Reaper Mechanical and Electrical Operations

Version 1.29 – Last revision 26 Jan 2008

This document describes the installation, operation and maintenance of mechanical

and electrical equipment onboard the Reaper.

All aboard should be familiar with the contents so we can minimise the consequences
of Mr Cock-up, should he come aboard. An Engine Room Log is kept aboard –
please use it for routine events such as running hours, fuelling, oil/coolant top-ups and
things that you break, fix or change. Daily and Weekly maintenance schedules will
accompany the log (specimens attached). Comments and updates are most welcome
(to bm8@st-andrews.ac.uk, mobile 07764 161891).

MacPhail.

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Engine

The Reaper is powered by an 8 litre Daewoo L136 (serial no. 404807ENCKM) diesel
engine. It generates 160 HP at 2200 rpm into a DMT70T 3.46:1 reduction gearbox
(serial no. 04061129). The manual states a fuel consumption of 32 litres / hour.
Hydraulic and pneumatic power is taken from a Dong-I E087A/D Take Off (serial no.
01070035).

Operation
START UP
1) Ensure gearbox in neutral.
2) Key to ON.
3) Key to START.
4) Monitor engine panel and ensure cooling water is discharging.

SHUT DOWN
1) Press OFF button.
2) Key to OFF.
3) In case of fire the fuel valves may be remotely closed using the two toggles
next to the bunks in the aft cabin. This may result in the need for the fuel
system to be bled.

The control panel has a built in alarm should either the water temperature or oil
pressure warning light illuminate. By design this should immediately stop the engine,
but this function is disabled on the Reaper. Instead it is planned to have a klaxon
sound to alert the skipper.

Normal (warmed up) running engine panel readings are:

Battery voltage1 28-29 V charging, 24 V engine off

Oil pressure 1 kg/cm2 (1.0 bar) at idling, 3-5 kg/cm2 (3–5 bar) at rated speed
Water temp 71-85°C
Gearbox oil pressure 20-24 bar
Revs 2,200 rpm max

Cooling
The engine is cooled by a 25 litre closed freshwater system (Figure 1). The level in
the header tank should be topped up with 50% fresh water, 50% antifreeze / corrosion
inhibitor.

Sea water enters through starboard seacock (1). Operating this seacock requires the
special spanner which should always be kept on the bulkhead above the electric
control panel. Water is pumped through four heat exchangers – main engine fresh
water, hydraulic oil, gear box oil and finally (regulated by valve 3) the exhaust jacket.
1
This reads at the same point, and thus should be the value, as the voltmeter on the main distribution
panel when switched to ‘starter’ batteries

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Bilge pumping

A bilge alarm float switch is located just above the electric bilge pump, close to the
base of the air compressor. Two switches on the Bilge Control Panel (a midships of
the 24v Control Panel) control whether the siren and/or the strobe light on the mitch
are in armed.

There are four ways of pumping the bilges.

Giljector
Engine cooling water passes through a Venturi system which uplifts bilge water
which is discharged, together with the cooling water, to the port side. Note that such
permanent discharge of bilge may be in contravention of harbour bye-laws.

Deckwash
Pump 2 is engaged via an electric clutch operated by a 24Vcircuit breaker (a flashing
LED signals when the clutch is engaged). This normally pumps sea water from the
port seacock up through to the deck wash hose. The end fitting of the deck wash may
connect to the fire hose fitting. However valves 4 and 5 can be set so that water is
drawn instead from the fore and/or aft bilges (see Figure 2). If valves 4 and 6 are left
in a half open position a back siphon can form which will flood the bilges and sink
the Reaper. Thus always ensure that valve 5 is fully closed when the bilges are not
being pumped. Bilge pumping should be continuously monitored in case the pump
runs dry and the rubber impeller burns out.

Automatic
Bilge water may also be pumped by a small electrical pump. This is controlled by a
switch on the Bilge Alarm panel. It will only operate when there is water to pump. In
theory it should stop when sufficient water has been pumped out. In practice it just
carries on – so regard it as a non-automatic pump and remember to switch it off when
it has done its job.

Submersible pump
The submersible pump is powered by 240V. Thus, at sea the, generator must be
started and the 240V taken directly from the step up (110-240V) transformer.

Hydraulics and compressed air

The power take offs engage the air compressor and the hydraulic pump and are
engaged by two control levers. Use great care when operating these levers -
especially with the pneumatic compressor take off - due to the nearby moving belts.
There are three positions for each leaver: up - engaged, level - disengaged, down –
brake. A take off should never be braked while the other is engaged. For this reason
the brake position is unavailable via the control rods.

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Compressed air operation
< to be completed >

Hydraulics operation
< to be completed >

Electrical

Refer to Figures 3 and 4

Batteries
There are two separate 24V banks of lead acid batteries – a ‘starter’ set and a 150 Ah
AGM deep cycle lighting set. Both are charged by the alternator through a diode
splitter – they are thus electrically independent. Alternator current is monitored by
the ammeter. The voltmeter can be switched to either battery or to ‘off’.

When shore-side power is on or the diesel generator is running, the batteries can also
be charged by the (110V input) Centaur 16A battery charger. This is an intelligent
charger which means two things. First, whilst not good practice, it will not be harmed
by starting the engine while charging. More importantly, it can be left on indefinitely
without harming the batteries. Furthermore, the two outputs of the charger are
independent and so each battery will be charged according to its own requirements.
Note that the lighting set will be charged even when its Isolator Switch (S1) is set to
off (vertical). If the starting set fails, use the jump leads (stowed in the engine room)
to start the engine from the lighting set.

24V circuit
The 24V distribution panel is shown in Figure 5. All power comes from the lighting
battery set and through the ‘Main Switch’ circuit breaker on the panel.

The Bilge Alarm is independent of this panel and takes its power directly from the
lighting battery set. Thus it is armed all the time regardless of the position of the
Battery Isolator (S1), but only draws power if activated by a flood. In this case a siren
and strobe will be activated. Either can be disarmed by switches on the Bilge Alarm
Panel (S4).

110V circuit
The 110V distribution panel is shown in Figure 6. Shore-side power enters via a
socket on the mitch. Ensure that the blanking socket is attached during sailing to keep
the water out. Shore power is then enters a switching panel (S3). The left-most
switch is the master switch – the one that should be set to Off when leaving the
Reaper for any length of time. Beside it are two 16A circuit breakers – one
energizing the mains socket just below and the other energising the 240-110V
transformer. 110V may also be provided by the Ruggerini diesel powered Markon
generator. The choice of shore-side or generator supply is controlled by the position

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of switch S2. As a safety feature, this switch is centre-off and therefore isolates the
two supplies. Thus, in theory, both shore-side and generator could be energised at the
same time without causing a bang - only one can be brought into circuit at any one
time. The voltage of whichever source is chosen is shown on the voltmeter (V1).

The 110-240V transformer may be switched in circuit to provide 240 V to run the
fridge, toaster and life’s other little essentials – and also the emergency submersible
pump. However power tools or other heavy loads should be run directly from shore-
side power socket mentioned above. The key to the Anstruther shore-side power
distribution box is in the f’wd cabin.

How to leave the Reaper

See Figure 3.

110V. Switch off shore side power by toggling the leftmost switch in the shore-side
power panel to Off (up).

24V. Switch off lighting battery set Isolator Switch (S1 – vertical is Off). This
means that the gas alarm is also switched off and will bleep, and must be reset, when
the Isolator Switch is switched on again.

Gas

Gas containers should be stowed on deck – never below.

< to be completed >

Fire Fighting Equipment

< to be completed >

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Figures

outflow inflow

Venturi bilge uplift

2

exhaust heat
exchanger 4 P
6 deck wash

3
oil heat exchanger

heat exchanger
hydraulic heat

Engine cooling
exchanger

engine

1
aft bilge f’wd bilge 1 f’wd bilge 2

inflow

F filter

P pump

1 stbd sea cock

2 port sea cock

exhaust regulator valve
3

Figure 1. Cooling system and bilge pumping.

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 F’wd
5 Aft
4 6

Off

F’wd Aft
From
bilge
F’wd & Aft

From
seacock
Except when bilge pumping, VALVES MUST ALWAYS BE LEFT
AS :
4. “From seacock”
5. Off
6. Off

Theses positions are shown in the picture above

Figure 2. Bilge pumping valves. Valves numbers refer to Figure 1.

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Figure 3. Physical electrical layout

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Figure 4. Wiring diagram.

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 B

Figure 5. 24V circuits.

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Figure 6. 110V circuits

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Appendix 1. Manuals
Daewoo L136 Operation and Maintenance Manual (65.99897-8080)
Daewoo L136 Installation Instructions (65.99898-8001B)
Daewoo L136 Parts Book (65.99898-8082)

Dong-I Industrial Power Take Off (Model DPO 087) Service Parts List
Dong-I Industrial Power Take Off (Model DPO 087) Service Manual

Markon Generator
Ruggerini Diesel Manual

Appendix 2. Lubricants (and related) required aboard.

API CH-4 SAE 15W40 (engine dipstick min-max is 6 litres)
API CH-4 SAE 30 (PTO)
API CC SAE 30 (gearbox)
API CH-4 SAE 15W40 (generator)
SAE 15W40 (compressor)
Hydraulic Fluid
Antifreeze / corrosion inhibitor.
Bilgex

Appendix 3. Spares required aboard

Pump impellors
Emergency link belt
Jump leads
Fuel, oil filters

Appendix 4. Contacts
Bernie McConnell 07764 161891 (mobile)
01333 451126 (home)
01334 463280 (work)
Sandy Morrison (Watermota) 01626 830910 (HQ, Devon)
(mobile)
Jimmy Bett 01333 310847
Grant Talbot 01241 871320
07947 656774
Harry Simpson 01241 872879
01241 876992 (after hours)

Appendix 5. Compressor details

Type BV41
Output 35 cf / min.
Design Revs To operate between 650 to 950 rpm.
Oil Pressure Adjustable to run at approx 12psi
Oil Type Any good quality engine oil (petrol engine) 20/50

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Weekly engine room check sheet

Date: Engine hours:

Checked by:

Port & Stbd fuel levels

Check bilges for oil and water – add Bilgex if needed
Check electric bilge pump operation
Check bilge alarm
Oil – generator SAE 15W40
Oil – engine SAE 15W40
Oil – PTO SAE 30
Oil – gearbox SAE 30
Water separator bulb
Coolant level

Starting battery charge (v)

Lighting battery charge (v)
______________________
______________________

Comments: Action taken:

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Monthly engine room check sheet

Date: Engine hours:

Checked by:

Complete weekly check

Run engine
Ensure control panel readings within spec
Check belt tension / wear
Run deckwash
Run hydraulics
Run compressor
Run generator
Check lubricant stocks
Check battery electrolyte levels
Grease propeller shaft bearing
Check seacock filters
______________________
______________________
______________________

Comments: Action taken:

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- 15 -
Start up Shut down

Ensure emergency fuel valves are open Press OFF button

Ensure gearbox in neutral Key to OFF
Key to ON In case of fire close emergency fuel valves
Key to START remotely using the two pull-toggles next to the
Monitor engine panel & cooling discharge bunks in the aft cabin.

Voltage charging 28-29 V Gearbox oil neutral 2-4 bar

engine off 24 V pressure engaged 20-24 bar
Water temp 71-85 °C Revs 2,200 rpm max

Oil pressure idling 1 bar Engine Control Panel Notice

rated speed 3-5 bar

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