way for free fall release of the boat. An A-frame with pivot point at the
lower end of the launch ramp, complete with hydraulic winch and cylinders, allows
for recovery and launch by wire of the lifeboat. Power, to the hydraulic power
pack, from the ships main or emergency power supply, must be available in order
for these operations to be carried out.
The free fall escape is the main means of evacuation. Always use this
concept whenever possible.

Norsafe as
Supplier information
Norsafe A/S was established in 1903 as Jørgensen & Vik in Grimstad. At first they
manufactured wooden lifeboats and during the 1. world war the first partially
enclosed lifeboats were delivered. Aluminium was used from 1952 to 1958. Since
1958 fibreglass has been used as building material.
Norsafe A/S moved in 1990 from Grimstad to Arendal, and delivers today a wide
range of different lifeboats; from small rescue boats, through free-fall boats to
conventional lifeboats.
Our market is ship owners and shipbuilders, and offshore oil field installations
worldwide.
Norsafe A/S is headed by the company manager, and the organisation is divided
into six departments; Administration, Sales/Marketing, Research and Development,
Contract, Purchase and Production, which all are headed by a dept. managers.
Postal address:
Norsafe AS
P.O.Box 115
N-4852 FÆRVIK
Norway
Visiting address: Nedre Tybakken, Tromøy, Arendal, Norway

Phone: +47 37 05 85 00
Telefax: +47 37 05 85 01

Norsafe as
How to order spare parts
Please quote the Norsafe davit build number and the boat build number when
contacting Norsafe. The numbers are given on enclosed certificates, and are also
shown at the nameplate close to the lifeboats aft door.
IMPORTANT:
Direct all inquiries regarding spare parts and service to:
Norsafe AS
Postbox 115
N-4852 FÆRVIK
NORWAY
Telephone: Int. + 47 37 05 85 00
Telefax: Int. + 47 37 05 85 01
Due to continuous development, we reserve the right to change our product

specifications and manuals without notice.

Please note that all claims will be fully invoiced until accepted as a warranty claim
by Norsafe a.s. Please also enclose a copy of the relevant boat/davit certificate.
The warranty period is normally limited to max. 18 months from delivery of
equipment or 12 months from delivery of vessel to owner, whichever comes first.
All claims are handled according to "Orgalime S 92" which is enclosed in this
manual under section 13, Appendix D. Please fill in a copy of the "call for service
form" under section 14, Appendix E.

Norsafe as
1 DAVIT OPERATION
1.1 Free Fall launching mode (normal)

Before attempting any free fall launch it is vital that the crew of the craft ensures
that the boat will achieve a clean unrestricted path down the skid way and that the
launch zone is clear of obstructions. The following checks should be made before
commencing free fall launch mode.
1. Lowering/retrieval hooks have been disconnected from the lifeboat lifting slings
and the slings are securely stowed on top of boat. The boat shall always have
the lifting sling disconnected, leaving boat ready for immediate use in an
emergency.
2. Lashing arrangement has been disconnected.
3. All ropes etc. are clear of the lifeboat and launching ramp.
For further details refer to the boat user manual.
1.2 Launching using the winch and fall wire

If the free-fall launching procedures appear unacceptable for reasons such as
solid objects floating in water in the area of the lifeboat expected splash down or
any other reason, the craft can be lowered to the water using the winch and fall
wire. The launch by wire method of lowering the lifeboat is dependent on
electrical power from the ship's power supply, and an operator to be positioned at
the manoeuvring controls. This method is used when full control of the launch is
required, i.e. for training purposes.

Norsafe as
Method:
1. Start the Hydraulic power pack by pushing the

start button. Swing the a-frame until it is approx
0,5 – 1,0 meter over its parking stays.
2. Push the control lever labelled

"Winch" to the "down position until the
hooks on the traverse assembly are
on level with the end links on the
lifting slings on the boat. When the
hooks are on level with the lifting
slings, unclip the rings on the lifting
slings from their securing clips and
hook into the traverse hooks.
3. Lift traverse, by pulling winch operating

lever to the "lift" position, until wires are
tight. (Fig. 3)
4. Remove boat lashing and electrical

supply plug from the rear of lifeboat.
5. Personnel to board the lifeboat, take

seats and secure their seat belts.
6. Make sure no loose objects are stored in

the boat.
FIG. 3
7. Operate the free fall release mechanism
from inside the boat until the boat is free of the bolt on the davit.

Norsafe as
FIG. 4
8. Lower the traverse by pulling the control lever for the winch to the "Down" position,
until the front of the skid angle on the boat passes the end of the skid way. (Fig. 4)
FIG. 5
9. Swing out the A-frame by pushing the control lever labelled "JIB" to the "Out"
position, and holding it there until the A-frame stops. (Fig. 5)

Norsafe as
10. Lower the boat to the water until the wire falls become slack, and the boat is fully
waterborne. (Fig. 6)
FIG. 6
11. Unhook the boat falls from the traverse and navigate boat clear of danger.
12. Stop the hydraulic power pack by pressing the stop button
located near the manoeuvring controls.
(Fig. 7)
FIG. 7

Norsafe as
13. The lifting traverse, not designed to be hoisted without load.

If the traverse shall hoist without the boat, use a small weight (min. 25 kg).
Connect the two hooks to the traverse with two straps (approx. 2 m). This will
secure that the traverse will come up horizontal, and not vertical.
1.3 Recovery of lifeboat

Method:
1. Start the Hydraulic power pack by pushing the start button.

NB!
Before the boat is placed in the davit, both the
hydraulic release jacks must have returned to their
upper position.
2. Swing out the A-frame by pushing the control lever

labelled "JIB" to the "Out" position, and holding it there
until the A-frame stops in the full out position.

Norsafe as
3. Navigate the lifeboat underneath the lifting traverse. Lower the lifting
traverse by pushing the control lever labelled "Winch" to the "Down" position; take
care not to hit the lifeboat or the personnel on the lifeboat with the traverse. (Fig. 9)
FIG. 9
Warning
When performing this operation take care in moving the levers smoothly,
avoid all abrupt motions of the davit arm and the suspended life boat.

Norsafe as
4. Lift the traverse and the lifeboat by pulling the control lever labelled "Winch" to the
"up" position. Lift the lifeboat until the undersides of the skid angles are slightly
above the top of the davit skid way (max. 0.5m above!). (Fig.10)
FIG. 10
Now manoeuvre the suspended lifeboat up on to the skid way by alternating
between lifting the lifeboat and pulling in the A-frame until the lifeboat is resting on
the skid way. (Fig. 11)
FIG. 11

Norsafe as
5. When the lifeboat is resting firmly on the skid

way, lower the A-frame until it is standing
approx. 1.2m - 1.5m above its support and
use the winch to pull the lifeboat up until its
release mechanism engages with the bolts
on the davit. (Fig. 12)
FIG. 12
6. With the lifeboat in its correct position, (Fig. 13) make sure to check that the
lifeboat release mechanism is securely engaged in the davit bolt.
FIG. 13
Then lower the traverse until the lifeboat slings become slack. Secure the lifeboat
lashing. Unhook the slings from the traverse and secure them in their clips.

Norsafe as
Lift the traverse until it engages in its parking stay. Stop the hydraulic power pack
by pressing the button marked "Stop" on the control panel. (Fig. 14).
Connect the electrical supply plug to the rear of the lifeboat.
FIG. 14
WARNING!!!
When boat has been fully recovered and before attempting to disconnect the lifting
slings, ensures that the boat is securely engaged on the bolt on davit.
1.4 To ensure boat is securely engaged with bolt

on davit.
1. Recover the boat following the instructions above.
2. Visually check that securing bracket on boat has passed over the bolt on davit.
3. Carefully release the winch brake to allow the boat to lower on to the bolt on davit. It
may help to stand on the aft end of the boat as it is gently lowered.
4. From below the boat check that the brackets on the boat have settled down on the
bolt on the davit. The correct position will leave a gap of approx. 1 - 5 mm from
underside of bracket to the bolt.

Norsafe as
1.5 Boat stowage

described launching modes. The following check list should be followed as a
minimum. In addition the detailed maintenance schedules and procedures should
always be maintained:
1. Ensure boat is securely locked in the bolt on the davit.

2. Secure lashing arrangement.
3. Lower the davits traverse and disconnect the lifeboat lifting slings storing the sling in
the clips provided.
4. Connect lifeboat power supply.
NOTE: The power supply must only be connected when the boats main power
is in “OFF” position.
For further details refer to the boat user manual.

Norsafe as
All crewmembers on the mother ship should be familiar with the operating
Important!
procedures for this launching appliance and lifeboat. Failure to follow the
procedures detailed in this manual may result in serious personnel injury or
material damage.
Caution!
When operating the control levers, take care to move the levers smoothly,
and avoid all abrupt motions of the davit arm or the suspended lifeboat.

Norsafe as
2 MAINTENANCE
The international maritime organization and the Maritime Safety Committee approved Guidelines on
inspection and maintenance of lifeboats, on – load release gear and launching appliances.
These Guidelines establish a uniform, safe and documented servicing and maintenance performed by either
personnel assigned by the manufacturer, or the crew of the ship under the supervision of the manufacturers
representative.
Norsafe AS has implemented these guidelines into its servicing system. Please do not hesitate to inquire
should there be any questions about the Guidelines or any other fact concerning Norsafe service
applications.
Following are the Guidelines and IMO document MSC/Circ.1093
INTERNATIONAL MARITIME ORGANIZATION

4 ALBERT EMBANKMENT
LONDON SE1 7SR
Telephone: 020 7735 7611

Fax: 020 7587 3210
Telex: 23588 IMOLDN G
IMO
E
Ref. T4/3.01 MSC/Circ.1093

17 June 2003
GUIDELINES FOR PERIODIC SERVICING AND MAINTENANCE OF LIFEBOATS,
LAUNCHING APPLIANCES AND ON-LOAD RELEASE GEAR
1 The Maritime Safety Committee, at its sixty-second session (24 to 28 May 1993), approved Guidelines on
inspection and maintenance of lifeboat on-load release gear, issued as MSC/Circ.614.
2 Recognizing the experience gained since the approval of the Guidelines by MSC 62 and that the
implementation of expanded and improved guidelines could contribute towards a reduction of the
incidence of accidents with lifeboats, the Maritime Safety Committee, at its seventy-seventh session
(28 May to 6 June 2003), approved the Guidelines for periodic servicing and maintenance of
lifeboats, launching appliances and on-load release gear, set out in the annex, which could also be
used for the periodic servicing and maintenance of liferafts, rescue boats and fast rescue boats and
their launching appliances and on-load release gear.
3 Member Governments are invited to give effect to the annexed Guidelines as soon as possible
and to bring them to the attention of shipowners, ship operators, ship personnel, surveyors,
manufacturers and all others concerned with the inspection and maintenance of lifeboats, liferafts,
rescue boats and fast rescue boats and their launching appliances and on-load release gear.
4 This circular supersedes MSC/Circ.614.
***
MSC/Circ.1093
ANNEX
Norsafe as
Page 1
ANNEX
GUIDELINES FOR PERIODIC SERVICING AND MAINTENANCE OF LIFEBOATS,
LAUNCHING APPLIANCES AND ON-LOAD RELEASE GEAR
General
1 The objective of these Guidelines is to establish a uniform, safe and documented performance
of periodic servicing and maintenance of lifeboats, launching appliances and on-load release gear.
2 These Guidelines relate to the application of the ISM Code to periodic servicing and
maintenance of lifeboat arrangements and should therefore be reflected in procedures developed for a ship
under that Code.
3 These Guidelines can also be used for the periodic servicing and maintenance of liferafts,
rescue boats and fast rescue boats and their launching appliances and release gear.
4 Detailed guidance regarding some procedures covered by these Guidelines is provided in the
appendix.
SOLAS regulations
5 The Guidelines relate to the requirements contained in:

.1 SOLAS regulation III/20 - Operational readiness, maintenance and inspections; and
.2 SOLAS regulation III/36 - Instructions for on-board maintenance.
Responsibility
6 The company* is responsible for servicing and maintenance onboard its ships in accordance
with SOLAS regulation III/20 and for the establishment and implementation of health, safety and
environment (HSE) procedures covering all activities during servicing and maintenance.
7 The personnel carrying out servicing and maintenance are responsible for the performance of
the work as authorized in accordance with the system specified in paragraph 9.
8 The above personnel is also responsible for complying with HSE instructions and procedures.
9 Where satisfied with an organization’s ability to carry out these functions, the Administration
may authorize such organization to perform the functions of the manufacturer as assigned under
these Guidelines, if the manufacturer is unable to provide the service.
Authorization
10 Where these Guidelines require certification of servicing personnel, such certification should
be issued by the manufacturer in accordance with an established system for training and
authorization.
Qualification levels
11 Weekly and monthly inspections, and routine maintenance as defined by the manufacturer,
should be conducted under the direct supervision of a senior ship’s officer in accordance with the
instructions provided by the manufacturer.
12 All other inspections, servicing and repair should be conducted by the manufacturer’s
representative or a person appropriately trained and certified by the manufacturer for the work to be done.
MSC/Circ.1093
ANNEX
Page 2
Norsafe as
Reports and records
13 All reports and checklists should be correctly filled out and signed by the person who carries
out the inspection and maintenance work and should also be signed by the company’s representative.
14 Records of inspections, servicing, repairs and maintenance should be updated and filed
onboard the ship.
15 When repairs, thorough servicing and annual servicing are completed, a statement confirming
that the lifeboat arrangements remain fit for purpose should be issued by the manufacturer’s
representative.
* For the purpose of these Guidelines, company is as defined in SOLAS regulation IX/1.2.
SPECIFIC PROCEDURES FOR MAINTENANCE AND SERVICING
1 GENERAL
1.1 Any inspection, servicing and repair should be carried out according to the system for
inspection and services developed by the manufacturer.
1.2 A full set of maintenance manuals and associated documentation issued by the manufacturer
should be available on board for use in all operations involved in the inspection, maintenance,
adjustment and re-setting of the lifeboat and associated equipment, such as davits and release gear.
1.3 The manufacturer’s system for inspection and services should include the following items as
a minimum.
2 THOROUGH EXAMINATION
2.1 As items listed in checklists for the weekly/monthly inspections also form the first part of the
thorough examination, the inspection of these items should be performed by the ships. crew in the
presence of the manufacturer’s representative or a person appropriately trained and certified by the
manufacturer for the work to be done.
2.2 Inspection and maintenance records of inspections and routine maintenance carried out by the
ship’s crew and the applicable certificates for the launching appliances and equipment should be
available.
2.3 Repairs and replacement of parts should be carried out in accordance with the manufacturer’s
requirements and standards.
Lifeboat
2.4 The following items should be examined and checked for satisfactory condition and
operation:
.1 condition of lifeboat structure including fixed and loose equipment;
.2 engine and propulsion system;
.3 sprinkler system, where fitted;
.4 air supply system, where fitted;
.5 manoeuvring system;
.6 power supply system; and
.7 bailing system.
MSC/Circ.1093
ANNEX
Page 3
Release gear
Norsafe as
2.5 The following should be examined for satisfactory condition and operation:
.1 operation of devices for activation of release gear;
.2 excessive free play (tolerances);
.3 hydrostatic interlock system, where fitted;
.4 cables for control and release; and
.5 hook fastening.
Notes:
1 The setting and maintenance of release gear are critical operations with regard to maintaining the safe
operation of the lifeboat and the safety of personnel in the lifeboat. All inspection and maintenance
operations on this equipment should therefore be carried out with the utmost care.
2 No maintenance or adjustment of the release gear should be undertaken while the hooks are under load.
3 Hanging-off pennants may be used for this purpose but should not remain connected at other times, such as
when the lifeboat is normally stowed and during training exercises.
2.6 Operational test of on-load release function:

.1 position the lifeboat partially into the water such that the mass of the boat is substantially supported by the
falls and the hydrostatic interlock system, where fitted,is not triggered;
.2 operate the on-load release mechanism; and
.3 reset the on-load release mechanism.
2.7 Operational test of off-load release function:

.1 position the lifeboat fully waterborne;
.2 operate the off-load release gear;
.3 reset the on-load release gear; and
.4 recover the lifeboat to the stowed position and prepare for operational readiness.
Note:
Prior to hoisting, check that the release gear is completely and properly reset. The final
turning-in of the lifeboat should be done without any persons on board.
Davit
2.8 The following items should be examined for satisfactory condition and operation:
.1 davit structure, in particular with regard to corrosion, misalignments, deformations and excessive free play;
.2 wires and sheaves, possible damages such as kinks and corrosion;
.3 lubrication of wires, sheaves and moving parts;
.4 functioning of limit switches;
.5 stored power systems; and
.6 hydraulic systems.
MSC/Circ.1093
ANNEX
Page 4
Winch
2.9 The following items should be examined for satisfactory condition and operation:
Norsafe as
.1 open and inspect brake mechanism;

.2 replace brake pads, if necessary;
.3 remote control system; and
.4 power supply system.
3 DYNAMIC WINCH BRAKE TEST

3.1 Annual operational testing should preferably be done by lowering the empty boat. When the
boat has reached its maximum lowering speed and before the boat enters the water, the brake should be
abruptly applied.
3.2 Five-yearly operational testing should be done by lowering the boat loaded to a proof load of
1.1 times the maximum working load of the winch, or equivalent load. When the boat has reached
its maximum lowering speed and before the boat enters the water, the brake should be abruptly
applied.
3.3 Following these tests, the brake pads and stressed structural parts should be re-inspected.
Note:
In loading the boat for this test, precautions should be taken to ensure that the stability of the
boat is not adversely affected by free surface effects or the raising of the centre of gravity.
4 OVERHAUL OF ON-LOAD RELEASE GEAR
Overhaul of on-load release gear includes:

.1 dismantling of hook release units;
.2 examination with regard to tolerances and design requirements;
.3 adjustment of release gear system after assembly;
.4 operational test as per above and with a load according to SOLAS regulation III/20.11.2.3; and
.5 examination of vital parts with regard to defects and cracks.
Note:
Non-destructive examination (NDE) techniques, such as dye penetrants (DPE), may be

suitable.
____________
2.1 Maintenance instructions for davit / winch.

Norsafe as
This lifeboat and davit installation is a life saving appliance and hence
should always be ready for use. Hence it should never be used for the
attachment of lines or other objects, nor should loose objects be stored on
the boat or davit, or be so placed as to obstruct the escape path of the
lifeboat.
Painting!
When painting the davit take care not to paint lubrication points, bearings,
rubber O-rings, PEHD strip (A,B) or other objects which should be free to
move.
A- Apply grease
B- Use lubricant spray

Norsafe as
MAINTENANCE AND LUBRICATION LOG
Every Statoil lubrication

Description: Weekly Monthly
year grease:
Over -10°C:
A-Check oil level in hydraulic Hydraway HVX A32
power pack * Under -10°C:
Hydraway HVX A22
B-Start power pack and check that
Control levers, winch and A-
*
frame
functions as intended
C-Inspect all hydraulic connections
*
for Leakage, wear and tear.
*
Uniway C2N
D-Lubricate all grease points (100 h)
*
Greaseway OG N
E-Lubricate winch wire (50 h)
*
F-Check oil level in winch gearbox.
Over -10°C:
G-Change hydraulic oil in power Hydraway HVX A32
pack. * Under -10°C:
Hydraway HVX A22
*
H-Change oil filter.
(500 h)
*
When
exposed
I-Change gear oil in winch gearbox to API-GL-3SAE 85 W,
damage 3 litres
or repair
J-Inspect davit/launching ramp to

ensure that the lifeboat will achieve
*
a clean unrestricted path down the
skidway.
K-Run lifeboat engine ahead and
astern for min. 3 min. max 10 min. *
When required
L-Turn winch wire end for end.
At least every 30 months
When required due to
M-Replace winch wire deterioration.
At least every 5 years

Norsafe as
A- Check oil level in hydraulic power pack. The oil level indicator is found
on the General Arrangement drawing of the Hydraulic Power Unit.
D- Lubricate all grease points. The following grease points exist:

1. Hydraulic Power pack, two grease nipples on motor.
E- Lubricate winch wire. Apply grease to the wire every 50 hours of
operation or at least once every month.
F- Check oil level in winch gearbox.

Norsafe as
G- Change hydraulic oil in power pack. A new oil filter cartridge is

installed and the oil reservoir drained prior to delivery. It is recommended
that the hydraulic oil should be changed after 1000 running hours or at
least once a year. With large quantities of oil an oil analysis may be
profitable.
H- Change oil filter. The filter element should be changed every 500
hours of operation or at least once a year.
I- Change gear oil in winch gearbox. To change gear oil, operate the
winch until it is warm. Drain oil through plug on rotating part of gearbox.
Rotate the winch until the plug is in centre, measured from horizontal.
If the winch has not been exposed to damage, it is usually not necessary
to change gear oil.

Norsafe as
2.2 Preservation / hot oil flushing of hydraulic

power system for Norsafe davit systems
To carry out flushing / hot oil flushing use the following flushing / hot oil
flushing procedure:
Required cleanliness for systems subject to hot oil flushing shall
be in accordance with:
NAS class 7 This procedure is to be achieved before mechanical
completion of yard supply pipelines, and connection to Norsafe
supply pipelines.
If NAS class 10 appears, it is too poor quality for the system.
ALTERNATIVE FLUSHING (Summary of norsok standard) :

SYSTEM SYSTEM PIPE FLUSH TEST W / CHEM. DRYING PRESER FINAL CLEANING/
DESCRIPTION MATR. WATER / PRESERV. CLEAN. VATION REQUIRED
AIR FLUID YES/NO CLEANLINESS
65 HYDRAULIC AISI WATER NO NO YES NORMAL HOT OIL FLUSH

POWER SYSTEM 316 ISI 44O6 15/12
Detailed procedure for hot oil flushing:

To be prepared by yard acc. to yard supply pipelines.
(Connection of loops etc. )
Filters used for hot oil flushing shall be:
• 3µm ABS for hydraulic systems.
Flushing and sampling to verify cleanness shall take place at turbulent flow,
upstream any filters.
The Reynolds number shall be min. 4000.
The level of cleanness shall be documented from an automatic particle counter or
a membrane checked in a microscope before a flushing operation is considered
finalised.
A flow meter shall be installed to verify flow used during flushing operation.
Maximum water content in oil used for flushing shall be less than 500 ppm.
Norsafe as
The Norsafe pipelines are already cleaned acc. to above mentioned cleanness
qualities.
If the sealing of Norsafe pipelines is broken before connecting to the hydraulic
power system, Norsafe will not guarantee the cleanness to be in accordance with
required cleanness class.
2.3 Maintenance of falls.

SOLAS Chapter III, Regulation 19:
Falls used in launching shall be turned end for end at intervals of not more
than 30 months and be renewed when necessary due to deterioration of
the falls or at intervals of not more than five years, whichever is the earlier.

Norsafe as
2.4 Monthly maintenance inspection report.

Use a copy of this report for each inspection.
Monthly maintenance inspection report.

Check no._____
Task description Checke Date: Yearly

d by:
A- Check Oil level in hydraulic power pack.

B- Start power pack & check that control levers,
winch and A-frame functions as intended.
C- Inspect all hydraulic connections for leakage,
wear and tear.
D- Lubricate all grease points.
E- Lubricate winch wire.
F- Check oil level in winch gearbox. *
G- Change hydraulic oil in power pack. *
H- Change oil filter. *
I- Change gear oil in winch gearbox. When
required
J- Inspect davit/launching ramp to ensure that the
lifeboat will achieve a clean unrestricted path
down the skidway.
K- Let the lifeboat engine idle for min. 3 minutes,
max. 5 minutes.
L- Turn winch wire end for end. When required.
At least every 30
months.
M- Replace winch wire. When required due
to deterioration.
At least every 5
years.

Norsafe as
2.5 Inspection log for monthly maintenance

inspections.
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

Norsafe as

27
28
29
30
31
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

Norsafe as

57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86

Norsafe as

87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116

Norsafe as

117
118
119
120

Norsafe as
2.6 Lubrication charts.
MAINTENANCE SYSTEM FOR NORSAFE PRODUCTS
LSS NO: 01
LUBRICATION NIPPLES, GENERAL
Last updated: 11.10.94

LUBRICATION INSTRUCTION:
Operate the equipment while applying grease. Use enough grease so that
excess grease can be seen on the bearings.
LUBRICATION SPECIFICATION:
SUPPLIER: LUBRICATION SPECIFICATION: COMMENTS:

BP BP ENERGREASE LS EP 2
CHEVRON DURA LITH GREASE 2
ESSO BEACON EP 2
MOBIL MOBILUX EP 2
STATOIL UNIWAY C2N
CASTROL SPEEROL AP2 / EPL 2
SHELL ALVANA GREASE R3
TEXACO MULTIFAK EP2

Norsafe as
LSS NO: 02
WIRE

Operate the equipment while applying grease. Use enough grease so that
excess grease can be seen on the bearing. Apply grease to every 50 hours
of operation or at least every 2nd month.

BP BP ENERGOL GR 3000 or GREASE OG
CHEVRON PINION GREASE MS
ESSO SURRET N5K
MOBIL MOBILTAC 81
MOBILTAC D (Not for arctic)
STATOIL GREASEWAY OG N
SHELL CARDIUM COMPOUND D
TEXACO CRATER 2 X FLUID
CASTROL GRIPPA 60S
MOLYCOTE 165 LT

Norsafe as
LSS NO: 03
WINCH GEARBOX

To change gear oil, operate slew gear until it is warm. Drain oil through plug
on lower part of gearbox. Fill until oil comes out of oil level plug. Check oil
level after every 500 hours use or at lease once a year. If the winch is not
exposed to damage, it is usually not necessary to change the gearoil.
LUBRICATION SPECIFICATION: API-GL-3 SAE 85W

BP Temp. over -10 deg C: HYDRAULIC TF8
Temp. under - 10 deg C:
CHEVRON Temp. over -10 deg C:
ESSO Temp. over -10 deg C: ESSO TORQUE
FLUID 62
MOBIL Temp. over -10 deg C: MOBIL FLUID 422
OR HD80W
STATOIL Temp. over -10 deg C:
SHELL Temp. over -10 deg C: DONAX TT
TEXACO Temp. over -10 deg C: TEXTRAN TDH
CASTROL Temp. over -10 deg C: DEUSOL WBL OR
AGRICASTROL MF

Norsafe as
LSS NO: 04
HYDRAULIC SYSTEM OIL

The hydraulic system has been tested by NORSAFE. A new oil filter
cartridge is installed and the oil reservoir drained prior to delivery. We
recommend that the hydraulic oil should be changed after 1000 running
hours or at least once a year. With large quantities of oil a oil analyse may
be profitable.
SUPPLIER: LUBRICATION SPECIFICATION:

BP Temp. over -10 deg C: ENERGOL SHF 32
Temp. under - 10 deg C: ENERGOL SHF 22
CHEVRON Temp. over -10 deg C: AUTOM.TRANS.FLUID
Temp. under - 10 deg C: AVIATION HYDR.FLUID A or C
ESSO Temp. over -10 deg C: UNIVIS N 32
Temp. under - 10 deg C: UNIVIS N 22
MOBIL Temp. over -10 deg C: DTE15 or DTE13
Temp. under - 10 deg C:DTE11
STATOIL Temp. over -10 deg C: HYDRAWAY HVX A32
Temp. under - 10 deg C: HYDRAWAY HVX A22
SHELL Temp. over -10 deg C: TELLUS T 37
Temp. under - 10 deg C: TELLUS T 15
TEXACO Temp. over -10 deg C: RANDO OIL HDZ32 / HDAZ32
Temp. under - 10 deg C: RANDO OIL HDZ 32 / HDAZ 22
CASTROL Temp. over -10 deg C: HYSPIN AWH 32
Temp. under - 10 deg C: HYSPIN AWH 15

Norsafe as
3 APPENDIX A
3.1 Installation / first time start up:

1 INSTALLATION OF NORSAFE HYDRAULIC DAVIT TO VESSEL:
Norsafe davits are normally delivered for welding directly to deck and bulkhead or
some other type of substructure.
As a minimum requirement the deck must be designed to withstand the davits

maximum bending moment with necessary safety factor. The requirement for this
kind of life saving equipment is a safety factor of 4,5 against the guaranteed
material tensile strength.
CHECK THE FOLLOWING:
Deck structure must be free from cracks, rust, oil and other species that will inhibit
welding of foundation to surface.
The field welds are shown on the relevant Davit General Arrangement drawing.
Certified welders must do welding. WPS and WPQ are subject to class approval
prior to start welding. The yard is responsible to carry out the installation and field
welding as required by class society.
Be sure that no dust or other pollution enters the hydraulic system.
IMPORTANT:
ALL HYDRAULIC CONNECTIONS SHOULD BE RE-TIGHTENED BEFORE
INSTALLATION.
2 FIRST TIME START UP:
Connect the electric motor according to drawing the corresponding el. wiring
diagram.
Fill the hydraulic system oil tank with the correct amount of approved oil. The oil
level is to be visible at all times. (Approx. middle of level glass)
It is of the outmost importance that only pure clean oil is used. Under no conditions
must water, dirt and other foreign matter enter the tank. Impurities and moisture will
reduce the efficiency and life span of the hydraulic system. The hydraulic oil shall be
filled through the systems oil filter.
The hydraulic system has been operated and tested at our workshop prior to delivery.

Norsafe as
However, improper storage and handling during transportation may result in some oil
leakages.
Therefore, check the oil level in the slew gearbox and the winch gearbox and top up
if necessary. Make sure to use those oils recommended in the manual.
All pressure control handles have been adjusted by Norsafe and should not need
to be altered. However, due to the yard-supplied pipes (when applicable), the
transport, the oil change, the hydraulic pressure should be checked and corrected
if necessary. This operation is described in the davit manual.
Connect the electric motor.
As a final check before starting, check the rotation of the electric motor. The
motor must rotate in a counter clockwise direction seen from the motors fan end.
lf the motor is rotating in the wrong direction, interchange 2 phases and check
again for counter clockwise rotation.
The pump must not be allowed to run in the wrong direction for an extended
period of time, as this will adversely affect the life span of the hydraulic
pump.
Upon completion of initial test run, check the oil level in the system oil tank, top up
if necessary.
When the system is started the first time there will be air in the system. Let the
power pack run for a couple of minutes without pressure and shut down for 10
minutes before restarting. The winch will automatically let out air from its system
when operated. Be sure that all air in system is ventilated before lifting any load or
swinging out the a-frame of the davit.
If you have any problems during installation, please do not hesitate to contact Your
nearest Norsafe representative or our main office in Norway. For address/phone
number, please see the first page of this manual.
Remember that this is a safety device. It should always be ready for use. Follow the
installation and maintenance description carefully.
Due to transport, stowage and temperature changes, all hydraulic connections

should be re-tightened after installation on board, to prevent leakage.

4 APPENDIX B
4.1 Warranty conditions

Warranty conditions - ORGALIME S92
GENERAL CONDITIONS
for the
SUPPLY OF MECHANICAL, ELECTRICAL AND

ASSOCIATED ELECTRONIC PRODUCTS
Brussels, October 1992
PREAMBLE
These General Conditions shall apply when the parties agree in writing or otherwise thereto. When
the General Conditions apply to a specific contract, modifications of or deviations from them must be
agreed in writing. The object(s) to be supplied under these conditions is(are) hereinafter referred to as
the Product.
PRODUCT INFORMATION
All information and data contained in product brochures and price lists are binding only to the
extent that they are by reference expressly included in the contract.
DRAWINGS AND DESCRIPTIONS

All drawings and technical documents relating to the Product or its manufacture submitted by
one party to the other, prior or subsequent to the formation of the contract, shall remain the
property of the submitting party. Drawings, technical documents or other technical
information received by one party shall not, without the consent of the other party, be used
for any other purpose than erection, commissioning, operation or maintenance of the Product.
They may not, without the consent of the submitting party, otherwise be used or copied,
reproduced, transmitted or communicated to a third party.
At the start of the period referred to in Clause 23 the Supplier shall, if so requested by the
Purchaser, free of charge provide information and drawings which are necessary to permit
the Purchaser to erect, commission, operate and maintain the Pr<>duct. Such information
and drawings shall be supplied in the number of copies agreed upon or at least one copy of
each. The Supplier shall not be obliged to provide manufacturing drawings for the Product or
spare parts.
ACCEPTANCE TESTS
Acceptance tests provided for in the contract shall, unless otherwise agreed, be carried out
at the place of manufacture during normal working hours. If the contract does not specify the
technical requirements, the tests shall be carried out in accordance with general practice in
the appropriate branch of industry concerned in the country of manufacture.
The Supplier shall notify the Purchaser of the acceptance tests in sufficient time to permit the
Purchaser to be represented at the test. If the Purchaser is not represented, the test report
shall be sent to the Purchaser and shall be accepted as accurate.
If the acceptance tests show the Product not to be in accordance with the contract, the
Supplier shall without delay remedy any deficiencies in order to ensure that the Product
complies with the contract. New tests shall then be carried out at the Purchaser’s request,
unless the deficiency was insignificant.

The Supplier shall bear all costs for acceptance tests carried out at the place of manufacture.
The Purchaser shall however bear all travelling and living expenses for his representatives in
connection with such tests.
DELIVERY. PASSING OF RISK

Any agreed trade term shall be construed in accordance with the INCOTERMS in force at the
formation of the contract. If no trade term is specifically agreed the delivery shall be Ex
works (EXW).
If, in the case of delivery Ex works, the Supplier, at the request of the Purchaser, undertakes
to send the Product to its destination, the risk will pass not later than when the Product is
handed over to the first carrier. Partial shipments shall be permitted unless otherwise
agreed.
TIME FOR DELIVERY. DELAY

If the parties, instead of specifying the date for delivery, have specified a period of time on
the expire of which delivery shall take place, such period shall start to run on the date when
the Supplier receives the Purchaser’s order or the date of formation of the contract,
whichever is the later.
If the Supplier anticipates that he will not be able to deliver the Product at the time for
delivery, he shall forthwith notify the Purchaser thereof in writing, stating the reason, and, if
possible, the time when delivery can be expected.
If delay in delivery is caused by any of the circumstances mentioned in Clause 39 or by an
act or omission on the part of the Purchaser, including suspension under Clauses 20 or 42,
the time for delivery shall be extended by a period which is reasonable having regard to all
the circumstances in the case. This provision applies regardless of whether the reason for
the delay occurs before or after the agreed time for delivery.
If the Product is not delivered at the time for delivery (as defined in Clauses 10 and 12), the
Purchaser is entitled to liquidated damages from the date on which delivery should have
taken place.
The liquidated damages shall be payable at a rate of 0.5 per cent of the purchase price
for each completed week of delay. The liquidated damages shall not exceed 7.5 per
cent of the purchase price. If only part of the Product is delayed, the liquidated
damages shall be calculated on that part of the purchase price which is attributable to
such part of the Product as cannot in consequence of the delay be used as intended
by the parties. The liquidated damages become due at the Purchaser’s written
demand but not before delivery has been completed or the contract is terminated
under Clause 14. The Purchaser shall forfeit his right to liquidated damages if he has
not lodged a claim for such damages within six months after the time when delivery
should have taken place.
If the delay in delivery is such that the Purchaser is entitled to maximum liquidated damages
under Clause 13 and if the Product is still not delivered, the Purchaser may in writing demand
delivery within a final reasonable period which shall not be less than one week. If the
Supplier does not deliver within such final period and this is not due to any circumstance for
which the Purchaser is responsible, then the Purchaser may by notice in writing to the
Supplier terminate the contract in respect of such part of the Product as cannot in
consequence of the Supplier’s failure to deliver be used as intended by the parties.
If the Purchaser terminates the contract he shall be entitled to compensation for the
loss he has suffered as a result of the Supplier’s delay. The total compensation,

including the liquidated damages which are payable under Clause 13, shall not exceed
15 per cent of that part of the purchase price which is attributable to the part of the
Product in respect of which the contract is terminated.
Liquidated damages under Clause 13 and termination of the contract with limited compensation
under Clause 14 are the only remedies available to the Purchaser in case of delay on the
part of the Supplier. All other claims against the Supplier based on such delay shall be
excluded, except where the Supplier has been guilty of gross negligence. In these
conditions gross negligence shall mean an act or omission implying either a failure to pay
due regard to serious consequences, which a conscientious supplier would normally foresee
as likely to ensue, or a deliberate disregard of the consequence of such actor omission.
If the Purchaser anticipates that he will be unable to accept delivery of the Product at the
delivery time, he shall forthwith notify the Supplier thereof stating the reason, and, if possible,
the time when he will be able to accept delivery. If the Purchaser fails to accept delivery at
the delivery time he shall nevertheless pay any part of the purchase price which becomes
due on delivery as if delivery had taken place. The Supplier shall arrange for storage of the
Product at the risk and expense of the Purchaser. The Supplier shall also, if the Purchaser
so requires, insure the Product at the Purchaser’s expense.
Unless the Purchaser’s failure to accept delivery is due to any such circumstance as
mentioned in Clause 39, the Supplier may by notice in writing require the Purchaser to
accept delivery within a final reasonable period. If, for any reason for which the Supplier is
not responsible, the Purchaser fails to accept delivery within such period, the Supplier may
by notice in writing terminate the contract in whole or in part. The Supplier shall then be
entitled to compensation for the loss he has suffered by reason of the Purchaser’s default.
The compensation shall not exceed that part of the purchase price which is attributable to
that part of the Product in respect of which the contract is terminated.
PAYMENT
Unless otherwise agreed, the purchase price shall be paid with one third at the formation of
the contract and one third when the Supplier notifies the Purchaser that the Product, or the
essential part of it, is ready for delivery. Final payment shall be made when the Product is
delivered.
Whatever the means of payment used, payment shall not be deemed to have been effected
before the Supplier’s account has been fully and irrevocably credited.
If the Purchaser fails to pay by the stipulated date, the Supplier shall be entitled to interest
from the day on which payment was due. The rate of interest shall be as agreed between
the parties. If the parties fail to agree on the rate of interest, it shall be 12 per cent per
annum.

In case of late payment the Supplier may, after having notified the Purchaser in writing,
suspend his performance of the contract until he receives payment.
If the Purchaser has not paid the amount due within three months the Supplier shall
be entitled to terminate the contract by notice in writing to the Purchaser and to claim
compensation for the loss he has incurred. The compensation shall not exceed the
agreed purchase price.
RESERVATION OF TITLE
The Product shall remain the property of the Supplier until paid for in full to the extent that
such retention of property is valid under the applicable law. The Purchaser shall at the
request of the Supplier assist him in taking any measures necessary to protect the Supplier’s
title to the Product in the country concerned. The retention of title shall not affect the passing
of risk under Clause
9.
LIABILITY FOR DEFECTS

Pursuant to the provisions of Clauses 23-37 inclusive, the Supplier shall remedy any defect
resulting from faulty design, materials or workmanship.
The Supplier’s liability is limited to defects which appear within a period of one year from
delivery. If the daily use of the Product exceeds that which is agreed, this period shall be
reduced proportionately.
When a defect in a part of the Product has been remedied, the Supplier shall be liable for
defects in the repaired or replaced part under the same terms and conditions as those
applicable to the original Product for a period of one year. For the remaining parts of the
Product the period mentioned in Clause 23 shall be extended only by a period equal to the
period during which the Product has been out of operation as a result of the defect.
The Purchaser shall without undue delay notify the Supplier of any defect which appears.
Such notice shall under no circumstances be given later than two weeks after the expire of
the period given in Clause 23. Where the defect is such that it may cause damage, the
notice shall be given immediately. The notice shall contain a description of the defect. If the
Purchaser does not notify the Supplier of a defect within the time-limits set forth in this
Clause, he shall lose his right to have the defect remedied.
On receipt of the notice in writing under Clause 25 the Supplier shall remedy the defect
without undue delay and at his own cost as stipulated in Clauses 22-37 inclusive. Repair
shall be carried out at the place where the Product is located unless the Supplier deems it
appropriate that the defective part or the Pr(>duct is returned to him for repair or replacement.
The Supplier is obliged to carry out dismantling and re-installation of the part if this requires
special knowledge. If such special knowledge is not required, the Supplier has fulfilled his
obligations in respect of the defect when he delivers to the Purchaser a duly repaired or
replaced part.
If the Purchaser has given such notice as mentioned in Clause 25, and no defect is found for
which the Supplier is liable, the Supplier shall be entitled to compensation for the costs he
has incurred as a result of the notice.
The Purchaser shall at his own expense arrange for any dismantling and reassemble of
equipment other than the Product, to the extent that this is necessary to remedy the defect.

Unless otherwise agreed, necessary transport of the Product and/or parts thereof to and from
the Supplier in connection with the remedying of defects for which the Supplier is liable shall
be at the risk and expense of the Supplier. The Purchaser shall follow the Supplier’s
instructions regarding such transport.
Unless otherwise agreed, the Purchaser shall bear any additional costs which the Supplier
incurs for repair, dismantling, installation and transport as a result of the Pr(>duct being
located in a place other than the destination stated in the contract or - if no destination is
stated - the place of delivery.
Defective parts which have been replaced shall be made available to the Supplier and shall
be his property.
If, within a reasonable time, the Supplier does not fulfil his obligations under Clause 26, the
Purchaser may, by written notice, fix a final time for completion of the Supplier’s obligations.
If the Supplier fails to fulfil his obligations within such final time, the Purchaser may
himself undertake or employ a third party to undertake necessary remedial works at
the risk and expense of the Supplier. Where successful remedial works have been
undertaken by the Purchaser or a third party, reimbursement by the Supplier of
reasonable costs incurred by the Purchaser shall be in full settlement of the Supplier’s
liabilities for the said defect.
Where the defect has not been successfully remedied,
a)the Purchaser is entitled to a reduction of the purchase price in proportion to the reduced
value of the Product, provided that under no circumstance shall such reduction exceed 1 5
per cent of the purchase price, or
b)where the defect is so substantial as to significantly deprive the Purchaser of the benefit of
the contract, the Purchaser may terminate the contract by written notice to the Supplier. The
Purchaser is then entitled to compensation for the loss he has suffered up to a maximum of
15 per cent of the purchase price.
The Supplier is not liable for defects arising out of materials provided by, or a design
stipulated or specified by the Purchaser.
The Supplier is liable only for defects which appear under the conditions of operation
provided for in the contract and under proper use of the Product. The Supplier’s liability does
not cover defects which are caused by faulty maintenance, incorrect erection or faulty repair
by the Purchaser, or by alterations carried out without the Supplier’s consent in writing.
Finally the Supplier’s liability does not cover normal wear and tear or deterioration.
Notwithstanding the provisions of Clauses 22-35 the Supplier shall not be liable for defects in
any part of the Product for more than two years from the beginning of the period given in
Clause 23.
Save as stipulated in Clauses 22-36, the Supplier shall not be liable for defects. This applies
to any loss the defect may cause including loss of production, loss of profit and other indirect
loss. This limitation of the Supplier’s liability shall not apply if he has been guilty of gross
negligence as defined in Clause 15.

DIVISION OF LIABILITY FOR DAMAGE CAUSED BY THE
PRODUCT
The Supplier shall not be liable for any damage to property caused by the Product after it has been
delivered and whilst it is in the possession of the Purchaser. Nor shall the Supplier be liable for any
damage to products manufactured by the Purchaser, or to products of which the Purchaser’s products
form a part.
If the Supplier incurs liability towards any third party for such damage to property as described in the
preceding paragraph, the Purchaser shall indemnify, defend and hold the Supplier harmless.
If a claim for damage as described in this Clause is lodged by a third party against one of the parties,
the latter party shall forthwith inform the other party thereof in writing.
The Supplier and the Purchaser shall be mutually obliged to let themselves be summoned to the court
or arbitral tribunal examining claims for damages lodged against one of them on the basis of damage
allegedly caused by the Product.
The limitation of the Supplier’s liability in the first paragraph of this Clause shall not apply where the
Supplier has been guilty of gross negligence as defined in Clause 15.
FORCE MAJEURE
Either party shall be entitled To suspend performance of his obligations under the contract to
the extent that such performance is impeded or made unreasonably onerous by any of the
following circumstances: industrial disputes and any other circumstance beyond the control
of the parties such as fire, war (whether declared or not), extensive military mobilisation,
insurrection, requisition, seizure, embargo, restrictions in the use of power and defects or
delays in deliveries by sub-contractors caused by any such circumstances referred to in this
Clause.
A circumstance referred to in this Clause which had occurred prior to the formation of
the contract shall give a right to suspension only if its effect on the performance of the
contract could not be foreseen at the time of the formation of the contract.
The party claiming to be affected by Force Majeure shall notify the other party in writing
without delay on the intervention and on the cessation of such circumstance.
If Force Majeure prevents the Purchaser from fulfilling his obligations, he shall
compensate the Supplier for expenses incurred in securing and protecting the
Product.
Regardless of what might otherwise follow from these General Conditions, either party shall
be entitled to terminate the contract by notice in writing to the other party if performance of
the contract is suspended under Clause 39 for more than six months.
ANTICIPATED NON-PERFORMANCE
Notwithstanding other provisions in these conditions regarding
suspension, each party shall be entitled to suspend the performance of his obligations under
the contract, where it is clear from the circumstances that the other party will not be able to
perform his obligations. A party suspending his performance of the contract shall forthwith
notify the other party thereof in writing.

CONSEQUENTIAL LOSSES
Save as elsewhere stated in these conditions there shall be no liability for either party
towards the other party for loss of production, loss of profit, loss of use, loss of contracts or
for any consequential, economic or indirect loss whatsoever.
DISPUTES AND APPLICABLE LAW

All disputes arising in connection with the contract shall be finally settled under the Rules of
Conciliation and Arbitration of the International Chamber of Commerce by one or more
arbitrators appointed in accordance with the said rules, supplemented as necessary by the
procedural rules of the law of the country of the Supplier’s place of business most closely
connected with the contract.
The contract shall be governed by the substantive law of the country of the Supplier’s
place
of business most closely connected with the contract.
This is an Orgalime publication. Orgalime groups the central trade federations of the mechanical, electrical, electronic and
metalworking industries in sixteen European countries and provides liaison between these organisations in the legal,
technical and economic fields.
All rights reserved
©
Editeur responsible - T.F. GAY
ORGALIME (liaison group of the European mechanical, electrical, electronic and metalworking industries)
Rue de Stassart 99 - 8 - 1050 Bruxelles - Tel : (32) 2-511.34.84 & 97 - Fax : 51 2.99.70

5 APPENDIX C
5.1 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. +47 370 58501.
All sales and service are acc. To Orgalime S92. Norsafe must accept all
warranty claims in writing AS prior to dispatch of parts or service personnel.
Davit / boat build no:
Davit type:
Voltage/frequency
onboard:
Ship is built 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 Service only Spare parts and service
Quote price first Send parts immediately without quoting
Warranty claim Ordinary service call
Description of problem (please add more sheets if necessary

3. MANUALS FOR MIDGET 530 MKII RESCUE BOAT
3.1 Operation & Maintenance manual for Midget 530MKII Rescue boat
Operation and maintenance manual
for Norsafe rescue boat type
Midget 530
Water-jet version w/ K4FM release hook
Norsafe AS, P.O.Box 115, N-4852 Færvik

Norway
Phone: +47 37 05 85 00 Fax: +47 37 05 85 01

Email: mail@norsafe.com
Internet: www.norsafe.com
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Revision Table
Rev No. Description By Chk App Date

A Preliminary, issued for prototype KS 17.01.2003
0 General update JTO BS 29.02.2008
1 Revise acc to MSC.1205 and 1206 ATE POP BS 04.03.2010
Norsafe AS, Postbox 115, N-4852 FÆRVIK

NORWAY
Service:
Phone: + 47 37 05 63 33 Fax: + 47 37 06 27 51 E-mail: service@norsafe.no
After sales:
Fax: + 47 37 05 85 11 E-mail: spareparts@norsafe.no
Claim:
Fax: + 47 37 06 27 51 E-mail: warrantyclaim@norsafe.no
Please quote the Norsafe boat build number when contacting Norsafe. The numbers are
given on enclosed certificates, and is also shown on the name plate on the rescue boat.
During the warranty period, all necessary spare parts must be supplied by Norsafe AS.
Norsafe AS are released from all responsibility regarding malfunction or failure of the
equipment if maintenance is not completed according to Norsafe maintenance
manuals/instructions, or if maintenance requiring Norsafe trained and certified personnel
are performed by non certified personnel. Ref MSC.1/Circ. 1206 Annex 1, item 11 and
12.
Side 2 Q:\Boats\Midget 530\C Instruction manuals Rev.1

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Identification symbols for levels of risk used in this manual:
Highest level of risk.

Incorrect or incomplete operation may result in death or serious injury.
Second highest level of risk.

Incorrect or incomplete operation may result in equipment damage.
Less critical mandatory instructions.
Important note that should be emphasized.
A prohibited action.
Incorrect action may result in death of occupants.
Q:\Boats\ Midget 530\C Instruction manuals Rev.1 Side 3

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TABLE OF CONTENTS
1 METHOD OF CHECKING PROPER CLOSURE OF RELEASE HOOK ........................................... 7
2 LAUNCHING OPERATION ...................................................................................................................... 8

2.1 PREPARATION BEFORE LAUNCHING. .................................................................................................... 8
2.2 SETTING OF PAINTER............................................................................................................................ 9
2.3 BOARDING THE RESCUE BOAT ............................................................................................................ 10
2.4 LAUNCHING PROCEDURE ................................................................................................................... 11
2.5 OFF-LOAD RELEASE ........................................................................................................................... 12
2.6 PAINTER RELEASE AND RESCUE BOAT OPERATION ............................................................................. 13
3 RECOVERY OPERATION ...................................................................................................................... 14
3.1 RESETTING PROCEDURE OF RELEASE HOOK ....................................................................................... 14
3.2 RECOVERY PROCEDURE OF RESCUE BOAT .......................................................................................... 14
3.3 CONNECTION OF THE SUSPENSION LINK ............................................................................................. 16
3.4 HOISTING THE RESCUE BOAT ............................................................................................................. 17
3.5 STOWAGE PROCEDURE ....................................................................................................................... 17
4 OFF-LOAD RELEASE GEAR SYSTEM ................................................................................................ 19
4.1 RELEASING PROCEDURE NORSAFE K4 HOOK. .................................................................................... 19
5 OPERATION OF EQUIPMENT .............................................................................................................. 20
5.1 STARTING THE ENGINE....................................................................................................................... 20
5.2 ENGINE OPERATION ........................................................................................................................... 21
5.3 FLOW DEFLECTOR .............................................................................................................................. 21
5.4 THROTTLE / SHIFTING GEARS ............................................................................................................. 21
5.5 STOPPING THE ENGINE (NORMAL) ...................................................................................................... 22
5.6 STOPPING THE ENGINE (EMERGENCY) ................................................................................................ 22
5.7 ENGINE COOLING ............................................................................................................................... 22
5.8 DEAD MAN SWITCH ............................................................................................................................ 22
5.9 RESCUE OF PERSONS IN THE WATER ................................................................................................... 23
5.10 TOWING ............................................................................................................................................. 24
5.11 ROWING ............................................................................................................................................. 24
5.12 LOOSE EQUIPMENT ............................................................................................................................ 24
5.13 STRAPS FOR SECURING STRETCHER.................................................................................................... 24
5.14 FUEL TANK ........................................................................................................................................ 24
5.15 FUEL SHUT OFF VALVE ....................................................................................................................... 24
5.16 EMERGENCY STEERING ...................................................................................................................... 25
5.17 RADAR REFLECTOR AND MARKER LIGHTS.......................................................................................... 25
5.18 BATTERY CHARGER ........................................................................................................................... 25
5.19 IN CASE THE BOAT IS CAPSIZED .......................................................................................................... 25
6 INSPECTION AND MAINTENANCE .................................................................................................... 26
6.1 GENERAL PRECAUTIONS AND PRODUCT LIABILITY INFORMATION ..................................................... 26
6.2 LOOSE EQUIPMENT ............................................................................................................................ 27
6.3 HATCHES ........................................................................................................................................... 27
6.4 LIFTING HOOK ................................................................................................................................... 27
6.5 ENGINE .............................................................................................................................................. 27
6.6 FUEL .................................................................................................................................................. 27
6.7 ENGINE OIL LEVEL ............................................................................................................................. 27
6.8 COOLING SYSTEM .............................................................................................................................. 27
6.9 WATER JET ........................................................................................................................................ 28
6.10 WATER SEAL ..................................................................................................................................... 28
6.11 DRIVE SHAFT UNIVERSALS................................................................................................................. 28
6.12 SACRIFICIAL ANODES......................................................................................................................... 28
6.13 ELECTRICAL SYSTEM ......................................................................................................................... 28

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6.14 GENERAL ........................................................................................................................................... 28
6.15 INSPECTION AND MAINTENANCE OF RESCUE BOAT AND RELEASE GEAR SYSTEM ............................... 29
6.16 INSPECTION AND MAINTENANCE PLAN ............................................................................................... 29
6.17 INSPECTION PROCEDURE AND MAINTENANCE PLAN FOR BOAT........................................................... 30
6.18 INSPECTION PROCEDURE AND MAINTENANCE PLAN FOR ENGINE ....................................................... 31
6.19 INSPECTION PROCEDURE AND MAINTENANCE PLAN FOR ELECTRIC PARTS. ........................................ 32
6.20 INSPECTION PROCEDURE AND MAINTENANCE PLAN FOR RESCUE BOAT EQUIPMENT. ......................... 32
6.21 INSPECTION AND MAINTENANCE OF LAUNCHING APPLIANCES (DAVITS AND WINCHES) ..................... 32

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General
The craft has been designed and constructed for offshore use in rough water. It
will provide high sustained speed in rough offshore environments. The boat is
moulded from fire retardant polyester resin. The space between the hull and liner
is filled with polyurethane buoyancy foam, which provides the craft with enough
buoyancy to remain afloat even if holed below the waterline.
Carrying capacity is up to 6 persons including space for a stretcher. The boat is
self-bailing and protected by a rubber fender going completely around the
boat.(MK II) Lifelines and handgrips are fitted around the gunwale.
An approved Off Load single point lifting hook for attaching the fall from a davit or
crane is mounted on the centre console. The hook can only be opened when
there is no load on the fall and must be used together with the painter release
hook on the bow for safe launching of the boat.
In the event that the boat capsizes, it is possible for 2 men to righten the boat
back to the upright position.
Fuel is filled at the side of the seat in bow of the boat. Access to the fuel tank is
via a hatch on the deck in front of the console. Draining of the tank is made here.
Loose equipment is placed in a storage locker under deck forward or mounted in
the boat. A bilge pump and a fire extinguisher are mounted in the aft part of the
boat. Two batteries are installed under the seat, and a battery charger is
mounted inside the console. When running, the engine will charge the batteries.
When the boat is in the stowed position, the charger will take over. The charger
is supplied with 42V AC from the ship via a plug on the front side of the console.

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1 Method of checking proper closure of release hook
Safe use and operation of rescue boats during drills, inspection and maintenance is dependent
on knowing that the release gear is properly reset.
Ensuring release hook closure. The first thing to check whenever entering the rescue boat when
it is (or will be) supported by the falls is properly reset as follows:
No Operation guide Schematic diagram/picture

1 Check that the hook is in closed Master link
position and the master link is locked
behind the mousing unit.
Mousing unit
2 Check that the safety pin on the hook

is in its correct secured position. Safety pin
Saft pin

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2 Launching operation
2.1 Preparation before launching.

1 Prepare transceivers, and confirm the
communication condition.
2 Turn on the power switch of davit start

panel.
3 Detach the cable for the

storage battery charge. Power
supply plug
4 Remove any lashing.

Lashings

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5 Put on life jackets.
2.2 Setting of painter

1 Confirm the connection of the painter on
the painter release hook of the rescue
boat.
Painter
Painter release
release hook handle
2 Confirm the connection of the painter as

far forward as practicable inboard of the
falls but outboard of everything else.
Painter
Ensure the painter is lead from the painter hook outboard of the vessel as
far as practicable. Failure to do so will result in severe difficulties clearing
the vessel during abandonment.

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2.3 Boarding the rescue boat

1 Board the rescue boat.
2 Open the fuel shut-off valve.

Fuel shut-off
valve
3 Turn on the main power switch.

Secondary
power switch
Main power
switch
Make sure that the persons onboard the rescue boat is seated in their
correct positions to maintain a good trim of the boat.

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2.4 Launching procedure

1 Confirm that all crew boarded in the
rescue boat are seated.
2 Launch the rescue boat by operating the

the winch using the push-button switch
following the instruction by the officer
in charge.
 Ensure that no gripe or lashing is tangled around the boat.

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2.5 Off-load release

This is the only method of launch and
release and is conducted when the rescue
boat is fully waterborne.
Confirm the following before the operation:

 Rescue boat is fully waterborne.
 The engine is started.
 All crew members are in their seats.

1 Confirm that the lifeboat is
waterborne.
2 Start engine. (Press the green start

button on control panel)
Note: The rescue boat can be equiped

with different control panels.
3 Designated crew member goes forward Safety pin

to remove safety pin on release hook,
stand clear and inform the helmsman
that the hook is active.

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4 Helmsman pull the release control wire
Release control wire
until master link are clear of the hook.
The boat is now hanging by the painter.
Do not put your foot on the release pedal before the rescue boat is water
born. When lowering the boat, a sudden stop may cause the wire to
behave elastic which can efect a slack wire. Stepping on the pedal can
then release the hook and the boat will fall freely. This may result in
injury or death to the crew.
2.6 Painter release and rescue boat operation

1 Helmsman engage gear, and designated crew
member goes forward and release the painter
by pulling the release handle at top of the
forward spray hood.
Painter Painter
release release
hook handle
2 Lifeboat operation
Ahead, astern, turning, marking light, and
other performances.
If the ship is making headway and the painter is released before the fall
wire, this may result in injury or death to the crew of the rescue boat.

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 Do not turn the steering wheel while the painter is connected.

 The rescue boat should get clear of the vessel promptly when the
painter has been released.
3 Recovery operation
3.1 Resetting procedure of release hook

1 Rotate the hook back in closed position and
replace the hook safety pin. Check that the hook is
locked by the safety pin
3.2 Recovery procedure of rescue boat
The recovery procedure is to be in accordance with the following steps only after completing
the release gear resetting.

1 Manouver the boat toward the loose
painter end hanging from the vessel.

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2 Attach the painter to the painter release
hook
Painter
Painter release
release hook handle
3 Let the boat drift slowly until the

painter is taut. The rescue boat should
now be located directly under the
davit or lifting crane.
If the ship is making headway and the painter is not fastened to the
painter release hook before lifting the rescue boat out of the water, this
may result in death or serious injuries.

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3.3 Connection of the suspension link

1 Designated crew member connects the
suspension link to release hook.
2 Turn off the engine. (Press the red stop button

on the control panel)
3 Hoist the boat just clear of water and confirm

that release hook is propely connected.
 Do not connect the suspension link of the fall wire to the release
hook until reset of the hook has been completed. It is dangerous
to connect the suspension link during resetting operation of the
release hook, and may result in an incomplete reset.

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3.4 Hoisting the rescue boat
1 Hoist the rescue boat by operating the
winch using the push-button switch
following the instruction by the officer
in charge.
2 Hoist the rescue boat until it is in the up-

most position.
3 Disembark from the rescue boat.
3.5 Stowage procedure

1 Secure the rescue boat by lashings to the davit or
cradle. Lashings
2 Connect the external power supply.

Power
supply plug

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3 Refill oil and fuel.
3 Close fuel shut-off valve.

Fuel shut-off
valve
4 Put on the consol cover or boat cover.
2 Make sure that all loose equipment are onboard

the rescue boat according to the list inside the
equipment compartment.

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4 Off-load release gear system
This section describes the details of the release gear system. Read this section
carefully for safe operation. Lifting is by a single point arrangement. .
4.1 Releasing procedure Norsafe K4 hook.

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5 OPERATION OF EQUIPMENT
5.1 Starting the engine

As the boat may be fitted with different engines, please refer to engine manual
for details about engine operation and maintenance. Only a few general points
are covered here.
1. Bilge pump 12. Start

2. Navigation light 13. Main battery switch
3. Working light 14. Emergency battery switch
4. Spare 15. Alarm(inside console)
5. Engine check 16. Throttle / Gearshift
6. Water temp. 17. Compass
7. Oil pressure/Preheating 18. Water jet control
8. Battery charge 19. Dead man switch
9. RPM 20. Searchlight contact
10. Fuel tank
11.On/Off
1 Disconnect the external power-supply to the boat.
Battery chargers may be damaged or overload its fuses if

engine is started with power-supply connected.
2 Turn main battery switch to “ON” position by turning clockwise.

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3 Fix the dead man switch on the engine control panel in the run position by
pressing a special clip onto the switch. This clip has a lanyard that is to be
attached to the driver’s clothing. This ensures that the engine will stop if the
driver is removed from his position.
4 Check that the throttle control is in idle position.
5 Push the red ON/OFF button to activate engine.
6 Push the green start button until engine start, but no longer than 15 seconds
at a time to avoid overheating. When the engine starts, release button.
7 If main battery is not able to supply enough power to turn the engine over,
transfer battery switch key to emergency battery and turn on. Starting may
now continue from step 4 with the emergency start battery.
8 If the engine does not start after 2-3 attempts, investigate and rectify the
problem before starting is continued. Repeated starting attempts will only
deplete batteries and damage engine.
5.2 Engine operation

When the engine has started, leave the engine running at idle for a few seconds
before engaging gear.
When the engine is running, make sure that water is coming out of the exhaust
pipe. This indicates that the cooling water system is in order.
Check immediately after starting that the oil pressure gauge and the voltmeter
show normal values and that all alarms are quiet. If abnormal values are shown,
or any alarm sounds during operation, the engine should be stopped immediately
and the cause investigated.
5.3 Flow deflector

The flow deflector mounted to the stator is when lowered into the jet stream,
designed to force the water-trust forward. This enables the boat to reverse and a
skilled helmsman can with semi-engaged deflector accurately manoeuvre or
position the boat even in rough water or currents.
Forward
Push control lever forward, away from you. In topmost position the flow deflector
will be out of the jet stream and the boat may accelerate forward.
Reverse
Push control lever backward, towards you. In down-most position, the flow
deflector will be in the jet stream and the boat may accelerate backward.
5.4 Throttle / shifting gears

This boat is not equipped with a gear to disengage the waterjet.
To select forward lift the reverse deflector up, by pushing the right lever forward.
To increase speed, push the left (throttle) lever forward. When it stops, the
engine is running at maximum forward speed.

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To select reverse, lower the reverse deflector by pulling the right lever
backwards. This will lower the reverse deflector, and direct the water beam
forward/down, stopping the boat at a minimum of distance.
Exercise care when operating in reverse gear. Do not operate

engine at high speed when in reverse. Full throttle may be
inaccessible in reverse, so do not force levers.
5.5 Stopping the engine (normal)

After high speed running, leave engine to cool down at low RPM (around 1000)
for 1 to 2 minutes. Pull engine throttle to idle position. Push the red ON/OFF
button until engine stops.
5.6 Stopping the engine (emergency)

In an emergency the engine can be stopped at any speed.
Push the stop button until engine stops.
Engine will also stop if the dead man switch lanyard is removed.
5.7 Engine cooling

A mix of fresh water and antifreeze, which is circulated by a water pump, cools
the engine. This mix is again cooled by seawater in a heat exchanger.
The seawater comes from the water jet, through a filter to the heat exchanger,
and is expelled through the exhaust pipe. Taking water from the water jet
eliminates the seawater pump on the engine and its dry run problems when the
boat is stowed. It will also ensure a more continuous water flow through the
engine, especially in choppy seas.
For most water jet equipped rescue boats, cooling water to

the engine comes from the jet. Therefore the engine will have
no cooling when the jet is not running, ie gearbox in neutral
or reverse. Engine may run for a substantial time at idling
from cold, but after high speed running it must cool down as
explained above to avoid overheating.
5.8 Dead man switch

The purpose of the dead man switch is to stop the engine when the operator
leaves his control station accidentally either by falling into the boat or by falling or
being ejected overboard.
The dead man switch consists of a lanyard with clip at both ends. One end is
secured to the operator of the boat and the other end is fastened to the run / off
switch on the engine control panel. If the operator is removed from his position
the lanyard will pull the clip out of the switch and stop the engine.

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If lanyard with clips is missing it is possible to manually hold the dead man switch
in "on" position, enabling the crew to temporarily operate the boat.
Activation of the dead man switch at high speed will cause an immediate
deceleration of the craft, therefore all passengers should remain seated at
all times especially when the boat is proceeding with speed..
5.9 Rescue of persons in the water

A person in the water will be drifting due to the effects of wind and sea, therefore
it is important for the helmsman to plan any rescue and inform the crew of the
plan.
To effectuate a safe and successful rescue bear in mind the following:
Set a course that puts the boat in a position where the person in the water is
drifting towards the boat.
Reduce speed when close to the person in the water. It is better to stop short
than to overshoot and have to go around again.
When very close to the person, let him drift into the side of the boat..
Two crew members should position themselves on the side of the boat on which
the rescue is to be effected.
When contact is made, the crew should grab the person under the arms and
together pull him up into the boat. If the person is injured he should be placed on
the stretcher keeping his head elevated.
The helmsman should pay careful attention to the position of the

person in the water.
Make sure he is always clear of the water jet. If in doubt, put engines
in neutral position.
Never attempt to bring someone into the boat over the stern.
Always use the side of the boat.

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5.10 Towing
A principal function of a rescue boat is to tow and marshal life rafts. Two towing
bollards are located under the self-righting arch.
During towing, keep the towing cable away from the water jet.
5.11 Rowing
Should it be required to row the boat, a set of paddles is supplied. These are
secured to the port inside of the boat.
5.12 Loose equipment

Loose equipment according to regulation is supplied. A loose equipment list is
located together with the equipment inside the equipment compartment. This
equipment must be periodically checked to verify that it is in serviceable
condition, and that it is complete.
5.13 Straps for securing stretcher

A strap with snap hook for securing stretcher, when stretcher is placed on angle
bar mounted on the hatch in front of the console, is stowed inside the equipment
locker under the forward part in the boat. Two lashing eyes, one on each side of
console, are mounted for attachment the strap.
5.14 Fuel tank

A 57 litres fuel tank is installed below deck level in front of the console. Only
clean fuel of a grade specified by the engine supplier must be used. Careful
periodic inspection of the entire fuel system is mandatory, particularly after
storage. All fuel components including fuel tank, fuel lines, fittings, and fuel filters
should be inspected for leakage, deterioration or corrosion. Any sign of leakage
or deterioration necessitates replacement before further engine operation.
Fire and explosion hazard. Fuel leakage from any part of

the fuel system can be a fire and explosion hazard that
can cause serious bodily injury or death.
5.15 Fuel shut off valve

A fuel shut off valve is situated at aft. side of the fuel tank. Turn handle clockwise
to close all fuel delivery in situations with fire or explosion hazard, and while
docked.

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5.16 Emergency steering
If case of steering failure an emergency steering tiller is placed in water jet
compartment. For use of emergency steering, open water jet compartment and
remove lock splint and bolt securing steering wire and remove steering wire.
Place emergency steering tiller over steering control lever and secure with lock
splint and bolt.
5.17 Radar reflector and marker lights

A radar reflector is mounted on the top of the console. After the boat is launched,
the reflector must be secured in the vertical position to work as required. Before
recovery of the boat, the reflector must be put back to the stowed condition to
avoid damage.
A bracket for position indicating light (white) is mounted on the port side of the
console. The position indicating light itself is secured to the port inside of the
boat.
5.18 Battery charger

Inside the central console is a battery charger for charging the batteries when the
rescue boat is docked onboard the ship. Power is supplied to the charger via the
quick disconnect plug located on the aft side of the engine compartment.
Supplied current at 42 V AC is converted by the battery charger to 12 V DC
charging both batteries. Before starting the engine disconnect the 42 V AC
supply.
The batteries are charged independently, and the charger has indicator lights
showing battery status.
5.19 In case the boat is capsized

The boat is able to be righted by 2 men back to its normal position.
1. After the boat has returned to the upright position, climb back into the boat,
either over the side or the transom, where the water jet protection bar can
be used to step on. Let the boat drain and check compartments for water.
Also verify that no oil leaks have occurred.
2. Run the starter motor on the engine in short bursts of one second a couple
of times with the cord on the dead man switch removed. If the engine
turns over normally, it is confirmed that no water has entered the cylinders.
3. Replace cord on dead man switch and start engine.

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6 Inspection and maintenance
6.1 General precautions and product liability information
SOLAS regulation III/20 requires that all life-saving appliances shall be in working order
and ready for immediate use before the ship leaves port and at all times during the voyage.
Lifeboats, launching appliances and release gear are required by SOLAS regulation III/20
to be inspected weekly and monthly according to the instructions for on-board
maintenance complying with the requirements of SOLAS regulation III/36. Also,
MSC.1/Circ.1206 describes more detailed procedures for periodic servicing and
maintenance of lifeboats, launching appliances and release gear.
This manual includes only the weekly and monthly inspection and maintenance, which are
conducted on board under the direct supervision of a senior ship’s officer.

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6.2 Loose equipment
Loose equipment should be periodically checked to ensure equipment is properly
stowed and is in serviceable condition.
6.3 Hatches
Rubber gaskets around hatches should be checked for deterioration. If any sign
of cracking or brittleness exist, gasket should be replaced immediately.
6.4 Lifting hook

Lifting hook should be checked for any visual damage or deterioration. Check if
safety pin is free to move.
6.5 Engine
The engine maintenance and checks should be performed in accordance with
the engine manufacturer instruction manual, although some basic engine checks
will be covered here.
The engine should be started using both main and emergency batteries during
the periodic checks.
Lubrication and greasing points are specified in the engine manufactures manual
6.6 Fuel
Use only diesel of a quality equal to or higher than prescribed in manufactures
manual. If refilling from a drum, allow drum to stand 3 to 4 days to precipitate the
water and dirt to the bottom. Then use the fuel at the top.
A fuel filter and water-separator is installed in the engine compartment. This must
be drained and filter cleared or changed as required.
6.7 Engine oil level

Check the lube oil level before starting. Ensure that the oil level is within the
marked field on the dipstick. Refill if necessary on top of the crankcase, make
sure not to exeede the maximum mark on the dipstick
6.8 Cooling system

As soon as the engine has cooled down,the cap may be opened by ¼ turn.
Check the cooling water level against the lower edge of filler socket in the
expansion tank. Refill tank from the top cap up till the lower edge of filler
socket in the expansion tank.
Raw water cooling
The cooling water is taken from the pressure side of the water jet.
This system prevents possible damaged rubber impellers, which can create
hazardous situations. It will also ensure a more conbinous water flow through
engine, especially in choppy seas.
NOTE :Maximum 20 minutes idle speed running in sea.

Maximum 5 minutes idle speed running in davit.

Norsafe as
6.9 Water jet
This unit has been designed to require the absolute minimum of maintenance.
However, it is recommended that the unit be dismantled and inspected for the
wear on bearings, seals etc, and corrosion annually as a minimum requirement.
Furthermore, to comply with the recommended maintenance, follow this manual
and the provided manual from the manufacturer, will ensure maximum utilization
of the boat.
Grease the jet according to the manufacturers manual.
6.10 Water seal

Any leakage through the water seal is detected by water flowing directly into the
hull from under the bearing housing.
Inspect this area periodically to ensure that the main seal is sound. To inspect
seal, see dismantling procedure in manufacturer handbook.
6.11 Drive shaft universals

Every 30 hours sparingly grease the universal joints and sliding splines. Do not
over grease.
6.12 Sacrificial anodes

The unit is fitted with zinc anodes for cathodic protection. They will waste away in
sea or contaminated water. (See manufacturer manual for exact anode
locations).
Regularly inspect these anodes and replace if eroded by more than 50%. If
allowed to disappear, corrosion will start on the aluminium parts, which could
eventually damage the unit.
NOTE!
The rate at which anodes erode away will vary considerably depending on the
nature of the water. Check anodes monthly initially until a safe longer check
interval can be established from experience

The main engine start battery, emergency start battery and radio battery, if fitted,
should be checked to ensure the terminals are tight and clean. Should the
terminals show any sign of corrosion, disconnect and clean thoroughly and
smear with some vaseline grease.
Check search light and signal light. If failing to work inspect wires, contact and
bulb. Clean or replace if necessary.
Check instrumentation and engine controls. Replace defective lamps and fuses if
necessary.
6.14 General
Keep the boat clean and tidy. Minor damage to the orange gel coat surface
should be repaired from time to time. Larger damage needs more immediate
attention.

Norsafe as
Combat any signs of corrosion, particularly on steel parts, by brushing with a
steel wire brush and painting. Alternatively, a good quality aerosol inhibitor, or
even wiping with an oily rag, may be used.
6.15 Inspection and maintenance of rescue boat and release gear system
6.16 Inspection and maintenance plan
Rescue boats should be inspected and maintained weekly, monthly in accordance with
below tables, and according to engine manual. The tables lists the items to be checked,
the method of inspection, the procedures to be followed, and the frequency at which the
items are to be attended to.
As a result of inspection, any defective parts should be repaired in accordance with

following procedures. Any shortage of quantity should be supplemented to the correct
number. Defective parts other should be recorded along with their details and ordered for
maintenance and repair by the manufacturers.
Table 6.17 covers the basic rescue boat (including release gear).
Table 6.18 covers the rescue boat engine.
Table 6.19 covers the electric parts.
Table 6.20 covers the rescue boat equipment.

Norsafe as
6.17 Inspection procedure and maintenance plan for boat
Maintenance plan
Items Method Inspection Procedure When
Weekly Monthly
required
Inspect for deformations or other defects.
Outside hull Visual Inspect for peeling or any damage of
X X
retro-reflective material
GRP
Visual Inspect for deformation or other defects X X
Inside
Boat
Metal
Visual Inspect for corrosion X X
Check resetting condition. Remove any

Release gear Visual X X
dirt on moving parts
Painter Checking resetting condition. Remove
Visual X X
release device any dirt on moving parts.
Visual
Inspect for easy operation and good
All hatches X X
Operation condition of gasket.
Inspect for any damage steering gear and

Visual X X
connections to engine.
Steering gear
Inspect for good operation of main
Operation X X
steering and emergency tiller

Norsafe as
6.18 Inspection procedure and maintenance plan for engine
Maintenance plan
Weekly Monthly
required
Visual Check in good condition X
Engine
Start and operate engine.
Operation X X
Check operation of throttle.
Lubrication Visual Check amount of oil. X X

Oil
Operation Change lubrication oil. X
Visual Inspect for any damage X X

Water jet During operation of engine, check sooth
Operation rotation of water jet impeller. Remember X
to add grease in end bearing .
Check securing condition of the tank
Fuel oil tank Visual (corrosion or leakage and connecting X X
parts). Check an amount of fuel oil.
Fuel oil pipe Visual Check any leakage on connecting parts. X X
Water cooler Visual Check an amount of fresh water. X
Cooling water
Visual Check any leakage of pipe. X
pipe
Start/stop
switch Operation Check operation properly. X X
Glow Lamp Operation Check light on when pre-heating X X
Tachometer Operation Check proper indication of revolution X X
Oil pressure
warming
Operation Stop the engine X X
lamp, Charge
lamp

Norsafe as
6.19 Inspection procedure and maintenance plan for electric parts.
Maintenance plan
Weekly Monthly
required
Visual Check battery condition. X X
Battery Measure voltage of battery. When
Measure X X
voltage is low, charge battery
Search light Operation Check light on. X
Electric
Visual Check any defects on wiring. X
wiring
Indication
Operation Check light on. X
light
6.20 Inspection procedure and maintenance plan for rescue boat equipment.
Check for condition, quantity and expiry date where applicable according to loose
equipment list inside equipment compartment.
Maintenance plan
No. Items Weekly Monthly
1 Oars X
2 Thole pins or crutches X
3 Boat hooks X
4 Buoyant bailer X
5 Buckets X
6 Compass X
7 Sea-anchor X
8 Painters X
9 Hatches X
10 Waterproof electric torch + spare batteries X
11 One whistle X
12 A first aid kit X
13 A jack knife X
14 Two buoyant rescue quoits X
15 Portable fire-extinguisher X
16 A radar reflector X
17 Thermal protective aids X
18 Compartments for storage X
19 Buoyant line min.50 m X
20 Search light X
6.21 Inspection and maintenance of launching appliances (davits and winches)

Ref davit and winch manual.

3.2 Operation & Maintenance manual for Bukh Steyr 114HP engine
————————————————————————————————————————————————————————————————
3.3 Operation & Maintenance manual for Alamarin 185j
______________________________________________________________________________________________________________________
Operation
and maintenance manual

We congratulate You on purchasing a new alamarin-jet water jet propulsion unit and
hope that you can enjoy it.
Alamarin-Jet Oy has developed and manufactured water jet propulsion units since 1976.
The propulsion units are used e.g. in pleasure and work boats, as well as in fast rescue
boats with a number of different engines. Thousands of users around the world rely on
the alamarin-jet water jet propulsion unit.
The aim of this instruction is to give important information on the operation, use and
maintenance of the unit. We recommend reading this manual carefully before the
implementation of the unit and before You set out to test Your new jet boat for the first
time. This is how You get the most pleasure and benefit out of it.
With best regards,
Alamarin-Jet Oy
Tuomisentie 16
62300 Härmä
Finland
tel. +358-10-7745 260

fax. +358-10-7745 269
www.alamarinjet.com
Version 1.1
alamarin-jet water jet propulsion unit
OPERATION AND MAINTENANCE MANUAL
Alamarin-Jet Oy has published this manual in order to guide the owners and users of
boats equipped with alamarin-jet water jet propulsion unit.
Alamarin-Jet Oy has published other manuals separately for technical designers,

mechanics and repair men.
From here on in this manual the alamarin-jet water jet propulsion unit will be refer-
red to as ”jet”. This term refers exlusively to a propulsion unit manufactured by Alama-
rin-Jet Oy.
The instruction covers the following jet propulsion models:
Jet-160 Jet-180 Jet-185 Jet-230
If the given information is type specific, this will be expressed in the text.
In this manual, clarifying figures will be used.
The symbols used in the manual:
ARROW DESCRIBING MOTION
INDICATOR ARROW
X PART MARKING
HINT - the text includes useful additional information or a hint which facilitates the work
performance or procedure
NOTE - the text includes a warning of a slight danger or a possibility of minor damage to
equipment
WARRANTY
GUARANTEE MATTER - the text includes a guarantee clause
WARNING - the text includes a warning of a danger that can lead to personal injury, breaking
down of equipment or serious malfunction of equipment
STOP! SERIOUS DANGER - the text includes a warning of danger to life
Version 1.1
Operation

Index..................................................................................................................... 4
List of Appendixes................................................................................................ 5
After Sales Questionnaire.................................................................................... 6
Declaration of Conformity..................................................................................... 8
1. The Jet Propulsion Unit.................................................................................... 9
2. Operation........................................................................................................ 10
2.1. Using for the First Time........................................................................... 10
2.2. Steering and Controlling.......................................................................... 11
.... 2.2.1. Steering............................................................................................ 12
.... 2.2.2. Controlling........................................................................................ 12
2.3. Operating in Shallow Water..................................................................... 14
2.4. Operating in Reedy Water....................................................................... 15
2.5 Cavitation and Ventilation........................................................................ 16
.... 2.5.1. Cavitation......................................................................................... 16
.... 2.5.2. Ventilation........................................................................................ 17
3. Functions........................................................................................................ 18
3.1. Transmission........................................................................................... 18
3.2. Bearing.................................................................................................... 19
3.3. Control System........................................................................................ 19
.... 3.3.1. Electronic Reversing Deflector Control System............................... 19
.... 3.3.2. Hydraulic Reversing Deflector Control System................................ 20
3.4. Raw Water Cooling................................................................................. 22
3.5. Corrosion Protection............................................................................... 22
.... 3.5.1. Cathodic Protection.......................................................................... 22
.... 3.5.2. Painting............................................................................................ 23
4. Maintenance................................................................................................... 24
4.1. Tools........................................................................................................ 24
4.2. Periodical Maintenance........................................................................... 24
.... 4.2.1. Washing the Jet............................................................................... 25
.... 4.2.2 Lubricating the Bearings................................................................... 25
.... 4.2.3. Lubricating the Control System........................................................ 26
.... 4.2.4 Changing the Zinc Anodes................................................................ 26
.... 4.2.5. Adjusting the Impeller....................................................................... 27
.... 4.2.6. Checking the Seals.......................................................................... 27
.... 4.2.7. Maintenance of the Hydraulic System............................................. 27
4.3. The Impeller............................................................................................ 29
.... 4.3.1. Removing the Impeller..................................................................... 31
.... 4.3.2. Fitting the Impeller........................................................................... 33

Version 1.1
APPENDIXES
Appendix 1. Maintenance Manual.......................................................................... 35
Appendix 2. SE-01................................................................................................. 36
Appendix 3. SE-02................................................................................................. 37
Appendix 4. Recommended Greases and Oils and tightening Torques
of the Screws..................................................................................... 38
Appendix 5. Exploded Views.................................................................................. 39
Version 1.1
AFTER SALES
QUESTIONNAIRE

AFTER SALES QUESTIONNAIRE
In order to improve our products and operations, we at Alamarin-Jet Oy are col-

lecting feedback from the end users of water jet propulsion units. This form is
intended to make it as simple as possible for you to give us that feedback. You
can fill out the form in the User’s Manual and send it to us via mail, fax or e-mail
(if you are using the electronic form on the CD).
Only answer questions to which you know the answer.
Customer’s/end user’s contact information:

(Boat owner)
Contact information of person answering the questionnaire:
Delivery information of project/device:

(For instance the serial number of the propulsion unit or other relevant docu-
ment)
Test information for ALAMARIN-JET:

(Use table on the next page)
Customer service received from retailer/importer/manufacturer prior to

delivery:
(Quotation, technical guidance, documentation, etc.)
Delivery of propulsion unit:

(Timeliness of delivery, contents of delivery, packaging, documentation)
After sales services:

(Include prior experiences of retailer’s/manufacturer’s services)
Spare parts services:
Other comments:
Version 1.1
AFTER SALES QUESTIONNAIRE
Return address: ALAMARIN-JET OY

Tuomisentie 16
FI-62300 HARMA
FINLAND
EUROPE
Fax: 00 358 10 7745 269
E-mail: sales@alamarinjet.com
TEST REPORT Date:

Test weight of boat Number of persons Wind speed m/s Water temperature
Jet serial number Engine and gear GPS/clock Signature
Engine speed Speed in direction 1 Speed in direction 2 Average speed

2400
2500
2600
2700
2800
2900
3000
3100
3200
3300
3400
3500
3600
3700
3800
3900
4000
4100
4200
max rpm
Notes:
If possible, include pictures in your feedback.
Version 1.1
Operation

DECLARATION OF CONFORMITY
Directive 98/37/EY
Manufacturer : Alamarin-Jet Oy
Address: 62300 Härmä, Finland
Tel.: +358 10 7745260
Fax.: +358 10 7745269
Email: info@alamarin-jet.com
Guarantees that the devices:
Model: Serial number:
are intented as a structural part or to be connected to the unit, so that they

together constitute a device intented in directive 98/37/EY and the amendments
pertaining to it.
The following harmonised standards must be observed in connection with them:
EN 12100-1 , EN 12100-2 , EN 294
In addition, we declare that the unit must not be introduced to use before the
unit for which it is intented has been brought into accordance with directive
98/37/EY and validating national regulations. This applies to the whole unit,
including the unit mentioned in this declaration.
Place: Alahärmä, Finland
Date: …………………………………………..………
Signature: …………………………………………………………………………
Version 1.1
1. The Jet Propulsion Unit
Alamarin-jet water jet propulsion unit is a single stage axial flow pump, which produces
a high volume flow rate and thrust with high efficiency.
The operation of the unit is based on increasing the water flow rate in the nozzle. The
change in the flow rate creates a reacting force in the direction of the flow, which thrusts
the boat forward. By changing the direction of the jet, it is possible to steer the boat in
the desired direction.
Main Parts (figure 1-1):
The intake duct (A), whose A

function is to lead the water from
outside the boat to the intake
side of the impeller with as little
loss as possible and an even
distribution of velocity.
The impeller (B), which is

rotated by the driving motor
through direct drive, increases
the water’s flow rate. B
The nozzle converts the pressure

energy produced by the impeller
to motion energy.
The steering device (C) is used

to change the direction of the jet D
flow coming out of the nozzle,
which creates the force needed
for turning.
The controlling device (D)

Lowering the reversing deflector
causes the boat to reverse. The
direction of the jet flow changes
obliquely forward under the C
boat, which is when the thrust
is directed forward and down.
The reversing deflector is also Figure 1-1
used for stopping the boat. See
section: Steering and Controlling,
page 10
Version 1.1
Operation
10
1010
Every propulsion unit has its own

serial number. The serial number has
been marked on the type label and in
addition it has been stamped both on
the frame of the propulsion unit and on
the inspection hatch cover.
Figure 1-2
The places in which the serial number

can be found have been designated in
figures 1-2 and 1-3. The serial number
has also been recorded on page 6 of the
Instructions for Use and Maintenance.
Figure 1-3
2. Operation
2.1. Using for the First Time
Before you set the boat afloat for the first time, make sure that the jet
has been installed according to the Installation Instruction.
This prevents the emergence of unexpected fault situations which can

lead to damages.
Starting:
In starting an engine equipped with the jet, the following things should be observed:
- The reversing deflector control lever must be in centre position.
- The possible gear must be in ”neutral” position.
- In a system without a gear the accelerator must be in ”idle” position.
See the effect of the position of the reversing deflector control lever on the position of
the reversing deflector on page 11.
Version 1.1
11 Operation and maintenance manual
When you start the engine for the first time:
- It may be possible that ”clinking” is heard from the jet during the first minutes. This
should usually disappear, however, when the impeller gap becomes fit.
- The reversing deflector’s hydraulic control system needs more oil because the hoses
and cooler are empty. The oil pump noise may be loud at first, but as the system fills up
with oil the noise disappears. Observe the oil level in the beginning because leakages
cause environmental pollution.
- Checking the oil level has been described in section 3.3.2. The oil type has been given
in appendix 4.
- Ensure the functioning of the system carefully, at low speeds.
- Observe the engine manufacturer’s instructions on running in. The jet does not
require special running in.
WHEN THE ENGINE IS STARTED UP, THE INTERMEDIATE

SHAFT AND THE MAIN SHAFT START TO ROTATE. AT THIS
STAGE, IT IS NOT ALLOWED TO GO NEAR THE ROTATING
PARTS!
THE INSPECTION HATCH MUST BE KEPT CLOSED WHILE

THE ENGINE IS RUNNING!
2.2. Steering and Controlling
IN THIS SECTION, CONTROLLING THE jet boat IS DESCRIBED

IN A WAY THAT IT IS DONE THROUGH A SYSTEM THAT HAS
BEEN INSTALLED AS INTENTED BY THE MANUFACTURER.
WARRANTY Alamarin-Jet Oy IS NOT LIABLE FOR DAMAGES WHICH

DERIVE FROM INCORRECT INSTALLATION OF THE SYSTEM.
Steering denotes exclusively moving the steering nozzle. Steering means changing the
boat’s bow angle.
Controlling denotes exclusively moving the reversing deflector. Controlling means

changing the boat’s driving direction (forward - astern).
Version 1.1
Operation
12
1212
2.2.1. Steering
The boat is steered by turning the steering wheel. The connection from the wheel to the
steering lever can be either mechanical or hydraulic (figure 2.2.1-1). The lever moves
the nozzle through the shaft and the joint.
Figure 2.2.1-1
- Steering is possible when the power of the jet flow is sufficient. This is why the
engine must run on sufficiently high revs when steering. 1200-1800 rpm is a suitable
number of revolutions, depending on the engine.
- In sharp curves, turning the nozzle causes the boat to slow down. This is normal and
increases safety.
- The turning of the nozzle from one extreme position to the other takes ~2 turns of the
wheel.
2.2.2. Controlling
Driving direction is controlled with the reversing deflector. The reversing deflector
is moved with the lever which is usually next to the throttle lever. With this lever, it
is possible to control the hydraulic system mechanically or the mechanical system
electrically.
In models Jet-160 and Jet-180/185 a fully mechanical system can be used, as long as it
is sturdy enough.
Version 1.1
The reversing deflector can be

lowered in front of the jet flow,
changing its direction forward
and down. There are two
different types of deflectors.
The round type reversing Figure 2.2.1-1

deflector (figure 2.2.2-1) fits in
assemblies in which width is
critical. By using the tube type
reversing deflector (figure 2.2.2-
2), a higher reversing power
is attained, but the deflector is
wider.
In figure 2.2.2-2 is shown the
Jet-230 hydraulic deflector
control system.
For models Jet-160 and Jet-

180/185, only the round type
reversing deflector is available. Figure 2.2.2-2
When the reversing

deflector control lever
is in forward position,
the deflector is not
blocking the jet flow
and the boat moves
forward (figure 2.2.2-
3).
Figure 2.2.2-3
When the lever is

in the rear position
(figure 2.2.2-4), the
deflector is in front of
the jet flow and the
boat moves astern.
Figure 2.2.2-4
Version 1.1
Operation
14
1414
The centre position of the reversing deflector corresponds to gear’s ”idle” position; even
though the drive is on, the boat stays still. The centre position is not absolute, it depends
on the power of the jet flow. Finding the centre position is done by testing during the
first driving hours.
When moving at low speeds, the reversing deflector is used to control the boat’s speed.
Because the engine is being run at 1200-1800 rpm to enhance steering, the boat may
travel faster than desired. In this case the deflector is lowered in front of the jet flow
to reduce the thrust directed towards the driving direction. Steerability remains good
however.
At high speeds, the deflector is not used to reduce speed. Instead, speed is controlled
with engine revolution.
It is possible to turn the boat in place when the deflector is in centre position. When the
nozzle is turned to the desired direction, the boat rotates about its central axis.
When reversing, steering is inversed in comparison to driving forward. If you want to

turn the boat to the left, the wheel must be turned to the right. A good mnemonic is that
the boat’s bow always turns in the same direction as the wheel.
When fast turns are needed, the engine revolutions are not reduced, but instead the turn
is done through combined motion of the nozzle and the deflector.
If you have never driven a jet boat before, familiarize yourself with the separate guide
“Steering and controlling jet boats”. You can find the guide on the CD attached to the
back cover of the paper version of the Operation and maintenance manual, for example.
2.3. Operating in Shallow Water
The jet boat can be used in very shallow water, but it must be taken into account that
especially on high revolutions the suction power of the intake is high (cf. figure 2.3-1).
Loose objects may get sucked into the intake screen and small objects wash through the
jet. Stones may cause damage. In sandy conditions wearing inevitably takes place. The
maintenance procedures required by a worn impeller are described in the maintenance
section of this manual. See Adjusting and Fitting the Impeller, page 24.
Figure 2.3-1
Version 1.1
2.4. Operating in Reedy Water

At planing speeds, a jet boat usually crosses reed fields without difficulty. In difficult
conditions however, clogging may be possible. In boats equipped with a gear box,
cleaning the intake duct is easy because at reverse gear, a back flow is created in the
duct.
THE JET HAS BEEN DESIGNED TO RUN ON REVERSE GEAR
ONLY MOMENTARILY AND ON LOW REVOLUTIONS. A TOO
HEAVY LOAD ON REVERSE GEAR CAN LEAD TO JAMMING
OF THE IMPELLER OR BREAKING DOWN OF HYDRAULICS!
The sleeve shown in figure 2.4-1 on the axle has a left-handed threading. If the engine is
run at too high revolutions on reverse gear, the sleeve may loosen and the impeller may
get stuck against the duct walls.
Figure 2.4-1
If clogging occurs on a boat that does not have a gear box, the following procedures are
recommended:
1. Stop the engine. This causes the extraneous objects in the grass rake simply to
drop off.
2. Let the engine run on high revolutions for a few times. This often sucks the
extraneous objects through the jet and cleans it.
3. If the boat is moving forward, raise the boat speed as much as possible and then
shut down the engine. The speed of the boat often sweeps the grass rake clean.
4. Drive the boat on reverse as fast as possible. As the boat moves astern, shut
down the engine and move the deflector control lever to forward position.
This causes water to flow backwards through the jet and usually opens any
blockage whatsoever.
Version 1.1
Operation
16
1616
With these simple instructions it is

possible practically without exception
to clean the jet even after the boat has
stopped completely in reedy water.
Unlike with other propulsions, in boats

equipped with the jet the engine stops
very rarely as a result of a reed blockage.
If the measures mentioned above are

not of help, the propulsion is equipped
with an inspection hatch (figure 2.4-2),
through which the blockage can be seen Figure 2.4-2
and removed.
Remember to close the hatch! The wing screw is tightened by hand!
2.5. Cavitation and Ventilation
2.5.1. Cavitation
The most common malfunction in water jet propulsion units manifests as cavitation.
Engine overdrive and stopping of thrust are signs of this.
Cavitation is a phenomenon in which the water pressure decreases locally in such an

extent that water vaporizes on the surface of the impeller blade, creating steam bubbles.
The bubbles move on the surface of the blade and when they reach a higher pressure
area they collapse. Cavitation incurs considerable reduction in capacity and damages the
impeller.
Usually the cause is the reduction of pressure in the whole intake duct, which is induced
by a blockage.
Cavitation can often be heard as a rumbling sound.
Any factor that hinders the flow of water in the jet increases the chance of cavitation.
Version 1.1
If cavitation is apparent, the following things

should be checked.
Check through the inspection hatch that:
1. The grass rake (figure 2.5.1-1) is not

clogged (by grass, reed, plastic, stones etc.).
Figure 2.5.1-1
2. There are no extraneous objects in the stator

or nozzle unit or the impeller (figure 2.5.1-2)
(rope, reed entagled in the drive shaft, stones
in the outlet port)
Figure 2.5.1-2
3. The impeller (figure 2.5.1-3) is not

damaged. It should be smooth and it should
not have any sharp cuts.
If the boat runs slowly even though the engine

runs on high revolutions, find out the cause. Figure 2.5.1-3
2.5.2. Ventilation
Ventilation produces similar symptoms as cavitation but is caused by different reasons.
Ventilation is created when air gets to drift into the intake duct. The air causes the
impeller to lose grip and the thrust weakens. Ventilation can be heard as a similar sound
as cavitation.
Ventilation can be caused e.g. by the following things:
- The inspection hatch cover is open or a seal is damaged.
- The installation height of the jet is wrong, air is allowed to pass along the surface of
the cavitation plate into the intake duct.
- During installation, places accordant with the instructions have not been sealed.
Version 1.1
Operation
18
1818
3. Functions
3.1. Transmission
The jet takes its propulsion power from a petrol or a diesel engine. The most common
way to transmit the power is through a 1:1 gear box, but direct drive is also possible
and functional. The greatest benefits of a gear box are a real neutral gear and an intake
duct backflush.
In the direct drive or so-called bobtail installation it is commendable to use a flywheel

adapter provided by the engine manufacturer. It protects the flywheel from mechanical
damages and e.g. corrosion.
The auxiliary shaft which is connected between the jet and the engine usually depends
on the boat manufacturer. If necessary, the jet manufacturer supplies the auxiliary shaft
with the propulsion unit. It is also possible to get instructions and recommendations
from the manufacturer on which auxiliary shaft to use. In the end, the shaft
manufacturer gives instructions on the installation and maintenance of the shaft. Below
is a list of example shafts which have been used with the jet.
1. Constant speed shaft
- Joint structure based on balls rolling on a spherical surface.
2. Cardan shaft
- Joint structure based on pivoted grids.
3. Silent block shaft
- Joint structure based on an elastic rubber element

THE AUXILIARY SHAFT MUST ABSOLUTELY BE OF
HIGH ENOUGH QUALITY AND PROPERLY BALANCED. A
POOR SHAFT CAN CAUSE EXCESSIVE DAMAGE TO THE
PROPULSION UNIT.
THE ALIGNMENT OF THE AUXILIARY SHAFT MUST BE KEPT

ACCURATE. IT MUST BE CHECKED AT LEAST ONCE EVERY
DRIVING SEASON (YEAR).
Version 1.1
3.2. Bearing
The jet’s bearing is very simple (figure 3.2-1). There are bearings at both ends of the
direct shaft. The structure of the front bearing (A) is receptive to axial pressure. In
addition, at the front end there is the supporting bearing (B) of the coupling flange and
the auxiliary shaft.
Rolling type bearing is used at the front end and slide bearings are used at the rear (C).
Both bearings are stock grease lubricated. It is possible to install a water lubricated
bearing at the rear end.
A
C
Figure 3.2-1
Lubricate front bearings every 50 hours or twice a year at minimum. The bearings are
lubricated through the hose in the engine room.
The boat should be lifted out of water when lubricating the rear bearings. It is advisable
to add grease to the rear bearings whenever the boat is lifted out of water. At minimum,
however, this should be done every 100 hours or twice a year.
3.3. Control System
3.3.1. Electronic Reversing Deflector Control System
The system is available for models Jet-160, Jet-180 and Jet-185.
The main components that the system consists of are #1 a control lever (potentiometer),
#3 an electronics unit and #4 a spindle motor. See figure SE-01 in Appendixes.
The electronics unit changes the position of the lever into a signal to to the spindle
motor.
The repair and adjustment instructions for the system can be found in Repair Manual 1.
Version 1.1
Operation
20
2020
3.3.2. Hydraulic Reversing Deflector Control System
The system is available for models Jet-230 and Jet-235. It includes a patented rotary
valve which simplifies the system considerably.
The reversing deflector is controlled (cf. figure 3.3.2-1) mechanically with a cable (A)
which operates the valve regulator (B).
Figure 3.3.2-1
The cylinder gets its power from the oil pump which has been integrated in the
propulsion unit.
In a stock delivery, the system does not include a control lever or a cable, so their type
varies depending on the boat manufacturer. However, the different types of systems
have the following things in common:
- The operation of the deflector must be separate from the throttle and the gear.
- The stroke length of the cylinder is always the same.
- The incoming direction of the cable can be chosen freely.
The oil circulating in the system must be cooled in order to prevent excessive heating.
This is done with a separate heat exchanger or a possible cooler in the engine.
Version 1.1
IF THE OIL IN THE SYSTEM IS NOT COOLED, THE

MANUFACTURER IS NOT RESPONSIBLE FOR POSSIBLE
DAMAGES WHICH DERIVE DIRECTLY OR INDIRECTLY FROM
THE OIL OVERHEATING!
An extra cooler must be installed in the following cases:
1. If there is no cooler in the engine.
2. If the cooler in the engine is reserved, e.g. for cooling the transmission oil.
In the figure below 3.3.2-2 is a system in which the cooling water comes from the jet
(see next chapter). The system can consist of different looking components depending
on the boat manufacturer. What is essential is the correct order of the components.
Notice especially the cooler’s place after the filter. A system equipped with a separate
raw water intake pump has the same main components.
If it is necessary to add oil to the system, add it in the oil reservoir. There is a dipstick
on the reservoir cap with markings for maximum and minimum level. See picture 3.3.2-
2.
The type of oil to be used has been described in appendix 4.
Oil reservoir
Cylinder
Max. level
Min. level
Pump
Filter
Cooler
Figure 3.3.2-2
Version 1.1
Operation
22
2222
3.4. Raw Water Cooling

The jet comes complete with the possibility to connect the engine cooling water (cf.
Figure 3.4-1). The engine does not need a separate water pump. However, if the cooling
water is taken with a separate pump, the jet’s raw water line is stoppered.
At the beginning of the line, there must be a tap with which the line can be shut
temporarily for example during cleaning of the filter or other maintenance.
1. Raw water connector (G 3/4”)

2. Tap
3. Filter
4. Raw water intake
Figure 3.4-1
3.5. Corrosion Protection
3.5.1. Cathodic Protection
The raw materials used for manufacturing the jet parts are mainly aluminum, acid-proof
steel, and plastic.
Materials that have different electrochemical properties can form a so-called galvanic
couple while they are in electrolytic fluid (salt water). A galvanic couple forms an
electric circuit, because the materials have different inherent voltages. This in turn leads
to electron movement and corrosion of the weaker material. Cathodic protection is used
to try and prevent the propagation of galvanic corrosion. Cathodic protection means
introducing into the same circuit a third material, the electrochemical properties of
which are weaker.
The jet is protected from galvanic corrosion with passive cathodic protection. Every
critical aluminum casting has its own zinc anode. In figure 3.5-1 are shown the places of
the anodes.
Version 1.1
2 1. Inspection hatch cover

1 2. Reversing deflector
3. Steering nozzle
4. Stator
5. Frame (2 pcs)
5 4
Figure 3.5-1
3.5.2. Painting
The aluminum castings have also been protected by painting. Painting efficiently
prevents the propagation of various forms of corrosion e.g. pit corrosion.
Bare aluminum is liable to corrosion in difficult conditions. This is why it is important

to carry out touch-up painting if paint comes loose and aluminum is exposed. Touch-
up painting can be done in various ways. What is important is that the paints used are
suitable for aluminum and that the paint manufacturer’s instructions are followed during
painting.
If the boat is going to be used in waterways where the growth and sticking of organisms
around the boat’s bottom and the propulsion unit is heavy, the propulsion unit can be
painted with antifouling paint after installation. Generally speaking, antifouling paints
are based on various soluble substances, for example copper. Because the propulsion
unit is made mainly of aluminium, copper forms a highly unfavourable galvanic couple
with the propulsion unit. The aluminium starts to corrode because it functions as an ano-
de.
IF COPPER BEARING ANTIFOULING PAINT IS USED FOR PAINTING

THE PROPULSION UNIT, THE RESULT WILL BE HEAVY CORRO-
SION AND DESTRUCTION OF THE PROPULSION UNIT. DO NOT USE
ANY OTHER ANTIFOULING PAINTS FOR PAINTING THE PROPULSI-
ON UNIT EXCEPT THOSE INTENDED FOR ALUMINIUM SURFACES!
Version 1.1
Operation
24
2424
Instead, a boat bottom made of reinforced plastic can be painted using copper bearing
antifouling paint. In this case, leave a 50mm unpainted area around the propulsion unit
in the stern and on the bottom of the boat. See picture 2.3-1.
Stern
Stern
Mounting
template
Boat Mounting
bottom template
Figure 3.5.3.-1
4. Maintenance
4.1. Tools
The following items are included in the tool kit delivered with the propulsion unit if or-
dered separately:
- Wrench 10 mm - Allen wrench 6 mm
- Wrench 13 mm - Allen wrench 8 mm
- Wrench 17 mm - Knife
- Allen wrench 5 mm - Universal pliers
Most of the maintenance and repair procedures can be carried out with these tools.
4.2. Periodical Maintenance

The jet is designed and manufactured to be as simple as possible. This is why the need
for maintenance is low and maintenance can be carried out on shore.
Version 1.1
4.2.1. Washing the Jet

Every time the boat is lifted out of the water, it is advisable to wash it with fresh
water. This clears possible salt accruals and impurities, which leads to the reduction of
corrosive effect due to conditions.
4.2.2 Lubricating the Bearings
4.2.2.1. Lubricating the Front Bearing
The lubrication of the front bearing is carried out from the engine compartment side.
To facilitate greasing, there is a hose with a grease nipple at one end connected to the
bearing housing. The end of the hose can be attached in the loose space so that using the
grease gun is easy.
Excess grease exits the bearing housing automatically. When lubricating, only add 4-5
injections of grease with the grease gun.
The lubrication interval for the bearing is 50 hours or twice a year at minimum.
4.2.2.2. Lubricating the Rear Bearing
It is easiest to carry out the lubrication of the rear

bearing when the boat is out of the water, but it
can also be done while the boat is in the water. The
lubrication is carried out through the steering nozzle
from the nipple in the middle of the stator (figure
4.2.2.2-1).
Excess grease exits the bearing housing

automatically. When lubricating, only add 2-3
injections of grease with the grease gun.
The lubrication interval for the bearing is 50 hours or

twice a year at minimum.
The rear end bearing supports the shaft and centers it

in respect of the duct. This is why excessive wearing Figure 4.2.2.2-1
of the bearing affects the behaviour of the impeller.
When the bearing has been worn enough, excess
vibration builds up in the unit and “clinking” can
be heard from the impeller. In this case the impeller
wears also and its efficiency is reduced.
A worn bearing should be replaced with a new one

when the aforementioned symptoms appear.
Version 1.1
Operation
26
2626
Technical specifications for the Example greases:

lubricant greases:
- Würth Multi-Purpose Grease
- lithium soap and a thickener with EP III
additives
- FAG Multi2
- mineral oil as a base oil
- FAG Load 220
- NLGI class 2
- Mobil XHP 222
- operating temperature range –
25…130˚C
- Neste Allrex EP2
- continuous operating temp. min. 75˚C

- Shell Retinax Grease EP2
4.2.3. Lubricating the Control System

The joints and shaft bushings that belong to the control systems are essentially
maintenance-free, but lubrication prolongs their operating life. Below (figure 4.2.3-1) is
a list of objects, in which water-proof vaseline is added in connection with maintenance.
When the plastic bearings of the joints wear and gaps are created, they must be replaced.
3
2 4
1
1. Shaft bushing in the stern 3. Pivoting of the reversing deflector

on both sides of the stator
2. Shaft bushings in the rear flange 4. Pivoting of the nozzle on both
sides of the stator
Figure 4.2.3-1
4.2.4 Changing the Zinc Anodes

The jet is protected with passive cathodic protection. The functioning of the zinc anodes
is crucial from the point of view of corrosion. The zinc anodes must be changed when
they have worn down to half of their original size. Every aluminum component has been
protected separately with a zinc anode. The places of the anodes are described in chapter
3.5.1.
Version 1.1
4.2.5. Adjusting the Impeller
Depending on driving conditions, the impeller wears, and a gap develops between
the duct wall and the tip of the blade. When it expands enough, the jet’s performance
decreases. By adjusting the impeller, the operating life can be prolonged considerably
The adjustment of the impeller should be done whenever it is necessary, but checking
must be done at least once a year.
Adjusting the impeller is done by removing the impeller and reinstalling it. See next
chapter.
4.2.6. Checking the Seals
The seals to be checked are

e.g. the O-ring seal of the
inspection hatch (A) and the
sealings of the steering shaft
bushings (B) (figures on the
side). When the inspection
hatch seal leaks, it causes A
ventilation and the sealings
of the steering shaft bushings
cause water to leak in the bilge.
B
If water gathers in the bilge,
the cause for this must be
determined immediately and
the possible leak must be Figure 4.2.6-1
repaired. Water can damage
e.g. the starter motor.
4.2.7. Maintenance of the Hydraulic System
The reversing deflector hydraulic control system requires maintenance as follows:
- checking the oil level
- checking the condition of the V-belt and replacing it if necessary
- checking the condition of the hoses and replacing them if necessary
Version 1.1
Operation
28
2828
The Maintenance and Repair Table gives detailed instructions for checking different
targets.
Service and Maintenance Chart
daily weekly montly every 6 months yearly

Hydraulic reverse bucket operating system
hydraulic oil amount X
possible leaks (hoses, couplings) X
cable fastening X
test run and accuracy of reverse bucket X
movement
tightness of v-belt X
condition of spare v-belt X
general technical condition X
Engine raw water cooling system

if cooling water from jet
possible leaks (hoses, couplings) X
function of valve (if mounted) X
possible blocks in system X
Reverse bucket
zinc anode (1 pcs) X
tightness of bolts X
paint X
Frame of the jet

zinc anodes (2 pcs) X
paint X
cavitation plate’s technical condition and paint X
Stator
paint X
no blocks in stator intakes X
condition of intakes X
Steering nozzle and steering system

function of steering nozzle and steering system X
technical condition of control shaft and levers X
steering nozzle paint X
Version 1.1
daily weekly montly every 6 months yearly

Jet inlet duct
cleaness of inlet surfaces x
(no marine growth etc.)
Front bearing
Lubrication x x
tightness of bolts x
general technical condition of bearing x
End bearing
Lubrication x x
general technical condition of bearing x
Impeller
allowance of impeller x
technial condition of impeller blades x
tightness of adjuster sleeve x
tightness of bolts x
technical condition of impeller mounting cone x
technical condition of impeller housing x
Main shaft
general technical condition x
condition of shaft sleeve (part no 23028) x
technical condition of jet flange x
tightness of intermediate shaft fastening bolts x x
All maintenance that has been done to the propulsion unit can be entered in the
Maintenance Manual. The Maintenance Manual is Appendix 1.
4.3. The Impeller
The impeller usually wears on the outer edge of the blades. It operates in a cone-shaped
space and its position can be adjusted in the direction of the shaft in accordance with the
blade wear.
The gap between the outer edge of the blades and the cone should be as small as
possible to achieve best efficiency. (Factory installation gap 0.2 mm).
The longitudinal position of the impeller in the duct reveals its power demand. The
deeper the impeller sits, the less power it takes from the engine, because the diameter
of the impeller is smaller. The pitch and the length and number of blades naturally also
affect the power demand.
Version 1.1
Operation
30
3030
The size marking of the impeller can be found both at the front and rear end (figure 4.3-
1). It can be seen through the inspection hatch and by removing the stator.
Marking showing the

size of the impeller
Figure 4.3-1
The condition of the front edge of the

impeller blades is important. A damaged
front edge causes cavitation.
The front edge can be repaired by

carefully hammering the marks caused
by bigger stones and grinding them
smooth. The front edge must not be
sharpened, it must be left about 2mm
thick and rounded
r
r = 2 mm.
Figure 4.3-2
You can also return the impeller to the factory for checking and repairing.
If you suspect that there is a malfunction in the impeller, do as follows:
1. Shut down the engine and open the inspection hatch.
2. Check that nothing is blocking the intake duct.
3. Check the impeller visually. Notice especially the gap between the outer
edge of the blade and the duct wall.
Version 1.1
4. If there is no apparent fault, the boat must be lifted out of the water for closer
inspection.
5. Remove the impeller. See section Removing the Impeller below.
6. Check the impeller more closely. You can always ask the importer or manufacturer
for instructions.
4.3.1. Removing the Impeller
1. Remove the joint between the reversing deflector and the hydraulic cylinder by
opening the bolt marked by the arrow (A) (Jet-230). In models that do not have a
hydraulic reversing deflector control, the loop joint (B) which connects the reversing
deflector and the steering shaft, is removed.
Figure 4.3.1-1
2. Remove the joint between

the steering nozzle and the
steering shaft (figure 4.3.1-2).
Figure 4.3.1-2
Version 1.1
Operation
32
3232
3. Open the fastening bolts (4 pcs) of the

stator. After this, the stator, the deflector
and the nozzle come off as a whole. (In
figure 4.3.1-3 the reversing deflector has
been removed for clarity).
Figure 4.3.1-3
The fitting of the stator and the hull of the propulsion unit with
each other is tight. You can help the detachment by cranking with a
screwdriver.
4. Loosen the impeller’s fastening bolts

(figure 4.3.1-4) and completely remove
one of them. Screw it in the adjacent
threaded hole in line with the wedge
groove and tighten carefully. The plastic
fastening cone is released and the
impeller can be pulled off the shaft.
If the fitting is very tight, multiple bolts

are used as help.
Figure 4.3.1-4
Version 1.1
4.3.2. Fitting the Impeller
1. Screw the adjuster sleeve (A) and the

possible additional ring on the shaft.
The sleeve has a left-handed threading.
Set the wedge (B) in the groove A

reserved for it.
B
Figure 4.3.2-1
2. The place of the fastening cone

wedge groove is marked on the impeller
with a line. Set the cone so that the
wedge groove is aligned with the line as
in figure 4.3.2-2.
Figure 4.3.2-2
Version 1.1
Operation
34
3434
3. Place the impeller on the shaft along with the cone. Tighten the screws finger tight.
4. Push the impeller as far in the intake duct as it goes (B).
BE CAREFUL NOT TO LEAVE YOUR FINGERS BETWEEN

THE IMPELLER AND THE CONE! Use the working position (A)
shown in figure 4.3.2-1!
Tighten the screws to a torque of 20 Nm.
Screw the adjuster sleeve through the inspection hatch so that it sits tightly against the
impeller’s plastic cone. If the adjusting sleeve is left loose (B), the impeller gets stuck in
the duct cone. Reference C shows a correctly tightened sleeve.
A B C
D
Figure 4.3.2-1
There can be a gap of 0.2 mm between the impeller blade and the cone (D). During
installation, the lower edge lies on the cone and there can be a slightly bigger gap at
the upper part of the impeller due to the weight of the impeller and the axle. This gap
disappears when the stator finally centers the shaft.
Too wide a gap between the cone and the impeller blade leads to loss of power.
If the impeller does not rotate properly after the installation, open the impeller screws,
pull it slightly outwards, and tighten the screws.
5. Close the inspection hatch.
6. Install the reversing deflector, the steering nozzle and the stator in place as a whole in
a reverse order than when removing. The tightening torque for M10 bolts is 50Nm and
80Nm for M12 bolts.
Version 1.00
1.1
APPENDIXES - Operation and 35
maintenance manual
Appendix 1: MAINTENANCE MANUAL
MAINTENANCE LOG
Commissioning Service
Made by:
Date:
Made by:
Date:
Made by:
Date:
Made by:
Date:
Made by:
Date:
Made by:
Date:
Version 1.1
maintenance manual
Appendix 2: SE-01
Version 1.1
37 APPENDIXES - Operation and
maintenance manual
Appendix 3: SE-02
Version 1.1
maintenance manual
Appendix 4: RECOMMENDED GREASES AND OILS AND TIGHTENING

TORQUES OF THE SCREWS
1. The grease used for lubricating the bearings of the propulsion unit must meet
the requirements below.
- lithium soap and a thickener with EP additives

- mineral oil as a base oil
- NLGI class 2
- operating temperature range –25…130˚C
- continuous operating temperature min. 75˚C
The following grease brands are recommended as an example:
Würth Multi-Purpose Grease III, FAG Multi2, FAG Load 220, Mobil XHP 222,
Neste Allrex EP2, Shell Retinax Grease EP2.
A grease that has equivalent properties to those mentioned above can also be
used for lubricating.
2. The operating hydraulic system of the reversing deflector has been designed
operate with automatic transmission oil.
Kinematic viscosity 40˚C 33…36 mm2/s

Kinematic viscosity 100˚C 7.1…7.7 mm2/s
Viscosity index min 170
Density 15˚C 0.835…0.890 g/cm3
Pour point max. 42˚C
Flashpoint min. 180˚C
The following oil brands are recommended as an example:
Mobil ATF 320, FormulaShell ATF DEXRON III, Neste ATF-X, BP Autran DX III
3. The tightening torques in the table below must be used when tightening
the screws on the propulsion unit. The values 8.8, 10.9, and 12.9 signify the
strength classes of the screws. The strength class of the A4-80 acid-proof screw
corresponds to a 8.8 class screw.
Tightening torques of the
screws
Tightening torque
Thread (Nm)
8.8 10.9 12.9
M5 5.5 8.1 9.5
M6 9.6 14 16
M8 23 34 40
M10 46 67 79
M12 79 115 135
M16 145 215 250
Version 1.1
39 APPENDIXES - Operation and
maintenance manual
Appendix 5: EXPLODED VIEWS
When delivering this manual in paper form, the manufacturer has added to the following
pages the exploded views of the propulsion unit model with which the manual is
delivered. In the electronic version the exploded views as a separate file.
Version 1.1
3.4 Operation manual for K4 hook
4．OPERATION & MAINTENANCE MANUALS FOR NDSC-
25DAVIT
OPERATION AND
MAINTENANCE MANUAL
NDSC DAVITS
NORSAFE AS
P.O. Box 115
N-4852 Færvik
Norway
Telephone: +47 37 05 85 00
Telefax: +47 37 05 85 01
IMPORTANT NOTE!
NORSAFE AS.
The use of spare parts supplied by other suppliers violates and forfeits the
warranty.
0 ISSUED FOR CONSTRUCTION 2011.11.02 WAGU SOPO

1 UPDATE ALL INFORMATIONS 2012.04.18 ALJI WAGU
2 UNIFY THE MANUAL FOR NDSC DAVIT 2012.07.29 ALJI WAGU
3 SMALL CORRECTION ON FORMAT 2012.09.14 ALJI WAGU
Rev.3 /2012 Operation and Maintenance Manual - NDSC Davits Page 1

LIST OF CONTENTS
1. INTRODUCTION............................................................................................. 3
1.1. Introduction/validity ...................................................................................................... 3
1.2. Supplier information...................................................................................................... 3
2. TECHNICAL DESCRIPTION / SPECIFICATION ........................................... 4
2.1. Winch operating description ......................................................................................... 4
2.2. General description of NDSC davit............................................................................... 5
2.2.1. General introduction ............................................................................................... 5
2.2.2. Davit steel structure ................................................................................................ 5
2.2.3. Electric winch ......................................................................................................... 5
2.2.4. Wire rope ................................................................................................................ 6
2.2.5. Hydraulic power unit .............................................................................................. 6
2.2.6. Starter cabinet and davit control system ................................................................. 6
2.2.7. Safety systems ........................................................................................................ 6
2.2.8. Surface treatment .................................................................................................... 7
2.2.9. Spare parts .............................................................................................................. 7
2.3. Technical specifications ................................................................................................ 8
2.4. Restrictions in use ......................................................................................................... 9
2.5. Operating instructions ................................................................................................... 9
2.6. Launching in normal operation ................................................................................... 11
2.7. Launching using the stored power system .................................................................. 12
2.8. Recovery of the rescue boat ........................................................................................ 14
2.9. Manual hoisting of the rescue boat.............................................................................. 14
2.10. Manual lowering empty hook .................................................................................. 14
2.11. Raft operation........................................................................................................... 15
3. MAINTENANCE INSTRUCTIONS DAVIT AND WINCH ...............................16
3.1. Maintenance instructions davit and winch .................................................................. 16
3.2. Maintenance of falls .................................................................................................... 17
3.3. Monthly maintenance inspection report. ..................................................................... 18
3.4. Inspection log for monthly maintenance inspections .................................................. 19
3.5. Lubrication charts ........................................................................................................ 24
4. INSTALLATION INSTRUCTIONS .................................................................29
4.1. IMPORTANT INFORMATION-read this when receiving the davit ......................... 29
4.2. Maintenance during storage ........................................................................................ 29
4.3. Storage ......................................................................................................................... 29
4.4. Long time storage ........................................................................................................ 29
4.5. Assembly instructions ................................................................................................. 29
5. ON BOARD TESTING DAVIT AND BOAT ...................................................31
5.1. Test 1, 1.1 x SWL - Loaded lowering test................................................................... 32
5.2. Test 2, Recovery test: .................................................................................................. 32
6. PARTS/SPARE PARTS INTERCHANGEABILITY RECORD .......................34
6.1. How to order spare parts ............................................................................................. 34
6.2. Recommended spare parts davit .................................................................................. 35
7. CALL FOR SERVICE FORM .........................................................................36
Rev. 02 /2012 Operation and Maintenance Manual - NDSC Davits Page 2

1. INTRODUCTION
1.1. Introduction/validity
This manual is valid for Norsafe NDSC rescue boat davits.

1.2. Supplier information
Norsafe A/S was established in 1903 as Jørgensen & Vik in Grimstad. At first they
manufactured wooden lifeboats and during the 1st World War the first partially enclosed
lifeboats were delivered. Aluminium was used from 1952 to 1958. Since 1958 fibreglass has
been used as building material.
Norsafe A/S moved from Grimstad to Arendal in 1990, and delivers today a wide range of
different lifeboats and davits.
Postal address: Norsafe AS

P.O.Box 115
N-4818 FÆRVIK
Norway
Visiting address: Nedre Tybakken, Tromøy, Arendal, Norway

Phone: +47 37 05 85 00
Telefax: +47 37 05 85 01

2. TECHNICAL DESCRIPTION / SPECIFICATION
2.1. Winch operating description
The electrically driven winch includes an incorporated gearbox with a mechanical released
brake. The winch is fitted with a fail-safe multi-disc brake which is always engaged during
hoisting. A one-way brake in the transmission between electric motor and the drum ensures
safe hoisting with the brakes engaged. In the event of loss of electric power when hoisting,
the one-way brake will transfer the torque to the parking brake, and the motion will stop.
Further on a centrifugal service brake is included in connection with the gearbox to limit the
lowering speed according with regulations. Totally 4 methods of operation can be done,
electrical hoisting, manual hoisting, gravity lowering and manual lowering of empty hook.
Manual hoisting and manual lowering of empty hook is done by the hand crank attached to
the winch.
Methods of operation
1 - Lowering
Gravity lowering is done by the remote release handle from the boat.
«Stop & go»
By changing the tension at the remote control line it is possible to slow down the lowering
speed even to a full stop.
2 - Manual working
Manual hoisting and manual lowering empty hook is done by the hand crank attached to the
winch. The hand crank has an electrical interlock device so that electrical operation of the
winch is not possible when crank is used. See figure 2.1

Figure 2.1
2.2. General description of NDSC davit
2.2.1. General introduction
The NDSC davit system is designed for the safe and efficient launch and retrieval of Norsafe
rescue boats and life rafts. The davit system is designed for long time operation in a tough
and corrosive marine/offshore environment. The davit system is designed to fulfil all
requirements as given in latest SOLAS/IMO requirements.
The system will allow:

-Hoisting of the fully loaded boat up to 20°list and 10°trim.
-Gravity lowering of the fully loaded boat/raft up to 20°list and 10°trim, completely
independent of any power supply.
The davit system is based on a hydraulically driven crane system for arm slewing and an
electric driven winch. The swing unit system is supplied with hydraulic energy from a power
unit.
A hydraulic power pack is included, and is placed inside the crane pedestal.
All internal hydraulic piping is properly done and completed on the entire davit system.
All selected equipment is chosen and installed to ensure the lowest possible emission of
sound and to give good access for maintenance.
2.2.2. Davit steel structure
The davit consists of foundation and a swing arm.

The slewing is done by a hydraulic motor.
The electric winch is installed in the swing crane structure. The davit structure is built of
plate elements, steel profiles and hollow sections for easy maintenance.
All shafts are made of stainless steel.
2.2.3. Electric winch
The winch is a standard electrical rescue boat davit winch.

The brakes are designed to take the full load plus any additional dynamic forces acting on
the winch. The winch has a built-in centrifugal brake for controlling the lowering speed.
Stainless steel control wires which control the winch break are wound in a separate drum.
When pulled by operator, the winch will lower the boat with a speed of 40~60m/min.

2.2.4. Wire rope
The davit is equipped with a steel wire. The wire is galvanised, of non-rotating type.
2.2.5. Hydraulic power unit
The hydraulic power unit is built on the basis of a tank where the electric motor is mounted
vertically in the top plate. The tank is equipped with breather filter system and drain valve.
The tank cover is further equipped with a high pressure filter and main safety pressure valve.
CAUTION: Empty accumulator before attempting to change high pressure filter (every 5
years).
The hydraulic power unit has an electric motor driving the hydraulic pump. The motor is
mounted to the adapter flange installed on top of the tank. A flexible coupling is installed in
between the pump shaft and the electric motor shaft.
The hydraulic pump is a high pressure, heavy-duty gear pump of low noise design, and runs
clockwise.
2.2.6. Starter cabinet and davit control system
An electric motor starter cabinet for direct start (DOL) of the power pack electric motor and
winch motor control is included in the delivery. The cabinet contains thermal overload
relays, control power transformer and all other required equipment
The davit is controlled by a remote control unit, with spring returns buttons for swinging the
davit in both directions, spring return button for running the winch for hoisting and
emergency stop button.
2.2.7. Safety systems
The davit system is fitted with the following safety systems:

Lashing systems:
The lashing avoids the boat from being damaged in rough sea. This lashing will be engaged
and released by the operator.
Spring returned control buttons:
All control buttons are spring returned. In order to operate the davit the relevant control
button has to be pushed to cause the desired movement. Once the button is released it will
return, and the activated motion will stop.
Overload protection:

The hydraulic slewing system is protected against overload by hydraulic safety valves. The
winch electric motor and electrical motor for hydraulic pump are protected from overload by
thermal overload relays.
Hook stop systems:
The davit is fitted with a limit switch on the davit head.
Swing unit limitation:
Limit switches stops the slewing both ways.
Stored power for dead ship situation:
The davit is equipped with a nitrogen accumulator that stores the power in case of a dead
ship situation. The power is sufficient to swing out the davit arm even on high side during
20°list / 10°trim. The winch can then be gravity lowered, controlled by the remote control
wire. This wire will follow the boat and is controlled by the operator in the boat.
2.2.8. Surface treatment
The external surfaces are sandblasted to Sa 2.5 and painted:

1x 50µm DFT Zink Epoxy Primer.
Additional paint specification may be supplied as per contract agreement.
2.2.9. Spare parts
Upon request a separate offer for the supply of spare parts may be prepared and offered.

2.3. Technical specifications
NDSC davit systems for Norsafe rescue boats
Materials: Main structural steel: S355 (Q345) or equivalent

Outfitting steel: S235 (Q235) or equivalent
Capacities:
Lifting/lowering speed: 0-18 m/min at max load (Solas version)
Lowering speed: max 60 m/min
Max list/trim for operation: 20°/ 10°
Operation temp. range: -20°C to 50°C
Winch falls data:

Wire type: Non-rotating
Corrosion protection wire: Galvanized
Inner wire end: Secured to drum
Outer wire end: Swaged eye
Power consumption:
Power supply: 440V 60Hz / 400V 50Hz
(May be changed to suit the vessel's power supply)
El. motor protection: IP 56
Heating element in el. motor: 220V/40W in motor
Duty class: S2-10min
Oil filter system: Full flow 10 my nominal filtration
Hydraulic piping and fittings:

System type: Ermeto L-series
Materials; Pipes: AISI 316 Stainless steel
Fittings and hose fittings: Chromated
Scope of yard supply: Assembly/Erection/all welding to deck
Deck foundations
Cable for power supply.
Testing acc. to regulations.
Packing/Shipment: Packed in container for overseas transportation.

OPERATING INSTRUCTIONS
NOTE!
All crewmembers on the mother ship should be familiar with the
operating procedures for this launching appliance and lifeboat.
Failure to follow the procedures detailed in this manual may result
in serious personnel injury or material damage.
2.4. Restrictions in use
Norsafe davit is only to be used in lowering/hoisting operation with boat/raft connected to

hook.
Norsafe davit is not to be used as a crane, meaning replacement of boat with e.g. cargo net is
not allowed unless the davit has been made for this purpose.
Norsafe davit is only to be used with boat weight not exceeding S.W.L. for the davit
arrangement.
The davit is designed for use between -20C and +50C, (-4F and +122F).
For operation of the rescue boat, please refer to the relevant user manual for the boat.
Any violation to these restrictions may invalidate the guarantee conditions.
2.5. Operating instructions
To assure a safe and well-executed davit handling, an instruction plate 错误!未找到引用

源。 has been delivered. This instruction plate, showing the sequence of the launching and
recovery procedure, is placed near the embarkation position. Follow the instructions to
achieve safe handling!

错误!未找到引用源。 Operating instruction
WARNING!
DO NOT release the painter line before releasing the winch wire!

2.6. Launching in normal operation
Before doing anything else, check that no persons or any obstructions will interfere with the
launch path. Check carefully that there is no vessel or any obstructions on the sea in the
rescue boat landing area.
1. At least one operator should embark the boat.
2. Connect the painter line to the painter release hook on the boat. The painter line
should be pre-arranged so that the length corresponds with lowering height to the sea
level.
3. Remove the lashings and the electrical supply (if fitted) from the boat.
4. Slewing out the davit arm using remote control.
5. The person in the boat will lower the boat to the embarkation area, using the remote
control wire.
6. As an alternative, all of the operators will embark the boat at stowed position in order
to avoid any unnecessary stops.
7. Pay attention to the painter line. Board the boat. Make sure that the boat is boarded
evenly so that the boat doesn’t tilt.
8. If necessary, one of the operators will swing the boat further out.
NOTE!
Please note that most outboard engines only must be started
when the boat is water borne.
9. Watch the painter line, the painter line should be pre-arranged so that the length
corresponds with lowering height to the sea level.
10. When the boat is waterborne;

 Start the rescue boat engine
 Release the winch wire
 Release the painter line
WARNING!

Read carefully the user manual for the boat. Follow the operating instructions carefully.
As an alternative, the operator on deck can lower the boat, raising the counter-weight on the
winch which releases the winch break. The operator on deck must at all times have contact
with the crew in the boat. Pay attention to the remote control wire on the winch drum. If the
wire gets jammed on the drum, it may get stuck between the winch drums. Check carefully
that the wire follows the boat all the way down. The best way to avoid the control wire to be
jammed is to use it frequently, and to let one of the crew members in the boat hold on to the
remote control wire at all time. This will also avoid the weight and wire to start swinging.
When the boat is waterborne;

a. Start the rescue boat engine
b. Release the winch wire
c. Release the painter line
Read carefully the user manual for the boat. Follow the operating instructions.
2.7. Launching using the stored power system
Before doing anything else, check that no persons or any obstructions will interfere with the
launch path. Check carefully that there is no vessel or any obstructions on the sea in the
rescue boat landing area.
1. At least one operator should embark the boat.
2. Connect the painter line to the painter release hook on the boat. The painter line
should be pre-arranged so that the length corresponds with lowering height to the sea
level.
3. Remove the lashings and the electrical supply (if fitted) from the boat.
4. Select the slewing direction (in or out) from valve DV1 located on HPU by the side
of electrical motor, and close the ball valve GV1 and GV2. Slewing out the arm
using handle line to operate the valve for slewing (Valve ESV).(See figure 2.7)

Figure 2.7
5. The person in the boat will lower the boat to the embarkation area, using the remote
control wire.
6. As an alternative, all of the operators will embark the boat at stowed position in order
to avoid any unnecessary stops.
7. Pay attention to the painter line. Board the boat. Make sure that the boat is boarded
evenly so that the boat doesn’t tilt. Please refer to the boat’s user manual for starting
instructions.
8. If necessary, one of the operators will swing the boat further out.
NOTE!
Please note that most outboard engines only must be started
when the boat is water borne.
9. Watch the painter line to see that the length is sufficient until the boat is waterborne.
10. When the boat is waterborne;

 Start the rescue boat engine
 Release the winch wire
 Release the painter line
WARNING!

Read carefully the user manual for the boat. Follow the operating instructions carefully.
2.8. Recovery of the rescue boat
1. Make sure that the main switch is “ON”.

2. Swing the crane out to recovery position.
3. Connect the painter line to the boat. Then, connect the winch wire. Lift the boat.
The operator on deck must at all times have contact with the crew in the boat.
4. The crew will disembark the boat, either at the boarding area or with the boat stowed
on deck.
5. Stowage the boat on supports on deck.
6. Connect the lashings and the electrical supply. Make sure that the boat is resting
firmly.
7. After use, always drain the boat. Flush the engine with fresh water. Please refer to
the user manual for the boat for any further details.
8. Tighten the lashings.
9. ALWAYS leave the boat suspended from the winch wire, ready for immediate use.
2.9. Manual hoisting of the rescue boat
Switch off the power of motor and take out the manual handle attached on winch and insert
into position where is the label “HOISTING”. Start to turn the handle and the boat will be
recovered manually.
Note: On considering of the personal safety, while operating manually, it should be strictly
prohibited to switch on the electrical power to start the motor. After use, the manual handle
must be taken out immediately and returned to original position.
2.10. Manual lowering empty hook
If it is needed to lower the empty hook in the special case, switch off electrical power of
motor and rise counter-weight which release the winch break and keep in that position. Take
out the manual handle attached on the winch and insert it into position where is label
“LOWERING” and start to turn (pay attention to the remote control wire on the winch
drum). Upon the completion of operating, take the manual handle out and put down the
counter-weight
Note: On considering of the personal safety, while operating manually, it should be strictly
prohibited to switch on the electrical power to start the motor. After use, the manual handle
must be taken out immediately and returned to original position
.

2.11. Raft operation
The davit is equipped with two lashing wires for pull the painter line when no electric power
is available. The normal procedure for “dead ship” raft service is:
1. Choose direction for slewing from valve DV1 located by the side of electrical motor,
and close the ball valve GV1 and GV2. Slewing out the arm to launching position by
using stored power (operate valve ESV)
2. Pull main wire in by control wire.
3. Connect the raft hook on the wire fall to the raft.
4. Disconnect lashings on the raft.
5. Manual hoist the raft (see chapter 2.9. Manual hoisting)
6. One of the operators will push the raft to swing the raft further out
7. Connect the painter line to the raft. The painter line should be pre-arranged so that the
length corresponds with lowering height to the sea level.
8. Embarkation.
9. The crew will lower the raft by using remote control wire.
10. For releasing the raft: Follow the instructions given by the raft hook maker and the raft
maker.
Read carefully the user manual for the raft. Follow the operating instructions carefully.

3. MAINTENANCE INSTRUCTIONS DAVIT AND WINCH
3.1. Maintenance instructions davit and winch
This boat and davit installation is a lifesaving appliance and hence should always
be ready for use. Hence it should never be used for the attachment of lines or other
objects, nor should loose objects be stored on the boat or davit, or be so placed as
to obstruct the launch path of the boat.
Please follow recommended maintenance schedule. Apply grease on positions marked A on
figure 3.1.
Figure 3.1 Greasing point

As a general rule, all paint damage will be repaired as soon as possible to avoid future
corrosion problems.
All hydraulic couplings (unless those made of stainless steel) will be protected by Denso
tape or similar greasy protection tape, to avoid corrosion.
Check regularly that the hydraulic hoses are moving freely and are not exposed to
mechanical wear.
WARNING!
ALWAYS ISOLATE MAIN POWER BEFORE
MAINTENANCE!

3.2. Maintenance of falls
SOLAS Chapter III, Regulation 19:

Falls used in launching shall be turned end for end at intervals of not more than 30
months and be renewed when necessary due to deterioration of the falls or at
intervals of not more than five years, whichever is the earlier.
The wire should be greased according to maintenance schedule in this manual.

3.3. Monthly maintenance inspection report.
Use a copy of this report for each inspection.
Monthly maintenance inspection report.

Check no._____
Task description Checked by: Date: Period:
A- Check Oil level in hydraulic power pack.
B- Drain 2-3 litres of hydraulic oil from the power Every 6

pack drain plug, and inspect for water ingress. months
Refill with new oil.
C- Change hydraulic oil in power pack. Refer to Yearly

hydraulic oil system maintenance information
D- Change oil filter. (500 h)
E- Inspect all hydraulic connections for leakage, wear Monthly

and tear.
F- Grease all grease points. Monthly
G- Grease the winch wire. Every 2

months
H- Check oil level in winch gearbox Monthly
I- Change gear oil in winch gearbox – Refer to *

winch maintenance information
J- Check oil level for winch one way break Monthly
K- Change oil for winch one way break Every year
L- Inspect davit/launching path to ensure that the boat Weekly

can be launched safely, without obstructions.
M- Run the davit and check function Weekly
N- Turn winch wire end for end. When required.

Note: If the wire is fitted with a swaged eye, At least every 30 months.
this is not possible.
O- Replace winch wire. When required due to

deterioration.
At least every 5 years.

3.4. Inspection log for monthly maintenance inspections
Check. No: Date: Sign.: Condition: Actions taken:
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

25
26
27
28
29
30
31
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
64
65
66
67
68
69
70
71
72

73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96

97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
After 10 years we assume that you will need a new manual. Please
contact Norsafe for a new copy.

3.5. Lubrication charts
LSS NO: 01
LUBRICATION NIPPLES, GENERAL
(Wire sheaves, swing gear etc.)
Last updated:
Operate the equipment while applying grease. Use enough grease so that excessive
grease can be seen on the bearings.
BP BP ENERGREASE LS EP 2
CHEVRON DURA LITH GREASE 2
ESSO BEACON EP 2
MOBIL MOBILUX EP 2
STATOIL UNIWAY C2N
CASTROL SPEEROL AP2 / EPL 2
SHELL ALVANA GREASE R3
TEXACO MULTIFAK EP2

LSS NO: 02
WIRE
Last updated:
Operate the equipment while applying grease. Use enough grease so that excess
grease can be seen on the bearing. Apply grease to every 50 hours of operation or at
least every 2nd month.
BP BP ENERGOL GR 3000 or GREASE OG
CHEVRON PINION GREASE MS
ESSO SURRET N5K
MOBIL MOBILTAC 81
MOBILTAC D (Not for arctic)
STATOIL GREASEWAY OG N
SHELL CARDIUM COMPOUND D
TEXACO CRATER 2 X FLUID
CASTROL GRIPPA 60S
MOLYCOTE 165 LT

LSS NO: 06
WINCH GEARBOX MW 25
Last updated:
To change gear oil, operate winch gear until it is warm. Drain the oil, and refill.
Approx. quantity: 30 litres.
LUBRICATION SPECIFICATION: ISO VG68

IMPORTANT: USE ONLY THIS SPECIFICATION!

BP Temp. over -10 deg C:Energol GR XP68
CHEVRON Temp. over -10 deg C:MEROPA 68
ESSO Temp. over -10 deg C: SPARTAN EP68
MOBIL Temp. over -10 deg C:MOBILGEAR XP68
STATOIL Temp. over -10 deg C: LOADWAY MARINE 68
SHELL Temp. over -10 deg C: OMALA 68
TEXACO Temp. over -10 deg C:MEROPA 68
CASTROL Temp. over -10 deg C:ALPHA SP68

LSS NO: 06
BRAKE FOR WINCH MW 25
Last updated:
To change gear oil, operate winch gear until it is warm. Drain the oil, and refill.
Approx. quantity: 0, 3 litres.
LUBRICATION SPECIFICATION: ISO VG32

IMPORTANT: USE ONLY THIS SPECIFICATION!

BP Temp. over -10 deg C: ENERGOL HLP 32
CHEVRON Temp. over -10 deg C: AV HYD 32
ESSO Temp. over -10 deg C: NUTO H32
MOBIL Temp. over -10 deg C:DTE 24
STATOIL Temp. over -10 deg C:
SHELL Temp. over -10 deg C: TELLUS 32
TEXACO Temp. over -10 deg C: RANDO 32
CASTROL Temp. over -10 deg C: HYSPIN AWS32

LSS NO: 04
HYDRAULIC SYSTEM OIL
Last updated:
The hydraulic system has been tested by NORSAFE. A new oil filter cartridge is
installed and the oil reservoir drained prior to delivery. We recommend that the
hydraulic oil should be changed after 1000 running hours or at least once a year.
With large quantities of oil a oil analyse may be profitable.
SUPPLIER: LUBRICATION SPECIFICATION:
BP Temp. over -10 deg C: ENERGOL SHF 46

Temp. under - 10 deg C: ENERGOL SHF 32
CHEVRON Temp. over -10 deg C: AUTOM.TRANS.FLUID
Temp. under - 10 deg C: AVIATION HYDR.FLUID A or C
HDZ
ESSO Temp. over -10 deg C: UNIVIS N 46
Temp. under - 10 deg C: UNIVIS N 32
MOBIL Temp. over -10 deg C: DTE15
Temp. under - 10 deg C: DTE13
STATOIL Temp. over -10 deg C: HYDRAWAY HVX A46
Temp. under - 10 deg C: HYDRAWAY HVX A32
SHELL Temp. over -10 deg C: TELLUS T 46
Temp. under - 10 deg C: TELLUS T 32
TEXACO Temp. over -10 deg C: RANDO OIL HDZ46 / HDAZ46
Temp. under - 10 deg C: RANDO OIL HDZ32 / HDAZ32
CASTROL Temp. over -10 deg C: HYSPIN AWH 46
Temp. under - 10 deg C: HYSPIN AWH 32

4. INSTALLATION INSTRUCTIONS
4.1. IMPORTANT INFORMATION-read this when receiving the davit
When receiving the davit, please check carefully against material packing list (MPL).
Any deviation between the MPL and the received goods must immediately be reported
to your Norsafe contact person. When finished checking, sign MPL and send one copy
to Norsafe AS in order to maintain warranty agreements.
Norsafe davits are normally delivered for welding directly to deck and bulkhead or some
other type of substructure.
As a minimum requirement the deck must be designed to withstand the davits maximum
bending moment with necessary safety factor. The requirement for this kind of life saving
equipment is a safety factor of 4.5 against the guaranteed material tensile strength.
4.2. Maintenance during storage
DURING STORAGE, THE BOAT AND DAVIT SHOULD BE MAINTAINED AS IF

INSTALLED ONBOARD THE VESSEL.
4.3. Storage
Crane may be stored outdoors prior to installation under a cover/canvas for up to two
months. Use anti-corrosion spray on bolts, chains, links, hooks and wire sheaves to obtain a
watertight film.
4.4. Long time storage
If the equipment is stored for more than two months, the hydraulic power pack should be
filled completely with oil. All hydraulic components should be sprayed with anti-corrosion
oil. It is recommended that all parts are stored indoors.Check the following before installing:
Deck structure must be free of cracks, rust, oil and other species that will inhibit welding of
foundation to surface.
Be sure that no dust or other pollution enters the hydraulic system.

Check if the preservation procedure is completed.
4.5. Assembly instructions
The installation instructions are made for the basic version of the davit. You may have a
customised system, If any of the actions shown in this manual are not required for your
system, please skip that item and go to the next step.

Use an area of at least 4 x 6 m., with solid and even foundation. Use a crane and soft slings
to handle the davit.
The field welds are shown on the relevant Davit General Arrangement drawings.
Welding must be done only by certified welders. WPS and WPQ are subject to class
approval prior to start welding. The yard is responsible to carry out the installation and field
welding as required by class society.
Weld the foundation to deck.
Install the davit, and tighten all bolts with the correct torque.
Install all the components as shown on the attached drawings.
Connect the main power supply. (Check carefully that the power supply matches the
specification for the davit.

5. On board testing davit and boat
This testing procedure follows the requirements of Chapter III, SOLAS 1974, 1983
Amendments.
Using IMO resolution MSC81(70) "Part II, Production and installation tests, Chapter 6,
launching and stowage arrangements" for guidelines to the procedures.
Should the approving authority have different requirements, or newer IMO resolutions be
amended, these should be followed and the testing procedure altered to suit.
WARNING!
These procedures should be performed as instructed below; other
procedures may result in damages to the davit structure, or result in
problems with the approving authority.
Therefore if you have any doubt about how to carry out the tests,
please contact Norsafe AS in Norway for assistance.
WARNING!
Do not under any circumstances attempt to lift or lower more than the
certified SWL of the davit (+10 % for testing purpose) by using the
winch and the davit arm.

5.1. Test 1, 1.1 x SWL - Loaded lowering test
IMO, MSC81(70) part II. §6.1.5

"The survival craft or rescue boat loaded with its normal equipment or an equivalent mass
and a distributed mass equal to that of the number of persons, each weighing 82.5 kg, it is
permitted to accommodate + 10 % of the working load should be released by the operation
of the launching controls on the deck. When the craft has reached its maximum lowering
speed, the brakes should be abruptly applied to demonstrate that the attachments of the
davits and the winches to the ships structure are satisfactory. The maximum lowering speed
established by the Administration should not be exceeded."
Test procedure
Please find your correct Safe Working Load from the nameplate on the boat, or on the boat
certificate.
Use a concrete / steel / some other suitable weight to test the davit. Before the full load is
applied, the davit shall be tested with a smaller load, 10% to 20% of the full load. Move the
arm in and out. Run the winch up and down several times with the smaller load before
connecting the full test load.
When the system is working properly, you may connect the test load (1,1xSWL). Now
lower the load at maximum speed, and release the counter-weight on winch so that the
winch brake stops the boat automatically. Repeat the brake test two or three times before the
load reaches the water surface.
5.2. Test 2, Recovery test:
IMO, MSC81(70) part II. §6.1.11.

In the case of rescue boat launching appliances, it should be demonstrated that the fully
equipped rescue boat when loaded with a mass equal to that of the number of persons it is
approved to carry can be recovered by means of a winch at a rate of no less than 0.3m/s
Test procedure.
Load the boat to 1.0 x SWL. Connect the boat to the davit. Measure the lifting height. If
necessary, use guidelines on the boat. Lift the boat by the winch at full speed. Measure the
time. Recover the boat to its stowed position by following the procedure outlined in this
operation manual.
Take care to handle the loaded boat gently.

Test 3, Hand cranking
IMO, MSC81(70) part II. §6.1.8. says that it shall be possible to recover the boat by means
of operating the hand gear.
Load the boat with evenly distributed weights so that the total weight of the boat is equal to
the SWL of the boat.
Test procedure.
Make sure that the electrical power is switched off. Insert the manual handle attached on
winch in the position where label “HOISTING” and start to turn. It is normally sufficient to
lift the boat one or two meters to demonstrate that it is possible to lift. In case it is required
to lift the boat all the way up, several people should alternate to hand crank the boat.

6. PARTS/SPARE PARTS INTERCHANGEABILITY
RECORD
6.1. How to order spare parts
Please quote the Norsafe davit build number and the boat build number when contacting
Norsafe. The numbers are given on enclosed certificates, and are also shown at the
nameplate on the boat and davit. In addition, the davit build number is weld tagged to all
structural members.
IMPORTANT:
Norsafe AS
Postbox 115
N-4818 FÆ RVIK
NORWAY
Telephone: Int. + 47 37 05 85 00
Telefax: Int. + 47 37 05 85 01
NOTE!
Due to continuous development, we reserve the right to change
our product specifications and manuals without notice.

Please note that all claims will be fully invoiced until accepted as a warranty claim by
Norsafe as. Please also enclose a copy of the relevant boat/davit certificate for all warranty
claims.
The warranty period is normally limited to max. 18 months from delivery of equipment or
12 months from delivery of vessel to owner, whichever comes first. Please refer to Warranty
Card supplied with the Documentation Dossier.
All claims are handled according to "Orgalime S2000". Please fill in a copy of the
"Call for service form" for all service or warranty claims.

6.2. Recommended spare parts davit
Part Part description Reference: Total number

no. required @
davit:
1 Hydraulic oil filter According to GA drawing of 2

HPU.
2 Shackle for main wire According to cert. 1
3 Winch wire According to wire certificate 1
4 Remote control wire Ø 3mm, AISI 316 stainless 1

steel. Length: equal to main
wire
5 Wire clamp for remote AISI 316 stainless steel 1

control wire
6 Counter weight/handle for 1

remote control wire
7 Blocks for remote control AISI 316 stainless steel 2

wire
8 Shackles for blocks for AISI 316 stainless steel 2

remote control wire

7. 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. +47 370 58501.
All sales and service are acc. to Orgalime S92. All warranty claims must be accepted
in writing by Norsafe AS prior to dispatch of parts or service personnel.
Davit / boat build no:
Davit type:
Voltage/frequency
onboard:
Ship is built 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 Service only Spare parts and service
Quote price first Send parts immediately without quoting
Warranty claim Ordinary service call
Description of problem (please add more sheets if necessary):

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INSTRUCTION MANUALS

Norsafe Order No. 5292

Issue date and place 10.05.2013 Jiangyin, China

Rev. Issue date Prepared by Checked by Approved by

1. MANUALS FOR GES40MKII FREE FALL LIFEBOAT

2. OPERATION & MAINTENANCE MANUALS FOR HD40 DAVIT

4. OPERATION & MAINTENANCE MANUALS FOR NDSC-25

OPERATION AND MAINTENANCE

GES 40 / GES 40 ULS / GES 40 MB ULS

5 MAINTENANCE INSTRUCTIONS LIFEBOAT. ................................................. 29

5.6 ELECTRICAL SYSTEM ....................................................................................... 31

8 LOOSE EQUIPMENT LIST ................................................................................ 45

Tanker version only:

Postal address: Norsafe AS

Visiting address: Tybakken, Tromøy, Arendal, Norway

Due to continuous development, we reserve the right to change our product

How to order spare parts

Regarding warranty claims:

Principal GES 40 GES 40 GES 40 GES 40

2 OPERATING INSTRUCTIONS LIFEBOAT

2.1 Restrictions in use

2.2 Boarding the lifeboat

Lifeboat crew prepares the lifeboat by:

2.3 Free Fall launching mode (normal)

7. All hatches and openings are securely closed and locked.

2.4 Free-Fall launching mode (emergency)

2.5 Recovery of lifeboat

2.6 To ensure boat is securely engaged with bolt on davit.

2.7 Securing of lifting slings

Proper storage and securing of the lifting

Before attempting any free fall launch, always

2.8 Boat stowage

2.9 Procedure for training free fall operation

6. Release aft lashing arrangement.

3.2 Steering console

3.3 Steering system

3.4 Checks before starting

3.5 Engine starting (normal)

1. Before attempting to start the engine, the operator should be familiar

3.6 Engine starting (emergency)

3.8 Stopping engine

3.9 Free Fall hook release system

as should be contacted as this system is of vital importance to the operation of the

3.10 Sprinkler system (tanker version only)

3.11 Emergency air supply system (tanker version only)

1. 4 x 50 Lt. air cylinders pressurised to 200 BAR.

3.12 Operating the emergency air system (tanker version only)

1. Decide on launching mode to be used and follow the detailed

3.13 Under- and overpressure relief valves

3.15 Bilge system

3.16 Emergency steering tiller

3.17 Fuel tank

3.18 Water and provision tank

3.19 Sea anchor

3.20 Electrical system

5 MAINTENANCE INSTRUCTIONS LIFEBOAT.

5.1 Loose equipment

5.2.1 Fuel / Diesel system

5.2.2 Engine oil level

5.2.3 Cooling system

5.3.1 Drive shaft

5.4 Free Fall Release system

5.4.3 Testing WITH equipment for simulated free fall